UNIT FOR FORMING AN ORDERED GROUP OF FRUSTUM-SHAPED

CIGARETTES

Technical field

This invention relates to a unit for forming an ordered group of frustum- shaped cigarettes.

This invention is thus applicable in particular in the tobacco industry, especially in those market places, such as Indonesia, for example, where there is a demand for conical or frustum shaped cigarettes having a major base and a minor base (corresponding to the filter).

Background art

In the tobacco industry, frustum-shaped cigarettes are normally formed into groups and placed inside a packet by hand after the packet has been partly made. The cigarettes are placed manually inside the packet through an open side wall of the packet and when all the cigarettes in the group have been placed, the packet is closed.

This method, besides being onerous in terms of man/hours, is obviously slow and imprecise because it depends entirely on the productivity and skill of the individual worker.

Moreover, handling the packet and filling it by hand leads to unattractive creasing on the finished packet, considerably reducing the user's perception of its quality.

In the past, automated solutions have been proposed in order to overcome these drawbacks and to allow groups of cigarettes to be formed more quickly and precisely.

A solution of this kind is known from patent EP0838401 , in the name of the Applicant, which describes a unit for the formation of tapered cigarettes into ordered groups. The unit is equipped with a plurality of "drawers" for receiving the frustum-shaped cigarettes supplied by a plurality of hoppers, each hopper being equipped with a plurality of channels which are especially shaped to feed a single cigarette of the packet to the pocket.

More precisely, the channels are partly curved to allow the cigarettes in the columns to remain substantially horizontal.

It should be noted that the unit described in that document has four hoppers, facing each other in pairs, and each designed to supply ¼ of the cigarettes necessary to make up the packet, so that the simultaneous insertion of the cigarettes of a single layer of the packet from both sides of the conveyor enables the cigarettes to remain in position (thanks also to the presence of special removable presser means).

Disadvantageously, in engineering terms, this solution is very complicated because it requires numerous moving components which must operate at very high speed and in perfect synchrony.

Moreover, it should not be forgotten that the pocket of document EP0838401 entails the presence of a presser having a plurality of longitudinal fins constituting partitions which keep the cigarettes separate from each other but whose transversal movement might tear or otherwise damage the cigarette wrapping material.

Disclosure of the invention

This invention therefore has for an aim to provide a unit for forming an ordered group of frustum-shaped cigarettes and which can overcome the above mentioned drawbacks of the prior art.

More specifically, this invention has for an aim to provide a unit for forming an ordered group of frustum-shaped cigarettes and which is fast and precise.

Another aim of the invention is to provide a unit for forming an ordered group of frustum-shaped cigarettes, which can be easily controlled by a single operator and which is convenient to maintain. These aims are achieved by a unit for forming an ordered group of frustum-shaped cigarettes, having the features described in the appended claim 1 and, more specifically, provided with forming means for forming the ordered group equipped with at least one conveyor movable along a direction of movement and provided with a plurality of drawers accessible transversely to the direction of movement and shaped to receive the frustum-shaped cigarettes, at least two loading stations positioned at the sides of the conveyor and configured to position the frustum-shaped cigarettes inside each drawer according to the first or the second orientation respectively, in such a way as to form the ordered group of cigarettes, wherein each loading station comprises a hopper extending between an upper portion and a lower portion, facing the conveyor and equipped with at least a first face, proximal to the conveyor, and a second face, opposite to the first and distal from the conveyor, and at least two units for feeding a flow of frustum-shaped cigarettes, each operatively located upstream of a respective loading station and configured to discharge a flow of frustum-shaped cigarettes in the upper portion of the respective hopper.

According to one aspect of the invention, each hopper comprises a plurality of channels extending along a feed path between the upper portion and the lower portion, each shaped to house a column of frustum- shaped cigarettes oriented transversely to the feed path, wherein each channel has a front portion, proximal to the first face and forming a rectilinear stretch of the feed path, and a rear portion, proximal to the second face and defining a curved stretch of the feed path, so as to keep all the frustum-shaped cigarettes lined up in each channel and oriented along a substantially horizontal direction.

According to a further aspect of the invention, each drawer has a plurality of rectilinear through holes separated from each other and extending parallel with each other from a first end, which can be positioned opposite the lower portion of a hopper, and a second end, which can be positioned opposite the lower portion of the other hopper, each shaped to receive and hold a frustum-shaped cigarette in position.

Advantageously, forming the group of cigarettes is thus simple and precise because the cigarettes are held in place not by the action of each cigarette pressing against the ones adjacent to it but by the "honeycomb" structure of the drawers.

It should be noted that the rectilinear holes of each drawer are positioned in such a way as to define at least two substantially horizontal rows and a plurality of juxtaposed columns.

According to another aspect of this invention, the channels of each hopper are provided, at the lower portion, with respective outlet mouths which can face and be aligned with a corresponding rectilinear hole of the drawer, The outlet mouths (of a single hopper) are spaced equally from each other in such a way as to face rectilinear holes belonging to columns (of a single drawer) which are not adjacent to each other. In other words, the outlet mouths of the channels of a single hopper are, when the respective drawer is in the loading position, aligned with rectilinear holes belonging to alternate columns.

Advantageously, it is thus possible for the operator, by simply changing the row onto which each outlet mouth discharges the cigarette, to form groups of cigarettes of various configurations, that is to say, either where the orientation of each cigarette is alternated with that of the adjacent cigarette and where the cigarettes are collected in groups having a defined orientation alternated with each other.

A further important aspect of the invention is linked to the fact that the feed unit comprises at least one conveyor belt and at least one tray located above the conveyor belt and containing a predetermined quantity of frustum-shaped cigarettes having the first or the second orientation (depending on whether the tray feeds one loading station or the other). The tray is preferably defined by a box-shaped body having at least one base, at least one rear wall, at least two side walls and at least one central wall interposed between the side walls, all rising from the base, away from it, to form two compartments arranged side by side for housing the predetermined quantity of frustum-shaped cigarettes.

Preferably, the compartments are trapezoidal in cross section concordant with each other, that is having the minor base at the rear wall and major base opposite to it.

Advantageously, it is thus possible to contain a large number of cigarettes without upsetting their orientation either in the horizontal plane or in the vertical plane.

It should be noted that the base is preferably removable, that is, movable, to allow an operator to move it from a closed position to an open position when the tray is positioned (and fixed) above the conveyor belt.

In this regard, each tray is preferably provided with quick connect means to allow it to be quickly attached to a supporting body which keeps it above the conveyor belt.

Brief description of the drawings

These and other features will become more apparent from the non-limiting example description of a preferred embodiment of a unit for forming an ordered group of frustum-shaped cigarettes, as illustrated in the accompanying drawings, in which:

- Figures 1 and 2 are a side assembly view and a plan assembly view of a unit according to this invention for forming an ordered group of frustum- shaped cigarettes;

- Figure 3 shows a detail of the forming unit of Figure 1 ;

- Figures 4 and 4a show a further detail of the forming unit of Figure 1 in a side view and a front view;

- Figures 5a-5c are perspective views of a particular component of the forming unit according to the invention;

- Figure 6 is a perspective view of another component of the forming unit according to the invention. Detailed description of preferred embodiments of the invention

With reference to the accompanying drawings, the numeral 1 denotes a unit for forming an ordered group of frustum-shaped cigarettes according to this invention.

The forming unit 1 is installed in a packing machine (not illustrated) for frustum-shaped cigarettes configured to pick up the frustum-shaped cigarettes 100 one by one, form them into ordered groups thanks to the forming unit 1 and wrap them in suitable wrapping material to make the packet of cigarettes.

It should be noted that the expression frustum-shaped cigarettes 100 is used to mean any elongate smokers' article extending along its main direction between a minor base 100a and a major base 100b, preferably both circular.

In the preferred embodiment, the minor base 100a defines the filter tip, whilst the major base 100b defines the point of combustion of the frustum- shaped cigarette 100.

Thus, to keep the packet in the shape of a parallelepiped, the frustum- shaped cigarettes 100 are grouped according to two different orientations in order to compensate for the difference in size between the major bases and the minor bases.

Thus, the ordered group "G" of frustum-shaped cigarettes 100 formed by the unit 1 according to the invention is made up of a plurality of cigarettes 100, some of which are positioned according to a first orientation and the others according to a second orientation, opposite to the first.

The forming unit 1 thus comprises forming means 2 for forming the ordered group "G" of cigarettes 100, equipped with at least one conveyor 3 movable along a direction of movement "A" and provided with a plurality of drawers 4 accessible transversely to the direction of movement "A" and shaped to receive the frustum-shaped cigarettes 100 in order to form the ordered group "G". Preferably, the direction of movement "A" is substantially horizontal.

More precisely, the drawers 4 are defined by containment elements linked to the conveyor and arranged in succession in such a way as to move along a closed feed and return line along the direction of movement.

It should be noted that each drawer 4 is removably connected to the conveyor 3, not only to facilitate maintenance but also to allow rapid changeover.

Preferably, each drawer 4 has a plurality of rectilinear through holes 5 extending transversely, preferably at right angles, to the direction of movement.

The rectilinear holes 5 are separated from each other and extend parallel with each other from a first end 5a, proximal to one lateral edge of the conveyor 3, to a second end, proximal to the other lateral edge of the conveyor 3.

Thus, each rectilinear hole 5 is shaped to receive and hold in position a (single) frustum-shaped cigarette 100.

Therefore, the drawer 4 (and hence the holes 5) extend transversely to the direction of movement "A" for a length which is greater than or equal to the length of a cigarette 100.

Further, the drawer 4 has as many rectilinear holes 5 as there are cigarettes 100 in the packet to be made.

Thus, the drawers 4 are substantially defined by honeycomb blocks, where each cell is defined by a rectilinear hole 5.

Preferably, each rectilinear hole 5 is cylindrical or frustum-shaped. In other words, the rectilinear holes 5 preferably have a circular cross section.

To facilitate insertion of each cigarette 100 into the rectilinear hole 5 (that is, into the cell) there is a chamfer 6, or guide, made at the insertion end 5a, 5b of the frustum-shaped cigarette 100.

To allow universal use of the drawer 4 (that is, to allow it to be used independently of how the cigarettes 100 in the group "G" are arranged), each rectilinear hole 5 has a chamfer 6, or guide, both at the first end 5a and at the second end 5b.

Preferably, the rectilinear holes 5 of each drawer 4 are arranged in such a way as to form at least two substantially horizontal rows "R" and a plurality of columns "C" transversal, preferably at right angles, to the rows "R" (and more preferably, vertical).

In the embodiment illustrated, the drawer 4 has two rows and six columns, because it is designed to form a group "G" of 12 frustum-shaped cigarettes 100.

Thus, each row "R" defines a "half-layer" of the group of cigarettes "G". Alternatively, however, the rows and columns might differ in number and arrangement as a function of the number of cigarettes 100 in the packet. The forming unit 1 also comprises at least two loading stations 7 positioned at the sides of the conveyor 3 and configured to position the frustum-shaped cigarettes 100 inside each drawer 4 (in particular, inside each rectilinear hole 5), respectively, with the first or second orientation as a function of the required arrangement.

Thus, a first loading station 7a is positioned on one side of the conveyor 3 to insert the cigarettes 100 into the drawers 4 with the first orientation, whilst a second loading station 7b is positioned on the other side of the conveyor 3 to insert the cigarettes 100 into the drawers 4 with the second orientation, opposite to the first orientation.

Thus, each drawer 4 has at least two loading positions where it receives the frustum-shaped cigarettes 100 from a loading station 7.

In other words, the forming means 2 are associated with a control unit (not illustrated) configured to move the conveyor 3 along the direction of movement "A" and to stop its movement for a predetermined time interval when each drawer 4 is at a loading position (that is, aligned with a loading station 7).

Each loading station 7 comprises a hopper 8 extending between an upper portion 8a and a lower portion 8b, facing the conveyor 3. Thus, each hopper 8 extends mainly vertically to guide the cigarettes 100 from an upper level to a lower level, where it is aligned with the conveyor 3 (that is, with the drawer 4).

In this regard, it should be noted that the first end 5a of each rectilinear through hole 5 of the drawers 4 can be aligned with the lower portion 8b of a hopper 8 (that is, of the hopper 8 of a loading station 7), whilst the second end 5b can be aligned with the lower portion 8b of the other hopper 8 (that is, the hopper 8 of the other loading station 7).

The hopper 8, comprises at least a first face 9a, proximal to the conveyor 3, and a second face 9b, opposite the first face 9a and distal from the conveyor 3.

It should be noted that each hopper 8 is located next to the conveyor 3 and the distance of the two faces 9a, 9b from the conveyor 3 is measured with reference to the respective edge (and thus at right angles to the direction of movement "A").

According to one aspect of the invention, each hopper 8 comprises a plurality of channels 10, each extending along a feed path "B" of the cigarettes 100. More precisely, each channel is shaped to receive a column (vertical) of frustum-shaped cigarettes 100 oriented transversely to the feed path "B".

The feed path "B" extends between the upper portion 8a and the lower portion 8b of the hopper in such a way as to guide each cigarette 100 from an upper level to a lower level, at an outlet mouth 11 , which can be made to face and be aligned with a corresponding rectilinear hole 5 of a drawer 4.

According to one aspect of the invention, each channel 10 has a front portion 10a, proximal to the first face 9a and forming a rectilinear stretch "B1" of the feed path "B", and a rear portion 10b, proximal to the second face 9b and defining a curved stretch "B2" of the feed path "B".

Advantageously, that way, all the frustum-shaped cigarettes 100 are kept in a column in each channel 10 and oriented along a substantially horizontal direction. In other words, the channel 10 is shaped in such a way that each cigarette 100, as it moves along the feed path "B", undergoes rotation in the horizontal plane with centre of rotation substantially at the front portion 10a.

This compensates the difference in diameter between the two faces of the frustum-shaped cigarette 100 and prevents excessive inclination of the cigarette.

Thus, each section of the channel 10 has an orientation which is inclined at an angle (in the horizontal plane) to both the preceding and the following section.

It should be noted that the curved stretch "B2" of the feed path "B" preferably has a substantially sinusoidal shape with a central axis parallel and co-planar with the rectilinear stretch "B1".

Preferably, each outlet mouth 11 of the channels 10 can be aligned with at least one rectilinear hole 5 of each drawer 4 (when it is in the loading position).

More precisely, the outlet mouths 11 of a single hopper 8 can face and be aligned with a corresponding rectilinear hole 5 of the drawer 4 and spaced from each other in such a way as to face rectilinear holes 5 belonging to columns "C" which are not adjacent to each other.

More precisely, the channels 10 of a single hopper 8 are shaped in such a way that the outlet mouths 11 are spaced from each other to face rectilinear holes 5 of one drawer 4 belonging to alternate columns "C". In other words, each outlet mouth 11 is spaced from the adjacent one by an amount greater than or equal to the section of a single rectilinear hole 5.

It should be noted that to allow maximum variability in the arrangement of the cigarettes 100 in the group "G", the unit 1 preferably comprises four loading stations 7 arranged in twos on opposite sides of the conveyor 3 and each equipped with a respective hopper 8.

In other words, the unit comprises two loading stations 7 on one side of the conveyor 3, following one another and configured to insert the cigarettes 100 into the drawers 4 with the first orientation.

Further, the unit comprises two loading stations 7 on the other side of the conveyor 3, following one another and configured to insert the cigarettes 100 into the drawers 4 with the second orientation.

Preferably, the loading stations 7 on the same side of the conveyor have an inlet portion 23 (or funnel) which is designed to convey the cigarettes 100 towards both of the hoppers 8.

It should be noted that the loading stations 7 might be facing each other in twos, thus defining only two loading positions.

To make machine design and maintenance simpler, however, the loading stations 7 are spaced from each other along the direction of movement "A" of the conveyor 3.

In other words, each drawer 4 has as many loading positions as there are loading stations 7 (that is, four).

Preferably, each loading station 7 is equipped with one hopper 8 whose channels 10 have outlet mouths 11 which are aligned with each other and face rectilinear holes 5 belonging to the same row "R".

Preferably, therefore, the outlet mouths 11 of the channels of one hopper 8 are located at the same height.

Alternatively, the outlet mouths 11 of each channel 10 might be offset, that is to say, partly aligned with one row and partly with the other, so as to maximize flexibility in the distribution of the frustum-shaped cigarettes 100 in the drawers 4.

It should be noted that in order to load the cigarettes 100 into the drawers, each loading station 7 comprises at least one pusher unit 12 substantially aligned with the outlet mouths 11 for pushing each cigarette 100 out of the respective channel 10 and into the rectilinear hole 5 facing it.

The forming unit 1 also comprises at least two units 13 for feeding a flow of frustum-shaped cigarettes 100, each operatively located upstream of a respective loading station (7) and configured to discharge a flow of frustum-shaped cigarettes 100 in the upper portion 8a of the respective hopper 8.

More precisely, the feed units 13 are movable along an operating direction "D" substantially parallel to the direction of movement "A" of the conveyor 3 and are mounted above the conveyor.

The hoppers 8 are therefore interposed between the feed units 13 and the conveyor 3.

In the preferred embodiment, each of the two feed units 13 is associated with both of the loading stations 7 located on one side of the conveyor 3. Advantageously, a single operator can thus control the flow of cigarettes 100 into at least two hoppers 8.

Preferably, the inlet portion 23 (or funnel) is located between the feed unit 13 and the two respective loading stations 7.

Preferably, each feed unit 13 comprises at least one conveyor belt 14 and at least one tray 15 located at a height above the conveyor belt 14 and containing a predetermined quantity of frustum-shaped cigarettes 100.

The conveyor belt 14 thus extends along the operating direction "D" from a feed zone to a release portion 14a facing the loading stations 7.

The inlet portion 23 is shared by the two loading stations 8 and is located in the proximity of a release portion 14a of the conveyor belt 14.

It should be noted that the cigarettes 100 are housed in the tray 15 with a predetermined orientation and it is the positioning of the tray 15 relative to the belt 14 which defines the first or the second orientation of the cigarettes 100 in the unit 1.

Preferably, each feed unit 13 comprises at least two trays 15 located in succession along the operating direction "D" so as to guarantee an uninterrupted flow of cigarettes 100 by changing the trays 15 alternately.

The forming unit 1 thus comprises four trays 15, arranged in twos along the conveyor belts 14.

Preferably, the trays 15 of a single feed unit 13 are located along the conveyor belt 14 in succession at different heights. In other words, a first tray 15a is proximal to the hopper 8 and at a predetermined first distance (that is, a first height) from the conveyor belt 14, whilst a second tray 15b is distal from the hopper 8 and at a predetermined second distance (that is, at a second height), smaller than the first distance, from the conveyor belt 14.

Advantageously, it is thus possible to increase the cigarette flow rate in distributed manner, allowing the first tray 15a to form a base layer of cigarettes 100 along the conveyor belt 14 and the second tray 15b to complete the distribution by placing the cigarettes on top of the base layer. Preferably, each tray 15 is defined by a box-shaped body 16 equipped with at least one base 16a, at least one rear wall 16b, at least two side walls 16c and at least one central wall 16d interposed between the side walls 16c.

The rear wall 16b, the side walls 16c and the central wall 16d rise up and away from the base 16a to define two juxtaposed compartments 17 for housing the predetermined quantity of frustum-shaped cigarettes 100. It should be noted that in the preferred embodiment, the size of each tray 15 (and hence of the compartments 17) is such as to contain between 100 and 200 frustum-shaped cigarettes 100, preferably between 120 and 140 cigarettes.

To allow the compartments 17 to be filled correctly, the side walls 16c and the central wall 16d are shaped in such a way that each side wall 16c, as it approaches the rear wall 16b, converges with the central wall 16d.

In other words, the cross section of each compartment 17 (viewed transversely to the side walls 16c and to the rear wall 16b) is substantially trapezoidal in shape.

More precisely, the minor base of the trapezoidal cross section is defined by a portion of the rear wall 16b.

In other words, each compartment 17 has the shape of a prism with a trapezoidal cross section extending from an upper portion towards the base 16a along its direction of extension "E" (which, in use, is vertical). It should be noted that the tray 15 preferably has a front opening 18, opposite the rear wall .

The tray 15 also has an upper opening 19, opposite the base 16a.

Advantageously, this makes it easier to fill the compartments 17 with the frustum-shaped cigarettes 100.

It should be noted that each tray 15 is located above the respective conveyor belt 14 in such a way that the base 16a faces the conveyor belt 14.

To allow the frustum-shaped cigarettes 100 to flow out quickly and correctly onto the conveyor belt 14, the base 16a of each tray 15 is preferably removable by an operator.

In this regard, the base 16a of the tray 15 is preferably defined by a partition 20, substantially at right angles to the side walls 16c and rear wall 16b, and which is movable between a closed position and an open position.

In the closed position, the partition 20 defines the base 16a preventing the frustum-shaped cigarettes 100 from coming out of the compartments 17. In the open position, the partition 20 is removed by the user to form a gap 21 through which the cigarettes 100 can pass. Thus, in the open position, the frustum-shaped cigarettes 100 can flow out towards the conveyor belt 14.

Preferably, the partition 20 defining the base 16a is slidably associated with the side walls 16c and with the rear wall 16b so that it can be moved manually by the operator (between the closed and the open position). Advantageously, therefore, the operator can divide the flow of cigarettes 100 towards the conveyor belt 14, keeping one compartment 17 open and one closed.

In other words, the partition 20 can be set to an intermediate position allowing the cigarettes 100 to flow out from one compartment 17 only. In this regard, the partition 20 is provided with at least one handle 20a or handgrip which can be used by the operator to push/pull the partition 20. Alternatively, the base 16, that is, the partition 20, is pivoted or rotatably coupled (in tilting fashion) to the side walls 16c or to the rear wall 16b to rotate between the open and closed positions.

Preferably, each feed unit 13 also comprises at least one supporting body 21 located in the vicinity of the conveyor belt 14.

Preferably, the supporting body 21 is located at the side of the conveyor belt 14 and can be coupled, removably, to a tray 15 in such a way as to support it above the conveyor belt 14 itself.

In this regard, each tray 5 is preferably provided with at least one groove or pin which can be engaged with the supporting body 21 in such a way as to remain in an operating position where the base 16a is superposed on and at a predetermined distance from the conveyor belt 14.

Preferably, each tray 15 has a shoulder 22 projecting away from the rear wall 16b and shaped in such a way as to form a groove 22a for receiving a portion of the supporting body 21. Alternatively, the shoulder might project from the side walls 6c.

In the preferred embodiment, the supporting body 21 can be slidably inserted and removed from the groove 22a of the shoulder 22 to allow quick coupling and uncoupling between the tray 15 and the supporting body 21.

In other words, it is easy for the operator to connect and disconnect the tray 15 and the supporting body 21 to and from each other by simply engaging and disengaging them with a simple vertical movement.

It should also be noted that in an alternative embodiment, the groove or recess is made in the supporting body 21 , thus exchanging the male- female coupling functions with the tray 15.

The invention achieves the above mentioned aims and brings important advantages.

In effect, the combination between the shape of the channels and the "honeycomb" structure of the drawers makes it possible to automatically and precisely form the groups of frustum-shaped cigarettes to be packed. Moreover, the use of hoppers having outlet mouths at different heights allows maximizing the versatility of the forming unit, which can make all the combinations and configurations of the packets.

It should also be noted that trays with an openable partition at the base can be quickly and easily positioned, thereby increasing machine productivity.

Furthermore, the ease with which the trays can be mounted and removed allows the operator to substitute an empty tray very quickly, thereby preventing interruptions in the production cycle.

Lastly, it should be noted that the provision of two trays in succession, preferably at different heights not only allows producing a uniform and distributed flow of cigarettes but also prevents interrupting the flow because the two trays are never changed simultaneously.