VANE for smoking article packing machine

Abstract

A vane for supporting a flow of smoking articles in a smoking article packing machine is disclosed, the vane (300) comprising: a first main surface (325) configured, in use, to support the flow of smoking articles from a first end (330) of the vane along a main longitudinal axis of the first main surface, wherein the first main surface comprises at least one flow channel (350) that extends from the first end of the vane across the first main surface to guide loose material off the first main surface.

Description

[0001] VANE FOR SMOKING ARTICLE PACKING MACHINE

[0002] FIELD OF THE INVENTION

[0003] The present invention relates to vanes for smoking article packing machines to sort a collation of smoking articles, like cigarettes, into position before packing.

[0004] BACKGROUND

[0005] In manufacturing a packet of cigarettes, a cigarette making machine is used to assemble a plurality of cigarettes and deposit the assembled cigarettes into a bin of a hopper in a cigarette packing machine. The hopper can be arranged in a way between the cigarette making process and cigarette packing process to act as a buffer due to the difference in speeds between cigarette assembly and the packing of cigarettes. A known cigarette packing machine is described in GB350015A.

[0006] Cigarettes in the hopper are vibrated such that they pass or are fed in a horizontal (side-on) orientation through a row of vertical channels, defined by a set of vanes, in single file. The vanes form a funnel section of the hopper to bring together a desired number of cigarettes from the bin of the hopper onto a conveyor grid as a row of cigarettes. The row of cigarettes is then pushed off the conveyor grid by a pusher piece in order for a next row of cigarettes to be set onto the conveyor grid. The next row of cigarettes may then be pushed off the conveyor grid such that it stacks on top of the previous row of cigarettes.

[0007] The conveyor grid is typically also movable in a lateral manner to vary the number of cigarettes in a particular row. Also, vanes often have a tapered thickness and smooth or substantially flat surfaces to provide a funnelling effect from the hopper to the conveyor grid.

[0008] When a desired number of rows of cigarettes have passed through the vanes and been pushed off the conveyor grid to form a collation or set of stacked rows, the set of stacked cigarette rows are maintained in position and further passed through the cigarette packing machine to be wrapped and boxed. A standardpacket of twenty cigarettes may include: a bottom row of seven cigarettes; a middle row of six cigarettes; and a top row of seven cigarettes.

[0009] It has been found by the inventors that cigarettes can sometimes tilt away from the horizontal orientation as they pass through a vertical channel. This may often be due to loose tobacco that has fallen out of the assembled cigarettes in the hopper (due to the vibrations of the hopper I cigarette packing machine) and subsequently fall into and obstruct the vertical channels. The loose tobacco fallen out of freshly assembled cigarettes often has a relatively high moisture content to account for moisture loss from the tobacco during the packing process. This, however, can increase the likelihood of accumulation of loose material or the loose material getting stuck on the surface of the vanes.

[0010] The tilting of cigarettes in the vertical channels can cause cigarettes to be missing from a row of cigarettes on the conveyor grid or cause an entire vertical channel to be obstructed or blocked, which undesirably results in manufacturing stoppages, downtime, and reject products.

[0011] An object of the invention is to provide an improved vane for packing machines for smoking articles, particularly for cigarettes.

[0012] SUMMARY OF INVENTION

[0013] For simplicity, tobacco and cigarettes will be used in the present specification as an example, but the skilled person will understand that other smoking consumable materials and other forms of articles containing loose material with an exposed end, such as heated tobacco sticks, may be suitably used with the present invention.

[0014] The present invention provides a vane that can be used in a smoking article packing machine to improve the flow of smoking articles, such as cigarettes, by preventing obstructions or accumulations of loose material, such as loose tobacco, that can fall from the hopper or from the open end of cigarettes into the vertical channels defined by the vanes. Accumulation of loose material can cause tilting of smoking articles or even obstruction of the smoking article flow whichresults in stoppages in the packing assembly line and reduces the overall equipment effectiveness (OEE) and mean time between failures (MTBF). Obstructions or blockages can also damage smoking articles in the assembly flow and so it is desirable to remove loose material from the flow of smoking articles in an effective manner. Vanes of the present disclosure improve manufacturing efficiency and costs by overcoming these problems.

[0015] According to a first aspect of the invention, there is provided a vane for supporting a flow of smoking articles in a smoking article packing machine, the vane comprising: a first main surface configured, in use, to support the flow of smoking articles from a first end of the vane along a main longitudinal axis of the first main surface, wherein the first main surface comprises at least one flow channel that extends from the first end of the vane across the first main surface to guide loose material off the first main surface.

[0016] In an example, the vane may be arranged in a substantially vertical orientation such that the first end of the vane is a top end of the vane, and the first main surface is a front surface of the vane. Preferably, the vane has a tapered thickness. In this way, the vanes can be effectively used to funnel the smoking articles from the hopper to the conveyor grid.

[0017] It has been found that loose tobacco can break away from assembled cigarettes in a hopper, which can accumulate and cause the cigarette packing process to be impeded or blocked. For example, tobacco may fall away from the tobacco rod of a cigarette in the bin of a hopper during the vibrational operation and be shaken into the vertical channels of the funnel section of the hopper.

[0018] Advantageously, the invention provides a flow channel having an entry point at the top end (first end) of the vane and an exit point that is lower than the entry point. In practice, this means that the entry point is upstream of the exit point along the direction of flow of smoking articles along the vane (or the exit point is downstream of the entry point). In a possible embodiment, the main longitudinal axis of the vane matches with the direction of flow of cigarettes along the vane, so the entry point is upstream of the exit point along the main longitudinal axis of the frontsurface (or the exit point is downstream of the entry point). Accordingly, the at least one flow channel may comprise an entry point at the first end of the vane and an exit point in the first main surface away from the first end. The entry point is for receiving loose material (e.g. loose tobacco) as the flow of smoking article passes across the first main surface of the vane, and the exit point is for disposing of the loose material that has accumulated in the at least one flow channel. As will be explained further below, the exit point of a flow channel may be an end of the flow channel where the loose material is disposed into another groove in the vane surface (for further guiding away from the first main surface). Alternatively, the exit point of a flow channel may be an edge or end of the vane where loose tobacco falls off vane surface.

[0019] In an example, a known smoking article packer has four funnel sections to form four packs simultaneously. Each funnel section has two side walls and six vanes in between to form 7 rows of cigarettes. A side wall may be considered as a vane, where the surface of the side wall is a first main surface against which a flow of smoking articles is supported. As should be appreciated, one or both of the main surfaces of a vane may be used to support one or two flows of smoking articles. Accordingly, a first main surface of a side wall may comprise at least one flow channel in accordance with an embodiment of the present invention.

[0020] The furthermost side walls of a hopper may not have a tapered thickness and instead may have a constant thickness. In addition, the tapering of the side walls between adjacent funnels in the hopper may be opposite to the tapering of a vane (i.e. a sidewall may be thicker at the bottom end and thinner at the top end in a vertical orientation, and a vane may be thinner at the bottom end and thicker at the top end in a vertical orientation).

[0021] When the loose tobacco accumulates or gets pressed against the surfaces of the vanes in the funnel section (which define the vertical channels), the flow of cigarettes may be impeded and result in the packing assembly line to fail and require shutdown and maintenance. A reason for the blockage is due to tobacco accumulating or being stuck against the surface of a vane which can reduces thewidth of the gap formed by the vanes for single file cigarette flow or cause tilting of the cigarettes as they descend the vertical channels.

[0022] The present invention according to the first aspect involves the front surface of the vane having at least one flow channel extending from the first end (e.g. top end) of the vane to guide loose material / tobacco away from the first main surface (e.g. front surface). As such the flow channel(s) effectively prevent obstruction or blockage of the flow of smoking articles due to loose tobacco, or other loose material by ensuring that loose tobacco that falls into the funnel section of a hopper can be captured at the first end of the vane and directed away from the first main surface of the vane.

[0023] The vane may have a tapered thickness, and, preferably, the vane is thickest toward the first end. The tapered thickness of the vane may gradually decrease from the first end of the vane towards a second end of the vane. The first end may be a top end and the second end may be a bottom end. Alternatively, for side wall vanes in between the separate funnel sections in a hopper, the orientation is vertically inverted such that a top end of a side wall vane is the thinner end and the bottom end of the side wall vane is the thicker end. This allows the vanes and side wall vanes to be arranged in ways to effectively provide a funnelling effect in the hopper. Advantageously, the vane being thicker at its top end where the at least one flow channel is located prevents premature fatigue failure.

[0024] The flow channel may be a channel that is machined into the first main surface of the vane. The flow channel may have an arc-shaped cross-section. An arcshaped cross-section or curved (concave) surface flow channel prevents loose tobacco from being trapped in the flow channel. Alternatively, the flow channel may have a square-shaped or rectangular-shaped cross-section. As an example, the flow channel may have a maximum depth in the range of 1.0 mm to 1.3 mm and a maximum width in the range of 2.5 mm to 3.5 mm. Other dimensions and shapes of the flow channel will be apparent to the skilled person. As will be appreciated, the dimensions and shapes of a flow channel(s) should be selected in consideration of the dimensions of a smoking article such that the flow channel does not disrupt the flow of smoking articles. Preferably, a maximum width of aflow channel is no more than half a width of a smoking article or cigarette for which the vane is configured to support. In this way, the flow channel can effectively capture loose tobacco without causing the flow of cigarettes to tilt. Preferably, the flow channel is a channel that extends along a straight line. Preferably, the at least one flow channel extends in a direction in line with the main longitudinal axis. This reduces likelihood of loose material accumulating in the flow channel, thereby reducing the likelihood of blockages.

[0025] Preferably, the at least one flow channel extends in an angled direction from the first end of the vane away from the main longitudinal axis. For example, the at least one angled flow channel extends from the first end at an oblique angle of 70° or less with respect to the main longitudinal axis, such as at 45°. Preferably the at least one flow channel extends in a 45 degree direction from the first end. In this way, loose tobacco can be effectively directed away from the first main surface of the vane. By providing an end (open end) of the flow channel(s) at the first end (top end), loose tobacco can directly enter the flow channel(s) as it is received by the vane. The angled flow channel(s) allows any loose tobacco to preferentially fall away from the vane (and prevent it from sitting in the flow channel) when it is received in the flow channel, and are particularly effective to collect loose tobacco as they run across at least a portion of a width of the vane, thereby capturing and guiding away from the vane loose tobacco not captured at its open end.

[0026] Preferably, the first main surface of the vane comprises at least two flow channels, more preferably wherein the at least two flow channels are arranged in a parallel configuration. In this way, multiple flow channels can be arranged across the top end of the vane to receive any loose tobacco. This advantageously ensures that loose tobacco can be directed away from the front surface at multiple points across the vane and further enhances the amount of loose tobacco that can be collected across the width of the vane.

[0027] Preferably, the vane further comprises a groove in the first main surface extending along the main longitudinal axis. In this way, the groove provides a further flow channel for loose tobacco in a direction that is in line with the flow of the smoking articles. As an example, the groove may have a depth of around 1.0 mm and amaximum width in the range of 2.5 mm to 3.5 mm. Other dimensions will be apparent to the skilled person. As will be appreciated, the dimensions should be selected in consideration of the dimensions of a cigarette such that the flow channel does not disrupt the flow of smoking articles. Preferably, a maximum width of the groove is no more than half a width of a smoking article or cigarette for which the vane is configured to support. In this way, groove can effectively capture loose tobacco without causing the flow of cigarettes to tilt.

[0028] Preferably, the at least one flow channel extends from the first end of the vane to the groove. In this way, the groove acts as a gutter to collect the tobacco from the one or more flow channel(s) and dispose of the collected loose tobacco. It can be understood that the groove acts as a central gutter and the flow channel(s) and / or flow path(s) are branches that extend from the central gutter to receive loose tobacco from the top end of the vane. Preferably, at least one of the at least one flow channel, the groove, and / or at least one flow path comprises an exit point on the first main surface for loose tobacco to fall away from the vane. In one example, the groove comprises the exit point and the flow channel(s) and flow path(s) direct collected loose tobacco to the groove for removal. In another example each of the flow channel(s), groove, and flow path(s) comprises respective exit points for loose tobacco to be directed off the first main surface at different points across the first main surface. Importantly, the flow channel(s), flow path(s) and groove(s) comprise an exit point on the first main I front surface of the vane for loose tobacco to be removed. Typically, a lower collection bin may be placed below the hopper for collection of the removed loose tobacco.

[0029] Preferably, the vane further comprises: a first portion having a first length, a first width, a first length side, and a second length side; and a second portion having a second length and a second width, the second portion extending from the first length side of the first portion at the first end of the vane, wherein the second length and the second width of the second portion are less than the first length and the first width of the first portion respectively. Preferably, the first width is configured to support at least half of a length of a tobacco rod of a smoking article as it flows along the first main surface such that, in use, a tobacco end of acigarette is arranged toward the first length side of the first portion and a filter end of the cigarette is arranged toward the second length side of the first portion and that loose tobacco falls away from the first main surface of the vane at the first length side.

[0030] The vane may comprise first and second portions. The first portion has a first length, a first width, a first length side, and a second length side. The second portion has a second length and a second width. The second portion extends from the first length side of the first portion at the first end of the vane, wherein the second length and the second width of the second portion are less than the first length and the first width of the first portion respectively. Preferably, the first width is configured to support at least half of a length of a smoking article as it flows along the first main surface such that, in use, a tobacco end of a cigarette is arranged toward the first length side of the first portion and a filter end of the cigarette is arranged toward the second length side of the first portion and that loose tobacco falls away from the first main surface of the vane at the first length side.

[0031] In this way, loose material I tobacco can readily fall away from the first main surface below the second portion (as smoking articles I cigarettes descend or flow along the vane). In normal operation, the second portion may be connected to a smoking article packing machine. Cigarettes, or smoking articles, may flow along a vane in a sideways orientation where a first end of the cigarette is a filter end and a second end is an open tobacco end. Commonly, the second open end of a cigarette may be arranged toward the second portion of the vane and the first filter end of the cigarette extends beyond the second length side of the first portion away from the second portion.

[0032] Preferably, the first width of the first portion is greater than more than half of a length of a cigarette that the vane is configured to support. In use, a portion of the tobacco rod and a portion of the filter of a cigarette may both be supported by the first portion as it flows along the vane. The filter end and the open end of the tobacco rod may both extend beyond the length sides of the vane. Preferably, the first width is equal to or less than 60 mm, preferably equal to or less than 50 mm,and preferably wherein the second width is equal to or greater than 5 mm, preferably equal to or greater than 10 mm, more preferably equal to or greater than 20 mm.

[0033] In this way, an adequate spacing can be provided between the first length side of the first portion and the side of the second portion used for connection with a smoking article machine. The second width may effectively determine the length of a smoking article that is unsupported from the second open end of the smoking article. Cigarettes normally have a standard length of around 84 mm (there may be varieties of different lengths). Accordingly, by providing a first width of 60 mm or less, a greater length of the cigarette can be exposed and separate from the vane as the cigarette flows along the vane, allowing loose tobacco to more easily fall away from the cigarette and the vane. The first width of the first portion is selected to ensure good and adequate support of the smoking articles as they flow along the vane, whilst providing a space for loose tobacco to fall away. In this example, the second length of the second portion is shorter than the first length of first portion such that any loose tobacco on the second portion would not readily accumulate below the second portion of the vane.

[0034] Preferably, the at least two flow channels are evenly spaced along the first end of the vane, preferably, wherein the at least two flow channels are evenly spaced along the first portion of the vane. In this way, it can be better ensured that loose material I tobacco is collected at the first (top) end of the vane as the flow of smoking articles is received.

[0035] Preferably, the at least one flow channel extending from the first end of the vane extends from the first end of the vane in the first portion of the vane to the second portion of the vane. In other words, the at least one flow channel extends from the top end of the vane and ends at interface between the first portion and the second portion of the vane. As described above, the second portion of the vane may have smaller length / width dimensions and may be thinner than the first portion of the vane. As such loose tobacco can more readily fall away from the first main surface of the vane at or around the second portion of the vane. It istherefore preferable to guide the loose tobacco from the first portion of the vane toward the second portion of the vane.

[0036] Preferably, the groove extends along the first length side of the first portion from the first end of the vane to an end of the second portion opposite the first end. Preferably, the groove is arranged in the second portion along the first length side of the first portion. Preferably, the groove extends from the first end of the vane along the main longitudinal axis to an end of the second portion opposite the top end. In this way, the groove provides a further flow channel for loose tobacco in a direction that is in line with the flow of the smoking articles. The groove is preferably provided on the first surface of the second portion to be guided away from the vane. As an example, the groove may have a depth of around 1.0 mm and a maximum width in the range of 2.5 mm to 3.5 mm. Other dimensions will be apparent to the skilled person. As will be appreciated, the dimensions should be selected in consideration of the dimensions of a cigarette such that the flow channel does not disrupt the flow of smoking articles. Preferably, a maximum width of the groove is no more than half a width of a smoking article or cigarette for which the vane is configured to support. In this way, groove can effectively capture loose tobacco without causing the flow of cigarettes to tilt.

[0037] Preferably, the second portion comprises at least one flow path that guides loose tobacco from the flow of smoking articles towards the groove. In this way, loose tobacco across the surface of the second portion can be effectively directed to the groove for removal from the vane. In one example, the surface of the second portion may comprise a first plane and a second plane, wherein an angled ledge is formed between the first plane and the second plane and configured, in use, to provide a flow path to direct loose tobacco from the flow of smoking articles towards the groove. In another example, the at least one flow path may comprise a groove or flow channel that is machined into the first surface of the second portion.

[0038] Preferably, the second portion has a thickness less than a thickness of the first portion so as to provide a first step in the first main surface of the vane. To put it in another way, the second portion preferably has a thickness less than athickness of the first portion so as to provide a first step in the front surface of the vane between a first surface of the first portion and a first surface of the second portion. Preferably the thickness of the second portion is tapered as the thickness of the first portion is tapered. As should be understood, the first main surface of the vane comprises the first surface of the first portion and the first surface of the second portion. In this way, loose tobacco is less likely to get trapped or accumulate on the surface of the second portion. The front surface of the first portion is mainly used to support the flow of smoking articles I cigarettes, and the second portion is mainly used for connecting the vane to the smoking article packing machine.

[0039] Preferably, the at least one flow channel extends from the first end to the first step. Preferably, the at least one flow channel is arranged to extend from the first end of the vane to the groove in the first main surface. In this way, the groove acts as a gutter to collect the tobacco from the one or more flow channel(s) and dispose of the collected loose tobacco. Preferably, the at least one flow channel is arranged in the first portion of the vane and the groove is arranged in the second portion of the vane, such that the one or more flow channels in the first portion of the first surface are arranged to collect loose tobacco from the first I top end of the vane and guide the loose tobacco toward the groove in the second portion of the vane. The flow path of the second portion can also direct loose tobacco received at the top end of the vane at the second portion to the groove. It can be understood that the groove acts as a central gutter and the flow channel(s) and / or flow path(s) are branches that extend from the central gutter to receive loose tobacco from the top end of the vane. Preferably, at least one of the at least one flow channel, the groove, and / or at least one flow path comprises an exit point on the first main surface for loose tobacco to fall away from the vane. In one example, the groove comprises the exit point and the flow channel(s) and flow path(s) direct collected loose tobacco to the groove for removal. In another example each of the flow channel(s), groove, and flow path(s) comprises respective exit points for loose tobacco to be directed off the first main surface at different points across the first main surface. Importantly, the flow channel(s), flow path(s) and groove(s) comprise an exit point on the first main / front surface of the vane for loose tobaccoto be removed. Typically, a lower collection bin may be placed below the hopper for collection of the removed loose tobacco.

[0040] Preferably, the one or more flow channels extends from the first end to the groove. In this way, loose material I tobacco from the surface of the first portion can be readily collected into the one or more flow channels and guided away from the flow of smoking articles and the main longitudinal axis of the surface of the first portion into the groove of the second portion.

[0041] Preferably, the vane further comprises: a third portion extending from the first portion toward a second end of the vane, wherein the third portion is configured for connection to the cigarette packing machine, preferably wherein at least part of the third portion is offset with respect to the first portion. The third portion of the vane may comprise an increased width with respect to the first portion to provide additional support to the flow of smoking articles as it passes to a conveyor grid. The third portion of the vane may be configured to slot into the conveyor grid and allow the vane to be laterally displaced when the conveyor grid is moved in a lateral manner. The second end of the vane may be a bottom end of the vane in a vertical orientation.

[0042] Preferably, the vane further comprises a second main surface opposite to the first main surface of the vane configured, in use, to support a second flow of smoking articles along a main longitudinal axis of the second main surface, wherein the second main surface comprises at least one flow channel that extends from the first end of the vane across the second main surface to guide loose material off the second main surface. Preferably, a vane further comprises a rear surface opposite to the front surface of the vane configured, in use, to support a second flow of smoking articles along a main longitudinal axis of the rear surface, wherein the rear surface comprises at least one flow channel that extends from the top end of the vane across the rear surface to guide loose tobacco off the rear surface. The second main surface may be a rear surface of the vane. The second main surface (rear surface) of the vane may be substantially a mirror image of the first main surface (front surface).The features described in reference to the first main surface of the vane (the front surface) may also be equally applicable to the second main surface of the vane (the rear surface). It should be understood that both main surfaces of a vane may be used in the funnel section of a hopper to support separate flows of smoking articles from the bin section to the conveyor grid. Accordingly, loose material may accumulate or get stuck on either main surface of the vane and the features of the present disclosure may be provided on either or both of the main surfaces to prevent undesirable accumulation of loose material on the vane.

[0043] Preferably, the at least one flow channel of the first main surface is offset to the at least one flow channel of the second main surface across a transverse axis of the vane. In this way, the reduction of thickness in the vane due to the flow channel(s) of the first main surface does not overlap with the reduction of thickness in the vane due to the flow channel(s) of the second main surface so as to ensure the structural integrity of the vane and to prevent premature fatigue failure. The vertical groove and the inclined flow channel in the second portion may not be offset. It should therefore be understood that some flow channel(s), flow path(s) or grooves in the first main surface may or may not be offset against corresponding flow channel(s), flow path(s) or grooves in the second main surface. As should be appreciated, the specific arrangements or positions of the flow channel(s), paths or grooves in the first main surface and the second main surface may be apparent to the skilled person taking into account design requirements, manufacturing tolerances and material properties to ensure the physical integrity of the vane whilst ensuring that loose material can be readily collected and directed away from the main surfaces of the vane.

[0044] Preferably, the vane comprises connection features. The connection features may comprise holes and / or stud portions for connection to the hopper. For example, the studs may be inserted into machined blind holes and the holes may be configured to receive corresponding studs of the hopper. Preferably, the connection features are arranged in the vane to avoid any cross-sectional overlap with the at least one flow channel, the groove, and / or the at least one flow path. This advantageously prevents excessive weakening of the vane that could lead toearlier fatigue failure. Preferably, an edge between the first end and the first main surface and / or an edge between the first end and the second main surface is rounded or curved. In this way, the first I top end of the vane preferentially allows loose tobacco to fall from the first end to the front surface and / or rear surface of the vane. Aflat end may undesirably become a ledge for loose tobacco to collect I accumulate and lead to obstruction.

[0045] Preferably, the second portion provides a second step in the second main surface between the first portion and the second portion. Preferably, the second step is arranged between an opposite surface to the first surface of the second portion and an opposite surface to the first surface of the first portion. To put it in another way, preferably, the second portion forms a second step in the second main surface (e.g. rear surface) between the surface, opposite the first surface, of the first portion and a second surface, opposite to the first surface, of the second portion. In this way, both major sides I surfaces of the vane can be used to support flows of smoking articles in a smoking article assembly line. The opposite surfaces of the respective first and second portions of the vane may comprise any of the features described above with respect to the surfaces of the first and second portions in the first and second aspects of the present invention.

[0046] According to another aspect of the invention, there is provided a smoking article packing machine comprising at least one vane according to any of the preceding aspects. The smoking article packing machine may comprise a hopper and a conveyor grid. The hopper may comprise a bin for holding a plurality of assembled smoking articles and a funnel section to channel the assembled smoking articles from the bin to the conveyor grid to provide a stacked set of smoking articles. A plurality of vanes according to the present disclosure may be arranged in the funnel section of a hopper in the smoking article packing machine such that the spacing between respective vanes provide a flow channel for a flow of smoking articles to pass through. The flow of smoking articles may be in single-file to allow controlled stacking of the smoking articles onto the conveyor grid.

[0047] The conveyor grid may be movable in a lateral manner to shift the lower part of the funnel section and adjust the number of cigarettes that pass through the funnelsection onto the conveyor grid. For example, the funnel section may be shifted by the conveyor grid such that only six cigarettes passing through the flow channels are placed onto the conveyor grid (and one cigarette is impeded in a flow channel). This allows a standard set of twenty cigarettes to be collated, the standard set / collation having three stacked rows of cigarettes of: a bottom row of seven cigarettes; a middle row of six cigarettes; and a top row of seven cigarettes.

[0048] BRIEF DESCRIPTION OF DRAWINGS

[0049] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0050] Figures 1 A and 1 B show a hopper of a cigarette packer;

[0051] Figures 2A and 2B show an exemplary known vane;

[0052] Figures 3A, 3B, and 3C show a possible embodiment of a vane according to the present invention;

[0053] Figure 4 shows a vane in the art and a vane according to the present invention; and

[0054] Figure 5 shows a graph comparing the stoppage statistics of a cigarette packer using known vanes and vanes according to the present invention.

[0055] DETAILED DESCRIPTION

[0056] As explained above, tobacco and cigarettes will be used as a specific example to describe the invention, but other smoking consumable materials and other forms of articles containing loose material with an exposed end, such as heated tobacco sticks, may be suitably used.

[0057] Figure 1A shows a hopper 100 of a cigarette packer. The hopper 100 includes a bin 102 for holding a plurality of assembled cigarettes 110 received from a cigarette making machine or process. To arrange the cigarettes into a stacked set of cigarette rows, the assembled cigarettes 110 are passed through a funnelsection 104 of the hopper 100 in a plurality of single-file flow channels 120 to place a row of cigarettes on a conveyor grid 106 at the bottom the funnel section 104.

[0058] The hopper 100 can be vibrated to position and ‘shake’ the cigarettes to fall into the flow channels 120 of the funnel section 104. Since the cigarettes have an exposed I open end (opposite a filter end of a cigarette), loose tobacco can detach and fall from the tobacco rod of a cigarette in the hopper 100 as it is being vibrated. The loose tobacco inevitably also gets shaken into the funnel section 104 of the hopper 100.

[0059] The funnel section 104 comprises a plurality of vertical I top-to-bottom flow channels 120 that are defined by a set of vanes 130, where the vanes 130 have a tapered thickness to allow cigarettes to be widely received from the bin 102 and focussed together into a discrete row at the bottom of the funnel section 104.

[0060] In the specific example of Figures 1A and 1 B, the funnel section 104 includes four separate flows each having seven flow channels 120 such that four separate rows of up to seven cigarettes can be drawn from the bin 102 to be placed on the conveyor grid 106 at a same time. A magnified view of the funnel section 104 is shown in Figure 1B.

[0061] The conveyor grid 106 is movable in a lateral manner to shift the lower part of the funnel section 104. This can adjust the number of cigarettes that pass through the funnel section 104 onto the conveyor grid 106. For example, the funnel section 104 is shifted by the conveyor grid 106 such that only six cigarettes passing through the flow channels 120 are placed onto the conveyor grid 106 (and one cigarette is impeded in a flow channel 120). This allows a standard set of twenty cigarettes to be collated, the standard set / collation having three stacked rows of cigarettes of: a bottom row of seven cigarettes; a middle row of six cigarettes; and a top row of seven cigarettes.

[0062] Figure 2A shows a schematic representation of a known vane 200. The vane 200 is substantially L-shaped, with the long arm of the L205, in use, supporting a flow of cigarettes from a top end 210 of the vane 200 towards the conveyor grid 106 ofthe hopper 100, and the short arm of the L215, in use, serving a twofold purpose, connecting the vane 200 to the hopper 100 and guiding the cigarettes onto the conveyor grid 106 to form a row of stacked cigarettes. The short arm of the L 215 may be inclined with respect to the long arm of the L 205 to position the cigarettes onto the conveyor grid 106 - see Figure 2B. The vane 200 further includes a top connecting portion 220 to connect the vane 200 at the top to the hopper 100.

[0063] In use, cigarettes are received at a top (first) end 210 of the vane 200 (between the respective top ends of two vanes 200) from the bin of a hopper and move in a downward direction toward a second end of the vane (toward the bottom of the third portion 215 / top of the fourth portion 220). In Figure 2A, schematic cigarettes 150 placed on the front (first) surface of the vane to show how the cigarettes 150 move across the vane 200 in a flow direction 180. In use, a filter end 155 of a cigarette 150 is arranged toward and passes along a first side 250 of the vane 200 and the exposed I open end 160 of the cigarette passes along a second side 255 of the vane 200, the second side 255 of the vane 200 having the connecting portion 220 that is connected to the cigarette packer.

[0064] The rear (opposite to the front) surface of the vane 200 may also be used to direct I guide a flow of cigarettes 150, as shown in Figure 1 B, where a row of vanes 200 are arranged to provide a channelling stage in the funnel section of a hopper for multiple single-file cigarette flows.

[0065] The connecting portion 220 includes connection features (holes or stud portions) 240 on a side of the for connection to the cigarette packer. The studs are inserted into machined blind holes between the vane 200 and the cigarette packer.

[0066] A possible embodiment of the vane 300 of the present invention will now be described in reference to Figure 3. Figure 3A shows a vane 400 according to the present invention for use in a hopper of a cigarette packer. Figure 3B is a side profile view of the vane 300 and Figure 3C is a magnified view of a portion of the side profile view of Figure 3B as indicated by the oval 390.The vane 300 can be divided into portions, namely: a first portion 305 which, in use, supports a flow of smoking articles; a second portion 310 for connecting to a component in the assembly line; and a third portion 315 extending from a bottom end of the first portion 305 for guiding the cigarettes into position on the conveyor grid to stack cigarettes in a row next to each other. The third portion 315 is also used for connection to a conveyor grid by a bottom connection that slots into the conveyor grid. At least part of the third portion 315 is angled with respect to the surface of the first and second portions, which may be for the lateral movement of a set of vanes 300 to control the number of cigarettes being provided onto the conveyor grid.

[0067] The gradual widening of the top part of the first portion 305 toward the (bottom) end of the first portion 305 at a filter end side of the first portion 305 to ensure structural integrity of the vane to withstand the insertion forces occasioned by fitting the vane into the hopper.

[0068] Cigarettes 150 are arranged on the vane 300 to show the flow direction 180 of smoking articles from a top (first) end 330 of the vane 300 to the bottom end of the vane 300. In use, cigarettes are received at a top (first) end 330 of the vane 300 (between the respective top ends of two vanes 300) from the bin of a hopper and move in a direction toward a second end of the vane (toward the third portion 315).

[0069] The rear (opposite) surface 335 of the vane 300 may also be used to direct / guide a flow of smoking articles 150, as shown in Figure 1 B, where a row of vanes 300 is arranged to provide a channelling stage in the funnel section of a hopper for multiple single-file cigarette flows. In use, a filter end of a cigarette is arranged toward and passes a first side 380 of the vane 300 and the exposed I open end of the cigarette passes along a second side 385 of the vane 300, the second side 385 of the vane 300 having the second portion 310 that is connected to the cigarette packer.

[0070] The front surface 325 of the vane 300 includes a plurality of oblique flow channels 350, where each flow channel 350 is arranged at an angle of 45 degrees andextends from the top end 330 of the vane 300 to a side of the first portion 305. The flow channels 350 are therefore, in this specific example, in a parallel configuration and are evenly spaced along the first portion 305 across the top end 330 of the vane 300. The spacing between two flow channels 450 may be between 8.0 mm to 9.0 mm.

[0071] A flow channel 350 is a machined groove in the front surface 325 of the vane 300 and has a curved I arc-shaped or concave profile, as shown in Figure 3C. The width of a flow channel 350 may be 1.2 mm to 1.3 mm. This width is approximately half of the width of a standard cigarette such that the movement of a cigarette does not readily get affected or impeded by a flow channel 350.

[0072] The top end 330 of the vane 300 includes the first portion 305 and the second portion 310, such that the second portion 310 provides a greater width to the vane 300 along a top segment of the first portion 305. The second portion 310 includes connection features (holes or stud portions) 340 on a side of the second portion 310 for connection to the hopper. The studs are inserted into machined blind holes between the vane 300 and the cigarette packer. The holes in the vane 300 are machined to avoid any cross-sectional overlap with any of the flow channels, paths or grooves that guide loose tobacco away from the front or rear surface of the vane 300. This prevents excessive weakening of the vane 300 that could lead to earlier fatigue failure.

[0073] Figure 3B is a side profile view of the vane 300 which shows a tapered thickness from the top end 330 of the vane 300. The top end 300 of the vane is rounded.

[0074] As can be seen in Figure 3C, the thickness of the second portion 310 is less than the thickness of the first portion 305 along its length by at least the depth of the flow channels 350 (1.3 mm in this example). The second portion 310 also has a tapered thickness such that a surface of the second portion 310 is parallel to a corresponding surface of the first portion 305. As explained above, in use a cigarette is arranged to pass across a surface of the vane 300 such that the filter end of the cigarette is toward the first side 380 of the vane 300 and the open I tobacco rod end of the cigarette is toward the second side 385 of the vane 300.This gap or step between the front surface 325 of the first portion 305 and the front surface of the second portion 310 allows a maximum depth of the flow channels 350 to be at least in line with a front surface of the second portion 310. To ensure that any loose material I tobacco is not trapped or obstructed at the interface between the first portion 305 and the second portion 310, a vertical groove 355 is provided in the front surface of the second portion 310 along the interface between the first portion 305 and second portion 310. This vertical groove 355 provides another flow path for loose tobacco received from the flow channels 350 in the first portion 305 to readily fall away from the front or rear surface of the vane 300. In this example, the vertical groove has a depth of 1.0 mm.

[0075] The front surface of the second portion 310 further includes another flow path 360 that is machined into the front surface of the second portion 310 from the top end of the second portion 310. This flow path 360 provides an angled ledge that directs loose tobacco from the top end of the second portion 310 toward the vertical groove 355. The depth of this flow path 360 in the second portion 310 is less than the depth of the vertical groove 355 such that loose material can readily fall into the vertical groove 355 and be further guided away from the surface of the vane 400. The depth of the flow path 360 in the second portion 310 may be 0.5 mm (where the depth of the vertical groove 355 may be 1.0 mm, as indicated above). In this example, the flow path 360 is provided as a recessed portion (that is triangular shaped). It should be understood that the second portion 310 may alternatively comprise flow channels similar to the flow channels 350 provided in the first portion.

[0076] As can be seen in Figures 3B and 3C, the topographical features (i.e. the flow channels 350, vertical groove 355, and flow path 360 of the second portion 310, and the varying thicknesses of the second portion 310) are provided on both the front and rear surfaces of the vane 300. It should be understood that both front and rear surfaces 325, 335 of the vane 330 of the present invention can be used to effectively guide loose tobacco away from a flow of cigarettes in a cigarette packing machine.It can also be seen in Figure 3C that the oblique flow channels 350 in the front surface 325 of the vane 300 are not aligned with the oblique flow channels 350 in the rear surface 335 of the vane 300. In other words, the oblique flow channels in the front surface 325 are offset to the oblique flow channels in the opposite rear surface 335. This prevents excessive weakening of the vane 300 that could lead to earlier fatigue failure.

[0077] It should also be appreciated that the dimensions and angles provided are exemplary and that different dimensions (e.g. thicknesses) and configurations such as different numbers of channels, grooves, should be readily apparent to the skilled person in view of the present disclosure.

[0078] Figure 4 shows images of a known vane, such as the vane 200 described in reference to Figure 2, next to a vane 300 according to the present disclosure, described in reference to Figure 3. Smoking articles 150 are placed on the front (first) surface of the known vane 200 and the presently disclosed vane 300 to show how the smoking articles 150 are received from a top end 230, 330 of the respective vane 200, 300 and move in a flow direction 180 across the respective vane 200, 300.

[0079] As can be seen in Figure 4, the vane 300 of the present disclosure has a narrower width across a large portion (the first portion 305) of the vane 300 compared to the known vane 200. This allows the open end of a cigarette to be more exposed and allow loose material I tobacco to more readily fall away from the surface of the vane 300.

[0080] Figure 5 shows a graph 500 comparing the stoppage statistics of a FOCKE & CO F8 packer using its regular vanes (see the left bar of each set of results in figure 5) against vanes according to the present disclosure (see the right bar of each set of results in figure 5). The graph includes the number of stoppages due to:

[0081] Cigarette vanes I flow channels being empty 510

[0082] A first missing filter track 520

[0083] A second missing filter track 530- An issue with a right turret cover 540

[0084] - An issue with a left turret cover 550

[0085] - A total amount of stoppages 560.

[0086] Statistics for operations performed in a two months period using the regular known vanes 200 are provided in the left bar of each set of results and statistics for operations performed in the two months period using the vanes 300 of the present invention are provided in the right bar of each set of results. The results are presented in Table 1 below:

[0087] &

[0088]

[0089] It has been found that the vanes of the present invention have effectively improved manufacturing operations over the previous vanes by: reducing stoppages by 24.5%; improving overall equipment effectiveness (OEE) by 35.4%; reducing the amount of rejects by 67%; and reducing the mean time between failures (MTBF) by 32.6%.

Claims

23CLAIMS1. A vane for supporting a flow of smoking articles in a smoking article packing machine, the vane comprising:a first main surface configured, in use, to support the flow of smoking articles from a first end of the vane along a main longitudinal axis of the first main surface,wherein the first main surface comprises at least one flow channel that extends from the first end of the vane across the first main surface to guide loose material off the first main surface.

2. A vane according to claim 1, wherein the at least one flow channel extends in an angled direction from the first end of the vane away from the main longitudinal axis.

3. A vane according to any of claims 1 or 2, wherein the first main surface of the vane comprises at least two flow channels, preferably wherein the at least two flow channels are arranged in a parallel configuration.

4. A vane according to any of claims 1, 2 or 3 comprising a groove in the first main surface extending along the main longitudinal axis.

5. A vane according to claim 4, wherein the at least one flow channel extends from the first end of the vane to the groove.

6. A vane according to any of the preceding claims further comprising:a first portion having a first length, a first width, a first length side, and a second length side; anda second portion having a second length and a second width, the second portion extending from the first length side of the first portion at the first end of the vane, wherein the second length and the second width of the second portion are less than the first length and the first width of the first portion respectively,preferably wherein the first width is configured to support at least half of a length of a tobacco rod of a smoking article as it flows along the first main surface such that, in use, a tobacco end of a cigarette is arranged toward the first length side of the first portion and a filter end of the cigarette is arranged toward the second length side of the first portion and that loose tobacco falls away from the first main surface of the vane at the first length side.

7. A vane according to any of claims 3 to 6, wherein the at least two flow channels are evenly spaced along the first end of the vane, preferably wherein the at least two flow channels are evenly spaced along the first portion of the vane.

8. A vane according to claim 6 or 7, wherein the groove extends along the first length side of the first portion from the first end of the vane to an end of the second portion opposite the first end.

9. A vane according to any of claims 6, 7 or 8, wherein the second portion comprises at least one flow path that guides loose tobacco from the flow of smoking articles towards the groove.

10. A vane according to any of claims 6 to 9, wherein the second portion has a thickness less than a thickness of the first portion so as to provide a first step in the first main surface of the vane, preferably wherein the at least one flow channel extends from the first end to the first step.

11. A vane according to any of the preceding claims further comprising a second main surface opposite to the first main surface of the vane configured, in use, to support a second flow of smoking articles along a main longitudinal axis of the second main surface, wherein the second main surface comprises at least one flow channel that extends from the first end of the vane across the second main surface to guide loose material off the second main surface.

12. A vane according to claim 11 , wherein the at least one flow channel of the first main surface is offset to the at least one flow channel of the second main surface across a transverse axis of the vane.

13. A vane according to any of the preceding claims, wherein an edge between the first end and the first main surface and / or an edge between the first end and the second main surface is rounded or curved.

14. A smoking article packing machine comprising at least one vane according to any of the preceding claims.

15. A smoking article packing machine according to claim 14, comprising a hopper and a conveyor grid, preferably the hopper comprises a bin for holding a plurality of assembled smoking articles and a funnel section to channel the assembled smoking articles from the bin to the conveyor grid to provide a stacked set of smoking articles.

Images