The invention relates to an apparatus and method for the disassembly of rod-shaped articles, in particular smoking articles or semi-finished smoking articles. The apparatus and method finds particular application in the recovery of elements of a smoking article such as, for example, tobacco, filter elements, capsules or heat sources.

It is known to use cigarette rippers to recover tobacco from rejected cigarette material. The ripper opens the cigarette paper to allow the removal of tobacco from the cigarette. However, the presence of filter elements during the ripping process may be disadvantageous, as the tobacco recovered by the ripping process may comprise filter material. This applies in particular to specific cigarette filter elements, such as filter elements comprising charcoal or capsules with additional flavour, such as menthol. But even for common acetate fiber filter elements, great care has to be taken to prevent that the acetate fibre contaminates the recovered tobacco. Further, today's ripping process is rather destructive and the maintenance of the integrity of recovered non-tobacco parts is at risk.

In addition, today, smoking articles are getting more complex, and smoking articles may comprise more than two sections and sections of different length. The smoking articles that need to be disassembled may comprise for example broken or bent smoking material rods, filter rods of different lengths, rods comprised of smoking material for two cigarettes and two filter sections in the middle, single rejected cigarettes, and a wide variety of smoking articles that comprise of more than just a tobacco rod and an acetate tow filter, such as for example smoking articles comprising smoking article sections such as charcoal filters. Aside from the tobacco, these other smoking article sections may have a substantial value and there may be a desire to recover at least some of these smoking article sections as well. Alternatively, or in addition, these smoking article sections may be undesirable in the recovered tobacco, like for example charcoal, menthol or acetate tow and there is therefore a need to make sure that the recovered tobacco can be readily and fully reused without requiring subsequent removal of foreign materials. In addition, it is of interest to recover the maximum amount of valuable components of rejected smoking articles and rejected semi-finished smoking articles. Further, smoking articles may comprise different components, which should be processed separately, such as filters comprising liquid capsules or filters comprising charcoal. Moreover, prior art apparatus allow only the removing of smoking article sections which are at the end of the smoking article. In particular, it is not possible to remove double filters of semi-finished products.

An object of the invention is to provide an apparatus and a method for the disassembly of rod-shaped articles, which enable separating the rod-shaped articles into longitudinal portions in a flexible and reliable manner independent of the orientation and the configurations of the rod- shaped articles. In particular, an object of the invention is to enable the processing of a variety of smoking articles and semi-finished smoking articles in an individual manner.

One object of the invention is attained by an apparatus for the disassembly of rod-shaped articles, which are extending in a longitudinal direction, in particular, smoking articles or semifinished smoking articles, wherein the apparatus comprises an engagement means, which is adapted to engage the rod-shaped article along its longitudinal direction, wherein the engagement means comprises a plurality of segments, which are individually movable in a sliding direction different from the longitudinal direction of the engaged rod-shaped article, such that the rod-shaped article can be severed into longitudinal portions that substantially correspond to one or a plurality of segments of the engagement means.

The smoking articles are, in particular, rejected smoking articles, which are rejected, for example, by means of a quality control system during a manufacturing process. The smoking articles comprise cigarettes, and smoking articles for smoking devices with a dedicated heat source, like for example a carbonaceous heat source or electrical heating elements. In this respect, the smoking articles may also comprise tobacco rods that are engineered to operate in conjunction with smoking devices that heat the tobacco rods without burning the tobacco.

The severing of the rod-shaped articles by means of the segments relates to breaking, cutting or separating by means of shear force.

The movement of the segments in a direction different from the longitudinal direction may apply shear forces to the article at predetermined locations, in particular, where relative movement of the segments occurs, in particular some segments are moved and the other, in particular, adjacent segments either remain not moved or moved in an alternative direction, preferably, the opposite direction.. Thus, the article can be severed into predefined longitudinal portions. In particular, neighboring segments are movable in substantially parallel sliding directions, respectively.

In particular, at least two or a plurality of segments, preferably two to ten segments are assigned to a longitudinal portion of the rod-shaped article. Preferably, these grouped segments move together. However, for each smoking article or a semi-finished smoking article, different segments can be grouped into such a group. In one embodiment, the number of segments that are assigned to a group is fixed, whereas the position of the group of segments within the chain of segments is flexible. For example, in a chain of 100 segments, the smallest group size may be 5 segments, but the position of the group, that is, which segment is the first segment of the group can be freely assigned. Alternatively, both the position of the group and the number of segments in a group may be assignable. Preferably, the assigning of the group of segments is performed in reaction to a signal from a control unit. Preferably, the position of the group or the number of segments in a group, or both the position and the number of segments in a group is determined in reaction to a sensor signal that is indicative of the position and length of the longitudinal portion of the rod shaped article that is to be severed from the remainder of the rod shaped article.

The segments preferably each have a length of between about 0.5 millimeters and about 6 millimeters in the longitudinal direction, more in particular, between about 1 millimeter and about 3 millimeters.

Preferably, actuation means are provided, which are adapted to move the segments individually or in groups. These actuation means may be linear motors or servo drives. Furthermore, these actuation means may be stationary or moving cams, which engage with the individual segments or a combination of linear motors, servo drives and stationary or moving cams.

The term "semi-finished smoking article" is used herein to relate to semi products during the production of smoking articles that comprise either a tobacco column or at least one other longitudinal portion of the smoking article that is intended to be recovered from the semi-finished smoking article. Semi-finished smoking articles are for example: tobacco rods, double length filters with one or two tobacco rods attached to the double filter, other combinations of filter segments and tobacco rods or bent tobacco rods.

The term "longitudinal portion" is preferably used herein to relate to any individual smoking article section. The term "longitudinal portion" is also used to encompass combinations of two or more individual smoking article sections. The term "smoking article section" is used herein to refer to the smallest individual rod shaped element of the rod shaped article. For example, a filterless smoking article comprises just a single smoking article section, that is, the tobacco rod. A simple filter cigarette comprises two smoking article sections, that is, the tobacco rod and the filter. Other smoking articles may comprise additional sections like, for example; a filter tow plug with carbon particles, a filter tow plug with plant material, a filter tow plug with a flavor thread, a filter tow plug with a capsule, a filter tow plug with multiple capsules, a filter tow plug with cellulose beads or granules, a filter segment with a cavity that is filled with for example, cellulose or carbon beads or granules, capsules or one or more non cuttable objects like flow restrictors, such as for example a hollow tube. Further examples for smoking article sections are a tobacco rod segment with beads or capsules, a tobacco plug with particular tobacco, for example, oriental tobacco, a heat source, for example a carbonaceous heat source, a section comprising a sheet material such as for example paper, cardboard, metal, such as for example aluminum, or a tobacco web, and sections comprising combinations of two or more of the elements above, for example a acetate tow filter plug with a thread and charcoal particles interspersed within the acetate tow. Typically, the individual "smoking article sections" have a sharp edge. Typically, the individual "smoking article sections" are manufactured separately and then, at a later stage, combined to the final smoking article in a series of combining steps, for example on a filter combiner or on a cigarette combiner, or on specialized machinery. Typically, the individual smoking article sections are connected to each other by the use of a wrapper, such as for example, porous plug wrap or tipping paper. The aforementioned size of the segments is in particular useful when processing smoking articles in the form of smoking articles with a length between about 40 mm and about 120 mm.

In particular, the present invention allows the simple and efficient disassembly of a series of rod-shaped articles that are randomly oriented in the longitudinal direction, such as smoking articles that arrive filter first or tobacco rod first at the apparatus for disassembly. This greatly simplifies the process of disassembly as the step of flipping a rod shaped article about its longitudinal direction of travel is very difficult at high speed. Furthermore, the apparatus according to the invention allows the removal of a central longitudinal portion from a rod shaped article, that is a longitudinal portion that is not bound by an end of the rod shaped article, like, for example a central filter element, as present in double-length semi-finished products.

Preferably, the adjacent segments of the engagement means are connected to each other by a sliding connection allowing the segments to slide with respect to each other in the sliding direction that is different from the longitudinal direction of the engaged rod-shaped article. In particular, the sliding connection may be a track that is provided in the sliding direction on the one side of a segment while the other side of the segment comprises a protrusion, which engages in the track of an adjacent segment.

In particular, the track and the protrusion can be dovetail-formed. Further, it is possible that the track is a slit or a groove, while a protruding element, such as a protrusion on a segment formed by a sheet metal, engages in the groove or the slit.

In a preferred embodiment, the engagement means is a conveying means adapted to convey the rod-shaped articles, substantially in the longitudinal direction. The conveying means is preferably an endless belt or chain. The conveying means may be formed of the segments that are connected to each other in the longitudinal direction. Alternatively, the conveying means may comprise at least one further component, which connects the segments. The segments may be provided along the whole length of the conveying means. Where the engagement or conveying means has a sufficient length, several rod-shaped articles may be arranged therein at the same time and may be disassembled simultaneously. In one embodiment, the conveyor comprises a base element on which the individual segments are arranged by a sliding connection, such that they can slide individually with respect to the base element. The base element may be an endless belt or chain, on which the individual segments may be provided, each by means of a sliding connection, respectively. A sliding connection may, for example, be a track on the base element or on the segment and a protrusion on the respective other of the base element and segment. The track and protrusion connection may in particular be in the form of a dovetail connection. In other embodiments, the sliding connection may be in the form of a sheet metal extending into a groove or a slit.

Actuation means may be provided on the base element to move the individual segments.

In one embodiment, the conveying means comprises two conveyors adapted to receive the rod-shaped article in between them. Each of the conveyors may be composed of segments, which are sequentially arranged along the conveyor, wherein the segments are connected to each other in the conveying direction and are movable in the sliding direction different from the conveying direction. In particular, the segments are movable in a sliding direction substantially perpendicular to the conveying direction. This enables the rod-shaped article to be held securely in the conveyor. Each of the conveyors may be composed of segments, which are individually movable in the sliding direction with respect to each other. In particular, the two conveyors may engage the articles from opposite sides. Thus, the articles are held stably in the conveyor, in particular, if the segments engaging the article from opposite sides are individually movable with respect to each other.

In another embodiment, each of the segments comprises a recess, wherein the recesses can be aligned with each other to allow the receiving of the rod-shaped article by a plurality of segments. When, a plurality of segments is aligned for receiving the rod-shaped article, their recesses are aligned to form a groove together. Subsequently the segments may be moved with respect to each other in the sliding direction to apply a shear force to the rod-shaped article. The recess corresponds substantially in its width to the diameter of the rod-shaped articles. Preferably, the segments are U-formed. In particular, this embodiment corresponds to the previous embodiment, wherein the left and right segments are connected. Thus, the left and right segments are movable together such that an individual actuation means for the segments on both sides is not required. The recess is in particular a holding means, while in other embodiments, a separate holding means can be provided in the recess. Where the recess is the holding means, its width is preferably slightly smaller than the diameter of the rod-shaped article, such that the rod-shaped article is held stably by the elastic forces in the recess. A separate holding means may be a clip, spring, elastic element, or locking element in the recess. In one embodiment, downstream receiving means are provided, wherein the conveying means are adapted to provide the individual longitudinal portions of the rod-shaped article to a selected downstream receiving means, respectively, depending on the position of the segments assigned to the individual portion. The downstream receiving means are in particular output channels, conveyors, storing elements or buffers.

Preferably, the segments are individually movable in the direction perpendicular to the longitudinal direction. This advantageously enables that by movement of the segments in the perpendicular direction to the conveying direction the rod-shaped articles may be severed and separated into different downstream receiving means. According to the invention, the perpendicular movement is not limited to a horizontal movement, but encompasses movement in any direction perpendicular to the longitudinal direction, including horizontal and vertical movement and any combination thereof. It is for example possible, to construct the apparatus according to the invention such that it is configured to move a tobacco rod section horizontally sideways, a carbon containing section vertically upward and an acetate tow section vertically downwards. This can greatly simplify the subsequent sorting and further processing of the severed longitudinal sections.

In one embodiment, a sensor is provided to determine the configuration of the rod-shaped article along its longitudinal extension while a control device controls the movement of the segments to sever the rod-shaped article in correspondence with its configuration. The configuration of the rod-shaped article is, in particular, the material of the article in each of the longitudinal portions. The sensor may be a laser sensor, X-ray sensor, microwave sensor or an optical sensor. The sensor may further be a capacitive sensor, an ultrasonic sensor, an optical sensor by means of transmission or reflection, an optical sensor in the X-ray range of the electromagnetic spectrum, a microwave sensor, a magnetic or inductive sensor, a pressure or force sensor, as well as an image processing sensor or combinations thereof. The initial image obtained by the sensor may be image-processed to determine the configuration of the smoking articles. In particular, the sensor may determine one of the following configurations of the smoking article or combinations thereof: the type of the smoking article segments, the length of one, more than one or all smoking article segments, or the upstream edge of one, more than one or all smoking article segments. This enables that different segments or subsets of segments can be assigned to the longitudinal portions of the rod-shaped article. Thus, by moving the respective segments or subsets of segments, this enables that the individual longitudinal portions of the smoking article can be severed and separated from each other.

The invention further provides a tobacco recovery unit for rejected smoking articles comprising an apparatus according to the invention for separating tobacco rods and filter elements of the rejected smoking articles or semi-finished smoking articles. The rejected smoking articles or semi-finished smoking articles are rod-shaped articles. In particular, an alignment unit, for example, an alignment bowl in the form of an orbital bowl feeder or a cascade alignment unit may be provided upstream of the apparatus according to the invention. The cascade alignment unit preferably comprises at least a first set of alignment grooves and a second set of alignment grooves, wherein the first set of alignment grooves is located upstream of the second set of alignment grooves, and wherein the number of alignment grooves in the second set of alignment grooves is at least double the number of alignment grooves in the first set of alignment grooves. More preferably, the first set of alignment grooves is arranged above the second set of alignment grooves and below the lowermost sections of the first set of alignment grooves are arranged above the uppermost sections of the second set of alignment grooves. Further, the width of the alignment grooves of the second set is preferably half the width of the alignment grooves of the first set. Thus, from one alignment groove of the first set of alignment grooves, the smoking articles or semi-finished smoking articles will fall in a first alignment groove or a second alignment groove of the second set of alignment grooves according to a stochastic distribution. In particular, a third set of alignment grooves may be arranged downstream of the second set of alignment grooves, wherein the third set of alignment grooves comprises a number of alignment grooves, which is at least double the number of alignment grooves of the second set of alignment grooves. Accordingly, a fourth, fifth, sixth set or more sets of alignment grooves may be provided, each having twice the number of alignment grooves compared to the respective previous upstream set. The alignment grooves may preferably be formed in a V-shape or by semi-circular channels. In some embodiments, the alignment unit may be actuated, in particular to vibrate to facilitate the movement of the smoking articles or semi-finished smoking articles therein.

Furthermore, the tobacco recovery unit may comprise ripping equipment for opening the tobacco rods and a unit for separating tobacco from the wrapping material. The unit for separating the tobacco from the wrapping material may be in particular a sieving unit or a cyclone unit. The ripping equipment is adapted to receive only the tobacco-containing longitudinal portions of the smoking articles after the smoking articles have been severed from the remaining longitudinal portions of the smoking articles, such as filter plugs. In particular, the ripping equipment cuts open the smoking article or semi-finished smoking article along one longitudinal side, such that the smoking material and the wrapping material of the smoking article or semi-finished smoking article can be separated. According to the invention, at that time other longitudinal portions of the smoking articles have already been removed, such that the risk of mixture with parts of the removed longitudinal portion, for example, filtration material, such as acetate tow is avoided. In particular, the ripping equipment is adapted to cut open the cigarette paper of tobacco rods.

According to the invention, a method for the disassembly of rod-shaped articles is provided, that method comprising the steps of first engaging the rod-shaped article along its longitudinal extension by means of a plurality of segments consecutively arranged in the longitudinal direction, then individually moving the segments in a sliding direction different from the longitudinal direction of the engaged rod-shaped article, such that the rod-shaped article is severed into longitudinal portions, which substantially correspond to one or a plurality of segments.

Preferably, the method further comprises the step of detecting the configuration of the rod- shaped article along its longitudinal extension and moving the segments in accordance with this information. The detection of the configuration can be carried out with a sensor as specified above.

In particular, the method further comprises the step of conveying the rod-shaped article in the longitudinal direction while severing the rod-shaped article into individual segments. The conveying may be conducted by means of a conveyor belt comprised of the segments or by the segments being arranged on a conveyor.

Preferably, the method further comprises the step of positioning the segments, such that the individual portions of the rod-shaped article are moved to at least two different downstream locations, thus enabling the separation of the different longitudinal portions of the rod-shaped article. The two different downstream locations include locations that are separate from each other in any of the three dimensions or combinations thereof.

The invention will now be further explained with reference to exemplary embodiments as shown in the following figures.

Figure 1 shows a side view of the apparatus according to an embodiment of the invention.

Figure 2 shows a cross-section through a smoking article and the segments of an apparatus according to an embodiment of the invention.

Figure 3 shows a cross-section through a smoking article and the segments of an apparatus according to another embodiment of the invention.

Figure 4 shows a top view of an apparatus according to an embodiment of the invention at a first stage of processing a smoking article.

Figure 5 shows the apparatus according to figure 4 at a second stage of processing the smoking article.

Figure 6 shows the apparatus according to figure 4 at a third stage of processing the smoking article. Figure 7 shows the apparatus according to figure 4 at a fourth stage of processing the smoking article.

In figure 1 , an embodiment of an apparatus according to the invention is shown in a side view. The apparatus comprises a feeding conveyor belt 1 , on which the rod-shaped smoking article 2 is transported to an engagement means in the form of a conveying means 3. The smoking article 2 is transported in its longitudinal direction. The conveying means 3 comprises a plurality of segments 4, which are arranged adjacent to each other, along the whole extension of the conveying means 3. In an engagement section 5, which is constituted in the present embodiment by the segments 4 extending in the lower part of the conveying means 3, the conveying means 3 engages the smoking article 2. The smoking article 2 is transported through the engagement section 5 and simultaneously severed into longitudinal portions. In particular, the longitudinal portions of the smoking article correspond to different smoking article sections, such as a filter section 6 and a tobacco rod 7.

The conveying means 3 is an endless conveyor belt, which is extending substantially horizontally and moves at its lower side in the conveying direction 8.

A sensor 9 is provided at the upstream end of the engagement section 5 or at a further upstream position. The sensor 9 analyzes the configuration of the smoking article 2, in particular, of which smoking article sections the smoking article 2 is composed.

In particular, the sensor 9 is stationary while the smoking article 2 is conveyed through a measurement area of the sensor 9. The sensor 9 determines the beginning, length and type of each smoking article section of the smoking article 2. Thus, the configuration of the smoking article 2 along its longitudinal extension is known and can be forwarded to the control means, which is adapted to control the movement of the segments 4 of the conveying means 3.

In particular, the feeding conveyor belt 1 is moving at the same speed in the conveying direction 8 as the conveying means 3. The smoking article 2 is moving at the same speed as the conveying means 3 at least in the engagement section 5. Thus, each of the segments 4 will be assigned to specific longitudinal portions of the smoking article. A plurality of segments 4 may be assigned to one longitudinal portion forming a smoking article section, such as the filter section 6 or the tobacco rod 7. As the sensor 9 is synchronized with the conveying means 3, the control means can determine the information, which longitudinal portion of the smoking article 2 is assigned to which segments 4. By the movement of the segments 4 in a sliding direction 10, substantially perpendicular to the conveying direction 8, the longitudinal portions 6, 7 are severed from each other. It should be noted, that the sliding direction includes a sliding motion in the direction indicated by the arrow as well as in the opposite direction in order to return to the initial position. Downstream of the conveying means 3, a downstream receiving means 11 , in particular in the form of a further conveying means or a storing element or a combination thereof, is provided. The downstream receiving means may comprise a conveyor, which further conveys the tobacco rods 7 to a ripping equipment, and a storage element, which stores the filter sections 6 of the smoking articles 2.

In figure 2, a cross section of the conveyor means 3, the smoking article 2 and the feeding conveyor belt 1 , as seen in the conveying direction 8, is shown. The conveying means 3 comprises a base element 12, which is arranged above the segments 4, wherein the segments 4 are slidably arranged on the base element 12 in the sliding direction 10. Thus, when the smoking article 2 enters the conveying means 3, the segments 4 may individually move towards the smoking article 2 to engage the smoking article 2 as shown in figure 4. For this purpose, actuation means may be arranged on the base element 4, or in a stationary manner next to the conveying means 3. When the segments 4 engage the smoking article 2, the smoking article 2 is securely held in the conveying means 3. Alternatively, the feeding conveyor belt 1 may extend all along the engagement section 5 of the conveying means 3, such that it supports the smoking article 2. The base element 4 may be provided with transparent portions or openings to allow that the sensor 9 can determine the configuration of the smoking article 2. Alternatively the sensor 9 may be arranged below the engagement section 5.

In figure 3, another embodiment of the conveying means 3 is shown. In this case, the smoking article 2 is held by only one segment 4, wherein the segment comprises a recess 13, in which the smoking article 2 is arranged. The recess 13 may correspond in its dimensions substantially to the width of the smoking article. In the embodiment of figure 3, no engagement motion as shown in figure 4 is possible and, thus, the segment portions arranged on opposite sides of the smoking article 2 can only be moved as one.

In figures 4 to 7, the severing of longitudinal portions of a smoking article 2, in particular, the filter section 6 and tobacco rod 7 is shown in different stages of the disassembly method. At the beginning the smoking article 2 is inserted into the conveying means 3 as shown in figure 4 and some of the segments 4 of the conveying means 3 engage and hold the smoking article. The engagement step as shown in figure 4 is optional, and therefore might not be carried out in other embodiments, such as the embodiment shown in figure 3. The longitudinal portions of the smoking article 2 are determined by means of the sensor 9. Accordingly, the individual segments assigned to the different longitudinal portions 6, 7 of the smoking article 2 can be moved in different directions.

At a first stage, different segments 4 can be moved to create an inclined channel with respect to the conveying direction 8 as shown in figure 5. However, it is also possible that the segments assigned to a longitudinal portion of the smoking article simultaneously move in a parallel manner as shown in figure 6. In some embodiments, the stages of figure 5 and figure 6 are carried out subsequently.

Finally, the segments 4 are arranged as shown in figure 7, such that the tobacco rod 7 is released on one side, while the filter section 6 is released on the other side in the sliding direction 10 to the downstream receiving means 11.

In particular, the apparatus according to the invention allows the severing of smoking articles or other rod-shaped articles of more complex configurations, such as articles comprising more than two longitudinal portions of varying lengths. The individual configurations will be detected by the sensor 9. Then the different segments 4 can be adapted in their movement to various configurations of the smoking articles, by assigning the different segments 4 to individual longitudinal portions of the articles and accordingly moving the assigned segments 4 in the sliding direction 10.

Furthermore, it is possible that the downstream receiving means 11 comprises more than two different reception areas, such that several different types of longitudinal portions of smoking articles can be received, such as filters comprising charcoal, filters comprising capsules, and filter plugs. In this way, as the different longitudinal portions of the smoking articles have been divided, each of them can be further processed in an efficient manner.

In particular, the tobacco rod 7 will be further conveyed to a ripping equipment, which opens the tobacco rod, and further separates the cigarette wrapper from the tobacco. Thus, the tobacco material will not get mixed with filtration material because the tobacco rods are already cleanly separated from the filter sections.

In the present embodiment, a stationary sensor has been described. However, it is also possible that the sensor moves together at least along a given distance with the segments.

The benefits of the present invention include the feature that the apparatus has a high flexibility and can process a variety of different rod-shaped articles. Only little alignment of the smoking articles have to be performed in order to be disassembled due to the possibility to separate portions from the rod shaped articles based at arbitrary positions, based on the sensor signals. Further, it can be easily combined with existing ripping equipment. Due to the flexible and precise severing of the longitudinal portions of the smoking articles, the yield and the quality of the product can be increased. In particular, longitudinal portions in the form of clean sections of the smoking article, which are available for further usage, such as recycling or reuse, can be generated. The invention allows producing tobacco rods and tobacco ripper shorts that are free from charcoal particles, acetate fibers or any other components comprised in the filter section of smoking articles. Furthermore, there is no need for filter cleaning steps as described in many prior art teachings.

Further, the degradation of the tobacco fibers in the tobacco rod can be reduced, as the severing process of the tobacco rod from the further longitudinal portions of the smoking article is relatively gentle compared to other filter separation units known in the prior art. The inventive apparatus allows quickly processing smoking articles, while at the same time, an increased ripper throughput can be obtained, as it can be guaranteed that filter sections have been removed from the smoking articles.