Claims:1. An improved paper feed mechanism in a cigarette maker machine, comprising:
at least one clutching mechanism comprising one or more suction rollers,
at least one snapping mechanism comprising one or more snapping cylinders;
at least one compressed air flywheel;
wherein, during normal operation of said cigarette maker machine, said clutching mechanism and said snapping mechanism provided in a disengaged condition; and
wherein, during a fault in said cigarette maker machine, said snapping mechanism and said clutching mechanism gets engaged and said snapping mechanism enables separation of a paper web in two sections while said clutching means stops the continuous flow of overwrapping paper, and said compressed air flywheel adapted to gather up the remaining paper to prevent wastage of said paper during said fault.

2. The mechanism as claimed in claim 1, wherein said snapping cylinders is pneumatically or electrically actuated to create a tear in the overwrap layer.

3. The mechanism as claimed in claim 2, wherein said suction rollers includes plurality of apertures with a negative pressure generated in them, so as to hold said overwrapping paper onto said cylinders and prevents further unwinding.

4. The mechanism as claimed in claim 3, wherein clutching means comprises a pneumatic clutch to separate said suction roller from the machine drive.

5. The mechanism as claimed in claim 2, wherein said snapping mechanism comprises said snapping cylinders with a striking head.

6. The mechanism as claimed in claim 1, wherein said compressed air flywheel includes roller means that gathers one end of the snapped paper and rotates to wind the remaining paper on itself.

7. A method for preventing wastage of overwrapping papers fed into an improved paper feed mechanism, during a fault in cigarette maker machine, wherein said method comprising:

engaging a snapping mechanism having snapping cylinders for creating a tear in said overwrapping paper; and engaging a clutching mechanism having suction rollers, for holding the paper onto the cylinder and preventing further unwinding of additional said overwrapping paper;
collecting by a compressed air flywheel remaining paper to prevent wastage.
, Description:TECHNICAL FIELD OF THE INVENTION

[001] The present subject matter described herein, in general, relates to cigarette machinery, and more particularly relates to a paper feed mechanism in cigarette makers.

BACKGROUND OF THE INVENTION

[002] Cigarette manufacturing involves use of high speed machinery and a continuous process. The cigarette rod is produced at a continuous high speed during production and subsequently cut into smaller sizes. However, there are often stops on the machine due to unforeseeable circumstances such as part failure, quality defects, jams, stoppages, rod breakage and the like.

[003] During such stops, the maker machine needs to slow down from its running speed (in the range of 9000 to 20000 cigarettes per minute) to a stop. This process of slowing down takes place over 4 to 5 seconds and causes a significant amount of material wastage as illustrated in figure 2. To compound this problem, maker machine stops can occur as frequently as 20 to 50 times per hour of maker machine operation.

[004] Referring to figure 2 , the overwrap layer threading during machine stoppage for prior art has been illustrated .The figure shows possible paper accumulation and formation of loop in paper drag roller during rod breakages when the machine stops due to unforeseeable circumstances such as parts failures, quality defects, jams , stoppages , rod breakage which is caused because during such stops the machine needs to slow down from its running speed and causes significant amount of material wastage. During each of the described stops, the wasted product chiefly comprises of a continuous cigarette rod ranging from 20 to 30 meters. From these continuous cigarette rods, it is theoretically possible to recover and reuse the tobacco. However, recovering the cigarette paper is not possible as it damages the product. Therefore, maker stops are a major source of cigarette paper wastage.

[005] Accordingly, there is a dire need of a process of building a reservoir of unwound paper that works both during regular operation and during the bobbin changeover process such that there is no wastage of overwrapping layer during the process of manufacturing

[006] For some existing paper feed mechanism in cigarette makers, reference is made to US4883074 A issued on Nov 28, 1989, which relates to a cigarette manufacturing machine having a horizontal bed, at least one belt for forming a continuous cigarette rod, a belt having a portion extending above and along the bed between first and second end thereof, a device for feeding a continuous stream of tobacco onto the belt portion. However this document teaches basic paper feed mechanism in a cigarette making machine.

[007] Reference is further made to U.S. Pat. No. US4697408 A dated October 06, 1987, which discloses an apparatus for controlling the amount of delivery in a wrapping material feed system , including a rotation drive means for rotating a bobbin with a wrapping material wound thereon ; a winding diameter detecting means for detecting winding diameter of the wrapping material; and an adjusting means for changing torque and brake forces of the bobbin to adjust the amount of delivery of the wrapping material, and a control means for controlling the adjusting means. However, this document suggest controlling feed of wrapping material during normal operation of machine using rotational means and a memory system .

[008] Reference is made to WO0016647A1 dated March 30, 2000, which discloses a cigarette manufacturing apparatus comprising of a tobacco maker for making double length tobacco rods , a tipper for applying filters to tobacco rods to form filter tipped cigarettes , and a transfer apparatus for transferring double length tobacco rods from the rod maker to the tipper. However, this document teaches the method to manufacture cigarettes at high speed, including control of entire processes such as rod making, attaching tipping and the like.

[009] Reference is also made to GB1086065A dated July 20, 1964 which describes a we b feeding and splicing mechanism comprising a container 1 in which a reserve of running web 2 can be accumulated prior to splicing , a variable speed servo motor 13 which drives roller 11 of a pair of nip rollers 11, 12 and splicing means which includes a diamond in pregnated surface 28 attached to a pivoted arm 26 and a stationary surface 23 made of a resilient material

[0010] Reference is made to a GB2171676 B dated September 3, 1986 which discloses a reservoir for a bobbin changer that includes a movable deflector arranged to engage and deflect the paper as it enters the reservoir and to promote folding of the paper into loops in which the paper can safely be stored in the reservoir.

[0011] All these prior arts as discussed in the above patent references attempt to minimize paper wastage during stops. These documents teach method of ensuring continuous operation of the cigarette making machine, especially during changeover of a cigarette paper bobbin which is accomplished by the process of building a reservoir of unwound paper and then splicing the ends. However, this process functions only during the bobbin changeover process and not during regular operation.

[0012] Thus, in view of the drawbacks of the existing paper feeding mechanism of cigarette making machines, there exists a dire need to provide an improved paper feed mechanism in cigarette makers that can prevent formation of large quantities of cigarette rod during a stop. Thus, a mechanism that can inhibit the production of continuous cigarette rod during a machine fault, by stopping the supply of cigarette paper resulting in significant material saving and efficient utilization of the leftover material to minimize wastage of overwrap material is needed to overcome the drawbacks of the prior arts.

SUMMARY OF THE INVENTION

[0013] The following presents a simplified summary of the invention in order to provide a basic understanding of some aspects of the invention. This summary is not an extensive overview of the present invention. It is not intended to identify the key/critical elements of the invention or to delineate the scope of the invention. Its sole purpose is to present some concept of the invention in a simplified form as a prelude to a more detailed description of the invention presented later.

[0014] An object of the present invention is to provide an improved paper feeding mechanism in cigarette maker machine that solves the problem of material wastage by inhibiting the flow of overwrap material into the cigarette making machine during a stoppage.

[0015] Another object of the present invention an improved an improved paper feeding mechanism in cigarette maker machine that collects leftover material and uses it efficiently to minimize wastage of overwrap material.

[0016] Still another object of the present invention is to provide the efficient working of the cigarette making machine during normal operation and prevents production of continuous cigarette rod during machine stoppage.

[0017] Accordingly to one aspect, the present invention provides an improved paper feed mechanism in a cigarette maker machine, comprising:
at least one clutching mechanism comprising one or more suction rollers,
at least one snapping mechanism comprising one or more snapping cylinders;
at least one compressed air flywheel;
wherein, during normal operation of said cigarette maker machine, said clutching mechanism and said snapping mechanism provided in a disengaged condition; and
wherein, during a fault in said cigarette maker machine, said snapping mechanism and said clutching mechanism gets engaged and said snapping mechanism enables separation of a paper web in two sections while said clutching means stops the continuous flow of overwrapping paper, and said compressed air flywheel adapted to gather up the remaining paper to prevent wastage of said paper during said fault.

[0018] In another aspect, there is provided a method for preventing wastage of overwrapping papers fed into an improved paper feed mechanism, during a fault in cigarette maker machine, wherein said method comprising: engaging a snapping mechanism having snapping cylinders for creating a tear in said overwrapping paper; and thereby engaging a clutching mechanism having suction rollers, for holding the paper onto the cylinder and preventing further unwinding of additional said overwrapping paper; collecting by a compressed air flywheel remaining paper to prevent wastage.

[0019] Other aspects, advantages, and salient features of the invention will become apparent to those skilled in the art from the following detailed description, which, taken in conjunction with the annexed drawings, discloses exemplary embodiments of the invention.

BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS

[0020] The above and other aspects, features, and advantages of certain exemplary embodiments of the present invention will be more apparent from the following description taken in conjunction with the accompanying drawings in which:

[0021] Figure 1 illustrates the components of one embodiment of the current invention.

[0022] Figure 2 illustrates the operation of a conventional cigarette making machine during a machine stoppage.

[0023] Figure 3 illustrates the operation of a cigarette making machine with an embodiment of the present invention during a machine stoppage.

[0024] Persons skilled in the art will appreciate that elements in the figures are illustrated for simplicity and clarity and may have not been drawn to scale. For example, the dimensions of some of the elements in the figure may be exaggerated relative to other elements to help to improve understanding of various exemplary embodiments of the present disclosure. Throughout the drawings, it should be noted that like reference numbers are used to depict the same or similar elements, features, and structures.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

[0025] The following description with reference to the accompanying drawings is provided to assist in a comprehensive understanding of exemplary embodiments of the invention. It includes various specific details to assist in that understanding but these are to be regarded as merely exemplary.

[0026] Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the embodiments described herein can be made without departing from the scope of the invention. In addition, descriptions of well-known functions and constructions are omitted for clarity and conciseness.

[0027] The terms and words used in the following description and claims are not limited to the bibliographical meanings, but, are merely used by the inventor to enable a clear and consistent understanding of the invention. Accordingly, it should be apparent to those skilled in the art that the following description of exemplary embodiments of the present invention are provided for illustration purpose only and not for the purpose of limiting the invention as defined by the appended claims and their equivalents.

[0028] It is to be understood that the singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

[0029] By the term “substantially” it is meant that the recited characteristic, parameter, or value need not be achieved exactly, but that deviations or variations, including for example, tolerances, measurement error, measurement accuracy limitations and other factors known to those of skill in the art, may occur in amounts that do not preclude the effect the characteristic was intended to provide.

[0030] Features that are described and/or illustrated with respect to one embodiment may be used in the same way or in a similar way in one or more other embodiments and/or in combination with or instead of the features of the other embodiments.

[0031] It should be emphasized that the term “comprises/comprising” when used in this specification is taken to specify the presence of stated features, integers, steps or components but does not preclude the presence or addition of one or more other features, integers, steps, components or groups thereof.

[0032] Herein, the concept of continuous cigarette rod refers to a continuous rod of tobacco overwrapped in cigarette paper and sealed with glue and the term “overwrapping paper” refers to the cigarette paper.

[0033] Figure 2 illustrates the operation of a conventional cigarette making machine during a machine stoppage. As illustrated, this results in a substantial amount of overwrap layer wastage without the presence of elements from the current invention such as said snapping or clutching means.

[0034] Figure 1 illustrates the components of one embodiment of the current invention. The illustration shows the disengaged position of the suction roller and the snapping cylinder, which are key components of the clutching and snapping means respectively. The threading of the overwrap layer during regular machine operation is also clearly shown in this illustration.

[0035] In one implementation, a system and a method for manufacture of cylindrical shaped articles having an overwrapped layer, such that there is no wastage of overwrapping layer is provided comprising: a clutching means (2) to prevent said overwrapping layer from being wasted; a snapping mechanism (1) to stop the continuous flow of said overwrapping material when not required; and a compressed air flywheel (3) to collect any excess of said overwrapping material.

[0036] In one implementation, during normal operation of the cigarette making machine both the clutching means and the snapping mechanism are kept in disengaged condition which allows the cigarette paper to move easily from the bobbin holder to the garniture section through the pressure roller, drag roller, guide roller and garniture bullet roller.

[0037] Figure 3 illustrates the operation of a cigarette making machine with the aid of the current invention during a machine stoppage. As illustrated, the snapping means will get engaged in breaking the overwrap layer feed and said clutching means will get engaged in slowing down the overwrap layer.

[0038] In one implementation, during a machine fault, the steps follows will be as under–
• The snapping means engages. It comprises of a snapping cylinder (1) that can be pneumatically or electrically actuated and creates a tear in the overwrap layer.
• The clutching means engages. It comprises of a suction roller (2). This roller may include plurality of tiny apertures on it with a negative pressure generated in them. This suction holds the paper onto the cylinder and prevents further unwinding. Additionally, the suction roller will also get disconnected from the main drive reducing its rotational velocity, preventing it from pulling additional paper.
• The compressed air flywheel (3) gathers up the remaining paper to prevent wastage. In one implementation, the flywheel can be an independent roller means that gathers one end of the snapped paper (after the snapping cylinder creates the tear) and rotates to wind the remaining paper on itself.

[0039] In one implementation, referring to Figures 3, an overwrap layer threading during machine stoppage for current invention has been illustrated. During machine stoppage, the snapping mechanism creates a tear in the paper and separates the paper web into two sections. The snapping means could comprise of an actuating mechanism such as a snapping cylinder or pneumatic cylinder that pushes against the cigarette paper to create high tension force, thereby snapping it into two.

[0040] In the implementation, the clutching mechanism will slow down the speed of the paper web and prevents it from being wasted. This can be done by multiple means. One method is to use the clutching means to disengage the suction roller from the machine drive. Another method involves having apertures on the suction roller wherein said apertures use negative pressure to hold the cigarette paper web and prevent it from unwinding further. These two methods can be used in isolation or simultaneously as well. Further, to prevent formation of loop in the paper when the paper drag roller stops, a compressed air flywheel may be added to hold the paper.

[0041] Some of the advantages of the present invention, are as follows:
• In the present invention, the cigarette rods are produced efficiently at a continuous high speed during production and subsequently cut into smaller sizes.
• The present invention inhibits the production of continuous cigarette rod by stopping the supply of cigarette paper. In one example, 20 to 30 meter paper per stop is saved resulting in significant material saving.
• The rod shaped articles are manufactured at real time operating speed in the range of 0 to 20000 units per minute.
• Overwrap waste is reduced and leftover material is efficiently utilized to minimize wastage

[0042] Although a paper feed mechanism of cigarette making machine has been described in language specific to structural features and/or methods, it is to be understood that the embodiments disclosed in the above section are not necessarily limited to the specific features or methods or devices described. Rather, the specific features are disclosed as examples of implementations of paper feed mechanism and methods of manufacture of cylindrical rod shaped articles having an overwrapped layer.