Apparatus and method for insertion of capsules into filter tows

Abstract

An apparatus for insertion of capsules into cigarette filter tows is disclosed. The apparatus may include a tow processing unit, a capsule insertion unit and a filter rod making unit. The capsule insertion unit may include a hopper, a capsule presorter, a belt, an inlet pipe, a capsule insertion wheel, and a tow gathering funnel.

1 . An apparatus for insertion of capsules into cigarette filter tows, comprising:
 a tow processing unit coupled to a capsule insertion unit and a filter rod making unit coupled to the capsule insertion unit,   the tow processing unit further comprising a tow bale, a plurality of rollers, a plurality of banding jets and a plasticizer chamber;   the capsule insertion unit further comprising a hopper, a presorting unit, an endless belt disposed between said presorting unit and an inlet pipe, an insertion wheel rotating about an axis of rotation, said insertion wheel further comprising a circular cavity in communication with said inlet pipe and a distribution disk disposed within said cavity, and a tow gathering funnel configured to receive an edge of said insertion wheel; and   the rod making unit further comprising a garniture bed, a sensor, a knife carrier and an ejector.   
     
     
         2 . The apparatus of  claim 1 , wherein the insertion wheel further comprises:
 at least one capsule quality sensor;   a plurality of radial channels in communication with said circular cavity, each of said radial grooves configured to receive a plurality of capsules;   a plurality of insertion channels, each of said insertion channels being in communication with a corresponding radial channel and terminating at the outer edge of the insertion wheel; and   a plurality of separation mechanisms, each of said plurality of separation mechanisms disposed between a corresponding radial channel and a corresponding insertion channel.   
     
     
         3 . The apparatus of  claim 1 , wherein each of said plurality of separation mechanisms further comprises:
 a vertical channel in communication with a corresponding radial channel and a corresponding insertion channel;   a sliding member slidably disposed within said vertical channel, the sliding member comprising a cavity configured to receive a single capsule; and   a bearing assembly coupled to said sliding member and received within a groove of a cam.   
     
     
         4 . The apparatus of  claim 1 , wherein said presorting unit further comprises:
 a vibrating mechanism;   a plurality of transport threads;   a rotating brush having an axis of rotation perpendicular to the direction of said transport threads;   at least two aspiration devices configured to provide negative air pressure and coupled to extraction pipes; and   a control unit for varying the amount of negative air pressure supplied to at least one of said at least two aspiration devices.   
     
     
         5 . The apparatus of  claim 2 , wherein said radial channels have a linear shape. 
     
     
         6 . The apparatus of  claim 2 , wherein said radial channels have an arcuate shape. 
     
     
         7 . The apparatus of  claim 2 , wherein the at least one capsule quality sensor further comprises a microwave sensor. 
     
     
         8 . The apparatus of  claim 2 , wherein the at least one capsule quality sensor further comprises an optical sensor. 
     
     
         9 . The apparatus of  claim 2 , wherein the at least one capsule quality sensor further comprises a laser sensor. 
     
     
         10 . The apparatus of  claim 2 , wherein the at least one capsule quality sensor further comprises an inductive sensor. 
     
     
         11 . The apparatus of  claim 2 , wherein the at least one capsule quality sensor further comprises a capacitive sensor. 
     
     
         12 . The apparatus of  claim 2 , wherein the at least one capsule quality sensor further comprises a video camera. 
     
     
         13 . The apparatus of  claim 1 , wherein said tow gathering funnel further comprises:
 at least one guide member; and   at least one tongue member.   
     
     
         14 . An apparatus for inserting capsules into filter tows, comprising:
 a hopper;   a presorting unit, said presorting unit further comprising a vibrating mechanism, a plurality of transport threads, a rotating brush having an axis of rotation perpendicular to the direction of said transport threads, at least two aspiration devices configured to provide negative air pressure and coupled to extraction pipes and a control unit for varying the amount of negative air pressure supplied to at least one of said at least two aspiration devices;   an endless belt disposed between said presorting unit and an inlet pipe;   a insertion wheel rotating about an axis of rotation, said insertion wheel further comprising a circular cavity in communication with said inlet pipe, a distribution disk disposed within said circular cavity, a plurality of radial channels in communication with said circular cavity, each of said radial channels configured to receive a plurality of capsules, and a plurality of insertion channels, each of said insertion channels being in communication with a corresponding radial channel and terminating at the outer edge of the insertion wheel;   a plurality of separation mechanisms, each of said plurality of separation mechanisms disposed between a corresponding radial channel and a corresponding insertion channel;   and a tow gathering funnel, said tow gathering funnel comprising at least one guide member and at least one tongue member, and configured to receive an edge of said insertion wheel.   
     
     
         15 . The apparatus of  claim 8 , wherein each of said plurality of separation mechanisms further comprises:
 a vertical channel in communication with a corresponding radial channel and a corresponding insertion channel;   a sliding member slidably disposed within said vertical channel, the sliding member comprising a cavity configured to receive a single capsule; and   a bearing assembly coupled to said sliding member and received within a groove of a cam.   
     
     
         16 . The apparatus of  claim 1 , wherein said capsules have a diameter between approximately 0.5 mm and approximately 8 mm. 
     
     
         17 . A method for insertion of capsules into filter tows, comprising:
 placing a plurality of capsules in a hopper of a capsule insertion unit;   withdrawing said capsules from said hopper;   determining the quality of said capsules;   discarding capsules that do not meet desired quality standards;   distributing said capsules into a plurality of radial channels of an insertion wheel;   individually separating said capsules; and   positioning said capsules at a desired position within a filter tow.