Manufacturing machine for rod used in aerosol-generating article and method for manufacturing said rod

Abstract

A manufacturing machine (2) for a rod (1) used in an aerosol-generating article (80) comprises: a sheet supply section (10) that supplies a sheet (4), which is a material for the rod (1), to a conveyance path (14); a sheet processing section (20) that processes the sheet (4) being conveyed on the conveyance path (14); and a fine powder removal section (30) that has a removal unit (32) which removes fine powder from the sheet (4) being conveyed on the conveyance path (14), wherein the removal unit (32) is provided with a removal head (34) that has a separation part (42) which separates the fine powder from the sheet (4) and an attraction part (44) which attracts and removes the fine powder separated from the sheet (4) at the separation part (42).

Description

Machine for manufacturing rods used in aerosol products and method for manufacturing said rods

[0001] The present invention relates to a machine for producing rods for use in aerosol products and a method for producing such rods.

[0002] Patent Document 1 discloses a method and apparatus for processing a strip of tobacco filter material (filter tow). In this processing method and apparatus, the filter tow strip is guided tightly around a pair of rollers in an S-shape or loop shape, forming a gap between the rollers to prevent the rollers from contacting each other and preventing wear on the roller surfaces. Furthermore, the rollers can be equipped with a dust removal device, and dust adhering to the rollers can be removed by disposing a brush on the roller or irradiating the roller with ultrasound, thereby further improving the filter tow processing process.

[0003] Japanese Patent Application Laid-Open No. 2006-223305

[0004] It is known that in rod manufacturing machines for tobacco-containing aerosol products, fine particles (paper dust and other dust) adhere significantly to the surface of the sheets from which the rods are made during the sheet manufacturing and processing processes. Such fine particles adhere to and accumulate on the rod forming unit, contaminating the equipment, and adhere to the rods, resulting in a deterioration in the quality of the rods and ultimately the aerosol products. Therefore, rather than removing the fine particles from rollers as in the above-mentioned conventional technology, there is a need for a method for efficiently removing the fine particles directly and efficiently from the sheets being conveyed during the rod manufacturing process, thereby efficiently preventing the fine particles from contaminating the equipment and the deterioration in the quality of the rods and ultimately the aerosol products.

[0005] The present invention has been made in consideration of such problems, and aims to provide a manufacturing machine for rods used in aerosol products and a manufacturing method for such rods that can efficiently prevent contamination of equipment due to fine powder and deterioration of the quality of the rods and ultimately the aerosol products due to fine powder.

[0006] In order to achieve the above-mentioned object, one embodiment of a rod manufacturing machine for use in aerosol products comprises a sheet supply section that supplies a sheet, which is the material for the rod, to a conveying path, a sheet processing section that processes the sheet as it is conveyed along the conveying path, and a fine powder removal section having a removal unit that removes fine powder from the sheet as it is conveyed along the conveying path, and the removal unit comprises a removal head that has a peeling section that peels fine powder from the sheet and a suction section that sucks and removes the fine powder peeled from the sheet in the peeling section.

[0007] In addition, a method for manufacturing a rod used in an aerosol product according to one embodiment includes a sheet supply step for supplying a sheet, which is the material for the rod, to a conveying path, a sheet processing step for processing the sheet while it is being conveyed along the conveying path, and a fine powder removal step for removing fine powder adhering to the sheet while it is being conveyed along the conveying path, the fine powder removal step including a fine powder peeling process for peeling the fine powder from the sheet, and a fine powder suction process for sucking and removing the fine powder peeled from the sheet in the fine powder peeling process.

[0008] According to the rod manufacturing machine and method for manufacturing the rods used in the aerosol products of the above-mentioned aspect, it is possible to efficiently prevent contamination of the equipment due to fine powder and deterioration of the quality of the rods and, ultimately, the aerosol products due to fine powder.

[0009] 1. A schematic diagram of a rod manufacturing machine according to a first embodiment. 2. A flowchart illustrating a method for manufacturing a rod using the manufacturing machine of FIG. 1. 3. A cross-sectional view of the removal unit of FIG. 1. 4. A transverse cross-sectional view of the rod of FIG. 1. 5. A longitudinal cross-sectional view of an aerosol product comprising the rod of FIG. 4. 6. A longitudinal cross-sectional view of an alternative aerosol product comprising the rod of FIG. 4. 7. A cross-sectional view of a removal unit according to a second embodiment. 8. A cross-sectional view of a removal unit according to a third embodiment. 9. A schematic diagram of a cutting section according to a fourth embodiment. 10. A partial cross-sectional view of a removal unit installed in the knife of FIG. 9. 11. A flowchart illustrating a method for manufacturing a rod using the cutting section of FIG. 9. 12. A perspective view of a sheet supply section according to a fifth embodiment. 13. A partial cross-sectional view of a removal unit installed in the knife of FIG. 12. 14. A flowchart illustrating a method for manufacturing a rod using the sheet supply section of FIG. 12. 15. A schematic diagram of a combiner section according to a sixth embodiment. 16. A perspective view of a removal unit installed in the knife of FIG. 15. 17. A flowchart illustrating a method for manufacturing an article using the combiner section of FIG. 15.

[0010] Hereinafter, a manufacturing machine 2 for rod 1 used in an aerosol product and a manufacturing method for rod 1 will be described with reference to the drawings. <First Embodiment> Fig. 1 shows a schematic diagram of the manufacturing machine 2 for rod 1 according to a first embodiment, and Fig. 2 shows a flowchart explaining a manufacturing method for rod 1 using the manufacturing machine 2 of Fig. 1. The manufacturing machine 2 includes, in order from the upstream side in the conveying direction of a sheet 4, which is the material for rod 1, a sheet supply section 10, a sheet processing section 20, a fine powder removal section 30, a gathering section 40, a wrapping section 50, and a cutting section 60.

[0011] The sheet supply section 10 includes a roll 6 on which the sheet 4 is wound, multiple guide rollers 8, multiple dancer rollers 9, and feed rollers 12. Each guide roller 8 guides the sheet 4 along a conveying path 14, and each dancer roller 9 is allowed to move up and down, applying tension to the sheet 4 on the conveying path 14. The feed roller 12 pulls and pays out the sheet 4 from the roll 6 via the guide rollers 8 and dancer rollers 9. When the production of rod 1 begins, the sheet supply section 10 configured in this manner continuously pays out the sheet 4 from the roll 6 via the rollers 8, 9, and 12 and supplies it to the conveying path 14 in the manufacturing machine 2 (S1: sheet supply step).

[0012] Next, the sheet processing section 20 processes the sheet 4 being transported along the transport path 14 (S2: sheet processing step). More specifically, the sheet processing section 20 includes crimping rollers 22, which convey the sheet 4 by sandwiching it between a pair of rollers 22A and 22B, thereby crimping the sheet 4 (P1: crimping process). The crimping process is a process for forming uneven patterns on the sheet 4 at intervals. By performing this crimping process, crimped portions 4a (see FIG. 4) with uneven wrinkles are formed on the sheet 4. Next, the fine powder removal section 30 removes fine powder from the sheet 4 being transported along the transport path 14 (S3: fine powder removal step).

[0013] More specifically, the fine powder removal section 30 includes a removal unit 32, which has a removal head 34 that removes fine powder, such as paper dust and other dirt, adhering to the sheet 4 from the sheet 4. In this embodiment, the removal head 34 includes a first removal head 34A and a second removal head 34B. The first removal head 34A removes fine powder adhering to the front surface (top surface in FIG. 1 ) of the sheet 4. The second removal head 34B removes fine powder adhering to the back surface (bottom surface in FIG. 1 ) of the sheet 4. That is, the fine powder removal step S3 removes fine powder adhering to both the front and back surfaces of the sheet 4.

[0014] The removal unit 32 also includes support rollers 36 positioned opposite the removal head 34 with the sheet 4 sandwiched between them. The support rollers 36 support the sheet 4 during transport so as to bring it close to the removal head 34. Specifically, the distance between the removal head 34 and the support rollers 36 is set to, for example, approximately 1 mm to 3 mm. The support rollers 36 in this embodiment include a first support roller 36A and a second support roller 36B. The first support roller 36A supports the sheet 4 so as to bring it close to the first removal head 34A. The second support roller 36B supports the sheet 4 so as to bring it close to the second removal head 34B. Guide rollers 8 are respectively arranged upstream of the first support roller 36A and downstream of the second support roller 36B.

[0015] Furthermore, the removal unit 32 includes a static eliminator (i.e., ionizer) 38 located upstream of the removal head 34 in the conveyance direction of the sheet 4. The static eliminator 38 removes static electricity from the sheet 4 in the fine powder removal step S3 before the fine powder peeling process P3 (described later) (P2: static elimination process). The static eliminator 38 in this embodiment includes a first static eliminator 38A and a second static eliminator 38B. The first static eliminator 38A is disposed between the first support roller 36A and the guide roller 8 located upstream thereof. The second static eliminator 38B is disposed between the second support roller 36B and the guide roller 8 located downstream thereof.

[0016] FIG. 3 shows a cross-sectional view of the removal unit 32. The removal head 34 constituting the removal unit 32 has a peeling section 42 and a suction section 44. The peeling section 42 peels off fine powder from the sheet 4 in the fine powder removal step S3 (P3: fine powder peeling process). The suction section 44 has a vacuum pump (not shown) and the like, and sucks and removes the fine powder peeled off from the sheet 4 in the peeling section 42 (P4: fine powder suction process). More specifically, in this embodiment, the peeling section 42 has an ultrasonic generator 46 that irradiates ultrasonic waves onto the sheet 4 during transport. The ultrasonic generators 46 are provided both upstream and downstream of the suction section 44 in the transport direction of the sheet 4.

[0017] That is, in this embodiment, two peeling units 42, i.e., two ultrasonic generators 46, are provided, and one suction unit 44 is provided. In this embodiment, the fine powder peeling process P3 peels fine powder from the sheet 4 being conveyed in a non-contact manner by applying ultrasonic waves (shown by thin solid lines) both upstream and downstream of the suction unit 44. The fine powder suction process P4 sucks and removes the fine powder peeled from the sheet 4 by suction (shown by thick solid lines) using the suction unit 44. Next, the gathering section 40 gathers the sheet 4 from which the fine powder has been removed in the fine powder removal section 30 in the width direction intersecting with the longitudinal direction, in other words, gathers and bundles the sheet 4 to reduce its diameter, thereby forming a focusing rod 70 (S4: gathering step).

[0018] Specifically, the gathering section 40 includes, in order from upstream in the conveying direction of the sheet 4, a liquid addition booth 16, a granule addition unit 18, a trumpet guide 24, and tongs 26. The liquid addition booth 16 sprays a liquid additive onto the sheet 4 before gathering as needed (P5: liquid addition process). The additive is a liquid containing, for example, a plasticizer or a fragrance. The granule addition unit 18 includes a hopper 18a and a spray roller 18b. The hopper 18a stores granules, and the spray roller 18b sprays the granules supplied from the hopper 18a onto the sheet 4 before gathering as needed (P6: granule addition process).

[0019] The granules are particulate additives, such as activated carbon or fragrance particles. The trumpet guide 24 is cylindrical, and the diameter of its inner circumferential surface gradually decreases from the upstream side of the conveying path 14. The trumpet guide 24 randomly gathers the sheet 4 conveyed along the conveying path 14, reducing its diameter into a rod-like shape, and discharges the sheet 4 toward the cylindrical tongues 26. As the gathered rod-shaped sheet 4 passes through the tongues 26, the diameter of the rod-shaped sheet 4 is further reduced and formed into a converging rod 70.

[0020] Next, the wrapping section 50 further reduces the diameter of the converging rod 70 formed in the gathering section 40, and sprays glue onto a wrapping paper 72 supplied to the wrapping section 50 using a spray gun (not shown), wrapping the converging rod 70 with the wrapping paper 72 to form a continuous rod material 74 (S5: wrapping step). Next, the cutting section 60 cuts the rod material 74 formed in the wrapping section 50 into shorter rods 1 (S5: cutting step). The rods 1 produced in this manner are used as various packing elements that constitute aerosol products.

[0021] Fig. 4 shows a cross-sectional view of the rod 1, and Fig. 5 shows a longitudinal cross-sectional view of an aerosol production article 80 including the rod 1. As shown in Fig. 4, the rod 1 is formed by gathering and reducing the diameter of a sheet 4 having a large number of crimped portions 4a formed therein, and wrapping the sheet with a wrapping paper 72. The aerosol production article 80 (hereinafter simply referred to as article 80) shown in Fig. 5 is of a non-combustion heating type, and is composed of an aerosol generating element 82, a cooling element 84, and a filter element 86. The elements 82, 84, and 86 are arranged side by side in the axial direction and butt against each other, and the article 80 is formed by wrapping the elements with tipping paper 88.

[0022] The aerosol-generating element 82 is heated by a heater in a device (aerosol generator) (not shown), causing the components of the aerosol-generating raw material 82a to volatilize. The aerosol-generating raw material 82a may be, for example, shredded tobacco, shredded tobacco sheets, or gathered tobacco sheets. The aerosol-generating raw material 82a may also be a sheet made from tobacco-free pulp to which a flavoring agent has been added, shredded sheets made from non-tobacco plants, or such sheets folded into a corrugated pattern. The cooling element 84 may be, for example, a cylindrical cardboard tube made from a single- or double-ply paper web, and forms an airflow path in the article 80.

[0023] A plurality of ventilation holes 84a are formed on the circumferential surface of the cooling element 84 for drawing air into the article 80 when the article 80 is inhaled. The components volatilized from the aerosol generating element 82 are cooled by the air drawn in through the ventilation holes 84a in the cooling element 84 to form an aerosol, and the user inhales the aerosol that has passed through the filter element 86. In the case shown in FIG. 5 , the rod 1 is used as a filter element 86 having an optimal airflow resistance as a filter body. Note that the rod 1 can also be used as the aerosol generating element 82 or the cooling element 84 by selecting the material of the sheet 4. The sheet 4 can be made of various materials, such as a paper web, a nonwoven fabric, a tobacco sheet, or a film, depending on the application of the rod 1.

[0024] FIG. 6 shows a longitudinal cross-sectional view of another aerosol-producing article 80 including a rod 1. In this article 80, the rod 1 is used as a plug element 90 located at the tip adjacent to the aerosol-generating element 82. In this case, the sheet 4 may be a paper web or a nonwoven fabric. When the sheet 4 is a nonwoven fabric, it is preferable to use a dry nonwoven fabric in which plant pulp is bonded together with a water-soluble binder. The plant pulp may also be wood pulp from a non-tobacco plant. When the rod 1 is used in the article 80 of FIG. 6, it is preferable to spray a liquid additive onto the sheet 4 before gathering in the liquid addition process P5 described above.

[0025] The additive soaked in the plug element 90 is heated together with the aerosol-generating element 82 by the heater of the device, causing the additive components to volatilize. The additive may be, for example, a flavor liquid, which may contain tobacco extract. Furthermore, because the plug element 90 is positioned at the tip of the article 80, it also functions as a support element, preventing the aerosol-generating raw material 82a from spilling out of the aerosol-generating element 82. Although not shown, the rod 1 can also be used as a filter element or a cooling element for a combustion-heated aerosol product.

[0026] As described above, the rod 1 manufacturing machine 2 of this embodiment includes a fine powder removal section 30 equipped with a removal unit 32 that removes fine powder from the sheet 4 being transported along the transport path 14. The removal head 34 that constitutes the removal unit 32 has a peeling unit 42 and a suction unit 44. The peeling unit 42 peels fine powder from the sheet 4 in the fine powder peeling process P3, and the suction unit 44 sucks and removes the fine powder peeled from the sheet 4 in the fine powder suction process P4. This allows fine powder to be directly and efficiently removed from the sheet 4 being transported during the rod 1 manufacturing process. This effectively prevents the fine powder from contaminating the equipment and from degrading the quality of the rod 1 and, ultimately, the aerosol product 80.

[0027] Furthermore, by providing the support roller 36 in the removal unit 32, the sheet 4 being transported along the transport path 14 can be brought as close as possible to the removal head 34 while maintaining a constant distance between the sheet 4 and the removal head 34. This allows fine powder to be more efficiently peeled off and removed from the sheet 4. The removal unit 32 also has a static eliminator 38 that removes static electricity from the sheet 4, located upstream of the removal head 34 in the transport direction of the sheet 4. The static eliminator 38 removes static electricity from the sheet 4 in the static elimination process P2 before the fine powder peeling process P3. This allows the fine powder to be more effectively peeled off from the sheet 4 in the peeling section 42 by removing static electricity in advance.

[0028] The removal head 34 also includes a first removal head 34A that removes fine powder adhering to the front surface of the sheet 4 and a second removal head 34B that removes fine powder adhering to the back surface of the sheet 4. In the fine powder removal step S3, the first removal head 34A and the second removal head 34B remove fine powder adhering to both the front and back surfaces of the sheet 4. This ensures that fine powder is removed from both the front and back surfaces of the sheet 4.

[0029] The peeling unit 42 also includes an ultrasonic generator 46 that irradiates ultrasonic waves onto the sheet 4 being conveyed. The ultrasonic generators 46 are provided both upstream and downstream of the suction unit 44 in the conveyance direction of the sheet 4. In the fine powder peeling process P3, the ultrasonic generators 46 peel fine powder from the sheet 4 being conveyed without contact. This allows the fine powder to be reliably peeled and removed from the sheet 4 without being affected by the thickness, strength, processing mode, etc. of the sheet 4, while preventing damage to the sheet 4. Specifically, when the sheet 4 is crimped by the crimping rollers 22 in the sheet processing section 20, as in this embodiment, it is difficult to peel fine powder from the sheet 4 having the crimped portions 4a through physical contact. Therefore, by using ultrasonic waves, the fine powder can be reliably peeled and removed from the sheet 4 even in such cases.

[0030] In particular, in the case of this embodiment, by providing ultrasonic generators 46 both upstream and downstream of suction section 44, fine powder that has not been completely removed from sheet 4 on the upstream side of suction section 44 can be reliably removed downstream of suction section 44. This makes it possible to more efficiently remove fine powder from sheet 4. In fact, in the case of this embodiment, it has been experimentally proven that the "fine powder reduction rate" obtained by measuring the fine powder adhering to sheet 4 before and after fine powder removal step S3 is the largest, and that fine powder can be most effectively removed.

[0031] Second Embodiment Figure 7 shows a cross-sectional view of a removal unit 32 according to a second embodiment. In the following description of each embodiment, features different from the first embodiment will be mainly described, and features similar to those of the first embodiment will be denoted by the same reference numerals in the drawings and will not be described again. The suction units 44 constituting the removal head 34 of this embodiment are provided on both the upstream and downstream sides of the ultrasonic generators 46 in the conveyance direction of the sheet 4. That is, in this embodiment, two suction units 44 are provided, and one peeling unit 42, and therefore one ultrasonic generator 46, is provided.

[0032] In this embodiment, ultrasonic waves are applied between the two suction units 44 (shown by thin solid lines), causing fine powder to be detached from the sheet 4 being conveyed without contact and then sucked up by each suction unit 44 (shown by thick solid lines). This achieves the same effects as the first embodiment. In particular, in this embodiment, by providing suction units 44 both upstream and downstream of the ultrasonic generator 46, fine powder detached from the sheet 4 by ultrasonic irradiation and scattered can be reliably captured and removed over a wide area upstream and downstream of the ultrasonic generator 46. Furthermore, fine powder detached from the sheet 4 by simply removing electricity using the static eliminator 38 can be sucked up and removed in advance in the suction unit 44 upstream of the ultrasonic generator 46. This allows for even more efficient removal of fine powder from the sheet 4.

[0033] Third Embodiment Fig. 8 shows a cross-sectional view of a removal unit 32 according to a third embodiment. The stripping unit 42 constituting the removal head 34 of this embodiment has a brush 52 that rotates while contacting the sheet 4 being conveyed, and the suction unit 44 suctions both the upstream side and the downstream side of the brush 52 in the conveyance direction of the sheet 4. Specifically, the brush 52 is positioned so that a portion of it protrudes from the housing 42a of the stripping unit 42, and gaps 54 are formed between the brush 52 and the housing 42a on both the upstream side and the downstream side of the brush 52. The suction unit 44 is disposed above the brush 52 as viewed in Fig. 8, and air is drawn into the housing 42a through the gaps 54 by suction from the suction unit 44.

[0034] The fine powder peeled off from the sheet 4 by contact with the brush 52 is taken from the peeling unit 42 into the suction unit 44 by the air flow indicated by the arrows. A cleaner 56 is disposed between the peeling unit 42 and the suction unit 44. As the rotating brush 52 approaches the cleaner 56, the fine powder adhering to the brush 52 is scattered and sucked into the suction unit 44, thereby maintaining the brush 52 in a clean state. In this embodiment, the brush 52 provided in the peeling unit 42 peels off the fine powder from the sheet 4 being conveyed by physical contact in the fine powder peeling process P3.

[0035] This ensures that fine powder firmly attached to the sheet 4 can be reliably peeled off and removed. Therefore, in this embodiment, if the fine powder has characteristics such as high adhesion and is difficult to peel off from the sheet 4, or if the sheet 4 is strong enough to withstand the friction of the brush 52, it is possible to efficiently remove the fine powder from the sheet 4. Note that if it is difficult to peel the fine powder from the sheet 4 having the crimped portions 4a through physical contact with the brush 52, the crimping treatment of the sheet 4 in the sheet processing section 20 may not be performed.

[0036] Fourth Embodiment FIG. 9 is a schematic diagram of a cutting section 60 according to a fourth embodiment. The cutting section 60 of this embodiment includes a rotating drum 64 to which a knife 62 is attached. The knife 62 cuts the rod material 74 formed in the lapping section 50 to form short rods 1. The cutting section 60 of this embodiment also includes a removal unit (knife removal unit) 100 that removes fine powder adhering to the blade 62a of the knife 62. A removal head (knife removal head) 102 constituting the removal unit 100 is disposed in the path of rotation of the knife 62. As the rotating drum 64 rotates in the direction indicated by the arrow, the knife 62 passes through the removal head 102, thereby removing the fine powder adhering to the blade 62a of the knife 62. A polishing unit 103 is disposed in the path of rotation of the knife 62. As the rotating drum 64 rotates, the knife 62 passes through the polishing unit 103, thereby polishing the knife 62.

[0037] FIG. 10 shows a partial cross-sectional view of a removal unit 100 installed on the knife 62 of FIG. 9 , and FIG. 11 shows a flowchart illustrating a method for manufacturing a rod 1 using the cutting section 60 of FIG. 9 . The removal head 102 constituting the removal unit 100 has a peeling section (knife peeling section) 104 and a suction section (knife suction section) 106. The peeling section 104 peels off fine powder that adheres to the blade portion 62 a of the knife 62 when cutting the rod material 74 in the cutting step S5 (P7: fine powder peeling process). The suction section 106 sucks and removes the fine powder that has been peeled off from the blade portion 62 a in the peeling section 104 (P8: fine powder suction process).

[0038] More specifically, as shown in FIG. 10 , the removal head 102 of this embodiment has a slit 108 into which the blade portion 62a is inserted without contact. The peeling unit 104 also has an ultrasonic generator (knife ultrasonic generator) 110 that irradiates ultrasonic waves onto the blade portion 62a inserted into the slit 108, and the suction unit 106 sucks up the fine powder using a vacuum pump (not shown). In this embodiment, the ultrasonic generator 110 irradiates ultrasonic waves onto the blade surfaces 62b on the front and back sides of the blade portion 62a (shown by thin solid lines). The suction unit 106 also sucks up the fine powder at a position facing the cutting edge 62c of the blade portion 62a (shown by thick solid lines). Note that the steps other than the cutting step S6 in FIG. 11 are the same as those in the first embodiment, and therefore will not be described here.

[0039] As described above, the rod 1 manufacturing machine 2 of this embodiment includes, in the cutting section 60, the knife 62 that cuts the rod material 74 and the knife removal unit 100. The removal head 102 that constitutes the removal unit 100 has a peeling unit 104 and a suction unit 106. The peeling unit 104 peels fine powder from the blade 62a of the knife 62 in the fine powder peeling process P7, and the suction unit 106 sucks and removes the fine powder peeled from the blade 62a in the fine powder suction process P8. This allows fine powder to be directly and efficiently removed not only from the sheet 4 being conveyed during the rod 1 manufacturing process, but also from the blade 62a of the knife 62 that cuts the rod material 74. This further effectively prevents contamination of the equipment by fine powder and deterioration of the quality of the rod 1 and, ultimately, the aerosol product 80 due to fine powder.

[0040] The removal head 102 also has a slit 108, and an ultrasonic generator 110 provided in the peeling unit 104 irradiates ultrasonic waves onto the blade portion 62a inserted into the slit 108. More specifically, the ultrasonic generator 110 irradiates ultrasonic waves onto the front and back blade surfaces 62b of the blade portion 62a, and the suction unit 106 suctions fine powder at a position facing the cutting edge 62c of the blade portion 62a. This allows fine powder adhering to the blade portion 62a of the knife 62 to be directly and efficiently removed without interfering with the rotation of the knife 62.

[0041] Fifth Embodiment FIG. 12 shows a perspective view of a sheet supply section 10 according to a fifth embodiment, FIG. 13 shows a partial cross-sectional view of a removing unit 100 installed in the knife 68 of FIG. 12 , and FIG. 14 shows a flowchart illustrating a method for manufacturing a rod 1 using the sheet supply section 10 of FIG. 12 . The sheet supply section 10 of this embodiment has a guide roller 112 positioned immediately downstream of the roll 6 in the conveying direction of the sheet 4. The guide roller 112 is rotatably supported on a rotary shaft 114, to which a knife 68 is coaxially attached. The knife 68 is a rotary knife having a cutting edge 68 a formed along its outer periphery, and the knife 68 is equipped with a removing unit 100 similar to that of the fourth embodiment. In the sheet supply step S1 of this embodiment, the knife 68 cuts and divides the sheet 4 conveyed along the conveying path 14 in two in a width direction Y intersecting with the longitudinal direction X, thereby forming a first sheet 4A and a second sheet 4B (P9: sheet dividing process).

[0042] The first sheet 4A is used as a filler for the rod 1 through steps S1 to S6 described above. Meanwhile, the second sheet 4B is supplied to the wrapping section 50 as wrapping paper 72 and wraps the filler formed by the first sheet 4A. The removal head 102 constituting the removal unit 100 has a peeling section 104 and a suction section 106. The peeling section 104 peels off fine powder that has adhered to the blade portion 68a of the knife 68 when the sheet 4 was cut in the sheet dividing process P10 from the blade portion 68a (P10: fine powder peeling process).

[0043] The suction unit 106 sucks and removes the fine powder peeled off from the blade portion 68a in the peeling unit 104 (P11: fine powder suction process). The removal head 102 of this embodiment has a structure similar to that of the fourth embodiment, and the ultrasonic generator 110 irradiates ultrasonic waves (shown by thin solid lines) to the front and back blade surfaces 68b of the blade portion 68a. The suction unit 106 also sucks (shown by thick solid lines) the fine powder at a position opposite the cutting edge 68c of the blade portion 68a. Note that the steps other than the sheet supply step S1 in FIG. 13 are the same as those in the fourth embodiment, and therefore will not be described here.

[0044] In this embodiment, as in the fourth embodiment, fine powder can be directly and efficiently removed not only from the sheet 4 being conveyed during the manufacturing process of the rod 1 but also from the blade 68a of the knife 68 that cuts the sheet 4. This makes it possible to more effectively prevent contamination of the equipment by fine powder and deterioration of the quality of the rod 1 and, ultimately, the aerosol product 80. Furthermore, the above-described structure having the slit 108 in the removal head 102 allows fine powder adhering to the blade 68a of the knife 68 to be directly and efficiently removed without impeding the rotation of the knife 68.

[0045] Sixth Embodiment Fig. 15 is a schematic diagram of a combiner section 120 according to a sixth embodiment. In the combiner section 120, rods 1 produced by a manufacturing machine 2 are cut into shorter segments 130 to produce articles 80. The combiner section 120 includes a rod hopper 122 that stores a large number of rods 1, and the lower opening of the rod hopper 122 is closed by a portion of the outer circumferential surface of a take-out drum 124. The outer circumferential surface of the take-out drum 124 is provided with a large number of take-out grooves 126, which are formed at equal intervals around the circumference of the take-out drum 124. The take-out drum 124 rotates in the direction of the arrow, and as the take-out drum 124 rotates, the take-out grooves 126 positioned at the lower opening of the rod hopper 122 receive the rods 1 and take them out of the rod hopper 122.

[0046] A plurality of knives 68, similar to those in the fifth embodiment, are rotatably arranged near the periphery of the take-out drum 124. As the take-out drum 124 rotates and the rod 1 passes through the take-out groove 126, each knife 68 cuts the rod 1 into a plurality of equal parts, forming an assembly of a plurality of segments 130. The assembly of the formed segments 130 is discharged from the take-out groove 126 into the conveying path 14 located directly below the take-out drum 124. Each knife 68 is provided with a removing unit 100, similar to those in the fourth and fifth embodiments.

[0047] Figure 16 shows a perspective view of the removal unit 100 installed on the knife 68, and Figure 17 shows a flowchart illustrating a method for manufacturing articles 80 using the combiner section 120 of Figure 15. A partial cross-sectional view of the removal unit 100 is shown in Figure 13, which has already been described. When the manufacturing of articles 80 begins in the combiner section 120, first, a rod 1 is supplied from the rod hopper 122 to the removal groove 126 (S11: rod supply step). Next, the rod 1, which is transported in the removal groove 126 as the removal drum 126 rotates, is cut by each knife 68 (S12: cutting step).

[0048] 13 , the removal head 102 constituting the removal unit 100 includes a peeling unit 104 and a suction unit 106, similar to the fifth embodiment. The peeling unit 104 peels off the fine powder that adheres to the blade portion 68a when the rod 1 is cut from the blade portion 68a in the cutting step S12 (P11: fine powder peeling process). The suction unit 106 sucks and removes the fine powder that has been peeled off from the blade portion 68a in the peeling unit 104 (P12: fine powder suction process). The removal head 102 of this embodiment has a structure similar to that of the fifth embodiment, and the ultrasonic generator 110 irradiates ultrasonic waves to the blade surfaces 68b, which form the front and back sides of the blade portion 68a inserted into the slit 108.

[0049] The suction unit 106 also sucks fine powder at a position opposite the cutting edge 68c of the blade 68a. Next, the segment 130 formed in the cutting step S12 is supplied to the conveying path 132, aligned with other segments (not shown) (S14: segment alignment step), and wrapped with the tipping paper 88 (S15: wrapping step). If the rod formed in the wrapping step S15 has a length, for example, twice that of the article 80, the rod is cut at its longitudinal center (S16: cutting step), completing the manufacture of the article 80. In the cutting step S16, the rod can be cut using the same knife 68 as used in the cutting step S12. Alternatively, a removal unit 100 may be attached to the knife 68 used in the cutting step S16 to perform the fine powder removal process P11, the fine powder removal process P13 similar to the fine powder suction process P12, and the fine powder suction process P14.

[0050] As described above, in this embodiment, as in the fifth embodiment, the peeling unit 104 peels fine powder from the blade 68a of the knife 68 in the fine powder peeling processes P11 and P13, and the suction unit 106 sucks and removes the fine powder peeled from the blade 68a in the fine powder suction processes P12 and P14. This allows fine powder to be directly and efficiently removed from the blade 68a of the knife 68 that cuts the rod 1 during the manufacturing process of the article 80. This further effectively prevents contamination of the equipment caused by the fine powder and deterioration of the quality of the rod 1 and, ultimately, the article 80. Furthermore, as in the fifth embodiment, the ultrasonic generator 110 irradiates ultrasonic waves to the blade surfaces 68b on both sides of the blade 68a, and the suction unit 106 sucks the fine powder at a position facing the cutting edge 68c of the blade 68a. This allows fine powder adhering to the blade 68a of the knife 68 to be directly and efficiently removed without impeding the rotation of the knife 68. The fine powder peeling process P13 and the fine powder suction process P14 do not necessarily have to be performed.

[0051] The above is the description of each embodiment, but the above embodiments are not limiting and various modifications can be made without departing from the spirit of the present invention. For example, in the first embodiment, the ultrasonic generator 46 is provided both upstream and downstream of the suction unit 44 in the conveyance direction of the sheet 4. In the second embodiment, the suction unit 44 is provided both upstream and downstream of the ultrasonic generator 46 in the conveyance direction of the sheet 4. However, this is not a limitation, and the ultrasonic generator 46 may be provided only upstream or downstream of the suction unit 44, or the suction unit 44 may be provided only upstream or downstream of the ultrasonic generator 46. In the third embodiment, the suction unit 44 sucks both upstream and downstream of the brush 52 in the conveyance direction of the sheet 4. However, this is not a limitation, and the suction unit 44 may suck only upstream or downstream of the brush 52.

[0052] The removal head 34 includes a first removal head 34A that removes fine powder adhering to the front surface of the sheet 4 and a second removal head 34B that removes fine powder adhering to the back surface of the sheet 4. However, it is not necessary to use both the first removal head 34A and the second removal head 34B; only one of them may be installed to remove fine powder from only one of the front and back surfaces of the sheet 4. In the first to third embodiments, the removal heads 34 shown in FIGS. 3, 7, and 8 are used as the first removal head 34A and the second removal head 34B, respectively. However, this is not limiting, and the first removal head 34A and the second removal head 34B may be combined in different forms from the first to third embodiments depending on the processing mode of the sheet 4 and the mode of adhesion of fine powder to the sheet 4.

[0053] In the fourth embodiment, assuming that the rod 1 manufacturing machine 2 has the fine powder removal section 30, the removal unit 100 removes fine powder adhering to the blade portion 62a of the knife 62 in the cutting section 60. However, this is not limiting, and it is also possible to provide the removal unit 100 in the cutting section 60 and not provide the fine powder removal section 30. In the fifth embodiment, assuming that the rod 1 manufacturing machine 2 has the fine powder removal section 30 and the cutting section 60 also has the removal unit 100, the removal unit 100 removes fine powder adhering to the blade portion 68a of the knife 68 in the sheet supply section 10.

[0054] However, the present invention is not limited to this, and it is also possible to adopt a configuration in which the sheet supply section 10 and the cutting section 60 are each provided with a removing unit 100, and no fine powder removing section 30 is provided. It is also possible to adopt a configuration in which the sheet supply section 10 is provided with a removing unit 100, and the cutting section 60 is not provided with a removing unit 100 or a fine powder removing section 30. Even in these configurations, fine powder can be directly and efficiently removed from at least one of the sheet 4, knife 62, and knife 68, thereby effectively preventing contamination of equipment due to fine powder and deterioration of the quality of the rod 1 and, ultimately, the aerosol product 80 due to fine powder.

[0055] Furthermore, in the first, second, fourth, fifth, and sixth embodiments, the peeling units 42 and 104 are provided with ultrasonic generators 46 and 110, respectively. However, this is not a limitation, and peeling means other than the ultrasonic generators 46 and 110 may be used as long as the fine powder can be peeled off from the sheet 4 or the blade units 62a and 68a without contact. Furthermore, in the third embodiment, the peeling unit 42 is provided with a brush 52. However, this is not a limitation, and peeling means other than the brush 52 may be used as long as the fine powder can be peeled off from the sheet 4 with physical contact. Furthermore, in the sheet processing step S2, it is also permissible to perform some processing on the sheet 4 by performing a process other than crimping on the sheet 4.

[0056] Furthermore, some or all of the above embodiments can be expressed by describing the aspects shown below: (Aspect 1) A manufacturing machine for rods used in aerosol products, comprising: a sheet supply section that supplies a sheet, which is a material for the rod, to a conveying path, a sheet processing section that processes the sheet being conveyed along the conveying path, and a fine powder removal section having a removal unit that removes fine powder from the sheet being conveyed along the conveying path, wherein the removal unit comprises a removal head that has a peeling section that peels the fine powder from the sheet and a suction section that sucks and removes the fine powder peeled from the sheet in the peeling section.

[0057] (Aspect 2) The machine for manufacturing rods for aerosol products according to Aspect 1, wherein the removal unit includes a support roller that supports the sheet being transported along the transport path so as to bring the sheet close to the removal head, at a position facing the removal head with the sheet sandwiched therebetween. (Aspect 3) The machine for manufacturing rods for aerosol products according to Aspect 2, wherein the removal unit includes a static eliminator that removes static electricity from the sheet, located upstream of the removal head in the transport direction of the sheet. (Aspect 4) The machine for manufacturing rods for aerosol products according to Aspect 3, wherein the removal head includes a first removal head that removes the fine powder adhering to the front surface of the sheet and a second removal head that removes the fine powder adhering to the back surface of the sheet.

[0058] (Aspect 5) The machine for manufacturing a rod for use in an aerosol product according to Aspect 1, wherein the sheet processing section includes a crimping roller that crimps the sheet. (Aspect 6) The machine for manufacturing a rod for use in an aerosol product according to any one of Aspects 1 to 5, wherein the peeling unit has an ultrasonic generator that irradiates ultrasonic waves to the sheet while it is being conveyed, and the ultrasonic generators are provided both upstream and downstream of the suction unit in the conveying direction of the sheet. (Aspect 7) The machine for manufacturing a rod for use in an aerosol product according to any one of Aspects 1 to 5, wherein the peeling unit has an ultrasonic generator that irradiates ultrasonic waves to the sheet while it is being conveyed, and the suction units are provided both upstream and downstream of the ultrasonic generator in the conveying direction of the sheet.

[0059] (Aspect 8) The machine for manufacturing rods for use in aerosol products according to any one of Aspects 1 to 5, wherein the peeling unit has a brush that rotates while contacting the sheet being conveyed, and the suction unit sucks both the upstream side and the downstream side of the brush in the conveyance direction of the sheet. (Aspect 9) The machine for manufacturing rods for use in aerosol products according to Aspect 1, comprising: a knife that cuts the sheet or a rod material formed from the sheet; and a knife removal unit that removes fine powder adhering to a blade of the knife, wherein the knife removal unit comprises a knife removal head having a knife peeling unit that peels the fine powder from the blade and a knife suction unit that sucks and removes the fine powder peeled from the blade in the knife peeling unit.

[0060] (Aspect 10) A machine for manufacturing rods for use in aerosol products according to aspect 9, wherein the knife removal head has a slit into which the blade portion is inserted without contact, the knife peeling unit has a knife ultrasonic generator that irradiates ultrasonic waves to the blade portion inserted into the slit, the knife ultrasonic generator irradiates the ultrasonic waves to each of the front and back blade surfaces of the blade portion, and the knife suction unit suctions the fine powder at a position opposite to the cutting edge of the blade portion.

[0061] (Aspect 11) A method for manufacturing a rod used in an aerosol product, comprising: a sheet supplying step for supplying a sheet that is the material of the rod to a conveying path; a sheet processing step for processing the sheet while it is being conveyed along the conveying path; and a fine powder removal step for removing fine powder adhering to the sheet from the sheet while it is being conveyed along the conveying path, wherein the fine powder removal step comprises a fine powder peeling process for peeling the fine powder from the sheet, and a fine powder suction process for sucking and removing the fine powder peeled from the sheet in the fine powder peeling process.

[0062] (Aspect 12) The method for manufacturing a rod for use in an aerosol product according to Aspect 11, wherein the fine powder removal step includes a static elimination process for removing static electricity from the sheet before the fine powder peeling process. (Aspect 13) The method for manufacturing a rod for use in an aerosol product according to Aspect 12, wherein the fine powder removal step removes the fine powder adhering to both the front and back surfaces of the sheet. (Aspect 14) The method for manufacturing a rod for use in an aerosol product according to any one of Aspects 11 to 13, wherein the fine powder peeling process peels the fine powder off the sheet in a non-contact manner during transport.

[0063] (Aspect 15) The method for manufacturing a rod used in the aerosol product according to any one of Aspects 11 to 13, wherein the fine powder peeling process involves physical contact to peel off the fine powder from the sheet during conveyance.

[0064] REFERENCE SIGNS LIST 1 Rod 2 Manufacturing machine 4 Sheet 10 Sheet supply section 14 Conveying path 20 Sheet processing section 22 Crimping roller 30 Fine powder removal section 32 Removal unit 34 Removal head 34A First removal head 34B Second removal head 36 Support roller 38 Discharger 42 Peeling section 44 Suction section 46 Ultrasonic generator 52 Brush 62 Knife 62a Blade section 62b Blade surface 62c Blade tip 68 Knife 68a Blade section 68b Blade surface 68c Blade tip 74 Rod material 80 Aerosol product 100 Removal unit (knife removal unit) 102 Removal head (knife removal head) 104 Peeling section (knife peeling section) 106 Suction section (knife suction section) 108 Slit 110 Ultrasonic generator (ultrasonic generator for knife) S1 Sheet supply step S2 Sheet processing step S3 Fine powder removal step P2 Discharge process P3 Fine powder peeling process P4 Fine powder suction process

Claims

1. A machine for manufacturing rods used in aerosol products, comprising: a sheet supply section that supplies a sheet, which is the material for the rod, to a conveying path; a sheet processing section that processes the sheet as it is conveyed along the conveying path; and a fine powder removal section having a removal unit that removes fine powder from the sheet as it is conveyed along the conveying path, wherein the removal unit comprises a removal head having a peeling section that peels the fine powder from the sheet and a suction section that sucks and removes the fine powder peeled from the sheet in the peeling section.

2. A rod manufacturing machine for aerosol products as described in claim 1, wherein the removal unit is provided with a support roller that supports the sheet being transported along the transport path at a position opposite the removal head with the sheet sandwiched therebetween, so as to bring the sheet close to the removal head.

3. The machine for manufacturing rods for use in aerosol products according to claim 2, wherein the removal unit has an electrostatic eliminator for removing static electricity from the sheet, located upstream of the removal head in the conveying direction of the sheet.

4. A rod manufacturing machine for use in an aerosol product as described in claim 3, wherein the removal head includes a first removal head that removes the fine powder adhering to the surface of the sheet, and a second removal head that removes the fine powder adhering to the back surface of the sheet.

5. The machine for manufacturing rods for use in aerosol product according to claim 1, wherein the sheet processing section includes a crimping roller for crimping the sheet.

6. A manufacturing machine for rods used in aerosol products according to any one of claims 1 to 5, wherein the peeling section has an ultrasonic generator that irradiates ultrasonic waves onto the sheet during transport, and the ultrasonic generator is provided on both the upstream and downstream sides of the suction section in the transport direction of the sheet.

7. A manufacturing machine for rods used in aerosol products according to any one of claims 1 to 5, wherein the peeling section has an ultrasonic generator that irradiates ultrasonic waves onto the sheet during transport, and the suction section is provided on both the upstream and downstream sides of the ultrasonic generator in the transport direction of the sheet.

8. A manufacturing machine for rods used in aerosol products according to any one of claims 1 to 5, wherein the peeling unit has a brush that rotates while in contact with the sheet being transported, and the suction unit sucks both the upstream and downstream sides of the brush in the transport direction of the sheet.

9. A manufacturing machine for rods used in aerosol products as described in claim 1, comprising: a knife for cutting the sheet or rod material formed from the sheet; and a knife removal unit for removing fine powder adhering to the blade of the knife, wherein the knife removal unit comprises a knife removal head having a knife peeling section for peeling the fine powder from the blade, and a knife suction section for sucking and removing the fine powder peeled from the blade in the knife peeling section.

10. A rod manufacturing machine for use in an aerosol product as described in claim 9, wherein the knife removal head has a slit into which the blade portion is inserted without contact, the knife peeling portion has a knife ultrasonic generator that irradiates ultrasonic waves to the blade portion inserted into the slit, the knife ultrasonic generator irradiates the ultrasonic waves to each of the blade surfaces that form the front and back of the blade portion, and the knife suction portion suctions the fine powder at a position opposite the cutting edge of the blade portion.

11. A method for manufacturing a rod used in an aerosol product, comprising: a sheet supply step for supplying a sheet that is the material for the rod to a conveying path; a sheet processing step for processing the sheet while it is being conveyed along the conveying path; and a fine powder removal step for removing fine powder adhering to the sheet while it is being conveyed along the conveying path, wherein the fine powder removal step comprises a fine powder removal process for peeling the fine powder from the sheet, and a fine powder suction process for sucking and removing the fine powder peeled from the sheet in the fine powder removal process.

12. The method for manufacturing a rod for use in an aerosol product according to claim 11, wherein the fine powder removal step includes a static elimination process for removing static electricity from the sheet before the fine powder peeling process.

13. The method for manufacturing a rod for use in an aerosol product according to claim 12, wherein the fine powder removal step removes the fine powder adhering to both the front and back surfaces of the sheet.

14. A method for manufacturing a rod for use in an aerosol product according to any one of claims 11 to 13, wherein the fine powder removal process removes the fine powder from the sheet during transport without contact.

15. A method for manufacturing a rod for use in an aerosol product according to any one of claims 11 to 13, wherein the fine powder removal process involves physical contact to remove the fine powder from the sheet during transport.

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