The present invention relates to a valve for controlling a flow of solid objects. The invention relates further to an apparatus for supplying solid objects to a reservoir comprising such valve. For example, the solid objects may be capsules or beads which are to be introduced into a continuous flow of filter material during manufacture of filter segments of smoking articles such as filter cigarettes.

Various proposed methods for modifying the sensory attributes of smoke involve using filter elements as vehicles for adding additional flavor to the mainstream smoke in the smoking article. For example, it has been suggested to introduce solid objects such as capsules into the filter material during manufacture of the filter segments.

Various methods and apparatuses have been suggested for the introduction of solid objects into filter tow material during manufacture of filter elements. One such apparatus for the introduction of capsules into a continuous flow of filter tow material is described in WO-A-2011/024068.

The solid objects may contain substances that have a sticky consistency or exhibit a strong odor or both upon getting crushed or damaged. For example, the solid objects may be capsules comprising menthol. Thus, in case damaging of the solid objects occurs the manufacturing units can get clogged due to the stickiness of the content. In addition, the manufacturing units may have to be extensively cleaned to remove the strong odor from the manufacturing facilities that may otherwise contaminate products from subsequent production runs. Accordingly, damaging of the solid objects must be avoided during the feeding and transport of the solid objects. This requirement must be complied with during the entire manufacturing process, and in particular it must when the feeding of solid objects is stopped, for example for maintenance.

There is therefore a need for a means to control the flow of solid objects that minimizes the mechanical forces on the solid objects during operation.

Accordingly, the present invention provides a valve for controlling a flow of solid objects, for example a flow of capsules or beads. The valve comprises an inlet, an outlet, a housing, and a valve body which is rotatably arranged in the housing between the inlet and the outlet. The valve body is rotatable between an open position in which the solid objects are allowed to pass through the valve, and a closed position in which the solid objects are prevented from passing through the valve. The valve body comprises a chamber which is open on the side facing the inlet of the valve. The chamber is closed on the side facing away from the inlet of the valve. The entry opening of the chamber has a constant geometrical shape relative to the inlet as the valve body is rotated from the open position to the closed position. The valve further comprises fluid connection means extending between the inlet and the outlet of the valve. The fluid connection means form a fluid connection from the inlet to the outlet when the valve body is in the open position, in the closed position, and in any intermediate position between the open position and the closed position.

The term "solid objects" as used in connection with the present invention denote objects that have a geometrical shape with well-defined boundaries, in contrast to liquids or gases. By way of example, solid objects include objects which are entirely made of solid state substances, objects having a shell made of a solid substance enclosing a liquid or gaseous core, and objects like gelatine capsules also having well-defined boundaries. For the avoidance of doubt, the solid object according to the invention may be elastic, deformable and crushable if a sufficiently high force is applied.

The term "fluid connection means" as used in connection with the present invention denotes means forming a connection which allows fluids, such as gases and liquids, to pass from an inlet to an outlet. By way of example, the fluid connection means may be formed by a channel.

The valve works thus on the principle difference of the flow behaviour of solid objects and the flow behaviour of fluids, like gases or liquids under the influence of gravity. Simplified, gases will take up the available space, that is, gases will also flow upwards to maintain a constant gas pressure throughout the fluid connection. Liquids will flow upwards through a fluid connection under certain circumstances, following Bernoulli's principle. On the other hand, solid objects have only a little tendency to flow upwards under the influence of gravity but tend instead to jam within a fluid connection before moving upward.

The closure of the wall of the chamber that faces the inlet provides a stop of the solid objects that enter the chamber. Due to the constant geometrical shape of the entry opening relative to the inlet even during rotation of the valve body, no crushing forces are generated on the objects during rotation of the valve body. Neither are any crushing forces generated on the solid objects entering through the inlet of the valve, nor are any crushing forces generated on the solid objects that have already entered into the chamber of the valve body. Simply stated, from the point of view of the solid objects entering the valve nothing changes when the valve is turned except that the flow of solid objects through the outlet of the valve is interrupted as the valve body reaches the closed position. Sliding or shearing surfaces that could lead to damaging of the solid objects are not provided.

This means that, while the material flow of the objects is interrupted when the valve is moved from the open to the closed position, the fluid connection remains intact throughout. Thus liquid or gaseous medium, for example air, can always pass through the valve regardless of whether the valve body is in the open position, in the closed position, or in any intermediate position. This measure also assists in preventing crushing forces on the solid objects to occur.

According to one aspect of the valve according to the invention, the valve body comprises a groove on the outer surface of the shell. The groove runs in circumferential direction over the entire circumference of the shell. Thus, a circumferential channel is formed between the outer surface of the shell and the inner surface of the housing. The valve body further comprises an exit opening provided in the shell. This exit opening connects the chamber to the circumferential channel.

In accordance with this aspect there is always an open connection between the inlet of the valve and the outlet of the valve not only for fluids but also for the solid objects. Starting at the inlet of the valve, the connection from the inlet of the valve to the chamber via the entry opening is always open. This is due to the fact that the geometrical shape the geometrical shape of the entry opening does not change. From the chamber to the circumferential channel there is an open connection via the exit opening. Since the circumferential channel runs over the entire circumference of the valve body, there is also an open connection from the circumferential channel to the outlet of the valve.

Preferably, the chamber is defined by an entry opening arranged on that side of the valve body facing the inlet, by a circumferential wall portion forming a shell, and by a lateral wall portion forming an end wall. The end wall is arranged on that side of the valve body facing away from the inlet of the valve.

When the valve body is in the open position, the exit opening of the valve body is typically arranged in the region of the lowermost possible position where the outlet of the valve is arranged. In this open position of the valve body, the flow of the solid objects then occurs through the inlet of the valve, further through the entry opening into the chamber of the valve body, and subsequently through the exit opening in the valve body and the outlet of the valve. Typically the flow of solid objects is solely caused by gravitational forces. When the valve body is rotated and reaches the closed position, the exit opening is arranged in the region of the uppermost possible position. While the connection from the chamber to the circumferential channel via the exit opening still remains open, the flow of the solid objects through the outlet of the valve is interrupted, since the flow of objects is not sufficiently strong to make the solid objects overcome the gravitational forces. As a consequence, the solid objects do not pass any more through the exit opening into the 360 degrees circumferential channel. Thus, although in principle the connection is open the flow of objects through the outlet of the valve is interrupted. Since the circumferential channel runs along the entire circumference of the valve body, no crushing forces act upon any solid objects which are present in the channel as the valve body is rotated from the open position to the closed position.

Thus, in the open position, the solid objects freely flow through the chamber and through the exit opening in the bottom. When the valve body is turned, the solid objects continue for a while to flow through the exit opening on the side into the circumferential channel until the moment when the location of the exit opening is so far towards the top of the chamber that only a few solid objects are pushed through the exit opening, until finally the exit opening reaches its closed position where no solid objects leave the chamber anymore. The solid objects are then jammed inside the chamber due to the gravitational forces that otherwise move the solid objects onward, until the valve body is turned back into the direction of the open position.

Preferably, the exit opening of the valve body has a smallest cross-section that is between about 4 and about 30 times larger than the diameter of the solid objects, preferably between about 6 and about 15 times larger than the diameter of the solid objects. This allows for an unobstructed transmission of the solid objects through the valve.

Preferably, the groove on the outer surface of the shell has a smallest cross-section that is between about 2 and about 20 times larger than the diameter of the solid objects, preferably between about 4 and about 12 times larger than the diameter of the solid objects. This also allows for an unobstructed transmission of the solid objects through the valve.

Preferably, the chamber has a diameter that is between about 5 and about 50 times larger than the diameter of the solid objects, preferably between about 8 and about 15 times larger than the diameter of the solid objects. This also allows for an unobstructed transmission of the solid objects through the valve.

In accordance with a further aspect of the valve according to the invention, the housing comprises a stop member arranged on an outer surface of the housing facing away from the inlet.

The valve body comprises a handle member arranged on the outer surface of the end wall of the valve body. The stop member and the handle member are arranged relative to one another in a manner such that the handle member abuts against the stop member when the valve body is in the open position and in the closed position, respectively.

According to this aspect the two end positions, that is, the open position and the closed position, are well-determined by the stop and the handle. Thus, either an operator or a suitable automatic drive means may rotate the valve body from one end position to the other end position by simply rotating the handle in the respective direction until it abuts against the stop. From a constructional point of view this is a simple solution for determining the end positions of the valve body. According to another aspect of the valve according to the invention, the inlet comprises a socket for accommodating a supply tube. This is an easy constructional approach for the valve to allow the supply of solid objects through a supply tube which can be easily and reliably connected to the inlet of the valve.

According to yet another aspect of the valve according to the invention, the outlet comprises a tubular spout. The tubular spout allows the solid objects to flow through the tubular spout into the reservoir of the unit for introducing the solid objects into the flow of filter material. Through the tubular spout the solid objects can be reliably directed and discharged.

Another general aspect of the invention relates to an apparatus for supplying solid objects to a reservoir of a unit for introducing solid objects into a continuous flow of material. For example, the reservoir may be the reservoir of a unit for introducing solid objects into a flow of filter material for smoking articles. The apparatus comprises a frame and a first container mounted to the frame. The first container is mounted to the frame in a manner so as to be movable along the frame between a loading position in which the solid objects can be loaded to the first container and a discharge position. The apparatus further comprises a drive for moving the first container along the frame from the loading position to the discharge position. Still further, the apparatus comprises a second container fixedly mounted to the frame. The second container is mounted to the frame at a location in which the second container is capable of receiving the solid objects discharged from the first container when the first container is in the discharge position. The second container comprises a discharge opening through which the solid objects can be supplied from the second container to the reservoir of the unit for introducing the solid objects into a continuous flow of material. Yet further, the apparatus comprises a valve according to the invention, as it is described above. The valve is arranged at the discharge opening of the second container.

The apparatus according to the invention is advantageous in that it allows the loading of the reservoir of the unit for introducing the solid objects into the flow of filter material in a very convenient manner. Loading the solid objects into the reservoir is one of the most cumbersome and time-consuming processes to be performed by an operator during the manufacturing process. The solid objects can be loaded into the first container while the first container is arranged at a level where the operator does not have to perform any lifting operations in order to fill the solid objects into the first container. Thereafter, the first container can be moved (lifted) along the frame until it reaches a discharge position where the solid objects can be discharged into the second container. The lifting operation can be performed, for example, with the aid of a motor or with the aid of a manually operated actuator, for example with a hydraulic actuator. The second container preferably has a volume larger than that of the first container so as to allow loading of the first container to be performed at a point of time when the second container is not completely empty. This gives the operator sufficient time to conveniently perform the refilling operation. This prevents the reservoir of the unit for introducing the solid objects into the flow of filter material from getting empty.

According to one aspect of the apparatus according the invention, the apparatus comprises a feed tube and a second valve according to any of the embodiments described above. The inlet end of the feed tube is connected to the outlet of the first valve which is arranged at the discharge opening of the second container. The outlet end of the feed tube is arranged to supply the solid objects to the reservoir of the unit for introducing the solid objects into a continuous flow of material. The second valve is arranged at the outlet end of the feed tube.

This provides even more flexibility to the apparatus according to the invention, since the feed tube can be mounted or adjusted such that the second valve provided at the outlet end of the feed tube is arranged above the reservoir. However, if needed, the second valve at the outlet end of the feed tube may be displaced to a service position in which it is not arranged above the reservoir of the unit for introducing the solid objects into the flow of filter material. This is possible by simply changing the position of the feed tube. For example, when the second container must be emptied for cleaning or for maintenance purposes, the objects can be discharged from the second container while the feed tube is in the service position.

Also, the two-valve embodiment allows interrupting the flow of solid objects into the reservoir of the unit for introducing the solid objects into the flow of filter material. For example in case the manufacturing process is interrupted, the second valve (and optionally also the first valve) can be closed. In case the feed tube must be maintained or cleaned, the first valve is closed in any event and the objects in the feed tube are discharged. Thereafter, maintenance or cleaning of the feed tube may be performed.

In accordance with a further aspect of the apparatus according to the invention, the apparatus further comprises means for moving the apparatus from a location remote from the reservoir of the unit for introducing the solid objects into the continuous flow of material to a location where the objects can be supplied to the reservoir of the unit. The loading can then conveniently be performed at a location remote from the reservoir of the unit for introducing the solid objects into the flow of filter material. For example, the loading of solid objects can be performed at a location where the solid objects are stored, so that it is not necessary to transport large amounts of solid objects.

Accordingly, as the operator recognizes (or a suitable sensor indicates) that the remaining amount of solid objects in the second container is only small, the operator may move the apparatus away from the unit for introducing the solid objects into the filter material for refilling. At a location remote from the unit, the operator may fill the first container with solid objects and move the first container up along the frame into the discharge position. At the discharge position, the solid objects are discharged into the second container. Then the operator may move the apparatus back to the reservoir of the unit for introducing the solid objects into the filter material.

Alternatively, the operator may fill the first container with solid objects and then move the apparatus back to the reservoir of the unit for introducing the solid objects into the filter material. Only then, the operator moves the first container up along the frame to the discharge position where the solid objects are discharged into the second container. In any of these variants, the cumbersome filling of solid objects into the first container can be conveniently performed at a location remote from the unit for introducing the solid objects into the filter material. In particular, the first container can be filled with solid objects while it is arranged at a level where the operator may perform the filling operation easier.

The invention is further directed to a method of controlling the flow of solid objects, the method comprising the steps of providing a first reservoir and a second reservoir, providing a fluid connection between the first reservoir and the second reservoir, providing solid objects in the first reservoir such that they objects are enabled to travel from the first reservoir to the second reservoir and providing a valve according the invention described above. The method further comprises the step of controlling the flow of the solid object by regulating the position of the valve body of the valve between the open position and closed position.

Preferably, the solid objects are breakable capsules. Further, preferably, one of the first or second reservoirs is a hopper for a capsule inserter in a filter making machine.

Further advantageous aspects of the invention become apparent from the following description of embodiments and aspects of the valve and the apparatus according to the invention with the aid of the drawings, in which:

Fig. 1 shows a perspective view of an embodiment of the valve according to the invention;

Fig. 2 shows a sectional view of the embodiment of the valve of Fig. 1 , with the valve body being in the open position;

Fig. 3 shows a sectional view of the embodiment of the valve of Fig. 1 , with the valve body being in the closed position;

Fig. 4 shows a perspective view of an embodiment of the apparatus according to the invention, with the first container being arranged in the loading position; In Fig. 1, Fig. 2 and Fig. 3 an embodiment of a valve 1 according to the invention is shown. Fig. 1 shows a perspective view of valve 1 , and Fig. 2 and Fig. 3 show sectional views of valve 1. Valve 1 comprises a housing 10, an inlet 11, an outlet 12, and a valve body 13 rotatably arranged in housing 10 between inlet 11 and outlet 12. Valve body 13 can be rotated between a closed position shown in Fig. 2 and an open position shown in Fig. 3.

Valve body 13 comprises a chamber 130 which has an entry opening 131 on that side of valve body 13 which faces inlet 11. Chamber 130 is defined by a circumferential wall portion 132 forming a shell and by a lateral wall portion 133 forming an end wall. Lateral wall portion 133 is arranged on the side facing away from inlet 11. As can be seen in Fig. 2 and Fig. 3, entry opening 131 has a geometrical shape which remains constant relative to inlet 11, regardless of whether valve body 13 is in the open position, in the closed position, or in any intermediate position between the open position and the closed position.

On the outer surface of the shell valve body 13 comprises a groove 134 running in circumferential direction over the entire circumference of the circumferential wall portion 132 forming the shell. Groove 134 forms a circumferential channel between the outer surface of the shell and the inner surface of housing 10. In addition, valve body 13 comprises an outlet opening 135 provided in the shell. Outlet opening 135 connects chamber 130 with groove 134 forming the circumferential channel.

Housing 10 comprises a stop member 100 which is arranged on an outer surface of housing 10, more particular on an outer surface facing away from inlet 11. Valve body 13 comprises a handle member 136 which is arranged on the outer surface of wall portion 133 forming the end wall of valve body 13. Handle member 136 abuts against stop member 100 both when valve body 13 is in the open position (Fig. 2) and when valve body 13 is in the closed position (Fig. 3).

Inlet 11 of valve 1 comprises a socket 110 for accommodating a supply tube 2 through which the solid objects such as capsules 20 or beads can be transported by gravitational forces to inlet 11 of valve 1. In Fig. 2 and Fig. 3 an end of supply tube 2 is shown in a state where it is accommodated by socket 110. Outlet 12 comprises a tubular spout 120 through which the solid objects can be discharged as valve body 13 is in the open position (see Fig. 2) while no solid objects are discharged through tubular spout 120 as valve body 13 is in the closed position (see Fig. 3).

Since groove 134 extends over the entire circumference of valve body 13 and since exit opening 135 is always connected with groove 134, there is always a fluid connection from inlet 11 to outlet 12. Accordingly, air (and to a certain extent liquid) can always flow through inlet 11, chamber 130, exit opening 135, groove 134 and outlet 12, regardless of the actual position of valve body 13.

In operation, as the valve body 13 is in the open position (see Fig. 2) the exit opening 135 faces downwardly towards tubular spout 120. Solid objects 20 are passing through supply tube 2, entry opening 131, chamber 130, exit opening 135 and tubular spout 120 under the gravitational forces acting on the solid objects 20.

As valve 1 is closed, valve body 13 is rotated either manually or automatically with the aid of handle 136 until valve body 13 reaches the closed position (see Fig. 3). During rotation of valve body 13 there are no sliding surfaces that could crush or otherwise damage the solid objects 20. Groove 134 extends along the entire circumference of valve body 13, so that no forces are created acting upon any solid objects 20 which may be in groove 134 during rotation of valve body 13. Accordingly, any solid objects which are in groove 134 during rotation of valve body 13 are not damaged and may pass through tubular spout 120. The geometrical shape of entry opening 131 remains constant throughout the operation of the valve 1. However, as valve body 13 reaches the closed position the gravitational forces acting upon the solid objects 20 entering valve 1 are no longer sufficient to cause the solid objects 20 to pass upwardly through exit opening 135 and into circumferentially running groove 134. Thus, the flow of solid objects 20 through valve 1 is interrupted, although there is still an open connection between inlet 11 and outlet 12 of valve 1. However, any air or liquid may pass through valve 1 so that there is always a fluid connection between inlet 11 and outlet 12 of valve 12, regardless of whether valve body 13 is in the open position (see Fig. 2), or in the closed position (see Fig. 3), or in any intermediate position between the open position and the closed position.

An embodiment of an apparatus 3 according to the invention is shown in Fig. 4. The embodiment of the apparatus 3 comprises a frame 30 and a first container 31 mounted to the frame 30. First container 31 is movable along frame 30 from a loading position (see Fig. 4) where solid objects 20 (see Fig. 2) can be loaded to first container 31 to a discharge position. Apparatus 3 further comprises a drive for performing the movement of first container 31 from the loading position to the discharge position and vice versa. By way of example, the drive may comprise a mechanism which can be manually operated to move first container 31 along frame 30. Alternatively, the mechanism may comprise a motor causing movement of first container 31.

Apparatus 3 further comprises a second container 32 which is fixedly mounted to frame 30 at a location in which it is capable of receiving the solid objects discharged from first container 31 when first container 31 is in its discharge position. In Fig. 4, second container is arranged near the upper end of frame 30. A cover 320 may be arranged above second container 32 to prevent unwanted items from entering into second container 32.

Second container 32 has a discharge opening at the bottom of the front wall (not shown) where a first valve 33 as described above is arranged. First valve 33 allows the solid objects to be retained in or to be discharged from second container 32, depending on whether first valve 33 is closed or open. First container 31 is pivoted to cause the discharge of solid objects from first container 31 into second container 32. Second container 32 has a volume larger than the volume of first container 31 , as will be explained below.

A feed tube 34 is connected to the outlet end of first valve 33. The outlet end of feed tube 34 in turn is arranged to supply solid objects transported through feed tube 34 to a reservoir of a solid object processing unit (not shown), like for example a capsule inserter that is adapted to insert capsules into a flow of filter material. At the outlet end of feed tube 34, a second valve 35 as described above is arranged. Second valve 35 may be provided with a tubular spout, as has already been explained above. Second valve 35 allows the solid objects to be supplied through feed tube 34 and through the tubular spout into reservoir. Alternatively or in addition, tubular spout 210 allows interrupting the supply of solid objects, depending on whether second valve 35 is open or closed.

Finally, apparatus 3 may comprise rollers 36 for moving the apparatus 3 away from reservoir 40 to a location where first container 31 can be conveniently loaded with solid objects.

In operation, as the operator recognizes (or a suitable sensor indicates) that second container 32 contains only a small amount of solid objects and that it is necessary to refill second container 32, the operator may close second valve 35 (and optionally also close first valve 33), so that the supply of solid objects to reservoir 40 is interrupted. In case feed tube 34 is to be cleaned or is to be replaced, first valve 33 must be closed in any event.

For example, apparatus 3 is moved to a location where the solid objects are stored. First container 31 is then moved to the loading position in case it is not in the loading position already.

In the loading position, first container 31 is arranged at a level where the operator may conveniently fill the solid objects into first container 31. Once this filling operation is completed, the operator causes first container 31 to move upwardly until it reaches the discharge position. In the discharge position, first container 31 is pivoted so that the solid objects are discharged from first container 31 into second container 32. The movement of first container 31 along frame 30 as well as the pivoting of first container 31 is performed with the aid of guide rails, as this is known in the art. Since there are still some solid objects left in second container 32 during discharge of the objects from first container 31 into second container 32, the volume of second container 32 must be larger than the volume of first container 31. This allows that the refill operation be performed well in advance of second container 32 getting empty, so that the operator has sufficient time to conveniently perform the refill operation.

Having described embodiments of the valve and of the apparatus according to the invention with the aid of the drawings, the invention is not limited to the described embodiments, but rather various modifications and changes are contemplated without departing from the teaching of the present invention.