EP3490891B1 - Method and apparatus for manufacturing a liquid-filled capsule - Google Patents
Method and apparatus for manufacturing a liquid-filled capsule Download PDFInfo
- Publication number
- EP3490891B1 EP3490891B1 EP17742264.9A EP17742264A EP3490891B1 EP 3490891 B1 EP3490891 B1 EP 3490891B1 EP 17742264 A EP17742264 A EP 17742264A EP 3490891 B1 EP3490891 B1 EP 3490891B1
- Authority
- EP
- European Patent Office
- Prior art keywords
- capsule
- shell
- liquid
- sheet material
- open end
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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Links
- 239000002775 capsule Substances 0.000 title claims description 136
- 239000007788 liquid Substances 0.000 title claims description 72
- 238000004519 manufacturing process Methods 0.000 title claims description 28
- 238000000034 method Methods 0.000 title claims description 22
- 239000000463 material Substances 0.000 claims description 43
- 238000011049 filling Methods 0.000 claims description 38
- 238000007789 sealing Methods 0.000 claims description 24
- 230000002950 deficient Effects 0.000 claims description 23
- 238000005520 cutting process Methods 0.000 claims description 16
- 230000000391 smoking effect Effects 0.000 claims description 15
- 230000007547 defect Effects 0.000 claims description 6
- 239000012530 fluid Substances 0.000 claims description 2
- 235000019504 cigarettes Nutrition 0.000 description 8
- 238000007689 inspection Methods 0.000 description 8
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 6
- 239000000126 substance Substances 0.000 description 5
- 241000208125 Nicotiana Species 0.000 description 4
- 235000002637 Nicotiana tabacum Nutrition 0.000 description 4
- 239000008213 purified water Substances 0.000 description 3
- 230000032258 transport Effects 0.000 description 3
- 239000004698 Polyethylene Substances 0.000 description 2
- 239000000796 flavoring agent Substances 0.000 description 2
- 235000019634 flavors Nutrition 0.000 description 2
- 230000014509 gene expression Effects 0.000 description 2
- 239000002650 laminated plastic Substances 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 238000000465 moulding Methods 0.000 description 2
- 230000003287 optical effect Effects 0.000 description 2
- 239000008188 pellet Substances 0.000 description 2
- 238000007493 shaping process Methods 0.000 description 2
- 239000000779 smoke Substances 0.000 description 2
- VGGSQFUCUMXWEO-UHFFFAOYSA-N Ethene Chemical compound C=C VGGSQFUCUMXWEO-UHFFFAOYSA-N 0.000 description 1
- 229920002301 cellulose acetate Polymers 0.000 description 1
- 230000001010 compromised effect Effects 0.000 description 1
- 230000001419 dependent effect Effects 0.000 description 1
- 238000010586 diagram Methods 0.000 description 1
- 238000007599 discharging Methods 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 229920001684 low density polyethylene Polymers 0.000 description 1
- 239000004702 low-density polyethylene Substances 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 230000005499 meniscus Effects 0.000 description 1
- 230000002093 peripheral effect Effects 0.000 description 1
- 239000002861 polymer material Substances 0.000 description 1
- 238000004064 recycling Methods 0.000 description 1
- 230000000717 retained effect Effects 0.000 description 1
- 230000001953 sensory effect Effects 0.000 description 1
- 239000002699 waste material Substances 0.000 description 1
- 238000004804 winding Methods 0.000 description 1
Images
Classifications
-
- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
- A24D3/00—Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
- A24D3/06—Use of materials for tobacco smoke filters
- A24D3/061—Use of materials for tobacco smoke filters containing additives entrapped within capsules, sponge-like material or the like, for further release upon smoking
-
- A—HUMAN NECESSITIES
- A24—TOBACCO; CIGARS; CIGARETTES; SIMULATED SMOKING DEVICES; SMOKERS' REQUISITES
- A24D—CIGARS; CIGARETTES; TOBACCO SMOKE FILTERS; MOUTHPIECES FOR CIGARS OR CIGARETTES; MANUFACTURE OF TOBACCO SMOKE FILTERS OR MOUTHPIECES
- A24D3/00—Tobacco smoke filters, e.g. filter-tips, filtering inserts; Filters specially adapted for simulated smoking devices; Mouthpieces for cigars or cigarettes
- A24D3/04—Tobacco smoke filters characterised by their shape or structure
- A24D3/048—Tobacco smoke filters characterised by their shape or structure containing additives
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B3/00—Packaging plastic material, semiliquids, liquids or mixed solids and liquids, in individual containers or receptacles, e.g. bags, sacks, boxes, cartons, cans, or jars
- B65B3/003—Filling medical containers such as ampoules, vials, syringes or the like
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B3/00—Packaging plastic material, semiliquids, liquids or mixed solids and liquids, in individual containers or receptacles, e.g. bags, sacks, boxes, cartons, cans, or jars
- B65B3/04—Methods of, or means for, filling the material into the containers or receptacles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B43/00—Forming, feeding, opening or setting-up containers or receptacles in association with packaging
- B65B43/42—Feeding or positioning bags, boxes, or cartons in the distended, opened, or set-up state; Feeding preformed rigid containers, e.g. tins, capsules, glass tubes, glasses, to the packaging position; Locating containers or receptacles at the filling position; Supporting containers or receptacles during the filling operation
- B65B43/54—Means for supporting containers or receptacles during the filling operation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B57/00—Automatic control, checking, warning, or safety devices
- B65B57/10—Automatic control, checking, warning, or safety devices responsive to absence, presence, abnormal feed, or misplacement of articles or materials to be packaged
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
- B65B—MACHINES, APPARATUS OR DEVICES FOR, OR METHODS OF, PACKAGING ARTICLES OR MATERIALS; UNPACKING
- B65B7/00—Closing containers or receptacles after filling
- B65B7/16—Closing semi-rigid or rigid containers or receptacles not deformed by, or not taking-up shape of, contents, e.g. boxes or cartons
- B65B7/162—Closing semi-rigid or rigid containers or receptacles not deformed by, or not taking-up shape of, contents, e.g. boxes or cartons by feeding web material to securing means
- B65B7/164—Securing by heat-sealing
Definitions
- the step of dispensing the volume of liquid into the shell comprises providing the capsule with a filling ratio above a predetermined minimum, and preferably within a pre-defined range.
- the filling ratio of the capsule is a ratio of the volume of liquid dispensed to a filling capacity of the cavity.
- the predetermined minimum of the filling ratio is preferably 0.5.
- the pre-defined range of the filling ratio is preferably from 0.5 to 0.9, more preferably from 0.75 to 0.9, and most preferably 0.8 to 0.9. A filling ratio of 0.88 has been found to provide exceptionally good production and performance characteristics of the capsule.
- the pre-defined space or clearance is at least 0.4 mm, more preferably at least 0.6 mm, particularly preferably at least 0.8 mm.
- the sealing station comprises a supply roll of the sheet material, a heat-sealing device for fusing the sheet material to a rim at the open end of each capsule, and/or a cutting device for cutting excess sheet material from the rim at the end of each capsule.
- the sheet material is preferably drawn from the supply roll by a feed roller.
- the cutting device is preferably configured to cut the excess sheet material and to contour or shape the rim at the end of each capsule.
- the apparatus further comprises a rejecting station at which a defective capsule is removed.
- a conveyor arm (not shown) picks up the tray 10 and conveys it to a shell inspection station 2.
- the conveyor arm moves or transports the tray 10 while maintaining the positioning reference of the individual shells 101.
- the height and diameter of each shell 101 is measured, preferably optically measured by means of an optical measuring device, such as a camera. If the measured height and/or the measured diameter of any one of the shells 101 deviate(s) from a target value such that it is not within an established or predetermined tolerance band, that shell 101 is then identified as defective. This is an optional inspection step that can also be omitted without departing from the invention.
- the shells 101 are desirably supported and held on the tray 10 such that the open ends 105 of the shells 101 face upwards towards the nozzles, which fill the shells 101 from above.
- the turntable C is rotated (in the clockwise direction, as shown in Fig. 4 ) to move the tray 10 to a sealing station 4 where a sheet material is provided to cover and seal all of the open ends 105 of the shells 101.
- the sheet material is typically supplied or fed from a supply roll, preferably via a feed roller (not shown), such that the open ends 105 of all the shells 101 are covered simultaneously.
- the sheet material is heat-sealed to the rim 107 of each shell 101.
Landscapes
- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Chemical & Material Sciences (AREA)
- Materials Engineering (AREA)
- Basic Packing Technique (AREA)
- Closing Of Containers (AREA)
- Auxiliary Devices For And Details Of Packaging Control (AREA)
- Cigarettes, Filters, And Manufacturing Of Filters (AREA)
- Manufacturing Of Micro-Capsules (AREA)
- Medical Preparation Storing Or Oral Administration Devices (AREA)
Description
- The present invention relates to a method and an apparatus for manufacturing a liquid-filled breakable capsule for use in a smoking article, such as a cigarette or the like.
- Smoking articles, such as cigarettes or the like, are popular consumer products that typically have a generally cylindrical rod shaped configuration and include a charge, roll, or column of a smokable material, such as shredded tobacco (e.g. in cut filler form), surrounded by a paper wrapper forming a so-called "tobacco rod". A cigarette will also usually have a cylindrical filter element aligned in end-to-end relationship with the tobacco rod. The filter element may, for example, comprise cellulose acetate tow, and the tow is circumscribed by a paper material known as "plug wrap". Typically, the filter element is attached to one end of the tobacco rod using a circumscribing wrapping material known as "tipping paper".
- In recent years there has been increasing consumer demand for smoking articles providing modified sensory attributes, and particularly for cigarettes incorporating filter elements which may act as vehicles for adding flavour to mainstream smoke of the cigarettes. Specifically, these smoking articles have included flavour-altering substances in breakable pellets or capsules. During cigarette manufacture, the filter material is formed into a continuous filter rod having such pellets or capsules positioned within that rod; e.g., along a longitudinal axis thereof. The continuous filter rod is then divided or cut at predetermined intervals to form a plurality of filter elements, such that each filter element includes at least one of the capsules. The capsules are then manually broken by the consumer to release a substance into the filter material which, in turn, may act to alter the flavour or taste of the mainstream smoke during smoking.
- For this purpose, a breakable capsule having a shell or casing containing a liquid is used. The shell or casing defines a cavity for receiving and holding the liquid and includes an open end, which is typically sealed or covered with a cap. The casing or shell may include a predefined rupture region such that, when the consumer applies pressure to the capsule, the casing or shell breaks preferentially in the rupture region. In this manner, it is possible to control release of the liquid to ensure that it is directed to a desired area.
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Japanese unexamined patent application published as JP H 05-330503 Figure 4 of that Japanese patent application (included asFig. 1 of the present application), a tray feed zone B supplies atray 3 upon which a plurality ofcapsule shells 2 are arranged and positioned under asheet 1 fed or supplied from a sheet feed zone A. A heat seal apparatus C hot welds thesheet 1 to each of theshells 2 on thetray 3 and a cross-feed device D cuts thesheet 1 welded to each of theshells 2 to form a square cover on eachshell 2. Top-cover wrap equipment E then bends an edge region of the cover to an outer peripheral surface of the shell. A discharge device G discharges thetray 3 with the finished capsules and a sheet winding portion F winds up remainingsheet 1 from which the covers were cut. - It has been found that the known techniques for manufacturing such liquid-filled capsules produce an excessive number of capsules which do not meet the desired operating or use requirements; for example, with respect to the amount of liquid contained within the capsule and/or the sealing efficacy. It is therefore an object of the invention to provide an improved method and apparatus for manufacturing a liquid-filled capsule for use in a smoking article. In particular, it is an object of the invention to increase a yield of the manufacturing process for this type of capsule with adequate capsule filling and/or sealing.
- In accordance with this invention, a method and an apparatus for manufacturing a liquid-filled capsule for use in a smoking article is provided having the features as recited in
claim 1 and claim 9, respectively. Advantageous or preferred features of the invention are recited in the dependent claims. - In this regard, the inventors have ascertained that the amount of liquid within the cavity has a significant impact or influence upon the production and performance characteristics of the capsule. For example, the ability to seal the open end of the shell can be compromised, especially when the speed of the production process is increased. On the one hand, if the filling ratio of the capsule is less than a pre-defined threshold value, the capsule will generally not contain sufficient liquid and a consumer may experience an unsatisfactory smoking experience. On the other hand, if the space or clearance between the open end of the shell and the liquid is less than a predefined threshold value, the capsule may not seal properly and may leak in situ before the smoking article reaches a consumer.
- It will be noted that the term "filling ratio" as used herein refers to a ratio of volume of liquid contained in the capsule to a filling capacity of the capsule cavity. It will also be noted that the term "filling capacity" as used herein refers to a nominal value of the volume of the cavity defined by the shell and not to a real value of the volume of the cavity that takes into account accepted manufacturing tolerances.
- In a preferred embodiment, the space or clearance is a linear dimension measured from an upper surface of the liquid dispensed into the cavity and the open end of the capsule shell. That is, the clearance is typically measured between the upper surface of the liquid and a rim or an edge of the open end of the shell. In this regard, it will be appreciated that this measurement is typically performed with the capsule positioned in an upright orientation; that is, with the sealed open end (i.e. the filling end) of the capsule facing upwards. The space or clearance is preferably at least 0.4 mm, but is more preferably at least 0.6 mm, and further preferably at least 0.8 mm.
- The clearance may be measured, for example, using a laser measuring device that makes two relative distance measurements from a reference position. In this regard, a first relative distance corresponds to a distance between the sealed end (excluding a thickness of the sealing sheet or "cap") and the reference position, while a second relative distance corresponds to a distance between the upper surface of the liquid and the reference position. The clearance is then calculated as the absolute value of the subtraction of the first and second relative distances.
- In a preferred embodiment, the liquid dispensed may comprise purified water or a water-based liquid which contains a dissolved or suspended flavouring substance. Such a liquid typically generates a negative meniscus and, thus, the upper surface of the liquid would be located at a position where the liquid in the cavity contacts a side wall of the shell.
- In a preferred embodiment, the step of dispensing the volume of liquid into the shell comprises providing the capsule with a filling ratio above a predetermined minimum, and preferably within a pre-defined range. As noted above, the filling ratio of the capsule is a ratio of the volume of liquid dispensed to a filling capacity of the cavity. The predetermined minimum of the filling ratio is preferably 0.5. The pre-defined range of the filling ratio is preferably from 0.5 to 0.9, more preferably from 0.75 to 0.9, and most preferably 0.8 to 0.9. A filling ratio of 0.88 has been found to provide exceptionally good production and performance characteristics of the capsule.
- In a preferred embodiment, the step of sealing the open end of the shell includes: covering the open end of the capsule shell with a section of the sheet material; fusing or bonding the section of sheet material to seal said end of the shell; and cutting excess sheet material from the section of sheet material at the sealed end of the shell, especially from a rim. Preferably, the step of sealing the open end of the shell comprises substantially contouring or shaping the end of the shell during cutting of the excess sheet material from the sealed end of the shell. The cover or closure formed by the sheet material over the end of the shell may be referred to as a cap. The sheet material is cut with a rotary blade cutter due to the relatively small size of the capsules, which typically have a diameter in the range of between 2.5 mm and 8.0 mm. Alternatively, however, a laser or a punch may be used to cut the sheet material.
- In a preferred embodiment, the method further comprises the steps of: inspecting the liquid-filled capsule or a component thereof (e.g. the capsule shell, the cover, or the liquid contained in the shell) for a manufacturing defect; and identifying the capsule as defective if a manufacturing defect is detected. Possible manufacturing defects may, for example, include a deviation or discrepancy in shell dimensions, a misalignment of the cover and shell, a deviation or discrepancy in the capsule dimensions, and/or liquid leakage. The term "manufacturing defect" used herein is understood as an unacceptable deviation or discrepancy from a target or desired manufacturing parameter, i.e. outside a predetermined tolerance band. Preferably, the method comprises the step of rejecting a capsule which has been identified as defective. In this way, a defective capsule can be ejected or removed from further processing in the production of the smoking articles. This, in turn, avoids wasting manufacturing effort on capsules which are unsatisfactory for use in the smoking article (e.g. which will not operate satisfactorily for a consumer in use) or are likely to break during production of the smoking article (i.e. creating waste and/or soling of equipment).
- In a preferred embodiment, the method comprises the steps of: providing a holding device to hold the capsule shell; and conveying the holding device together with the capsule shell during and/or between one or more of the steps of: introducing a liquid into the cavity, sealing the open end of the shell, inspecting the capsule or a component thereof, identifying the capsule as defective, and rejecting a capsule identified as defective. In a particularly preferred embodiment, the holding device is configured to hold a plurality of capsule shells. Thus, the holding device may be configured as a tray having a plurality of cells or receptacles, each of which is adapted or designed to hold a respective capsule shell, which is conveyed along or between two or more of the dispensing, sealing, inspecting, identifying and rejecting steps.
- As will be appreciated, the step of dispensing the liquid into the cavity through the open end of the capsule shell involves substantially filling the cavity of the shell with the liquid. In the event that a holding device configured to hold a plurality of capsule shells is employed, the step of dispensing the liquid or of filling the cavity may occur for the plurality capsule shells simultaneously. In this regard, a liquid dispensing device may be employed which is configured to dispense or inject the liquid into a plurality of shell cavities simultaneously.
- In the event that a holding device configured to hold a plurality of capsule shells is employed, in a preferred embodiment the method includes the steps of:
- positioning a plurality of capsule shells on the holding device;
- referencing a position of each individual shell relative to the holding device; and
- conveying the holding device with a position reference conveyor system between at least two steps selected from the steps of: introducing or dispensing a liquid into the cavity, sealing the open end of the shell, inspecting the capsule or a component thereof, identifying the capsule as defective, and rejecting a capsule identified as defective.
- By referencing the position of each individual shell relative to the holding device and conveying the holding device with a position reference conveyor system, the relative position of each individual shell can be known and tracked along a path of the manufacturing process. As a result, when a defective capsule is identified and/or rejected, it is possible to trace the origin of the capsule, thereby reducing maintenance time.
- In the event that a holding device configured to hold a plurality of capsule shells is employed in the method of this invention, the step of sealing the open end of the shell may include: covering the open end of each a plurality of capsule shells with the sheet material; fusing or bonding the sheet material to seal said end of each of the plurality of shells; and cutting excess sheet material from the sheet material at the sealed end of each shell. As noted above, the step of sealing the open end of the shells may comprise substantially contouring or shaping the ends of the shells, which may occur during cutting of the excess sheet material from the sealed ends of the shells.
- As noted above, in a preferred embodiment the pre-defined space or clearance is at least 0.4 mm, more preferably at least 0.6 mm, particularly preferably at least 0.8 mm.
- In a preferred embodiment, the holder for holding the one or more capsule shells comprises a tray having a plurality of cells, each of which is configured to receive and hold a respective capsule shell. The conveyor for moving or transporting the holder may comprise one or more of a conveyor arm, a conveyor belt, and a turntable. The filling station preferably comprises one or more nozzles in fluid connection with a supply reservoir of the liquid. Each nozzle is configured to dispense a predetermined volume of the liquid into a respective one of the shells via an open end of each shell.
- In a preferred embodiment, the sealing station comprises a supply roll of the sheet material, a heat-sealing device for fusing the sheet material to a rim at the open end of each capsule, and/or a cutting device for cutting excess sheet material from the rim at the end of each capsule. The sheet material is preferably drawn from the supply roll by a feed roller. The cutting device is preferably configured to cut the excess sheet material and to contour or shape the rim at the end of each capsule.
- In a preferred embodiment, the apparatus further comprises a discharge conveyor for discharging the capsules from an inspecting station to a delivery station. The discharge conveyor is preferably configured as a vacuum conveyor that suctions or draws (via suction) the capsules from the holder.
- In a preferred embodiment, the apparatus further comprises a rejecting station at which a defective capsule is removed.
- According to a further aspect, the present disclosure provides a liquid-filled capsule for use in a smoking article, the capsule comprising: a capsule shell defining a cavity and having an end with a filling opening; a volume of liquid contained within the cavity; and a cap which covers and seals the filling opening. The capsule has a pre-defined space or clearance provided between an upper surface of the liquid contained in the cavity and the end of the shell.
- In a preferred embodiment, a maximum diameter of the capsule is in the range from 2.5 mm to 8.0 mm, preferably from 3.0 mm to 7.5 mm, more preferably from 3.5 mm to 7.0 mm. In this regard, a maximum capsule diameter at the lower end of the range is naturally preferred for fat slim cigarettes and super slim cigarettes.
- In a preferred embodiment, a height of the capsule is in the range from 3 mm to 17 mm, preferably from 6 mm to 14 mm, further preferably from 8 mm to 12 mm, and particularly preferably from 9 mm to 11 mm.
- In a preferred embodiment, the pre-defined space or clearance is at least 0.4 mm, preferably at least 0.6 mm, more preferably at least 0.8 mm; e.g. about 1.0 mm.
- In a preferred embodiment, a filling ratio of the capsule is above a predetermined minimum, and preferably within a pre-defined range. The predetermined minimum of the filling ratio is 0.5, and the pre-defined range of the filling ratio is from 0.5 to 0.9, preferably from 0.75 to 0.9, and more preferably 0.8 to 0.9. In this regard, the filling capacity of the cavity may be in the range of 50µl to 300µl, preferably in the range of 75µl to 250µl, and optionally in the range of 100µl to 200µl.
- For a more complete understanding of the invention and the advantages thereof, exemplary embodiments of the invention are explained in more detail in the following description with reference to the accompanying drawing figures, in which like reference characters designate like parts and in which:
- Fig. 1
- is a schematic illustration of a known manufacturing method and apparatus from the prior art;
- Fig. 2a
- is a perspective side view of a capsule manufactured according to one preferred embodiment of the invention;
- Fig. 2b
- is a perspective side view of a capsule manufactured according to another preferred embodiment of the invention;
- Fig. 2c
- is a cross-sectional view of a capsule manufactured according to a further preferred embodiment of the invention;
- Fig. 2d
- is a schematic side view of a capsule manufactured according to a preferred embodiment of the invention;
- Fig. 3
- shows a schematic example of a holding device used to convey shells in a manufacturing method and apparatus according to an embodiment of the invention; and
- Fig. 4
- is a diagram schematically illustrating an apparatus for performing a method of manufacturing a capsule according to an embodiment of the invention.
- The accompanying drawings are included to provide a further understanding of the present invention and are incorporated in and constitute a part of this specification. The drawings illustrate particular embodiments of the invention and together with the description serve to explain the principles of the invention. Other embodiments of the invention and many of the attendant advantages of the invention will be readily appreciated as they become better understood with reference to the following detailed description.
- It will be appreciated that common and well understood elements that may be useful or necessary in a commercially feasible embodiment are not necessarily depicted in order to facilitate a more abstracted view of the embodiments. The elements of the drawings are not necessarily illustrated to scale relative to each other. It will further be appreciated that certain actions and/or steps in an embodiment of a method may be described or depicted in a particular order of occurrences while those skilled in the art will understand that such specificity with respect to sequence is not actually required. It will also be understood that the terms and expressions used in the present specification have the ordinary meaning as is accorded to such terms and expressions with respect to their corresponding respective areas of inquiry and study, except where specific meanings have otherwise been set forth herein.
- With reference now to
Figs. 2a ,2b, 2c and 2d of the drawings, three embodiments of a liquid-filledbreakable capsule 100 manufactured according to the invention are illustrated. In each case, thecapsule 100 comprises an open-endedshell 101 which is closed and sealed with acap 102. Theshell 101 has a side wall orlateral wall 103 that extends from anend wall 104 to anopen end 105 and thus surrounds or defines acavity 106 in theshell 101. Preferably, thelateral wall 103 ends in arim 107 at theopen end 105 to facilitate application of thecap 102. Thelateral wall 103 may be generally cylindrical (cf.Figs. 2a and2c ) or may be faceted (cf.Fig. 2b ). The side orlateral wall 103 may taper or narrow from theopen end 105 towards theend wall 104. - The
end wall 104 of eachshell 101 may include one or more lines of weakness or one or morestress concentrator elements 108 to create a weakened region, in which theshell 101 is configured to break preferentially upon application of a compressive force to its side wall orlateral wall 103. In other words, theshell 101 includes a predefined rupture region such that, when the consumer compresses the sides of thecapsule 100, theshell 101 will break preferentially in the rupture region. Theshell 101 is typically made from a resiliently deformable material, such as a polymer material. Thecap 102 is typically formed and cut from a section or an expanse of sheet material, such as a laminated plastic sheet material. The liquid L in the capsule may comprise purified water or a water-based liquid which contains a dissolved or suspended flavouring substance. As shown schematically inFig. 2d , a volume of liquid L dispensed into thecavity 106 through theopen end 105 of eachshell 101 is selected to provide a pre-defined space or clearance δ between an upper surface of the liquid L and theend 105 of theshell 101. The pre-defined space or clearance δ may, for example, be selected to be in the range of about 0.8 to about 2.0 mm, and preferably in the range of about 0.9 mm to about 1.5 mm. An example of abreakable capsule 100 that can be adequately manufactured with the method of the invention comprises ashell 101 made of LDPE and acap 102 made of a plastic laminate having a layer of PE and a layer of PET, where the PE layer is the layer that is in contact with therim 107 of theshell 101 in thefinished capsule 100. The thickness of such a laminate layer is typically about 0.05 mm; i.e. 50 µm. The liquid dispensed into thecapsule 100 comprises purified water with a flavouring substance. - The target height of the
shell 101 is 10.0 mm and the target outer diameter of theshell 106 is 6.28 mm. Such ashell 101 has a filling capacity of 131 µl. The target height of thecapsule 100 is 10.0 mm, whereas the target outer diameter of theshell 101 is 6.70mm. The target volume of retained liquid is 115µl and the target weight of the capsule 100 (shell 101,cap 102, and water) is 195 mg. In this case, thisexemplary capsule 100 has a clearance δ of about 0.95 mm and a filling ratio of about 0.88. - With reference now to
Fig. 3 and Fig. 4 of the drawings, an embodiment of the method and apparatus of the invention will be described. Theshells 101 may be moulded, preferably injection-moulded, in amoulding station 1 with a pair of dies (not shown) configured to produce a batch ofshells 101. Theshells 101 are then positioned on atray 10 having a plurality ofcells 11 configured to receive and hold theshells 101, preferably arranged in an array. Thecells 11 are referenced such that their position within thetray 10 is known. As a result, eachindividual shell 101 has a known position within thetray 10. Thetray 10 may have capacity for holding one or more batches of multiple mouldedshells 101. - Once the
tray 10 is fully loaded withshells 101, a conveyor arm (not shown) picks up thetray 10 and conveys it to ashell inspection station 2. The conveyor arm moves or transports thetray 10 while maintaining the positioning reference of theindividual shells 101. At theshell inspection station 2, the height and diameter of eachshell 101 is measured, preferably optically measured by means of an optical measuring device, such as a camera. If the measured height and/or the measured diameter of any one of theshells 101 deviate(s) from a target value such that it is not within an established or predetermined tolerance band, thatshell 101 is then identified as defective. This is an optional inspection step that can also be omitted without departing from the invention. - Thereafter, the conveyor arm again picks up the
tray 10 holding theshells 101 and conveys or transports it to afilling station 3 located on a turntable C. As before, the conveyor arm conveys thetray 10 while maintaining the positioning reference of theindividual shells 101. The fillingstation 3 includes a liquid reservoir connected to a plurality of nozzles, which are configured and arranged to dispense the liquid into thecavities 106 of all theshells 101 on the tray substantially simultaneously. As an alternative, however, the fillingstation 3 could include a reduced number of nozzles configured and arranged to dispense to, and to fill, only a selection of theshells 101 at any given time. Each of the nozzles is adapted to dispense a volume of liquid to fill therespective shell cavity 106. In this connection, theshells 101 are desirably supported and held on thetray 10 such that the open ends 105 of theshells 101 face upwards towards the nozzles, which fill theshells 101 from above. After theshell cavities 106 have been filled with the liquid at fillingstation 3, the turntable C is rotated (in the clockwise direction, as shown inFig. 4 ) to move thetray 10 to a sealing station 4 where a sheet material is provided to cover and seal all of the open ends 105 of theshells 101. The sheet material is typically supplied or fed from a supply roll, preferably via a feed roller (not shown), such that the open ends 105 of all theshells 101 are covered simultaneously. Next, the sheet material is heat-sealed to therim 107 of eachshell 101. - The turntable C is then rotated further (in the clockwise direction, shown in
Fig. 4 ) to move thetray 10 to a cuttingstation 5 where the sheet material sealed over the now covered ends 105 of theshells 101 is cut around eachrim 107 to form anindividual cap 102 on eachcapsule 100. The cuttingstation 5 includes a rotary blade cutter (not shown), which may be embodied as a roller having blades shaped to contour the shell rims 107. In this way, a batch of liquid-filledbreakable capsules 100 is obtained at this stage, with eachcapsule 100 containing a volume of dispensed liquid. - Further rotation of the turning table C (in the clockwise direction, shown in
Fig. 4 ) causes thetray 10, now containing a batch of liquid-filledbreakable capsules 100, to rotate to acapsule inspection station 6. Here the height and diameter of eachcapsule 100 is measured or assessed. Additionally, any misalignment of thecap 102 to theshell 101 can be measured. It is also possible to inspect an aspect of the liquid L at thecapsule inspection station 6, especially an opacity of the liquid L. These parameters are desirably measured optically, e.g. via an optical measuring device, such as a camera. If any of the measured parameters of aspecific capsule 100 is determined to deviate from a target value such that it is not within a specific predetermined tolerance band, thatcapsule 100 is identified as defective. - The turning table C is then rotated further (in the clockwise direction in
Fig. 4 ) to move thetray 10 to a rejectingstation 7 at which any defective capsules are able to be rejected and removed. In this regard,defective capsules 100 may preferably be ejected from thetray 10 by a jet of compressed air. Thedefective capsules 100 removed or ejected may be collected for disposal or recycling. - In an alternative embodiment, a vacuum discharge conveyor (not shown) may be employed to remove a batch of the liquid-filled
breakable capsules 100 from thetray 10 by applying a suction force and to convey them to a discharge area. During this transport of thecapsules 100, any defective capsules may be ejected from the batch by discontinuing the suction force exerted on thedefective capsules 100, thus allowing them to drop from the conveyor at a rejection station. - Instead of employing a turn-table in this embodiment, it will be appreciated that the filling, sealing, cutting, inspection and rejecting stations could be provided along a belt-type conveyor without departing from the invention.
- Although specific embodiments of the invention have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and/or equivalent implementations exist. It should be appreciated that the exemplary embodiment or exemplary embodiments are only examples, and are not intended to limit the scope, applicability, or configuration in any way. Rather, the foregoing summary and detailed description will provide those skilled in the art with a convenient road map for implementing at least one exemplary embodiment, it being understood that various changes may be made in the function and arrangement of elements described in an exemplary embodiment without departing from the scope as set forth in the appended claims.
-
- 1
- moulding station
- 2
- shell inspection station
- 3
- filling station
- 4
- sealing station
- 5
- cutting station
- 6
- capsule inspection station
- 7
- rejecting station
- 10
- tray
- 11
- cell
- 100
- capsule
- 101
- shell
- 102
- cap
- 103
- side wall or lateral wall
- 104
- end wall
- 105
- open end
- 106
- cavity
- 107
- rim
- 108
- line of weakness or stress concentrator
- δ
- space or clearance
- L
- liquid
- C
- turntable
Claims (11)
- A method of manufacturing liquid-filled capsules for use in smoking articles, the method comprising the steps of:providing a capsule shell (101) defining a cavity (106) and having an open end (105);dispensing a volume of liquid (L) into the cavity (106) through the open end (105) of the shell (101), whereby a space or clearance (δ) is provided between an upper surface of the liquid (L) dispensed into the cavity (106) and the open end (105) of the shell (101); andsealing the open end (105) of the shell (101) with a portion of sheet material to provide a liquid-filled capsule (100) containing the volume of liquid (L),wherein the step of sealing the open end of the shell comprises:covering the open end (105) of the capsule shell (101) with the portion of sheet material;fusing or bonding the portion of sheet material to a rim of the shell to seal said end (105) of the shell (101); andcontouring the rim of the shell's end with a rotary blade cutter of a cutting device while cutting excess sheet material from the portion of sheet material at the sealed end of the shell (101).
- A method according to claim 1, wherein the clearance (δ) is at least 0.4mm, preferably at least 0.6 mm, and more preferably at least 0.8 mm.
- A method according to claim 1 or claim 2, wherein the step of dispensing the liquid (L) into the shell (101) comprises providing the capsule (100) with a filling ratio above a predetermined minimum, and preferably within a pre-defined range, whereby the filling ratio of the capsule (100) is a ratio of the volume of liquid (L) dispensed to a filling capacity of the cavity (106), and wherein the predetermined minimum of the filling ratio is 0.5, and wherein the pre-defined range of the filling ratio is preferably from 0.5 to 0.9, more preferably from 0.75 to 0.9, and most preferably 0.8 to 0.9.
- A method according to claim 3, wherein the filling ratio is 0.88.
- A method according to any one of the preceding claims, further comprising the steps of:inspecting the liquid-filled capsule (100) or a component thereof for a manufacturing defect;identifying the capsule (100) as defective if a manufacturing defect is detected; andrejecting a capsule (100) identified as defective.
- A method according to any one of the preceding claims, further comprising the steps of:providing a holding device to hold the capsule shell (101); andconveying the holding device together with the capsule shell (101) between at least two steps selected from the steps of: introducing or dispensing a liquid into the cavity (106), sealing the open end (105) of the shell (101), inspecting the capsule (100) or a component thereof, identifying the capsule (100) as defective, and rejecting a capsule (100) identified as defective.
- A method according to claim 6, wherein the holding device is configured to hold a plurality of capsule shells (101) and wherein the method includes the steps of:positioning a plurality of capsule shells (101) on the holding device;referencing a position of each individual shell (101) relative to the holding device; andconveying the holding device with a position reference conveyor system between at least two steps selected from the steps of: introducing or dispensing a liquid into the cavity (106), sealing the open end (105) of the shell (101), inspecting the capsule (100) or a component thereof, identifying the capsule (100) as defective, and rejecting a capsule (100) identified as defective.
- A method according to any one of the preceding claims, wherein the step of sealing the open end (105) of the shell (101) comprises the steps of:covering the open end (105) of each of a plurality of capsule shells (101) with the portion of sheet material;fusing or bonding the portion of sheet material to seal said end (105) of each of the plurality of shells (101); andcutting excess sheet material from the portion of sheet material at the sealed end of each shell (101), preferably substantially contouring the open end (105) of the shell (101).
- An apparatus for manufacturing liquid-filled capsules for use in smoking articles, comprising:a holder for holding one or more capsule shells (101);a conveyor for moving or transporting the holder with the one or more capsule shells (101);a filling station (3) for dispensing a liquid into a cavity (106) of each of the capsule shells (101) held by the holder, wherein the filling station (3) is configured to leave a pre-defined space or clearance (δ) between the liquid dispensed into the cavity (106) and the open end (105) of each shell (101); anda sealing station (4) for covering and sealing an open end (105) of each capsule shell (101) with a sheet material to form a capsule (100),wherein the sealing station (4) comprises: a supply roll of the sheet material, which is preferably driven via a feed roller, a heat-sealing device for fusing the sheet material to a rim (107) at the open end (105) of each shell (101), anda cutting device, comprising a rotary blade cutter, for contouring the rim (107) of each shell (101) while cutting excess sheet material from the rim (107) at the end (105) of each capsule.
- An apparatus according to claim 9, wherein the filling station (3) comprises one or more nozzles in fluid connection with a supply reservoir of the liquid, wherein each nozzle is configured to dispense a predetermined volume of the liquid to a respective one of the shells (101).
- An apparatus according to any of claims 9 to 10, wherein the holder for holding one or more capsule shells (101) comprises a tray (10); and/orwherein the conveyor for moving or transporting the holder comprises one or more of a robotic conveyor arm, a conveyor belt, and a turntable (C); and/orwherein the apparatus further comprises a rejecting station (7) at which any defective capsule (100) is able to be removed.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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PL17742264T PL3490891T3 (en) | 2016-07-27 | 2017-07-26 | Method and apparatus for manufacturing a liquid-filled capsule |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP16181524 | 2016-07-27 | ||
PCT/EP2017/068846 WO2018019868A1 (en) | 2016-07-27 | 2017-07-26 | Method and apparatus for manufacturing a liquid-filled capsule |
Publications (2)
Publication Number | Publication Date |
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EP3490891A1 EP3490891A1 (en) | 2019-06-05 |
EP3490891B1 true EP3490891B1 (en) | 2021-09-15 |
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Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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EP17742264.9A Active EP3490891B1 (en) | 2016-07-27 | 2017-07-26 | Method and apparatus for manufacturing a liquid-filled capsule |
Country Status (11)
Country | Link |
---|---|
US (1) | US20190216128A1 (en) |
EP (1) | EP3490891B1 (en) |
JP (1) | JP7216636B2 (en) |
KR (1) | KR102407787B1 (en) |
CN (1) | CN109476389A (en) |
CA (1) | CA3029166A1 (en) |
EA (1) | EA201990287A1 (en) |
ES (1) | ES2897894T3 (en) |
PL (1) | PL3490891T3 (en) |
TW (1) | TW201803466A (en) |
WO (1) | WO2018019868A1 (en) |
Families Citing this family (5)
Publication number | Priority date | Publication date | Assignee | Title |
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WO2020017971A1 (en) * | 2018-07-19 | 2020-01-23 | Sluis Cigar Machinery B.V. | Processing line comprising processing modules for performing processing operations on a product or part thereof, and simulated smoking device manufacturing line |
CN109292126A (en) * | 2018-11-21 | 2019-02-01 | 苏州英派克自动化设备有限公司 | A kind of cigarette cup-shaped capsule fluid injection packaging system |
GB2587340B (en) * | 2019-09-18 | 2023-07-05 | Alexander Charles Gort Barten | Beverage capsule manufacture |
IT202000016105A1 (en) * | 2020-07-03 | 2022-01-03 | Gd Spa | METHOD OF MAKING A SMOKE CAPSULE, SMOKE CAPSULE, AND USE OF SUCH A CAPSULE IN AN AUTOMATIC MACHINE |
US20230312154A1 (en) * | 2020-08-07 | 2023-10-05 | G.D S.P.A. | Control method in a production process for articles and a production apparatus for articles operating according to this method |
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SE454168B (en) * | 1982-09-27 | 1988-04-11 | Tetra Pak Ab | SET AND DEVICE FOR DOSING OF FILLED GOODS IN THE MANUFACTURE OF PACKAGING CONTAINERS |
SE467001B (en) * | 1990-03-26 | 1992-05-11 | Norden Pac Dev Ab | DEVICE AND PROCEDURES FOR HEAT TRANSMISSION OF A TUBE-PLASTIC PLASTIC PACKAGING |
DE4022793A1 (en) * | 1990-07-18 | 1992-02-06 | Max Planck Gesellschaft | Sealing off reaction tests on sheet - by thermo-forming impressions polycarbonate sheet to contain reactions and welding thinner polycarbonate film over each impression |
JPH05330503A (en) * | 1992-05-29 | 1993-12-14 | Japan Tobacco Inc | Apparatus for heat-sealing upper lid for cylindrical container |
JPH10129605A (en) * | 1996-10-31 | 1998-05-19 | O M Ltd | Continuous type tray seal machine |
US6418982B1 (en) * | 2000-11-21 | 2002-07-16 | Amphastar Pharmaceuticals Inc. | Process of bulk filling |
JP4596411B2 (en) * | 2004-02-09 | 2010-12-08 | 憲司 中村 | Easily destructible capsule and its product |
FR2876986B1 (en) * | 2004-10-25 | 2006-12-29 | Cryolog Sa Sa | METHOD FOR HERMETICALLY AND HIGH-FREQUENCY CONDITIONING, AN ACTIVE GEL RICH IN WATER AND / OR CONTAINING MICRO-ORGANISMS |
JP4905683B2 (en) * | 2007-01-22 | 2012-03-28 | 東洋製罐株式会社 | Liquid content filling and sealing method for pouch with spout and apparatus therefor |
JP5050859B2 (en) * | 2008-01-08 | 2012-10-17 | セイコーエプソン株式会社 | Dispensing method and dispensing apparatus |
WO2011060484A1 (en) * | 2009-11-19 | 2011-05-26 | Scatterbrain Pty Ltd Atf Scatterbrain Trust | Method and apparatus for liquid dosing system |
JP2015012806A (en) * | 2011-10-28 | 2015-01-22 | 日本たばこ産業株式会社 | Capsule and cigarette with filter using the same |
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EP2964536B1 (en) * | 2013-03-06 | 2017-02-01 | GIMA S.p.A. | Beverage capsule machine for making single use beverage capsules |
UA118772C2 (en) * | 2013-12-20 | 2019-03-11 | Філіп Морріс Продактс С.А. | Smoking article having a filter including a capsule |
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-
2017
- 2017-07-26 EA EA201990287A patent/EA201990287A1/en unknown
- 2017-07-26 CN CN201780045168.6A patent/CN109476389A/en active Pending
- 2017-07-26 US US16/312,731 patent/US20190216128A1/en not_active Abandoned
- 2017-07-26 JP JP2019502653A patent/JP7216636B2/en active Active
- 2017-07-26 KR KR1020197004791A patent/KR102407787B1/en active IP Right Grant
- 2017-07-26 WO PCT/EP2017/068846 patent/WO2018019868A1/en unknown
- 2017-07-26 PL PL17742264T patent/PL3490891T3/en unknown
- 2017-07-26 EP EP17742264.9A patent/EP3490891B1/en active Active
- 2017-07-26 CA CA3029166A patent/CA3029166A1/en not_active Abandoned
- 2017-07-26 ES ES17742264T patent/ES2897894T3/en active Active
- 2017-07-26 TW TW106125109A patent/TW201803466A/en unknown
Also Published As
Publication number | Publication date |
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EP3490891A1 (en) | 2019-06-05 |
CA3029166A1 (en) | 2018-02-01 |
KR102407787B1 (en) | 2022-06-13 |
KR20190029713A (en) | 2019-03-20 |
EA201990287A1 (en) | 2019-06-28 |
TW201803466A (en) | 2018-02-01 |
JP2019526502A (en) | 2019-09-19 |
US20190216128A1 (en) | 2019-07-18 |
WO2018019868A1 (en) | 2018-02-01 |
JP7216636B2 (en) | 2023-02-01 |
PL3490891T3 (en) | 2022-01-31 |
CN109476389A (en) | 2019-03-15 |
ES2897894T3 (en) | 2022-03-03 |
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