Apparatus and method for automatically forming housing comprising filter for smoking article

Abstract

An apparatus (10) for automatically forming a housing (100) comprising a filter (200) for a smoking article comprises a first forming unit (11) configured to form a filter (200) starting from a shaped first sheet (202) and a second forming unit (51) configured to form the housing (100) starting from a shaped second sheet (202). The first forming unit (11) comprises at least one first forming mandrel (22) capable of rotating about its first axis of rotation (AR1) to form the filter tip (200); and the second forming unit (51) comprises at least one second forming core rod (52) so as to form the shell (100).

Description

Technical Field

[0001] The present invention relates to an apparatus and a method for automatically forming a housing provided with a filter for a smoking article, the housing being subsequently intended to be filled with a smokable product such as tobacco or the like. Background Art

[0002] In the field of smoking articles, there is an increasing need to manufacture cigarette-sized housings which guarantee high production rates and full automation.

[0003] Typically, the outer shell for smoking articles has a generally cylindrical or truncated cone shape and is made of extremely fragile thin paper (thickness of about a few hundredths of a millimeter) that is non-toxic and smokeable, and is therefore difficult to handle mechanically.

[0004] Furthermore, a filter is arranged corresponding to the mouth end of the housing, which is made by folding different types of paper (non-smokable with a thickness of a few tenths of a millimeter) and wrapping it around itself.

[0005] In particular, a device is known for forming a casing by winding shaped flat elements made of flexible paper material, which overlap around a respective forming member, called a forming mandrel, which has a substantially cylindrical or possibly truncated cone shape.

[0006] However, the known device has the disadvantage of being too complicated and is used to first form the shell and then insert the filter therein. More specifically, the shaped shell is transferred to a corresponding rotating member which positions the shell in a position for inserting the filter. Another disadvantage of the known device is that, during the transfer and transportation of the shell, there is a risk of possible damage to the shell, in particular at the end corresponding to the mouthpiece thereof (where the filter will be arranged), since the shell is made of a very fragile material and is operated by mechanical members.

[0007] Furthermore, in the known devices, there must be perfect alignment between the housing and the member allowing the filter to be inserted therein, which otherwise leads to slowing down and interruption of the working cycle, in addition to damage to the housing itself.

[0008] Documents WO 2021 / 156817 A1 and WO 2021 / 156818 A1 describe a machine and method for producing a tubular element provided with a filter tip at one end. The machine provides a rotary conveying device provided with at least one tubular pocket having a base inside it, which negatively replicates the shape of the tubular element and is suitable for receiving the tubular element. In addition, the machine comprises: at least one transfer station in which the tubular element is transferred to the inside of the base of the pocket; and an insertion station in which the filter tip is inserted into the corresponding tubular element already formed and accommodated in the respective base. Corresponding to the transfer station, there is a truncated cone-shaped tubular insert, which is partially introduced into the tubular element already formed and accommodated in the base to allow the filter tip to be inserted by means of a propulsion element. The use of several transfer and insertion devices to transfer the tubular element and / or insert the corresponding filter tip means that the machine is particularly complex. Furthermore, inserting the filter into the machine is a very delicate operation, since the tubular element, usually of very thin paper, is already formed and may break or become damaged during the manipulation thereof in order to allow the filter to be inserted.

[0009] Therefore, there is a need to improve an apparatus for automatically forming a housing including a filter tip that overcomes at least one of the disadvantages of the prior art.

[0010] To this end, the following technical problems must be solved: producing the assembly defined by the filter and the shell in a fast, simple and reproducible manner without damaging the shell and / or the filter, and ensuring a high final quality of the obtained assembly and a high production rate of approximately more than 10,000 pieces / hour.

[0011] In particular, an object of the present invention is to provide an apparatus for automatically forming a shell including a filter and to perfect a method for automatically forming a shell including a filter, which allows rapid positioning of the filter relative to the shell and minimizes the risk of damaging the shell itself.

[0012] Another object of the present invention is to provide an apparatus for automatically forming a casing including a filter and to perfect a method for automatically forming a casing including a filter, which is efficient and versatile and allows a high productivity to be obtained.

[0013] Another object of the present invention is to provide an apparatus for automatically forming a shell including a filter tip and to perfect a method for automatically forming a shell including a filter tip, which can be integrated into a more complex machine while being able to perform other processing on the shell (for example, a finished smoking article of the shell).

[0014] The Applicant has devised, tested and embodied the present invention to overcome the shortcomings of the state of the art and to obtain these and other purposes and advantages. Summary of the invention

[0015] The invention is set forth and characterized in the independent claims. The dependent claims describe other characteristics of the invention or variants to the main inventive idea.

[0016] According to the above-mentioned purpose, in order to solve the above-mentioned technical problems in a new and original new way, and at the same time achieve considerable advantages compared with the prior art, an apparatus for automatically forming a shell with a filter for a smoking article according to the present invention comprises: a first forming unit, configured to form a filter starting from a first sheet material, and a second forming unit, configured to form a shell starting from a second sheet material, wherein the first forming unit comprises at least one first forming core rod, which is capable of rotating around its first rotation axis to form the filter and capable of moving axially along the first rotation axis, the first forming core rod being provided with a retaining device to retain at least a first portion of the first sheet material, and wherein the second forming unit comprises at least one second forming core rod, which is configured to wrap the second sheet material on its outer surface to form the shell.

[0017] According to one embodiment of the present invention, the second forming mandrel is provided with a through axial cavity inside. In addition, at least one first forming mandrel is configured to push the filter along the through axial cavity by means of a rotational translation movement around and along the first rotation axis when the second forming mandrel with the second sheet wrapped on its outer surface is aligned with the first forming mandrel along the common insertion axis.

[0018] According to another aspect of the invention, the first forming unit comprises at least one abutment element which is arranged coaxially with the first rotation axis at a fixed axial position relative to the first forming mandrel and which is operatively associated with the holding device.

[0019] According to another aspect of the invention, the abutment element comprises a through cylindrical cavity coaxial with the first axis of rotation and into which the retaining device and at least a first portion of the first sheet can be inserted, and a side slit tangential to the cylindrical cavity to allow the second flat portion of the first sheet to pass.

[0020] According to another aspect of the invention, the second forming mandrel has a generally frustoconical shape or surface.

[0021] According to another embodiment of the present invention, the first forming unit includes a first moving device, which is configured to move at least one first forming core rod around and along its first rotation axis and also along a first processing path, which first processing path includes at least a first forming area of ​​the filter and a transfer area of ​​the filter away from the first forming area.

[0022] According to another aspect of the present invention, the first moving device comprises at least a first rotating member which can rotate around a first main rotating axis parallel to the first rotating axis, and the first machining path is substantially a circumferential arc coaxial with the first main rotating axis and having a first radius.

[0023] Furthermore, the first rotating member is provided with at least a first peripheral through hole, corresponding to which at least one abutment element is mounted such that the cylindrical cavity is coaxial with the through hole.

[0024] Preferably, the first forming unit comprises one or more first forming mandrels, one or more abutment elements and one or more first through holes operatively associated with each other.

[0025] According to another embodiment of the present invention, the second forming unit includes a second moving device, which is configured to move at least one second forming core rod along at least a second processing path, and the second processing path includes at least an insertion area for the filter tip to enter the through-going axial cavity and an extraction area for the shell including the filter tip from the second forming core rod.

[0026] According to another aspect of the invention, the second moving device comprises a second rotating member capable of rotating about a second main rotation axis parallel to the first main rotation axis, and the second machining path is substantially a circumferential arc coaxial with the second main rotation axis and having a second radius. In addition, the first machining path and the second machining path corresponding to the transfer area and the insertion area, respectively, are tangent to a common insertion axis, which is parallel to the first main rotation axis and the second main rotation axis, and the first forming mandrel and the second forming mandrel are temporarily aligned with each other along the common insertion axis.

[0027] According to another aspect of the invention, at least one second forming plug comprises respective elastic and flexible retaining means configured to elastically retain the filter when the filter is inserted into the cavity corresponding to the first end.

[0028] Preferably, the second forming unit comprises one or more second forming mandrels operatively associated at least with respective first forming mandrels.

[0029] Furthermore, the cavity comprises an inlet opening for inserting the filter and an outlet opening opposite the inlet opening and associated with the first end to allow extraction of the filter together with the housing.

[0030] According to another aspect of the present invention, the first end is formed to have two or more elastic and flexible foils to elastically hold the filter when the filter is inserted into the cavity.

[0031] According to another aspect of the invention, the first end is provided with at least two slots formed on the respective foils at diametrically opposite positions and connected to the outlet holes, wherein the at least two slots have the function of exposing two respective parts of the filter to allow extraction thereof.

[0032] According to another aspect of the present invention, the second forming unit includes an adjacent member, which is constructed to selectively cooperate with the respective retaining devices so as to define the end point of the axial stroke of the filter in the cavity and limit the expansion of the respective retaining devices when the filter is inserted into the through axial cavity. According to some embodiments provided herein, the retaining device is constructed, for example, as an elastic and flexible foil.

[0033] According to another aspect of the invention, the second forming unit further comprises extraction means shaped and configured to contact the shell by clamping the filter so as to extract the shell including the filter from the second forming plug by means of a translational movement along an extraction axis.

[0034] According to another aspect of the invention, the second forming unit further comprises at least one holding member configured to temporarily hold the second sheet material against an outer surface of the second forming mandrel.

[0035] The invention also relates to a method for forming a housing with a filter for a smoking article, the method comprising the following steps:

[0036] - forming the filter starting from a first sheet by means of at least one first forming plug rotatable about its first axis of rotation;

[0037] - holding at least a first portion of the first sheet on the first forming mandrel by means of a holding device; and

[0038] - Wrapping a second sheet material around the outer surface of at least one second forming mandrel to form the shell.

[0039] According to another embodiment of the present invention, the method further comprises the following steps:

[0040] - positioning a first forming plug with a filter held by a holding device and a second forming plug with a second sheet wrapped around its outer surface aligned with each other along a common insertion axis; and

[0041] - Pushing the filter by means of the first forming plug along a through axial cavity formed inside the second forming plug, performing a rotational-translational movement around and along the first axis of rotation.

[0042] According to another embodiment of the present invention, in the step of forming a filter, at least one first forming core rod cooperates with a corresponding adjacent element in a fixed axial position to form a filter, wherein at least one first forming core rod holds the first part in the cylindrical cavity of the adjacent element by means of a retaining device, and the second part of the first sheet is arranged in the side seam of the adjacent element, and wherein at least one first forming core rod cooperates with the cylindrical cavity by rotating around a first rotation axis so as to wrap the second part around the first part, thereby forming the filter before the filter is pushed into the through axial cavity.

[0043] According to another embodiment of the present invention, the step of pushing the filter tip includes the following sub-steps:

[0044] a first translating sub-step in which the first forming mandrel is advanced from a first operative position along the insertion axis at a first speed and into the through axial cavity to reach a second operative position;

[0045] a first insertion sub-step, wherein during advancement, the first forming plug is rotated in a first rotational direction about its first rotational axis to impart a helical motion to the filter to facilitate its insertion into the through axial cavity;

[0046] a second inserting sub-step, wherein the first forming mandrel reverses the direction of rotation before reaching the second operative position; and

[0047] A second translating sub-step in which the first forming mandrel is moved rearwardly along the insertion axis from the second operative position at a second speed greater than the first speed so as to return to the first operative position.

[0048] According to another aspect of the invention, the method comprises the step of extracting the casing and the filter from the second forming plug by means of a translational movement of the extraction device along the extraction axis.

[0049] According to another aspect of the invention, during the step of pushing the filter, the latter is pushed by the first forming plug until it partially comes out of the first end of the second forming plug, without making it come out of the housing. BRIEF DESCRIPTION OF THE DRAWINGS

[0050] These and other aspects, features and advantages of the invention will become apparent from the following description of some embodiments given as non-limiting examples, taken in conjunction with the accompanying drawings, in which:

[0051] - Figure 1 is a schematic front view of an apparatus for automatically forming a housing including a filter for a smoking article according to the present invention;

[0052] - Figure 2 yes Figure 1 A top view of the device;

[0053] - Figure 3 yes Figure 1 an enlarged perspective exploded view of a detail of a first forming unit of an apparatus for forming a filter, showing a first forming plug for forming a filter;

[0054] - Figure 4 yes Figure 3 An enlarged perspective view of a detail of Figure 3 The first forming mandrel is in a determined operating state;

[0055] - Figure 5 yes Figure 3 An enlarged perspective view of a detail of Figure 3 The first forming mandrel is in another operating state;

[0056] - Figure 6 is with the help of Figure 1 The operation sequence of the first forming unit forming the filter;

[0057] - Figure 7 yes Figure 1 an enlarged perspective view of a detail of a second forming unit of the apparatus showing a second forming mandrel for forming the shell;

[0058] - Figures 8 to 10 is with the help of Figure 3 The first forming plug is inserted into the filter Figure 7 A cross-sectional side view of a second forming sequence of operations within a mandrel;

[0059] - Fig.11 , Fig.12 and Fig.13 is a perspective view of an operation sequence for extracting a housing including a filter;

[0060] - Fig.14 and Fig.15 They are Fig.12 and Fig.13 Detailed view of the sequence of operations shown.

[0061] It must be clarified that in this description, the words and terms used as well as the figures in the described drawings have the sole function of better illustrating and explaining the present invention, their function being to provide a non-limiting example of the invention itself, since the scope of protection is defined by the claims.

[0062] To facilitate understanding, the same reference numerals are used, where possible, to identify the same common elements in the drawings. It should be understood that elements and features of one embodiment may be conveniently combined or incorporated into other embodiments without further explanation. DETAILED DESCRIPTION

[0063] See also Figure 1 , the apparatus 10 according to the invention is suitable and can be used to automatically form a housing 100 including a filter 200 for a smoking article, such as a cigarette or the like.

[0064] According to a potential embodiment of the present invention, the apparatus 10 may be part of a more complex machine (not shown) which may include other equipment for processing the shell 100 or the filter 200 .

[0065] Before describing the device 10 in detail, in order to better understand the present invention, an outer shell 100 for a smoking article and a filter 200 which may be positioned within the shell 100 corresponding to the mouth end 101 of the shell will now be described.

[0066] The filter 200 may be made of paper having a thickness (e.g., a few tenths of a millimeter) greater than the thickness of the housing 100. In particular, the filter 200 is obtained starting from a shaped first sheet 202 provided with a first portion 203 and a second flat portion 204 ( Figure 3 ).

[0067] The shell 100 can be made of extremely thin and light paper (such as cigarette paper having a thickness of a few hundredths of a millimeter). Each shell 100 is formed from a flat second sheet 102 ( Figure 1 ) is obtained, and the second sheet is obtained in a known manner.

[0068] For example, the shaped second sheet 102 may be obtained as described in Italian Patent Application No. 102021000032735 (IT'735) filed in the name of the Applicant.

[0069] Device 10( Figure 1 and Figure 2 ) comprises at least a first forming unit 11 and a second forming unit 51, the first forming unit 11 being configured to form the filter 200 starting from a formed first sheet 202, and the second forming unit 51 being arranged downstream of the first forming unit 11 and being configured to form the housing 100 starting from a formed second sheet 102. The first forming unit 11 and the second forming unit 51 are mounted on a fixed support structure 13.

[0070] The first forming unit 11 comprises a plurality of operating areas or operating stations arranged sequentially along the first processing path PL1, including at least:

[0071] a first feeding area 15 in which already formed first sheets 202 of known type or to be developed in the future are fed one at a time from a feeding unit not shown in the figure until they intersect the first processing path PL1;

[0072] a first forming zone 16 in which the filters 200 are formed one at a time starting from (i.e. using) a respective already formed first sheet 202, as described above;

[0073] A transfer zone 17 in which the filters 200 are transferred one at a time to the second forming unit 51 .

[0074] Preferably, the first machining path PL1 is closed into a loop and forms a circle with a first radius R1. Specifically, the operation segment of the first machining path PL1 is substantially a circular arc. It should be understood that in other embodiments not shown in the drawings, the first machining path PL1 may be linear or have at least one linear segment.

[0075] The first forming unit 12 includes a first moving device 20 configured to move a first forming mandrel 22 at least along a processing path PL1 .

[0076] The mobile device 20 comprises a disc-shaped first rotating member 19, which is arranged parallel to the support structure 13 and is located on a first machining plane PW1. The first rotating member 19 can rotate around a first main rotation axis X1 and, corresponding to its periphery, it defines a first machining path PL1, which is therefore coaxial with the first main rotation axis X1. In the example given here, the first main rotation axis X1 is horizontal and perpendicular to the support structure 13, and the first machining plane PW1 is perpendicular to the first main rotation axis X1.

[0077] The rotation of the first rotating member 19 can occur both clockwise and counterclockwise, with constant angular increments or pitches α; this allows multiple operations to be performed simultaneously on the formed first sheet 202, thus increasing the overall productivity of the device 10. In particular, the rotation of the first rotating member 19 is obtained by means of a first drive member or device 18, for example by means of an electronically controlled stepper motor.

[0078] exist Figure 1 In the illustrated embodiment, the angular pitch α is 45°, but the angular pitch may be different (ie, larger or smaller) depending on the design and structural choices of the device 10 .

[0079] In addition, the first rotating member 19 is provided with one or more first through holes 21 ( Figure 2 and Figures 8 to 10 ), these first through holes are formed at certain radial positions and are angularly offset according to the same angular interval α.

[0080] The first forming unit 11 includes one or more first forming mandrels 22 ( Figure 3 , Figure 4 and Figure 5 ) and one or more adjacent elements 23, the first forming core rod 22 can be rotated around its first rotation axis AR1 to form the filter 200, and the one or more adjacent elements 23 are arranged coaxially with the first rotation axis AR1 at a fixed axial position relative to the first forming core rod 22.

[0081] Specifically, the adjacent element 23 is mounted on the first rotating member 19 coaxially with the first through hole 21, and the first forming core rods 22 are respectively positioned in their respective first through holes 21, so that at least a portion of the first forming core rods 22 protrudes from the first through holes 21 so as to cooperate with the corresponding adjacent element 23, which will be described in detail below.

[0082] Please note that each first rotation axis AR1 is parallel to the first main rotation axis X1 ( Figure 2 ).

[0083] In the example given here, the number of first through holes 21, first forming mandrels 22 and abutment elements 23 is eight ( Figure 1 ), since the angular interval α is 45°; obviously, in other embodiments, their number may be greater or less than eight, being selected in any case according to the number of angular intervals α.

[0084] according to Figure 3 , Figure 4 and Figure 5 In the illustrated embodiment, each adjacent element 23 has a generally tubular shape and includes a through cylindrical cavity 26 and at least one side slit 25; the cylindrical cavity 26 is coaxial with the first rotation axis AR1 and at least the first portion 203 of the formed first sheet 202 can be inserted therein; and the side slit 25 is tangential to the cylindrical cavity 26 and has the function of allowing the second flat portion 204 of the formed first sheet 202 to pass through.

[0085] According to other embodiments of the present invention, not shown in the accompanying drawings, the adjacent element 23 may be different from the adjacent element described and / or shown herein; for example, the adjacent element may be formed by two approximately semi-cylindrical parts and conform in a manner allowing for accommodation of the formed first sheet 202.

[0086] The first forming mandrels 22 each include a rectangular body provided with a holding device 27 for holding the first portion 203 corresponding to one end thereof.

[0087] like Figure 4 and Figure 5As shown, along the first machining path PL1 , each first forming mandrel 22 is arranged in a first operating position PO1 , where the corresponding holding device 27 is arranged in the cylindrical cavity 26 .

[0088] Holding device 27 ( Figure 3 ) comprises or consists of at least two clamping elements 29 (e.g., clamping jaws) that are opposite to each other with respect to the first rotation axis AR1 and are configured to hold the first portion 203 in the cylindrical cavity 26 ( Figure 4 and Figure 5 ). In particular, the two clamping elements 29 are fixed and spaced apart such that they hold the first portion 203 by interference.

[0089] According to another embodiment not shown in the drawings, the clamping element 29 can be selectively opened and closed to respectively hold and release the formed first sheet 202. In addition, it is obvious that according to other embodiments, other holding devices 27 suitable for holding the formed first sheet 202 can be adopted.

[0090] The first forming core rods 22 are capable of rotating independently about their first rotation axis AR1 relative to the rotation of the rotating member 19 about the first main rotation axis X1. For example, during a single angular pitch α of the rotating member 19, each first forming core rod 22 is capable of performing more than one 360° rotation about its first rotation axis AR1 in order to wind the second portion 204 around the first portion 203 to form the filter 200.

[0091] According to another embodiment of the present invention, each first forming core rod 22 can also be moved axially along its own first rotation axis AR1 between a first operating position PO1 and a second operating position PO2; at the second operating position PO2, the first forming core rod 22 is in a forward position to push the filter 200 by means of a rotational translation movement and insert it into the corresponding second forming core rod 52 of the second forming unit 51 (especially the through axial cavity 53 or cavity 53 of the second forming core rod 52), as will be described in detail below.

[0092] It must be clarified that the first moving device 20 is constructed to be able to selectively move each first forming mandrel 22 around and along its own first rotation axis AR1; for example, the first moving device 20 may also include a planetary gear mechanism and / or an electric or mechanical cam mechanism of a known type and not shown in the figure associated with each first forming mandrel 22.

[0093] The second forming unit 51 ( Figure 1 and Figure 2) comprises a plurality of operating areas or operating stations arranged in sequence along the second processing path PL2, including at least:

[0094] - Insertion zone 54: in this insertion zone 54, one filter 200 is inserted at a time into the cavity 53 of the corresponding second forming plug 52 by means of the first forming plug 22;

[0095] - Second feeding area 55: In this second feeding area 55, the formed second sheets 102 are fed one at a time until they intersect the second processing path PL2;

[0096] a second forming area 56 in which the housings 100 are formed one at a time, starting from (ie using) the respective already formed second sheets 102, in which the filters 200 are located; and

[0097] Extraction zone 57 : in this extraction zone 57 , each housing 100 comprising a filter 200 is extracted by means of extraction means 59 and placed on a transfer device 60 situated downstream of the second forming unit 51 .

[0098] Preferably, the second machining path PL2 is closed into a loop and forms a circle with a second radius R2. Specifically, the operation segment of the second machining path PL2 is substantially a circular arc. It should be understood that in other embodiments not shown in the drawings, the second machining path PL2 may be linear or have at least one linear segment.

[0099] The second forming unit 51 includes a second moving device 62 configured to move the second forming mandrel 52 at least along the second processing path PL2.

[0100] The second moving device 62 comprises a disc-shaped second rotating member 61, which is arranged parallel to the support structure 13 and is located on the second machining plane PW2. The second rotating member 61 can rotate around a second main rotation axis X2 parallel to the first main rotation axis X1, and corresponding to its periphery, it defines a second machining path PL2, so that the second machining path PL2 is coaxial with the second main rotation axis X2.

[0101] The first processing plane PW1 and the second processing plane PW2 are parallel to and spaced apart from each other so as not to interfere with each other.

[0102] In particular, the sum of the first radius R1 and the second radius R2 is equal to the longitudinal distance or the distance S between the centers of the first rotation axis X1 and the second rotation axis X2, whereby the machining paths PL1, PL2 corresponding to the respective transfer area 17 and insertion area 54 are tangent to the common insertion axis X3.

[0103] The insertion axis X3 is parallel to the first rotation axis X1 and the second rotation axis X2, and the first forming plug 22 and the second forming plug 52 are temporarily aligned with each other along the insertion axis X3 to correctly insert the filter 200 into the cavity 53. It should be noted that when the first forming plug 22 and the second forming plug 52 are aligned along the insertion axis X3, the corresponding rotation axes AR1, AR2 are located on the same insertion axis X3.

[0104] The rotation of the second rotating member 61 may occur clockwise, with a constant angular increment or pitch β; this allows multiple operations to be performed simultaneously on the formed second sheet 102 , thus increasing the overall productivity of the apparatus 10 .

[0105] In the example given here, the angular pitch β is equal to the angular pitch α and the angular velocities of the first 19 and second 61 rotating members are equal to each other so as to synchronize their rotations and thereby ensure correct alignment of the first 22 and second 52 forming mandrels along the insertion axis X3.

[0106] It should be understood that according to other embodiments not shown in the drawings, the angular pitches β and α may be different from each other and the angular speed of rotation allows the rotation of the first rotation member 19 and the second rotation member 61 to be synchronized.

[0107] The rotation of the second rotating member 61 is carried out by means of a second driving member or device 64 ( Figure 1 and Figure 2 ) is obtained, the second drive member or device 64 may be of any known type and may, for example, comprise an electronically controlled stepper motor.

[0108] The second rotating member 61 is provided with one or more second through holes 63 ( Figure 2 and Figures 8 to 10 ), these second through holes are formed at determined radial positions and are angularly offset according to the same angular interval β. In the example given here, since the angular interval β is 45°, there are eight second through holes 63 ( Figure 1 ).

[0109] The second forming unit 51 includes one or more second forming mandrels 52 ( Figure 7 ), the second forming core rod 52 can be rotated around its second rotation axis AR2 to form the shell 100.

[0110] The second forming mandrels 52 are mounted on the second rotating member 61 corresponding to the respective second through holes 63 , and each second rotation axis AR2 is parallel to the second main rotation axis X2 .

[0111] It should be clarified that the second moving device 62 ( Figure 1 and Figure 2 ) is constructed to be able to selectively rotate each second forming mandrel 52 around its own second rotation axis AR2; for example, the second moving device 62 may also include a planetary gear mechanism and / or an electric or mechanical cam mechanism of a known type not shown in the figure associated with each second forming mandrel 52.

[0112] Each second forming mandrel 52 is configured to wrap the formed second sheet material 202 on an outer surface thereof, thereby forming the housing 100 .

[0113] Specifically, each second forming mandrel 52 ( Figures 7 to 10 ) include a supporting portion 65 and a central forming portion 66; the supporting portion 65 has a cylindrical shape and is configured to be associated with the second rotating member 61; the central forming portion 66 has an outer peripheral surface that roughly has a truncated cone shape or a possible cylindrical shape, which negatively replicates the shape of the shell 100 to be manufactured, and is configured to cooperate with the formed second sheet 102 to form the shell 100.

[0114] The forming portion 66 includes a first end 67 and a second end 69; the first end 67 is opposite to the support portion 65 and corresponds to the mouthpiece end 101 of the housing 100; and the second end 69 generally corresponds to the ignition end of the housing 100 and is associated with the support portion 65. Figure 7 As shown, if the formed portion 66 has a truncated cone shape, the first end 67 is smaller than the diameter of the second end 69 .

[0115] Each second forming mandrel 52 is provided with a through axial cavity 53 ( Figures 8 to 10 );The through axial cavity 53 includes an inlet hole 71 and an outlet hole 72, wherein the inlet hole is connected to the corresponding second through hole 63 for inserting the filter 200, and the outlet hole 72 is opposite to the inlet hole 71 and is associated with the first end 67 to allow the filter 200 to be extracted together with the shell 100.

[0116] In particular, the cavity 53 has a cross-section allowing the first forming plug 22 to pass therethrough and is configured to at least temporarily accommodate the filter 200 in correspondence with the first end 67 .

[0117] The second forming plug 52 includes respective elastic and flexible retaining means 74 configured to elastically retain the filter 200 when the filter 200 is inserted into the cavity 53 corresponding to the first end 67 .

[0118] According to the embodiment shown here, the first end 67 and the respective retaining means 74 comprise two or more elastic and flexible foils 75 for elastically retaining the filter 200 when the filter 200 is inserted into the cavity 53. Preferably, the foils 75 are four and have a length greater than the length of the filter 200.

[0119] Furthermore, the first end 67 is provided with two slots 76 which are formed on the respective foils 75 at diametrically opposite positions with respect to the second rotation axis AR2 and are connected to the outlet hole 72. Specifically, the two slots 76 have the function of exposing two respective parts of the filter 200 so as to extract it with the aid of the extraction device 59, as will be described in detail below.

[0120] Each second forming mandrel 52 is also provided with at least one retaining member 77 ( Figure 7 ), which is arranged outside the central forming portion 66 and is restricted on the supporting portion 65 at one end.

[0121] In particular, the retaining member 77 includes a clamping jaw 79 that can be selectively driven to temporarily retain the corresponding formed second sheet 102 against the outer peripheral surface of the central forming portion 66 ( Figure 1 ). The selective opening and closing of the clamping jaws 79 is achieved, for example, by means of a dedicated actuator (not shown in the figure).

[0122] In addition, there may be a plurality of suction holes 78 on the outer peripheral surface of the central forming portion 66, which are operably connected to a suction device (not shown in the figure) and have the function of selectively holding one formed second sheet 102 at a time against the outer peripheral surface of the central forming portion 66 during the formation process of the shell 100.

[0123] The second forming unit 51 corresponding to the insertion area 54 includes an adjacent member 80, which has, for example, the shape of a sleeve and is constructed to selectively cooperate with the foil 75 of each second forming core rod 52 so as to define the axial stroke end point of the filter 200 in the cavity 53 and also limit the radial expansion of the foil 75 when the filter 200 is inserted into the cavity 53.

[0124] For example, the feed area 55 of the formed second sheet 102 and the forming area 56 of the shell 100 may be the same as the feed area and the forming area described in the above-mentioned patent application IT'735, and thus they will not be described and shown in detail.

[0125] Furthermore, corresponding to the extraction zone 57, the device 10 comprises extraction means 59 having the function of extracting the casing 100 comprising the filter 200 from the second forming plug 52 by means of a translation movement along an extraction axis X4 in order to transfer it to the transfer means 60. The extraction axis X4 is parallel and aligned with the second main rotation axis X2.

[0126] The extraction device 59 is shaped and constructed to contact the housing 100 by clamping the filter 200 .

[0127] The extraction device 59 comprises two selectively closable jaws 81 for clamping the housing 100 including the filter 200 in a controlled manner corresponding to the respective mouthpiece ends 101. In particular, the jaws 81 are provided with respective clamping elements 82 which are opposite to each other and are shaped to be inserted between the foils 75 (i.e. in the slots 76) so as to contact the housing 100 and clamp the filter 200, thereby extracting them together with a translational movement.

[0128] Preferably, the clamping element 82 may be coated with a paper having a roughness greater than that of the paper making the housing 100 so as to generate a friction force to prevent sliding between the contact surfaces of the clamping plug 82 and the housing 100 .

[0129] The transfer device 60 has the function of transferring each housing 100 provided with the filter 200 to a processing device or area (not shown in the figure).

[0130] In the example given here, the transfer device 60 comprises or consists of a conveyor belt 83 having a plurality of tubular seats 84 defining a receiving seat for each shell 100 comprising a filter 200 .

[0131] Each tubular base 84 is provided with a hole 85, which is oriented toward the second rotating member 61 to allow the insertion of the housing 100 including the filter 200. Note that the rotation speed of the second rotating member 61 and the transfer device 60 synchronizes the movement of the transfer device so as to allow the housing 100 including the filter 200 to be correctly transferred from the extraction area 57 to the respective tubular base 84 by means of the extraction device 59.

[0132] Furthermore, in order to facilitate the insertion of each housing 100 including a filter 200 into the tubular base 84, there may also be guiding or retaining means associated with the latter of known type or to be created in the future and not shown in the figures. Furthermore, an actuating member (such as a linear actuator) may also be provided, which operates from the inside of the second forming core rod 52 to facilitate the insertion of the housing 100 including the filter 200 into the tubular base 84.

[0133] According to another aspect of the present invention, the device 10 includes a central control unit 86 ( Figure 2 ), the central control unit is programmed to control and command the driving of the moving devices 20 and 62, so that the rotation of the rotating members 19 and 61 is synchronized with the movement of the first forming mandrel and the second forming mandrel 22 and 52. In addition, the central control unit 86 is also programmed to command the driving of the extraction device 59 and the transfer device 60 in relation to the rotation of the second rotating member 61.

[0134] The operation of the above-described device 10 corresponding to the method according to the invention comprises the following steps.

[0135] It must be clarified that what is described for a single formed first sheet 202 and a single formed second sheet 102 is valid for each cycle of the formed first sheet 202 and the formed second sheet 102, and the filter 200 and the shell 100 are obtained using the formed first sheet 202 and the formed second sheet 102 respectively.

[0136] In an initial preparation step, the central control unit 86 is programmed to control and coordinate the driving of the first and second moving devices 20 and 62 , the extraction device 59 and the transfer device 60 .

[0137] The method includes a step of feeding the formed first sheet 202 into the first feed area 15, wherein each formed first sheet 202 is inserted positively (i.e., in front) into the cylindrical cavity 26 of the adjacent element 23 with the aid of an insertion member 87, so that its first part 203 is interlocked and retained at least by an interference fit between the clamping elements 29 of the retaining device 27, and its second part 204 is positioned in the corresponding side seam 25.

[0138] Subsequently, when the rotating member 19 rotates about its first main rotation axis X1 to bring the formed first sheet 202 to the transfer area 17, in the step of forming the filter 200, the first forming plug 22 rotates about its first rotation axis AR1 in the first rotation direction S1 and, by cooperating with the corresponding abutment elements 23 (in particular with the cylindrical cavity 26), it wraps the second portion 204 of the formed first sheet 202 around the first portion 203 and the clamping element 29, thereby forming the filter 200. Please note that in both the step of feeding the formed first sheet 202 and the step of forming the filter 200, the first forming plug 22 is in the first operating position PO1.

[0139] Once the filters 200 are formed, a step of pushing the filters 200 into the cavities 53 with the aid of the first forming plugs 22 is performed corresponding to the transfer area 17. Specifically, the first forming plugs 22, which are moved from the first operating position PO1 to the second operating position PO2, push one filter 200 at a time and then insert it into the cavity 53 of the corresponding second forming plugs 52, which are aligned with the first forming plugs 22 along the insertion axis X3.

[0140] In particular, the step of pushing the filter 200 includes the following sub-steps:

[0141] - A first translation sub-step in which the first forming mandrel 22 advances from the first operating position PO1 along its first rotation axis AR1 (ie along the insertion axis X3) at a first speed V1 and enters the cavity 53 through the access hole 71 so as to reach the second operating position PO2 ( Figure 8 );

[0142] - a first insertion sub-step in which, during advancement, the first forming plug 22 rotates about its first rotation axis AR1 in a first rotation direction S1 , causing the filter 200 to perform a spiral movement in order to facilitate its insertion into the cavity 53 ;

[0143] - a second insertion sub-step in which, when the first forming mandrel 22 reaches the position corresponding to the foil 75 (i.e. before reaching the second operating position PO2), it reverses its direction of rotation by a few degrees, to a second direction of rotation S2 different from the first direction of rotation S1, so as to release the latter into the cavity 53 corresponding to the first end 67 when reaching the second operating position PO2 ( Fig. 9 );as well as

[0144] - A second translation sub-step: wherein the first forming core rod 22 moves backward from the second operating position PO2 along the insertion axis X3 at a second speed V2 (which is much higher than the first speed V1, for example, can be about one or two orders of magnitude higher) to complete the release of the filter 200 in the cavity 53, and then returns to the first operating position PO1 ( Fig.10 ).

[0145] It should be noted that, during the step of pushing the filter 200 , the latter is pushed by the first forming plug 22 until it partially comes out of the first end 67 of the second forming plug 52 , without causing it to come out of the housing 100 .

[0146] Once the insertion has been completed, the filter 200 is located inside the second forming plug 52 and the first forming plug 22 is in the first operating position PO1 .

[0147] It must be clarified that in the step of pushing the filter 200, the abutment member 80 is positioned in contact with the first end 67 ( Figure 8 ) so as to cooperate with it to close the outlet hole 72, thereby defining the end point of the travel of the filter 200 and also limiting the expansion of the foil 75 when the filter 200 is inserted into the corresponding one ( Fig. 9 and Fig.10 ). Once the insertion of the filter 200 has been concluded, the abutment member 80 moves away from the second forming plug 52 to allow it to be transported by the rotating member 61 .

[0148] Then, the second rotating member 61 rotates around its second main rotation axis X2 and brings the second forming plug 52 with the filter 200 inside from the insertion area 54 to the feeding area 55 of the formed second sheet 102. It should be noted that in the step of pushing the filter 200, the retaining member 77 of the second forming plug 52 is in an open state.

[0149] The method then comprises the step of feeding and conveying the formed second sheet 102 to the second forming mandrel 52. For example, the feeding and conveying of the formed second sheet 102 can be carried out in the manner described in patent application IT'735.

[0150] Subsequently, corresponding to the second forming area 56, a step of forming the shell 100 is performed by means of a respective second forming plug 52 in which the filter 200 is present. For example, the forming of the shell 100 can be carried out in the manner described in patent application IT'735.

[0151] Once the shell 100 has been formed, the second rotating member 61 is once again rotated about the second main rotation axis X2 so as to bring the second forming plug 52 provided with the shell 100 on the outside and with the filter 200 on the inside to correspond to the extraction zone 57 .

[0152] Then, a step of extracting the shell 100 and the filter 200 simultaneously from the second forming mandrel 52 by means of the extraction device 59 is performed. In particular, in this step, the extraction device 59 approaches the second forming mandrel 52 so as to position the jaws 81 ( Fig.11 ). Then tighten the clamping jaws 81 so that the clamping plug 82 contacts the housing 100 and enters between the slots 76, thereby also clamping the filter 200 ( Fig.12 ). Then, if Fig.13 As shown, the casing 100 including the filter 200 is extracted by a translation movement along the extraction axis X4 so as to transfer the casing 100 so as to be inserted into a corresponding tubular seat 84 of the transfer device 60 .

[0153] Finally, in a final transport step, the transfer device 60 transports the housing 100 including the filter 200 to another processing area or unit (not shown).

[0154] It is obvious that components may be substituted and / or added to the apparatus 10 and the method described above without departing from the field and scope of the present invention as defined in the claims.

[0155] Furthermore, it is obvious that, although the invention has been described in conjunction with certain specific examples, a person skilled in the art will be able to realize other equivalent forms of equipment for automatically forming a shell including a filter for a smoking article, which equivalent forms have the characteristics described in the claims and therefore all fall within the field of protection defined by the claims.

[0156] In the following claims, the only purpose of reference signs in parentheses is to facilitate reading and these reference signs should not be considered as limiting factors for the scope of protection defined by the claims.

Claims

1. An apparatus (10) for automatically forming a housing (100) having a filter (200) for a smoking article, comprising: A first forming unit (11) configured to form the filter (200) from a first sheet material (202), and a second forming unit (51) configured to form the shell (100) from a second sheet material (102), wherein the first forming unit (11) comprises at least one first forming core rod (22), the first forming core rod (22) being rotatable about its first rotation axis (AR1) to form the filter (200) and being axially movable along the first rotation axis (AR1), the first forming core rod (22) being provided with a retaining device (27) to retain at least a first portion (203) of the first sheet material (202), and wherein the second forming unit (51) It includes at least one second forming core rod (52), which is configured to wrap the second sheet material (102) on its outer surface to form the shell (100), characterized in that the second forming core rod (52) is provided with a through axial cavity (53) inside, and characterized in that the at least one first forming core rod (22) is configured to push the filter tip (200) along the through axial cavity (53) by means of a rotational translational movement around and along the first rotation axis (AR1) when the second forming core rod (52) wrapped with the second sheet material (102) on its outer surface is aligned with the first forming core rod (22) along a common insertion axis (X3).

2. The device (10) according to claim 1, characterized in that The first forming unit (11) comprises at least one abutment element (23) which is arranged coaxially with the first rotation axis (AR1) at a fixed axial position relative to the first forming mandrel (22) and is operatively associated with the holding device (27).

3. The device (10) according to claim 2, characterized in that The adjacent element (23) comprises a through cylindrical cavity (26) coaxial with the first rotation axis (AR1) and into which the retaining device (27) and at least the first portion (203) of the first sheet (202) can be inserted, and a side slit (25) tangential to the cylindrical cavity (26) to allow the second flat portion (204) of the first sheet (202) to pass.

4. The device (10) according to claim 3, characterized in that The second forming mandrel (52) has a generally frustoconical shape.

5. The device (10) according to any one of the preceding claims, characterized in that The first forming unit (11) includes a first moving device (20), which is configured to move the at least one first forming core rod (22) around and along its first rotation axis (AR1) and also along a first processing path (PL1), wherein the first processing path (PL1) includes at least a first forming area (16) of the filter (200) and a transfer area (17) of the filter (200) away from the first forming area (16).

6. The device (10) according to claim 5, characterized in that The first moving device (20) comprises at least a first rotating member (19), which is rotatable around a first main rotating axis (X1) parallel to the first rotating axis (AR1), and the first processing path (PL1) is substantially a circular arc coaxial with the first main rotating axis (X1) and having a first radius (R1).

7. The device (10) according to any one of the preceding claims, characterized in that The second forming unit (51) includes a second moving device (62), which is configured to move the at least one second forming core rod (52) at least along a second processing path (PL2), wherein the second processing path (PL2) includes at least an insertion area (54) for the filter tip (200) to enter the through axial cavity (53) and an extraction area (57) for the shell (100) including the filter tip (200) from the second forming core rod (52).

8. The device (10) according to claim 7 as appended to claim 6, characterized in that The second moving device (62) includes a second rotating component (61), which is capable of rotating around a second main rotation axis (X2) parallel to the first main rotation axis (X1), and the second processing path (PL2) is roughly a circular arc coaxial with the second main rotation axis (X2) and having a second radius (R2), and is characterized in that the first processing path and the second processing path (PL1, PL2) corresponding to the transfer area (17) and the insertion area (54), respectively, are tangent to the common insertion axis (X3), the common insertion axis (X3) is parallel to the first main rotation axis and the second main rotation axis (X1, X2), and the first forming core rod and the second forming core rod (22, 52) are temporarily aligned with each other along the common insertion axis (X3).

9. The device (10) according to any one of the preceding claims, characterized in that The at least one second forming core rod (52) includes respective elastic and flexible retaining devices (74), which are configured to elastically retain the filter (200) when the filter (200) is inserted into the cavity (53) corresponding to the first end (67).

10. The device (10) according to claim 9, characterized in that The second forming unit (51) includes an adjacent member (80), which is constructed to selectively cooperate with the respective retaining devices (74) so ​​as to define the end point of the axial stroke of the filter (200) in the cavity (53) and to limit the expansion of the respective retaining devices (74) when the filter (200) is inserted into the through axial cavity (53).

11. The device (10) according to any one of the preceding claims, characterized in that The second forming unit (51) also includes an extraction device (59), which is shaped and constructed to contact the shell (100) by clamping the filter (200) so as to extract the shell (100) including the filter (200) from the second forming core rod (52) by means of a translational movement along an extraction axis (X4).

12. The device (10) according to any one of the preceding claims, characterized in that The second forming unit (51) further comprises at least one holding member (77) configured to temporarily hold the second sheet material (102) against an outer surface of the second forming mandrel (52).

13. A method for forming a housing (100) having a filter (200) for a smoking article, the method comprising the steps of: - forming the filter (200) starting from a first sheet (202) by means of at least one first forming plug (22) rotatable about its first axis of rotation (AR1); - holding at least a first portion (203) of the first sheet (202) on the first forming mandrel (22) by means of a holding device (27); as well as - wrapping a second sheet material (102) around the outer surface of at least one second forming mandrel (52) to form the housing (100); It is characterized in that it also includes the following steps: - positioning said first forming plug (22) with said filter (200) held by said holding means (27) and said second forming plug (52) with said second sheet (102) wrapped on its outer surface so as to be aligned with each other along a common insertion axis (X3); and - said filter (200) is pushed by means of said first forming plug (22) along a through axial cavity (53) formed inside said second forming plug (52), performing a rotational-translational movement around and along said first axis of rotation (AR1).

14. The method according to claim 13, characterized in that In the step of forming the filter (200), the at least one first forming core rod (22) cooperates with the corresponding adjacent element (23) in a fixed axial position to form the filter (200), wherein the at least one first forming core rod (22) retains the first part (203) in the cylindrical cavity (26) of the adjacent element (23) by means of the retaining device (27), and the second part (204) of the first sheet (202) is arranged in the side seam (25) of the adjacent element (23), and wherein the at least one first forming core rod (22) cooperates with the cylindrical cavity (26) by rotating around the first rotation axis (AR1) so as to wrap the second part (204) around the first part (203), thereby forming the filter (200) before pushing the filter (200) into the through axial cavity (53).

15. The method according to claim 13 or 14, characterized in that The step of pushing the filter tip (200) comprises the following operating sub-steps: a first translation sub-step, wherein the first forming mandrel (22) is advanced from a first operating position (PO1) along the insertion axis (X3) at a first speed (V1) and into the through axial cavity (53) so as to reach a second operating position (PO2); a first insertion sub-step, wherein, during said advancement, said first forming core rod (22) is rotated in a first rotational direction (S1) about its first rotational axis (AR1) to cause said filter tip (200) to perform a spiral motion to facilitate its insertion into said through axial cavity (53); a second insertion sub-step, wherein the first forming mandrel (22) reverses the direction of rotation before reaching the second operating position (PO2); and A second translation sub-step, wherein the first forming mandrel (22) is moved backwards along the insertion axis (X3) from the second operating position (PO2) at a second speed (V2) greater than the first speed (V1) so as to return to the first operating position (PO1).

16. The method according to any one of claims 13 to 15, characterized in that It comprises the step of extracting said shell (100) and said filter (200) from said second forming plug (52) by means of a translational movement of an extraction device (59) along an extraction axis (X4).

17. The method according to any one of claims 13 to 16, characterized in that During the step of pushing the filter (200), the latter is pushed by the first forming plug (22) until it partially comes out of the first end (67) of the second forming plug (52) without making it come out of the shell (100).

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