WO2019150102A1

WO2019150102A1 - Apparatus for manufacturing a rod of aerosolisable material and method of manufacturing a rod of aerosolisable material

Info

Publication number: WO2019150102A1
Application number: PCT/GB2019/050252
Authority: WO
Inventors: Gerhard Le Roux; John Richardson
Original assignee: British American Tobacco Investments Ltd
Current assignee: British American Tobacco Investments Ltd
Priority date: 2018-01-30
Filing date: 2019-01-30
Publication date: 2019-08-08
Anticipated expiration: 2020-07-30
Also published as: GB201801518D0

Abstract

Apparatus and Method for Manufacturing a Rod of Aerosolisable Material Apparatus for manufacturing a rod of aerosolisable material is disclosed. The apparatus comprises a first suction conveyor (12) arranged to convey a first aerosolisable material (4), a second suction conveyor (13) arranged to combine the first aerosolisable material (4) with a second aerosolisable material (5), and an intermediate conveyor (14) arranged to transfer the first aerosolisable material from the first suction conveyor to the second suction conveyor.

Description

Apparatus for Manufacturing a Rod of Aerosolisable Material and Method of Manufacturing a Rod of Aerosolisable Material

Field

The present invention relates to apparatus for manufacturing a rod of aerosolisable material, for example a tobacco rod for a tobacco industry product.

Background

Known apparatus for manufacturing a tobacco rod includes a suction conveyor that draws tobacco material from a vertical tobacco feeder onto a moving suction belt. The tobacco material is entrained on the suction belt and trimmed to the correct size and amount. The stream of tobacco material is then transferred to a garniture for wrapping with a paper wrap to form a wrapped tobacco rod. Summary

According to the present invention, there is provided apparatus for manufacturing a rod of aerosolisable material, the apparatus comprising a first suction conveyor arranged to convey a first aerosolisable material, a second suction conveyor arranged to combine the first aerosolisable material with a second aerosolisable material, and an intermediate conveyor arranged to transfer the first aerosolisable material from the first suction conveyor to the second suction conveyor.

The first suction conveyor may comprise a first suction belt configured to apply suction to retain the first aerosolisable material on an underside of the first suction belt.

The second suction conveyor may comprise a second suction belt configured to apply suction to retain the first aerosolisable material and the second aerosolisable material on an underside of the second suction belt. The intermediate conveyor may comprise an intermediate suction belt configured to apply suction to retain the first aerosolisable material on an upper side of the intermediate suction belt. The first and second suction conveyors and the intermediate conveyor may comprise, respectively, first, second and intermediate suction belts configured to apply suction to retain the aerosolisable material on the suction belts. In some examples, each of the first and second suction conveyors and the intermediate conveyor comprises a suction chamber arranged to provide suction.

Each of the first, second and intermediate suction belts may comprise suction holes through which suction acts to retain aerosolisable material on the first, second and intermediate suction belts.

The suction holes of the first suction belt may be arranged in a profile such that the first aerosolisable material is retained on the first suction conveyor in a profile. The profile of the suction holes of the first suction belt may comprise spaced suction regions, each suction region having one or more suction holes.

The profile of the suction holes on the first suction belt further may comprise groups of connecting suction holes disposed between the suction regions. The groups of connecting suction holes may have a lower density than the suction holes in the suction regions such that less of the first aerosolisable material is retained by the connecting suction holes than by the suction holes in the suction regions.

The suction holes of the intermediate suction belt may be arranged in a profile such that the first aerosolisable material is retained on the intermediate conveyor in a profile.

The profile of the suction holes of the intermediate suction belt may comprise spaced suction regions, each suction region having one or more suction holes.

The profile of the suction holes on the intermediate suction belt may further comprise groups of connecting suction holes disposed between the suction regions. The groups of connecting suction holes may have a lower density than the suction holes in the suction regions such that less of the first aerosolisable material is retained by the connecting suction holes than by the suction holes in the suction regions. The apparatus may further comprise a first feeder disposed below the first suction conveyor and adapted to feed the first aerosolisable material to the first suction conveyor. The first feeder may be a vertical feeder, feeding the first aerosolisable material vertically onto the first suction conveyor.

The apparatus may further comprise a second feeder disposed below the second suction conveyor and adapted to feed the second aerosolisable material to the second suction conveyor. The second feeder may be a vertical feeder, feeding the second aerosolisable material vertically onto the second suction conveyor.

The apparatus may further comprise a removal drum arranged to remove some of the first aerosolisable material from the intermediate conveyor, such that the first aerosolisable material is arranged in a profile on the intermediate conveyor. The removal drum may comprise a rotor arranged to rotate. The rotor may comprise a plurality of removal passages for removing parts of the first aerosolisable material from the intermediate conveyor.

The removal drum may comprise at least one suction extraction tube connected to the removal passages for removal of parts of the first aerosolisable material from the intermediate conveyor.

In some examples, the intermediate conveyor may further comprise a suction break chamber arranged to release suction from the first aerosolisable material to transfer the first aerosolisable material from the intermediate suction conveyor to the second suction conveyor.

The suction break chamber may comprise an air jet. The air jet may be configured to provide pulses of air flow.

The first aerosolisable material may be transferred from the first suction conveyor to the intermediate conveyor at a first transfer region, and the first suction conveyor and the intermediate conveyor may be arranged adjacent to each other in the first transfer region for transfer of the first aerosolisable material. The first suction conveyor may comprise a first suction belt adapted to carry the first aerosolisable material on an underside of the first suction belt, and the intermediate conveyor may comprise an intermediate suction belt adapted to receive the first aerosolisable material on an upper side of the intermediate suction belt. In this arrangement, in the first transfer region the intermediate suction belt may be disposed below the first suction belt.

The first aerosolisable material may be transferred from the intermediate conveyor to the second suction conveyor at a second transfer region. The intermediate conveyor and the second suction conveyor may be arranged adjacent to each other in the second transfer region for transfer of the first aerosolisable material.

The intermediate conveyor may comprise an intermediate suction belt adapted to carry the first aerosolisable material on an upper side of the intermediate suction belt. The second suction conveyor may comprise a second suction belt adapted to receive the first aerosolisable material on an underside side of the second suction belt. In the second transfer region the intermediate suction belt may be disposed below the second suction belt. The apparatus may further comprise a trimmer arranged to trim the first aerosolisable material on the first suction conveyor.

The apparatus may further comprise a trimmer arranged to trim the combined first aerosolisable material and second aerosolisable material on the second suction conveyor.

The apparatus may further comprise a garniture arranged to receive the combined first aerosolisable material and second aerosolisable material from the second suction conveyor. The garniture maybe adapted to wrap a ribbon of paper about the combined first aerosolisable material and second aerosolisable material to form a continuous rod of aerosolisable material. The apparatus may further comprise a cutter adapted to cut the continuous rod of aerosolisable material.

According to another aspect of the present invention, there is provided a method of manufacturing a rod of aerosolisable material, the method comprising:

conveying a first aerosolisable material on a first suction conveyor, transferring the first aerosolisable material to a second suction conveyor via an intermediate conveyor, and

combining the first aerosolisable material with a second aerosolisable material on the second suction conveyor to form a combined stream of first aerosolisable material and second aerosolisable material.

The method may further comprise removing some of the first aerosolisable material from the intermediate conveyor such that the first aerosolisable material is arranged in a profile.

In examples, the first aerosolisable material may be received on the first suction conveyor in a profile.

The method may further comprise trimming the first aerosolisable material on the first suction conveyor.

The method may further comprise trimming the combined stream of first aerosolisable material and second aerosolisable material on the second suction conveyor. The method may further comprise transferring the combined first aerosolisable material and second aerosolisable material to a garniture. The method may further comprise wrapping the combined first aerosolisable material and second tobacco aerosolisable in a ribbon of paper to form a continuous rod of aerosolisable material. The method may further comprise cutting the continuous rod of aerosolisable material.

According to a further aspect of the present invention, there is provided a method of manufacturing a tobacco industry product, the method comprising manufacturing a rod of aerosolisable material according to the method described above, and further comprising combining the rod of aerosolisable material with a further component.

In various examples, the tobacco industry product is a cigarette.

Brief Description of the Drawings

Embodiments of the invention will now be described, by way of example only, with reference to the accompanying Figures, in which: FIGS. lA to lD show examples of tobacco industry products that include two different types of tobacco;

FIGS. 2A and 2B show examples of wrapped tobacco rods having two different types of tobacco, the wrapped tobacco rods being formed during the manufacture of the tobacco industry products of FIGS. lA to lD;

FIG. 3 shows a part of apparatus for manufacturing the example wrapped tobacco rods of FIGS. 2A and 2B;

FIG. 4 shows a more detailed view of the removal drum of the apparatus of FIG. 3;

FIG. 5 shows a more detailed view of the transfer point from the intermediate suction belt to the second suction belt of the apparatus of FIG. 3; and,

FIGS. 6A and 6B show example profiled suction belts of the apparatus of FIG. 3.

Detailed Description

FIGS. lA to lD show different examples of tobacco industry products. The tobacco industry products include a rod of aerosolisable material. In the described

embodiments, the tobacco industry products 1 are cigarettes, and the rod of

aerosolisable material is a tobacco rod 3.

As illustrated, each of the tobacco industry products 1 includes a filter 2 and a tobacco rod 3. The filter 2 may comprise a filtering material and a wrapper, and the tobacco rod 3 comprises tobacco material and a paper wrapper. The filter 2 and the tobacco rod 3 may be joined together by a joining wrapper that circumscribes and at least partially overlaps the filter 2 and the tobacco rod 3. For clarity, these details are omitted from FIGS. lA to lD, which schematically illustrate the arrangement of first and second tobacco materials 4, 5 in the tobacco rod 3.

As illustrated, in these examples the tobacco rods 3 include a first tobacco material 4 and a second tobacco material 5. The first and second tobacco materials 4, 5 are different. The first and second tobacco materials 4, 5 are arranged in distinct areas of the tobacco rod 3, such that a boundary is formed between the first tobacco material 4 and the second tobacco material 5 in the tobacco rod 3, as illustrated.

In the example of FIG. lA, the first tobacco material 4 extends from the end of the tobacco rod 3 adjacent to the filter 2, and the second tobacco material 5 extends from the open end 6 of the tobacco rod 3. The boundary between the first and second tobacco materials 4, 5 is angled with respect to the axial direction of the tobacco industry product l so that, while using the tobacco industry product 1, there is a gradual transition from the second tobacco material 5 to the first tobacco material 4.

The example of FIG. lB is similar to that of FIG. lA, although the first tobacco material 4 extends alongside the second tobacco material 5 to the open end 6 of the tobacco rod

3. In this example, the first tobacco material 4 extends from the filter 2 to the open end 6 of the tobacco rod 3, and overlaps the second tobacco material 5 along a part of the length of the tobacco rod 3. The examples of FIGS. lC and lD are similar to those of FIGS. lA and lB, but the first tobacco material 4 and the second tobacco material 5 are oppositely arranged with respect to the filter 2 and the open end 6 of the tobacco rod 3. In these examples, the second tobacco material 5 is located at the end of the tobacco rod 3 abutting the filter 2, and the first tobacco material 4 is extends to the open end 6 of the tobacco rod 3.

In other examples, the boundary between the first tobacco material 4 and second tobacco material 5 maybe a line that is perpendicular to the longitudinal direction of the tobacco industry product 1 at a location along the length of the tobacco rod 3. During manufacture of the tobacco industry products 1 a continuous wrapped tobacco rod is formed by wrapping a wrapper about a stream of tobacco material. The stream of tobacco material is formed of first tobacco material 4 and second tobacco material 5 arranged in the appropriate manner for forming the tobacco rods 3. The continuous wrapped tobacco rod is subsequently cut into tobacco rods for the individual tobacco industry products 1 shown in FIGS. lA to lD.

FIG. 2A shows an example continuous wrapped rod of aerosolisable material, for example a continuous tobacco industry rod 7. The continuous tobacco industry rod 7 is formed during the manufacture of the tobacco industry products 1 of FIGS. lA and lC.

FIG. 2B shows an example continuous wrapped rod of aerosolisable material, for example a continuous tobacco industry rod 7. The continuous tobacco industry rod 7 is formed during the manufacture of the tobacco industry products 1 of FIGS. lB and lD. FIGS. 2A and 2B are schematic drawings showing the arrangement of the first and second tobacco materials 4, 5 along the length of the continuous tobacco rods 7, and the lengths and widths illustrated are not dimensionally representative of the actual continuous tobacco rod 7. In particular, the length dimension is compressed and the width dimension is exaggerated to provide a clear illustration of the arrangement of the first and second tobacco materials 4, 5 along the continuous tobacco rod 7.

As shown, the first tobacco material 4 and second tobacco material 5 are arranged in an alternating pattern along the continuous tobacco rods 7. In particular, the first and second tobacco materials 4, 5 are arranged such that it can be cut at regular intervals to form the tobacco rods 3 for the tobacco industry products 1 of FIGS. lA to lD. The first and second tobacco materials 4, 5 are arranged such that after the continuous tobacco rod 7 is cut at lines 8 the individual tobacco rods are arranged in an opposing back-to- back manner (i.e. they are mirror-images of each other about the cut line). Cigarette assembly apparatus can then attach the filters 2 in the manner shown in FIGS. lA to lD.

Apparatus for manufacturing the tobacco industry products 1, in particular the tobacco rods 3, is described hereinafter. FIG. 3 is a schematic diagram of part of an apparatus 9 for manufacturing a continuous rod 7 of aerosolisable material, for example a continuous tobacco rod, for example the continuous tobacco rods 7 of FIGS. 2A and 2B. The apparatus 9 includes a first suction conveyor 12, a second suction conveyor 13, and an intermediate suction conveyor 14. The first suction conveyor 12 receives a first aerosolisable material 4, and that first aerosolisable material 4 is transferred to the intermediate suction conveyor 14. The intermediate suction conveyor 14 then transfers the first aerosolisable material 4 to the second suction conveyor 13. A second aerosolisable material 5 is added to the second suction conveyor 13 to create a stream of aerosolisable material comprising the first and second aerosolisable materials 4, 5. In the examples described below, the first and second aerosolisable materials are first and second tobacco materials 4, 5.

In various examples, described below, the first tobacco material 4 is formed into a profile on the first suction conveyor 12 and/or on the intermediate suction conveyor 14. The profiled first tobacco material 4 is then transferred, in profile, to the second suction conveyor 13. The second tobacco material 5 is then provided to form a stream of first and second tobacco materials 4, 5 suitable for forming a continuous tobacco rod 7, for example the continuous tobacco rod 7 of FIG. 2A or 2B.

A first vertical feeder 10 provides the first tobacco material 4 to a first suction conveyor 12. A second vertical feeder 11 provides the second tobacco material 5 to a second suction conveyor 13.

The first and second vertical feeders 10, 11 each have a vertical chimney 15 that receives first and second tobacco materials 4, 5, respectively. The tobacco material 4, 5 is fed into the bottom of the vertical chimney 15 and is urged upwards towards the suction conveyors 12, 13.

As explained further below, the suction conveyors 12, 13 include suction holes that draw the tobacco material 4, 5 onto the suction conveyors 12, 13. Optionally, air flow is induced within the vertical chimneys 15 to urge the tobacco material 4, 5 vertically upwards towards the first and second suction conveyors 12, 13.

The first suction conveyor 12 has a first suction belt 16 that is driven on rollers 19 such that the first suction belt 16 has an upper run 17 and a lower run 18, the lower run 18 moving to the left as illustrated in FIG. 3. The first vertical feeder 10 is disposed beneath the lower run 18 of the first suction belt 16.

The first suction conveyor 12 also has a suction chamber 20 located between the upper and lower runs 17, 18 of the first suction belt 16. The suction chamber 20 is a closed box (or similar) defining a closed area within the first suction conveyor 12, and has one or more openings on its lower side, adjacent to the lower run 18 of the first suction belt 16. The suction chamber 20 is connected to a vacuum pump via an outlet 21.

The first suction belt 16 includes suction holes formed through the first suction belt 16. Therefore, a suction air flow is induced by the vacuum pump from the chimney 15 of the first vertical feeder 10, through the suction holes in the first suction belt 16, into the suction chamber 20 and outlet 21. This suction air flow urges the first tobacco material 4 onto the underside of the lower run 18 of the first suction belt 16. The suction holes are sized such that the first tobacco material 4 is retained on the underside of the lower run 18 of the first suction belt 16 by the suction. In this way, the first tobacco material 4 is entrained on the first suction conveyor 12. Guides may be provided to guide the first tobacco material 4 along the first suction conveyor 12 as the first suction belt 16 moves.

The first suction belt 16 is driven to rotate about rollers 19 to carry first tobacco material 4 towards the intermediate suction conveyor 14 on the underside of the lower run 18 of the first suction belt 16. As explained hereinafter, the first tobacco material 4 is then transferred from the first suction conveyor 12 to the intermediate suction conveyor 14. The intermediate suction conveyor 14 has an intermediate suction belt 22 that is driven on rollers 23 such that the intermediate suction belt 22 has an upper run 24 and a lower run 25.

The intermediate suction conveyor 14 also has a suction chamber 26 located between the upper and lower runs 24, 25 of the intermediate suction belt 22. The suction chamber 26 is a closed box (or similar) defining a closed area within the intermediate suction conveyor 14, and has one or more openings on its upper side, adjacent to the upper run 24 of the first suction belt 16. The suction chamber 26 is connected to a vacuum pump via an outlet 27.

The intermediate suction belt 22 includes suction holes formed through the

intermediate suction belt 22. Therefore, a suction air flow is induced by the vacuum pump from the outside atmosphere above the intermediate suction conveyor 14, through the suction holes in the intermediate suction belt 22, into the suction chamber 26 and outlet 27. After the first tobacco material 4 is transferred from the first suction conveyor 12 to the intermediate suction conveyor 14, the suction air flow acts to hold the first tobacco material 4 onto the upper side of the upper run 24 of the intermediate suction belt 22. The suction holes are sized such that the first tobacco material 4 is retained on the intermediate suction belt 22 by the suction.

As illustrated, the intermediate suction belt 22 is arranged to partially overlap a portion of the first suction belt 16 in a first transfer region 28. In the first transfer region 28 the intermediate suction belt 22 is disposed below the first suction belt 16, such that the lower run 18 of the first suction belt 16 is above the upper run 24 of the intermediate suction belt 22. In the first transfer region 28 the first tobacco material 4 is transferred from the first suction conveyor 12 to the intermediate suction conveyor 14. The suction chamber 20 of the first suction conveyor 12 is adapted to block vacuum to the suction holes on the first suction belt 16 in the first transfer region 28, such that the first tobacco material 4 is released from the first suction belt 16. The suction chamber 26 of the intermediate suction conveyor 14 is arranged to provide suction for the

intermediate suction belt 22 in the first transfer region 28. In this way, the first tobacco material 4 is transferred from the first suction belt 16 to the intermediate suction belt 22 in the first transfer region 28.

The intermediate suction belt 22 rotates about rollers 23 to carry first tobacco material 4 towards the second suction conveyor. As explained hereinafter, the first tobacco material 4 is transferred from the intermediate suction conveyor 14 to the second suction conveyor 13.

The second suction conveyor 13 has a second suction belt 29 that is driven on rollers 30 such that the second suction belt 29 has an upper run 31 and a lower run 32. The second vertical feeder 11 is disposed beneath the lower run 32 of the second suction belt 29.

The second suction conveyor 13 also has a suction chamber 33 located between the upper and lower runs 31, 32 of the second suction belt 29. The suction chamber 33 is a closed box (or similar) defining a closed area within the second suction conveyor 13, and has one or more openings on its lower side, adjacent the lower run 32 of the second suction belt 29. The suction chamber 33 is connected to a vacuum pump via an outlet 34. The second suction belt 29 includes suction holes formed through the second suction belt 29.

The first tobacco 4 is transferred from the intermediate suction belt 22 onto the second suction belt 29 in a second transfer region 35. As illustrated, the second suction belt 29 is arranged to partially overlap a portion of the intermediate suction belt 22 in the second transfer region 35. In the second transfer region 35 the second suction belt 29 is disposed below the intermediate suction belt 22, such that the lower run 32 of the second suction belt 29 is above the upper run 24 of the intermediate suction belt 22. In the second transfer region 35 the first tobacco material 4 is transferred from the intermediate suction conveyor 14 to the second suction conveyor 13. The suction chamber 26 of the intermediate suction conveyor 14 is adapted to block vacuum to the suction holes on the intermediate suction belt 22 in the second transfer region 35, such that the first tobacco material 4 is released from the intermediate suction belt 22. The suction chamber 33 of the second suction conveyor 13 is arranged to provide suction to the second suction belt 29 in the second transfer region 35. In this way, the first tobacco material 4 is transferred from the intermediate suction belt 22 to the second suction belt 29 in the second transfer region 35.

FIG. 5 schematically illustrates the second transfer region 35, where the first tobacco material 4 is transferred from the intermediate suction belt 22 to the second suction belt 29. It will be appreciated that inverting the arrangement illustrated in FIG. 5 results in the first transfer region 28, and so the below description is relevant to both the first and second transfer regions 28, 35.

As shown, the first tobacco material 4 on the intermediate suction belt 22 is arranged in a profile of spaced groups of first tobacco material 4. This is explained further hereinafter. However, it will be appreciated that the first tobacco material 4 may be arranged in any format on the intermediate suction belt 22. For example, the first tobacco material 4 may have a constant or variable thickness on the intermediate suction belt 22.

The suction chamber 26 of the intermediate suction conveyor 14 has an end wall approximately aligned with the roller 30 of the second suction conveyor 13, at the start of the second transfer region 35. The end wall 37 defines the extent of the suction chamber 26, such that after the intermediate suction belt 22 has passed the end wall 37 no (or very little) suction is provided to the suction holes on the intermediate suction belt 22. In this way, the first tobacco material 4 is released from the intermediate suction belt 22 in the second transfer region 35.

Preferably, an outlet 38 is provided within the intermediate suction conveyor 14. The outlet 38 can be vented to atmosphere, so that any residual vacuum from the suction chamber 26 is released. Alternatively, the outlet 38 may be provided with a positive air flow to counteract any residual suction from the suction chamber 26 and/or to push the first tobacco material 4 off of the intermediate suction belt 22, towards the second suction belt 29. As illustrated, in the second transfer region 35 the second suction belt 29 is disposed above the intermediate suction belt 22. The suction chamber 33 extends over the second transfer region 35. Therefore, as the first tobacco material 4 is released from the intermediate suction conveyor 22 it is drawn onto the second suction conveyor 13.

Thereafter, the second suction belt 29 with the first tobacco material 4 moves across the top of the second vertical feeder 11, as illustrated in FIG. 3, and the second tobacco material 5 is added to the second suction belt 29. Suction air flow induced by the vacuum pump creates air flow from the chimney 15 of the second vertical feeder 11, through the suction holes in the second suction belt 29, into the suction chamber 33 and outlet 34. This suction air flow draws the second tobacco material 5 onto the underside of the lower run 32 of the second suction belt 29, where the first tobacco material 4 provided from the intermediate suction conveyer 14 is also retained. The suction holes are sized such that the first and second tobacco materials 4, 5 are retained on the underside of the lower run 32 of the second suction belt 29 by the suction. In this way, the second tobacco material 5 is added to the first tobacco material 4 and together they are entrained on the second suction conveyor 13. Guides may be provided to guide the first tobacco material 4 and second tobacco material 5 along the second suction conveyor 13 as the second suction belt 29 moves.

In this way, the second suction belt 29 is provided with a combination of the first tobacco material 4 and the second tobacco material 5. The second suction belt 29 rotates about rollers 30 to carry the stream of first and second tobacco materials 4, 5 towards the garniture 36.

As illustrated in FIG. 3, the first, second and intermediate suction conveyors 12, 13, 14 are angled at a downwards slope towards the garniture 36. The suction belts 16, 22, 29 are parallel to each other and angled downwards in the direction that the tobacco materials 4, 5 move during use.

As briefly described above, the first tobacco material 4 may be evenly arranged on the intermediate suction belt 22, or it may have variable thickness on the intermediate suction belt 22. In one example, illustrated in FIG. 5, the first tobacco material 4 is arranged in spaced groups along the intermediate suction belt 22. In another example, the first tobacco material 4 may be arranged along the intermediate suction belt 22 with spaced thicker parts and intermediate thinner parts. In these examples, the second tobacco material 5 will fill in the gaps between the spaced areas of first tobacco material 4, thereby creating an arrangement of the tobacco materials 4, 5 suitable for forming the continuous tobacco rods 7 of FIGS. 2A and 2B.

To arrange the first tobacco material 4 into spaced groups, a removal drum 39 may be provided on the intermediate suction conveyor 14, as illustrated in FIG. 3. The removal drum 39 is configured to remove parts of the first tobacco material 4 from the intermediate suction belt 22 such that the first tobacco material 4 is arranged in a profile on the intermediate suction belt 22. The profiled first tobacco material 4 is then transferred onto the second suction conveyor 13 in that profile, as previously described.

The removal drum 39 is shown in more detail in FIG. 4. The removal drum 39 includes a rotor 40 that rotates above the upper run 24 of the intermediate suction belt 22, such that the circumferential surface 41 of the rotor rolls over the intermediate suction belt 22 as the intermediate suction belt 22 moves.

As illustrated, the rotor 40 includes a plurality of removal passages 42 spaced about the circumferential surface 41 of the rotor 40. The removal passages 42 are connected to a suction extraction tube 43 so that as a removal passage 42 meets the intermediate suction belt 22 during rotation of the rotor 40, first tobacco material 4 that is aligned with the removal passages 42 is removed from the intermediate suction belt 22.

Tobacco that is not aligned with a removal passage 42 remains on the intermediate suction belt 22.

Therefore, the arrangement of the removal passages 42 about the rotor 40 determines the profile of the first tobacco material 4 on the intermediate suction belt 22

downstream of the removal drum 39.

In some examples, the rotor 40 may contact the intermediate suction belt 22 as the rotor 40 rotates. In other examples, the rotor 40 may be spaced from the intermediate suction belt 22. In the example illustrated in FIG. 4, the removal passages 42 are configured to remove all of the first tobacco material 4 from the intermediate suction belt 22 in the region that they align with during rotation. However, in other examples the removal passages 42 may be configured to remove only part of the first tobacco material 4, so that some is left on the intermediate suction belt 22, creating a profile of first tobacco material 4 having varying thickness along the intermediate suction belt 22.

The proximity of the rotor 40 to the intermediate suction belt 22 and/ or the power of the suction provided to the removal passages 42 can be configured to determine how much of the first tobacco material 4 is removed from the intermediate suction belt 22.

Preferably, the suction extraction tube 43 is adapted to recycle the removed first tobacco material 4 into the first vertical material feeder 10. In an alternative example, the removal drum 39 is adapted to remove first tobacco material 4 from the intermediate suction belt 22 by pushing parts of the first tobacco material 4 off of the intermediate suction belt 22. For example, the rotor may include a series of angled blades that push first tobacco material 4 off of the side of the intermediate suction belt 22. In this example, the removal drum may rotate about an axis that is rotated in the plane of the intermediate suction belt 22 such that the angled blades push the first tobacco material 4 off of the intermediate suction belt 22. The removed first tobacco material 4 can be collected and recycled to the first vertical feeder 10. Preferably, as illustrated in FIG. 4, a suction break chamber 44 is disposed below the intermediate suction belt 22. The suction break chamber 44 is aligned with the position at which the removal passages 42 (or removal blades) are closest to the intermediate suction belt 22 - i.e. the location where first tobacco material 4 is removed. In one example, the suction break chamber 44 is sealed from the suction chamber 26, so that no suction is applied to the first tobacco material 4 as it is removed from the intermediate suction belt 22.

Alternatively, the suction break chamber 44 may not be sealed from the suction chamber 26, but may be provide with an air jet 45 that intermittently directs air flow onto the underside of the intermediate suction belt 22 to counteract the suction of the suction chamber 26 while first tobacco material 4 is removed. The air jet 45 is timed to coincide with the removal passages 42 (or removal blades).

In another example, the suction break chamber 44 is sealed from the suction chamber 26 and it may also include an air jet 45 that intermittently directs air flow onto the underside of the intermediate suction belt 22. The air jet 45 is timed to coincide with the removal passages 42 (or removal blades).

FIGS. 6A and 6B illustrate examples of profiled suction belts 48, 49 that could be used as an alternative to the removal drum 39, or in addition to the removal drum 39, to create a profiled stream of first tobacco material 4 on the intermediate suction conveyor 14·

As illustrated in FIG. 6A, the profiled suction belt 48 has suction holes 46 arranged in spaced regions 47 along the profiled suction belt 48.

Referring also to FIG. 3, if the profiled suction belt 48 is used as the first suction belt 16 the first tobacco material 4 from the first vertical feeder 10 is retained on the first suction belt 16 only in the suction regions 47, where the suction holes 46 are located.

If the profiled suction belt 48 is used as the intermediate suction belt 22, first tobacco material 4 is only transferred onto the intermediate suction conveyor 14 at locations corresponding to the suction regions 47. In another example, the profiled suction belt 48 may be used as both of the first suction belt 16 and the intermediate suction belt 22. In this example, the first and intermediate suction conveyors 12, 14 are coordinated such that the suction regions 47 in each of the first and intermediate suction belts 16, 22 are aligned with each other in the first transfer region 28.

FIG. 6B shows another example of a profiled suction belt 49 for use as one or both of the first suction belt 16 and the intermediate suction belt 22 in the same manner as described above. As shown, the suction holes 46 are arranged in suction regions 47 with connecting suction holes 50 extending between the suction regions 47. The connecting suction holes 50 have a lower density (fewer holes per unit area) on the profiled suction belt 49 than the suction holes 46 in the suction regions 47. In this way, less of the first tobacco material 4 is retained on the profiled suction belt 49 in regions of the connecting suction holes 50 than in the suction regions 47. Such a profiled suction belt 49 might be used, for example, in the production of the continuous tobacco rod 7 of FIG. 2B, where the first tobacco material 4 extends along the length of the continuous tobacco rod 7, but in varying amounts.

In a further example, a removal drum 39 like that described with reference to FIG. 4 maybe provided on the intermediate suction conveyor 14, in addition to use of a profiled suction belt 48, 49 as the first suction belt 16 and/ or the intermediate suction belt 22. The removal drum 39 can remove any excess first tobacco material 4 to ensure an accurate profile of first tobacco material on the intermediate suction conveyor 14.

As described above, a profiled suction belt 48, 49 and/ or a removal drum 39 can be used to arrange the first tobacco material 4 in a profile along the intermediate suction belt 22, which is then transferred to the second suction belt 29. The second suction belt 29 has suction holes along its full length, so that the second tobacco material 5 is retained on the second suction belt 29 in areas where no, or less, first tobacco material 4 is present. In this way, the first and second tobacco materials 4, 5 form a profiled stream of tobacco material 4, 5 that can be wrapped in the garniture to form the continuous wrapped tobacco rods 7 described with reference to FIGS. 2A and 2B.

It will be appreciated that aspects of the profiled suction belt 48, 49 and/or a removal drum 39 can be adapted such that the first and second tobacco materials 4, 5 can be arranged in various profiles along the second suction conveyor 13.

Preferably, as shown in FIG. 3, the first tobacco material 4 may be trimmed by a trimming unit 51. The trimming unit 51 can include a pair of counter-rotating blades 52 that are spaced from the first suction belt 16 so that they trim the first tobacco material to an appropriate thickness. Alternatively or additionally, the trimming unit 51 can include a paddle wheel that rotates and knocks first tobacco material off of the first suction belt 16. The trimming unit 51 can be arranged upstream of the first transfer region 28 so that the first tobacco material 4 is trimmed to the appropriate thickness before being transferred to the intermediate suction conveyor 14. A recycling device 53 maybe arranged to collect tobacco that is trimmed by the trimming unit 51 and recycle it to the first vertical feeder 10. More preferably, the combined first and second tobacco materials 4, 5 on the second suction belt 29 may be trimmed by a trimming unit 54. The trimming unit 54 can include a pair of counter-rotating blades 55 that are spaced from the second suction belt 29 so that they trim the first and/or second tobacco materials 4, 5 to an

appropriate thickness. Alternatively or additionally, the trimming unit 54 can include a paddle wheel that rotates and knocks first tobacco material off of the second suction belt 29. Depending on the arrangement of the first and second tobacco materials 4, 5 on the second suction belt 29, one or both of the first and second tobacco materials 4, 5 may be trimmed. The trimming unit 54 is arranged downstream of the second vertical feeder 11, before the tobacco materials 4, 5 are transferred onto the garniture 36.

The trimming unit 54 may include a recycling device 53 arranged to collect tobacco material that is trimmed by the trimming unit 54. If only one type of the first and second tobacco materials 4, 5 is trimmed from the second suction belt 29, then that trimmed tobacco material can be recycled to the first or second vertical feeder 10, 11, as appropriate. If the trimmed tobacco is a mix of first and second tobacco materials 4, 5, then the trimming tobacco material can be recycled for alternative uses, for example in different tobacco industiy products. The arrangement described above and illustrated in FIG. 3 creates a tobacco stream having two different tobacco materials 4, 5. However, one or more additional vertical feeders, suction conveyors, and intermediate suction conveyors (along with appropriate suction belts / removal drums) could be arranged in series to create a stream of tobacco material having three or more different types of tobacco material arranged in a profile.

Moreover, by placing the same type of tobacco material in the first and second vertical feeders 10, 11 the apparatus could be used to produce a tobacco rod having a single type of tobacco material. This is advantageous as it gives flexibility in the manufacturing process - i.e. the apparatus can be employed to produce various formats of tobacco rod, having one or more different types of tobacco material.

As described above, the combined stream of first and second tobacco materials 4, 5 is transferred from the second suction conveyor 13 into a garniture 36. The skilled person will be aware of suitable existing garnitures 36, but a brief description of the garniture 36 is provided below. The garniture comprises a continuous garniture belt 57 that drives a ribbon of paper 58 through the garniture 36. The garniture belt 57 is disposed below the ribbon of paper 58, and the tobacco material 4, 5 is transferred from the second suction conveyor 13 onto the top of the ribbon of paper 58. In this way, the tobacco material 4, 5 is arranged on the ribbon of paper 58, which is moved through the garniture 36 by the garniture belt 57.

An adhesive applicator (not illustrated) applies adhesive to the top of the ribbon of paper 58 along one side. The garniture includes a wrapping unit (not illustrated) through which the ribbon of paper 58 with tobacco material 4, 5 is conveyed. The wrapping unit wraps the ribbon of paper 28 about the tobacco material 4, 5 and the adhesive glues the ribbon of paper 58 in place to form a continuous tobacco rod 7, for example a continuous tobacco rod as illustrated in one of FIGS. 2A and 2B. The continuous tobacco rod is then cut to the appropriate length for forming tobacco industry products, for example the tobacco industry products 1 shown in FIGS. lA to lD. In various examples, the continuous tobacco rod is cut on the tobacco rod making machine and/or on subsequent assembly apparatus. In various examples, the continuous tobacco rod can be cut into double-length rods, quadruple-length rods, and so on, and transferred to an assembly machine for further cutting and combining with a filter to produce complete tobacco industry products. In examples, this can be referred to as a‘two-up’ or‘four-up’ manufacturing process.

Advantageously, the first and second vertical feeders 10, 11 and first and second suction conveyors 12, 13 can be produced by modification of conventional apparatuses already used in the tobacco product industry. For example, the Hauni Protos cigarette making machine includes a vertical feeder and a suction conveyor arrangement, commonly known as a‘V.E’. This machine can be adapted to be used as the first vertical feeder 10 and first suction conveyor 12 described with reference to the examples. This machine can also be adapted to be used as the second vertical feeder 11 and second suction conveyor 13 described with reference to the examples. For example, modification might include replacement of the suction belts, modification of the suction chambers, and/or addition of trimming units. Two of the modified machines can be combined in the described manner by provision of the intermediate suction conveyor 14 and/or addition of the removal drum 39. As used herein, the term‘aerosolisable material’ includes materials that provide volatilised components upon heating, typically in the form of vapour or an aerosol. In some examples, as described above, the aerosolisable material includes a tobacco material. In other examples, the aerosolisable material consists of a tobacco material, or a blend of different tobacco materials. In other examples, the aerosolisable material is free from tobacco material. The apparatus described herein maybe used to manufacture a rod of any aerosolisable material.

In various examples, the first and second tobacco materials 4, 5 are different tobacco materials. For example, the first and second tobacco materials 4, 5 may have different types of tobacco leaf (e.g. hurley, oriental, Virginia), or different blends of these different types of tobacco leaf. Alternatively or additionally, the first and second tobacco materials 4, 5 may have tobacco that is dried, cured or treated differently (e.g. flue-cured, air-cured etc.). Alternatively or additionally, the first and second tobacco materials 4, 5 may have different additives. Additives may include, for example flavourants (e.g. menthol) in the form of granules or liquid additives, burn rate modifiers, smoke modifiers etc. Alternatively or additionally, the first and second tobacco materials 4, 5 may include tobacco substitutes, for example reconstituted tobacco materials, or blends of tobacco substitutes with tobacco materials.

As used herein, the term“tobacco industry product” is intended to include smoking articles comprising combustible smoking articles such as cigarettes, cigarillos, cigars, tobacco for pipes or for roll-your-own cigarettes, (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material), electronic smoking articles such as e-cigarettes, heating devices that release compounds from substrate materials without burning such as tobacco heating products, hybrid systems to generate aerosol from a combination of substrate materials, for example hybrid systems containing a liquid or gel or solid substrate; and aerosol-free nicotine delivery articles such as lozenges, gums, patches, articles comprising breathable powders and smokeless tobacco products such as snus and snuff.

In one embodiment, the tobacco industry product is a smoking article for combustion, selected from the group consisting of a cigarette, a cigarillo and a cigar. In one embodiment, the tobacco industry product is a non-combustible smoking article.

In one embodiment the tobacco industry product is a heating device which releases compounds by heating, but not burning, an aerosolisable substrate material. The aerosolisable substrate material may be for example tobacco or other non-tobacco products, which may or may not contain nicotine. In one embodiment the heating device is a tobacco heating device. In one embodiment, the apparatus or method is used to manufacture a consumable for a heating device.

In another embodiment the tobacco industry product is a hybrid system to generate aerosol by heating, but not burning, a combination of aerosolisable substrate materials. The aerosolisable substrate materials may comprise for example solid, liquid or gel which may or may not contain nicotine. In one embodiment, the hybrid system comprises a liquid or gel substrate and a solid substrate. The solid substrate may be for example tobacco or other non-tobacco products, which may or may not contain nicotine. In one embodiment the hybrid system comprises a liquid or gel substrate and tobacco. In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration various embodiments in which the claimed invention(s) maybe practiced and provide for superior apparatus for manufacturing a rod of aerosolisable material, and a superior method of manufacturing a rod of aerosolisable material. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. They are presented only to assist in understanding and teach the claimed features. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope and/ or spirit of the disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of, various combinations of the disclosed elements, components, features, parts, steps, means, etc. In addition, the disclosure includes other inventions not presently claimed, but which may be claimed in future.

Claims

Claims l. Apparatus for manufacturing a rod of aerosolisable material, the apparatus comprising a first suction conveyor arranged to convey a first aerosolisable material, a second suction conveyor arranged to combine the first aerosolisable material with a second aerosolisable material, and an intermediate conveyor arranged to transfer the first aerosolisable material from the first suction conveyor to the second suction conveyor.

2. The apparatus of claim l, wherein the first suction conveyor comprises a first suction belt configured to apply suction to retain the first aerosolisable material on an underside of the first suction belt.

3. The apparatus of claim l or claim 2, wherein the second suction conveyor comprises a second suction belt configured to apply suction to retain the first aerosolisable material and the second aerosolisable material on an underside of the second suction belt.

4. The apparatus of any of claims l to 3, wherein the intermediate conveyor comprises an intermediate suction belt configured to apply suction to retain the first aerosolisable material on an upper side of the intermediate suction belt.

5. The apparatus of claim 1, wherein the first and second suction conveyors and the intermediate conveyor comprise, respectively, first, second and intermediate suction belts configured to apply suction to retain the aerosolisable material on the suction belts.

6. The apparatus of claim 5, wherein each of the first and second suction conveyors and the intermediate conveyor comprise a suction chamber arranged to provide suction.

7. The apparatus of claim 6, wherein each of the first, second and intermediate suction belts comprises suction holes through which suction acts to retain aerosolisable material on the first, second and intermediate suction belts.

8. The apparatus of claim 7, wherein the suction holes of the first suction belt are arranged in a profile such that the first aerosolisable material is retained on the first suction conveyor in a profile.

9. The apparatus of claim 8, wherein the profile of the suction holes of the first suction belt comprises spaced suction regions, each suction region having one or more suction holes.

10. The apparatus of claim 9, wherein the profile of the suction holes on the first suction belt further comprises groups of connecting suction holes disposed between the suction regions, the groups of connecting suction holes having a lower density than the suction holes in the suction regions such that less of the first aerosolisable material is retained by the connecting suction holes than by the suction holes in the suction regions.

11. The apparatus of any of claims 7 to 10, wherein the suction holes of the intermediate suction belt are arranged in a profile such that the first aerosolisable material is retained on the intermediate conveyor in a profile.

12. The apparatus of claim 11, wherein the profile of the suction holes of the intermediate suction belt comprises spaced suction regions, each suction region having one or more suction holes.

13. The apparatus of claim 12, wherein the profile of the suction holes on the intermediate suction belt further comprises groups of connecting suction holes disposed between the suction regions, the groups of connecting suction holes having a lower density than the suction holes in the suction regions such that less of the first aerosolisable material is retained by the connecting suction holes than by the suction holes in the suction regions.

14. The apparatus of any preceding claim, further comprising a first feeder disposed below the first suction conveyor and adapted to feed the first aerosolisable material to the first suction conveyor.

15. The apparatus of any preceding claim, further comprising a second feeder disposed below the second suction conveyor and adapted to feed the second

aerosolisable material to the second suction conveyor.

16. The apparatus of any preceding claim, further comprising a removal drum arranged to remove some of the first aerosolisable material from the intermediate conveyor, such that the first aerosolisable material is arranged in a profile on the intermediate conveyor.

17. The apparatus of claim 16, wherein the removal drum comprises a rotor arranged to rotate, the rotor comprising a plurality of removal passages for removing parts of the first aerosolisable material from the intermediate conveyor.

18. The apparatus of claim 17, wherein the removal drum comprises at least one suction extraction tube connected to the removal passages for removal of parts of the first aerosolisable material from the intermediate conveyor.

19. The apparatus of any of claims 16 to 18, wherein the intermediate conveyor further comprises a suction break chamber arranged to release suction from the first aerosolisable material to transfer the first aerosolisable material from the intermediate suction conveyor to the second suction conveyor.

20. The apparatus of claim 19, wherein the suction break chamber comprises an air jet.

21. The apparatus of claim 20, wherein the air jet is configured to provide pulses of air flow.

22. The apparatus of any preceding claim, wherein the first aerosolisable material is transferred from the first suction conveyor to the intermediate conveyor at a first transfer region, and wherein the first suction conveyor and the intermediate conveyor are arranged adjacent to each other in the first transfer region for transfer of the first aerosolisable material.

23. The apparatus of claim 22, wherein the first suction conveyor comprises a first suction belt adapted to carry the first aerosolisable material on an underside of the first suction belt, and wherein the intermediate conveyor comprises an intermediate suction belt adapted to receive the first aerosolisable material on an upper side of the intermediate suction belt, and wherein in the first transfer region the intermediate suction belt is disposed below the first suction belt.

24. The apparatus of any preceding claim, wherein the first aerosolisable material is transferred from the intermediate conveyor to the second suction conveyor at a second transfer region, and wherein the intermediate conveyor and the second suction conveyor are arranged adjacent to each other in the second transfer region for transfer of the first aerosolisable material.

25. The apparatus of claim 24, wherein the intermediate conveyor comprises an intermediate suction belt adapted to carry the first aerosolisable material on an upper side of the intermediate suction belt, and wherein the second suction conveyor comprises a second suction belt adapted to receive the first aerosolisable material on an underside side of the second suction belt, and wherein in the second transfer region the intermediate suction belt is disposed below the second suction belt.

26. The apparatus of any preceding claim, further comprising a trimmer arranged to trim the first aerosolisable material on the first suction conveyor.

27. The apparatus of any preceding claim, further comprising a trimmer arranged to trim the combined first aerosolisable material and second aerosolisable material on the second suction conveyor.

28. The apparatus of any preceding claim, further comprising a garniture arranged to receive the combined first aerosolisable material and second aerosolisable material from the second suction conveyor.

29. The apparatus of claim 28, wherein the garniture is adapted to wrap a ribbon of paper about the combined first aerosolisable material and second aerosolisable material to form a continuous rod of aerosolisable material.

30. The apparatus of claim 29, further comprising a cutter adapted to cut the continuous rod of aerosolisable material.

31. A method of manufacturing a rod of aerosolisable material, the method comprising:

conveying a first aerosolisable material on a first suction conveyor,

transferring the first aerosolisable material to a second suction conveyor via an intermediate conveyor, and

32. The method of claim 31, further comprising removing some of the first aerosolisable material from the intermediate conveyor such that the first aerosolisable material is arranged in a profile.

33. The method of claim 31 or claim 32, wherein the first aerosolisable material is received on the first suction conveyor in a profile.

34. The method of any of claims 31 to 33, further comprising trimming the first aerosolisable material on the first suction conveyor.

35· The method of any of claims 31 to 34, further comprising trimming the combined stream of first aerosolisable material and second aerosolisable material on the second suction conveyor.

36. The method of any of claims 31 to 35, further comprising transferring the combined first aerosolisable material and second aerosolisable material to a garniture.

37. The method of claim 36, further comprising wrapping the combined first aerosolisable material and second tobacco aerosolisable in a ribbon of paper to form a continuous rod of aerosolisable material.

38. The method of claim 37, further comprising cutting the continuous rod of aerosolisable material.

39. A method of manufacturing a tobacco industry product, the method comprising manufacturing a rod of aerosolisable material according to the method of any of claims 31 to 38, and further comprising combining the rod of aerosolisable material with a further component.

40. The method of claim 39, wherein the tobacco industry product is a cigarette.