(19)
(11) EP 4 544 922 A1

(12) EUROPEAN PATENT APPLICATION

(43) Date of publication:
30.04.2025 Bulletin 2025/18

(21) Application number: 23205419.7

(22) Date of filing: 24.10.2023
(51) International Patent Classification (IPC): 
A24D 3/02(2006.01)
(52) Cooperative Patent Classification (CPC):
A24D 3/0204; A24D 3/0212; A24D 3/0229; A24D 3/10; A24D 3/14
(84) Designated Contracting States:
AL AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HR HU IE IS IT LI LT LU LV MC ME MK MT NL NO PL PT RO RS SE SI SK SM TR
Designated Extension States:
BA
Designated Validation States:
KH MA MD TN

(71) Applicant: MPRD Limited
Milton Keynes, Buckinghamshire MK14 6LY (GB)

(72) Inventors:
  • RIGHI, Maurizio
    MILTON KEYNES, MK14 6LY (GB)
  • KOTYSKA, Tomas
    MILTON KEYNES, MK14 6LY (GB)

(74) Representative: Studio Torta S.p.A. 
Via Viotti, 9
10121 Torino
10121 Torino (IT)

   


(54) A MANUFACTURING MACHINE FOR PRODUCING A STRAND OF MATERIAL FOR A SMOKING ARTICLE AND A RELATED METHOD


(57) A manufacturing machine (100) for producing a strand of material for a smoking article, wherein the manufacturing machine (100) comprises: a first processing unit (101) configured to process a first material (M1); a second processing unit (102) configured to process a second material (M2), which is different with respect to the first material (M1); and a forming unit (103) configured to receive the first material (M1) from the first processing unit (101) or the second material (M2) from the second processing unit (102); the forming unit (103) comprises a forming device configured to form a continuous material strand by gathering the first material (M1) or the second material (M2). The manufacturing machine (100) comprises a switching unit (104) configured to selectively switch between the first processing unit (101) and the second processing unit (102) so as to choose if the first material (M1) or the second material (M2) has to be fed to the forming unit; or vice versa.




Description

PRIOR ART



[0001] In the tobacco industry, in particular in the field of filter making machines, different materials are processed (or worked) for producing subunits of a smoking article, like the filters.

[0002] Filters are typically made of cellulose acetate. However, in recent times other materials are also used to produce filters.

[0003] To switch from one material to another it is necessary to carry out a format change (called also as changeover) which involves disassembling units (typically processing units) of a material and replacing them with units (typically processing units) of the other material.

[0004] This requires long machine stops at each format change. After each format change it is also necessary to re-setup the manufacturing machine which requires a new calibration and setting for adapting the manufacturing machine to the processing of a new and different material.

[0005] Another disadvantage of the known manufacturing machines is that at the format change the manufacturing machine has to be emptied of any residue of the precedent material, so as to reduce the risk of cross contamination of the formed material strand.

DESCRIPTION OF THE INVENTION



[0006] The aim of the present invention is to provide a manufacturing machine for producing a strand of material for a smoking article and a related method which are without the drawbacks described above and which are easy and economical to implement.

[0007] According to the present invention, a manufacturing machine for producing a strand of material for a smoking article, according to what is claimed in the appended claims is furnished.

[0008] According to the present invention, also a method for producing a strand of material for a smoking article is furnished.

[0009] The claims describe preferred embodiments of the present invention forming an integral part of the present description.

BRIEF DESCRIPTION OF THE DRAWINGS



[0010] The present invention will now be described with reference to the attached drawings, which illustrate some nonlimiting embodiments thereof, wherein:
  • Figure 1 is a schematic front view of a manufacturing machine;
  • Figure 2 is a schematic front view (with some parts removed for clarity) of a possible embodiment of two processing units of the manufacturing machine of figure 1; and
  • Figures 3 and 4 are two enlarged and schematic views (with some parts removed for clarity) of each processing unit of figure 2;
  • Figure 5 is a schematic view of a possible material feeding of the manufacturing machine of figures 1-4; and
  • Figure 6 is an enlarged view of a part of figure 5.

PREFERRED EMBODIMENTS OF THE INVENTION



[0011] In Figure 1, number 100 denotes, as a whole, a manufacturing machine for producing a strand of material M1 or M2 for a smoking article, in particular for producing a subunit of the smoking article. Preferably, the manufacturing machine 100 is a filter making machine configured to produce at least a segment of a filter (subunit) of the smoking article. According to a possible alternative embodiment, the manufacturing machine is a maker machine configured to produce at least a segment (subunit) comprising tobacco or a substrate forming aerosol.

[0012] In the attached figures, the materials M1 and M2 are schematically illustrated with a line.

[0013] Preferably the subunit is achieved by cutting, in particular transversally (more in particular orthogonally to its longitudinal extension) a continuous material strand produced by the manufacturing machine 100.

[0014] The manufacturing machine 100 comprises two processing units 101 and 102, a forming unit 103 and a switching unit 104. A supplementary unit 105 illustrated in figure 1, is optional. The two processing units 101 and 102 are configured for being actuated alternately and not simultaneously.

[0015] According to a first embodiment, the manufacturing machine 100 comprises the two processing units 101 and 102, the forming unit 103, the switching unit 104 and the supplementary unit 105. While, according to a second embodiment, the manufacturing machine 100 comprises the two processing units 101 and 102, the forming unit 103 and the switching unit 104 (whilst the supplementary unit 105 is absent) .

[0016] In addition, the manufacturing machine 100 comprises a feeding unit 120 configured to draw the material M1 or M2 from a respective storage and to feed the material M1 or M2 to the respective processing unit 101 or 102 (as will be disclosed in detail below).

[0017] According to the attached figures, which are not limitative, the processing unit 102 is arranged on the processing unit 101. According to a possible alternative embodiment, which is not illustrated, the processing unit 101 is arranged on the processing unit 102.

[0018] The processing unit 101 is configured to process a material M1. While the processing unit 102 is configured to process a material M2. The material M2 is different with respect to the material M1. The processing units 101 and 102 are thus configured to subject the material M1 or M2 to treatments in preparation of its gathering for forming the continuous material strand.

[0019] Preferably the material M1 comprises at least one between: paper, cellulose, non-woven material, or a combination of them. Preferably the material M2 comprises cellulose acetate.

[0020] In according to a preferred embodiment, the processing unit 101 is configured to process the material M1 in form of a web. In other words, the material M1 fed to the processing unit 101 is in the form of a web. The web material (namely the material M1) comprises at least one material between: paper, cellulose, non-woven material, or a combination of them.

[0021] Preferably, the processing unit 102 is configured to process the material M2 in form of a tow material. In other words, the material M2 fed to the processing unit 102 is in the form of a filament. The tow material M2 comprises (in particular is constituted by) cellulose acetate.

[0022] The forming unit 103 is configured to receive the material M1 from the processing unit 101 or the material M2 from the processing unit 102. The forming unit 103 comprises a forming device 106 configured to form the continuous material strand by gathering the material M1 or M2. The forming device 106 is of the known type and comprises a forming beam configured to gather the material M1 or M2 which passes into it and preferably to wrap the continuous material strand with a paper strip so as to achieve a wrapped continuous material strand.

[0023] The switching unit 104 is configured to selectively switch between the processing unit 101 and the processing unit 102 so as to choose if the material M1 or M2 has to be fed to the forming unit 103; or vice versa.

[0024] Preferably, the switching unit 104 is configured for being operated at the format change, in which the manufacturing machine 100 passes from producing the continuous strand made of the material M1 to producing the continuous strand made of the material M2; or vice versa.

[0025] According to a possible embodiment, which is not limitative, the switching unit 104 is an interface (in particular an input interface or an input-output interface) through which an operator can select which processing unit 101 or 102 activate and which material M1 or M2 feed to the forming unit 103.

[0026] According to a possible alternative embodiment, the switching unit 104 comprises a mechanical element, for example a bulkhead, that allows to intercept the feeding of the unselected material, in such a way as to allow the feeding of the only chosen material M1 or M2 to the forming unit 103.

[0027] Advantageously, as illustrated in figures 1, 2 and 4, the processing unit 101 comprises a crimping device 107 configured to crimp the material M1. The crimping device 107 comprises preferably a pair of counterrotating crimping rollers 108 (illustrated in figures 2 and 4). The crimping rollers 108 are configured to rotate continuously around horizontal rotation axis. The crimping device (in particular the crimping rollers 108) is configured to provide the material M1 with material weakenings, which are configured to promote the subsequent gathering of the material M1 in the forming unit 103. The material weakenings comprise: a plurality of folds and/or a plurality of cuts and/or incisions.

[0028] In particular, the plurality of fold and/or the plurality of cuts and/or incisions extend parallel to the longitudinal extension of the material M1 or are arranged according to a predetermined pattern. More in particular, the cuts and/or incisions extend continuously or intermittently along the longitudinal or transversal extension of the material M1. Advantageously, as illustrated in figures 1, 2 and 4, the processing unit 101 comprises a flavouring device 109 configured to apply a flavour (comprising an aroma or flavour) to the material M1. The flavouring device 109 is arranged downstream the crimping device 107. In particular, the flavouring device 109 comprises at least one nozzle configured to apply (in particular by spraying) or a roller configured to apply (in particular by transferring) the additive on the material M1. According to an alternative embodiment the flavouring device 109 comprises a reservoir comprising in turn the flavour, in which the material M1 is immersed. In correspondence of the flavouring device 109, the material M1 is already crimped.

[0029] Advantageously, but not limitedly, the material M1 is unwound from a bobbin or bale (of known type and not further described or illustrated) or drawn from a stack 1 (figures 5 and 6). In other words, the feeding unit 120 is configured to feed the material M1 by unwinding it from a bale or a bobbin or by drawn it from a stack 1.

[0030] In particular, in this latter case the feeding unit 120 is configured to feed the material M1, which is stacked so that it comprises a plurality of folds defined by folding lines 3 which extends transversally, in particular orthogonally, to the longitudinal L extension of the web material M1; wherein, each fold is made in alternating opposite folding directions D (illustrated schematically in figure 5), so that two subsequent layers obtained by folding the web are parallel to each other. In other words, the material M1, is "zig-zag" folded. Two subsequent layers obtained by folding the material M1 are superimposed on top of each other. As illustrated in figure 6, the stacks 1 are arranged on a transport structure 4 configured to be fed to a manufacturing machine 100 of the tobacco industry through a conveying unit 5. The transport structure 4 is configured to feed the material M1 to the manufacturing machine 100. Advantageously, but not limitedly, the transport structure 4 being a pallet (also called as skid or storage rack).

[0031] The transport structure 4 comprises preferably more than one stack 1 of material M1. In particular, in figure 6 the transport structure 4 is provided with six stacks 1 arranged on it. As disclosed before, the material M1 being continuous between all stacks 1 arranged on the transport structure 4 itself. In other words, a first end, in particular the terminal end (not illustrated in detail), of a stack 1 is connected with another end, in particular the initial end (not illustrated in detail), of an adjacent second stack 1, so that the material M1 of all the stacks 1 being continuous (namely, without interruption).

[0032] In addition, or alternatively, the feeding unit 120 unwinds the material M2 from a bale (of known type and not further described or illustrated). In other words, the feeding unit 120 is configured to feed the material M2 by unwinding it from a bale.

[0033] Advantageously, as illustrated in figures 1, 2 and 3, the processing unit 102 comprises a stretching device 110 configured to stretch the material M2 (which in this case comprises preferably cellulose acetate). Preferably the stretching device 110 comprises at least one pair of stretching rollers 111 (figure 2 and 3), which are configured to stretch the tow material M2 for shuddering the material M2 itself so that it increases its volume. The stretching rollers 111 are configured to rotate continuously around horizontal rotation axis. In addition, the processing unit 102 comprises an applying device 112 configured to apply an additive to the material M2. Preferably the additive comprises triacetin, which acts as plasticizer for the tow material M2.

[0034] As disclosed before, according to a possible embodiment, the manufacturing machine 100 comprises the supplementary unit 105, which is optional.

[0035] Preferably the supplementary unit 105, if present, is in place of the flavouring device 109 (for example in the case were the processing unit 101 is activated and the material M1 is already provided by a flavour through the flavouring device 109). In alternative both, namely the supplementary unit 105 and the flavouring device 109 of the processing unit 101 is present (for example for flavouring the material M2 processed by the processing unit 102). The supplementary unit 105 is arranged downstream of the processing units 101 and 102 is arranged upstream of the forming unit 103. The supplementary unit 105 is configured to provide the material M1 or M2 already processed by the respective processing unit 101 or 102 with an adding material. The adding material comprises at least one chosen between: a capsule, a granulate material, a flavour, or a combination of them.

[0036] According to an additional aspect of the present invention, a method for producing a strand of material for a smoking article, is provided.

[0037] Advantageously but not limitedly, the method is carried out by the manufacturing machine 100 previously described.

[0038] The method mainly comprises (but not exclusively) the steps of:
  • switching between the processing unit 101, configured to process the material M1, and the processing unit 102, configured to process the material M2 which is different with respect to the material M1, in order to choose if the material M1 or the material M2 has to be processed;
  • processing through the processing unit 101 the material M1 or processing through the processing unit 102 the material M2; and
  • forming a continuous material strand by gathering the material M1 or M2 in particular through the forming unit 103, which is configured to receive the material M1 from the processing unit 101 or the material M2 from the processing unit 102.


[0039] Advantageously, but not limitedly, the step of switching from the processing unit 101 to the processing unit 102, or vice versa, occurs at the format change, in which the manufacturing machine 100 passes from producing the continuous strand made of the material M1 to the continuous strand made of the material M2; or vice versa. In particular, the produced continuous material strand is at least a segment of a filter of the smoking article or a segment comprising tobacco or a substrate forming aerosol.

[0040] Advantageously but not limitedly, the processing step of the material M1 comprises a crimping step of the material M1 through the crimping device 107.

[0041] Advantageously, but not limitedly, the method (in particular the processing step of material M1) comprises a further step of applying a flavour on the material M1 through a flavouring device 109. In particular, in the flavouring step at least one nozzle applies (in particular by spraying) or a roller applies (in particular by transferring) the additive on the material M1: according to a further alternative, the flavouring device 109 comprises a reservoir comprising in turn the flavour in which the material M1 is immersed. The flavouring step occurs downstream of the crimping step. Advantageously, but not limitedly, the method (in particular the processing step of the material M2) comprises a further step of stretching the material M2 through the stretching device 110. The aim of the stretching the material M2 is to increase its volume.

[0042] Advantageously, but not limitedly, the method (in particular the processing step of material M2) comprises a further step of applying the additive on the material M2 through the applying device 112 of the processing unit 102. The applying step comprises preferably the step of applying triacetin on the stretched material M2.

[0043] Advantageously, but not limitedly, the method (in particular upstream to the processing step of material M1 or M2) comprises the further step of:
  • drawing the material M1 from a bobbin or a stack 1 or bale (as illustrated schematically in figures 5 and 6); wherein the material M1 is stacked on the stack 1 so that it comprises a plurality of folds defined by folding lines 3 which extends transversally, in particular orthogonally, to a longitudinal L extension of the material M1; wherein, each fold is made in alternating opposite folding directions (D), so that two subsequent layers obtained by folding the material M1 are parallel to each other; or
  • unwinding the material M2 from a bale (not illustrated). Advantageously, but not limitedly, the method (in particular upstream to the processing step of material M1 or M2 and downstream of the forming step) comprises the further step of providing through a supplementary unit 105 the material M1 or M2 processed by the respective processing unit 101 or 102 with an adding material. As disclosed before, the adding material comprises: at least a capsule, a granulate material, a flavour, or a combination of them. The adding step occurs downstream of the processing step of the material M1 or M2 and upstream of the forming step. The step of providing the adding material is an optional step.


[0044] The invention described so far comprises a plurality of advantages.

[0045] Firstly, it is possible to switch selectively from producing a material strand of material M1 to a material strand of material M2 in an easy way, without disassembling any unit of the machine 100.

[0046] Therefore, the invention permits also to avoid machine stops and long set-up times or calibrations of the machine 100 after the format change.

[0047] The switch occurs in a simple way merely by actuating the switching unit 104.

[0048] The manufacturing machine 100 according to the present invention does not require to remove all the precedent material, when processing the new one.

[0049] Secondly, the invention can also be easily implemented in pre-existing machines 100 without requiring major adaptation interventions, but simply by adding the further processing unit 101 or 102 and the switching unit 104.

[0050] The invention permits also to feed eventual web material (for example the material M2) fed from stacks of material and not only by unwinding it from bobbins.

LIST OF FIGURE REFERENCE NUMBERS



[0051] 

1 stack

3 folding line

4 transport structure

5 conveying unit

100manufacturing machine

101processing unit

102processing unit

103forming unit

104switching unit

105supplementary unit

106forming device

107crimping device

108crimping roller

109flavouring device

110stretching device

111stretching rollers

112applying device

120feeding unit

M1 material

M2 material

D folding direction

L Longitudinal extension




Claims

1. A manufacturing machine (100) for producing a strand of material for a smoking article, wherein the manufacturing machine (100) comprises:

a first processing unit (101) configured to process a first material (M1);

a second processing unit (102) configured to process a second material (M2), which is different with respect to the first material (M1);

a forming unit (103) configured to receive the first material (M1) from the first processing unit (101) or the second material (M2) from the second processing unit (102); the forming unit (103) comprises a forming device (106) configured to form a continuous material strand by gathering the first material (M1) or the second material (M2); and

a switching unit (104) configured to selectively switch between the first processing unit (101) and the second processing unit (102) so as to choose if the first material (M1) or the second material (M2) has to be fed to the forming unit (103).


 
2. The manufacturing machine (100) according to claim 1, wherein the switching unit (104) is configured for being operated at the format change, in which the manufacturing machine (100) passes from producing the continuous material strand made of the first material (M1) to producing the continuous strand made of the second material (M2); or vice versa.
 
3. The manufacturing machine (100) according to claim 1 or 2, wherein the manufacturing machine (100) is a filter making machine configured to produce at least a segment of a filter of the smoking article.
 
4. The manufacturing machine (100) according to any previous claim, wherein the first processing unit (101) is configured to process the material (M1) in form of a web; the web material comprises at least one between: paper, cellulose, non-woven material, or a combination of them.
 
5. The manufacturing machine (100) according to claim 4, wherein the first processing unit (101) comprises a crimping device (107) configured to crimp the first material (M1).
 
6. The manufacturing machine (100) according to claim 5, wherein the crimping device (107) is configured to provide the first material (M1) with material weakenings, which are configured to promote the subsequent gathering of the first material (M1) in the forming unit (103); wherein the material weakenings comprise:

a plurality of folds; and/or

a plurality of cuts and/or incisions; wherein the cuts and/or incisions extend continuously or intermittently along the longitudinal or transversal extension of the first material (M1) .


 
7. The manufacturing machine (100) according to any preceding claim, wherein the first processing unit (101) comprises a flavouring device (109) configured to apply a flavour to the first material (M1).
 
8. The manufacturing machine (100) according to any previous claim, comprising a feeding unit (120) configured to feed the first material (M1) or second material (M2) to the respective processing unit (101, 102).
 
9. The manufacturing machine (100) according to claim 8, wherein the feeding unit (120) is configured to feed the first material (M1) by unwinding it from a bale or a bobbin.
 
10. The manufacturing machine (100) according to claim 8 or 9, the feeding unit (120) is configured to feed the second material (M2) by unwinding it from a bale.
 
11. The manufacturing machine (100) according to any previous claim, wherein the second processing unit (102) comprises a stretching device (110) configured to stretch the second material (M2); in which preferably the second material (M2) comprises cellulose acetate.
 
12. The manufacturing machine (100) according to claim 11, wherein the second processing unit (102) comprises an applying device (112) configured to apply an additive to the second material (M2); the additive comprises preferably triacetin.
 
13. The manufacturing machine (100) according to any previous claim, comprising a supplementary unit (105) arranged downstream of the first or second processing unit (101, 102) and upstream of the forming unit (103); the supplementary unit (105) being configured to provide the first material (M1) or second material (M2) processed by the respective processing unit (101, 102) with an adding material; wherein the adding material comprises at least one chosen between: a capsule, a granulate material, a flavour, or a combination of them.
 
14. A method for producing a strand of material for a smoking article, in particular using the manufacturing machine (100) according to any claim from 1 to 13; the method comprises the following steps:

switching between a first processing unit (101), configured to process a first material (M1), and a second processing unit (102), configured to process a second material (M2) which is different with respect to the first material (M1), in order to choose if the first material (M1) or the second material (M2) has to be processed;

processing through the first processing unit (101) the first material (M1) or processing through the second processing unit (102) the second material (M2); and

forming a continuous material strand by gathering the first material (M1) or the second material (M2).


 
15. The method according to claim 14, wherein the step of switching from the first processing unit (101) to the second processing unit (102), or vice versa, occurs at the format change, in which the manufacturing passes from producing the continuous strand made of the first material (M1) to the continuous strand made of the second material (M2); or vice versa.
 




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