The present invention relates to a device and method for filling a block-bottom pouch with a tobacco product. Devices and methods for filling a block-bottom pouch with a tobacco product are known. Background of the invention

In a known method for filling a block bottom pouch, the pouch is conveyed by a conveyor to a filling station. The pouch has a flap and is conveyed in an open position, i.e. with the flap open and directed upward. A mouth of the block-bottom pouch is also open. The mouth provides access to the interior of the pouch. The mouth generally has an elongate shape. In this condition the block-bottom pouch is transported to the filling station, filled and transported further downstream.

Generally, the pouch is conveyed by a conveyor in a horizontal direction, the horizontal direction being substantially parallel to the elongate shape of the mouth. Other transport directions may be possible. The conveyor is generally of a start-stop type and has a certain interval distance between each stop. When the pouch reaches the filling station, the conveyor is stopped and pouch is filled. After the pouch has been filled with the tobacco product, the conveyor starts again. It was recognised in the present invention that it is difficult to fill the pouches evenly and fully, in the sense that the tobacco product is spread over the interior of the pouch in an even manner. In particular, the upper corner areas which are situated near the ends of the mouth of the pouch are difficult to fill. Object of the invention

It is an object of the present invention to provide a device and method for filling a block-bottom pouch in which the tobacco product is distributed more even over the interior of the pouch.

It is a further object of the present invention to fill the upper corners of the pouch which are situated near the ends of the mouth of the pouch better than in the prior art. It is a further object of the present invention to provide and alternative filling station for filling pouches with a tobacco product.

The invention

In order to achieve at least one object, the invention provides a tobacco pouch filling system for filling a pouch having a block bottom with a tobacco product, the pouch having an open flap which is directed upwards and a mouth which provides access to the interior of the pouch, the filling system comprising a filling station configured to be positioned along a start- stop conveyor, the filling station comprising:

- a chamber for holding the tobacco product, the chamber having a discharge opening through which a quantity of tobacco is ejected,

a compression-ejection device for ejecting the quantity of tobacco through the discharge opening and inserting the tobacco into the pouch via the mouth of the pouch,

- a flap engagement member for engaging the open flap of the pouch when the pouch is positioned at the filling station,

wherein the filling system comprises an engagement actuator for moving the flap engagement member and the open flap of the pouch toward one another in a engagement direction which is transverse to a main orientation of the mouth in order to position side portions of the flap which project in a forward direction from the flap on either side of the flap engagement member.

In the present invention, the side portions of the flap of the pouch are opened prior to filling. This has as a direct result that the side walls of the pouch are unfolded better and the mouth of the pouch is more open. The tobacco product which is inserted into the pouch has the opportunity to more evenly fill the pouch, in particular the volume near the upper corners of the pouch. The upper corners are located near the ends of the mouth which has an elongate shape. In an embodiment, the engagement actuator is configured for moving the flap engagement member relative to the tobacco chamber from a retracted position to an engaged position. In this way, the pouch can follow a straight trajectory and the flap engagement member can engage the flap when the leading side portion of the flap has passed the flap engagement member. A kinematic inversion is also possible as is explained below in connection with figure 8.

In an embodiment, the compression-ejection device makes a downward movement along an ejection path during the ejecting of the tobacco product from the tobacco chamber, and wherein in the retracted position the flap engagement member is at least partially in said ejection path. It was found that this is a very compact and practical configuration which makes good use of the available space. The flap engagement member does not hinder the ejection process when it is in the engaged position.

In an embodiment, in the retracted position the flap engagement member at least partially blocks the filling opening. It was found that this is a very compact and practical configuration. In an embodiment, the tobacco pouch filling system further comprises the start-stop conveyor for conveying the pouches, the conveyor being configured for moving the pouch with the conveyor in a transport direction toward the filling station, wherein the engagement actuator is configured for moving the pouch and the flap engagement member toward one another in an engagement direction which is oriented transverse to the transport direction. This embodiment allows a straightforward configuration of the conveyor, the flap engagement member and the engagement actuator.

In an embodiment, the engagement direction is horizontal, and the transport direction is horizontal. This enables the filling line to be arranged in an efficient manner. In an embodiment, the engagement direction is orthogonal to the transport direction.

In an embodiment, the engagement actuator is configured for moving the flap towards the flap engagement member. This embodiment enables the flap engagement member to be stationary, which results in a relatively simple device

In an embodiment, the filling station comprises a movable rear wall connected to horizontal compression actuator and a movable floor connected to a floor actuator, wherein the flap engagement member and the floor are constructed to keep the discharge opening closed during a horizontal compression of tobacco by the rear wall and a vertical compression of the tobacco by the compression-ejection device.

In an embodiment, the tobacco pouch filling system comprises a mechanism for unfolding a left side portion and a right side portion of the flap from a folded position in which the left side portion and the right side portion are folded against the flap to an unfolded position in which the left side portion and a right side portion project in the forward direction from the flap. In an embodiment, the pouch comprises a tobacco compartment defined by the block bottom, a front wall, a rear wall a left side wall and a right side wall, wherein the left and right side walls are divided into a front portion and a rear portion which are connected to one another along a fold, the front portion and rear portion can be folded open by unfolding the fold, thereby increasing the size of the mouth of the pouch, wherein the left and right rear portions are integral with the respective left and right side portions of the flap, and wherein the opening mechanism is configured for unfolding the front and rear portions of the left and right side walls, thereby opening the mouth of the pouch. In an embodiment, the tobacco pouch filling system comprises a horizontal compression member in the form of a movable rear wall which is actuated by an actuator and which is constructed to move from a rearward position to a forward position in order to horizontally compress the tobacco in the chamber, and wherein the compression-ejection device is configured for vertically compressing the tobacco after the horizontal compression and prior to the ejection

The present invention is further directed at a method for filling a pouch having a block bottom with a tobacco product, wherein the pouch has an open flap which is directed upwards and a mouth which provides access to the interior of the pouch, and wherein the method comprises:

providing a tobacco pouch filling system comprising a filling station and a conveyor of a start-stop type, wherein the filling station comprises a flap engagement member,

o a chamber for holding the tobacco product, the chamber having an opening through which a quantity of tobacco is ejected through the mouth of the pouch into the pouch,

o a compression-ejection device for ejecting the quantity of tobacco through the discharge opening and inserting the tobacco into the pouch via the mouth of the pouch,

o a flap engagement member for engaging the open flap of the pouch when the pouch is positioned at the filling station, wherein the filling system comprises an engagement actuator for moving the flap engagement member and the open flap toward one another in a direction which is transverse to a main orientation of the mouth conveying the pouch to the filling station in a transport direction, the pouch having a flap which is in an open position and directed upwards, the flap having a central portion and side portions which are also in an open position, stopping the conveyor when the pouch is positioned at the filling station and when a leading side portion of the flap has passed the flap engagement member,

moving said flap engagement member and the flap toward one another in a direction which is transverse to the main orientation of the mouth and engaging the flap engagement member and the flap with one another, and ejecting the quantity of tobacco through the opening, through the mouth and into the pouch,

wherein during the filling of the pouch the side portions of the flap extend on either side of the flap engagement member.

The method provides the same advantages as the tobacco pouch filling system according to the invention. In an embodiment of the method, the side portions engage the sides of the flap engagement member during the filling. In this way it is ensured that mouth stays fully open.

In an embodiment of the method, the engagement direction is horizontal, and the transport direction is horizontal, and the engagement direction is orthogonal to the transport direction. This enables a simple configuration

In an embodiment of the method, the flap engagement member is moved relative to the filling chamber of the filling station. This makes it possible for the pouch to follow a relatively straight trajectory at the filling station. In other words, the pouch may follow a substantially straight trajectory toward the filling station, remain stationary at the filling station during the filling and continue in the same straight direction after the filling. Obviously at some distance from the filling station the conveyor (and the trajectory) may have curves.

In an embodiment of the method, the flap engagement member is moved away from the filling chamber and towards the flap. It was recognized that this is an effective configuration.

In an embodiment of the method, the filling station comprises a filling opening and wherein a mouth of the pouch is positioned underneath said filling opening, and wherein after the mouth is positioned underneath the filling opening, the flap engagement member is moved towards the flap. This arrangement allows filling assisted by gravity and makes good use of the available space. In an embodiment, the method comprises:

- moving the pouch by the conveyor to a position in front of the filling station, but at a distance from the flap engagement member, and

- subsequently stopping the conveyor, and

- after the conveyor has stopped, moving the pouch toward the flap engagement member by the engagement actuator.

This embodiment is essentially a kinematic inversion of an embodiment in which the flap engagement member is moved toward the flap. It is also possible that the flap and the flap engagement member are both moved toward one another for the engagement.

In an embodiment of the method, the pouch comprises a block bottom, a front wall, a rear wall and left and right side walls, wherein the left and right side walls are divided in a front portion and a rear portion which are connected to one another in a fold, wherein the front and rear portion can be folded open by unfolding the fold, thereby increasing the size of the mouth of the pouch, wherein the left and right rear portions are integral with respective left and right side portions of the flap, the method comprising unfolding the front and rear portions of the left and right side walls and unfolding the left and right side portions of the flap from the flap and directing the left and right side portions of the flap forward. In an embodiment, the method comprises the steps of:

compressing the tobacco horizontally,

compressing the tobacco vertically, and

retracting the floor of the chamber from a forward position to a rear position, thereby opening the discharge opening of the chamber, and

- ejecting the tobacco downward through the discharge opening into the pouch.

In an embodiment of the method, the vertical compression member slides through a gap between the flap engagement member which is in the forward position and the rear wall which is also in the forward position during the vertical compression and the subsequent ejection.

These and other aspects of the invention will be more readily appreciated as the same becomes better understood by reference to the following detailed description and considered in connection with the accompanying drawings in which like reference symbols designate like parts. Brief description of the figures

Figure 1 shows an isometric view of a pouch for holding a tobacco product.

Figure 2A shows an isometric view of a tobacco pouch filling system according to the prior art and a pouch for holding a tobacco product.

Figure 2B shows a top view of a tobacco pouch filling system according to the prior art and a pouch for holding a tobacco product.

Figure 3A shows a pouch in the open state as provided and used in the invention. Figure 3A1 shows a schematic top view of the flap of the pouch.

Figure 3B show an isometric view of tobacco pouch filling system according to the invention.

Figures 3C and 3D show isometric views of an unfolding mechanism for unfolding the side portions of the flap.

Figure 3E shows a top view of a filling station according to the invention and a pouch for holding a tobacco product.

Figure 4 shows an isometric view of the filling station prior to engagement of the flap of the pouch.

Figure 5 shows an isometric view of the filling station after engagement of the flap of the pouch.

Figure 6 shows an isometric view of the filling station after horizontal compression of the tobacco.

Figures 7A, 7B, 7C and 7D show isometric views of a sequence of compression and ejection of the tobacco by a compression-ejection device.

Figure 8 shows an isometric view of another embodiment of the invention.

Figure 9 shows an isometric view of an alternative embodiment.

Detailed description of the figures

Turning to figure 1 , a pouch 1 as is generally used for "roll your own" tobacco is shown. The pouch comprises a flap 2, a front wall 3, a rear wall 4, a right side wall 5A and a left side wall 5B. The pouch further comprises a bottom 16. The right and left side walls 5A, 5B are divided into a front part 6F and a rear part 6R which are interconnected along a fold 7. The fold is also a weld line. The fold comprises a small ridge 81 which projects outwardly. The front part and rear part of the side walls 5A, 5B can be folded over said fold. When the front part and rear part of the side walls are parallel, a mouth of the pouch is completely opened. The walls are generally formed of two layers of plastic with a layer of carton or paper in between. Other configurations of the walls are possible. The bottom 16 is a block bottom, i.e. it has a length and a width. These pouches are called block bottom pouches in the field of the art.

The flap 2 has an engagement surface which is an inner surface. The flap also has a back surface. The pouch 1 further comprises side portions 8 of the flap 2. In figure 1 the side portions are only partially visible and lie underneath the flap. Each side portion 8 may be integral with a rear part 6R of the side walls. The flap is shown in the closed position, but when the pouch is being filled, the flap is open and generally directed upward. The front wall, rear wall, side walls and bottom wall define an interior compartment for holding the tobacco. The pouch has a mouth which is not shown in figure 1. The mouth is elongate and extends from left to right.

Turning to figures 2A and 2B, a pouch 1 with a filling station 100 according to the prior art is shown. The pouch is transported to the filling station 100 in a direction 101. After arrival at the filling station, the pouch is filled. It was recognized in the present invention that for filling systems of the prior art, it is difficult to evenly fill the pouch. It is in particular difficult to fill the upper corners 9 which are located near the ends of the mouth. It was recognized that this is due to the fact that the side portions 8 of the flap are folded against the flap, and that as a result the mouth is not fully opened. This makes it difficult to evenly fill the pouch.

Figure 2B shows the mouth 11 of the pouch 1. The mouth is oriented in a horizontal direction, is elongate and has opposite ends 12. Turning to figure 3A, in the present invention the pouch is filled while the side portions 8 of the flap 2 are in an open position and project forward from the flap. This opens the ends 12 of the mouth 11 more and provides better access to the corners 9 of the compartment. In this way, the pouch can be filled better and/or more evenly. As can be seen in fig. 3A1 , the side portions 8 make an angle of 90-160 degrees with the flap, in particular an angle a of 90-150 degrees (when seen in top view). The portion of the flap 2 between the side portions is called the central portion 19. The bottom has a fold 80. The fold 7 between the front part and rear part of the side wall has an outwardly projecting ridge 81.

Turning to figure 3B, a tobacco pouch filling system 10 according to the invention is shown. The system comprises a start-stop conveyor 50 which transports the pouches 1 in the direction 101. The pouches are held by the conveyor by the flap 2 thereof. Initially the mouth 11 of each pouch is closed. The conveyor may be of a type having an endless belt with suction holes for sucking the pouches against the endless belt. The suction hoses which generate under pressure behind the belt are indicated in figure 3B with numeral 58.

A first station 52 is provided which opens the pouches. To this end, an opening device 54 which comprises two engaging plates moves downward into the mouth of the pouch. The two plates are moved away from one another, thereby opening the mouth. The first station 52 is part of the prior art.

Turning to figures 3C and 3D, the pouch then continues to a second station 66 comprising an unfolding mechanism 53 which is constructed to unfold the side portions 8. The unfolding mechanism comprises a beam 54 connected to a mounting flange 55. The beam supports an actuator 56 which is configured to move two rollers 57A, 57B forward in direction 59 and away from one another in direction 60. In use, the rollers are pressed against the inside of the open flap 2 and rolled away from one another in direction 60. The rollers 57A, 57B then press the side portions open.

Turning to figure 3E, a filling station 15 according to the invention is shown in top view. The empty pouch 1 approaches the filling station 15 of the tobacco pouch filling system 10 in the transport direction 101. The pouch may be transported by the conveyor 50, which is not shown in this figure. The filling station 15 is positioned along the conveyor. The side portions 8 of the flap 2 are unfolded and project forward. The side portions also project away from one another.

Turning to figure 4, the filling station 15 of the tobacco pouch filling system 10 is shown when the pouch 1 (with the open side portions 8) has just arrived in front of the filling station 15. The filling station is the third station in line. The tobacco pouch filling system 10 comprises a chamber 20 for holding tobacco. The chamber has a floor 21 , side walls 22 (only one side wall 22 is shown) and an upper opening 23 for filling the chamber with a tobacco product.

The flap 2 is positioned in front of the flap engagement member 26 but at a distance from the flap engagement member 26. This distance is at least equal to the distance over which the side portions 8 of the flap 2 project forward. Otherwise the side portions 8 cannot pass the flap engagement member 26 when the pouch travels in the transport direction 101.

Further, a movable rear wall 24 is provided which is moveable with an actuator 29. The actuator 29 can move the movable rear wall 24 in direction 25. With the movable wall 24, the tobacco in the chamber can be pushed toward the flap engagement member 26 be compressed between the movable rear wall 24 and the flap engagement member 26. The engagement direction 25 is horizontal, and the transport direction 101 is horizontal. The engagement direction 25 is orthogonal to the transport direction 101.

The flap engagement member 26 has the form of a plate and is movable in direction 25 by an engagement actuator 27 from a retracted position to an engaged position. The flap engagement member 26 is movable relative to the fixed parts of the filling station, i.e. the floor 21 and the side walls 22. The direction of movement of the flap engagement member 26 and the rear wall 24 are the same. The flap engagement member 26 is configured for engaging the open flap 2 of the pouch when the pouch is positioned at the filling station 15. The floor 21 is also moveable in direction 25, namely by a floor actuator 31. The floor 21 is moveable between a retracted position and an extended position. The engagement direction 25 is transverse to a main orientation of the mouth 1 1.

Underneath the floor 21 at the front side of the filling station, a number of suction members 30 are provided. The suction members 30 are movable toward the front wall 3 of the pouch by an actuator. The suction devices 30 can suck the front wall 3 and pull it back in order to fully open the mouth 1 1.

Turning to figure 5, when the flap engagement member 26 is engaged with the flap 2, the side portions 8 of the flap 2 which project in a forward direction from the flap are positioned on the left and right side of the flap engagement member 26. The side portions 8 remain engaged with the sides of the flap engagement member during the filling.

The floor 21 is also moved to the forward position. The flap engagement member and the floor 21 make a joint movement which ensures that a front edge of the floor 21 remains in contact with a lower edge of the flap engagement member 26. This keeps the discharge opening 28 closed and provides a support surface for a later vertical compression of the tobacco. It is noted that a variant in which the discharge opening remains open is also possible. In such a variant there may not be vertical compression and the tobacco may be pushed into the pouch without any prior vertical compression. The tobacco may be vertically compressed in the pouch itself.

In the forward position, the flap engagement member 26 and the floor 21 block the mouth of the pouch or at least are positioned above the mouth. Turning to figure 6, the movable rear wall 24 is in the forward position and has ended its stroke at a distance 32 from the flap engagement member 26. The tobacco is now horizontally compressed between the movable rear wall and the flap engagement member. The ejection opening 28 is still closed.

Turning to figures 7A, 7B, 7C and 7D, a compression-ejection device 36 is shown. The compression-ejection device 36 comprises an elongate pusher member 38 which has a lower end 40. The compression-ejection device further comprises an ejection actuator which may be an electric linear actuator.

Turning to figure 7B, the compression-ejection device 36 makes a downward compression movement along an ejection path 37 from an upper position to an intermediate position. During this downward compression movement, the tobacco is compressed between the lower end 40 of the pusher member and the front ridge of the floor 21. Figure 7B shows the intermediate position of the pusher member.

In the retracted position the flap engagement member 26 is at least partially in the path of the pusher member, as can be seen in figure 4. Turning to figure 7C, the floor 21 is moved to the rear position in the direction of arrow 68. The discharge opening 28 is now open. The mouth 1 1 is also fully open as a result of the suction members 30 pulling back the front wall 3 of the pouch. The compartment of the pouch is now fully accessible. Turning to figure 7D, next, the pusher member 38 is moved further downward from the intermediate position to the lowest position. The lower end 40 travels between the flap engagement member 26 and the movable rear wall 24 and ejects the tobacco through the discharge opening. At the end of the stroke of the pusher member 38, all the tobacco is ejected from the filling station and via the mouth into the pouch.

Turning to figure 8, another embodiment is shown which is essentially a kinematic inversion of the first embodiment. In this embodiment, the flap is moved toward and against the flap engagement member 26 by the flap engagement actuator 27. The flap engagement actuator is a pusher which is positioned on the rear side of the flap 2, and not on the flap engagement member 26. From this embodiment it is clear that the flap engagement member 26 may be stationary. It will be recognized that an embodiment may not achieve all of the stated objects.

In the disclosed embodiment of figures 3B - 8, the actuators 27, 29, 31 are electric actuators. The skilled person will understand that hydraulic or pneumatic actuators are also possible. Turning to figure 9, the skilled person will understand that it is also possible that the engagement actuator 27, the horizontal compression actuator 29, and the floor actuator 31 are cam devices which are driven by one or more cams which run(s) through one or more cam tracks 101 , 102, 103. The term "actuator" as used in the claims is intended to be interpreted broadly and to cover this variant.

As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present invention in virtually any appropriately detailed structure. Further, the terms and phrases used herein are not intended to be limiting, but rather, to provide an understandable description of the invention. The terms "a" or "an", as used herein, are defined as one or more than one. The term plurality, as used herein, is defined as two or more than two. The term another, as used herein, is defined as at least a second or more. The terms including and/or having, as used herein, are defined as comprising (i.e., open language, not excluding other elements or steps). Any reference signs in the claims should not be construed as limiting the scope of the claims or the invention.

The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.