FIELD OF THE INVENTION
[0001] The present invention relates to a method and apparatus, and more particularly relates
to a method of fabricating cigarettes and to an apparatus for producing cigarettes.
BACKGROUND OF THE INVENTION
[0002] The manufacture of cigarettes is well known in the art and naturally, specialized
equipment is utilized by large cigarette manufacturers. However, there also exists
a niche of "roll your own" which is popular with some smokers as the separate purchase
of the tobacco and cigarette tube is substantially cheaper than the purchase of pre-manufactured
cigarettes.
[0003] Smaller machines for filling prepared cigarette papers also known. With this type
of machine, it is necessary to form a strand or plug which is inserted into the preformed
paper cigarette paper shell or tube. The bulk tobacco has to be separated and then
reformed into a continuous thin strand or skein in order to prevent the burning tobacco
from crumbling when the cigarette is smoked.
[0004] An example of a manual cigarette filling device is shown in
U.S. Patent 3,509,887 in which the tobacco supply is first collected by hand and then the amount needed
for one cigarette inserted in an elongated forming device. Subsequently, a contact
pressure dish is pressed onto the preformed tobacco strand and the tobacco pressed
together to form a rounded tobacco strand. By means of a manual lever device, the
preformed tobacco strand is then pressed into a cigarette paper tube which is positioned
on a mounting device and held by a contact pressure device. Other types of manual
cigarette filling devices have also been known in the art and are generally directed
to filling a single tobacco tube when required.
[0005] There is also a market for cigarette smokers who do not wish to use a small do it
yourself machine to roll their own cigarettes, but would rather have a machine which
could roll cigarettes at a relatively fast throughput. Also, some cigarette smokers
prefer to utilize a specific type of tobacco and tube while at the same time not wanting
to revert to the traditional roll your own cigarettes.
SUMMARY OF THE INVENTION
[0006] It is an object of the present invention to provide a method for smokers to have
a roll your own cigarette which is of a commercial quality.
[0007] It is a further object of the present invention to provided an apparatus which can
throughput a high number of cigarettes and which may be utilized by a number of users.
[0008] According to one aspect of the present invention there is provided an apparatus for
manufacturing cigarettes, the apparatus comprising a hopper for receiving pre-cut
tobacco, a compactor for compacting the pre-cut tobacco into a cylindrical tobacco
plug, a first transfer mechanism for transferring the pre-cut tobacco from the hopper
to the compactor; a transition section having at least one hollow cylindrical transition
tube designed to receive an empty tobacco tube thereabout, a second transfer mechanism
to transfer the tobacco plug to the hollow cylindrical transition tube, and a pushing
mechanism to push the tobacco plug into the cigarette tube and thereby discharge the
cigarette tube from the transition tube.
[0009] According to a further aspect of the present invention there is provided a method
of filling a tobacco tube with pre-cut tobacco to form a cigarette comprising the
steps of compacting the tobacco to form a cylindrical plug, placing the cylindrical
plug in a transition tube; placing a cigarette tube over the transition tube, and
pushing on the cylindrical plug of tobacco while in the transition tube to thereby
fill the cigarette tube with tobacco as the cigarette tube is discharged from the
transition tube.
[0010] According to a further aspect of the present invention there is provided a method
of filling a cigarette tube with pre-cut tobacco, the method comprising the steps
of providing a transition tube having a cylindrical configuration with an external
diameter slightly less than the internal diameter of a cigarette tube, inserting a
guide tube within the transition tube to extend through the free end of the transition
tube, placing an open end of the cigarette tube over the guide and over the transition
tube, withdrawing the guide member while continuing to place the cigarette tube on
the transition tube, and pushing a pre formed plug of tobacco into the transition
tube and continuing to push until the cigarette tube is discharged from the transition
tube with the pre cut tobacco therein.
[0011] The present invention is directed to a market wherein a smoker may go into a store
and purchase a supply of precut tobacco and preformed cigarette papers or tubes. The
user would then be able to insert the tobacco and tubes into a machine which would
produce a predefined number of cigarettes.
[0012] The apparatus according to the present invention will preferably include means for
supplying cigarette tubes to the apparatus. While a number of different storage devices
may be utilized, a preferred embodiment will utilize canisters of a desired capacity
which may then be inserted into the machine. Naturally, different numbers and types
of tubes may be utilized depending upon the requirements of the user.
[0013] The apparatus will also include an input hopper into which cut tobacco strands may
be placed. The precut tobacco is hermetically stored in a suitable container. As such,
the tobacco hopper will have an input and an output with the tobacco preferably being
transferred by a conveyor between the input and output. During the transfer, a combing
or dethatching device is provided for helping in the separation of the tobacco strands.
A suitable device may comprise a rotating shaft having teeth extending outwardly therefrom.
[0014] The tobacco is then compacted and formed into a tobacco plug. Although there are
many known ways of doing so, a preferred arrangement utilizes two conveyors which
may include a converging section. The conveyors advance in the same direction to move
the tobacco between half molds wherein it is formed into a plug. Alternatively, the
conveyors may each converge to a final discharge point. Preferably, the conveyors
are vertically aligned.
[0015] From the conveyors, the tobacco is preferably placed between two half molds, at least
one of which is moveable and which are arranged to form a plug of tobacco in a cylindrical
configuration.
[0016] Meanwhile, the arrangement for the tobacco tubes will involve singulating them and
advancing them to a desired position. According to the preferred aspect of the present
invention, a tobacco tube is placed over a transition tube which is sized to have
an exterior diameter which is substantially equal or slightly less than the inner
diameter of the cigarette tube.
[0017] In one arrangement, a moveable guide is utilized and which moveable guide has a conical
end which is substantially smaller than the diameter of the cigarette tube. The guide
member may extend through the transition tube such that when a cigarette tube is to
be placed on the transition tube, the guide will function to properly guide the cigarette
tube and allows for out of round cigarette tubes to be utilized. Once the cigarette
tube has started to be placed on the transition tube, the guide member is withdrawn
until the cigarette is firmly abutted against the transition tube.
[0018] As an alternative to the above, the transition cylinder may have a tapered end to
provide some guiding to the cigarette tube when it is placed thereon.
[0019] In one embodiment, the cigarette tubes are singulated from the canister and placed
on a rotating turret which has a plurality of recesses on the exterior surface thereof.
Each recess is sized to receive a single cigarette tube and the turret is advanced
sequentially through a number of stations as will be described in greater detail hereinbelow.
Alternatively, the turret can be eliminated as will be shown in the drawings.
[0020] The apparatus will include suitable sensing means at every step of the operation
to ensure that this particular operation is properly carried out. Also, one may incorporate
means for adjusting both the length of the cigarette and the compactness of the tobacco
plug.
[0021] Further embodiments of the invention are set out in the following numbered paragraphs:
- 1. An apparatus for manufacturing cigarettes, the apparatus comprising: a hopper for
receiving pre-cut tobacco; a compactor for compacting said pre-cut tobacco into a
cylindrical tobacco plug; a first transfer mechanism for transferring said pre-cut
tobacco from said hopper to said compactor; a transition section having at least one
hollow cylindrical transition tube designed to receive an empty tobacco tube thereabout;
a second transfer mechanism to transfer said tobacco plug to said hollow cylindrical
transition tube; and a pushing mechanism to push said tobacco plug into said cigarette
tube and thereby discharge said cigarette tube from said transition tube.
- 2. The apparatus of paragraph 1 wherein said hopper has a conveyor belt to move said
pre-cut tobacco to said first transfer device.
- 3. The apparatus of paragraph 2 wherein said hopper further includes a dethatching
device for said pre-cut tobacco.
- 4. The apparatus of paragraph 3 wherein said dethatching device comprises a rotating
shaft having fingers extending outwardly therefrom.
- 5. The apparatus of paragraph 1 wherein said first transfer mechanism comprises a
pair of generally vertically oriented conveyor belts).
- 6. The apparatus of paragraph 5 wherein at least one of said conveyor belts has an
angled converging section with respect to the other of said conveyor belts.
- 7. The apparatus of paragraph 1 wherein said compactor comprises a pair of half molds,
at least one of said half molds being moveable to thereby compact said pre-cut tobacco
placed therebetween.
- 8. The apparatus of paragraph 1 wherein said transition section comprises a base having
a plurality of said hollow cylindrical transition tubes extending outwardly therefrom.
- 9. The apparatus of paragraph 8 wherein each of said transition cylinders is tapered
at an end remote from said base.
- 10. The apparatus of paragraph 1 further including a rotatable turret having a plurality
of elongated recesses therein, each of said elongated recesses being sized to receive
and retain a single cigarette tube.
- 11. The apparatus of paragraph 10 further including a cigarette tube dispenser located
adjacent said rotatable turret.
- 12. The apparatus of paragraph 11 wherein said tube dispenser has a hinged wall and
a cylinder to move said hinged wall to permit dispensing of a single cigarette tube
on said rotatable turret.
- 13. The apparatus of paragraph 1 wherein said pushing mechanism to push said tobacco
plug into said cigarette tube comprises a pneumatic cylinder.
- 14. A method of filling a tobacco tube with pre-cut tobacco to form a cigarette comprising
the steps of: compacting said tobacco to form a cylindrical plug; placing said cylindrical
plug in a transition tube; placing a cigarette tube over said transition tube; and
pushing on said cylindrical plug of tobacco while in said transition tube to thereby
fill said cigarette tube with tobacco as said cigarette tube is discharged from said
transition tube.
- 15. The method of paragraph 14 wherein the step of compacting said tobacco to form
a cylindrical plug comprises the steps of placing said pre-cut tobacco between a pair
of conveyor belts, and transporting said pre-cut tobacco to a compacting mechanism
comprised of two half molds.
- 16. A method of filling a cigarette tube with pre-cut tobacco, the method comprising
the steps of: providing a transition tube having a cylindrical configuration with
an external diameter slightly less than the internal diameter of a cigarette tube;
inserting a guide tube within said transition tube to extend through the free end
of the transition tube; placing an open end of said cigarette tube over said guide
and over said transition tube, withdrawing said guide member while continuing to place
said cigarette tube on said transition tube; and pushing a pre formed plug of tobacco
into said transition tube and continuing to push until said cigarette tube is discharged
from said transition tube with said pre-cut tobacco therein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] Having thus generally described the invention, reference will be made to the drawings
illustrating an embodiment thereof, in which:
Figure 1 is an exploded view of an apparatus according to the present invention;
Figure 2 is a perspective view of the input hopper;
Figure 3 is a perspective view of a storage device for the cigarette tubes;
Figure 4 is a view of the cigarette tube storage device in an open position;
Figure 5 is an exploded view of the transfer device for transferring tobacco from
the input hopper to form a tobacco plug;
Figure 6 is a perspective view thereof;
Figure 7 is a perspective view of the turret for singulating and receiving the individual
cigarette tubes; and
Figure 8 is a perspective view of the device holding the cigarette tube when the tobacco
is inserted therein; and,
Figures 9 to 14 are perspective views of a slightly modified apparatus illustrating
operation of the same;
Figure 15 is a perspective view of a modified embodiment of the present invention;
Figure 16 is a perspective of a further modified embodiment of the present invention;
Figure 17 is a side view, partially in section, of a guiding mechanism which can be
incorporated in the present invention; and
Figure 18 A to 18F illustrate the sequence for placing a cigarette tube on a transition
tube and filling the same with tobacco.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Referring to the drawings in greater detail and by reference characters thereto,
there is illustrated in Figure 1 a cigarette making apparatus which is generally designated
by reference numeral 10. Apparatus 10 includes an input hopper generally designated
by reference numeral 12, a compactor generally designated by reference numeral 14,
a cigarette tube storage container generally designated by reference numeral 16, a
tube separator generally designated by reference numeral 18, a transfer device for
inserting a cigarette plug into a cigarette tube generally designated by reference
numeral 20, and a discharge container generally designated by reference numeral 22.
[0024] Input hopper 12, as may be best seen in Figure 2, has a main body 26 with an upper
inlet 28. Mounted at the bottom of main body 26 is a conveyor 30. Mounted proximate
to the outlet of input hopper 12 is a strand separator generally designated by reference
numeral 32 and which comprises a shaft 34 having a plurality of pins or combs 36 extending
outwardly therefrom. Shaft 34 is rotatably driven by an electric motor 38.
[0025] Compactor 14 as seen in Figures 1,5 and 6, has first and second side walls 42 and
44 which enclose a first conveyor 46 and a second conveyor 48. As best seen in Figure
5, first conveyor 46 includes an upper converging section 50 following which the conveyors
46 and 48 may be parallel or have a slight converging configuration. An electric motor
acts to drive first and second conveyors 46 and 48. Preferably, the conveyors are
driven for a preset period of time. Thus, the conveyors would be designed to discharge
a predetermined amount of tobacco which has been received from the input hopper. In
other words, preferably the operations are incremental.
[0026] Cigarette storage container 16 is illustrated in Figure 4 and reference will now
be had thereto. Container 16 has a pair of side walls 56 and 58 and it will be noted
that side wall 56 has a greater height and also has a flange 60 extending outwardly
from a peripheral edge thereof. End walls 62 and 64 define the rectangular configuration
while a bottom wall 66 is secured to end wall 62 by means of a hinge 68. Associated
with container 16 is a motor 70 to operate a piston 72 to move the body of the container
with respect to bottom wall 66.
[0027] The tobacco compaction occurs at the output of conveyors 46 and 48 and to this end,
there is provided a first half mold member 74 having a semi cylindrical recess 75
at the end thereof and which half mold 74 is driven by a motor 76 having a piston
78 associated therewith.
[0028] A second mold 80 likewise has a semi cylindrical recess 81 and is moveable by means
of motor 82 having piston 84 secured to half mold 80. A cylinder 75 having a piston
79 is provided for reasons which will become apparent herein below. Preferably, one
of the molds 74, 80 will have a cutting edge associated therewith to sever any tobacco
strands extending beyond the mold recess.
[0029] As may be seen in Figure 1, cigarette tube storage container 16 is positioned such
that the container can be lifted while maintaining hinged bottom wall 66 in position
such that cigarette tubes may be loaded onto a rotatably driven turret 88 which has
recesses 90 formed therein. The recesses 90 are sized to receive a single cigarette
tube. A cylinder 91 is provided to transfer the cigarette tubes. Alternatively, a
rotating cam could be utilized to open the container sufficiently for a cigarette
tube to be discharged.
[0030] As may be seen in the drawings, there is provided a tube receiving device currently
designated by reference numeral 24 in which has a base 96 with a plurality of transition
cylinders 98 extending therefrom. It will be noted that each transition cylinder 98
preferably has an end which is diagonally cut to ease insertion of the empty cigarette
tube thereabout.
[0031] In operation, turret 88 preferably has six stations or recesses for receiving the
cigarette tubes. At a first station, a cigarette tube 94 is loaded thereon and it
is then advanced through two more stations before the tobacco is inserted in the tube.
At a fifth station, the tubes are unloaded while at a sixth station, a cleaning operation
is carried out.
[0032] At the tobacco station, the tube is transferred from the turret to the transition
cylinder. A piston will push the tobacco plug into a transition cylinder 98 which
has a cigarette tube thereabout. The cigarette tube is also filled with tobacco while
a continuing push will cause the tube to retract from the transition cylinder. The
filled cigarette is then discharged.
[0033] A further station will verify that the tube has been fully fed; if not, it will be
rejected at a subsequent station. It will be noted that after a predefined number
of consecutive rejects, the machine will stop as the machine is probably missing either
tobacco or tubes.
[0034] In the embodiment of Figures 9 to 14, it will be noted that transition cylinders
198 have a tapered end 199. This arrangement ensures the easy placement of an empty
tube thereon.
[0035] In operation, and as shown in Figure 9, a cigarette tube 94 is loaded on turret 88.
The turret 88 is advanced through one station where cigarette tube 94 is aligned with
cylinder 91. As shown in Figure 10, cylinder 91 is operative to move cigarette tube
94 on to transition cylinder 98. After being placed on the transition cylinder 98
as is shown in Figure 11, turret 88 is advanced. Subsequently, as may be seen Figure
12, piston 77 of cylinder 75 is operative to push a tobacco plug 79 into a transition
cylinder 98. The motion is continued, as may be seen in Figure 13, to exert a force
on the now filled cigarette tube, as a completed cigarette.
[0036] The remaining stations of the turret may be used for cleaning of the same. As previously
mentioned, after the cigarette tube has been placed on the transition cylinder, an
inspection may be conducted using sensors to determine that the cigarette tube is
properly placed and that there is a full load of tobacco to insert therein.
[0037] In the embodiment of Figure 15, similar reference numerals have been utilized for
similar components. The main difference between this embodiment and previous embodiments
is in the use of a receiving member 22' which allows the cigarette to enter therein
from where it slides to a further container.
[0038] Turning to the embodiment of Figure 16, the prime differences are the elimination
of the turret and instead, the substitution of a member 93 having a single recess
95 therein to receive an empty tobacco tube. Also, it will be noted that transition
tubes 98 in this embodiment have a tapered end to allow placement of the cigarette
tubes thereon.
[0039] In the arrangement of Figure 17, there is provided a guide wheel 100 which has a
plurality of conically shaped openings 102 formed therein. Guide wheel 100 is secured
to base 96 by means of members 104. It will be noted that there is a conical shaped
opening 102 for each transition tube 98.
[0040] In the embodiment of Figure 18, there is provided a guide tube 104 positioned at
one of the stations and being sized to fit within transition cylinder 98. As seen
in Figure 18A, guide member 104 is driven in the direction indicated by arrow 106
so as to enter a transition cylinder and pass therethrough as shown in Figure 17B.
Guide member 104 has a tapered end and when extended through transition cylinder 98,
acts as a guide for cigarette tube 94 to extend thereover and then onto transition
tube 98 as shown in Figure 17C. As the cigarette tube is placed about transition cylinder
98, guide member 104 withdraws.
[0041] At the next location, the tobacco from molds 74, 80 is pushed into tobacco tube 94
by cylinder 86. Once the cigarette tube 94 has been filled with tobacco, continued
movement of rod 86 will cause the cigarette to be discharged. The arrangement of Figure
18 can be incorporated in any of the previous embodiments with the elimination of
the turret.
[0042] It will be understood that the drive systems utilized in the present invention may
be any suitable including pneumatic, electric, hydraulic, or combinations thereof.
1. A method of filling a cigarette tube with pre-cut tobacco, the method comprising the
steps of:
a. providing a transition tube (98) having a cylindrical configuration with an external
diameter less than the internal diameter of a cigarette tube (94);
b. inserting a guide tube (104) within said transition tube (98) to extend through
the free end of the transition tube (98);
c. placing an open end of said cigarette tube (94) over said guide tube (104) and
over said transition tube (98), withdrawing said guide tube (104); and
d. pushing a pre formed plug (79) of tobacco into said transition tube (98).
2. Method of claim 1, wherein said guide tube (104) is withdrawn while it is continued
to place said cigarette tube (94) on said transition tube (98).
3. Method of claim 1 or 2, further comprising the step of continuing to push until said
cigarette tube (94) is discharged from said transition tube (98) with said precut
tobacco therein.
4. Method of any of claims 1 to 3, wherein the guide tube (104), when being extended
through the transition tube (98), acts as a guide for the cigarette tube (94) to extend
thereover and then onto the transition tube (98).
5. Method of claim 3, wherein at a next location of the apparatus, the tobacco from molds
(74, 80) is pushed into the cigarette tube (94) by the cylinder (86).
6. Method of claim 3, wherein once the cigarette tube (94) has been filled with tobacco,
continued movement of the cylinder (86) will cause the cigarette to be discharged.
7. An apparatus for filling a cigarette tube (94) with pre-cut tobacco, comprising:
a transition tube (98) having a cylindrical configuration with an external diameter
less than the internal diameter of a cigarette tube (94);
a guide tube (104) for inserting within said transition tube (98) to extend through
the free end of the transition tube (98), for placing an open end of said cigarette
tube (94) over said guide tube (104) and then onto said transition tube (98); and
a cylinder (86) for pushing a pre formed plug (79) of tobacco into said transition
tube (98).
8. Apparatus of claim 7, wherein said guide tube (104) is further configured for withdrawing
said guide tube (104), when the cigarette tube (94) is placed about said transition
tube (98).
9. Apparatus of claim 7 or 8, wherein the cylinder (86) is further configured for continuing
to push until said cigarette tube (94) is discharged from said transition tube (98)
with said pre-cut tobacco therein.
10. Apparatus of any of claims 7 to 9, wherein the guide tube (104) is positioned at one
station of the apparatus.
11. Apparatus of any of claims 7 to 10, wherein the guide tube (104) is sized to fit within
the transition tube (98).
12. Apparatus of any of claims 7 to 11, wherein the guide tube (104) has a tapered end.
13. Apparatus of any of claims 7 to 12, wherein the guide tube (104) is configured, when
being extended through the transition tube (98), to act as a guide for the cigarette
tube (94) to extend thereover and then onto the transition tube (98).
14. Apparatus of any of claims 7 to 13, wherein the cylinder (86) is configured to push
the pre formed plug (79) of tobacco into the cigarette tube (94) at a next location
of the apparatus.
15. Apparatus of any of claims 7 to 14, wherein the cylinder (86) is configured for a
continued movement once the cigarette tube (94) has been filled with tobacco, in order
to cause the cigarette to be discharged.