EP2782461A1

EP2782461A1 - Apparatus and method for deconstructing a smoking article

Info

Publication number: EP2782461A1
Application number: EP12783532.0A
Authority: EP
Inventors: Martin JUNGFER; Charles Kilby; Euan Morrison; Niall MOTTRAM
Original assignee: Philip Morris Products SA
Current assignee: Philip Morris Products SA
Priority date: 2011-11-25
Filing date: 2012-11-08
Publication date: 2014-10-01
Also published as: WO2013075791A1

Abstract

The present invention relates to an apparatus for deconstructing smoking articles (12) or semifinished smoking articles (12), wherein the smoking articles (12) or semi-finished smoking articles (12) comprise a combination of smoking article sections. The apparatus comprises a dividing unit (3), wherein the dividing unit (3) is adapted to create a stream comprising smoking articles (12) or semi-finished smoking articles (12) with a pre-determined configuration of smoking article sections from a stream of smoking articles (12) or semi-finished smoking articles (12) comprising a variety of configurations of smoking article sections. Additionally, the apparatus comprises a further processing means for further processing the individual streams of smoking articles (12) or semifinished smoking articles (12), wherein the further processing means comprises a reorientation unit (4), wherein the reorientation unit (4) is adapted to change the orientation of smoking articles or semi-finished smoking articles with a pre-determined configuration of smoking article sections from a first orientation into a second, opposite orientation. The invention further relates to a method for deconstructing smoking articles (12) or semi-finished smoking articles (12).

Description

Apparatus and Method for Deconstructing a Smoking Article

The present invention relates to an apparatus and method for deconstructing a smoking article. The apparatus and method finds particular application in the recovery of elements of the smoking article such as for example tobacco, filter elements, capsules, heat sources, or the like.

In the prior art, it is known to use cigarette rippers to recover tobacco from rejected cigarette material. The ripper opens the cigarette paper to allow the removal of tobacco from the cigarette. However, the presence of filter elements during the ripping process may be disadvantageous, as the tobacco recovered by the ripping process may comprise filter material. This applies in particular for specific cigarette filter elements, such as filter elements comprising charcoal or capsules with additional flavour, such as menthol. But even for common acetate fiber filter elements, the acetate fibre may contaminate the recovered tobacco. Further, the ripping process is rather destructive and the maintenance of the integrity of recovered non-tobacco parts is difficult.

US-A-4,485,827 discloses such an apparatus for recovering tobacco particles from unsatisfactory filter cigarettes. Unsatisfactory cigarettes are segregated from satisfactory cigarettes by means of an ejector. The unsatisfactory cigarettes are aligned into a single file by means of a centrifugal aligning device wherein the wrappers of successive cigarettes are broken open to expose the tobacco fillers as well as the filters. Rollers beat the opened wrapper to liberate the fragments of tobacco, wherein the tobacco is separated from the opened wrappers, filters and other constituents of the cigarettes by means of a vibrating sieve. However, as previously explained the presence of filters may be detrimental.

In the prior art, cleaning steps after the ripping have been implemented, but it has been found more beneficial to remove the filter elements before the ripping process. Methods and apparatus for the filter removal are described for example in US-A-5, 076,291. A main problem for these processes remains that the individual smoking articles elements have to be provided in a specific orientation. However, the smoking articles that need to be ripped are generally a bulk of heterogeneous material. This is due to the fact, that these smoking articles are typically gathered either through reject systems, or are emptied manually from a cigarette maker or packer, when the machine is stopped. Hence, the smoking articles that need to be ripped may comprise for example big particles such as agglomerations of glued cigarette fragments, loose tobacco, paper, broken or bent smoking material rods, filter rods of different lengths, rods comprised of smoking material for two cigarettes and two filter sections in the middle, single rejected cigarettes, and a wide variety of smoking articles that comprise of more than just a tobacco rod and an acetate tow filter, such as for example smoking articles comprising smoking article sections such as charcoal filters, flavor capsules, tobacco plug filter segments, beads of plant material or charcoal, plant leaf material, non-cuttable objects like flow restrictors or carbonaceous heat sources, and combinations of the aforementioned. Aside from the tobacco, these other smoking article sections may have a substantial value and their may be a desire to recover at least some of these smoking article sections. Alternatively, or in addition, these smoking article sections may be undesirable in the recovered tobacco, like for example charcoal, menthol or acetate tow and there is therefore a need to make sure that the recovered tobacco is not contaminated.

The object of the present invention is to provide an improved means for deconstructing smoking articles, which is able to process a bulk of heterogeneous rejected material from a smoking article production process in an efficient and reliable manner.

According to the invention an apparatus for deconstructing smoking articles or semifinished smoking articles is provided, wherein the smoking articles or semi-finished smoking articles comprise a combination of smoking article sections. The apparatus comprises a dividing unit and a further processing unit for further processing the individual streams of smoking articles or semi-finished smoking articles. The dividing unit is adapted to create a stream comprising smoking articles or semi-finished smoking articles with a pre-determined configuration of smoking article sections from a stream of smoking articles or semi-finished smoking articles comprising a variety of configurations of smoking article sections.

The dividing unit comprises at least one sensor, wherein the sensor is adapted to detect the pre-determined configuration of smoking article sections in a smoking article or semi-finished smoking article. The apparatus further comprises an actuation means, wherein the actuation means is adapted to change the path of an individual smoking article or semi-finished smoking article. A control unit is provided, wherein the control unit is adapted to actuate the actuation means in response to a sensor signal. In particular, the actuation means is adapted to apply a force on a smoking article or semi-finished smoking article to change its path in the dividing unit.

The further processing means comprises a reorientation unit, wherein the reorientation unit is adapted to change the orientation of the aligned smoking articles or semi-finished smoking articles in at least one of the individual streams from a first orientation into a second, opposite orientation. Thus, the reorientation unit allows the convergence of smoking articles or semi-finished smoking articles in a first stream, where the smoking articles or semi-finished smoking articles with a pre-defined configuration are oriented in a first orientation and a second stream, where the smoking articles or semi-finished smoking articles with a pre-defined configuration are in a second, opposite orientation, such that, after the reorientation unit a single stream of smoking articles or semi-finished smoking articles with a pre-defined configuration are all in the second, opposite orientation. This increases significantly the efficiency and speed of the apparatus for subsequent operations.

The reorientation unit is not required to be able to act on all of the smoking articles or semi-finished smoking articles in the different individual streams. It is sufficient that the reorientation unit can act on the stream where the smoking articles or semi-finished smoking articles with a pre-determined configuration of smoking article sections are such that the orientation of smoking article sections is opposite to the orientation of smoking article sections of the smoking articles or semi-finished smoking articles in another stream with pre-determined configuration. In simple terms, if there were only filter cigarettes, then it is sufficient to reorient the filter cigarettes in the product stream where the tobacco rod is on the upstream side, such that after the reorientation of that stream, all cigarettes are oriented with the filter at the upstream side.

Also, for the example where the smoking article section that needs to be removed is a filter plug, this alignment improves the quality of the recovered tobacco due to a significant reduction in the inadvertent presence of filter material in the recovered tobacco. According to the invention the filter material can be more reliably removed in a stream of aligned smoking articles where the filter element is always at the same position of the tobacco rod. According to the invention, it is now easier to first remove the filter and then open the tobacco rod to recover the tobacco without contamination.

The term "semi-finished smoking article" is used herein to relate to semi products during the production of smoking articles that comprise either a tobacco column or at least one other smoking article section that should be recovered from the semi-finished smoking article. Semifinished smoking articles are for example: tobacco rods, double length filters with one or two tobacco rods attached to the double filter, other combinations of filter segments and tobacco rods or bent tobacco rods.

The term "smoking article section" is used herein to relate to any individual section of a smoking article. In addition, the term "smoking article section" is also used to encompass two or more combinations of individual smoking article sections. For example, a filterless smoking article comprises just a single smoking article section, that is, the tobacco rod. A simple filter cigarette comprises two smoking article sections, that is, the tobacco rod and the filter. Other smoking articles may comprise additional sections like, for example: a filter tow plug with carbon particles, a filter tow plug with plant material, a filter tow plug with a flavor thread, a filter tow plug with a capsule, a filter tow plug with multiple capsules, a filter tow plug with cellulose beads or granules, a filter segment with a cavity (space) that is filled with for example, cellulose or carbon beads or granules, capsules or one or more non cuttable objects like flow restrictors, such as for example a hollow tube. Further examples for smoking article sections are a tobacco rod segment with beads or capsules, a tobacco plug with particular tobacco, for example, oriental tobacco, a heat source, for example a carbonaceous heat source, a section comprising a sheet material such as for example paper, cardboard, metal, such as for example aluminum, or a tobacco web, and sections comprising combinations of the elements above. Typically, the individual "smoking article sections" have a sharp edge. Typically, the individual "smoking article sections" are manufactured separately and then, at a later stage, combined to the final smoking article in a series of combining steps, for example on a filter combiner or on a cigarette combiner, or on specialized machinery. Typically, the individual smoking article sections are connected to each other by the use of a wrapper, such as for example, porous plug wrap or tipping paper.

The term "pre-defined configuration" is used to describe a set of parameters that define criteria for the selection of a smoking articles or semi-finished smoking articles to be selected to continue into an individual stream of products. For example, a pre-defined configuration could mean a smoking article with a tobacco rod and a filter element, namely a filter plug. Such a predetermined configuration would thus select a smoking article that comprises a filter plug and a tobacco rod, but no additional smoking article sections. In this example, the pre-defined configuration may be set such that it does not encompass differently oriented smoking articles of the same construction, for example a smoking article comprising a tobacco rod and a filter plug, wherein the filter plug leads along the product stream, is in the pre-defined configuration, but a smoking article comprising a tobacco rod and a filter plug, wherein the tobacco rod leads along the product stream, is not in the pre-defined configuration.

The apparatus according to the invention can be efficiently used to deconstruct smoking articles that have been previously rejected or have not reached the end of the production line for other reasons. This allows for the recovery of valuable elements of the smoking article. In particular, the dividing unit allows transforming the homogenous bulk of smoking articles or semi-finished smoking articles into processable streams of smoking articles or semi-finished smoking articles for later deconstruction. This advantageously allows for a much more precise subsequent operation where the smoking articles or semi-finished smoking articles can be handled according to their particular configuration. This is particularly advantageous with the growing sophistication of smoking articles. Due to the division of the smoking articles or semifinished smoking articles in several streams of smoking articles or semi-finished smoking articles with different configurations, the contamination of the recovered materials can be efficiently reduced. The apparatus according to the invention is particularly advantageous in the recovery of tobacco. In an exemplary application of the apparatus, the apparatus according to the invention may be used for processing defective products of a smoking article production process, namely smoking material rods with and without a filter element and further, in particular, single filter elements, loose smoking material and paper. The apparatus according to the invention comprises a dividing unit, wherein the dividing unit is adapted to divide the stream comprising aligned smoking material rods at least into a stream of smoking material rods with the filter element in a first orientation and a stream of smoking material rods with the filter element in second, opposite orientation.

In addition, the apparatus according to the invention may comprise at least one conveyance means per stream of smoking articles or semi-finished smoking articles.

In some embodiments, the apparatus according to the invention may comprise a presorting unit. Where a pre-sorting unit is present, advantageously the smoking articles or semifinished smoking articles are already separated from many of the remaining defective products in the pre-sorting unit, such that their further processing is facilitated. Preferably, the pre-sorting unit is adapted to separate at least the smoking articles or semi-finished smoking articles, and optionally filter elements, from a variety of defective products.

The dividing unit may comprise one entry channel, and at least two exit channels, into which the smoking articles or semi-finished smoking articles are distributed by means of the actuation means. Different actuation means may be provided, such as a nozzle for providing pressurized air, a pushing element, which pushes the smoking article or semi-finished smoking article in the desired direction, or a gate which changes the path for the smoking article or semifinished smoking article, such as a trapdoor gate, a vertical pinball gate, that is a flap with a horizontal axis, or a horizontal pinball gate, that is a flap with a vertical axis.

The sensor for detecting the position of a filter element in a smoking article or semifinished smoking article may be a capacitive sensor, an ultrasonic sensor, an optical sensor by means of transmission or reflection, an optical sensor in the x-ray range of the electromagnetic spectrum, a microwave sensor, a magnetic/inductive sensor, a pressure or force sensor, as well as an image processing sensor.

In further embodiments, optical sensors may be provided, which are able to detect different pre-defined configurations of smoking articles or semi-finished smoking articles, and to divide the stream of such smoking articles or semi-finished smoking articles into respective separate output channels. This may in particular be obtained by arranging several dividing units subsequently, wherein one of the dividing units divides smoking articles or semi-finished smoking articles with a first pre-defined configuration, for example according to the orientation of a filter plug upstream of a tobacco rod, and a second dividing unit divides the remaining smoking articles or semi-finished smoking articles, for example according to the orientation of a filter plug downstream of a tobacco rod.

Preferably, a mechanical gate is provided, which changes the path of the smoking articles or semi-finished smoking articles from the input channel to one of the several output channels of the dividing unit. In another embodiment, air jets are provided to divert the smoking articles or semi-finished smoking articles into the different parallel output channels.

Preferably, the input channel and the output channels of the dividing unit are parallel. In one embodiment, the output channel for semi-finished smoking articles with a double length filter element, and smoking articles or semi-finished smoking articles without filter element are aligned with the input channel. In this embodiment the output channel for smoking articles or semifinished smoking articles with a filter element in a first orientation and the output channel for smoking articles or semi-finished smoking articles with a filter element in a second orientation are arranged parallel to the input channel, but offset in a direction perpendicular to the stream direction. The actuation means provides the necessary actuation force to the smoking articles or semi-finished smoking articles, such that they are conveyed into the desired output channel. This has the benefit that the actuation means mainly applies a force only to selected products of a relatively consistent configuration, while the other defective products are not changed in their path by the actuation means. This makes the dividing unit operate reliable.

In one embodiment, the further processing means comprises a separation means which is adapted to separate at least one smoking article section from a smoking article or semifinished smoking article. The separation means may be for example a cutting means, a shearing means, or a means which applies a sudden force to the smoking article section, for example a filter plug, such that the smoking article section is broken, cut or sheared from the smoking articles or semi-finished smoking articles.

In one embodiment, the separation means comprises a drum, wherein the drum comprises a number of seats in the circumference of the drum. The seats are adapted to hold a smoking article or semi-finished smoking article such that a smoking article section, like for example, a filter element, where present, protrudes over the outer parameter of the drum. The separation means further comprises a paddle that is adapted to remove the protruding smoking article section from the smoking article or semi-finished smoking article. This enables an effective smoking article section breaking process with a minimal loss of smoking material. In the example of a filter plug, this advantageously results in a clean separation between the filter plug that is at that point still tightly wrapped in the plug wrap and tipping paper. Preferably, the drum receives smoking articles or semi-finished smoking articles, such that the smoking article section that needs to be removed, for example the filter element, is oriented radially outwards, while the remainder of the smoking articles or semi-finished smoking articles is oriented radially inwards with respect to the drum. The paddle may be provided stationary, while the drum rotates, such that a shearing force separates the smoking article section from the smoking articles or semifinished smoking articles. However, preferably, the paddle moves, in particular rotates, to provide a higher shearing force on the smoking article section. Preferably, the smoking articles or semi-finished smoking articles are arranged in a substantially radial orientation in the seat of the drum. The drum preferably comprises a number of seats that are evenly distributed around the circumference of the drum. For example, depending on the diameter of the drum, 4, 6, 8, 10 or more seats may be provided on the drum. The seats are preferably distributed equidistantly on the circumference of the drum. The seats may have an open v-shaped form to receive the smoking article or semi-finished smoking article. Preferably, the drum receives the smoking articles or semi-finished smoking articles, when the seat is substantially at the uppermost position during the rotation of the drum. Preferably, the drum rotates around the horizontal axis. The drum and the paddle may be synchronized in their movement. In particular, the drum and the paddle may be mechanically coupled, preferably by a belt or a chain.

Preferably, a clamp mechanism is provided in the seat of the drum, the clamp mechanism being adapted to be actuated when the smoking article or semi-finished smoking article reaches the bottom of the seat, such as to clamp the smoking article or semi-finished smoking article. Thus, an accurate position of the smoking article or semi-finished smoking article in the seat may be obtained. If the actuation of the clamp mechanism would not be carried out precisely, when the smoking article or semi-finished smoking article reaches the bottom of the seat, the smoking article or semi-finished smoking article may rebound or not have yet reached the bottom of the seat, such that its arrangement in the seat may vary from the predetermined arrangement. This could negatively interfere with the separation process, as the separation process preferably requires a precise position of the smoking article or semi-finished smoking article to enable to only remove the filter without losing too much material that is intended for recover, for example, tobacco.

Preferably, the clamp mechanism is combined with a mechanism which assures the precise position of the smoking articles or semi-finished smoking articles within the seat. Preferably, this is achieved by a seat that is deeper than required and by a mechanism which pushes the clamped smoking articles or semi-finished smoking articles slightly out, in the required position.

The clamp mechanism may be actuated mechanically, in particular by a release mechanism that is activated when the smoking article or semi-finished smoking article reaches the bottom of the seat and releases a pretensioned part of the clamp mechanism, such as a mechanical arm, to clamp the smoking articles or semi-finished smoking articles in the seat. Preferably, once a smoking article or semi-finished smoking article has dropped into the seat, the spring activated mechanical arm closes around the smoking article or semi-finished smoking article. The pretension of the clamp mechanism may be enabled by a spring. The mechanical arm holds the smoking articles or semi-finished smoking articles in place as the drum rotates. The seats are adapted such that only the filter element of the smoking articles or semi-finished smoking articles protrudes from the drum and is exposed to the paddle, resulting in the separation of the filter element from the smoking article or semi-finished smoking article.

The actuation of the clamp mechanism may also be effected by a sensor, which issues a signal to a control system, when the smoking article or semi-finished smoking article reaches the bottom of the seat.

In one embodiment, the opening of the seat may be chamfered, while otherwise the seat corresponds to the width of the smoking articles or semi-finished smoking articles.

The clamp mechanism may be released to allow the smoking articles or semi-finished smoking articles to fall under gravity into a further processing means underneath the rotating drum. The further processing means can be a further conveying channel or a receiving tray.

Preferably, the depth of the seat may be adjustable, such that different types of smoking articles or semi-finished smoking articles and smoking articles or semi-finished smoking articles of different length may be processed. Furthermore, the diameter of the seats may be adjustable to accommodate differently sized smoking articles or semi-finished smoking articles, for example slim or king-sized smoking articles or semi-finished smoking articles.

Alternatively to a clamp mechanism, a vacuum holding mechanism may be provided in the seats of the drum. In particular, the vacuum holding mechanism may comprise at least one suction hole which is provided at the bottom wall of the seat in the drum, and which holds the smoking article or semi-finished smoking article by means of suction.

Furthermore, a filter capturing means may be provided, which is adapted to capture the filter elements which have removed from the smoking articles or semi-finished smoking articles. This is in particular effected by providing a vacuum-operated, respectively suction-operated, funnel, which is adapted to suck the filter elements in.

In one embodiment, the further processing means comprises an opening means, wherein the opening means is adapted to open the smoking articles or semi-finished smoking articles after at least one smoking article section, for example a filter plug, has been separated from the smoking article or semi-finished smoking article. In particular, the opening means may be a ripping means, which cuts open the smoking article or semi-finished smoking article along one g

longitudinal side thereof, such that the smoking material and wrapping material of the smoking article or semi-finished smoking article can be separated. As the at least one smoking article section is removed from the smoking article or semi-finished smoking article, the risk of contamination with parts of the removed smoking article section, for example filtration material such as acetate tow, is avoided.

In particular, the opening means is adapted to cut open the cigarette paper of a tobacco rod.

A further invention is directed to the reorientation unit as a separate unit, not in combination with the further downstream and upstream units of the apparatus for deconstructing smoking articles or semi-finished smoking articles.

Preferably, the reorientation unit comprises a stop against which the smoking articles or semi-finished smoking articles are conveyable and the reorientation unit further comprises a free turning area, wherein smoking articles or semi-finished smoking articles that are conveyed against the stop can freely turn around an axis perpendicular to their longitudinal extension. In particular, the smoking articles or semi-finished smoking articles fall under the influence of gravity in the reorientation unit, wherein the stop initiates a rotational movement around the axis perpendicular to the longitudinal extension of the respective smoking article or semi-finished smoking article in the free turning area. Thus, when the smoking article or semi-finished smoking article reaches the lower side of the reorientation unit, its orientation has been substantially inversed. The reorientation unit preferably consists of a combination of path guides which are adapted to re-orientate the smoking articles or semi-finished smoking articles using gravity. The upstream channel through which the smoking articles or semi-finished smoking articles enter the reorientation unit is provided at an upper location of the reorientation unit, while the downstream channel through which the reoriented smoking articles or semi-finished smoking articles leave the reorientation unit is provided at a lower position of the reorientation unit. A slope may lead into the downstream channel, to ensure a quick and guided movement of the reoriented smoking articles or semi-finished smoking articles into the downstream channel. The slope may be curved.

The reorientation unit may comprise multiple channels for smoking articles or semifinished smoking articles in parallel. Further, the reorientation unit may comprise a slope provided at the upper side of the upstream channel and extending to the stop, to ensure that the smoking articles or semi-finished smoking articles hit the stop in a defined manner.

Preferably, the filter element is arranged in the downstream direction in the first orientation. In particular, the smoking articles or semi-finished smoking articles are reoriented by 180 degrees around an axis perpendicular to their longitudinal axis in the reorientation unit. Further, the reorientation unit is adapted to process smoking articles or semi-finished smoking articles of different length. Several smoking articles or semi-finished smoking articles may be processed in parallel in the reorientation unit, in particular several channels for smoking articles or semi-finished smoking articles may be provided in parallel.

Preferably, the smoking articles or semi-finished smoking articles with a filter element are sorted into two channels depending on the orientation of the smoking article or semi-finished smoking article. Preferably, in the dividing unit, the smoking articles or semi-finished smoking articles move along a single channel on a conveyor. The conveyance speed is preferably between about 0.1 and about 1.5 meters per second.

In one embodiment, the apparatus may further comprise a stream changing unit, wherein the stream changing unit is adapted to change the stream of smoking articles or semi-finished smoking articles from a longitudinally oriented stream, where the direction of travel of the smoking articles or semi-finished smoking articles is substantially along the longitudinal axis of the smoking articles or semi-finished smoking articles, into a transversely oriented stream, where the direction of travel of the smoking articles or semi-finished smoking articles is substantially perpendicular to the longitudinal axis of smoking articles or semi-finished smoking articles, or vice versa.

The transport of smoking articles or semi-finished smoking articles in a direction substantially perpendicular to their longitudinal axis can save space in the production environment. Furthermore, the separation means may require a transverse stream of smoking articles or semi-finished smoking articles in subsequent processing steps.

Preferably, the apparatus comprises a post-sorting unit, wherein the post-sorting unit is adapted to sort the smoking article element of which the recovery is desired, for example smoking material such as tobacco or other smoking article elements. Preferably, the post-sorting unit is provided at a downstream location of the apparatus, downstream of the opening means. The post-sorting unit may comprise, for example at least one sieve to separate tobacco particles from paper.

Preferably, the apparatus further comprises an alignment unit. The alignment unit allows bringing the smoking articles or semi-finished smoking articles into a defined orientation. However, as the smoking articles or semi-finished smoking articles may still be in two substantially opposite orientations when they are aligned with each other, the dividing unit allows to separate the opposite oriented smoking articles or semi-finished smoking articles into different streams. The different individual streams of smoking articles or semi-finished smoking articles can then be further processed. In particular, the smoking articles or semi-finished smoking articles are aligned with their longitudinal axes in the aligned stream of smoking articles or semi-finished smoking articles. The longitudinal axis of the smoking article or semi-finished smoking article is the axis in the direction of the longest extension of the smoking article or semi-finished smoking article. In a substantially cylindrical smoking article or semi-finished smoking article, this is the central axis of the smoking article or semi-finished smoking article.

In particular, the alignment unit may comprise a cascade of at least a first set of alignment grooves and a second set of alignment grooves, wherein the first set of alignment grooves is located upstream of the second set of alignment grooves, and where the number of alignment grooves in the second set of alignment grooves is at least double the number of alignment grooves in the first set of alignment grooves. More preferably, the first set of alignment grooves is arranged above the second set of alignment grooves, and the lowermost sections of the first set of alignment grooves are arranged above the uppermost sections of the second set of alignment grooves. Further, the width of the alignment grooves of the second set is preferably half the width of the alignment grooves of the first set. Thus, from one alignment groove of the first set of alignment grooves, the smoking articles or semi-finished smoking articles will fall in a first or a second alignment groove of the second set of alignment grooves according to a stochastic distribution. In particular, a third set of alignment grooves may be arranged downstream of the second set of alignment grooves, wherein the third set of alignment grooves comprises a number of alignment grooves which is at least double the number of alignment grooves of the second set of alignment grooves. Accordingly, a fourth, a fifth, a sixth or more sets of alignment grooves may be provided, each having double the number of alignment grooves compared to the respective previous upstream set.

The alignment unit allows distributing smoking articles or semi-finished smoking articles evenly to several parallel alignment grooves in the most downstream set of alignment grooves. The alignment grooves may be either formed by v-shaped or by semi-circular channels. Preferably, the alignment unit may be actuated, in particular to vibrate, to facilitate the movement of the smoking articles or semi-finished smoking articles therein. The actuation of the alignment unit may be enabled by a motorized cam system. Further, the alignment unit may be inclined to enable movement of the smoking articles or semi-finished smoking articles. In particular, a uniform distribution of the smoking articles or semi-finished smoking articles in the different sets of alignment grooves may be obtained. Furthermore, rollers may be provided at the output of alignment unit to flatten bent smoking articles or semi-finished smoking articles.

Preferably four sets of alignment grooves are provided subsequently, wherein the first set comprises two alignment grooves, the second set comprises four alignment grooves, the third set comprises eight alignment grooves and the fourth set comprises sixteen alignment grooves. All alignment grooves preferably extend in parallel with each other, wherein the alignment grooves of each set are arranged at the same height, respectively. Alternatively, the alignment grooves could fan out along a downstream direction or be diverted into subsets of alignment grooves.

The invention also provides a method for deconstructing smoking articles or semifinished smoking articles, wherein the smoking articles or semi-finished smoking articles comprise a combination of smoking article sections, the method comprising the steps of creating a stream of smoking articles or semi-finished smoking articles; and dividing the stream comprising smoking articles or semi-finished smoking articles at least into a stream of smoking articles or semi-finished smoking articles with a pre-determined configuration of smoking article sections from a stream of smoking articles or semi-finished smoking articles comprising a variety of configurations of smoking article sections. The method according to the invention further comprises the step of further processing the individual streams of smoking articles or semifinished smoking articles. The further processing of the individual streams comprises changing the orientation of the aligned smoking articles or semi-finished smoking articles with a predetermined configuration of smoking article sections in at least one stream from a first orientation into a second, opposite orientation. Thus, by changing the orientation of the aligned smoking articles or semi-finished smoking articles in one of the streams all smoking articles or semi-finished smoking articles with filter elements can have the same orientation in the at least two different streams. The predetermined configuration may in particular refer to a configuration where the filter element is in a first orientation. After changing the orientation the filter element is preferably in the second opposite orientation.

In a particular embodiment, the method comprises processing defective products of a smoking article production process, namely smoking articles or semi-finished smoking articles with and without a filter element, and further in particular single filter elements, loose smoking material and paper, comprising the following steps: A variety of defective products is processed in a pre-sorting process to separate at least smoking articles or semi-finished smoking articles, and optionally separate filter elements, from other defective products. Then, a stream comprising aligned smoking articles or semi-finished smoking articles, and optionally other aligned defective products, is created. The stream comprising aligned smoking articles or semi-finished smoking articles is divided into a stream of smoking articles or semi-finished smoking articles with the filter element in a first orientation and a stream of smoking articles or semi-finished smoking articles with the filter element in a second, opposite orientation. Then, the individual streams of smoking articles or semi-finished smoking articles are further processed. Preferably, a pre-defined smoking article section is subsequently separated from the smoking articles or semi-finished smoking articles. For example, where filter plugs need to be removed in order to recover he smoking material, the smoking articles or semi-finished smoking articles where the filter plug has been removed can be further processed without the risk of contamination of the smoking material with parts of the filter.

In one embodiment, the smoking articles or semi-finished smoking articles are opened after the smoking article section, for example the filter element has been separated from the smoking article or semi-finished smoking article and the smoking material is separated from other components of the smoking article or semi-finished smoking article for further processing. The other components are in particular smoking material wrapper, more particularly cigarette paper.

The invention will now be further explained with reference to exemplary embodiments as shown in the following figures.

Figure 1 shows the general arrangement of several units according to an embodiment of the invention.

Figure 2 shows a perspective view of an alignment unit according to an embodiment of the invention.

Figure 3 shows a schematic view of a dividing unit according to an embodiment of the invention.

Figure 4 shows a schematic view of a dividing unit according to another embodiment of the invention.

Figure 5 shows a reorientation unit according to an embodiment of the invention.

Figure 6 shows a separation means according to an embodiment of the invention.

In Figure 1 , the general structure of the apparatus and method for processing defective products of a smoking article production process according to an embodiment of the invention is shown. A pre-sorting unit 1 is adapted to process a bulk of defective products of a smoking article production process, and separates smoking articles or semi-finished smoking articles and other substantially cylindrical objects, such as single and multiple filter elements, from other defective products, such as loose smoking material and paper. The smoking articles or semifinished smoking articles may comprise one or several filter elements. The pre-sorting unit 1 may in particular be a sieve, like for example a multilevel sieve, which filters larger and smaller parts, and ensures that only the smoking articles or semi-finished smoking articles and other substantially cylindrical objects are provided to the further downstream alignment unit 2.

In the alignment unit 2, the smoking articles or semi-finished smoking articles and other substantially cylindrical objects are aligned, such that they form a stream of several aligned smoking articles or semi-finished smoking articles and other substantially cylindrical objects. In particular, the alignment unit 2 provides several parallel streams of smoking articles or semifinished smoking articles and other substantially cylindrical objects, wherein streams may either be joined, or may be processed separately. At least one stream of aligned smoking articles or semi-finished smoking articles and other substantially cylindrical objects is provided to a dividing unit 3, wherein smoking articles or semi-finished smoking articles with a filter element in a first orientation and smoking articles or semi-finished smoking articles with a filter element in a second, opposite orientation are separated into different streams. Then, one of the streams is provided to a reorientation unit 4, wherein the smoking articles or semi-finished smoking articles of one of the streams are re-oriented from the first orientation into the second, opposite orientation. The smoking articles or semi-finished smoking articles that were already in the first orientation may bypass the reorientation unit 4. Thus, the at least two streams now comprise smoking articles or semi-finished smoking articles with the same orientation. The streams of the smoking articles or semi-finished smoking articles with the same orientation are then joined and further conveyed to a separation means 5, which is adapted to separate the filter element from the smoking articles or semi-finished smoking articles. Alternatively, the streams may be provided to several separate separation means 5. After the separation means 5, the smoking articles or semi-finished smoking articles are provided to an opening means 6, which opens the smoking articles or semi-finished smoking articles to obtain the smoking material comprised therein for further processing. In particular, the opening means 6 is a ripping equipment, which rips open the smoking articles or semi-finished smoking articles, which are in particular tobacco rods comprised in cigarette paper. Such ripping equipment is already known in the art.

Then, the smoking material and the opened wrapper are provided to a post-sorting unit 7, in which the wrapper, in particular cigarette paper, is separated from the smoking material, in particular tobacco. The smoking material can then be further processed in a smoking article manufacturing process.

In Figure 2, the alignment unit 2 is shown in detail. The alignment unit 2 comprises a first set 8 of alignment grooves, a second set 9 of alignment grooves, a third set 10 of alignment grooves and a fourth set 11 of alignment grooves. The different sets 8, 9, 10, 11 of alignment grooves are arranged subsequently in the stream direction 100 of the smoking articles 12 or semi-finished smoking articles 12 which are conveyed and aligned in the alignment unit 2. Preferably, each of the sets 8, 9, 10, 1 1 of alignment grooves is inclined downwards in the stream direction to enable the conveying of the smoking articles or semi-finished smoking articles 12. Furthermore, the sets 8, 9, 10, 11 of the alignment grooves may be agitated by means of a motorized cam such that the sets 8, 9, 10, 11 are vibrated, which enables the movement of the smoking articles or semi-finished smoking articles 12 on the inclined slopes provided by the individual grooves in the sets 8, 9, 10, 1 1. In particular, the sets 8, 9, 10, 1 1 may be formed by metal. The grooves provided in the sets 8, 9, 10, 11 are preferably v-shaped, wherein in some embodiments u-shaped grooves are possible as well. In particular, each downstream set of alignment grooves comprises double the number of alignment grooves than the respective next upstream set of alignment grooves. Further, the peaks and the lowest points of the upstream alignment grooves are arranged substantially above the peaks of the next downstream alignment grooves. Thus, the smoking articles or semi-finished smoking articles 12 comprised in one of the alignment grooves of an upstream set of alignment grooves fall with a probability of about 50 percent into either of the two alignment grooves of the subsequent downstream set of alignment grooves which are arranged beneath the upstream alignment groove. Thus, the smoking articles or semi-finished smoking articles 12 of one upstream alignment grooves are distributed substantially evenly into two downstream alignment grooves.

The first set 8 comprises two alignment grooves, the second set 9 comprises four alignment grooves, the third set 10 comprises eight alignment grooves and the fourth set 11 comprises sixteen alignment grooves.

In Figure 3, the dividing unit 3 is shown in a schematic view. Smoking articles or semifinished smoking articles 12 with filter elements 13 are provided in an aligned stream from the alignment unit 2 to the dividing unit 3. The filter elements 13 constitute a smoking article section of the smoking article or semi-finished smoking article 12, while another smoking article section is in particular a smoking material rod. Furthermore, other substantially cylindrical objects, such as smoking articles or semi-finished smoking articles without filter elements, and single filters may be provided in the same stream to the dividing unit 3. The smoking articles or semi-finished smoking articles 12 are conveyed in the stream direction 100 and pass a sensor 14, which determines if the smoking articles or semi-finished smoking articles 12 are provided with the filter element 13 in a first orientation, or in a second, opposite orientation. The orientation of the smoking article or semi-finished smoking article constitutes a configuration of smoking article sections. Depending on the orientation of the filter element 13 in the smoking article or semifinished smoking article 12, an actuation means 15, which comprises a mechanical gate 16, controls the flow of the smoking articles or semi-finished smoking articles in either a first channel 17 or a second channel 18. The mechanical gate 16 is pneumatically actuated by means of the actuation means 15. In particular, the mechanical gate 16 is held in the diverted position as shown by dashed lines in Figure 3 by means of a spring. When the mechanical gate 16 is pneumatically actuated, it is substantially parallel to the stream direction 100 of the smoking articles or semi-finished smoking articles 12. It is emphasized, that more than two different output channels 17, 18 can be provided, in particular if other material than the smoking articles or semi-finished smoking articles 12 with a filter element 13 is provided to the dividing unit 3. In particular, a third channel may be provided, which is adapted to receive all defective products which are not smoking articles or semi-finished smoking articles with a filter element, such as smoking articles or semi-finished smoking articles with several filter elements, single filter elements, and smoking articles or semi-finished smoking articles without filter elements.

In Figure 4 another embodiment of the dividing unit 3 is shown, which corresponds to the dividing unit 3 according to Figure 3 apart from the actuation means 15, which comprises a nozzle 19, which applies pressurized air to predetermined smoking articles or semi-finished smoking articles 12, to enable that they are conveyed to channel 18 instead of channel 17. Thus, the actuation means 15 with the nozzle 19 enables a dividing of smoking articles or semifinished smoking articles 12 into different channels 17, 18 as well.

In Figure 5, the reorientation unit 4 is shown in a side view. The reorientation unit 4 comprises an inlet channel 20 through which smoking articles or semi-finished smoking articles 12 from one of the channels 17, 18 from the dividing unit 3 are provided. Further, the reorientation unit 4 comprises an outlet channel 21 through which the smoking articles or semifinished smoking articles 12 leave the reorientation unit 4. The inlet channel 20 is slightly curved and leads the smoking articles or semi-finished smoking articles 12 towards a stop 22 in the form of a protruding wall. The downstream end of the smoking article or semi-finished smoking article 12 engages with the protruding wall, while the remaining smoking article or semi-finished smoking article 12 is free to rotate in a free turning area 23. Thus, by means of the stop 22, a rotational movement under the influence of gravity is initiated for the smoking article or semifinished smoking article 12 which freely falls in the free turning area 23 while rotating, until the smoking article or semi-finished smoking article 12 is caught by a curved slope 24, which guides the smoking article or semi-finished smoking article 12 into the outlet channel 21. In particular, the smoking article or semi-finished smoking article 12 enters the reorientation unit 4 with its filter element 13 provided at the downstream end, such that the filter element 13 contacts the stop 22 first. This provides the benefit, that less smoking material is lost from the smoking article or semi-finished smoking article, as the filter element 13 closes the side of the smoking article or semi-finished smoking article 12, which contacts the stop 22.

Thus, while the smoking articles or semi-finished smoking articles 12 enter the reorientation unit 4 with the filter element 13 at their downstream end, they leave the reorientation unit 4 with the filter element 13 at their upstream end. Thus, the orientation of the smoking articles or semi-finished smoking articles 12 is changed. After the reorientation unit 4, the divided streams of smoking articles or semi-finished smoking articles 12 may be joined and further conveyed to a separation means 5, or they may be separately conveyed to two separate separation means 5.

The separation means 5 is shown in Figure 6. The separation means 5 comprises a rotating drum 25, with a number of seats 26, in particular six seats 26 on its circumference. The seats 26 are adapted to hold the smoking articles or semi-finished smoking articles 12, wherein the smoking articles or semi-finished smoking articles 12 are provided to the seats 26 in such a manner, that their filter elements 13 protrude from the drum 25. The seats 26 are generally v- shaped, and comprise a clamp mechanism in the form of a mechanical holding means 27, which is arranged pivotally around a pivoting axis at the bottom of the seat 26. The holding means 27 is pretensioned in the direction of smoking article or semi-finished smoking article 12. In particular, the holding means 27 is pretensioned by a spring 28. Before the smoking article or semi-finished smoking article 12 is provided to the seat, the holding means 27 is in an open position. When the smoking article or semi-finished smoking article 12 enters the seat 26, a release mechanism releases the holding means 27, such that it moves by means of the spring towards the smoking article or semi-finished smoking article 12 and holds the smoking article or semi-finished smoking article against a wall of the seat 26. The release mechanism may be provided by a cam surface. In particular, the drum 25 rotates in the clockwise direction in the rotation direction 200, wherein the holding means 27 is pretensioned in the opposite direction. Preferably, the smoking articles or semi-finished smoking articles are provided in substantially the uppermost position of the drum 25 into the seat 26. The drum 25 rotates with the smoking article or semi-finished smoking article 12 held by the holding means 27 in the seat 26 until a paddle 30, which rotates in the same direction as the drum 25, knocks off the filter element 13 of the smoking article or semi-finished smoking article 12. In particular, the paddle 30 has a rotation axis which is parallel to the rotation axis of the drum 25. Preferably, the paddle 30 is synchronized in its movement to the drum, such that it engages each of the filter elements 13 of the smoking articles or semi-finished smoking articles 12 in the same position. In particular, the engagement in between the filter elements 13 and the paddle 30 is effected, while the paddle 30 is in its closest position to the drum 25. Preferably, the paddle 30 has only a small distance to the drum 25, for example between about 0.2 mm and about 1 mm, when engaging the filter element 13. The knocked off filter elements 13 are then collected, preferably by a vacuum suction device. The smoking articles or semi-finished smoking articles 12 without filter element 13 are further rotated on the drum 25, until the holding means 27 of the seat 26 is opened, and the smoking articles or semi-finished smoking articles 12 are further conveyed. In particular, the smoking articles or semi-finished smoking articles 12 may fall under the influence of gravity out of the drum 25, when the holding means 27 is opened.

Then, the smoking articles or semi-finished smoking articles 2 may be provided to an opening means 6, which cuts open the smoking article or semi-finished smoking article 12, and a post-sorting unit 7, which separates the smoking material from remaining parts, such as cigarette paper, of the smoking articles or semi-finished smoking articles 12.

Claims

1. Apparatus for deconstructing smoking articles or semi-finished smoking articles, wherein the smoking articles or semi-finished smoking articles comprise a combination of smoking article sections, the apparatus comprising

- a dividing unit, wherein the dividing unit is adapted to create a stream comprising smoking articles or semi-finished smoking articles with a pre-determined configuration of smoking article sections from a stream of smoking articles or semi-finished smoking articles comprising a variety of configurations of smoking article sections, wherein the dividing unit comprises at least one sensor, wherein the sensor is adapted to detect the pre-determined configuration of smoking article sections in a smoking article or semi-finished smoking article, an actuation means, wherein the actuation means is adapted to change the path of an individual smoking article or semi-finished smoking article, and a control unit, wherein the control unit is adapted to actuate the actuation means in response to a sensor signal, and

- a further processing means for further processing the individual streams of smoking articles or semi-finished smoking articles, wherein the further processing means comprises a reorientation unit, wherein the reorientation unit is adapted to change the orientation of smoking articles or semi-finished smoking articles with a pre-determined configuration of smoking article sections in at least one of the individual streams from a first orientation into a second, opposite orientation.

2. Apparatus according to claim 1 , wherein the further processing means comprises a separation means which is adapted to separate at least one smoking article section from a smoking article or semi-finished smoking article.

3. Apparatus according to claim 2, wherein the separation means comprises a drum, wherein the drum comprises a number of seats on the circumference of the drum, wherein the seats are adapted to hold a smoking article or semi-finished smoking article such that a filter element, where present, protrudes over the outer perimeter of the drum, where the separation means further comprises a paddle that is adapted to remove the protruding filter element from the smoking article or semi-finished smoking article.

4. Apparatus according to claim 3, wherein a clamp mechanism is provided in the seats of the drum, the clamp mechanism being adapted to be actuated when the smoking article or semifinished smoking article reaches the bottom of the seat, such as to clamp the smoking article or semi-finished smoking article.

5. Apparatus according to claim 3 or 4, wherein the further processing means comprises an opening means, wherein the opening means is adapted to open the smoking article or semifinished smoking article after the smoking article section has been separated from the smoking article or semi-finished smoking article.

6. Apparatus according to claim 1 , wherein the reorientation unit comprises a stop against which the smoking articles or semi-finished smoking articles are conveyable and wherein the reorientation unit further comprises a free turning area, wherein smoking articles or semi-finished smoking articles that are conveyed against the stop can freely turn around an axis perpendicular to their longitudinal extension.

7. Apparatus according to any preceding claim, further comprising a stream changing unit, wherein the stream changing unit is adapted to change the stream of smoking articles or semifinished smoking articles from a longitudinally oriented stream, where the direction of travel of the smoking articles or semi-finished smoking articles is substantially along the longitudinal axis of the smoking articles or semi-finished smoking articles, into a transversely oriented stream, where the direction of travel of the smoking articles or semi-finished smoking articles is substantially perpendicular to the longitudinal axis of the smoking articles or semi-finished smoking articles, or vice versa.

8. Apparatus according to any preceding claim, further comprising a post-sorting unit, wherein the post-sorting unit is adapted to sort smoking article elements.

9. Apparatus according to any preceding claim, wherein the apparatus further comprises an alignment unit, wherein the alignment unit comprises a cascade of at least a first set of alignment grooves and a second set of alignment grooves, wherein the first set of alignment grooves is located upstream of the second set of alignment grooves, and where the number of alignment grooves in the second set of alignment grooves is at least double the number of alignment grooves in the first set of alignment grooves.

10. Method for deconstructing smoking articles or semi-finished smoking articles, wherein the smoking articles or semi-finished smoking articles comprise a combination of smoking article sections, comprising:

i) creating a stream of smoking articles or semi-finished smoking articles; and ii) dividing the stream comprising smoking articles or semi-finished smoking articles at least into a stream of smoking articles or semi-finished smoking articles with a pre-determined configuration of smoking article sections from a stream of smoking articles or semi-finished smoking articles comprising a variety of configurations of smoking article sections, and iii) further processing the individual streams of smoking articles or semi-finished smoking articles, comprising changing the orientation of smoking articles or semi-finished smoking articles with a pre-determined configuration of smoking article sections in at least one stream from a first orientation into a second, opposite orientation.

11. The method according to claim 10, further comprising the step of

iv) separating at least one smoking article section from the smoking articles or semi-finished smoking articles.

12. Method according to claim 11 , further comprising the steps:

v) opening the smoking articles or semi-finished smoking articles after the at least one smoking article section has been separated from the smoking articles or semi-finished smoking articles, and

vi) separating the smoking material from the smoking articles or semi-finished smoking articles.