EP4651741A1

EP4651741A1 - Methods and assemblies for the manufacture of a hollow component for use in or with an aerosol provision system

Info

Publication number: EP4651741A1
Application number: EP24702583.6A
Authority: EP
Inventors: Andrei GRISHCHENKO; Gilbert AYINA; Louise ADAMS; Junior KABIRAT; Rosa GALATI
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2023-01-19
Filing date: 2024-01-19
Publication date: 2025-11-26
Also published as: WO2024153942A1; TW202432013A; GB202300834D0

Abstract

An assembly for manufacturing a hollow component of a consumable for use in or with an aerosol provision system. The assembly comprises a transport jet (26) having a funnel (261) and a mandrel (262). The mandrel is arranged within the funnel so that an outer surface of the mandrel is spaced from an inner surface of the funnel to define a channel (265) therebetween. The channel is configured to receive material for forming the hollow component into an inlet of the channel. In an upstream section (2614) of the channel, the outer surface of the mandrel and the inner surface of the funnel converge such that the cross-sectional area of the channel decreases between the inlet and a downstream section (2615) of the channel. The mandrel comprises an internal conduit (2619) and apertures (2620) that communicate the internal conduit with the channel. The apertures are disposed within the upstream section of the channel. Also disclosed is a method of operating such an assembly.

Description

Methods and Assemblies for the Manufacture of a Hollow Component for use in or with an Aerosol Provision System

The present invention relates to assembly for manufacturing a hollow component of a consumable for use in or with an aerosol provision system and a method for doing the same.

Background Aerosol provision systems include traditional systems such as cigarettes, as well as more recent systems such electronic aerosol generating devices and their associated consumables. These systems are complex and have many components, many of which can consist of non-biodegradable materials. There is therefore a drive to design new components with the same or better functionality and performance, but that have improved biodegradability for reduced environmental impact.

Summary of the invention

In a first aspect of the present invention, there is provided an assembly for manufacturing a hollow component of a consumable for use in or with an aerosol provision system, the assembly comprising a transport jet having a funnel and a mandrel, wherein the mandrel is arranged within the funnel so that an outer surface of the mandrel is spaced from an inner surface of the funnel to define a channel therebetween, the channel being configured to receive material for forming the hollow component into an inlet of the channel; wherein, in an upstream section of the channel, the outer surface of the mandrel and the inner surface of the funnel converge such that the cross-sectional area of the channel decreases between the inlet and a downstream section of the channel; and wherein the mandrel comprises an internal conduit and apertures that communicate the internal conduit with the channel, the apertures being disposed within the upstream section of the channel.

The apertures maybe disposed in the upstream section of the channel only. The apertures may be spaced along a length of the mandrel. The apertures may be regularly spaced along the length of the mandrel. The cross-sectional area of the channel may be substantially constant in the downstream section of the channel.

The assembly maybe provided with a heater to heat the outer surface of the mandrel and/ or the inner surface of the funnel.

The heater may be configured to heat the outer surface of the mandrel and/ or the inner surface of the funnel to a temperature of between 150 Celsius and 250 Celsius, or greater than about 200 Celsius.

The heater may be configured heat the outer surface of the mandrel and/or the inner surface of the funnel in the downstream section of the channel.

The assembly may comprise a pressurisation mechanism configured to pressurise the channel.

The pressurisation mechanism may comprises a nozzle configured to introduce a jet of air into the upstream section or downstream section of the channel. The nozzle may be configured to introduce a jet of air between the upstream section and the first downstream section.

The pressurisation mechanism may be configured to increase the static pressure within the channel to around 6 bar.

A length of the downstream section of the channel may be between 50% and 80% of the overall length of the channel.

The assembly may comprise a pre-folding unit. The pre-folding unit may comprise a series of grooves. The grooves maybe formed in a convex outer side wall of the prefolding unit. The grooves maybe formed in a concave inner side wall of the pre-folding unit. The grooves may extend along a helical path.

In a second aspect of the present invention, there is provided a method of operating the assembly of the first aspect, the method comprising: supplying a material into the channel of the transport jet; and applying a bonding agent to the material through the apertures of the mandrel.

Supplying the material may comprise supplying a fibrous material. The fibrous material maybe a continuous sheet of paper.

The continuous sheet of paper maybe a continuous sheet of crimped paper. The sheet material may comprise a non-woven material.

The crimped paper may comprise a crimp amplitude of between about o.imm and 0.2mm.

The bonding agent may comprise about 6wt% Pectin.

The method may further comprise heating the material to greater than about 200 Celsius after applying the bonding agent.

Brief Description of the Figures

Embodiments of the invention will now be described, by way of example only, with reference to accompanying drawings, in which: Fig. 1 illustrates a consumable in cross-section;

Fig. 2 schematically illustrates part of a manufacturing line for a component of the consumable;

Fig. 3 illustrates a section of sheet material following transit through a crimping station; Fig. 4 illustrates the section of sheet material following transit through a pre-folding unit;

Fig. 5 illustrates a crimping pattern impressed into the sheet material by the crimping station;

Fig. 6 illustrates a first example of the pre-folding unit; Fig. 7 illustrates a second example of the pre-folding unit;

Fig. 8 illustrates a transport jet in cross section;

Fig. 9a schematically illustrates a tapered portion of a mandrel of the transport jet;

Fig. 9b schematically illustrates a converging section of a funnel of the transport jet;

Fig. 10 is a flow chart of a method of manufacturing the component of the consumable; Fig. 11 is a flow chart of a method of processing the sheet material in the manufacture of the component of the consumable; and Fig. 12 illustrates a component formed in accordance with methods and apparatus described herein.

Detailed Description According to the present disclosure, a “combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is combusted or burned during use in order to facilitate delivery of at least one substance to a user. In some embodiments, the delivery system is a combustible aerosol provision system, such as a system selected from the group consisting of a cigarette, a cigarillo and a cigar.

In some embodiments, the disclosure relates to a component for use in a combustible aerosol provision system, such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosol-modifying agent release component such as a capsule, a thread, or a bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper.

According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.

In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.

In some embodiments, the non-combustible aerosol provision system is an aerosolgenerating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system. In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.

Typically, the non-combustible aerosol provision system may comprise a non- combustible aerosol provision device and a consumable for use with the non- combustible aerosol provision device.

In some embodiments, the disclosure relates to consumables comprising aerosolgenerating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

In some embodiments, the non-combustible aerosol provision system, such as a non- combustible aerosol provision device, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent. In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent. Fig. 1 shows an aerosol provision system 10 in the form of a rod-shaped consumable to for use with an electronic aerosol generating device. Fig. i is presented as a section taken along the system’s longitudinal axis. As illustrated, the system comprises a hollow component 11. By ‘hollow’ it is meant that the component comprises a central passage 12 along which aerosol may travel during use of the system io. In this example, the hollow component n is a tube n formed of a sheet of crimped paper gathered into the tube according to the method outlined herein. Other components of the system may vary according to the particular application of the system, but are readily selected by the skilled person and can include an aerosol generating section, a filter and other additive or active laden sections as required. In other examples, the tube n itself may be provided with aerosol generating material. In the illustrated example, the hollow component n is attached to a rod-shaped aerosol generating section 13 by an overlapping wrapping material 14 that circumscribes both. The wrapping paper 14 may be a tipping paper, a cigarette paper, a plug wrap or any other suitable combining overwrap that will be available to the skilled person.

Fig. 2 schematically illustrates part of a manufacturing line 20 for the component 11.

The line 20 comprises a supply 21 of continuous sheet material 22 at an upstream end ‘U’ of the line 20; and an endless garniture belt 27 at a downstream end ‘D’ of the line 20. The direction of travel of the continuous sheet material 22 during operation of the line 20 is herein referred to as the ‘machine direction’ and indicated by arrow ‘MD’. In order, from the upstream to the downstream end, the manufacturing line 20 further comprises a crimping station 23, an optional cutting station 24, an optional pre-folding unit 25, a transport jet 26, a pressure chamber 28 and a drying chamber 29. In operation the continuous sheet material 22 is processed to form a continuous hollow rod 30, which is output from the transport jet 26. The endless garniture belt 27 conveys the continuous hollow rod 30 before being cut into individual components for conveyance to further assembly stations for forming a consumable. The cutting of the continuous hollow rod 30 and the subsequent forming of the individual components 11 into a consumable 10 may be carried out in any way apparent to the skilled person and lies beyond the scope of this disclosure. However, it will be appreciated that forming a consumable 10 from a rod-shaped component 11 is well understood in the tobacco industry and its omission from this description would not present any difficulty to the skilled person in forming a consumable 10 like the one illustrated in Fig. 1. The supply of continuous sheet material 21 comprises a reel 211 about which is wound the continuous sheet material 22 (also referred to herein as simply ‘sheet material 22’ for brevity). During operation of the line 20, the sheet material 22 is unwound from the reel 211 and conveyed in the machine direction. The sheet material may comprise a non-woven material. The sheet material 22 is preferably a paper of cellulose fibres having paper weight of 30 gsm to 70 gsm, however other biodegradable materials having any suitable thickness maybe used. For example, the sheet material 22 can be any of paper, lyocell, viscose, silk, cotton, linen (1.0 - 5.0 denier) or jute. The width of the sheet material 22 is preferably between 70mm and 160mm and, in a particular example, is 90mm. The thickness of the sheet material 22 may be between 6op and loop and, in a particular example, is 8s .

The crimping station 23 comprises a pair of crimping rollers 231, 231’. Each roller 231, 231’ is a cylinder arranged to rotate about its axis. The rollers 231, 231’ are arranged with their axes parallel and their circumferential surfaces closely spaced such that, in use, the rollers 231, 231’ rotate to grip the sheet material 22 in between. The crimping rollers 231, 231’ maybe driven to assist in drawing the sheet material from the reel 21, or they maybe passive and rotate as a result of the sheet material 22 being drawn therebetween. For example, the sheet material may be drawn in the machine direction solely by the endless garniture belt 27 at the downstream end of the line 20.

One or both of the rollers 231, 231’ comprises an embossing pattern on its circumferential surface to impress the pattern into the sheet material 22 as it passes in between. The pattern comprises a series of ridges and grooves as shown in Figs. 3 and 5 and is referred to herein as the ‘crimp pattern’ or ‘crimping pattern’. Fig. 3 illustrates a section of the sheet material 22 as it emerges from the crimping station 23. The grooves impressed into the sheet material extend in a longitudinal direction LD of the sheet material 22, that is to say, in the machine direction MD. Fig. 5 illustrates the crimping pattern in more detail. The crimping pattern comprises a crimp amplitude A (also known as “crimping factor”), which refers to the depth of the grooves the crimping pattern forms in the sheet material 22. That is, crimping the sheet material 22 produces a plurality of peaks 221 and troughs 222 in the sheet material 22, where the crimp amplitude ‘A’ is the depth of the troughs 222, measured from their peak 221. The crimping factor has an influence on the hardness and roundness of the component 11 being produced. That is, increasing the crimping factor has been found to increase the hardness and roundness of the component 11, with associated benefits in terms of component integrity and quality. Furthermore, increasing the crimping factor has been found to increase the pressure drop across the component 11 as aerosol is drawn through the component 11 during use. This can be beneficial in controlling and obtaining consistency of pressure drop across the component 11 and thereby within consumables to comprising such a component 11. The crimping may form a ‘Zig-Zag’ formation or another shape. Adjacent grooves of the crimped sheet material are spaced by a distance, or have a pitch ‘P’. The pitch is preferably in the range of 100 pm to 1000 pm, or more preferably in the range of 100 pm to 500 pm. The crimp amplitude is preferably between 50 pm and 250 pm, or more preferably in the range of 100 pm and 200 pm. In a particular example, the crimped sheet material comprises a pitch of 300 pm and a crimp amplitude of 150 pm.

Following crimping, the sheet material may optionally pass to the cutting station 24 where the sheet material 22 is slit into individual strands 22’, 22”, 22”’ of sheet material 22, as shown in Fig. 2. If the cutting station 24 is omitted, the sheet material 22 is instead advanced directly to the pre-folding unit 25 without being divided into strands and remains intact. Advantageously, slitting the sheet material 22 into individual strands 22’, 22”, 22”’ results in a more uniform distribution of the sheet material 22 when it is gathered into the shape of the component 11 in the transport jet 25. This is explained further below. The cutting station 24 comprises an arrangement of blades 241 which extend into the path of the sheet material 22 to slice the sheet material 22 into the individual strands 22’, 22”, 22”’ as the sheet material 22 is drawn across the blades 241. Evidently, the number of blades depends on the desired number of individual strands. The blades 241 may comprise a straight edge or, alternatively, the blades 241 may be discs that cut the sheet material against an anvil roller or other cutting surface. Where the cutting station 24 is employed, the sheet material 22 may be cut into two, three, four or five strands, as desired. Following cutting, the sheet material 22 may be drawn over, or through, the pre-folding unit 25, depending on the design of the pre-folding unit as will be explained. Regardless of design, the pre-folding unit 25 comprises a series of grooves 251 that extend along a helical path. Fig. 6 shows a first example pre-folding unit 25 in which the grooves 251 are formed in a convex side of a curved wall 252 of the pre-folding unit 25. In this example, the curved wall 252 is the curved outer surface 252 of a solid frusto-conical, single piece component 25’. The component 25’ comprises an upstream end U which is configured to face the direction of incoming sheet material 22 and a downstream end D, opposite the upstream end. The upstream end is the larger diameter end of the frustum-cone. In the illustrated example, the component 25’ comprises five grooves 251 that each follow a helical path about the outer surface 252 of the component 25’, though any number of grooves may be adopted as required. In operation of the manufacturing line 20, sheet material 22 is drawn over the upstream end U the component 25’ and into the transport jet 26. An inlet to the transport jet 26 has a diameter equal to or less than the diameter of the downstream end D of the pre-component 25’ so that the sheet material 22 is drawn tightly over its curved surface 252 and into the grooves 251, causing the sheet material 22 to adopt the profile of the grooves 251. In this way the sheet material 22 is pre folded as the sheet material 22 remains in the shape imparted by the grooves 251 as it leaves the component 25’.

A second example pre-folding unit 25 is shown in Fig. 7 in which like features retain the same reference numbers. In this example, the grooves 251 are formed in a concave side

253 of a curved wall 254 of the pre-folding unit 25. The curved wall 254 forms a hollow frusto-conical, single piece component 25” with the grooves 251 provided in an inner surface 253 of the hollow component 25” in a manner similar to rifling. As with the solid component 25’, the hollow component 25” comprises an upstream end U which is configured to face the direction of incoming sheet material 22 and a downstream end D, opposite the upstream end, with the upstream end being the larger diameter end of the frustum-cone. In the illustrated example, the component 25” comprises eight grooves 251 that each follow a helical path about the inner surface 253 of the component 25”, though any number of grooves 251 may be adopted as required. In operation of the manufacturing line 20, sheet material is drawn into the upstream end and leaves through the downstream end before passing into the transport jet 26. Due to the decreasing diameter of the inner surface 253 between the upstream and downstream ends, the sheet material 22 closely follows the inner surface 253 of the component 25” and adopts the profile of the grooves 251. In this way, the sheet material is pre folded in the same manner as with the solid component 25’.

Fig. 4 shows a section of sheet material that has left the pre-folding unit 25. As illustrated, the sheet material 22 comprises a macro and micro fold pattern. The macro fold pattern refers to the shape imparted by the grooves 251 of the pre-folding unit 25 and comprises a series of ridges and grooves that are sinusoidal in appearance. The micro fold pattern refers to the much finer series of peaks 221 and troughs 222 imparted by the crimping rollers 23 as described above.

One advantage of the helical path of the grooves of the above-described pre-folding units 25 is that the continuous sheet material 22 itself begins to adopt a helical path as it passes from the pre-folding unit 25 into the transport jet 26. Where multiple strands of sheet material 22 are provided to the pre-folding unit 25, each individual strand is caused to adopt a helical path as it is passed into the transport jet 26. As explained further below, the sheet material 22 is gathered within the transport jet 26 to form a continuous hollow rod 30, with each strand of the gathered sheet material 22 following a helical path about the axis of the continuous hollow rod 30. An advantage of this is that the continuous hollow rod 30 is provided with more uniform distribution of gathered sheet material 22 along the length of the continuous hollow rod 30 than if the individual strands were not caused to adopt a helical shaped path.

The grooves 251 of the pre-folding units 25 described herein may have a pitch at the downstream end D of the pre-folding unit 25 of between 50mm and 550mm, such as between 200mm and 400mm. By ‘pitch’, it is meant the axial distance over which the helical path takes to complete one turn (i.e. to turn through 360 degrees). By pitch at the downstream end D, it is meant the pitch of the of the helical path at the diameter of the downstream end D of the pre-folding unit 25. The pitch at the downstream end will be substantially equal to the pitch of the individual strands of the sheet material 22 as they enter the transport jet 26. It will be appreciated that the pitch need not be constant across the length of the pre-folding unit 25. For example, the grooves 251 may have a pitch at the downstream end D of the pre-folding unit 25 that is less than the pitch at the upstream end U of the pre-folding unit 25. In this way, the helical path described by the grooves 251 may gradually tighten between the upstream and downstream ends U, D. In one example, the helical path may describe a conic helix. The illustrated pre-folding units 25 are machined from aluminium, steel or any other suitable material - a detailed description of which will be omitted for falling within the purview of the skilled person. They may be mounted to a bed of the manufacturing line 20 by bracket (not shown) or any other suitable way. What is important is that the axis X-X of the pre-folding unit 25 is parallel to the machine direction MD with the upstream end U facing the direction of incoming sheet material 22. The pre-folding units 25 should be positioned within the path of the sheet of material 22 such that the sheet material follows the grooves 251 of the pre-folding unit 25 in the way described.

The grooves 251 of the illustrated pre-folding units 25 may have a width of between 3mm and 20mm. The narrower the width of each groove 251, the more tightly the sheet material 22 is pre folded.

Fig. 8 illustrates the transport jet 26 in a section taken along its longitudinal axis. The transport jet 26 comprises a funnel 261 and a mandrel 262. The mandrel 262 is an elongate rod positioned within the funnel 261 so that an outer surface 263 of the mandrel 262 is spaced from an inner surface 264 of the funnel 261, forming an annular channel 265.

The mandrel 262 comprises a tapered portion 266 and a uniform portion 267. By ‘tapered’, it is meant that an overall diameter of the mandrel 262 decreases between an upstream end 2610 of the mandrel 262 and the uniform portion 267. By ‘uniform’, it is meant that an overall diameter of the uniform portion 267 is constant along its length to a downstream end 2611 of the mandrel 262. The funnel 261 comprises a converging section 268 and a uniform section 269, downstream of the converging section 268. An internal diameter of the funnel 261 in the converging section 268 decreases between an upstream end 2612 of the funnel and the uniform section 269, whereupon the internal diameter is constant for the length of the uniform section 269 to a downstream end 2613 of the funnel 261.

The mandrel 262 is positioned within the funnel 261 so that the tapered portion 266 of the mandrel 262 sits within the converging portion 268 of the funnel 261 and the uniform portion 267 of the mandrel 262 within the uniform section 269 of the funnel 261.

A taper angle of the tapered portion 266 of the mandrel 262 is less than a convergence angle of the converging section 268 of the funnel 261. Thus, the channel 265 comprises a section 2614 (herein referred to as an ‘upstream section 2614’) in which the outer surface 263 of the mandrel 262 and the inner surface 264 of the funnel 261 converge. In other words, the cross-sectional area of the upstream section 2614 of the channel 265 decreases between an inlet 2616 of the channel 265 and an intermediate-point 2617 of the channel 265. The intermediate-point 2617 of the channel 265 is a position along the length of the channel 265 where the upstream section 2614 meets a downstream section 2615 and is represented graphically in Fig. 8 by broken line. The downstream section 2615 is defined as a portion of the channel in which the cross-section area of the channel 265 is constant. In other words, it is the section of the channel 265 defined between the uniform portion 267 of the mandrel 262 and the uniform section 269 of the funnel 261. In the illustrated example, the downstream section 2615 extends from the intermediate-point 2617 to an outlet 2618 of the channel 265. The taper angle AT of the mandrel is given by the formula:

Where: AT is the taper angle;

DSM is the smaller diameter end of the tapered portion of the mandrel;

DLM is the larger diameter end of the tapered portion of the mandrel; and L_M is the length of the tapered portion of the mandrel. These features are illustrated in Fig. 9a, which shows the tapered portion 266 of the mandrel 262 schematically.

Similarly, the convergence angle Ac of the converging section 268 of the funnel 261 is given by:

Where:

Ac is the convergence angle; DSF is the smaller diameter end of the upstream section of the funnel;

DLF is the larger diameter end of the upstream section of the funnel; and LF is the length of the upstream section of the funnel. These features are illustrated in Fig. 9b, which shows the converging section 268 of the funnel 261 schematically. It shall be appreciated that the stated diameters DSF, D_LF of the funnel 261 are internal diameters of the funnel 261. Thus, the cross- sectional area of the inlet (CIN) is given by the equation: ectional area at the intermediate point (CIP) is given by:

In the example illustrated by Fig. 8, regardless of the actual values, A_T < Ac such that CIN > Cip. This ensures a smooth and gradual gathering of the sheet material 22 as it travels through the upstream section of the funnel.

The mandrel 262 comprises an internal conduit 2619 and apertures 2620 that communicate the internal conduit 2619 with the channel 265. The internal conduit 2619 is connected to a supply of bonding agent 210 which is pumped through the internal conduit 2619, out of the apertures 2620 and into the channel 265 during operation of the transport jet 26. The internal conduit 2619 and apertures 2620 are provided in the tapered portion 266 of the mandrel 262 such that the apertures 2620 communicate with the upstream section 2614 of the channel 265. Therefore, bonding agent is introduced into the upstream section 2614 of the channel 265 as the sheet material 22 is gathered around the mandrel 262. The apertures 2620 are regularly spaced along the length of the tapered portion 266 of the mandrel 262 so that bonding agent is evenly distributed into the sheet material 22 in the upstream section 2614 of the channel 265. Another advantage of regular aperture 2620 spacing is that it is possible to continually apply the bonding agent as the sheet material 22 moves over the apertures 2620. For a viscous agent, such as the intended bonding agents described below, this is necessary to provide the required amount of bonding agent to the sheet material 22. However, it will be appreciated that other aperture spacing may be employed. For example, the apertures 2620 may become more closely spaced with proximity to the intermediate point 2617 of the channel 265. The apertures maybe provided in groups of apertures 2620 that extend radially from the conduit 2619 at a position along the length of the tapered portion 266 of the mandrel 262. In this way, the bonding agent is even distributed about the circumference of the mandrel 262. Alternatively, the apertures may be grouped into spirals that extend along the length of the tapered portion 266 mandrel 262. A spiral of apertures 2620 is a group of apertures 2620 spaced along the length of the mandrel 262 in which each aperture 2620 extends along a radii that is angularly offset from the adjacent apertures 2620 in the group. In operation of the transport jet, each spiral of apertures 2620 maybe arranged to align with the helical direction taken by individual strands of sheet material 22 as they leave the pre-folding unit 25.

The downstream section 2615 of the channel 265 has a cross sectional area equal in size and shape to the cross section of the finished component 11. Therefore, following gathering of the sheet material 22 in the upstream section 2614 of the channel 265, the gathered sheet material 22 takes on the dimensions of the channel 265 in the downstream section 2615, emerging from the outlet 2618 as the continuous hollow rod 30 for cutting into individual components 11.

In order to help the bonding agent set, the downstream section 2615 of the mandrel 262 may be heated. This may be achieved by either heating the outer surface 263 of the mandrel 262 or by heating the inner surface 264 of the funnel 261. The funnel 261 and/or mandrel 262 maybe heated in any suitable way. For example, electrical filaments (not shown) may be embedded in the surface 263, 264 to be heated. The filaments are heated by electrical resistance so that applying a voltage to the filaments causes them to generate heat. The surface in which the filaments are embedded - i.e. the outer surface 263 of the mandrel 262 or the inner surface 264 of the funnel 261 - maybe made of a heat conductive material, such as a metal. In one example, the mandrel 262 and funnel 261 are machined from a machine grade aluminium or stainless steel. Tracks (not shown) maybe machined into the outer surface 263 of the mandrel 262 or the inner surface 264 of the funnel 261 into which the filaments maybe laid. When the filaments are heated, the heat is conducted into the funnel 261 or mandrel 262 to heat the gathered sheet material 22 passing through the channel 265.

In one example, the inner surface 264 of the funnel 261 and/or the outer surface of the mandrel 262 are heated to a temperature of between 150 Celsius and 250 Celsius, or greater than about 200 Celsius. In order to assist the gathering of sheet material 20 within the transport jet 26, a pressurisation mechanism 2621 may be provided in the upstream section 2614 of the channel 265. The pressurisation mechanism 2621 comprises a nozzle 2622 configured to direct a stream of air toward the inlet 2616 of the channel 265 and thereby increase the static pressure at the inlet 2616. The pressurisation mechanism may be configured to increase the static pressure at the inlet 2616 to between 4 bar and 8 bar. In one example, the pressurisation mechanism is configured to increase the static pressure at the inlet 2616 to 6 bar. Alternatively or additionally, a pressure chamber 28 and drying chamber 29 may be employed downstream of the transport jet 26. These chambers 28, 29 are enclosures having openings to allow the continuous hollow rod 30 to pass therethrough. The pressure within the pressure chamber 28 is greater than ambient and assists in setting the bonding agent and causing a hardening of the continuous hollow rod 30. The temperature within the drying chamber 29 is greater than ambient and further assists in setting the bonding agent and causing a hardening of the continuous hollow rod 30.

The transport jet 26 maybe mounted to the bed of the manufacturing line 20 by a bracket (not shown) or in any other suitable way. For example, the bracket may attach an outer surface of the funnel 261 to the bed. The mandrel 262 may be supported within the funnel 261 by a bracket of its own that either attaches the mandrel 262 to the inner surface 264 of the funnel 261 or, alternatively, to the bed of the manufacturing line 20. In one example, the tapered portion 266 of the mandrel 262 protrudes from the inlet 2616 beyond the funnel 261 and a bracket (not illustrated) secures the protruding part of the tapered portion 266 to the bed of the manufacturing line 20. The bracket needs to be configured for minimal obstruction of the inlet 2616. For example, the bracket maybe a fin shaped support that extends radially from the mandrel 262 to the bed. In this way, the bracket does not obstruct the helical path of the sheet material 22 as it travels through the channel 265. The bracket may include a line for the supply of bonding agent to the conduit 2619 of the mandrel 262.

A method 40 of manufacturing the hollow component 11 of the consumable 10 will now be described with reference to Fig. 10. The method 40 comprises using 41 the transport jet 26 to gather continuous sheet material 20 into the shape of the hollow component 11. According to the method, use 41 of the transport jet 26 comprises supplying 42 the sheet material 20 into the channel 265 of the transport jet 26, gathering 43 the sheet material 20 within the channel 265 and applying 44 a bonding agent to the gathered sheet material 20 through the apertures 2620 of the mandrel 262.

In examples, supplying 42 the material 20 comprises supplying a fibrous material. In examples, the fibrous material is a continuous sheet of paper. In examples, the continuous sheet of paper is a continuous sheet of crimped paper. In examples, the crimped paper comprises a crimp amplitude of between about 0.1mm and 0.2mm.

In examples, applying 44 the bonding agent comprises applying a bonding agent comprising about 6wt% of food grade pectin. In one example, the bonding agent may be 4wt% of food grade pectin. In other examples, a bonding agent other than pectin may be used such as a starch based bonding agent, a clay based bonding agent, BioWax, cellulose acetate (in one example 5% of cellulose acetate dissolved in triacetin) and a tree resin based bonding agent.

In examples, the method may further comprise setting 45 the bonding agent by heating a surface of the transport jet 26 to a temperature of between 150 Celsius and 250 Celsius, or greater than about 200 Celsius.

In examples, gathering 43 the sheet material may further comprise pressurising 46 the transport jet 26 to increase the static pressure within the channel 265 of the transport jet 26 to 6 bar. A method 50 of processing the sheet material in the manufacture of the hollow component 11 of the consumable 10 will now be described with reference to Fig. 11. The method 50 comprises drawing 51 the sheet material 20 through a groove 251 of the prefolding unit 25 such that the sheet material 20 at least partially adopts the profile of the groove 251.

In examples, the method of processing the sheet material may further comprise splitting 52 the sheet material into individual strands 22, 22”, 22”’ of sheet material 22 upstream of the pre-folding unit 25. Fig. 12 illustrates an example hollow component 11 formed using examples of the method and apparatus outlined above and, in particular, example apparatus using the optional pre-folding unit 25 illustrated by Figs. 6 and 7. The gathered sheet material of the component of Fig. 12 comprises individual strands 22’, 22”, 22”’ that each extend along a helical path about a longitudinal axis of the component. However, it will be appreciated that the component could alternatively comprise any number of strands, including a single strand.

The helical path of the or each strand has an angle of twist of between 5 degrees and 45 degrees for an example component having an axial length of 7cm. By ‘angle of twist’ it is meant the angle a radii will travel through tracing the helical path as it advances along the longitudinal axis by a given distance (7cm in this example). Thus the angle of twist per cm of axial length of the component 11 is between 0.7 degrees and 6.5 degrees. This equates to a pitch of between 50mm and 550mm. Therefore, the pitch of the helical path of the or each strand of the gathered sheet material 22 falls within a similar range to the pitch of the helical path of the grooves 251 of the pre-folding unit 25, though they may not be exactly the same in any given example. A pitch of between 50mm and 550mm adds stability to the component 11. However, a pitch greater than 550mm risks causing a blockage in the pre-folding unit 25.

In examples, the component comprises an axial length between 4mm and 12mm and, optionally, an internal diameter of between 2.5mm and 5.5mm and, optionally, a wall thickness of between imm and 1.5mm.

The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive.

It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention 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 of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

1. An assembly for manufacturing a hollow component of a consumable for use in or with an aerosol provision system, the assembly comprising a transport jet having a funnel and a mandrel, wherein the mandrel is arranged within the funnel so that an outer surface of the mandrel is spaced from an inner surface of the funnel to define a channel therebetween, the channel being configured to receive material for forming the hollow component into an inlet of the channel; wherein, in an upstream section of the channel, the outer surface of the mandrel and the inner surface of the funnel converge such that the cross- sectional area of the channel decreases between the inlet and a downstream section of the channel; and wherein the mandrel comprises an internal conduit and apertures that communicate the internal conduit with the channel, the apertures being disposed within the upstream section of the channel.

2. An assembly according to claim 1, wherein the apertures are disposed in the upstream section of the channel only.

3. An assembly according to claim 1 or claim 2, wherein the apertures are spaced along a length of the mandrel.

4. An assembly according to claim 3, wherein the apertures are regularly spaced along the length of the mandrel. 5. An assembly according to any preceding claim, wherein the cross- sectional area of the channel is substantially constant in the downstream section of the channel.

6. An assembly according to any preceding claim, wherein the assembly is provided with a heater to heat the outer surface of the mandrel and/or the inner surface of the funnel.

7. An assembly according to claim 6, wherein the heater is configured to heat the outer surface of the mandrel and/or the inner surface of the funnel to a temperature of between 150 Celsius and 250 Celsius, or greater than about 200 Celsius.

8. An assembly according to claim 6 or claim 7, wherein the heater is configured heat the outer surface of the mandrel and/or the inner surface of the funnel in the downstream section of the channel. . An assembly according to any preceding claim, wherein the assembly comprises a pressurisation mechanism configured to pressurise the channel.

10. An assembly according to claim 9, wherein the pressurisation mechanism comprises a nozzle configured to introduce a jet of air into the upstream section or downstream section of the channel.

11. An assembly according to claim 8, wherein the nozzle is configured to introduce a jet of air between the upstream section and the first downstream section. 12. An assembly according to any one of claims 10 to 11, wherein the pressurisation mechanism is configured to increase the static pressure within the channel to around 6 bar.

13. An assembly according to any preceding claim, wherein a length of the downstream section of the channel is between 50% and 80% of the overall length of the channel.

14. A method of operating the assembly of any of claims 1 to 13, the method comprising: supplying a material into the channel of the transport jet; and applying a bonding agent to the material through the apertures of the mandrel.

15. A method according to claim 14, wherein supplying the material comprises supplying a fibrous material.

16. A method according to claim 15, wherein the fibrous material is a continuous sheet of paper.

17. A method according to claim 16, wherein the continuous sheet of paper is a continuous sheet of crimped paper.

18. A method according to claim 17, wherein the crimped paper comprises a crimp amplitude of between about 0.1mm and 0.2mm.

19. A method according to any of claims 14 to 18, wherein the bonding agent comprises about 6wt% Pectin.

20. A method according to any of claims 14 to 19 further comprising heating the material to greater than about 200 Celsius after applying the bonding agent.