HIGH SPEED OBJECT INSERTER AND RELATED METHODS

Abstract

An apparatus for inserting one or more objects into a filter component of a tobacco rod. The apparatus includes: a storage apparatus that stores a plurality of the objects; an inserter wheel that inserts the objects into a band of filter material; and an acceleration chamber that transfers the objects from the storage apparatus to the inserter wheel. The acceleration chamber includes: a vortex chamber defining a periphery and an opening in the periphery; a source of air that accelerates the objects around the periphery of the vortex chamber; and a metering drum that rotates around the vortex chamber, the metering drum having metering holes movable into alignment with the opening in the periphery of the vortex chamber. The metering holes receive the objects through the opening in the periphery of the vortex chamber, and transfer the objects to the inserter wheel.

Description

CROSS-REFERENCE To RELATED APPLICATIONS

This patent application claims priority under 35 U.S.C. Section 119 of U.S. Provisional Application No. 61/607,296, filed Mar. 6, 2012. This patent application is also a continuation-in-part of Applicant's co-pending U.S. application Ser. No. 13/071,945, filed on Mar. 25, 2011, and U.S. application Ser. No. 13/232,150, filed on Sep. 14, 2011. The entire content of each of the foregoing applications is incorporated herein by reference in its entirety.

TECHNICAL FIELD

This patent application relates generally to apparatuses and methods for manufacturing tobacco products. More specifically, this patent application relates to apparatuses and methods for inserting objects, such as capsules or pellets, into the filter component of tobacco products.

BACKGROUND

International Publication No. WO 2010/107756, which is incorporated herein by reference in its entirety, describes an apparatus and associated method for forming a rod for use in the manufacture of cigarette filter elements. A continuous supply of a filter material is formed into a continuous filter rod by a rod-forming unit. An object insertion unit is configured to insert a plurality of first objects and a plurality of second objects into the continuous filter rod. A rod-dividing unit is configured to subdivide the continuous filter rod, at predetermined intervals along the longitudinal axis thereof, into a plurality of filter rod portions such that each filter rod portion includes at least one first object and at least one second object disposed therein, with the first objects being different from the second objects.

International Publication No. WO 2010/055120, which is also incorporated herein by reference in its entirety, describes an apparatus for introducing objects into a smoking article comprising a reservoir for providing a plurality of objects to be introduced into the smoking article, a rotatable wheel for delivering the objects to the location where the objects are to be introduced into the smoking article, a acceleration chamber for transferring the objects to the rotatable wheel, the acceleration chamber being arranged between the reservoir and the rotatable wheel and being designed such that the objects are aligned into a single vertically arranged layer therein, and means for moving the objects from the single layer in the acceleration chamber in a direction toward or along the peripheral surface of the rotatable wheel.

Due to the structure and function of these and other apparatuses known in the prior art, they are typically capable of operating at less than desired rod speeds, for example, at maximum rod speeds of approximately 85 meters per minute.

SUMMARY OF THE INVENTION

According to an embodiment, an apparatus for inserting one or more objects into a filter component of a tobacco rod comprises: a storage apparatus that stores a plurality of the objects; an inserter wheel that inserts the objects into a band of filter material; and an acceleration chamber that transfers the objects from the storage apparatus to the inserter wheel, wherein the acceleration chamber includes: a vortex chamber defining a periphery and an opening in the periphery; a source of air that accelerates the objects around the periphery of the vortex chamber; and a metering drum that rotates around the vortex chamber, the metering drum having metering holes movable into alignment with the opening in the periphery of the vortex chamber. The metering holes receive the objects through the opening in the periphery of the vortex chamber, and transfer the objects to the inserter wheel.

According to another embodiment, an apparatus for inserting one or more objects into a filter component of a tobacco rod comprises: a storage apparatus that stores a plurality of the objects; an inserter wheel that inserts the objects into a band of filter material; a tow guide located upstream of the inserter wheel, wherein the band of filter material passes through the tow guide; and a plow located at least partially within the tow guide, the plow defining a downstream end proximate to the inserter wheel, and an upstream end opposite to the downstream end. The plow is tapered from a first cross-section at the upstream end to a second cross-section at the downstream end, and the first cross-section is larger than the second cross-section.

According to another embodiment, an apparatus for inserting one or more objects into a filter component of a tobacco rod comprises: a storage apparatus that stores a plurality of the objects; an inserter wheel that inserts the objects into a band of filter material, the inserter wheel defining an outer periphery with a plurality of pockets distributed evenly around the outer periphery, each pocket adapted to support one of the objects; a drive motor adapted to rotate the inserter wheel; and a controller that controls rotation of the drive motor. The controller is adapted to vary the speed of rotation of the inserter wheel to insert the objects into the filter material at asymmetrical and/or symmetrical distances from one another.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing aspects and other features and advantages of the invention will be apparent from the following drawings, wherein like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements.

FIG. 1 is a front view of an object inserter according a first embodiment;

FIG. 2 is a three-dimensional view of an inserter wheel, pitch wheels, metering wheels, and other components of the object inserter of FIG. 1;

FIG. 3 is an enlarged view of a portion of FIG. 2;

FIG. 4 is a side, schematic representation of a portion of the inserter wheel of FIG. 1, showing an object supported by a pocket in the inserter wheel;

FIG. 5 is a front, perspective view of a portion of an inserter wheel and a tongue of FIG. 1;

FIG. 6 is another front, perspective view of a portion of an inserter wheel and a tongue of FIG. 1;

FIG. 7 is a three-dimensional view of an object inserter according to a second embodiment;

FIG. 8 is a three-dimensional view of an inserter wheel, acceleration chambers, and other components of the object inserter of FIG. 7;

FIG. 9 is an enlarged view of a portion of FIG. 8;

FIG. 10 is a side, perspective view of a third embodiment on an object inserter, which is a dual-filter-rod embodiment of the object inserter of FIG. 7;

FIG. 11 is a perspective view of an object inserter according to a fourth embodiment;

FIG. 12 is a front view of the object inserter of FIG. 11;

FIG. 13 depicts an embodiment of the acceleration chamber of FIG. 11, shown in various states of disassembly;

FIG. 13A is a detail view of the guide rings of FIG. 13;

FIGS. 14 and 15 are transverse cross-sectional views of the acceleration chamber of FIG. 11;

FIG. 16 is a perspective view of the acceleration chamber of FIG. 11, shown partially disassembled;

FIG. 17 is a partial, transverse cross-sectional view of an alternative embodiment of FIGS. 14 and 15;

FIG. 18 is a perspective view of an object inserter according to a fifth embodiment;

FIG. 19 is a side, close-up view of a portion of the hopper of FIG. 18;

FIGS. 20 and 21 are perspective views of a gathering roller and plow for shaping the tow band upstream of the object inserter of FIG. 18;

FIG. 22 is a front view of the object inserter of FIG. 18, shown with the insertion wheel in a raised position with respect to the tow band;

FIG. 23A depicts a top view of a portion of an inserter wheel, depicting an embodiment of an inserter wheel pocket; and

FIG. 23B depicts a cross-sectional view of a portion of the inserter wheel of FIG. 23A.

DETAILED DESCRIPTION

Embodiments of the invention are discussed in detail below. In describing embodiments, specific terminology is employed for the sake of clarity. However, the invention is not intended to be limited to the specific terminology so selected. A person skilled in the relevant art will recognize that other equivalent parts can be employed and other methods developed without departing from the spirit and scope of the invention. All references cited herein are incorporated by reference as if each had been individually incorporated.

The present invention relates to apparatuses and methods that can be used to insert objects into a smoking article, such as the apparatuses described in International Publication Nos. WO 2010/107756 A1 and WO 2010/055120 A1, the entire contents of which are incorporated herein by reference. The apparatuses and methods of the present invention can be used to insert objects into a component of a smoking article, such as the filter material. By way of example, the objects can be beads, capsules, or pellets, however, other types of objects are also possible. The objects may be used, for example, to enhance the sensory attributes of cigarette smoke. In particular, the objects can be used as vehicles for adding flavor or other substances to the mainstream smoke. Exemplary types of filter material that can be used with the present invention include cellulose acetate tow, gathered cellulose acetate web, polypropylene tow, gathered paper, strands of reconstituted tobacco, and the like.

Referring to FIG. 1, an exemplary object inserter 10 is shown. According to an embodiment, object inserter 10 can be located upstream (to the right in FIG. 1) of a conventional rod-forming unit (not shown). Filter material can be processed using a filter material processing unit 12 (e.g., a transport jet) and passed through the rod-forming unit to form a continuous rod. The object inserter 10 may be associated with the filter material processing unit 12 and/or with the rod-forming unit to insert one or more objects within the continuous length of filter material or the continuous filter rod. The continuous filter rod can then be subdivided using a rod cutting assembly (not shown) into a plurality of rod portions each having at least one object located therein. The rod portions can be collected for further processing in a collection device, for example, a tray, a rotary collection drum, a conveying system, or the like. According to an embodiment, the rod portions can then be transported directly to a cigarette making machine. Various aspects of the object inserter 10 described herein allow operation at higher speeds than prior art object inserters.

Still referring to FIG. 1, the filter material processing unit 12 can meter a continuous band of the filter material (e.g., filter tow) from a pair of delivery rollers 14a, 14b to a gathering roller 16 associated with the object inserter 10. According to an embodiment, the gathering roller 16 can define a circumferential profile that pre-folds the band of filter material to better facilitate object insertion. For example, the gathering roller 16 can define a substantially C-shaped, U-shaped, or V-shaped circumferential profile that bends or folds the filter material as it passes over the gathering roller 16, however, other configurations are possible.

The gathering roller 16 can feed the filter material to a tow guide 18, and then to a downstream tongue 20, as best seen in FIGS. 2, 5, and 6. After exiting the tongue 20, the filter material passes through the remainder of the rod-forming unit (not shown). Further details of the tow guide 18 and tongue 20 are discussed in detail below.

Still referring to FIG. 1, the object inserter 10 can include a storage apparatus 22, such as one or more hoppers, that stores a plurality of the objects to be inserted into the filter material. According to an embodiment, the objects can be substantially spherical in shape, and may be referred to as capsules, however, other shapes and configurations are possible. For ease of discussion, the objects will be referred to generally as “capsules” herein.

According to an embodiment, the storage apparatus 22 can feed the capsules to one or more feed chambers 24, 26, which in turn feed the capsules to first and second metering wheels 28, 30. According to an embodiment, the feed chamber 24 and/or the feed chamber 26 comprises a “single plane” feed chamber that feeds only a single plane of capsules to the periphery of the respective metering wheels 28, 30. For example, the capsules passing through the “single plane” feed chamber can be confined to an arrangement that is multiple capsules high, and multiple capsules deep, but only a single capsule wide. According to an alternative embodiment, not shown, the storage apparatus 22 can feed the capsules to one feed chamber, instead of two as shown, and the feed chamber can in turn feed the capsules to a single, or multiple, metering wheels. The storage apparatus 22 and/or the feed chambers 24, 26 can include vibrators or similar devices to assist in moving the capsules from the storage apparatus 22 to the metering wheels 28, 30.

Referring to FIGS. 2 and 3, the metering wheels 28, 30 are shown in more detail. The metering wheels 28, 30 each define an outer periphery 28a, 30a, a portion of which is located in registry with the lower exit ports 24a, 26a of the feed chambers 24, 26, respectively. See FIG. 2. The outer peripheries 28a, 30a can each define a set of metering wheel pockets 32, 34, which are distributed equidistantly about the respective outer peripheries 28a, 30a. The metering wheel pockets 32, 34 are adapted to receive the capsules from the lower exit ports 24a, 26a of the feed chambers 24, 26, and to transport the capsules at least partially within the metering wheels 28, 30.

According to an embodiment, the metering wheel pockets 32, 34 can be substantially cylindrical in shape, and can define a diameter and depth sufficient to receive all or a portion of the respective capsules. In the case of a cylindrical shape, the pockets can have a depth and diameter that are the same or slightly larger than the diameter of the respective capsules, in order to ensure precise positioning of the capsules within the pockets. According to alternative embodiments, the metering wheel pockets 32, 34 can be square, rectangular, conical, or other shapes known in the art, provided the pockets can securely and precisely receive and transport all or a portion of the respective capsules. A source of vacuum (not shown) can be applied to the pockets 32, 34 to aid in transfer of the capsules from the feed chambers 24, 26, and/or to aid in retention of the capsules within the pockets 32, 34 once there.

Still referring to FIGS. 2 and 3, the apparatus 10 can include intermediate wheels 36, 38 that receive capsules transferred from the metering wheels 28, 30. Referring to FIG. 3, the intermediate wheels 36, 38 can each define an outer periphery 36a, 38a, which can each define a set of intermediate wheel pockets 40, 42 distributed equidistantly about the respective outer peripheries 36a, 38a. The intermediate wheel pockets 40, 42 are adapted to receive the capsules from the metering wheels 28, 30, and to transport the capsules at least partially within the intermediate wheels 36, 38. The intermediate wheel pockets 40, 42 can be substantially the same as the metering wheel pockets 32, 34 described above, and won't be described in further detail herein. A source of vacuum (not shown) can be applied to the intermediate wheel pockets 40, 42 to aid in transfer of the capsules from the metering wheel pockets 32, 34 to the intermediate wheel pockets 40, 42, and/or to aid in retention of the capsules within the intermediate wheel pockets 40, 42 once there.

Referring to FIG. 3, a first metering guide 44 can be located between the first metering wheel 28 and the first intermediate wheel 36. Similarly, a second metering guide 46 can be located between the second metering wheel 30 and the second intermediate wheel 42. The metering guides 44, 46 can aid in the transfer of capsules between the metering wheel pockets 32, 34 and the intermediate wheel pockets 40, 42, respectively. For example, the first metering guide 44 can cover or block a portion of the first intermediate wheel pockets 32 as well as a portion of the first metering wheel pockets 40 until the time, or shortly before, a metering wheel pocket 32 comes into registry with a respective intermediate wheel pocket 40. The second metering guide 46 can have a similar arrangement.

For the metering wheel pockets that are covered by the metering guides 44, 46, the source of vacuum that is normally applied to the metering wheel pockets 32, 34 can be turned off and/or substituted with a jet of air directed out of the covered metering wheel pockets 32, 34. Once one of the metering wheel pockets 32, 34 rotates past the metering guide 44, 46, and is no longer blocked thereby, the jet of air may propel the capsule out of that metering wheel pocket and into the intermediate wheel pocket 40, 42 that is in registry therewith at that point in time. As a result, the metering guides 44, 46 can allow the jet of air that blasts the capsules out of the pockets to be applied earlier than if there were no metering guides 44, 46, without the risk of prematurely ejecting the capsules from the metering wheel pockets 32, 34. Accordingly, the speed and consistency at which capsules are transferred from the metering wheel pockets 32, 34 to the intermediate wheel pockets 40, 42 can be improved.

Still referring to FIGS. 2 and 3, the apparatus 10 can include an inserter wheel 50 that receives capsules from the intermediate wheels 36, 38 and inserts them into the band of filter material, for example, as it passes through the tongue 20 of the rod-forming unit. The inserter wheel 50 can define an outer periphery 50a having a plurality of inserter wheel pockets 52 distributed symmetrically or asymmetrically about the outer periphery 50a. The inserter wheel pockets 52 at least partially receive the capsules and support them on the inserter wheel 50, as will be described in more detail below. A source of vacuum (not shown) can be applied to the inserter wheel pockets 52 to aid in transfer of the capsules from the intermediate wheel pockets 40, 42 to the inserter wheel pockets 52, and/or to aid in retention of the capsules within the intermediate wheel pockets 52 once there.

The arrangement of the metering wheels 28, 30, intermediate wheels 36, 38, and inserter wheel 50 described above can help facilitate faster operation of the object inserter 10. For example, the metering wheels 28, 30 can operate at a relatively low speed (e.g., measured at the outer peripheries 28a, 30a) to ensure consistent transfer of the capsules from the feed chambers 24, 26 to the respective metering wheel pockets 32, 34. Simultaneously, the inserter wheel 50 can insert the capsules into the filter material at a high delivery speed, for a fast production rate.

According to an embodiment, a pitch increase and speed increase can occur upon transfer from the metering wheels 28, 30 to the intermediate wheels 36, 38. For example, according to an embodiment, the first and second intermediate wheels 36, 38 can rotate faster than the respective metering wheels 28, 30. Additionally or alternatively, the intermediate wheel pockets 40, 42 can be arranged at a greater pitch than the metering wheel pockets 32, 34.

According to an embodiment, faster speeds can be provided by alternately transferring capsules from the first and second intermediate wheel pockets 40, 42 to the inserter wheel pockets 52. For example, an intermediate wheel pocket 40 in the first intermediate wheel 36 can transfer a capsule to an inserter wheel pocket 52, and subsequently an intermediate wheel pocket 42 in the second intermediate wheel 38 can transfer a capsule to the immediate next inserter wheel pocket 52, and so on. A pitch increase and/or a speed increase can also occur upon transfer from the intermediate wheels 36, 38 to the inserter wheel 50. According to an embodiment, the first intermediate wheel 36, second intermediate wheel 38, and inserter wheel 50 can rotate at substantially the same speed, although other configurations are possible. For example, the inserter wheel 50 could alternatively rotate faster or slower than the first and second intermediate wheels 36, 38.

The following table lists exemplary parameters for operation of an object inserter 10:

TABLE A
	Holes/	Wheel	Operating
Wheel Set	Wheel	Dia. (mm)	RPM	Surface speed
Metering	30 each	137.5	133⅓	57.6 M/min
Wheels
Intermediate	10 each	95	400	119.38 M/min
Wheels
Inserter	20	190	400	238.76 M/min
Wheels

When used to form 108 mm filter rods having four capsules per filter, an embodiment of object inserter 10 using the above parameters resulted in a machine speed of approximately 216 meters of filter material per minute, for an output of 2,000 filters per minute (8,000 capsules per minute). One of ordinary skill in the art will recognize from this description that other parameters than those described above can be used.

Although the embodiment shown in FIGS. 1-3 has two metering wheels 28, 30 and two intermediate wheels 36, 38, one of ordinary skill in the art will appreciate based on this description that alternative embodiments may employ a single metering wheel and/or a single intermediate wheel. Likewise, one of ordinary skill in the art will appreciate based on this description that alternative embodiments may have more than two metering wheels and/or more than two intermediate wheels. Furthermore, while the embodiment shown in FIGS. 1-3 includes two feed chambers 24, 26, one of ordinary skill in the art will understand based on this description that a single feed chamber, or more than two feed chambers, may be used.

Referring to FIG. 4, a portion of an inserter wheel 50 having an inserter wheel pocket 52 is shown in detail. The object inserter 10 can be designed to operate with a capsule C having a predetermined shape and volume. For ease of description, the invention will be described in connection with a spherical capsule C, however, as mentioned previously, other shapes and sizes of capsules are possible.

In order to facilitate accurate placement of the capsule C in the filter material, the inserter wheel pocket 52 can support the capsule C such that a portion C1 of the capsule C, for example, between about one quarter and about one half of the capsule's volume, resides inside the pocket 52, with the remainder C2 of the capsule C protruding from the pocket 52 above the outer periphery 50a of the inserter wheel 50. As a result, the inserter wheel 50 can manually insert the capsule to substantially its desired position within the filter material, without having to rely on forced air to “shoot” the capsule C out of a deep pocket and to its desired position, resulting in higher control and accuracy in placing the capsule C, and/or allowing for higher operating speeds.

As shown in FIG. 4, for cylindrical capsules C, the inserter wheel pocket 52 can be shaped as a portion of a sphere, however, other configurations of the pocket 52 are possible. For example, the inserter wheel pocket can comprise a plurality of discreet surfaces that contact and support different points on the surface of the capsule C (e.g., a cylindrical pocket may be dimensioned to receive and support a portion of a spherical capsule C). According to an embodiment, the inserter wheel pockets 52 are configured to receive and support approximately one third of the total volume of the capsule C, with the remainder of each capsule's volume protruding from the inserter wheel pocket 52 and above the outer periphery 50a of the inserter wheel. For additional details relating to the inserter wheel pockets, see FIGS. 23A and 23B, and the corresponding description.

Referring to FIGS. 5 and 6, an embodiment is shown where the inserter wheel 50 inserts the capsules C directly into the tongue 20 of the rod forming unit. As shown, the tongue 20 can comprise a substantially conical shaped wall that compresses the band of filter material as it is drawn through the tongue 20, causing the filter material to take on a cylindrical shape. A slot 60 can extend through the conical wall along the direction of movement of the filter material, and a portion of the inserter wheel 50 can extend through the slot 60 into the interior of the tongue 20. As a result of this configuration, the inserter wheel 50 can deposit the capsule C directly into the filter material as it is being compressed by the tongue 20. By inserting the capsule C into the filter material as close to the rod formation point as reasonably possible, the capsule C may retain its desired position within the filter material.

Still referring to FIGS. 5 and 6, the inserter wheel pocket 52 can remain in contact and provide positive support to the capsule C until the capsule C is nearly or completely moved to the desired position within the filter material. For example, referring to FIG. 6, the conical wall of the tongue 20 may define an inner diameter D at the point where the capsule C is to be inserted into the filter material, and the tongue 20 may shape the filter material to have substantially the same diameter at that point. The inserter wheel 50 and inserter wheel pocket 52 may actively support the capsule C until the inserter wheel 50 positions the capsule C at a depth Y within the tongue 20, shown in FIG. 5. According to an embodiment, the depth Y may be substantially one half of the diameter D of the tongue 20, causing the capsule C to be deposited substantially centered within the filter material, however, other configurations are possible. Once the inserter wheel 50 and inserter wheel pocket 52 have moved the capsule to its desired position within the filter material, as shown in FIGS. 5 and 6, the vacuum that is normally applied to the inserter wheel pockets can be optionally switched to a short blast of positive air pressure, for example, to speed up the release of the capsule C from the respective inserter wheel pocket 52.

According to an embodiment, the linear speed of the outer periphery 50a of the inserter wheel 50, and hence the inserter wheel pockets 52, can be greater than the linear speed of the filter material through the tongue 20. This arrangement can result in greater accuracy in placing the capsules C in the filter material.

Still referring to FIGS. 5 and 6, a tow guide 62 and rod-shaped plow 64 can be located upstream of the tongue 20. The tow guide 62 can define a substantially conical or substantially cylindrical inner space. The plow 64 can extend longitudinally within the tow guide 62 and, together with the plow 64, can pre-form or pre-fold the filter material into a substantial C-shape or U-shape prior to entering the tongue 20. As a result of the substantial C-shape or U-shape pre-forming of the filter material, the inserter wheel 50 can insert the capsule C through the opening in the C-shaped or U-shaped filter material, and into the approximate center of the folded filter material. As a consequence of this configuration, the folded filter material may more reliably hold the capsule C in its desired position within the filter material and resulting filter. According to an embodiment, the position of the plow 64 can be adjusted with respect to the tow guide 62, for example, along the longitudinal axis of the tow guide 62.

Referring to FIGS. 7-9, a second embodiment of an object inserter is shown. For purposes of this description, the object inserter 110 of FIGS. 7-9 differs from the object inserter 10 shown in FIGS. 1-6 only in the structure and function of delivering the objects (e.g., capsules) from the storage apparatus 122 to the inserter wheel 150. Accordingly, for ease of explanation, discussion of structures and functions that are the same as, or substantially similar to, the embodiment of FIGS. 1-6 will be not be repeated.

Referring to FIG. 7, the object inserter 110 can generally include first and second gravity feeders 170, 172 that feed the capsules from the storage apparatus 122 to first and second acceleration chambers 174, 176, respectively. Although not shown, shutters, valves, or other metering devices can be used to meter the flow of capsules from the storage apparatus 122 to the first and second acceleration chambers 174, 176, respectively, as will be apparent to one of ordinary skill in the art based on this description. Although the embodiment shown in FIG. 7 has two gravity feeders 170, 172 and two acceleration chambers 174, 176, one of ordinary skill in the art will appreciate based on this description that alternative embodiments may employ only a single gravity feeder and a single acceleration chamber, or alternatively, more than two gravity feeders and more than two acceleration chambers.

Referring to FIG. 8, the first and second acceleration chambers 174, 176 and inserter wheel 150 are shown in more detail. The first and second acceleration chambers 174, 176 can be adapted to accelerate the capsules C to a speed that is substantially equal to the linear speed of the periphery 150a of the inserter wheel 150, and hence the inserter wheel pockets (not shown), to facilitate reliable and consistent transfer of the capsules C to the inserter wheel pockets when operating at high speed. To further facilitate high speed delivery of the capsules C by the inserter wheel 150, the first and second acceleration chambers 174, 176 can take turns supplying a capsule C to alternating pockets 152 in the inserter wheel 150.

Referring to FIG. 8, the first and second gravity feeders 170, 172 can deliver a continuous supply of the capsules C to the interior of the first and second acceleration chambers 174, 176, respectively, through inlet ports 178, 180. Each acceleration chamber 174, 176 defines an inner peripheral surface 182, 184, shown in FIG. 9. In the embodiment of FIGS. 7-9, the inner peripheral surfaces 182, 184 are substantially circular, however other shapes are possible, for example, elliptical.

Referring to FIG. 9, the inner peripheral surfaces 182, 184 can define tracks 182a, 184a that guide the capsules C around the inner peripheral surfaces in a predetermined pattern. A plurality of air nozzles 186, 188, act on the capsules C located in the tracks 182a, 184a to accelerate the capsules C around the inner peripheral surfaces 182, 184 within the tracks 182a, 184a, respectively, until the capsules C reach a linear speed substantially equal to the linear speed of the inserter wheel pockets (not shown) on the inserter wheel 150.

Referring back to FIG. 8, each acceleration chamber 174, 176 can include an exit 190, 192 (e.g., an elongated slot through the peripheral surfaces 182, 184) located along the tracks 182a, 184a. A portion of the outer periphery 150a of the inserter wheel 150 can extend through each exit 190, 192. The tracks 182a, 184a can be configured to guide the capsules C around the inner peripheral surfaces 182, 184, under the force of the air nozzles 186, 188, until the capsules C reach the respective exit 190, 192. Upon reaching the respective exit 190, 192, the capsule C may be at the same or similar linear speed as the outer periphery 150a of the inserter wheel 150, and will transition into an inserter wheel pocket (not shown) on the inserter wheel 150. Vacuum force applied to the inserter wheel pocket may assist with the transfer and retention of the capsule C into the inserter wheel pocket. In addition, according to an embodiment, a brush (not shown) may be located inside each acceleration chamber 174, 176 at the trailing edge 190a, 192a of each exit 190, 192 to aid in transfer of the capsules C to the inserter wheel pockets. In addition, air nozzles 194, 196 may direct an air curtain at each exit 190, 192, respectively, to protect the respective exit 190, 192, and/or to blow away extra capsules C that may erroneously pass through the exit 190, 192.

Referring to FIG. 10, a third embodiment of an object inserter is shown. For purposes of this description, the object inserter 210 of FIG. 10 differs from the object inserter 110 shown in FIGS. 7-9 primarily in that it includes two or more substantially parallel inserter wheels 250a, 250b and related feed components mounted to a common base. The arrangement of substantially parallel inserter wheels 250a, 250b allows capsules to be inserted into two or more substantially parallel bands of filter material, however non-parallel embodiments are also possible. For ease of explanation, discussion of structures and functions that are the same as, or substantially similar to, the embodiment of FIGS. 1-9 will be not be repeated. In addition, while the concept of an integrated object inserter for inserting capsules into two or more substantially parallel bands of filter material is described herein with respect to the embodiment of FIGS. 7-9, the same multi-line feature can be applied to all embodiments of an object inserter described herein.

As mentioned above, the object inserter 210 of FIG. 10 can include two substantially parallel inserter wheels 250a, 250b, each of which may have the same or similar configuration as the inserter wheels described in connection with FIGS. 1-9. For example, each inserter wheel 250a, 250b can include inserter wheel pockets 252a, 252b adapted to support a capsule C such that a portion of the capsule C, for example, between about one quarter and about one half of the capsule's volume, resides inside the pocket 252a, 252b, with the remainder of the capsule C protruding from the pocket 252a, 252b above the outer periphery of the respective inserter wheel 250a, 250b, as previously described herein. According to an embodiment, the inserter wheel pockets 252a, 252b can be configured to receive and support approximately one third of the total volume of the capsule C, with the remainder of each capsule's volume protruding from the inserter wheel pocket 252a, 252b and above the outer periphery of the respective inserter wheel 250a, 250b.

The inserter wheels 250a, 250b can insert the capsules C into substantially parallel bands of filter material, for example, that are transported through substantially parallel tongues 220a, 220b. The tongues 220a, 220b can have the same or similar configurations as the tongue 20 previously described and shown, for example, in FIGS. 1, 2, 5, and 6.

As shown in FIG. 10, each inserter wheel 250a, 250b can be fed capsules from one or more acceleration chambers. For example, an upper acceleration chamber 276a and a lower acceleration chamber 274a can feed inserter wheel 250a, and an upper acceleration chamber 276b and a lower acceleration chamber 274b (hidden from view) can feed the inserter wheel 250b, as shown and described in connection with FIGS. 7-9. According to an alternative embodiment, not specifically shown, the inserter wheels 250a, 250b can be fed capsules from substantially parallel arrangements of metering wheel 28, metering wheel 30, intermediate wheel 36, and intermediate wheel 38, for example, as shown and described in connection with FIGS. 1-3.

A single hopper (not shown) can supply capsules to all of the substantially parallel inserter wheels 250a, 250b. Alternatively, a separate hopper (not shown) can supply capsules to each of the inserter wheels 250a, 250b, or to a subset of the inserter wheels. The object inserter 210 is not limited to two substantially parallel arrangements of inserter wheels 250a, 250b, as shown in FIG. 10, but alternatively, can have as many substantially parallel configurations as desired, for example, to meet output needs.

The structures and operations discussed above can be utilized in methods to insert one or more objects into a filter component of a tobacco rod, as will be appreciated by one of ordinary skill in the art based on this description. The structures and operations can be utilized to insert the objects into a single band of filter material, or alternatively, into multiple, substantially parallel bands. As mentioned previously, the structures and operations described herein can result in a significant increase in speed and reliability as compared to prior art apparatuses and methods. For example, the apparatus shown in FIGS. 1-6 has been operated with the parameters listed in Table A, above, to form a single line of 108 mm filter rods having four capsules per filter, at a rate of approximately 216 meters of filter material per minute per line (output of 2,000 filters per minute), and with high consistency and reliability. This output speed is dramatically faster than what is possible with prior art machines, which have typically been limited to speeds of approximately 80 meters per minute to reliably produce similar filter rods. One of ordinary skill in the art will appreciate from this description that the parameters listed in Table A can be varied to provide similar high output speeds to prepare filter rods having different configurations.

FIGS. 11-15 depict a fifth embodiment of an object inserter. For purposes of this description, the object inserter 310 of FIGS. 11-15 differs from the object inserter 210 shown in FIGS. 7-9 primarily in the structure and function of the first and second acceleration chambers 374, 376 and the way they provide capsules to the inserter wheel 350. For ease of explanation, discussion of structures and functions that are the same as, or substantially similar to, the embodiment of FIGS. 7-9 will be not be repeated.

FIG. 13 depicts the first acceleration chamber 374 in various stages of disassembly. The second acceleration chamber 376 can have the same or substantially similar structure to that of the first acceleration chamber 374. The acceleration chamber 374 can include a combination of rotating and non-rotating parts. For example, the acceleration chamber 374 can include a base 301 that is mounted on the object inserter 310 in a stationary manner, for example, fixed to the back plate 303 (see FIGS. 11 and 12) of the object inserter 310. Outer and inner guide rings 305a, 305b can be mounted on the base plate 303 in a stationary manner, for example, by using screws or other fasteners. A cover plate 307 can be secured to the outer guide ring 305a, for example, using screws or other fasteners, to form a substantially enclosed vortex chamber, which is described in more detail in connection with FIG. 14. Still referring to FIG. 13, the acceleration chamber 374 can also include a metering drum 309 that rotates with respect to the aforementioned stationary components (e.g., under the power of a drive motor, to be described later), to deliver capsules to the inserter wheel 350. FIG. 13A is a detailed view of an embodiment of the guide rings 305a, 305b, and will be described in more detail later.

FIG. 14 is a transverse cross-sectional view of the acceleration chamber 374, showing the non-rotating components. FIG. 15 is a transverse cross-sectional view of the acceleration chamber 374 depicting both the non-rotating and rotating components. Referring to FIG. 14, the base 301, guide rings 305a, 305b, and cover plate 307 can define a vortex chamber 311 around which the capsules rotate, for example, under the force of propelled air supplied from chamber 313 through port holes 315. According to an embodiment, the propelled air rotates the capsules within the vortex chamber 311 at between about 150 and about 300 meters per minute, more specifically, at about 230 meters per minute, however, other rates are possible.

For a substantial portion of the vortex chamber's circumference (e.g., about 250° to about 300°, or about 270°), the capsules can be trapped in the vortex chamber 311 by a shield 317 covering the space between the guide rings 305a, 305b. However, as shown at the top of FIG. 14, a transfer region 319 of the vortex chamber 311 can be uncovered by the shield, thereby allowing the capsules to escape from the vortex chamber 311 between the guide rings 305a, 305b. According to embodiments, the transfer region 319 can extend around about 60° to about 110° of the vortex chamber's circumference, or more specifically, about 90° of the vortex chamber's circumference.

FIG. 15 is similar to FIG. 14, except it adds the rotating metering drum 309. The metering drum 309 can rotate under the power of a drive mechanism 321, such as a drive motor having an output shaft coupled to a hub mechanism 323 connected to the metering drum 309, however, other drive structures are possible.

Still referring to FIG. 15, capsules that escape from the vortex chamber 311 via the transfer region 319 are displaced into metering wheel pockets 325 (e.g., holes) in the rotating metering drum 309 (see also FIG. 16). Prior to transfer to the inserter wheel 350, the capsules are held in the metering wheel pockets 325 by a guide 327 (shown in FIGS. 12 and 15) that covers the metering wheel pockets 325 up until, or shortly before, transfer of the capsules to the pockets in the inserter wheel 350. The outer and inner guide rings 305a, 305b can include chamfered surfaces 331a, 331b. According to embodiments, the chamfered surfaces can be inclined by between about 30° and about 60° with respect to horizontal, for example, by approximately 45 degrees. The chamfered surfaces 331a, 331b can help direct the capsules into alignment with the metering wheel pockets 325.

Referring back to FIG. 12, the acceleration chambers 374, 376 and particularly, the metering drums 309, are shown in position relative to the inserter wheel 350. According to an embodiment, the metering drums 309 can rotate at about one half of the speed of the inserter wheel 350. At or about transfer point T, the capsules held in the metering drums 309 by guides 327 are transferred to the inserter wheel pockets 352. The inserter wheel 350, inserter wheel pockets 352, and related structures and functions can be the same as, or similar to, those described in connection with prior embodiments. The inserter wheel 350 and/or acceleration chambers 374, 376 can be mounted to the object inserter using quick release mechanisms, such as levers, thumb screws, or cams. The quick release mechanisms can allow the wheels to be released and subsequently rotated and/or slid axially, in order to facilitate alignment and/or registration of the acceleration chambers 374, 376 with the inserter wheel 350.

Still referring to FIG. 12, capsules can be supplied to the acceleration chambers 274, 276 from the storage chamber 322 using a combined airlock and metering unit and feed tubes 370, 372. According to an embodiment, the feed tubes 307, 372 can deliver the capsules into the acceleration chambers 274, 276 through openings 355, shown in FIG. 16. Openings 355 can include a chamfer that directs the capsules into the vortex chamber 311 at or about the same trajectory as the air stream flowing through the chamber. According to an embodiment, a sensor can be located in the vortex chamber 309 that detects the amount of capsules in the chamber, and controls the storage chamber 322 to supply capsules to the vortex chamber 309 when the level detected by the sensor drops below a predetermined level.

FIG. 16 depicts the metering drum 309 removed from the acceleration chamber 374, revealing the output shaft 329 of the drive mechanism 321 and the hub mechanism 323 connected to the metering drum 309.

Referring back to FIG. 13A, embodiments of the guide rings 305a, 305b can include a chicane region. As explained above, the guide rings 305a, 305b guide the capsules into the metering wheel pockets 325. Once a capsule in one of the metering wheel pockets 325 is delivered to the inserter wheel 350, a capsule in the vortex chamber 311 can subsequently enter the now vacant pocket 325. The chicane region 333 may prevent this from happening unintentionally.

The opening between the guide rings 305a, 305b can be out of alignment with the metering wheel pockets 325 in the metering drum 309. However, the chicane region 333, which may substantially coincide with the transfer region 319, can deflect the capsules laterally into alignment with the metering wheel pockets 325. This arrangement can prevent a capsule from entering a metering wheel pocket 325 at substantially the same time the previous capsule is transferred to the inserter wheel 350, and subsequently feeding that second capsule to the inserter wheel 350. This can deter unintentional misfeeding of an additional capsule to the inserter wheel 350.

Still referring to FIG. 13A, one or more jets of air 351 can be ejected from the guide ring(s)in the vicinity of the chicane 333, with the air being blown perpendicular to the rings' circumference. The jets of air can help redirect the capsule from movement that is generally tangential to the periphery of the metering drum 309, to movement that is generally perpendicular to the periphery, thereby facilitating faster transfer to the inserter wheel 350.

Referring again to FIG. 15, the guide 327 can define a ramped region upstream from the transfer point T (see FIG. 12). For example, in an embodiment, the distance between the outer perimeter of the metering drum 309 and the inner perimeter of the guide 327 can normally be approximately about 0.2 mm. However, for a distance of approximately 15 mm to 20 mm upstream from the transfer point T, the guide can have a ramped surface 353 (e.g., have an increase in inner diameter) to increase the distance from the outer perimeter of the metering drum 309, e.g., to up to 3 mm. As a result, a capsule in the metering drum 309 can ride along the ramped surface 353 and gradually rise up out of the metering wheel pocket 325 as it approaches the transfer point T, thereby ensuring a smooth and gradual transition of the capsule from the metering drum 309 to the inserter wheel pocket 352.

Referring to FIG. 17, an alternative embodiment of the guide 327 is shown, where the guide 327 has all or a portion of the guide 327 has a width that is slightly smaller than the diameter of the metering wheel pocket 325. For example, for a machine running 3.5 mm capsules, the metering wheel pockets 325 can have a diameter of approximately 4 mm, and the guide 327 can have a width of approximately 3 mm. The clearance between the lateral sides of the guide 327 and the outer perimeter of the metering wheel pockets 325 can allow air to pass between the metering drum 309 and the guide 327, which in operation, may be in close vertical proximity to one another (e.g., separated by a gap of approximately 0.2 mm). Allowing air to pass between the metering wheel pockets 325 and the sides of the guide 327 can prevent the capsules from floating in the holes 327 and/or from bursting under the air pressure applied to them by the air in vortex chamber 311. According to embodiments, all or a portion of the guide 327 can have an overall width that is about 0.5 mm to about 2.0 mm less than the width of the corresponding metering wheel pocket 325.

FIGS. 18-20 depict an object inserter according to a fifth embodiment. For purposes of this description, the object inserter 410 differs from the object inserter 310 shown in FIGS. 11-17 primarily in the structure and function of the storage chamber 422 and capsule feed mechanism. Additionally, the object inserter 410 includes a single acceleration chamber 474, instead of two in the previous embodiment. For ease of explanation, discussion of structures and functions that are the same as, or substantially similar to, the embodiment of FIGS. 11-17 will be not be repeated.

Referring to FIG. 19, pressurized air in a feed tube 461 pushes capsules from a capsule hopper 463 to the acceleration chamber 474. Referring to FIG. 18, a bridge 465 can separate the hopper 463 into an upper compartment 463a and a lower compartment 463b. According to an embodiment, the upper compartment 463a can be dimensioned to hold between about 3 kg and about 4 kg of capsules, and the lower compartment 463b can be dimensioned to hold between about 200 grams and about 400 grams of capsules, however, other capacities are possible.

Still referring to FIG. 19, the bridge 465 can include a hole (not visible), that is slightly larger than the capsule size (e.g., between about 8 mm and 12 mm in diameter, for example, about 11.5 mm) for feeding capsules to the lower compartment 463b. The bridge 465 can serve as a choke point to control the flow rate of capsules into the lower compartment 463b, for example, to about 11,000 capsules per minute.

According to an embodiment, the bridge 465 and/or lower compartment 463b can vibrate to facilitate feeding of the capsules. For example, when the level of capsules in the lower compartment 463b measured by capsule feed sensor 467 drops below a predetermined level, the bridge 465 and/or lower compartment 463b can vibrate to feed the capsules. When the level of capsules in the acceleration chamber 474 falls below a predetermined level (e.g., as measured by the level sensor in the vortex chamber), a venturi 469 feeds the capsules through feed tube 461 to the acceleration chamber 474. For a machine running at 30 meters/minute, and delivering capsules at a rate of approximately 11,600 capsules/minute, the hopper may feed approximately 12,000 capsules/minute. One of ordinary skill in the art will appreciate that other machine speeds and capsule feed rates are possible.

According to an embodiment, the object inserter 410 may include a capsule reservoir (not shown), for example, with a capacity of 5 to 20 kilograms. The capsule reservoir can cooperate with a sensor associated with the hopper 463. When the sensor detects that additional capsules are needed in the hopper 463, a pneumatic conveyer can convey the capsules from the capsule reservoir to the hopper 463 to replenish the hopper 463.

Referring to FIGS. 20 and 21, an embodiment of the gathering roller 416 and plow 464 are shown. As discussed previously in connection with FIG. 1, the gathering roller 416 can act as a pivot point to flatten the band of filter material before it enters the tongue 420. Additionally or alternatively, the gathering roller can pre-fold the band of filter material to better facilitate object insertion. According to an embodiment, the tow band passing through the gathering roller 416 can have a diameter of approximately 30 mm.

The plow 464 can then fold the filter material in to a U-shape having an open top through which the inserter wheel 450 inserts the capsules. According to an embodiment, the plow 464 can have a tapered cross section, e.g., it can taper conically from a larger cross-section at the upstream end (proximate to the gathering roller 416) to a smaller cross-section at the downstream end (proximate the inserter wheel 450).

According to an embodiment, the downstream end can have a downstream cross-section that is substantially equal in size to the width of the outer periphery of the inserter wheel 450. For example, the upstream end of the plow 464 can have a diameter of approximately 8 mm, and the downstream tip of the plow 464 can have a diameter of approximately 5 mm, and the outer periphery of the inserter wheel 450 can also have a width of approximately mm. While the plow 464 is shown as having a circular cross-section, other cross-sections are possible, such as square or rectangular. For example, and embodiment can have an 8 mm square cross section that tapers down to the dimension of the inserter wheel.

According to an embodiment, the plow 464 can be approximately 100 mm long from the upstream end to the downstream end. As best seen in FIG. 6, the downstream end of the plow 64 can be tapered to a shape that compliments the inserter wheel 50, e.g., is generally tangential to the inserter wheel's outer periphery.

Referring back to FIGS. 20 and 21, the plow 464 can pre-fold the filter material into a U-shape or C-shape into which the inserter wheel 450 places the capsules. By tapering the plow 464 as described above, the resulting fold in the filter material can gradually decrease in size until just prior to capsule insertion, at which point the opening in the top of the folded filter material is the same size or slightly larger than the width of the inserter wheel 450. By reducing the size of the fold in the filter material, the capsule can be inserted into a fold that is the same size, or only slightly larger than the capsule itself, providing increased accuracy and stability in the placement of each capsule in the filter material.

Referring to FIG. 22, according to an embodiment, the object inserter can be adjusted from a capsule-production mode to a capsule-free (“white filter”) mode, in which capsules are not added to the filter material. According to an embodiment, the inserter wheel 450 can be raised away from the tow band (e.g., by between about 160 mm and 220 mm) to the position shown in FIG. 22. This can be done to disable capsule insertion into the filter material. The inserter wheel 450 can subsequently be lowered back into the tow band to resume capsule-production mode.

According to embodiments, raising and lowering of the inserter wheel 450 can be accomplished pneumatically, for example, using hydraulic cylinders that raise at least the inserter wheel 450 with respect to the filter material. For example, the inserter wheel 450, and optionally other components, may slide on a vertical track with respect to the rest of the object inserter 410, under the power of hydraulic cylinders. One or more buttons 471 may be used to activate the cylinders. The gathering roller 416 and plow 464 (see FIG. 20) can optionally be removed when in the “white filter” mode, for example, using thumb screws or other quick release mechanisms.

According to embodiments, raising the inserter wheel 450 to the “white filter” mode may take as little as a minute. According to embodiments, the object inserter 410 can operate at 500 to 700 meters/minute in the white filter mode, for example, 600 meters/minute. In addition, embodiments can operate at 200 to 400 meters/minute in capsule-production mode, for example, 300 meters/minute, however, faster speeds are possible.

FIG. 23A depicts a top view of a portion of the inserter wheel 450, and FIG. 23B depicts a partial cross-sectional view of a portion of the inserter wheel 450. According to an embodiment, the inserter wheel pockets 452 can define a frustoconical or frustospherical countersink 473 that receives the capsules. A fluted portion 475 can be in fluid communication with each countersink 473 to apply pressure and/or vacuum to the capsules located in the pockets 452. According to an embodiment, all or a portion of the fluted portion 475 can have a cross-shaped (e.g., four leaf clover shaped) cross-section to provide increased volume. The fluted portions 475 can rotate around a supply wheel 477 having vacuum ports 479, some of which draw vacuum, and some of which expel pressurized air. The vacuum ports 479 can cooperate with the fluted portions 475 to provide vacuum or pressure, depending on the location of the pockets in the process cycle. Referring to the cross-sectional view of FIG. 23B, embodiments of the inserter wheel 450 can be tapered from the central region toward the outer peripheral region in order to facilitate insertion of the inserter wheel 450 and the capsules supported thereon into the filter material that is folded into a U-shape.

With reference to FIG. 10, the embodiments of the object inserter shown and described in connection with FIGS. 11-23 can also be used in dual-rod or multiple-rod filter production, meaning that multiple inserter wheels can be mounted in a side-by-side manner on a common base to insert capsules into substantially parallel bands of filter material, however, non-parallel embodiments are also possible. According to the dual-rod and multi-rod embodiments, multiple acceleration chambers may be arranged in a side-by-side manner, in registration with side-by-side inserter wheels. A single capsule storage mechanism may feed all of the inserter wheels, or an individual storage mechanism may feed each inserter wheel. Furthermore, for each band of filter material, embodiments may include multiple acceleration chambers to supply capsules to each inserter wheel (see, e.g., FIGS. 11 and 12 where acceleration chambers 374, 376 feed inserter wheel 350), or a single acceleration chamber may supply capsules to each inserter wheel (see, e.g., FIG. 18 where acceleration chamber 474 supplies capsules to inserter wheel 450). Alternatively, one acceleration chamber can be used to supply capsules to multiple inserter wheels.

According to the dual-rod or multi-rod embodiments discussed above, two or more side-by-side inserter wheels can be mounted on a single drive shaft. Likewise, each set of side-by-side acceleration chambers (e.g., the metering drums) can be mounted on a single drive shaft. A single drive motor can be used to turn all of the shafts, for example, using a gear mechanism, or alternatively, separate drive motors can be used for each shaft.

According to an alternative arrangement, each wheel, whether it is an inserter wheel or the metering drum of an acceleration chamber, can be located on its own shaft and driven by its own motor. Furthermore, combinations of individual and shared motors are possible. As an example, the metering drums from two side-by-side acceleration chambers can be mounted on a single shaft and driven by a single motor, while two side-by-side inserter wheels are mounted on individual shafts and driven by separate motors, or vice versa. One of ordinary skill in the art will appreciate from this description that various combinations and subcombinations of direct and shared drive are possible, regardless of whether the object inserter is a single-rod, dual-rod, or multi-rod embodiment.

Embodiments of the object inserter described herein can be used to provide either symmetrical spacing, or asymmetrical spacing, of the capsules along the length of the filter material. According to embodiments that provide asymmetrical spacing, the inserter wheel may include a position sensor that is used in connection with a controller (e.g., a PLC) to time the position of the inserter wheel pockets with the timing of the cutter head. The cutter head is a knife located downstream from the inserter wheel that cuts the filter material, wrapped in paper, into filter rod segments. For example, according to an embodiment, a proximity or light sensor can be located on the inserter wheel in registry with a particular inserter wheel pocket to synchronize the position of the inserter wheel pockets with the timing of the downstream cutter head. Alternatively, a shaft encoder on the inserter wheel can be used to synchronize the inserter wheel pockets with the timing of the downstream cutter head.

For asymmetrical spacing of the capsules, an asymmetrical inserter wheel can be used. More specifically, the inserter wheel may have the inserter wheel pockets spaced asymmetrically about its circumference. For example, adjacent inserter wheel pockets can be spaced apart at alternating 27 mm and 28 mm intervals, however, other increments are possible. With an asymmetrical inserter wheel, the wheel, once synchronized with the cutter head, can rotate at a substantially constant speed with respect to the filter material, and insert the capsules into the filter material at the selected asymmetrical intervals.

Alternatively, electronic control with a PLC can be used to provide asymmetrical spacing of the capsules with a fixed pitch inserter wheel, for example, by varying the speed of the inserter wheel with respect to the filter material to increase and decrease the interval between capsules. Furthermore, regardless of whether using symmetrical or asymmetrical insertion of the capsules, electronic control with a programmable logic controller (PLC) can be used to insert capsules into the filter material at a greater or lesser pitch than the physical spacing between the inserter wheel pockets. For example, for an inserter wheel having a 30 mm pitch between inserter wheel pockets, electronic control can be used to over rotate the inserter wheel with respect to the filter material, to result in a capsule spacing of 25 mm. Alternatively, for the same inserter wheel, electronic control can be used to under rotate the inserter wheel with respect to the filter material, to result in a spacing of 35 mm. One of ordinary skill in the art will understand from the above description that various combinations of symmetric and asymmetric inserter wheels, as well as electronic control schemes, can be used to result in varying symmetric and asymmetric distances between capsules in the filter material.

The embodiments illustrated and discussed in this specification are intended only to teach those skilled in the art the best way known to the inventors to make and use the invention. Nothing in this specification should be considered as limiting the scope of the present invention. All examples presented are representative and non-limiting. The above-described embodiments of the invention may be modified or varied, without departing from the invention, as appreciated by those skilled in the art in light of the above teachings. It is therefore to be understood that, within the scope of the claims and their equivalents, the invention may be practiced otherwise than as specifically described.

Claims

1. An apparatus for inserting one or more objects into a filter component of a tobacco rod, the apparatus comprising:

a storage apparatus that stores a plurality of the objects;

an inserter wheel that inserts the objects into a band of filter material; and

an acceleration chamber that transfers the objects from the storage apparatus to the inserter wheel, wherein the acceleration chamber includes: a vortex chamber defining a periphery and an opening in the periphery; a source of air that accelerates the objects around the periphery of the vortex chamber; and a metering drum that rotates around the vortex chamber, the metering drum having metering holes movable into alignment with the opening in the periphery of the vortex chamber;

wherein the metering holes receive the objects through the opening in the periphery of the vortex chamber, and transfer the objects to the inserter wheel.

2. The apparatus of claim 1, further comprising:

an outer guide ring and an inner guide ring, wherein the opening in the periphery of the vortex chamber is located between the outer guide ring and the inner guide ring.

3. The apparatus of claim 2, further comprising:

a shield that covers the opening between the outer guide ring and the inner guide ring for a portion of the periphery of the vortex chamber.

4. The apparatus of claim 2, wherein at least one of the outer guide ring and the inner guide ring defines a chamfer inclined toward the metering holes in the metering drum.

5. The apparatus of claim 2, wherein the outer guide ring and the inner guide ring define a chicane in the transfer region, wherein the chicane is aligned with the metering holes in the metering drum.

6. The apparatus of claim 5, further comprising at least one air jet proximate the chicane, the at least one air jet adapted to redirect the objects toward the inserter wheel.

7. The apparatus of claim 1, further comprising a guide that extends around a portion of the metering drum and covers the metering holes, wherein the guide retains the objects in the metering holes.

8. The apparatus of claim 7, wherein the metering drum defines an outer diameter and the guide defines an inner diameter located at a distance from the outer diameter of the metering drum, wherein the guide includes a ramped portion having an increased inner diameter that increases the distance between the outer diameter of the metering drum and the ramped portion.

9. The apparatus of claim 7, wherein the metering holes define a metering hole diameter, and a portion of the guide overlaying the metering holes defines a guide width, wherein the guide width is less than the metering hole diameter.

10. The apparatus of claim 1, further comprising a feed tube extending from the storage apparatus to the vortex chamber, wherein the feed tube defines a chamfered opening into the vortex chamber, and the chamfered opening is inclined with respect to the vortex chamber to direct the objects in substantially the same trajectory as the source of air flowing in the vortex chamber.

11. The apparatus of claim 1, further comprising at least one pneumatic cylinder adapted to raise the inserter wheel into a position out of contact with the band of the filter material.

12. The apparatus of claim 1, wherein the inserter wheel includes a plurality of pockets, and each pocket is adapted to support one of the objects with between about one quarter and one half of the volume of the object received in the pocket, and the remainder of the volume of the object protruding from the pocket.

13. The apparatus of claim 12, further comprising a fluted portion in communication with each pocket, wherein the fluted portion defines a substantially cross-shaped cross section.

14. The apparatus of claim 1, further comprising:

a first tongue that compresses the band of filter material into a substantially cylindrical shape, wherein the inserter wheel inserts the objects into the band of filter material;

a second tongue that compresses a second band of filter material into a substantially cylindrical shape, the first tongue and the second tongue adapted to guide the first and second bands of filter material along substantially parallel paths; and

a second inserter wheel that receives objects from a second acceleration chamber and inserts the objects into the second band of filter material.

15. An apparatus for inserting one or more objects into a filter component of a tobacco rod, the apparatus comprising:

a storage apparatus that stores a plurality of the objects;

an inserter wheel that inserts the objects into a band of filter material;

a tow guide located upstream of the inserter wheel, wherein the band of filter material passes through the tow guide; and

a plow located at least partially within the tow guide, the plow defining a downstream end proximate to the inserter wheel, and an upstream end opposite to the downstream end;

wherein the plow is tapered from a first cross-section at the upstream end to a second cross-section at the downstream end, and the first cross-section is larger than the second cross-section.

16. The apparatus of claim 15, wherein the inserter wheel has an outer periphery defining a width, and the second cross-section of the plow is substantially equal to the width of the outer periphery of the inserter wheel.

17. The apparatus of claim 15, wherein the inserter wheel has an outer periphery, and the downstream end of the tow guide is tapered in a direction generally tangential to the outer periphery.

18. An apparatus for inserting one or more objects into a filter component of a tobacco rod, the apparatus comprising:

a storage apparatus that stores a plurality of the objects;

an inserter wheel that inserts the objects into a band of filter material, the inserter wheel defining an outer periphery with a plurality of pockets distributed evenly around the outer periphery, each pocket adapted to support one of the objects;

a drive motor adapted to rotate the inserter wheel; and

a controller that controls rotation of the drive motor, wherein the controller is adapted to vary the speed of rotation of the inserter wheel to insert the objects into the filter material at asymmetrical distances from one another.

19. The apparatus of claim 18, further comprising:

a cutter head adapted to cut the band of filter material, the cutter head located downstream from the inserter wheel;

a position sensor associated with the inserter wheel; and

a controller in communication with the cutter head and the position sensor, wherein the controller synchronizes operation of the cutter head with the position of the inserter wheel.

20. The apparatus of claim 19, wherein the position sensor comprises a proximity sensor or a light sensor.

21. The apparatus of claim 19, wherein the position sensor comprises a shaft encoder associated with the inserter wheel.