Apparatus and method for automatically shaping filters for smoking articles

Abstract

A device (10) for automatically forming filters (100) for smoking articles starting from flat sheets (101) fed by a hopper (16), each flat sheet comprising an organ fold (102) and a straight portion (103) formed in a first forming unit (11). The first forming unit (11) comprises: at least one clamping member (22) configured to clamp one flat sheet (101) at a time and to freely project from the clamping member (22) a free portion (104) from which the organ fold (102) is to be created; and a pair of shaping members (25, 26) having respective mutually interlaced shaping protrusions (30, 31) that gradually converge to engage opposite faces of the free portion (104), thereby gradually forming and bringing the continuous folds close to each other with a gradually increasing shaping depth.

Description

Technical Field

[0001] The present invention relates to an apparatus and method for automatically forming filters for smoking articles intended to be filled with a snorkeling product, such as tobacco or the like. Background Technology

[0002] The demand for producing smoking products is growing, including elongated tubular outer shells (such as cylindrical or truncated cones) with a filter tip made of appropriately shaped and folded paper or cardboard at one end.

[0003] In order to produce this filter, some devices are known that fold a sheet of paper or cardboard of appropriate size and then roll it around itself so that it can then be inserted into an outer casing.

[0004] An apparatus is known in which filter tips are manufactured by spirally winding a sheet of cardboard in two distinct steps, first using one or more rotary grippers and then using a moving planar mechanism. However, this apparatus suffers from a lack of versatility because the rotary grippers must be removed to complete the filter tip forming, resulting in a slowdown in operation.

[0005] A device is also known from document US 2023 / 0108165 A1, in which a hopper contains singularized flat sheets, and positioning members position these flat sheets one by one into corresponding fixed slots in a conveyor, and a filter is subsequently formed along the conveyor. In this device, the flat sheets are shaped and folded in two or more shaping and folding steps, each step creating a corresponding V-shaped cut to form a serrated or accordion-shaped portion, and then the remaining flat or extended portion of the flat sheet is wrapped around the serrated or accordion-shaped portion.

[0006] However, the drawbacks of this device are its complexity and the fact that several shaping and folding steps are set up on a dedicated continuous station to manufacture the accordion-shaped parts, which increases the overall size of the machine and production time.

[0007] US 3,818,809 A describes another known solution in which a male and female shaping component work together to shape creases previously created on a continuous paper tape using an embossing roller.

[0008] Therefore, improvements are needed to the apparatus used for automatic filter tip forming to overcome at least one drawback of the prior art. Summary of the Invention

[0009] Therefore, it is necessary to solve the technical problem of providing a device that allows for the simple molding of filters for smoking products, and to optimize the number of operation steps in molding the accordion folds, thereby reducing operation and production time.

[0010] In particular, one object of the present invention is to provide an apparatus and a method for automatically forming filters for smoking products, which is efficient, versatile and capable of achieving high productivity.

[0011] Another object of the present invention is to provide an apparatus and a method for automatically forming filters for smoking articles, which can be integrated into a more complex machine that can also perform other processes, such as forming shells and / or packaging finished smoking articles.

[0012] The applicant designed, tested, and implemented the present invention to overcome the deficiencies of the prior art and to achieve the other objectives and advantages mentioned above.

[0013] The invention is set forth and its features are defined in the independent claims. The dependent claims describe other features of the invention or variations of the main inventive concept.

[0014] In accordance with the above objectives and in a novel and original manner, the above-mentioned technical problems are solved, and significant advantages are achieved compared with the prior art. According to the present invention, an apparatus for automatically forming a filter tip for a smoking product from a flat sheet is provided, the apparatus comprising a first forming unit configured to create an accordion fold on a portion of each of the flat sheets and to keep adjacent straight portions unfolded.

[0015] According to one aspect of the invention, the first forming unit includes at least one clamping member configured to clamp a straight portion of a flat sheet at a time and allow the free portion from which the accordion fold is to be created to protrude freely from the clamping member.

[0016] According to one aspect of the invention, the first forming unit further includes a pair of shaping members having shaping protrusions, the shaping protrusions converging in such a way that the distance between adjacent shaping protrusions of each shaping member gradually decreases from a corresponding shaping start end to a corresponding shaping end end.

[0017] The shaping protrusions of the first shaping member of the pair of shaping members are staggered relative to the shaping protrusions of the second shaping member of the pair of shaping members. Furthermore, the pair of shaping members are configured via the shaping protrusions to engage with opposite sides of the free portion of the flat sheet held by the clamping member, thereby gradually forming continuous pleats with progressively increasing shaping depth and bringing the continuous pleats closer together, thus creating the accordion fold on the free portion of the flat sheet.

[0018] In particular, the height of the profile of one or more shaping protrusions increases from the corresponding shaping start end to the corresponding shaping end end.

[0019] According to another aspect of the invention, the pair of shaping members consist of a pair of counter-rotating rollers, each roller having a corresponding arcuate shaping region on which the shaping protrusions are provided. In particular, the shaping protrusions of the first shaping member are configured to gradually insert between the shaping protrusions of the second shaping member, and vice versa, thereby creating wrinkles on the free portion.

[0020] According to another aspect of the invention, the device further includes an abutment member configured to lock the position of the flat sheet relative to the pair of shaping members by moving from a retracted position to an advanced position during the creation of the accordion fold, wherein in the retracted position the abutment member is spaced apart from the flat sheet, and in the advanced position the abutment member contacts the at least one clamping member such that the flat sheet is positioned between them.

[0021] According to another aspect of the invention, the first forming unit further includes a first rotating device, which is rotatable about a first main rotation axis to move the at least one clamping member along a first processing path, the first processing path passing through at least a transfer station, a shaping station and a conveying station.

[0022] According to another aspect of the invention, the at least one clamping member includes one or more gripping elements configured to pick up the flat sheet from the feeding unit by contacting one side of the flat sheet and keeping the opposite side free.

[0023] The advantage of doing this is that the flat sheet can be directly removed by the clamping component without the need for other mechanical means, thereby reducing operation and production time.

[0024] According to another aspect of the invention, the apparatus further includes a collapsing device arranged downstream of the pair of shaping members and movable between a rest position and a collapsing position, wherein in the rest position the collapsing device is spaced apart from the accordion fold of a corresponding flat sheet held by the at least one clamping member, and in the collapsing position the collapsing device engages with the accordion fold by an abutment wall and crushes the accordion fold against the impact wall of an impact plate present therein, thereby collapsing the accordion fold to stabilize its shape.

[0025] The collapsing device is also provided with an inclined surface, which is configured and sized such that when the abutment wall abuts against the impact wall such that the accordion fold of the sheet is located between the two, the inclined surface slides above the impact plate to accurately collapse the accordion fold.

[0026] In addition, an impact plate for flat sheet material is arranged in front of the collapse equipment. The impact plate is equipped with abutment, the shape of which is negatively matched with the shape of the collapse part, so as to allow the abutment wall to be inserted with minimal gap and temporarily accommodate the accordion fold to be collapsed.

[0027] The abutment is equipped with an impact wall, which provides the end point of the travel of the abutment wall and provides rear abutment when the accordion fold is crushed.

[0028] According to another aspect of the invention, push rods are arranged in the conveying area, laterally relative to the collapsing device, to engage the accordion folds that are collapsed and clamped by the collapsing device, particularly between the abutment wall and the impact wall, and to push the flat sheet with the collapsed accordion folds toward the conveying arm, which is configured to discharge the sheet pushed in by the push rods.

[0029] The conveyor arm is configured to stably clamp the flat sheet and alternately present a receiving position and a conveying position, in which it conveys the flat sheet with the collapsed accordion folds away from the first forming unit.

[0030] According to another aspect of the invention, the device includes a second forming unit having at least one forming mandrel with a clamping member configured to clamp at least a gusseted portion and rotate it about its axis of rotation; and at least one receiving element arranged coaxially with the axis of rotation of the forming mandrel and having a hollow cylinder, the clamping member being insertable into the hollow cylinder, the hollow cylinder having a side slit parallel to the axis of rotation, the side slit being configured to allow a straight portion wound around the clamping member to pass through when the forming mandrel rotates, thereby forming the filter tip.

[0031] According to another aspect of the invention, the second forming unit is provided with a moving device configured to move at least one forming mandrel about its own axis of rotation and along a second processing path, the second processing path including at least a shaping region and a region for conveying filter tips. The moving device includes a second rotating device rotatable about a second main axis of rotation, at least one receiving element coaxially mounted on a corresponding through-hole of the second rotating device, and at least one forming mandrel positioned inside the receiving element.

[0032] The present invention also relates to a method for automatically forming a filter tip for a smoking article by means of an apparatus, the apparatus comprising a first forming unit that performs a first forming step to form the filter tip from a flat sheet, such that accordion folds are created on a portion of each flat sheet and adjacent straight portions are kept unfolded.

[0033] According to another aspect of the invention, the clamping member of the first forming unit clamps one flat sheet at a time and allows the free portion of the accordion fold to be created to protrude freely from the clamping member, and moves the flat sheet toward a pair of shaping members of the first forming unit.

[0034] These shaping components have corresponding converging shaping protrusions, as defined above.

[0035] The first shaping step includes: engaging the free portion of the flat sheet held by the clamping member from opposite sides by the corresponding converging shaping protrusions, thereby gradually forming continuous pleats with gradually increasing shaping depth and bringing the continuous pleats together, thus creating the accordion fold on the free portion of the flat sheet.

[0036] The shaping protrusions are staggered, curved, and gradually converge, so that the lateral distance between each shaping protrusion gradually decreases from the corresponding shaping start end to the corresponding shaping end end.

[0037] According to another aspect of the invention, in the shaping step, the shaping protrusion of the first shaping member presses against one surface of the free portion and gradually inserts between the shaping protrusions of the second shaping member, while the shaping protrusion of the second shaping member presses against the other surface of the free portion, thereby creating the wrinkles.

[0038] According to another aspect of the invention, the method includes an extraction step, wherein the at least one clamping member extracts the flat sheet directly from the feeding unit by means of one or more corresponding gripping elements, and clamps the flat portion by contacting only one surface while keeping the opposite surface free.

[0039] According to another aspect of the invention, after the shaping step, the method includes a collapse step, wherein the flat sheet held by the at least one clamping member is fed to a conveying station of the first forming unit, the corresponding accordion fold facing and aligned with the collapse device, the collapse device translating toward the impact plate by moving from a rest position to a collapse position, the collapse device stabilizing the accordion fold by pressing it against the impact wall of the impact plate.

[0040] Furthermore, during the movement from the stationary position to the collapsed position, the inclined surface connected to the abutment wall slides over the impact plate to accurately perform the collapse.

[0041] According to another aspect of the invention, the method further includes a conveying step in which, within the conveying area, a push rod translates in a direction perpendicular to the collapsing device to engage the accordion folds collapsed and held by the collapsing device, particularly between the abutment wall and the impact wall, and pushes the flat sheet with the collapsed accordion folds toward the conveying arm, thereby disengaging the flat sheet from at least one clamping member, wherein the conveying arm stably clamps the flat sheet, moves it from the receiving position to the conveying position, and conveys it to the second forming unit.

[0042] According to another aspect of the invention, the method further includes a second forming step, downstream of the shaping step, in which a corresponding sheet having the accordion fold is received by a forming mandrel of a second forming unit, the forming mandrel clamping the accordion fold by a clamping member and engaging with a coaxially arranged receiving element to form the filter tip; the receiving element is provided with a hollow cylinder, the clamping member being insertable into the hollow cylinder, the hollow cylinder being provided with a side slit allowing a straight portion to pass through, and the forming mandrel rotating about its axis of rotation and engaging with the hollow cylinder to cause the straight portion to wrap around the clamping member and the accordion fold, thereby forming the filter tip.

[0043] According to another aspect of the invention, the pair of shaping members consist of a pair of rollers having corresponding arcuate shaping regions provided with shaping protrusions, wherein the rollers rotate in opposite directions during the shaping step to create the accordion fold.

[0044] According to some embodiments, a collapse unit is provided for collapsing an accordion fold near a straight portion of a sheet intended for forming a filter tip for a smoking product. The collapse unit includes a collapse device, an impact plate, and corresponding clamping members for clamping the sheet, wherein the collapse device is according to the embodiments described herein.

[0045] According to some embodiments, an apparatus is provided for automatically forming a filter tip for a smoking product from a flat sheet, including a shaping station and a conveying station. The shaping station includes a shaping element configured to shape a free portion of the flat sheet to create an accordion fold. The conveying station is used to convey the flat sheet having the accordion fold. Furthermore, the apparatus includes a collapsing unit and a pusher as described in the embodiments herein. The pusher is configured to engage the accordion fold, which is collapsed and held by the collapsing device, and push the sheet having the compressed, collapsed accordion fold toward a conveying arm configured to discharge the sheet pushed in by the pusher. Attached Figure Description

[0046] These and other aspects, features, and advantages of the present invention will become apparent from the following description of some embodiments with reference to the accompanying drawings, which are given by way of non-limiting example only, wherein: - Figure 1 This is a schematic simplified front view of an apparatus for automatically forming filters for smoking products according to the present invention; - Figure 2 yes Figure 1 A schematic simplified top view of the device; - Figure 3 It is a detailed top view of the flat sheet material used to obtain the corresponding filter tip; - Figures 4 to 6 It is a three-dimensional diagram of the process of extracting the flat sheet material used to obtain the filter tip; - Figures 7 to 9 It uses shaping elements to Figure 3 A three-dimensional diagram of the process of shaping a flat sheet material; - Figures 10 to 15 It uses shaping elements to Figure 3 A detailed top view of the process for shaping flat sheet materials; - Figures 10a to 15a Yes Figure 3 A schematic side view of the process of shaping a flat sheet material; - Figures 16 to 19 It is a conveyor Figure 3 A three-dimensional diagram showing the operation process of the flat sheet material; - Figures 20 to 23 It is a conveyor Figure 3 A partial sectional side view showing the operation process of the flat sheet material; - Figure 24 yes Figure 1 Enlarged perspective and exploded view of the details of the second molding unit of the device; - Figure 25 and Figure 26 It is a three-dimensional diagram showing the initial and final steps of forming a filter tip from a pre-processed flat sheet. - Figure 27 This is a schematic front view of the second unit used for forming filter tips, showing the forming operation process, including the initial and final steps as follows: Figure 25 and Figure 26 What I saw.

[0047] It should be noted that the wording and terminology used in this specification, as well as the illustrations in the accompanying drawings (including those related to their description), serve only to better illustrate and explain the invention. Their purpose is to provide non-limiting examples of the invention itself, as the scope of protection is defined by the claims.

[0048] For ease of understanding, the same reference numerals are used as much as possible to identify the same common elements in the figures. It should be understood that, without further explanation, elements and features of one embodiment can be readily combined or incorporated into other embodiments. Detailed Implementation

[0049] refer to Figure 1 The device 10 according to the invention is adapted to and can be used to automatically form a filter 100 of a smoking article (such as a cigarette).

[0050] According to a feasible embodiment, device 10 may be part of a more complex machine not shown in the figure, which may include other devices for processing the same filter 100 and / or the casing of smoking articles.

[0051] Before describing the device 10 in detail, the filter 100 will now be described in order to better understand the present invention.

[0052] Filter tip 100 is obtained from flat sheet 101, possibly after shaping ( Figure 3 The flat sheet is made of paper with a thickness of a fraction of a millimeter and is folded appropriately to include an accordion fold or serrated portion 102 and an adjacent straight portion 103, the straight portion 103 being wound around the accordion fold 102. Figure 15a and Figures 23 to 25 (as shown), to obtain the final shape of the filter 100.

[0053] The terms "accordion-shaped" or "serrated" should be understood as a portion having a profile characterized by a series of folds defined by a series of ridges and grooves forming a "V" shape and interconnected at the unfolded end along corresponding fold lines 105. Fold lines 105 may be pre-etched on a portion of the flat sheet 101.

[0054] The term "flat sheet" should be understood as an unfolded sheet cut to specifications to have the expected size and shape.

[0055] According to a preferred embodiment, the flat sheet 101 may have a circular crown arc shape. Figure 3 ).

[0056] Device 10 ( Figure 1 and Figure 2 The device includes at least a first forming unit 11 configured to create accordion folds 102 on each flat sheet 101 while adjacent straight portions 103 remain unchanged. The device 10 also includes a second forming unit 12 disposed downstream of the first forming unit 11, the second forming unit 12 configured to complete the forming of the filter 100 by winding the straight portions 103 around the folds 102.

[0057] The first molding unit 11 and the second molding unit 12 are mounted on the fixed support structure 13.

[0058] The first forming unit 11 includes multiple operating areas or stations arranged sequentially along the first processing path PL1, including at least the following areas, in Figure 1 The dashed line in the middle is used to illustrate: -At the removal station 15, the flat sheet 101 is fed in and prepared to be intercepted along the first processing path PL1; -Shaping station 17, a portion of flat sheet 101 is properly shaped to create fold 102; - At the conveying or exporting station 19, the fold 102 of the flat sheet 101 is collapsed, and the flat sheet 101 is conveyed to the second forming unit 12.

[0059] Device 10 includes a feeding unit or hopper 16 ( Figure 1 and Figures 4 to 6 ), wherein the flat sheet 101 is arranged therein in a stacked and contacting manner.

[0060] The first processing path PL1 is closed in a loop, forming a circle with a first radius. It should be understood that in other embodiments not shown in the figures, the first processing path PL1 may also be linear, or have at least one straight line segment.

[0061] The first forming unit 11 includes a first disc-shaped rotating device 20, which is arranged parallel to the support structure 13 and located on the first processing plane PW1. Figure 2 The first rotating device 20 is capable of rotating about a first main rotation axis X1, and defines a first processing path PL1 around its periphery.

[0062] The first main rotation axis X1 is perpendicular to the support structure 13, and the first machining plane PW1 is perpendicular to the first main rotation axis X1. According to other embodiments, 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.

[0063] The rotation of the first rotating device 20 occurs in constant angular increments or angular pitches α, such as counterclockwise; this allows multiple operations to be performed simultaneously on the flat sheet 101, thereby improving the overall productivity of the device 10. Specifically, the rotation of the first rotating device 20 is achieved by the first driving member 21 ( Figure 2 The first drive component 21, obtained from the above, includes, for example, one or more electrically controlled stepper motors.

[0064] exist Figure 1In the embodiment shown, the angular pitch α is 90°, but depending on the design and construction of the device 10, the angular pitch can also be different, i.e., larger or smaller.

[0065] The first forming unit 11 includes one or more clamping members 22 ( Figure 1 , Figure 2 and Figures 4 to 6 The clamping member 22 is configured to engage with one flat sheet 101 at a time, directly remove the flat sheet 101 from the feed hopper 16, and stably clamp it on one face or side along the first processing path PL1.

[0066] Preferably, the clamping member 22 is arranged on the first rotating device 20 at a specific radial position and offset at the same angular interval α.

[0067] The clamping member 22 can engage with the straight portion 103 of the flat sheet 101 to allow the free portion 104 to protrude, which will undergo shaping and then be compressed to create the accordion fold 102.

[0068] According to a feasible preferred embodiment, the clamping member 22 is capable of rotating about its own axis of rotation during the rotation of the first rotating device 20 in order to properly orient the flat sheet 101 during transport along the first processing path PL1 and at the corresponding shaping station 17 and transport station 19.

[0069] The clamping member 22 is provided with one or more gripping elements 23, which face outward of the first rotating device 20 and are capable of gripping the flat sheet 101 corresponding to the corresponding straight portion 103, contacting the flat sheet on only one side and keeping it positioned on the positioning plane PZ. The positioning plane PZ is defined by the arrangement of the gripping elements 23 and is transverse relative to the processing plane PW1.

[0070] Specifically, the gripping element 23 can clamp the flat portion 103 by contacting one side of the flat portion 103, while keeping the opposite side free.

[0071] According to a feasible embodiment, the gripping element 23 is able to hold the flat sheet 101 by adsorption.

[0072] According to other feasible embodiments, the gripping element 23 may include a suction cup or similar element, or be constituted therefrom.

[0073] Corresponding to the shaping station 17, the first forming unit 11 includes one or more rotary shaping elements 24, which are configured to advantageously perform shaping on the free portion 104 with a single movement, thereby defining an accordion-shaped profile.

[0074] Shaping element 24 ( Figure 1 , Figure 2 and Figures 7 to 15The device includes a pair of shaping members 25 and 26, namely the first shaping member 25 and the second shaping member 26. The shaping members 25 and 26 are parallel to the first rotating device 20 and are arranged on opposite sides relative to the placement plane PG on which the flat sheet 101 is placed when it corresponds to the shaping station 17. It should be noted that the placement plane PG is preferably perpendicular to the first processing plane PW1 and tangent to the pair of shaping members 25 and 26 corresponding to the shaping station 17. Furthermore, when the clamping member 22 corresponds to the shaping station 17, the placement plane PG coincides with the positioning plane PZ, and the flat sheet 101 is ready for shaping.

[0075] The shaping components 25 and 26 are mounted on the support element 27 and driven by the corresponding second driving component 28. Figure 2 ).

[0076] In addition, the shaping components 25 and 26 are provided with shaping protrusions or ridges 30 and 31, and the shaping protrusions 30 and 31 have corresponding shaping start ends 30a and 31a and shaping end ends 30b and 31b.

[0077] According to the feasible preferred embodiment shown in the accompanying drawings, the shaping members 25, 26 consist of a pair of counter-rotating rollers, each roller shaping such that each has a circular coronal arc shaping region 29, on which shaping protrusions 30, 31 are created.

[0078] In particular, in the specific cases of shaping members 25 and 26, they are capable of rotating in opposite directions about corresponding second rotation axes X3 and X4 that are parallel to each other, so as to gradually transition from the stopped state C1 to the shaped state C2. Figures 7 to 15 Conversely, the same applies, as will be described in detail below. The second rotation axes X3 and X4 are parallel to the first main rotation axis X1.

[0079] The shaping protrusions 30 and 31 of the shaping members 25 and 26 are staggered; specifically, the shaping protrusion 30 of the first shaping member 25 of the pair of shaping members 25 and 26 is staggered relative to the shaping protrusion 31 of the second shaping member 26 of the pair of shaping members 25 and 26. Especially during the transition from the stopped state C1 to the shaped state C2 ( Figures 7 to 15 The shaping protrusions 30 of the first shaping member 25 can be gradually inserted between the shaping protrusions 31 of the second shaping member 26, and vice versa, contacting the free portion 104 of the flat sheet 101 placed on the placement plane PG from opposite sides, thereby defining a series of V-shaped folds, which can form the folded portion 102. Figures 10a to 15a ).

[0080] According to feasible embodiments, shaping protrusions 30, 31 ( Figures 7 to 15 It is curved and gradually converges.

[0081] Shaping protrusions 30, 31 ( Figures 7 to 15 The converging manner is such that the lateral distance between adjacent shaping protrusions 30 and 31 of each shaping member 25 and 26 gradually decreases from the shaping start end 30a and 31a to the shaping end end 30b and 31b. According to some embodiments, the shaping protrusions 30 and 31 have different radii of curvature.

[0082] In addition, one or more shaping protrusions 30, 31 are created such that the height of the contour gradually increases from the shaping start end 30a, 31a to the shaping end end 30b, 31b.

[0083] Advantageously, the gradual convergence and increasing height of the shaping protrusions 30 and 31 allow for shaping, which can both compensate for the curvature of the free part 104, making the fold lines 105 of the folded part 102 basically parallel to each other, and gradually form V-shaped folds in the height direction, taking into account that the convergence causes the V-shaped folds to gradually move closer to each other.

[0084] Therefore, the shaping members 25 and 26 can gradually engage with the free part 104 from opposite surfaces or portions via the shaping protrusions 30 and 31, having a gradually increasing convergence and shaping depth, thereby gradually forming corresponding V-shaped folds and bringing them closer together during the transition from the stopped state C1 to the shaping state C2, thereby creating the folded part 102 at least temporarily.

[0085] In this case, the shaping protrusion 30 of the first shaping member 25 ( Figures 10 to 15 The clamp is defined by: a first outer protrusion 32a, which is arranged on the opposite side of the clamping member 22; a first inner protrusion 32b, which faces the clamping member 22; and at least one intermediate protrusion 32c, which is located between the first outer protrusion 32a and the first inner protrusion 32b.

[0086] As described above, the first outer protrusion 32a has a substantially constant height, while the contours of the inner protrusion 32b and the middle protrusion 32c have increased heights. The length of the first outer protrusion 32a is greater than the lengths of the inner protrusion 32b and the middle protrusion 32c; while the length of the first inner protrusion 32b is greater than the length of the middle protrusion 32c.

[0087] The shaping protrusion 31 of the second shaping member 26 is defined by at least the following: a second outer protrusion 33a, which is arranged on the opposite side relative to the clamping member 22; and an inner protrusion 33b, which faces the clamping member 22. The profiles of the second outer protrusion 33a and the inner protrusion 33b have substantially constant heights and substantially equal lengths.

[0088] like Figure 10As shown, the first outer protrusion 32a has a greater degree of convergence and its curvature is greater than that of the middle protrusion 32c, while the curvature of the middle protrusion 32c is slightly greater than that of the inner protrusion 32b. Similarly, the second outer protrusion 33a has a slightly greater degree of convergence and its curvature is also slightly greater than that of the second inner protrusion 33b.

[0089] First outer protrusion 32a ( Figures 10 to 15 The function of the first inner protrusion 32b is to engage with the end region of the free portion 104, thereby folding it toward the second outer protrusion 33a; while the function of the middle protrusion 32c and the first inner protrusion 32b is to cooperate with the second outer protrusion 33a and the second inner protrusion 33b to gradually form V-shaped folds in the height direction, and to gradually bring them closer together by means of corresponding curvature. In addition, the end portion of the first outer protrusion 32a extends beyond the inner protrusion 32b and the middle protrusion 32c, and its function is to press one of the V-shaped folds formed therefrom onto the other, thereby at least temporarily creating the accordion fold portion 102.

[0090] It should be noted that the term "at least temporarily" means that, due to the inherent properties of the material (paper) used to manufacture the filter 100, the fold 102 tends to open elastically again after the shaping operation is completed.

[0091] According to other feasible embodiments not shown in the accompanying drawings, the first shaping member 25 may be provided with two or more intermediate protrusions 32c, and the second shaping member 26 may also be provided with corresponding intermediate protrusions as needed for the number of V-shaped folds to be created on the free portion 104.

[0092] Corresponding to the shaping station 17, abutment component 35 is also provided. Figure 1 , Figure 2 and Figures 7 to 15 The flat sheet 101 is configured to adjust its position relative to a pair of shaping members 25, 26 by moving from a retracted position P1 to an advanced position P2 during the creation of the fold 102. In the retracted position P1, the abutment member 35 is spaced apart from the flat sheet 101, and in the advanced position P2, the abutment member 35 contacts the flat sheet 101 on the opposite side of the clamping member 22.

[0093] In particular, the abutment member 35 is arranged close to the first rotating device 20 and is provided with a corresponding impact wall 36 facing the first rotating device 20. In the forward position P2, the impact wall 36 can contact the flat portion 103 of the flat sheet 101 on the opposite side of the clamping member 22 that clamps the flat sheet 101.

[0094] Advantageously, the impact wall 36 may have an outer layer made of a generally soft or flexible material with a high coefficient of friction to prevent possible relative movement of the flat sheet 101 during shaping operations or steps. For example, the outer layer may be made of a rubber material.

[0095] Set the third driving component 37 ( Figures 7 to 9 ( ) to drive the abutment member 35 to move it from the retracted position P1 to the forward position P2, and vice versa.

[0096] The first forming unit 11, corresponding to the conveying area 19, includes a crushing device 39. Figure 1 , Figure 2 and Figures 16 to 23 The collapsing device 39 is adjacent to the first rotating device 20 and can move between the stationary position PP and the collapsing position PS. In the stationary position PP, the collapsing device 39 is separated from the folded portion 102. In the collapsing position PS, the collapsing device 39 engages with and collapses the folded portion 102 that has been partially elastically opened, thereby engaging with it and collapsing it toward the straight portion 103 held by the corresponding clamping member 22, thus obtaining the regular accordion folded portion 102 again.

[0097] Specifically, the collapsing device 39 is provided with at least a lower collapsing portion 40, which has an abutment or wall 41 that can engage with the outermost fold of the fold 102. In addition, the collapsing device 39 is also provided with an upper connecting portion 42 that protrudes relative to the abutment wall 41.

[0098] The connecting part 42 has a groove 43 that matches the shape of the clamping member 22.

[0099] The connecting portion 42 is configured to have a lower inclined surface 44, which connects to and is positioned and sized such that when the abutment wall 41 abuts against the impact wall 48 and the fold 102 is located between them, the lower inclined surface 44 is positioned above the impact plate 46. In particular, when the crushing device 39 moves from the rest position PP to the crushing position PS, the function of the lower inclined surface 44 is to engage with the fold 102 during use to guide it correctly toward the abutment wall 41, thereby performing accurate crushing.

[0100] Impact plate 46 ( Figure 1 , Figure 2 and Figures 16 to 23 It is arranged in front of the collapse device 39 and below the first rotating device 20 to provide abutment and support for the sheet 101 during the collapse fold 102.

[0101] The impact plate 46 is provided with abutment 47, the shape of which is negatively matched with the shape of the collapse portion 40, so as to allow insertion into the abutment wall 41 with minimal gap and temporarily accommodate the fold portion 102 ready to be collapsed.

[0102] In addition, the abutment seat 47 is provided with an impact wall 48, which provides the end point of the travel of the abutment wall 41 and provides rear abutment for the folded part 102 when the folded part 102 is crushed.

[0103] In other words, equipment 39 collapsed. Figures 16 to 23 It can translate toward the impact plate 46 in a direction perpendicular to the impact plate 46, moving from the rest position PP to the collapse position PS. In the rest position PP, the collapse device 39 is aligned with and separated from the clamping member 22 and the impact plate 46. In the collapse position PS, the collapse device 39 cooperates with the clamping member 22 through the corresponding abutment wall 41. The collapse device 39 can engage the folded part 102 and crush the folded part 102 against the impact wall 48.

[0104] It is important to emphasize that the connection between the clamping member 22 and the groove 43 allows for stable guidance of the translation of the collapse device 39.

[0105] Fourth driving component 49 ( Figure 1 The device is set to drive the collapse device 39 so that it moves from the rest position PP to the collapse position PS and vice versa.

[0106] It should be noted that the collapse device 39, the impact plate 46, and the corresponding clamping member 22 of the sheet 101 together define the unit for collapsing the accordion fold 102.

[0107] A push rod 50 is also provided corresponding to the conveying area 19. The push rod 50 is arranged laterally relative to the collapsing device 39 and can be translated perpendicularly to the collapsing device 39 so as to engage and collapse the fold 102 between the abutment wall 41 and the impact wall 48, and push it toward the conveying arm 51 arranged between the first forming unit 11 and the second forming unit 12, thereby exporting the sheet 101.

[0108] It should be noted that the thrust generated by the push rod 50 is sufficient to allow the sheet 101 to disengage from the clamping member 22. Preferably, the conveying of the sheet 101 can be achieved through horizontal translation.

[0109] The push rod 50 is capable of translating along the guide 54 of the fold 102 present in the impact plate 46. The guide 54 is manufactured to correspond to the end portion of the abutment 47, that is, to the impact wall 48, and intersects the abutment 47 perpendicularly.

[0110] Conveyor arm 51 ( Figures 16 to 19 The conveyor arm 51 is set at the receiving position PR to receive the sheet 101 pushed by the push rod 50 and convey it to the second forming unit 12. The conveyor arm 51 moves from the receiving position PR to the conveying position PT.

[0111] Movement from receiving position PR to delivery position PT ( Figure 24The horizontal rotation of the conveying arm 51 can be preferably achieved by the horizontal rotation of the conveying arm 51, which is driven or moved by the fifth drive member 52.

[0112] The conveying arm 51 is provided with a receiving seat 53 for accommodating the folded portion 102 of the sheet 101, and is provided with a clamping element 55 to stably clamp the straight portion 103.

[0113] For example, such as Figure 14 As shown, the clamping element 55 may include a plate attached to the conveying arm 51, the surface of which is at least partially coated with a highly adhesive material, such as an elastomer. The plate is arranged to leave a gap between itself and the conveying arm 51 below, the gap being configured to receive the straight portion 103.

[0114] It should be noted that, in addition to the conveyor arm 51, there may be another push rod component (not shown), which allows for the accurate conveying of the processed sheet 101 to the second forming unit 12.

[0115] Second molding unit 12 ( Figure 1 and Figure 2 This includes multiple operating areas or stations arranged sequentially along the second processing path PL2, including at least the following areas, in Figure 1 The dashed line in the middle is used to illustrate: - Receiving area 60, in which the processed sheets 101 are conveyed one by one by the conveyor arm 51 until they intersect with the second processing path PL2; - Forming area 61, in which the filter tip 100 is formed from the corresponding sheet 101 as described above; - Conveying area 62, in which one filter 100 is conveyed to another processing area at a time.

[0116] Preferably, the second processing path PL2 is a closed loop, forming a circle with a second radius. It should be understood that, in other embodiments not shown in the figures, the second processing path PL2 may be a straight line, or may contain at least one straight line segment.

[0117] The second forming unit 12 includes a moving device 63 configured to move a corresponding forming mandrel 66 for forming the filter tip 100 at least along the processing path PL2, as detailed below.

[0118] The moving device 66 includes a second disc-shaped rotating device 65 arranged parallel to the support structure 13 and located on a second processing plane PW2. The second disc-shaped rotating device 65 is rotatable about a second main rotation axis X2 parallel to the first main rotation axis X1, and defines a second processing path PL2 corresponding to its periphery. According to a feasible embodiment, the second main rotation axis X2 is horizontal and perpendicular to the support structure 13, while the second processing plane PW2 is vertical and perpendicular to the second main rotation axis X2.

[0119] Therefore, the first and second processing planes PW1 and PW2 are parallel to each other and spaced apart to avoid interference.

[0120] The rotation of the second rotating device 65 can occur clockwise and counterclockwise in constant angular increments or angular pitch β; this allows multiple operations to be performed simultaneously on the sheet 101, thereby improving the overall production efficiency of the device 10. Specifically, the rotation of the second rotating device 65 is achieved through the sixth drive member 67 ( Figure 2 For example, the sixth drive component 67 includes one or more electrically controlled stepper motors.

[0121] exist Figure 1 In the embodiment shown, the angular pitch β is 45°, but it can be different, i.e. larger or smaller, depending on the design and manufacturing choices of the device 10.

[0122] The second rotating device 65 is provided with multiple through holes 69. Figure 14 These through holes are set at defined radial positions and offset at the same angular interval β.

[0123] The second forming unit 12 includes: a forming mandrel 66 ( Figure 1 , Figure 2 and Figures 24 to 27 The forming mandrel is rotatable about its own rotation axis X5 to form the filter tip 100; and a receiving element 70 is arranged coaxially with the rotation axis X5 and in a fixed axial position relative to the forming mandrel 66. It should be noted that each rotation axis X5 is parallel to the second main rotation axis X2.

[0124] According to a preferred embodiment, the receiving element 70 is coaxially mounted with the through hole 69 on the second rotating device 65, and the forming mandrel 66 is located in the respective through hole 69 such that at least a portion of it protrudes from the through hole 69 to cooperate with the corresponding receiving element 70, as detailed below.

[0125] In the example given in this article, there are eight through holes 69, forming mandrels 69, and receiving elements 70. Figure 1 (This is because the angle interval β is 45°); obviously, in other embodiments, their number may be more or less than eight, in any case selected according to the number of the angle interval β.

[0126] according to Figure 14 In the embodiment shown, each receiving element 70 has a generally tubular shape and includes a hollow cylinder 71 that is coaxial with the rotation axis X5 and is formed through it. The hollow cylinder 71 can at least be inserted into the accordion fold 102 of the sheet 101. Each receiving element 70 also includes at least one side slit 72 that is tangent to the hollow cylinder 71 and functions to allow the straight portion 103 of the same sheet 101 to pass through.

[0127] According to other embodiments not shown in the accompanying drawings, the receiving element 70 may differ from the structure described and / or shown herein; for example, the receiving element 70 may be formed of two generally semi-cylindrical portions configured to allow for the reception of sheet 101.

[0128] Each of the forming mandrels 66 includes an elongated body, with a clamping member 75 at one end for clamping the folded part 102.

[0129] As from Figure 1 and Figures 24 to 27 As can be observed, along the second processing path PL2, each forming mandrel 66 is arranged in an operating position, in which a corresponding clamping member 75 is arranged inside the hollow cylinder 71.

[0130] The clamping member 75 includes or consists of at least two gripping elements 76 (e.g., jaws), which are opposite to each other relative to the rotation axis X5 and configured to clamp the folded portion 102 within the hollow cylinder 71. Figures 24 to 27 ).

[0131] According to a preferred embodiment, two gripping elements 76 are fixed and spaced apart, so that they clamp the folded portion 102 in an interference fit.

[0132] In other embodiments not shown in the accompanying drawings, the gripping element 76 can be selectively opened and closed to grip and release the sheet 101 accordingly. Furthermore, according to other embodiments, it is apparent that other gripping members 75 suitable for gripping the sheet 101 can be used.

[0133] The forming mandrel 66 is capable of rotating independently about its rotation axis X5 relative to the rotation of the second rotating device 65. For example, during a single angular pitch β, each forming mandrel 66 is capable of rotating 360° once or more about its rotation axis X5 to wind the straight portion 103 onto the folded portion 102 held by the clamping member 75, thereby forming the filter 100.

[0134] It should be noted that the moving device 63 is also configured to selectively move each forming mandrel 66 about and along its own axis of rotation X5; for example, the moving device 63 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 forming mandrel 66.

[0135] Corresponding to the conveying area 62, the same forming mandrel 66 may be used, which allows each filter tip 100 to be conveyed to another device, area, or processing equipment, for example, by sliding or axially translating to another operating position. Alternatively, other suitable conveying devices of known types but not shown in the figure may also be used.

[0136] Device 10 includes a central control unit 77 ( Figure 2 The central control unit 77 is programmed to control and command the activation of drive components 21, 28, 37, 49, 52 and 67 and moving device 63 to synchronize the rotation of rotating devices 20 and 65 and shaping element 24, as well as the movement of abutment component 35, crushing device 39, push rod 50, conveying arm 51 and forming mandrel 66.

[0137] The operation of the aforementioned device 10 corresponds to the method according to the present invention, including the following steps.

[0138] It should be noted that the description of a single sheet 101 will be valid cyclically for each sheet 101 used to obtain the filter 100.

[0139] In the initial preparation steps, the central control unit 77 is programmed to control and coordinate the drives of the rotating devices 20 and 65, the shaping element 24, the abutment member 35, the collapsing device 39, the push rod 50, the conveying arm 51, and the forming mandrel 66.

[0140] In the feeding step ( Figure 4 In the process, the flat sheet 101 is sent to the transfer station 15 through the feed hopper 16, so that they are positioned along the first processing path PL1.

[0141] Corresponding to the first forming unit 11, the first step is performed: forming the filter tip 100 starting from the corresponding flat sheet 101. The first forming step includes at least an extraction step, a shaping step, and a folding step of the flat sheet 101.

[0142] In the extraction step ( Figure 5 and Figure 6In the process, the rotation of the first rotating device 20 causes the corresponding clamping member 22 to intercept and engage the corresponding flat sheet 101, extracting it directly from the feed hopper 16 and clamping only one side of it. Specifically, the clamping member 22 clamps the flat sheet 101 with its gripping element 23 corresponding to the flat portion 103 of the flat sheet 101, contacting only one side of it, leaving the opposite side free and allowing the free portion 104 to protrude.

[0143] Then, the flat sheet 101 is conveyed to the shaping station 17 by the rotation of the rotating device 20.

[0144] In the shaping step ( Figure 7 In the positioning station 17, the flat sheet 101 is positioned so that it is aligned with and coplanar with the placement plane PG, and the abutment member 35 moves from the retracted position P1 to the forward position P2 so that the flat sheet 101 contacts the corresponding impact wall 36, thereby stabilizing its position. The abutment member 35 contacts the flat sheet 101 from the opposite side of the clamping member 22.

[0145] Subsequently, the shaping element 24 for shaping the free part 104 is driven. Figures 8 to 15 Specifically, during the shaping process, the shaping protrusion 30 of the first shaping member 25 acts on one surface of the free portion 104 and gradually inserts between the shaping protrusions 31 of the second shaping member 26, while the shaping protrusions 31 of the second shaping member 26 act on the other surface of the free portion 104, thereby creating wrinkles.

[0146] In particular, the shaping protrusions 30 and 31 gradually join the opposite sides of the free part 104 in a progressive manner with gradually increasing convergence and shaping depth, thereby gradually forming corresponding V-shaped folds and bringing them closer together, at least temporarily creating the folded part 102.

[0147] In a preferred embodiment, the shaping members 25 and 26 are rollers that rotate in opposite directions to switch from the stopped state C1 to the shaping state C2, and create folds 102 by means of corresponding shaping protrusions 30 and 31.

[0148] In this specific example, during the transition from the stopped state C1 to the fixed state C2, the first outer protrusion 32a engages with the end region of the free portion 104, thereby folding it toward the second outer protrusion 33a; simultaneously, the middle protrusion 32c and the first inner protrusion 32b cooperate with the second outer protrusion 33a and the inner protrusion 33b to gradually form V-shaped folds, and these folds gradually come together with the help of corresponding curvature. In addition, the end portion of the first outer protrusion 32a presses down the V-shaped folds formed therefrom one on top of the other, thereby at least temporarily creating the accordion fold 102.

[0149] Once the shaping process is complete, the shaping components 25 and 26 rotate in opposite directions to return to the stopped state C1.

[0150] Subsequently, the flat sheet 101 is conveyed to the conveying station 19 by the rotation of the rotating device 20.

[0151] In the collapse step ( Figure 16 In the process, the flat sheet 101 is arranged such that the partially elastically opened fold 102 faces and aligns with the collapse device 39.

[0152] In this step ( Figure 17 , Figure 18 and Figures 20 to 23 In this process, the collapsing device 39 moves from the rest position PP to the collapsing position PS, translating towards the impact plate 46 in a direction perpendicular to the impact plate 46, and together with the abutment wall 41, collapses the fold 102 against the impact wall 48, thereby obtaining the correct accordion fold 102 again. During the movement from the rest position PP to the collapsing position PS, at least a portion of the clamping member 22 is inserted into the groove 43 of the collapsing device 39, thereby stably guiding its movement, and the lower inclined surface 44 moves above the impact plate 46, correctly guiding the fold 102 towards the abutment wall 41, thereby accurately performing the collapsing.

[0153] Subsequently, at the transport station ( Figure 19 In the process, push rod 50 translates along guide 54 in a direction perpendicular to the collapsing device 39 to engage the fold 102 between the abutment wall 41 and the impact wall 48 and push it toward the conveyor arm 51 there, thereby disengaging sheet 101 from clamping member 22.

[0154] Then, once this operation is complete, the collapse device 39 returns to the stationary position PP, and the push rod 50 returns to the starting position.

[0155] It is important to emphasize that the conveyor arm 51 is positioned at the receiving position PR to receive the folded portion 102 of the sheet 101 moved by the push rod 50 in its receiving seat 53, and to stably clamp the straight portion 103 with the corresponding clamping element 55. Figure 19 Please note that in the receiving position PR, the receiver 53 is aligned with the export guide 54.

[0156] Subsequently, the conveyor arm 51 moves from the receiving position PR to the conveying position PT to convey the sheet 101 to the second forming unit 12.

[0157] Corresponding to the second forming unit 11, the second step is performed: the filter tip 100 is formed from the processed corresponding flat sheet 101.

[0158] The second forming step includes a receiving step ( Figure 24): Corresponding to the receiving area 60 of the second forming unit 12, the sheet 101 is received. In particular, the sheet 101 is inserted from the front end (i.e. from the front) into the hollow cylinder 71 of the receiving element 70 of the second rotating device 65 by means of the conveying arm 51 and possibly the push rod member, such that the folded portion 102 of the sheet 101 is inserted and at least interference-fitted between the gripping elements 76 of the clamping member 75 of the forming mandrel 66, and such that the straight portion 103 is positioned in the corresponding side seam 72.

[0159] Subsequently, in the second forming step ( Figures 25 to 27 In the process, when the second rotating device 65 rotates about its second main rotating axis X2, the forming mandrel 66 rotates about its rotating axis X5 in a specific rotation direction, and by cooperating with the corresponding receiving element 70, especially the hollow cylinder 71, it winds the straight portion 103 of the sheet 101 onto the folded portion 102 and the gripping element 76, thereby forming the filter 100.

[0160] Once the filter tip 100 has been formed, another conveying step is performed corresponding to the conveying area 62: conveying the filter tip 100 to another device, area or processing equipment.

[0161] According to some embodiments, this conveying can be achieved using the same forming mandrel 66, which conveys the corresponding filter 100 to another device, area, or processing equipment by moving to another operating position. Alternatively, this conveying can also be achieved using other suitable conveying devices of known types, not shown in the figures.

[0162] It is obvious that modifications and / or additions to the aforementioned apparatus 10 and method can be made without departing from the scope and domain of the invention as defined by the claims. It is also obvious that although the invention has been described with reference to specific embodiments, those skilled in the art will be able to implement other equivalent apparatuses and methods for automatically forming filters for smoking products. These apparatuses and methods have the features described in the claims and are therefore within the scope of protection defined by the claims. In the following claims, the reference numerals in parentheses are for ease of reading only and should not be considered as limitations on the scope of protection.

Claims

1. An apparatus (10) for automatically forming a filter (100) for a smoking product from a flat sheet (101), the apparatus (10) comprising a first forming unit (11) configured to create an accordion fold (102) on a portion of each of the flat sheets (101) and to keep adjacent straight portions (103) unfolded, the first forming unit (11) comprising at least one clamping member (22) configured to clamp one flat sheet (101) at a time and to allow a free portion (104) from which the accordion fold (102) to be formed to freely protrude from the clamping member (22), characterized in that, The first forming unit (11) further includes a pair of shaping members (25, 26), the pair of shaping members (25, 26) having corresponding shaping protrusions (30, 31), the shaping protrusions (30, 31) converging in such a way that the distance between adjacent shaping protrusions (30, 31) of each shaping member (25, 26) gradually decreases from the corresponding shaping start end (30a, 31a) to the corresponding shaping end end (30b, 31b), wherein the shaping protrusion (30a, 31) of the first shaping member (25) of the pair of shaping members (25, 26) has a corresponding shaping protrusion (30a, 31a). The shaping protrusions (31) of the second shaping member (26) of the pair of shaping members (25, 26) are staggered. The pair of shaping members (25, 26) are configured by the shaping protrusions (30, 31) to engage with the opposite sides of the free portion (104) of the flat sheet (101) held by the clamping member (22), thereby gradually forming continuous pleats with gradually increasing shaping depth and bringing the continuous pleats closer together, thereby creating the accordion fold (102) on the free portion (104) of the flat sheet (101).

2. The device (10) according to claim 1, characterized in that, The height of the profile of one or more of the shaping protrusions (30, 31) increases from the corresponding shaping start end (30a, 31a) to the corresponding shaping end end (30b, 31b).

3. The apparatus (10) according to claim 1 or 2, characterized in that, The pair of shaping members (25, 26) consist of a pair of counter-rotating rollers, each roller having a corresponding arc-shaped shaping area (29) on which the shaping protrusions (30, 31) are provided, wherein the shaping protrusions (30, 31) of the first shaping member (25) and the second shaping member (26) are configured to gradually insert into each other, thereby creating wrinkles on the free portion (104).

4. The apparatus (10) according to any one of the preceding claims, characterized in that, The device further includes an abutment member (35) configured to lock the position of the flat sheet (101) relative to the pair of shaping members (25, 26) by moving from a retracted position (P1) to an advanced position (P2) during the creation of the accordion fold (102), in the retracted position (P1) the abutment member (35) being spaced apart from the flat sheet (101), and in the advanced position (P2) the abutment member (35) contacting the at least one clamping member (22) to position the flat sheet (101) between them.

5. The apparatus (10) according to any one of the preceding claims, characterized in that, The first forming unit (11) further includes a first rotating device (20) which is capable of rotating about a first main rotating axis (X1) to move the at least one clamping member (22) along a first processing path (PL1) which runs through at least one transfer station (15), one shaping station (17) and one conveying station (19).

6. The apparatus (10) according to any one of the preceding claims, characterized in that, The at least one clamping member (22) includes one or more gripping elements (23) configured to pick up the flat sheet (101) from the feeding unit (16) by contacting one side of the flat sheet (101) and keeping the opposite side free.

7. The apparatus (10) according to any one of the preceding claims, characterized in that, The apparatus further includes a collapsing device (39) arranged downstream of the pair of shaping members (25, 26) and movable between a rest position (PP) and a collapsing position (PS). In the rest position (PP), the collapsing device is separated from the accordion fold (102) of the corresponding flat sheet (101) held by the at least one clamping member (22). In the collapsing position (PS), the collapsing device engages with the accordion fold (102) by abutting wall (41) and crushes the accordion fold (102) against the impact wall (48) of the impact plate (46), thereby crushing the accordion fold (102) to stabilize its shape.

8. The apparatus (10) according to claim 7, characterized in that, The collapsing device (39) is provided with an inclined surface (44), which is configured and sized such that when the abutment wall (41) abuts against the impact wall (48) such that the accordion fold (102) of the flat sheet is located between the two, the inclined surface (44) slides above the impact plate (46) to accurately collapse the accordion fold (102).

9. The apparatus (10) according to any one of the preceding claims, characterized in that, The device further includes a second forming unit (12) having at least one forming mandrel (66) with a clamping member (75) configured to clamp the accordion fold (102) and rotate it about a rotation axis (X5). The second forming unit also has at least one receiving element (70) coaxially arranged with the rotation axis (X5) of the forming mandrel (66) and provided with a hollow cylinder (71). The clamping member (75) is capable of being inserted into the hollow cylinder (71). The hollow cylinder (71) is provided with a side seam (72) parallel to the rotation axis (X5). The side seam (72) is configured to allow a straight portion (103) wrapped around the clamping member (75) to pass through when the forming mandrel (66) rotates, thereby forming the filter (100).

10. A method for automatically forming a filter (100) for a smoking article by means of an apparatus (10), the apparatus (10) comprising a first forming unit (11) performing a first shaping step to form the filter (100) from a flat sheet (101) to create an accordion fold (102) on a portion of each of the flat sheets (101) and to keep adjacent flat portions (103) unfolded, wherein a clamping member (22) of the first forming unit (11) clamps one flat sheet (101) at a time and allows a free portion (104) from which the accordion fold (102) to be formed to protrude freely from the clamping member (22), and moves the flat sheet (101) toward a pair of shaping members (25, 26) of the first forming unit (11), characterized in that, The pair of shaping members (25, 26) have corresponding converging shaping protrusions (30, 31), wherein the distance between adjacent shaping protrusions (30, 31) of each shaping member (25, 26) gradually decreases from the corresponding shaping start end (30a, 31a) to the corresponding shaping end end (30b, 31b), and the shaping protrusion (30) of the first shaping member (25) of the pair of shaping members (25, 26) is relatively large relative to the second shaping protrusion of the pair of shaping members (25, 26). The shaping protrusions (31) of the component (26) are arranged in an alternating manner. The first shaping step also includes engaging the free portion (104) of the flat sheet (101) held by the clamping component (22) from opposite sides by the corresponding converging shaping protrusions (30, 31), so that continuous folds with gradually increasing shaping depth are gradually formed and the continuous folds are brought closer together, thereby creating the accordion fold (102) on the free portion (104) of the flat sheet (101).

11. The method according to claim 10, characterized in that, In the shaping step, the shaping protrusion (30) of the first shaping member (25) presses against one surface of the free part (104) and gradually inserts between the shaping protrusions (31) of the second shaping member (26), and the shaping protrusions (31) of the second shaping member (26) press against the other surface of the free part (104), thereby creating the wrinkles.

12. The method according to claim 10 or 11, characterized in that, The method includes an extraction step, wherein the at least one clamping member (22) extracts the flat sheet (101) directly from the feeding unit (16) by means of one or more corresponding gripping elements (23) and clamps the flat portion (103) by contacting it on only one side while keeping the opposite side free.

13. The method according to claim 10, 11 or 12, characterized in that, Following the shaping step, the method includes a collapsing step, wherein the flat sheet (101) held by the at least one clamping member (22) is fed to the conveying station (19) of the first forming unit (11), with the corresponding accordion fold (102) facing and aligned with the collapsing device (39), the collapsing device (39) translating toward the impact plate (46) by moving from the rest position (PP) to the collapsing position (PS), the collapsing device (39) collapsing the accordion fold (102) against the impact wall (48) of the impact plate (46) by the abutment wall (41) to stabilize the accordion fold (102).

14. The method according to claim 13, characterized in that, During the movement from the stationary position (PP) to the collapsed position (PS), the inclined surface (44) connected to the abutment wall (41) slides over the impact plate (46) to accurately perform the collapse.

15. The method according to any one of claims 10 to 14, characterized in that, The method further includes a second shaping step, downstream of which a corresponding sheet having the accordion fold (102) is received by a shaping mandrel (66) of a second forming unit (12), the shaping mandrel clamping the accordion fold (102) by a clamping member (75) and cooperating with a coaxially arranged receiving element (70) to form the filter (100), the receiving element (70) being provided with a hollow cylinder (71), the clamping member (75) being insertable into the hollow cylinder (71), the hollow cylinder (71) being provided with a side slit (72) allowing a straight portion (103) to pass through, and the shaping mandrel (66) rotating about its axis of rotation (X5) and cooperating with the hollow cylinder (71) to cause the straight portion (103) to wrap around the clamping member (75) and the accordion fold (102), thereby forming the filter (100).

16. The method according to any one of claims 10 to 15, characterized in that, The pair of shaping members (25, 26) consist of a pair of rollers, each roller having a corresponding arc-shaped shaping area (29), the arc-shaped shaping area (29) being provided with the shaping protrusions (30, 31), and in the shaping step, the rollers rotate in the opposite direction to create the accordion fold (102).

17. A compression unit for compressing an accordion fold (102) near a straight portion (103) of a sheet (101) intended for forming a filter (100) for a smoking article, said compression unit comprising a compression device (39), an impact plate (46), and a clamping member (22) for clamping said sheet (101), characterized in that, The collapsing device (39) is configured to move from a stationary position (PP) to a collapsing position (PS). In the stationary position (PP), the collapsing device (39) is separated from the accordion fold (102). In the collapsing position (PS), the collapsing device (39) engages with the accordion fold (102) through an abutment wall (41) and crushes the accordion fold (102) against the impact wall (48) of the impact plate (46), thereby crushing the accordion fold (102) to stabilize the shape of the accordion fold (102).

18. The unit according to claim 17, characterized in that, The collapsing device (39) is also provided with an inclined surface (44), which is configured and sized such that when the abutment wall (41) abuts against the impact wall (48) so that the accordion fold (102) is located between the two, the inclined surface (44) slides above the impact plate (46).

19. An apparatus (10) for automatically forming a filter (100) for smoking products from a flat sheet (101), characterized in that, The device (10) includes a shaping station (17) and a conveying station (19), the shaping station including a shaping element (24) configured to shape the free portion (104) of the flat sheet (101) to create an accordion fold (102), the conveying station (19) for conveying the flat sheet (101) having the accordion fold (102), and the device (10) further including a collapsing unit and a push rod (50) as claimed in claim 17 or 18, the push rod (50) configured to engage the accordion fold (102) collapsed and held by the collapsing device (39) and push the flat sheet (101) having the compressed and collapsed accordion fold (102) toward a conveying arm (51), the conveying arm (51) configured to remove the flat sheet (101) pushed in by the push rod (50).

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