Introducing Objects Into Elongate Smoking Articles

Abstract

An apparatus for making an object assembly for use in the manufacture of smoking articles comprises a conveyance path for conveying an elongate member and a delivery mechanism configured to deliver objects onto the elongate member conveyed along the path such that a plurality of rows of objects are formed along the length thereof.

Description

This invention relates to an apparatus for making an object assembly for use in the manufacture of smoking articles having a filter element, for example filtered cigarettes. The apparatus may form part of a filter rod maker.

It is known to provide a frangible capsule containing a flavourant, for example menthol, inside the filter of a smoking article.

By applying pressure to the outside of the filter, the smoker may break the capsule therein and release the flavourant. Thus, a smoker wishing to add flavour to the inhaled gaseous flow from the cigarette may do so by simply squeezing the filter.

Filters for individual smoking articles such as cigarettes are usually cut from a filter rod made using a filter rod making machine. In known filter rod making machines, capsules are incorporated into cigarette filter rods by dispensing individual capsules one by one into a flow of stretched tow during filter rod manufacture.

One difficulty with this approach is that any relaxation of the stretched tow causes the capsules to move away from the position in which they are dropped, making it difficult to obtain precise positioning of the capsules within the eventual filter rod.

A further difficulty with this approach is that it is incompatible with the use of a stuffer jet, which is a device used in cigarette filter making machines to compress the filter tow before it is paper wrapped and cut. This is because passing a flow of tow having capsules individually dropped thereon through a stuffer jet would cause the positions of the individual capsules to become disarranged in the tow.

The present invention provides an alternative approach for providing objects such as frangible capsules in filter rods.

The present invention provides an apparatus for making an object assembly for use in the manufacture of smoking articles, the apparatus comprising a conveyance path for conveying an elongate member and a delivery mechanism configured to deliver objects onto the elongate member conveyed along the path such that a plurality of rows of objects are formed along the length thereof.

The apparatus may further comprise a shaping mechanism configured to shape the elongate member after the objects are delivered thereon.

The shaping mechanism may be configured to shape the elongate member into a trough, for example a trough having a U-shaped profile. Alternatively, the shaping mechanism may shape the elongate member into a tube.

The apparatus may further comprise a filter rod forming mechanism. In use, the filter rod forming mechanism may receive the object assembly and form filter rods, each filter rod comprising one or more of said objects.

The delivery mechanism may be configured to deliver a first object type such as fluid-containing members containing a first flavourant into a first of said rows and to deliver a second object type, such as second fluid-containing members containing a second flavourant into a second of said rows such that each object in the first row is adjacent to an object in the second row.

The delivery mechanism may have a first transport member configured to transport the objects of a first type from a first storage area to the first row, thereby delivering the objects of a first type into the first row, and a second transport member configured to transport the objects of the second type from a second storage area to the second row, thereby delivering the objects of the second type into the second row.

The first and second transport members may each comprise rotatable wheels. Alternatively, the first and second transport members may respectively comprise first and second circumferentially extending regions of a single rotatable wheel.

That is, the first transport member may comprise a first circumferentially extending region of the wheel and the second transport member may comprise a second circumferentially extending region of the wheel.

The invention also provides a method for making an object assembly for use in the manufacture of smoking articles, the method comprising conveying an elongate member along a path and delivering objects onto material drawn along said path such that a plurality of rows of objects are formed along the length thereof;

The invention also provides an apparatus for forming filter rods from filter rod material and configured to receive an object assembly from an object assembly source and to make filter rods having one or more objects therein, comprising a filter material diverting mechanism configured to divert filter material around the object assembly source,

The filter rod material diverting mechanism may comprise a splitter configured to split filter material into two paths and a combining member configured to receive filter material from each of the two paths and to receive the object assembly.

The invention also provides a maker for making filter rods, comprising an insert mechanism for inserting a plurality of types of objects into filter rods such that each filter rod comprises a plurality of objects of a first type and a plurality of objects of a second type and such that the objects of each type are arranged symmetrically with respect to a plane bisecting the filter rod, the plane being perpendicular to the longitudinal axis of the rod.

The invention also provides a method of making filter rods, comprising inserting a plurality of types of objects into filter rods such that each filter rod comprises a plurality of objects of a first type and a plurality of objects of a second type and such that the objects of each type are arranged symmetrically with respect to a plane bisecting the filter rod, the plane being at right angles to the longitudinal axis of the rod.

The invention also provides a filter rod having a plurality of objects of a first type and a plurality of objects of a second type, wherein the objects of each type are symmetrically arranged with respect to a plane bisecting the filter rod, the plane being perpendicular to the longitudinal axis of the rod.

The first type of objects may be frangible fluid-containing members containing a first flavourant and the second type of objects may be frangible fluid-containing members containing a second flavourant.

In order that the invention may be more fully understood, embodiments thereof will now be described by way of illustrative example with reference to the accompanying drawings, in which:

FIG. 1 shows a part of a filter rod making machine.

FIG. 2 shows a capsule delivery mechanism.

FIG. 3(a) shows a ribbon of paper having two rows of capsules thereon.

FIG. 3(b) shows a partially wrapped ribbon of paper.

FIG. 3(c) shows a paper tube containing a plurality of capsules.

FIG. 4 shows a filter having a tube therein, the tube containing two capsules.

FIG. 5 shows a filtered cigarette comprising the filter of FIG. 4.

FIG. 6(a) shows a ribbon of paper having three rows of capsules thereon.

FIG. 6(b) shows a partially wrapped ribbon of paper.

FIG. 6(c) shows a paper tube containing a plurality of capsules.

FIG. 7 shows another delivery mechanism

FIG. 8(a) shows a ribbon of paper having two rows of capsules thereon.

FIG. 8(b) shows a partially wrapped ribbon of paper.

FIG. 8(c) shows a paper tube containing a plurality of capsules.

FIG. 9 illustrates a cigarette assembly process.

FIG. 10 shows a part of another filter rod making machine.

FIG. 11 illustrates the tow path through the filter rod making machine.

FIG. 12 shows a splitter.

FIG. 13 shows a stuffer jet

FIG. 14 shows a capsule.

FIG. 15 shows a part of yet another filter rod manufacturing machine.

FIG. 16(a) shows a ribbon of paper having two rows of capsule thereon.

FIG. 16(b) shows the ribbon of paper having capsules thereon folded so as to have a U-shaped cross section.

FIG. 16(c) shows a front cross-sectional view of one of the capsules partially wrapped by the ribbon of paper.

FIG. 17 shows a feed unit for feeding capsules to the capsule delivery mechanism.

FIG. 1 shows part of a filter rod making machine 1. During operation of machine 1, filter tow 2 is drawn from a source of tow (not shown), stretched through a set of stretching rollers (not shown), compressed through stuffer jet 3 and through the tongue 4 of garniture 5, where it is paper wrapped with a plugwrap (not shown) and subsequently cut into segments by a cutter (not shown) to form filter rods.

As shown in FIG. 1, machine 1 has an assembly station 6 configured to assemble an object assembly in the form of a fluid encapsulation having a plurality of fluid-containing capsules 7 and a connecting member in the form of an elongate paper tube 8, which couples the capsules 7 to one another. As shown, during operation of the assembly station 6, fluid-containing capsules are delivered in two parallel rows onto a ribbon of glue-lined paper which is drawn along a path and wrapped to form the tube 8 of capsules 7.

Referring to FIG. 1, when machine 1 is in use, the elongate tube 8 of capsules 7 is assembled by the assembly station 6 and received into stuffer jet 3 and into the moving tow 2 so as to be incorporated into the eventual filter rods.

In this way, capsules can be precisely and stably positioned within the rod, since the positioning and spacing of the capsules is determined by their spacing within the paper tube 8, which does not undergo significant stretching when inserted into the tow 2 by the stuffer jet 3.

In the garniture 5, the tow 2 and the tube 8 enclosed therein are wrapped in a plug wrap drawn from a reel (not shown) via a roller (not shown), so as to form an elongate filter rod. An endless garniture tape (not shown) travels along the garniture bed and drags the plug wrap, the tow 2, and the tube 8 of capsules 7 into and through the garniture 5. In this way, the tube 8 of capsules 7 is pulled through the stuffer jet 3 together with the tow 2 and is thereby received into the tow 2.

The stuffer jet (also known as a transport jet) is a venturi device which acts to compact the tow. The linear speed at which the stuffer jet 3 receives tow is faster than the speed of the garniture tape and in this way a desired weight and therefore density of tow is incorporated into each eventual filter rod so that a desired resistance to flow, or pressure drop, can be achieved in the eventual filters.

The garniture tape curves inwardly as it travels through the garniture, thereby shaping the plug wrap such that the tow 2 and tube 8 of capsules 7 therein are cylindrically paper wrapped. A set of glue guns (not shown) apply an adhesive such as hot melt glue or polyvinyl acetate (PVA) to the plug wrap. A sealing unit (not shown), which has a heating or a cooling element, seals the plugwrap around the filter tow. PVA or glue may also be used to lay down an anchorage line on the plug wrap prior to combining it with the tow so that the tow and plug wrap stick together in the garniture 5.

The separation (also referred to herein as the pitch) between the capsules in the elongate filter rod is determined by the separation (or pitch) between the capsules in the elongate tube and may for example be 9 to 32 mm.

The machine 1 also includes a microwave detector (not shown) for detecting the presence or location of capsules 7, and a cutter with a knife for cutting the elongate filter rod and the tube 8, thereby forming filter rod segments.

On start up, the position of a capsule is determined by the microwave detector and the cut-off position of the cutter knife is adjusted to position the capsule relative to the knife so that the tube 8 is cut at a point between the capsules 7. Furthermore, the detected capsule position may be used to determine the time that the cutter should begin cutting. Alternatively, however, on start up the knife may be fixed in position and the tube may be drawn through the garniture to position the tube at an appropriate position relative to the knife so that the tube is cut at a desired point between the capsules 7.

In use, the cutter periodically cuts the elongate rod at a predetermined frequency so that the eventual filter rod segments are of a desired length containing a desired number of capsules 7. The desired number of capsules per rod segment is preferably 2 or 4 capsules, although alternatively it may be 1 capsule, 3 capsules or more than 4 capsules.

The microwave detector also acts as a quality detection device. The microwave detector detects defects in the fluid encapsulation 1, such as damaged or missing capsules in the rod. The machine has a shift register (not shown) which is configured to discard a detected defective element at a later stage in the assembly process. For example, if the microwave detector determines that a capsule is defective, the shift register may be configured such that the assembled filter rod containing that capsule is discarded.

Turning now to a more detailed description of the assembly of the tube 8 of capsules 7, referring to FIG. 1 assembly station 6 comprises a holder (not shown) for holding a paper reel 9, a glue gun 10 having two nozzles 10a, 10b, a capsule delivery mechanism 11, a feed unit comprising a pair of hoppers 12a, 12b for feeding the capsule delivery mechanism 11 with capsules, and a shaping mechanism comprising a forming block 13. The hopper 12a contains capsules 7a containing a first liquid flavourant and the second hopper 12b contains capsules 7b containing a second liquid flavourant, different to the first liquid flavourant. That is, the capsules 7a are of a different variety to the capsules 7b.

Suitable liquid flavourants include, for example menthol, spearmint, orange essence, mint, liquorice, eucalyptus, one or more of a variety of fruit flavours or any mixture of flavourants. However, the contents of the capsules 7a, 7b are not intended to be limited to flavourants and alternatively or in addition a humectant could be used, for example, or liquids such as water or Vitamin A solution for filtering certain elements from the cigarette smoke, or for other purposes

FIG. 14 shows a capsule 7 in more detail. As shown, the capsule 7 comprises an outer wall of gelatin 100 and an inner space filled with a liquid 101 such as a liquid flavourant.

In use, an elongate member in the form of a ribbon R shown in FIG. 1 of paper such as porous plugwrap paper is drawn from the reel 9 and is lined by the glue guns 10 with two parallel lines of glue 14a, 14b as it moves along a conveying path in the assembly station 6. The glue may, for example be hot melt glue or hot melt re-activated glue. Although the elongate connecting member is preferably a ribbon of paper such as a porous or non-porous plugwrap paper or a standard cigarette paper, alternatively the ribbon could, for example be made from a cellulose web, carbon paper, impregnated charcoal paper, a plastic, cellophane or any other suitable material.

Along the path, the ribbon R passes under capsule delivery mechanism 11, which delivers capsules sequentially onto the paper and into contact with the glue lines 14a, 14b so as to form two rows 15a, 15b of capsules 7 adhered to the glue lines 14a, 14b. Next, the ribbon R is fed around the forming block 13 so that it forms into a tube 8 with the capsules 7 disposed longitudinally inside. The tube 8 is then drawn into the stuffer jet 3 by the action of the garniture 5, as described in more detail above.

Referring to FIG. 1, capsule delivery mechanism 11 comprises two vertically oriented rotatable delivery wheels 16a, 16b having a common axis 17, the wheels being joined at a central point by a shaft 18 and thereby fixed relative to one another. As shown in FIG. 2, which shows a close-up view of the capsule delivery mechanism 11, each wheel 16a, 16b has a plurality of cavities 19a, 19b for receiving capsules evenly spaced around its circumference.

In use, the shaft 18 and the wheels 16a, 16b are rotated by a motor (not shown). As will be understood by those skilled in the art, the speed of the motor may be timed relative to the speed of the garniture and/or cutter, preferably using one or more encoders. The wheels 16a, 16b may be rotated at a faster or a slower speed, relative to the garniture speed and in this way the separation (or pitch) between neighbouring capsules may be controlled. Thus, the capsules may be delivered onto the moving ribbon R at a suitable rate so that a desired separation is achieved between capsules in each eventual filter rod and so that a desired number of capsules, for example 1, 2 or 4 capsules, are incorporated into each eventual rod.

As the wheels 16a, 16b rotate capsules 7a from hopper 12a fall under gravity into cavities 19a in the top part of the wheel 16a. Similarly, capsules 7b from hopper 12b fall into cavities 19b in the top part of the wheel 16b. Thus, the capsules are collected radially into the wheels 16a, 16b. As shown, the outlet of the hoppers 12a, 12b extend over a segment of the wheels 16a, 16b so that a plurality of cavities 19a, 19b are filled at the same time as the wheels 16a, 16b rotate.

The capsules 7a in the cavities 19a, are rotated around the axis 17 until they drop under gravity onto the glue lines 14a and adhere to the surface of the ribbon R of paper to form a row 15a of evenly spaced capsules fixed thereon.

In the same way, the capsules 7b in the cavities 19b, are rotated and subsequently dropped onto the glue line 14b to form a row 15b of evenly spaced capsules 7b fixed to the ribbon R, the row 15b of capsules 7b being parallel to the row 15a of capsules 7a.

Alternatively, or in addition the capsules 7 may be positively displaced from the wheels 16a, 16b onto the ribbon R. For example the capsule delivery mechanism 11 may comprise a propulsion mechanism such as one or more compressed air manifolds configured to propel the capsules out from the cavities 19a, 19b in the wheels 16a, 16b and onto the ribbon R, for example with jets of compressed air.

As shown in FIG. 2, the cavities 19a are evenly spaced around the circumference of the wheel 16a and the cavities 19b are evenly spaced around the circumference of the other wheel 16b. However, the cavities 19a of wheel 16a are not aligned with the cavities 19b of wheel 16b along the direction of the axis 17. Instead, the cavities 19a are arranged in an alternate fashion in relation to the cavities 19b. As shown, the angular position of each cavity 19a on wheel 16a is half way between the angular positions of two neighbouring cavities 19b on the wheel 16b.

As the glue lined paper ribbon R moves under the capsule delivery mechanism 11 and the wheels 16a, 16b rotate, the capsules 7a and capsules 7b alternately fall from their respective cavities 19a, 19b onto the ribbon R. That is, during operation of the machine 1, a capsule 7a drops from a cavity 19a onto the glue line 14a, then a capsule 7b drops from a cavity 19b onto the glue line 14b, then a capsule 7a drops onto the glue line 14a and so on. In this way two parallel rows of evenly spaced capsules are formed longitudinally along the ribbon R in the manner shown in FIG. 3a. As shown, the longitudinal separation L between capsules in row 15a is the same as the longitudinal separation between capsules in row 15b and the row 15a and the row 15b are laterally separated by a gap of width W. Capsules 7a in the row 15a are arranged alternately with respect to the capsules 7b in the row 15b, each capsule 7b in row 15b being arranged half way between two capsules 7a in row 15a. Thus, as shown in FIG. 5, the longitudinal spacing between a capsule 7a and the neighbouring capsule 7b is L/2.

FIG. 3 (b) shows in more detail the step of shaping the ribbon R around the forming block 13 to form a tube 8. As shown, shaping the ribbon comprises bringing the capsules 7a and the capsules 7b towards the center of the eventual tube 8. In this way, the capsules 7a and 7b become longitudinally evenly spaced within the tube 8, as shown in FIG. 3 (c). Referring to FIG. 3 (c), which shows the eventual tube 8, the capsules 7a and the capsules 7b are alternately positioned along the length of the tube 8 and are adhesively fixed to the inner wall of the tube 8. In the tube 8, the nearest capsule to each capsule 7a is a capsule 7b and vice versa. As shown, the separation between neighbouring capsules 7a, 7b in the tube is L/2.

As is described in more detail above, during operation of the filter rod making machine 1, the assembled tube 8 of capsules 7a, 7b is brought into contact with the tow 2 and the filter rod making machine forms cut filter rods.

The start-up procedure of the machine 1 will now be described. In a first step, the filter making machine is operated so that tow 2 is drawn into the stuffer jet, paper wrapped in a garniture and cut to form filter rods. In a second step, the ribbon R is manually fed from the holder through the forming block 13 and into the stuffer jet 3 until it is caught by the tow. Once caught by the tow, the ribbon R is automatically drawn from the holder, through the forming block and into the tow by the action of the garniture 5. Then, the glue gun 10 is engaged so that the glue lines 14a, 14b are formed on the ribbon R. Next, the capsule delivery wheels are caused to rotate, thereby guiding the capsules 7a, 7b onto the glue lines.

In this way, two or more fluid containing capsules 7a, 7b containing different fluids can be incorporated into each eventual filter rod manufactured by the machine 1. Furthermore, the machine 1 is capable of running at high speeds, for example in the range of 400 to 500 rod meters per minute or in the range 1000 to 4000 filter rods per minute.

As described above, the fluid encapsulation is pulled through the machine 1 by the garniture tape together with the plugwrap and the tow. Thus, the speed at which the encapsulation is fed into the machine is automatically synchronised with the garniture speed.

The tube 8 protects the capsules 7a, 7b as they pass through the garniture 5, resulting in gentler handling of the capsules and thus less waste.

In addition the tube 8 of capsules 7a, 7b inside the eventual filter rod improves the filter quality by making the filter harder.

Moreover, the assembly station 6 can be operated in combination with a standard filter rod making machine to make filter rods having capsules inside, without the need for significant modification of the standard filter rod making machine.

FIG. 4 shows an example of a filter rod 20 manufactured by the machine 1. The filter rod 20 comprises a plug of cellulose acetate tow 21 wrapped with a wrapper of porous plugwrap 22. A cut section 23 of the tube 8 is disposed inside the rod, the cut section 23 containing two fluid-containing capsules 7a, 7b. The separation between the capsules in the filter rod 20 is in the range 4-32 mm. The diameter of the filter is within the range 4-10 mm. The capsule diameter is within the range 2-6 mm.

These ranges are of course not intended to be limiting and the skilled person would understand that larger or smaller filter diameters, capsule diameters or capsule separations could be employed.

The filter rod 20 shown in FIG. 4 can be used in the assembly of a cigarette having two capsules in the filter, each capsule containing a different flavourant. Such a cigarette 24 is shown in FIG. 5. The cigarette 24 is assembled by axially aligning the filter rod 20 and a paper wrapped tobacco rod 25, and wrapping them with a glue coated segment of tipping paper 26 to join them together. Assembling stations for assembling cigarettes in this manner are well known per se and will not be described in detail herein.

By applying pressure to the outside of the part of the filter 20 which surrounds the capsule 7a, the smoker may break the capsule 7a and release the flavourant therein. Alternatively, or in addition, the smoker may apply pressure to the outside of the part of the filter 20 which surrounds the capsule 7b and thereby break the capsule 7b and release the other flavourant. Then, when the cigarette is smoked, part of the gaseous flow drawn by the smoker is flavoured as it passes through the flavourant or flavourants released by the smoker.

In this way, the smoker is provided with the option at any point while smoking the cigarette to: (1) not break either capsule; (2) break only one of the capsules; or (3) break both the capsules. Thus, the user of such a cigarette has several taste options.

The assembly station 6 shown in FIG. 1 comprises two glue guns, two capsule hoppers and two delivery wheels. However, any number of glue guns, capsule hoppers and delivery wheels could alternatively be used. For example, the assembly station may have three glue guns to line the paper ribbon with three lines of glue and the capsule delivery mechanism may comprise three delivery wheels to deliver capsules from three hoppers onto three rows on the paper ribbon. The ribbon may then be fed around a forming block to form a tube containing first, second and third capsules having first, second and third flavourants, all three flavourants being different to one another.

Such a ribbon R3 is illustrated in FIG. 6(a). As shown, ribbon R3 comprises three lines of glue 27a, 27b, 27c and three parallel rows 28a, 28b, 28c of capsules 29a, 29b and 29c respectively arranged along the glue lines 27a, 27b, 27c. As shown the rows 28a and 28c are side rows and the row 28b is a centre row. The capsules 29a, 29b, 29c of different rows contain different liquids.

FIG. 6(b) illustrates the step of wrapping the ribbon R3 into a tube 8. As shown, as the ribbon is formed into a tube, the capsules 29a of row 28a and the capsules 29c of row 28c are brought towards the center of the eventual tube 30, while the capsules 29b remain substantially in position relative to the moving ribbon R3.

The eventual tube 30 is illustrated in FIG. 6(c). As shown, the tube 30 contains first, second and third capsules 29a, 29b, 29c arranged in sequence longitudinally within the tube, the sequence of first, second and third capsules 29a, 29b, 29c being repeated along the length of the tube 30.

The tube 30 can be incorporated into filter rod segments in a similar manner to the manner described hereinabove in relation to the tube 8. Further, those skilled in the art will understand that cigarettes having a filter containing three or more capsules may be manufactured in a similar manner to that described above, thus providing cigarettes having further taste options for the smoker.

Although the shaping member is described above as a forming block configured to form the elongate member having the capsules attached thereto into a tube, alternatively, the elongate member may be shaped in different ways, for example into a trough having for example a U-shape or a V-shape cross-section, before it is received into the tow. Preferably the shaping member is configured to shape the elongate member such that the capsules are generally centrally positioned in the eventual filter rod.

Forming the elongate member material into a tube may cause the eventual filter element to have regions of air therein, enclosed in the tube between neighbouring capsules. These air gaps may lower the weight of tow in the filter to some extent. However, if the elongate member material is shaped into a trough, for example, filter material will fill the spaces between the capsules during manufacture of the filter rod. In this way, the eventual filter rod will not contain regions of air between the capsules if the elongate member has been shaped into a trough.

The forming block may be arranged such that when the elongate member having the capsules attached thereto runs over the forming block, it adopts the particular desired shape.

For example, the elongate member may run over the forming block and become shaped so as to have a U-shaped profile and the shaped elongate member may be received into the tow. Forming the elongate member in this way advantageously brings the capsules in the first and second rows towards the centre of curvature of the shaped elongate member, so that the capsules become approximately or generally centrally positioned in the elongate member.

Alternatively, or in addition, the forming member may comprise one or more ploughs, configured such that when the elongate member runs over the one or more ploughs, it adopts the particular desired shape.

For example, the forming member may comprise a single plough configured to partially bend or wrap one side of the elongate member.

Alternatively, or in addition the shaping member may comprise a deformation member configured to deform the elongate member having the capsules attached thereon before it is received into the tow. For example, the deformation member may crimp, bend, fold, twist, partially wrap and/or otherwise deform the elongate member prior to the elongate member being received into the tow.

Alternatively, the elongate member material may not be shaped before it is drawn into the tow.

Although the filter making machine 1 is described above as manufacturing “single length” filter rod for use in the manufacture of individual cigarettes, preferably the filter making machine 1 manufactures “double length” filter rods, each filter rod being suitable for manufacturing two cigarettes.

However, alternatively the filters manufactured by the machine may have any other length and may for example triple or quadruple length filters. Alternatively, the filters manufactured by the filter making machine may be filter segments intended to form part of a multi-segment filter.

Where the eventual cigarette filter element has a single section having a single capsule therein, the pitch (or separation) between neighbouring capsules in the fluid encapsulation is preferably in the range 18-32 mm.

Where the eventual cigarette filter element has a single section having two capsules therein, the pitch (or separation) between neighbouring capsules in the fluid encapsulation is preferably in the range 9-32 mm.

For multi-section filter segments having a single capsule therein, the pitch between neighbouring capsules in the fluid encapsulation is preferably in the range 8-18 mm.

For multi-section filter segments having two capsules therein, the pitch is preferably in the range 4-12 mm.

FIG. 7 shows another capsule delivery mechanism 31 in the form of a capsule delivery wheel 31a having a shaft 31b fixed relative to the wheel 31. The capsule delivery mechanism 31 is preferably used when “double length” filters are to be manufactured. As shown, wheel 31a has two circumferentially extending regions 32a, 32b. Rotation of the shaft 31b causes the regions 32a, 32b to rotate together. The capsule delivery mechanism 31 receives capsules 7a, 7b from a feed unit in a similar manner as the capsule mechanism 11 described above. That is, capsule delivery mechanism 31 receives capsules 7a containing a first liquid flavourant from the first hopper into the first circumferentially extending region 32a of the wheel and capsules 7b containing a second liquid flavourant from the second hopper into the second circumferentially extending region 32b of the wheel, the second flavourant being different to the first liquid flavourant,

As shown, each circumferentially extending region 32a, 32b has a corresponding sequence of cavities 33a, 33b arranged around the circumference thereof. As shown, the cavities 33a, 33b are arranged in pairs, the gap between neighbouring pairs in a region 32a, 32b being greater than the gap between the cavities 33a, 33b in a pair. However, as shown the pairs of cavities 33a of the region 32a are not aligned with the pairs of cavities 33b of the region 33b. Instead, pairs of cavities 33a are arranged alternately with respect to the pairs of cavities 33b.

As the glue lined ribbon R moves under the capsule delivery mechanism 11 and the wheel 31a rotates, capsules 7a, 7b fall in sequence from their respective cavities 32a, 32b onto the ribbon R. That is, first a capsule drops from a cavity 33a onto a first glue line on the ribbon R, then another capsule 7a drops from a cavity 33a onto the first glue line, then a capsule 7b drops from a cavity 33b onto a second glue line on the ribbon R, the another capsule 7b drops from a cavity 33b onto the second glue line, then a capsule 7a drops from a cavity 33a onto the first glue line, and so on.

In this way two parallel rows 34a, 34b of capsules are formed longitudinally along the ribbon R in the manner shown in FIG. 8(a). As shown, capsules 7a,7b are arranged in groups 35a, 35b, each group having two capsules and the groups 35a, 35b being evenly spaced along each row 34a, 34b. Groups 35a in the row 34a are arranged alternately with respect the groups 35b in the row 34b, each group 35a in row 34a being arranged half way between two groups 35b in row 34b.

FIG. 8(b) illustrates folding the ribbon R into a tube 36. However, as described above, alternatively the ribbon R could be shaped into a trough having, for example a U-shaped profile, or another suitable shape.

FIG. 8(c) illustrates the eventual tube 36. As shown, pairs of capsules 7a are arranged alternately with pairs of capsules 7b along the length of the tube 36.

The tube 36 is then fed into contact with tow 2 so as to be incorporated into the eventual filter rods, in the manner described above with reference to the tube 8.

The action of the cutter of the filter making machine 1 is timed so that each eventual filter rod 37 comprises two capsules 7a arranged towards the end regions of the rod 37 and two capsules 7b in a central region of the rod. Such a filter rod 37 is shown in FIG. 9 (a). As shown, the arrangement of capsules in the filter rod 37 has mirror symmetry with respect to a plane 37a bisecting the filter rod, the plane being perpendicular to the longitudinal axis of the rod.

Referring to FIG. 9, which shows a process of manufacturing cigarettes, filter rod 37 is longitudinally aligned with a pair of paper wrapped tobacco rods 38, 39 and cylindrically wrapped with a tipping paper 40 to join the rod 37 to the rods 38,39. The rod 37 is then cut generally centrally, thereby forming two cigarettes 41, 42, each having a filter element 43, 44. As shown, each filter 43, 44 comprises a first capsule 7a and a second capsule 7b. In each filter 43, 44, the capsule 7b is arranged closer to the mouth-end of the filter than the capsule 7a.

In this way, capsule delivery mechanism 31 delivers a pattern of capsules onto the ribbon R such that cigarette manufacture by the process illustrated in FIG. 9, the arrangement of capsules within the filter element of each eventual cigarette is the same.

This is achieved by selecting the arrangement of the cavities on the capsule delivery mechanism and the timing of the cutter of the filter maker such that each double length filter rod formed by the filter rod machine has a symmetric pattern of capsules therein. The arrangement of capsules in the filter rod has mirror symmetry with respect to a plane bisecting the filter rod, the plane being at right angles to the longitudinal axis of the rod.

Many other cavity arrangements will be evident to those skilled in the art in order to achieve any desired arrangement of capsules within the filter elements of each eventual cigarette.

For example, as described above a capsule delivery mechanism having three or more delivery wheels could be used to make double length filter rods having three or more different varieties of capsules therein. In this case, cavity arrangements on the delivery wheels will be evident to those skilled in the art in order to obtain a symmetric arrangement of three or more varieties of capsules in each double length rod. Each filter rod so produced may be used to make two cigarettes by the method shown in FIG. 9. Each cigarette manufactured in this way will have the same desired arrangement of three or more capsules therein because of the symmetric arrangement of capsules in the double length filter rods.

FIG. 10 shows part of a machine 45, which is yet another variation of the machine 1. As shown in FIG. 11, in the machine 45, tow 46 is divided into two paths 47, 48 by a splitter 49 and subsequently re-combined in stuffer jet 50.

As shown in FIG. 10, the machine 45 has an assembly station 51 for assembling a fluid encapsulation. The assembly station 51 is similar to the assembly station 6, but is positioned in the space between the two tow paths 47, 48. The tow 46 is guided along the tow paths 47, 48, around the assembly station 6 by guides (not shown) on each side of the assembly station 6. As is the case for assembly station 6, assembly station 51 has a capsule delivery mechanism 11 configured to deliver capsules onto a ribbon R of glue lined paper, which is subsequently shaped into for example a tube or trough and then received into the stuffer jet 50.

Referring to FIG. 12 shows the splitter 49 in more detail. As shown, the splitter has a tow receiving part 49a and a blade 52 which is configured to enter partially into the tow receiving part 49a through a slit therein. In use, tow 46 is received into the tow receiving part 49a and the blade 52 rotates, thereby splitting the tow 46 into two parts. As shown in FIG. 11, the first part of the tow takes the path 47 and the second part of the tow takes a different path 48.

Referring to FIG. 11, tow 46 is conveyed along the paths 47, 48 by the guides (not shown) on each side of the assembly station 51, and the fluid encapsulation 8 made by the assembly station 51 is drawn along another path 56 into the stuffer jet 50. In this way, the fluid encapsulation 8 follows a generally straight path 56 through assembly station 51 to the stuffer jet 50 and through the garniture (not shown) until is cut by the cutter. This is advantageous since the elongate connecting member may be weakened or may break in any region of curvature at high enough speeds.

FIG. 13 shows the stuffer jet 50 in more detail. As shown stuffer jet 50 has a trumpet shaped inlet 53 which receives tow from the paths 47, 48 and which receives the fluid encapsulation from the assembly station 51. As described above in relation to the machine 1, the tow 46 having the fluid encapsulation 8 therein is received from the stuffer jet 50 into a garniture, where it is paper wrapped with a plugwrap and subsequently cut to form filter rods.

FIG. 15 shows part of another filter rod making machine 54, which is yet another variation of the machine 1. As shown, the machine 54 comprises an assembly station 55, which is a variation of the assembly station 6 and has a capsule delivery mechanism 56, 31 comprising a delivery wheel of the type shown in FIG. 7. Referring to FIG. 15, machine 54 comprises a set of guides in the form of bobbins 57a, 57b, 57c and 57d arranged to divert the tow 58 around the wheel of the capsule delivery mechanism 56. The bobbin 57a is aligned with the delivery roller (not shown) of the tow processor (not shown) of the machine 54 and guides the tow 58 to the bobbin 57b. The tow is subsequently guided by the bobbins 57c and 57d and is received into stuffer jet 59.

Many other variations of the guides 57 will be evident to those skilled in the art. For example, the bobbins 57b, 57c, 57d may have a U-shaped profile such as the profile of the bobbin 57a. Alternatively, the bobbins could have a “V” shaped profile.

As described above, capsule delivery mechanism 56, 31 delivers capsules onto an elongate member in the form of a ribbon of paper 60 drawn from a holder (not shown). The ribbon is lined with glue and subsequently passes under the wheel of the capsule delivery mechanism 56, 31, for example 5 mm below the capsule delivery wheel. The bobbin 57d is disposed above the surface of the plate 61 so that the ribbon of paper 60 passes under and does not contact the bobbin 57d.

As shown, the ribbon of paper 60 is drawn along a straight line path from the holder along plate 61 of machine 54 and into the stuffer jet 59. As shown the paper 60 enters the stuffer jet at a lower level than the tow 58.

As described above, it is advantageous for the ribbon 60 to follow a straight line path since the ribbon may be weakened or may break in any region of curvature at high enough speeds.

Preferably, the plate 61 has a U-shaped channel formed therein so that the ribbon 60 adopts a U-shaped profile as it passes through the channel. Preferably, the channel is positioned so that the ribbon 60 is shaped after it passes under the capsule delivery mechanism 56, 31.

FIGS. 16(a) and 16(b) illustrates formation of the ribbon 60 having capsules 62 attached into a trough having a U-shaped profile with the capsules 62 therein. As shown in the front cross sectional view of FIG. 16(c), the shaped ribbon has a semi-circular cross section with an inner diameter equal to that of the capsules 62. That is, the paper ribbon 60 is partially wrapped around the capsules 62. In this way, the capsules are held securely within the paper. As shown, the capsules are centrally positioned within the U-shape and are generally aligned with one another along the longitudinal axis of the paper ribbon.

FIG. 17 shows a more detailed view of a capsule feed unit for feeding capsules into a capsule delivery mechanism 11, 31, 56 having one or more capsule delivery wheels 68.

As shown, the feed unit comprises two capsule holders in the form of cylindrical holes 63a, 63b, which may for example be manually filled with capsules of two different varieties. The feed unit further comprises a vacuum unit 64 configured to suck capsules from the holders 63a, 63b through pipes 65a 65b and to deposit capsules onto respective vibration conveyors 66a, 66b. Vibration conveyors 66a, 66b convey the capsules into the hoppers (also referred to herein as magazines) 67a, 67b, from which they fall under gravity into the cavities of capsule delivery wheel 68.

As shown in FIG. 17, the outlet of magazine 67a extends over a front segment of the wheel 68 and is arranged so that capsules are delivered into the cavities of a first circumferentially extending region of the wheel 68. The outlet of magazine 67b extends over a rear segment of the wheel 68 and is arranged so that capsules are delivered into the cavities of a second circumferentially extending region of the wheel 68.

Many other configurations of the magazines 67a, 67b are possible. For example, the magazines 67a, 67b may be arranged in side-by-side arrangement at the rear of the wheel of the capsule delivery mechanism, for example as shown in FIG. 1.

Alternatively, the magazines 67a, 67b may be arranged in side-by-side arrangement at the front of the wheel of the capsule delivery mechanism.

Many further modifications and variations will be apparent to those skilled in the art.

For example, instead of receiving the elongate member into the stuffer jet, the elongate member having the capsules attached may be received into the tongue of the garniture. For example, the tongue may have a hole through which the shaped elongate member may be fed. The elongate member may be received into the stuffer jet or tongue via a centering mechanism.

Alternatively, or in addition, the elongate member having the capsules attached may be positioned or adhesively fixed onto the plugwrap paper, prior to or during the step of wrapping the plugwrap around the tow in the garniture. In one example, the elongate member may be brought under the stuffer jet and onto the plugwrap paper.

Still further, although the objects are described above as frangible fluid-containing capsules, the objects could alternatively be pellets, strands, beads or any combination of pellets, strands, beads and capsules.

Still further, the objects may be held in place in the cavities of the delivery wheels 16a, 16b, 31a, by vacuum (ie: suction) applied to each pocket, so as to assist in ensuring that the objects are maintained in the cavities during transport. Capsule delivery wheels configured to apply vacuum to hold capsules in place until delivery are known per se. An example of a wheel which applies vacuum to hold capsules in pockets of the wheel until delivery is described in WO 2007/038053.

Still further, stationary guides may be provided around the peripheral regions of the rotatable delivery wheels 16a, 16b, 31a, to keep the objects in the wheels during transport. Such guides may be arranged to define an exit region at the bottom of the wheels 16a, 16b, 31a, through which the objects leave the wheel and fall onto the paper.

Further alternatively, in another example the elongate member may be the plugwrap paper which is wrapped around the tow. That is, the elongate member having the objects attached may be cylindrically wrapped around the tow in the garniture so as to form a paper wrapped elongate filter rod, which is subsequently cut by a cutter in the manner described above.

Many other modifications and variations will be evident to those skilled in the art, that fall within the scope of the following claims:

Claims

1. An apparatus for making filter rods for use in the manufacture of smoking articles, the apparatus comprising:

a conveyance path for conveying an elongate member;

a delivery mechanism configured to deliver objects onto the elongate member conveyed along the path such that first and second rows of objects are formed along the length thereof; and

a filter rod forming mechanism configured to receive the elongate member with the rows of objects thereon and to form filter rods each including objects from both of the rows.

2. The apparatus according to claim 1, further comprising a shaping mechanism configured to shape the elongate member after the objects are delivered thereon.

3. The apparatus according to claim 2, wherein the shaping mechanism is configured to shape the elongate member such that the objects in one row are brought towards the objects in another row.

4. The apparatus according to claim 2, wherein the shaping mechanism is configured to shape the elongate member into a trough.

5. The apparatus according to claim 2, wherein the shaping mechanism is configured to shape the elongate member into a tube.

6. The apparatus according to claim 1, wherein the objects comprise objects of a first type and objects of a second type and wherein the delivery mechanism is configured to deliver objects such that a plurality of objects of the first type and a plurality of objects of the second type are disposed in each of the filter rods.

7. The apparatus according to claim 6, wherein the arrangement of each type of objects in each filter rod is generally symmetric with respect to a plane bisecting the filter rod, the plane being perpendicular to the longitudinal axis of the rod.

8. The apparatus according to claim 6, wherein:

the first type of objects are frangible fluid-containing capsules containing a first fluid; and

the second type of objects are frangible fluid-containing capsules containing a second fluid.

9. The apparatus according to claim 1, wherein the filter rod forming mechanism is configured to form the filter rods from filter rod material, and further comprises a filter rod material diverting mechanism arranged to divert filter rod material around the delivery mechanism.

10. The apparatus according to claim 1, wherein the filter rod forming mechanism comprises:

a splitter configured to split filter material into two paths; and

a combining member configured to receive filter material from each of the two paths and to receive the elongate member with the rows of objects thereon.

11. The apparatus according to claim 10, wherein the elongate member with the rows of objects thereon follows a generally straight path into the combining member and through the filter rod forming mechanism.

12. The apparatus according to claim 10, wherein the combining member is a stuffer jet.

13. The apparatus according to claim 1, wherein the delivery mechanism is configured to:

deliver objects of a first type into the first of said rows; and

deliver objects of a second type into the second of said rows.

14. The apparatus according to claim 13, wherein the delivery mechanism comprises:

a first transport member configured to transport the objects of the first type from a first storage area to the first row, thereby delivering the objects of the first type into the first row; and

a second transport member configured to transport the objects of the second type from a second storage area to the second row, thereby delivering the objects of the second type into the second row.

15. The apparatus according to claim 13, wherein the delivery mechanism is further configured to:

deliver objects of a third type onto a third row such that each object of said third type in said third row is adjacent to an object of the second type in the second row.

16. The apparatus according to claim 15, wherein the delivery mechanism further comprises:

a first transport member configured to transport the objects of the first type from a first storage area to the first row, thereby delivering the objects of the first type into the first row;

a second transport member configured to transport the objects of the second type from a second storage area to the second row, thereby delivering the objects of the second type into the second row; and

a third transport member configured to transport objects of the third type from a third storage area to the third row, thereby delivering the objects of the third type into the third row.

17. The apparatus according to claim 13 wherein the objects are frangible fluid-containing capsules, the different types of objects being frangible fluid-containing capsules containing different flavorants.

18. The apparatus according to claim 14 wherein the transport members have cavities for receiving objects therein, and wherein the transport members are configured to rotate and thereby transport objects received in the cavities to the plurality of rows of objects, thereby delivering the objects into the rows.

19. The apparatus according to claim 18, wherein the transport members are configured to rotate around a common axis; and

wherein the cavities of the transport members are not aligned with one another in the direction of said axis.

20. The apparatus according to claim 13, wherein the delivery mechanism is configured such that each object of the first type in the first row is adjacent to an object of the second type in the second row.

21. The apparatus according to claim 1, wherein the filter rod forming mechanism has a stuffer jet mechanism and wherein the elongate member with the rows of objects thereon is received into the stuffer jet mechanism.

22. The apparatus according to claim 1, wherein the elongate member with the rows of objects thereon comprises a fluid-encapsulation.

23. The apparatus according to claim 1 wherein the objects are disposed centrally within the elongate member.

24. The apparatus according to claim 1, further comprising an adhesive applicator mechanism configured to apply a plurality of rows of adhesive to material drawn along said path, wherein the delivery mechanism is configured to deliver the objects into contact with adhesive applied by the adhesive applicator mechanism.

25. The apparatus according to claim 1, wherein the objects are fluid-containing capsules.

26. An apparatus for an object assembly for use in the manufacture of smoking articles, the apparatus comprising:

a conveyance path for conveying an elongate member; and

a delivery mechanism configured to deliver objects onto the elongate member conveyed along the path such that first and second rows of objects are formed along the length thereof,

wherein the objects are fluid-containing capsules.

27. A method for making filter rods for use in the manufacture of smoking articles, the method comprising:

conveying an elongate member along a path;

delivering objects onto material drawn along said path such that a plurality of rows of objects are formed along the length thereof; and

feeding the elongate member with the rows of objects thereon to a filter rod forming mechanism and thereby form filter rods each including objects from the plurality of rows.

28. The method according to claim 27, further comprising shaping the elongate member after the objects are delivered thereon.

29. (canceled)

30. An apparatus for forming filter rods comprising:

a filter maker to form a length of filter rod from filter rod material;

an object assembly station to assemble an elongate assembly of objects to be fed to the filter maker to be included in the length of filter rod to make filter rods having one or more of the objects therein; and

a filter material diverting mechanism configured to divert filter material around the object assembly station on its passage to the filter maker past the object assembly station.

31. The apparatus according to claim 30, wherein the filter material diverting mechanism comprises:

a splitter configured to split filter material into two paths; and

a combining member configured to receive filter material from each of the two paths and to receive the object assembly.

32. The apparatus according to claim 31, wherein the object assembly follows a straight path into the combining member and through a filter rod forming mechanism.

33. The apparatus according to claim 31, wherein the object assembly is received from an assembly station for making an object assembly.

34. The apparatus according to claim 33, wherein the assembly station comprises:

a conveyance path for conveying an elongate member; and

a delivery mechanism configured to deliver objects onto the elongate member drawn along the path such that a plurality of rows of objects are formed along the length thereof.

35. A method of forming filter rods from filter rod material, comprising:

using a filter maker to form a length of filter rod from filter rod material;

assembling an elongate assembly of objects at an assembly station;

feeding the assembly to the filter maker to be included in the length of filter rod to make filter rods having one or more of the objects therein; and

diverting the filter material around the object assembly station on its passage to the filter maker past the object assembly station.

36. The method according to claim 35, wherein diverting filter rod material comprises:

splitting filter rod material into two paths;

receiving filter material from each of the two paths at a combining member;

wherein the object assembly is also received at the combining member.

37. A maker for making filter rods, comprising an insert mechanism for inserting a plurality of types of objects into filter rods such that each filter rod comprises a plurality of objects of a first type and a plurality of objects of a second type and such that the objects of each type are arranged with mirror symmetry with respect to a plane bisecting the filter rod, the plane being perpendicular to the longitudinal axis of the rod.

38. The maker according to claim 37, wherein:

the first type of objects are frangible fluid-containing members containing a first flavorant; and

the second type of objects are frangible fluid-containing members containing a second flavorant.

39. A method of making filter rods, comprising inserting a plurality of types of objects into filter rods such that each filter rod comprises a plurality of objects of a first type and a plurality of objects of a second type and such that the objects of each type are arranged with mirror symmetry with respect to a plane bisecting the filter rod, the plane being at right angles to the longitudinal axis of the rod.

40. A filter rod having a plurality of objects of a first type and a plurality of objects of a second type, wherein the objects of each type are symmetrically arranged with respect to a plane bisecting the filter rod, the plane being perpendicular to the longitudinal axis of the rod.

41. A filter rod according to claim 40, wherein:

the first type of objects are frangible fluid-containing members containing a first flavorant; and

the second type of objects are frangible fluid-containing members containing a second flavorant.

42. The apparatus according to claim 16 wherein the transport members have cavities for receiving objects therein, and wherein the transport members are configured to rotate and thereby transport objects received in the cavities to the plurality of rows of objects, thereby delivering objects into the rows.

43. The apparatus according to claim 42, wherein the transport members are configured to rotate around a common axis; and

wherein the cavities of the transport members are not aligned with one another in the direction of said axis.