MACHINE FOR INSERTING DISCRETE COMPONENTS INTO A CONTINUOUS CORE OF THE TOBACCO INDUSTRY

Abstract

 A device (100) for inserting discrete components into a continuous core of the tobacco industry comprises a forming conveyor (10) extending along a feed direction (A) and defining a guide channel (11) in which the continuous core is made to advance. The device (100) also comprises a spreader (20) which is at least partly inserted in the guide channel (11) so as to be disposed above the continuous core and which is configured to impart a main deformation to an upper region of the continuous core, thereby making a longitudinal groove for accommodating the discrete components. The device (100) also comprises an inserting wheel (30) configured to hold a succession of discrete components and to place the discrete components in the groove in the continuous core. The device (100) also comprises a pre-forming element disposed upstream of the spreader and inserted in the guide channel so as to be disposed above the continuous core. The pre-forming element (40) is configured to impart to an upper region of the continuous core, a predeformation suitable for overlapping with the main deformation.

Description

[0001] This invention relates to a machine for inserting discrete components into a continuous core of the tobacco industry.

[0002] The term "discrete components" may be used, for example, to denote capsules of a flavouring substance.

[0003] The term "continuous core", on the other hand, is used to denote a filter core. Known in the prior art at present are devices for inserting discrete components into a continuous core, comprising a convergent conveyor configured to guide the sliding motion of the continuous core and a spreading element which interpenetrates the conveyor in such a way as to wedge itself into the core to impart a deformation to the latter, so as to produce a groove on the top of the core into which an inserting wheel having a plurality of peripheral retaining seats places a succession of discrete components. The wheel at least partly penetrates the conveyor so that once the continuous core is deformed, the discrete components can be placed precisely on the bottom of the groove created by the spreading element.

[0004] After the discrete components have been placed, the continuous core is reclosed around the discrete components just placed in it. That way, the discrete components occupy a central position in the continuous core and are completely enclosed with it.

[0005] A device of this kind is known, for example, from application EP2888957.

[0006] Disadvantageously, the prior art devices have some inherent drawbacks, however. In particular, for some sizes, the spreading element may be unable to deform the continuous core well enough to enable the discrete components to be positioned properly inside it.

[0007] In other words, in some cases, the groove made by the spreading element is not deep enough to receive the discrete components correctly. In this situation, when the continuous core is reclosed, the radial positioning of the discrete components may in some cases be such that the discrete components are not centred. The result is a tendency to produce a large number of non-conforming products which have to be rejected.

[0008] The technical purpose of this invention is therefore to provide a device for inserting discrete components into a continuous core of the tobacco industry and capable of overcoming the above-mentioned disadvantages of the prior art.

[0009] This invention therefore has for an aim to provide a device for inserting discrete components into a continuous core of the tobacco industry to allow obtaining continuous cores provided with discrete components which are correctly placed so that precise, high-quality products can be obtained in subsequent processes.

[0010] The specified technical purpose and aim are substantially achieved by a device for inserting discrete components into a continuous core of the tobacco industry, comprising the technical features described in one or more of the appended claims.

[0011] In particular, the specified technical purpose and aim are achieved by a device for inserting discrete components into a continuous core of the tobacco industry, comprising a forming conveyor extending along a feed direction and defining a guide channel in which the continuous core is made to advance. The device also comprises a spreader which is inserted at least partly in the guide channel so as to be disposed above the continuous core. The spreader is configured to impart a main deformation to an upper region of the continuous core, thereby making a longitudinal groove for accommodating the discrete components. The device also comprises an inserting wheel, disposed downstream of the spreader along the feed direction and rotating about an axis of rotation transverse to the feed direction. The inserting wheel is configured to hold a succession of discrete components and to place the discrete components in the groove in the continuous core. Advantageously, the device also comprises a pre-forming element disposed upstream of the spreader along the feed direction and inserted in the guide channel and configured to impart to an upper region of the continuous core, a pre-deformation suitable for overlapping with the main deformation. That way, the spreader operates in a region of the continuous core that is already pre-deformed and the groove can thus be formed in an easier and more reliable manner, without the risk of being formed in a way that makes it unsuitable for its intended purpose.

[0012] Further features of the invention and its advantages are more apparent in the non-limiting description below, with reference to a preferred embodiment of a device for inserting discrete components into a continuous core of the tobacco industry.

[0013] The description is set out below with reference to the accompanying drawings which are provided solely for purposes of illustration without restricting the scope of the invention and in which:

• Figure 1 shows a perspective view of a device according to this disclosure, for inserting discrete components into a continuous core of the tobacco industry;
• Figure 2 shows a cross-sectional view of a portion of the device of Figure 1;
• Figures 3A and 3B show respective cross-sectional views of a forming conveyor of the device of Figure 1;
• Figures 4A and 4B show respective perspective views of a pre-forming element of the device of Figure 1.

[0014] With reference to the accompanying drawings, the numeral 100 denotes a device for inserting discrete components, for example, capsules (beads) of flavouring material, into a continuous core, for example, a filter core, of the tobacco industry.

[0015] As is known, the capsules of flavouring material, are spherical elements containing a flavouring substance, usually in the liquid state. The flavouring capsules are placed in the filter core at regular intervals and when the filter core is cut into sections, single filters are formed, each containing a capsule. When a cigarette with this type of filter is made, the user, before smoking the cigarette, squeezes the filter in order to break the capsule so that the flavouring liquid is diffused in the filter. The device 100 comprises a forming conveyor 10, in particular made from metallic material, extending along a feed direction A and at least partly defining a guide channel 11 in which the continuous core is made to advance. The continuous core (not illustrated in the drawings) comes from specific forming means, for example, a unit for picking up a strip of tow from specific bales and treating it and then gathering it up to form a core which, for example, has a substantially circular cross section. A unit like this is described, for example, in application WO2012/156911 in the name of the present applicant.

[0016] Preferably, the guide channel 11 is convergent along the feed direction A, that is to say, the cross section of the guide channel 11 becomes progressively narrower.

[0017] The device 100 also comprises a spreader 20 which is at least partly inside the guide channel 11 so as to be disposed above the continuous core.

[0018] In the embodiment illustrated in the accompanying drawings, the spreader 20 has a substantially plate-shaped structure extending from a first, upper end on the outside of the guide channel 11, to a second, lower end, inside the guide channel 11 to define a sort of "fin" in the guide channel 11 itself, as shown in Figures 2 and 3B. The spreader 20 is configured to impart a main deformation to an upper region of the continuous core, thereby making a longitudinal groove for accommodating the discrete components.

[0019] In other words, the spreader 20 acts as an obstacle to the sliding movement of the continuous core in the guide channel 11 so as to force the continuous core to adopt a predetermined cross-sectional shape, and in particular, a shape substantially like that of a U, where the spreader 20 has flattened the upper region of the continuous core.

[0020] As shown, for example, in Figure 1, the device 100 also comprises an inserting wheel 30, located downstream of the spreader 20 along the feed direction A.

[0021] The inserting wheel 30 rotates about an axis of rotation X transverse to the feed direction A.

[0022] Preferably, the axis of rotation X of the inserting wheel 30 is perpendicular to the feed direction A and, in particular, is horizontal. The inserting wheel 30 is configured to hold a succession of discrete components and to place the discrete components in the groove in the continuous core at predetermined regular spacing intervals.

[0023] In the embodiment illustrated, the inserting wheel 30 (of known type) has a plurality of seats 31, distributed on a peripheral surface of the inserting wheel 30 itself.

[0024] Preferably, each seat 31 is provided with a suction system capable of retaining a discrete component and releasing the discrete component when the inserting wheel 30, during its rotation, positions the respective seat 31 inside the groove of the continuous core. In effect, as shown, for example, in Figure 1, the inserting wheel 30 at least partly interpenetrates the forming conveyor 10 so that once the continuous core has been spread open by the spreader 20, the inserting wheel 30 can place the discrete component precisely inside the groove just made.

[0025] In the embodiment illustrated, the inserting wheel 30 is provided with a hub which is rotatable about the axis X and is supported by means not illustrated, and a disc-like portion 32 integral therewith and larger in diameter. The disc-like portion 32 is inserted into a specific opening made in the forming conveyor 10 so as to penetrate the guide channel 11. In this situation, when the continuous core is deformed by the spreader 20, the groove created may be large enough to receive the disc-like portion 32 of the inserting wheel 30 so that the discrete components can be placed in the groove.

[0026] In use, therefore, as the continuous core is made to advance in the guide channel 11, it is progressively deformed by the spreader 20 which gives it a shape substantially like that of a U. Next, the continuous core thus deformed advances in proximity to the inserting wheel 30 so that one or more discrete components can be placed inside the groove just formed by the spreader 20.

[0027] As shown in Figure 2, it is noted that the spreader 20 has a concave front surface, facing the wheel 30, which follows the shape of the outer profile of the wheel 30 (and in particular, of the disc-like portion 32) so that it can be positioned in immediate proximity to the wheel 30 itself.

[0028] The device of this disclosure also comprises a pre-forming element 40 disposed upstream of the spreader 20 along the feed direction A.

[0029] The pre-forming element 40 is configured to impart a pre-deformation to the upper region of the continuous core. The pre-deformation is designed to overlap with the main deformation subsequently imparted by the spreader 20. The pre-forming element 40 is thus inserted in the guide channel 11 in such a way as to be disposed above the continuous core (Figure 2).

[0030] In other words, the pre-forming element 40 is configured to deform the upper region of the continuous core at the inlet to the guide channel 11, where the spreader 20 subsequently imparts its main deformation action creating the groove for accommodating the discrete components.

[0031] Advantageously, the pre-forming element 40 allows obtaining a continuous core of better quality. In particular, the presence of the pre-forming element 40 promotes the stability of the subsequent main deformation, making it conformant with an ideal groove profile and preventing the risk of forming grooves of non-conformant or unstable shape.

[0032] Thus, the presence of the pre-forming element 40 not only ensures that the groove, made after the pre-deformation and the main deformation, is deep enough to accommodate the discrete components and to enclose them in the continuous core but it also ensures that the main deformation following it is made in a "pre-deformed" region with greater control of the deformation stability. Preferably, as shown in the accompanying drawings, the pre-forming element 40 is fully inserted in the guide channel 11. Preferably, the pre-forming element 40 has a leading end section that is disposed substantially flush with the inlet section of the guide channel 11. In different embodiments, however, the pre-forming element 40 may be recessed relative to the inlet section of the guide channel 11 or it may protrude partly therefrom.

[0033] As shown in Figures 2 and 3A, the pre-forming element 40 comprises a coupling surface 40a applied to an inside surface 11a of the guide channel 11. In particular, the coupling surface 40a is applied to a top portion of the inside surface 11a.

[0034] The coupling surface 40a has a convex shape. Preferably, it is shaped to match the inside surface 11a and, more preferably, the profile of the coupling surface 40a has the shape, in transverse cross section, of a circular arc (Figure 3A).

[0035] The pre-forming element 40 also comprises an active surface 40b extending radially from the coupling surface 40a towards the inside of the guide channel 11 in order to make the pre-deformation on the continuous core.

[0036] In a possible embodiment, the pre-forming element 40 is made entirely as one with the forming conveyor 10.

[0037] Alternatively, the coupling surface 40a is provided with connecting means, specifically at least one threaded hole, adapted for reversibly mounting the pre-forming element 40 to the forming conveyor 10. The active surface 40b comprises a pair of side walls 41b extending away from the top wall 41a and converging with each other. The side walls 41b are configured, in use, to at least partly shape the continuous core flowing through the guide channel 11.

[0038] Preferably, the side walls 41 are flat.

[0039] Preferably, the angle made by the side walls 41b is between 80° and 150°. Still more preferably, the angle is equal to 100°.

[0040] The pre-forming element 40 also comprises a bottom wall 41c defining a contact surface 40c adapted, in use, to shape the upper region of the continuous core and configured to join the pair of side walls 41b to each other.

[0041] Preferably, the bottom wall 41c is arcuate in shape. In this situation, when the continuous core is made to flow into the forming conveyor 10, the bottom wall 41c imparts a flattening action to the upper region of the continuous core, forcing it to adopt an open U shape, that is to say, a shape where the curvature of the U is still not well defined but is useful as a "guide" or "trace" for the spreader 20.

[0042] Preferably, as shown in Figures 3A and 3B, the pre-forming element 40 has a tapered shape along a longitudinal direction of extension L which, in use, defines the feed direction A of the continuous core.

[0043] In other words, the transverse cross section of the pre-forming element 40 becomes narrower along the feed direction A. Preferably, the pre-forming element 40 has a cross sectional angular size which remains substantially constant along the feed direction A. In other words, the pre-forming element 40 follows the convergent shape of the guide channel 11, progressively decreasing its transverse cross section along the feed direction A but keeping its angular size constant. In this situation, for each transverse cross section of the guide channel 11, the pre-forming element 40 decreases the size of its cross section proportionally to that of the guide channel 11. Preferably, the angular size is defined by the aforesaid angle between the side walls 41b.

[0044] In use, therefore, the continuous core is made to advance into the guide channel 11 and its upper region impacts the pre-forming element 40. In this situation, the continuous core, to be able to proceed into the guide channel 11, is pre-deformed and, in particular, its upper region is at least partly flattened towards the centre of the continuous core.

[0045] Next, before the continuous core can overcome the pre-deforming action and return to its initial shape, the core reaches the spreader 20 so that the latter can operate on its upper region which has just been deformed. For this purpose, the spreader 20, in transverse cross section, preferably has a thinner shape than the pre-forming element 40, preferably a shape with substantially parallel side walls which, if necessary, are joined at the bottom by an arcuate portion. A shape of this kind has an efficacious deforming action suitable for forming the aforementioned groove which, immediately after being formed, receives the succession of discrete components from the wheel 10.

[0046] Preferably, the pre-forming element 40 is spaced from the spreader 20 along the feed direction A by a distance of between 0 mm and 30 mm, where such distance is measured as the distance between the mutually facing walls of the spreader 20 and of the pre-forming element 40. More preferably, this distance is 15 mm.

[0047] Moreover, preferably, the pre-forming element 40 is between 25 and 40 mm in length along the feed direction A.

[0048] In a possible embodiment, the forming conveyor 10 comprises, between the pre-forming element 40 and the spreader 20, an opening 12 for blowing air into the guide channel 11. The opening 12 may also be defined by a slot (longitudinal, elongate in shape) of the forming conveyor 10 in which the spreader 20 is inserted.

[0049] The pre-forming element 40 is protectable independently of the device according to the invention, in particular as an accessory element (insert) applicable thereto, preferably as a spare part or as an insert which can be replaced with a different insert in the event of size changeover.

[0050] In a variant embodiment not illustrated, the device can provide the core with a continuous insert, for example, a filament or an extruded material. For this purpose, the inserting wheel can be replaced with a nozzle for applying the filament. Moreover, the continuous core need not necessarily be formed from filter material but, alternatively, might be formed from a gathered web or gathered strips of tobacco or other plant fibre or even a gathered material of another kind (paper, PLA or the like).

[0051] The invention achieves the preset aims overcoming the drawbacks of the prior art.

[0052] In particular, the introduction of the pre-forming element allows obtaining a continuous core in which the discrete components are correctly positioned, in particular, optimally centred.

Claims

1. A device (100) for inserting discrete components into a continuous core of the tobacco industry, comprising:

- a forming conveyor (10) extending along a feed direction (A) and defining a guide channel (11) in which the continuous core is made to advance;

- a spreader (20) which is at least partly inserted in the guide channel (11) so as to be disposed above the continuous core, the spreader (20) being configured to impart a main deformation to an upper region of the continuous core, thereby making a longitudinal groove for accommodating the discrete components;

- an inserting wheel (30), disposed downstream of the spreader (20) along the feed direction (A) and rotating about an axis of rotation (X) transverse to the feed direction (A), the inserting wheel (30) being configured to hold a succession of discrete components and to place the discrete components in the groove in the continuous core;

the device (100) being characterized in that it comprises a pre-forming element (40) disposed upstream of the spreader (20) along the feed direction (A) and inserted in the guide channel (11) so as to be disposed above the continuous core, the pre-forming element (40) being configured to impart to an upper region of the continuous core, a pre-deformation suitable for overlapping with the main deformation.

2. The device according to claim 1, wherein the pre-forming element (40) comprises a coupling surface (40a) applied to an inside surface (11a) of the guide channel (11), specifically a top portion of the inside surface (11a), and an active surface (40b) extending radially from the coupling surface (40a) towards the inside of the guide channel (11) in order to make the pre-deformation on the continuous core, the coupling surface (40a) being preferably shaped to match the inside surface (11a), and more preferably, the coupling surface (40a) having a transverse cross section in the shape of a circular arc.

3. The device according to claim 2, wherein the coupling surface (40a) is provided with connecting means, specifically at least one threaded hole, adapted for reversibly mounting the pre-forming element (40) to the forming conveyor (10).

4. The device according to any one of the preceding claims, wherein the guide channel (11) is convergent in shape along the feed direction (A).

5. The device according to any one of the preceding claims, wherein the pre-forming element (40) is tapered in shape along the feed direction (A) and preferably has a cross sectional angular size which remains substantially constant along the feed direction (A).

6. The device according to any one of the preceding claims, wherein the pre-forming element (40) is inserted entirely in the guide channel (11) and preferably has an initial section that is substantially flush with an infeed section of the guide channel (11).

7. The device according to claim 1, wherein the pre-forming element (40) is made entirely as one with the forming conveyor (10).

8. The device according to any one of the preceding claims, wherein the spreader (20) and the pre-forming element (40) are spaced apart along the feed direction (A) by a distance of between 0 and 30 mm, preferably 15 mm.

9. The device according to any one of the preceding claims, wherein the pre-forming element (40) is between 25 and 40 mm in length along the feed direction (A).

10. The device according to any one of the preceding claims, wherein the forming conveyor (10) has at least one inlet opening (12) to allow air into the guide channel (11), the opening (12) being interposed between the spreader (20) and the pre-forming element (40).

11. A pre-forming element (40) for use in a device (100) for inserting discrete components into a continuous core of the tobacco industry, specifically in a device according to one or more of the preceding claims, comprising:

- a top wall (41a) defining a coupling surface (40a) with a convex cross section, specifically in the shape of a circular arc, suited to be coupled by a shape coupling to an inside surface (11a) of a guide channel (11) of the continuous core;

- a pair of side walls (41b) extending away from the top wall (41a) and converging with each other, the side walls (41a) being configured, in use, to at least partly shape the continuous core flowing through the guide channel (11);

- a bottom wall (41c) defining a contact surface (40c) adapted, in use, to shape the upper region of the continuous core and configured to join the pair of side walls (41b) to each other, the bottom wall (41c) being preferably arcuate in shape.

12. The pre-forming element according to claim 11, wherein the pair of side walls (41b) are flat.

13. The pre-forming element according to claim 11 or 12, wherein the angle made by the side walls (41b) is between 80° and 150°, the angle being preferably equal to 100°.

14. The pre-forming element according to any one of claims 11 to 13, wherein the top wall (41a) is provided with coupling means for reversibly coupling the inside surface (11a) of the guide channel (11), the coupling means preferably comprising a threaded hole.

15. The pre-forming element according to any one of claims 10 to 14, wherein the pre-forming element (40) has a tapered shape along a longitudinal direction of extension (L) defining, in use, the feed direction (A) of the continuous core.

Drawing