WO2020152460A1

WO2020152460A1 - Apparatus for manufacturing a rod of aerosolisable material and method of manufacturing a rod of aerosolisable material

Info

Publication number: WO2020152460A1
Application number: PCT/GB2020/050139
Authority: WO
Inventors: Karl KALIJURA
Original assignee: British American Tobacco Investments Ltd IFI
Current assignee: British American Tobacco Investments Ltd IFI
Priority date: 2019-01-25
Filing date: 2020-01-22
Publication date: 2020-07-30
Anticipated expiration: 2021-07-25
Also published as: GB201901063D0

Abstract

Apparatus (9) for manufacturing a rod (7) of aerosolisable material (4, 5) is disclosed. The apparatus comprises a suction band (11) arranged to convey an aerosolisable material (4, 5), and a pair of rotatable trimming disks (25, 27) arranged such that a peripheral edge of each trimming disk is aligned with the suction band to remove aerosolisable material from the suction band as the trimming disks rotate during use. The peripheral edge (32a, 32b) of each trimming disk has a material removal region (33) extending about a part of the peripheral edge of each trimming disk. The material removal regions are adapted to remove substantially all of the aerosolisable material from the suction band at regular intervals along the suction band. A method of manufacturing a rod of aerosolisable material is also disclosed, as well as a trimming disk for apparatus for manufacturing a rod of aerosolisable material.

Description

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

Field

The present invention relates to an apparatus and a method for manufacturing a rod of aerosolisable material, for example a tobacco rod for use in cigarettes.

Background

Tobacco rod manufacturing apparatus includes a suction conveyor that receives tobacco material and conveys the tobacco material on a suction band. The tobacco material is conveyed into a garniture that wraps a paper wrapper about the tobacco material to form tobacco rods. Trimming disks are arranged to trim excess tobacco material from the suction band so that the level of tobacco material on the suction band is appropriate for the wrapping process.

Summary

In accordance with aspects of the invention, there is provided apparatus for

manufacturing a rod of aerosolisable material, the apparatus comprising:

a suction band arranged to convey an aerosolisable material, and

a pair of rotatable trimming disks arranged such that a peripheral edge of each trimming disk is aligned with the suction band to remove aerosolisable material from the suction band as the trimming disks rotate during use,

wherein the peripheral edge of each trimming disk has a material removal region extending about a part of the peripheral edge of each trimming disk, the material removal regions being adapted to remove substantially all of the aerosolisable material from the suction band at regular intervals along the suction band.

In preferred examples, the suction band is arranged to convey the aerosolisable material on an underside of the suction band. In this arrangement, the pair of rotatable trimming disks are arranged underneath the suction band to remove aerosolisable material from the suction band during operation of the apparatus.

The rotatable trimming disks may be parallel to the suction band. The pair of rotatable trimming disks may be arranged to act against the suction band to remove the aerosolisable material from the suction band. That is, the pair of rotatable trimming disks may be arranged to operate while in contact with the suction band. Alternatively, the rotatable trimming disks may be disposed proximate to the suction band. For example, the rotatable trimming disks may be spaced from the suction band by a distance of less than 5 millimetres, or by a distance of less than 2 millimetres, by a distance of less than 1 millimetre, or preferably by a distance of less than 0.5 millimetres, or by a distance of less than 0.05mm.

A surface of each material removal region that faces the suction band may be planar. The planar surfaces allow the rotatable trimming disks to operate proximate to, or against, the suction band. The peripheral edge at each material removal region may comprise a chamfer, and wherein the chamfer may be disposed on a side of the peripheral edge that faces away from the suction band.

The peripheral edge of each trimming disk may comprise a recessed region. The recessed region may be configured to remove no aerosolisable material from the suction band. Alternatively, the recessed region may be configured to remove less aerosolisable material from the suction band than the material removal region. In this way, downstream of the trimming disks the tobacco aerosolisable material is arranged in spaced regions along the suction band.

The peripheral edge of each trimming disk may comprise a plurality of material removal regions and plurality of recessed regions arranged alternately about the peripheral edge of each trimming disk. For example, the peripheral edge of each trimming disk may comprise a four material removal regions and four recessed regions arranged alternately about the peripheral edge of each trimming disk.

The material removal region of one trimming disk may be configured to be aligned to the material removal region of the other trimming disk as the trimming disks rotate during operation of the apparatus. The apparatus may further comprise a material removal wheel arranged adjacent to the pair of trimming disks, opposite to the suction band. The material removal wheel may be arranged to rotate and remove aerosolisable material as it is removed from the suction band by the pair of trimming disks.

The material removal wheel may comprise a plurality of paddles extending radially from the material removal wheel.

The radius of the material removal wheel may vary about the circumference of the material removal wheel.

The apparatus may further comprise a first feeder arranged to provide the aerosolisable material to the suction band upstream of the pair of rotatable trimming disks. The apparatus may further comprise a second feeder arranged to provide a second aerosolisable material to the suction band downstream of the pair of rotatable trimming disks to combine the second aerosolisable material with the aerosolisable material on the suction band. The apparatus may further comprise a second trimming unit arranged downstream of the second feeder. The second trimming unit may be arranged to trim the combined aerosolisable material and second aerosolisable material.

The apparatus may further comprise a garniture arranged to receive the aerosolisable material from the suction conveyor and to wrap the suction conveyor in a wrapper to form a rod of aerosolisable material.

According to a further aspect of the present invention, there is also provided a method of manufacturing a rod of aerosolisable material, the method comprising conveying an aerosolisable material on a suction band, and removing substantially all of the aerosolisable material from the suction band at regular intervals along the suction band. Removal of substantially all of the aerosolisable material from the suction band at regular intervals along the suction band is preferably performed by a pair of rotatable trimming disks arranged such that a peripheral edge of each trimming disk is aligned with the suction band to remove aerosolisable material from the suction band as the trimming disks rotate during use. The method may further comprise providing a second aerosolisable material to the suction band after removing aerosolisable material from the suction band at regular intervals along the suction band.

The method may further comprise wrapping the aerosolisable material and second aerosolisable material in a wrapper to form a rod of aerosolisable material.

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

In examples, the tobacco industry product is a cigarette. The aerosolisable material may be a tobacco material.

According to a further aspect of the present invention, there is also provided a trimming disk for apparatus for manufacturing a rod of aerosolisable material, the trimming disk comprising a peripheral edge having a material removal portion and a recessed portion, and wherein a surface of the material removal portion is planar such that the trimming disk is positionable proximate to, or against, a suction band of the apparatus for manufacturing a rod of aerosolisable material to remove substantially all of the aerosolisable material from the suction band during use.

Brief Description of the Drawings

Embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which:

FIGS. lA and lB show example tobacco industry products that include a tobacco rod; FIG. 2 shows a continuous tobacco rod;

FIG. 3 shows apparatus for manufacturing the continuous tobacco rod of FIG. 2;

FIG. 4 shows a suction band of the apparatus of FIG. 3;

FIG. 5 shows a part of the apparatus of the FIG. 3, in particular the suction conveyor and the trimming unit;

FIG. 6 shows a trimming disk of the apparatus of FIG. 3;

FIG. 7A shows a top view of the trimming disks of the apparatus of FIG. 3; FIG. 7B shows the trimming disks of the apparatus of FIG. 3;

FIG. 8 shows a front view of the trimming disks and suction conveyor of the apparatus of FIG. 3;

FIG. 9 shows a view of the trimming disks and suction conveyor of the apparatus of FIG. 3, together with a tobacco removal wheel; and,

FIG. 10 shows the tobacco removal wheel of FIG. 9.

Detailed Description

FIGS. lA and lB show different examples of tobacco industry products 1. The tobacco industry 1 products include a rod of aerosolisable material that, during use, generates an aerosol for delivery to a user. In the described embodiments, the tobacco industry products are cigarettes, and the rod of aerosolisable material is a tobacco rod 3 that can be combusted or heated to generate an aerosol. 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 and lB, 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 1 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. In the example of FIG. lB 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 this example, 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 and lB.

FIG. 2 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 lB.

FIG. 2 is a schematic drawing showing the arrangement of the first and second tobacco materials 4, 5 along the length of the continuous tobacco rod 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 and lB. 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 and lB.

Apparatus for manufacturing the tobacco industry products 1, in particular the tobacco rods 3, is described hereinafter. However, it will be appreciated that the apparatus may be used to manufacture tobacco industry products that include a rod of aerosolisable material that is free from tobacco material, or that includes a material in addition to tobacco material. FIG. 3 is a schematic view of an example apparatus 9 for manufacturing a continuous rod of aerosolisable material, for example the continuous tobacco rod 7 of FIG. 2.

As shown in FIG. 3, the apparatus 9 includes a suction conveyor 10 that includes a suction band 11. The suction band 11 is arranged to run on rollers 12, 13 such that it has an upper run 14 and a lower run 15, the lower run 15 moving to the left as illustrated in FIG. 3. The lower run 15 of the suction band 11 receives tobacco material 4, 5 and conveys the tobacco material 4, 5.

The suction band 11 includes suction holes 16 that draw tobacco material 4, 5 onto the suction band 11 and retain tobacco material 4, 5 on the suction band 11 for conveyance. Guides may be provided to guide the tobacco material 4, 5 along the suction conveyor 10 as the suction band 11 moves.

The suction band 11 is illustrated in FIG. 4. As shown, the suction holes 16 are arranged in a continuous pattern along the suction band 11. As explained below, suction is applied through the suction holes 16 in the suction band 11 to retain tobacco material 4, 5 on the suction band 11 during use. The suction holes 16 are sized such that the tobacco material 4, 5 is retained on the underside of the lower run 15 of the suction band 11 by the suction.

Preferably, the suction band 11 is a metal suction band 11, for example steel. In alternative examples, the suction band 11 is rubber or other polymer.

As illustrated in FIG. 3, the suction band 11 receives a first tobacco material 4 in a first region 17, and a second tobacco material 5 in a second region 18. The second region 18 is downstream of the first region 17. That is, the lower run 15 of the suction band 11 passes through the second region 18 after having passed through the first region 17. In this way, the suction band 11 is provided with a combined stream of first and second tobacco materials 4, 5. In various examples, described below, the first tobacco material 4 is formed into a profile on the suction band 11 before the second tobacco material 5 is added to the suction band 11, such that the combined stream of first and second tobacco materials 4, 5 are arranged in a profile for manufacturing a continuous tobacco rod, such as the continuous tobacco rod 7 illustrated in FIG. 2.

As shown in FIG. 3, a first vertical feeder 19 is arranged to feed the first tobacco material 4 onto the suction band 11 in the first region 17, and a second vertical feeder 20 is arranged to feed the second tobacco material 5 onto the suction band 11 in the second region 18.

The first and second vertical feeders 19, 20 each have a vertical chimney 21 that receives first and second tobacco materials 4, 5, respectively. The tobacco material 4, 5 is fed into the bottom of the vertical chimney 21 and is urged upwards towards the suction conveyor 10. The first vertical feeder 19 is disposed beneath the lower run 15 of the suction band 11 in the first region 17. The second vertical feeder 20 is disposed beneath the lower run 15 of the suction band 11 in the second region 18, downstream of the first region 17. Optionally, air flow is induced within the vertical chimneys 21 of the first and/or second vertical feeders 19, 20 to urge the tobacco material 4, 5 vertically upwards towards the suction band 11.

Suction is provided to the suction band 11 by at least one suction chamber 22, which is connected to a vacuum pump via an outlet 23. The suction chamber 22 is located between the upper and lower runs 14, 15 of the suction band 11. In the first region 17, suction acts through the suction holes 16 in the suction band 11 to draw the first tobacco material 4 onto the underside of the lower run 15 of the suction band 11 as the suction band 11 passes over the first vertical feeder 19.

After the first region 17 the suction band 11 is carrying a stream of first tobacco material 4 on its lower run 15. A first trimming unit 24 is arranged to remove substantially all of the first tobacco material 4 from the suction band 11 at spaced locations along the suction band 11 as the first tobacco material 4 is conveyed. The first trimming unit 24 is disposed between the first region 17 and the second region 18, i.e. downstream of the first region 17 and upstream of the second region 18. In this way, space is created on the suction band 11 for the second tobacco material 5.

Subsequently, as the suction band 11 passes over the second vertical feeder 20 in the second region 18 suction acts through the suction holes 16 in the suction band 11 to draw the second tobacco material 5 onto the underside of the lower run 15 of the suction band 11.

The first trimming unit 24 can include an ecreteur having a pair of counter-rotating trimming disks 25 that trim the first tobacco material 4 from the suction band 11. Additionally, the first trimming unit 24 can include a paddle wheel that rotates and knocks first tobacco material 4 off of the suction band 11 as the counter-rotating trimming disks 25 remove the first tobacco material 4. The first trimming unit 24 is described in more detail hereinafter with reference to FIGS. 5 to 10.

In further examples, the combined stream of first and second tobacco materials 4, 5 on the suction band 11 may be trimmed by a second trimming unit 26. The second trimming unit 26 can include an ecreteur having a pair of counter-rotating trimming disks 27 that are spaced from the suction band 11 so that they trim the combined stream of first and second tobacco materials 4, 5 to an appropriate thickness.

Alternatively or additionally, the second trimming unit 26 can include a paddle wheel that rotates and knocks tobacco material 4, 5 off of the suction band 11. Depending on the arrangement of the first and second tobacco materials 4, 5 on the suction band 11, one or both of the first and second tobacco materials 4, 5 may be trimmed by the second trimming unit 26. The second trimming unit 26 is disposed downstream of the second region 18, i.e. after the second vertical feeder 20.

At the end of the suction conveyor 10 the combined stream of first and second tobacco materials 4, 5 is transferred to a garniture 28. As illustrated in FIG. 3, the suction conveyor 10 is angled at a downwards slope towards the garniture 28. The skilled person will be aware of suitable existing garnitures, but a brief description of the garniture 28 is provided below. The garniture 28 comprises a continuous garniture belt 29 that drives a ribbon of paper 30 through the garniture 28. The garniture belt 29 is disposed below the ribbon of paper 30, and the combined stream of first and second tobacco materials 4, 5 is transferred from the suction conveyor 10 onto the ribbon of paper 30. In this way, the tobacco material 4, 5 is arranged on the ribbon of paper 30, which is moved through the garniture 28 by the garniture belt 29. At the end of the lower run 15 of the suction band 11, where the garniture 28 is located, no suction is provided to the suction band 11 such that the tobacco materials 4, 5 are released from the suction band 11 for transfer to the garniture 28.

An adhesive applicator (not illustrated) applies adhesive to the top of the ribbon of paper 30 along one side. The garniture 28 includes a wrapping unit (not illustrated) through which the ribbon of paper 30 with the combined stream of first and second tobacco materials 4, 5 is conveyed. The wrapping unit wraps the ribbon of paper 30 about the tobacco materials 4, 5 and the adhesive glues the ribbon of paper 30 in place to form a continuous tobacco rod, for example a continuous tobacco rod 7 as illustrated in FIG. 2A.

The continuous tobacco rod 7 is then cut to the appropriate length for forming tobacco industry products, for example the tobacco industry products 1 shown in FIG. lA and lB. In various examples, the continuous tobacco rod 7 is cut on the tobacco rod making machine and/or on subsequent assembly apparatus. In various examples, the continuous tobacco rod 7 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.

FIG. 5 shows the first trimming unit 24 in more detail. As shown, the suction band 11 carries a stream of first tobacco material 4 towards the first trimming unit 24, and the trimming disks 25 remove substantially all of the first tobacco material 4 from the suction band 11 at spaced locations along the suction band 11. This leaves spaced areas of first tobacco material 4 on the suction band 11 downstream of the first trimming unit 24. As schematically shown in FIG. 5, the first trimming unit 24, in particular the trimming disks 25, remove substantially all of the first tobacco material 4 from the suction band 11 at the spaced locations along the suction band 11. FIG. 6 shows a trimming disk 25a, which is mounted on a drive shaft 31 for rotating the trimming disk 25a. As illustrated, the trimming disk 25a has a peripheral edge 32a. The peripheral edge 32a includes a tobacco removal region 33 and a recessed region 34. In this example, the peripheral edge 32a has four tobacco removal regions 33 and four recessed regions 34. The tobacco removal regions 33 and recessed regions 34 are arranged alternately about the peripheral edge 32a of the trimming disk 25a.

As explained further hereinafter, the peripheral edge 32a of the trimming disk 25a acts to trim tobacco material (4, see FIG. 5) from the suction band (11, see FIG. 5). In the tobacco removal regions 33 the peripheral edge 32a is planar at a height that removes substantially all of the tobacco material (4, see FIG. 5) from the suction band (11, see

FIG. 5). In the recessed regions 34 the peripheral edge is deflected vertically, so that the peripheral edge 32a is at a different height. In this way, the recessed regions 34 remove less tobacco material (4, see FIG. 5) from the suction band (11, see FIG. 5) than the tobacco removal regions 33. In some examples, no tobacco material (4, see FIG. 5) is removed from the suction band (11, see FIG. 5) by the recessed regions 34. In other examples, some tobacco material (4, see FIG. 5) is removed by the recessed regions 34, but less than by the tobacco removal regions 33.

As illustrated, the top surface 35 of the trimming disk 25a in the tobacco removal regions 33 is planar. The top surface 35 of the trimming disk 25a is flat. The peripheral edge 32a on the top surface 35 (i.e. within the tobacco removal regions 33) is flat on top, without rounding or a chamfer. In this way, as described further below, the trimming disk 25a can be arranged close to, or against, the suction band (11, see FIG. 5) so that substantially all of the tobacco material (4, see FIG. 5) is removed by the tobacco removal regions 33. In practice, the trimming disk 25a is arranged as close as possible to the suction band 11 to remove as much tobacco as is possible.

It will be appreciated that in other examples the trimming disk 25a may have one tobacco removal region 33 and one recessed region 34, or two of each, or three of each, or any number of each. The number of tobacco removal regions 33 and recessed regions 34 is determined by the circumference of the trimming disk 25a and by the rotational speed during operation.

As shown in, FIGS. 7A and 7B, on the apparatus 9 for manufacturing tobacco rods, the first trimming unit 24 has two trimming disks 25a, 25b are arranged adjacent to each other, such that the peripheral edges 32a, 32b are proximate to each other, or abutting each other, in line with the suction band 11. In the illustration of FIG, A the suction band 11 moves downwards, and the trimming disks 25a, 25b rotate in opposite directions such that where the trimming disks 25a, 25b overlie the suction band 11 the peripheral edges 32a, 32b are moving in the same direction as the suction band 11. The trimming disks 25a, 25b are rotated such that the tangential speed of the peripheral edges 32a, 32b matches the speed of the suction band 11 at the point where the peripheral edges 32a, 32b are closest to each other or abutting each other. In this way, as the suction band 11 carries tobacco material 4 the trimming disks 25a, 25b rotate and remove substantially all of the tobacco material 4 from the suction band 11 by the tobacco removal regions 33 at spaced locations along the suction band 11, and such that less (or no) tobacco material 4 is removed from the suction band 11 by the recessed regions 34. The alternating tobacco removal regions 33 and recessed regions 34 provide the suction band 11 with spaced regions of tobacco material 4 along the suction band 11 as shown in FIG. 5.

As shown in FIGS. 6 and 7B, in the recessed regions 34 the peripheral edge 32a, 32b is set back relative to the tobacco removal portions 33, i.e. the trimming disks 25a, 25b have a smaller radius in the recessed regions 34 than in the tobacco removal regions 33. When the first trimming unit 24 including the trimming disks 25a, 25b are arranged in the apparatus 9 they are spaced such that the tobacco removal regions 33 are proximate to each other or abutting each other. Therefore, as the recessed regions 34 move into alignment during operation, less (or no) tobacco material 4 is removed from the suction band 11. The recessed regions 34 may remove some tobacco material 4 to trim the tobacco material 4 to an appropriate level so that the spaced regions of tobacco material 4 downstream of the first trimming unit 24 are appropriately sized and shaped.

As shown in FIG. 8, the planar top surfaces 35 of the trimming disks 25a, 25b are parallel to each other. The planar top surfaces 35 are also parallel to the suction band 11. The drive shafts (31, see FIG. 6) of the trimming disks 25 rotate about an axis that is perpendicular to the suction band 11. In this way, the trimming disks 25a, 25b can be positioned proximate to, or against, the suction band 11 such that during operation substantially all of the tobacco material 4 is removed from the suction band 11 by the tobacco removal regions 33. In FIG. 8 the trimming disks 25a, 25b are spaced a small distance from the suction band 11. Preferably, the trimming disks 25a, 25b are as close as possible to the suction band 11, against the suction band 11, or spaced from the suction band 11 by a small distance. For example, the planar top surfaces 35 of the trimming disks 25a, 25b may be spaced from the suction band 11 by less than 5 millimetres, or less than 2 millimetres, or less than 1 millimetre, or preferably less than 0.5 millimetres, or even 0.05mm.

The tobacco material 4 is held on the suction band 11 by suction acting through suction holes (16, see FIG. 4) in the suction band 11. As the trimming disks 25a, 25b move across the suction band 11 some of the suction holes (16, see FIG. 4) are blocked by the trimming disks 25a, 25b, allowing the tobacco material 4 to fall away from the suction band 11.

In addition, as shown in FIG. 8, the peripheral edges 32a, 32b of the trimming disks 25a, 25b are provided with a chamfer 36 on the lower surfaces (the surfaces on the opposite side to the planar top surfaces 35). The chamfers 36 act to push the tobacco material 4 off the suction band 11 in the tobacco removal regions 33. In this way, the tobacco removal regions 33 remove substantially all of the tobacco material 4 from the suction band 11. In examples where the trimming disks 25a, 25b act against, or close to, the suction band 11 the trimming disks 25a, 25b may act to shear the first tobacco material 4 from the suction band 11.

As shown in FIG. 8, the peripheral edges 32a, 32b of the trimming disks 25a, 25b are abutting each other. In other examples, the peripheral edges 32a, 32b of the trimming disks 25a, 25b are proximate to each other, for example spaced from each other by less than 1 millimetre, or less than 0.5 millimetres.

Also shown in FIG. 8, the trimming disks 25a, 25b in the tobacco removal regions 33 are thinned such that the peripheral edges 32a, 32b of the trimming disks 25a, 25b are form cutting edges for removal of the tobacco material 4 from the suction band 11. FIG. 9 shows the trimming disks 25a, 25b and suction conveyor 11 of FIG. 8, with an additional tobacco removal wheel 37. The tobacco removal wheel 37 is disposed below the trimming disks 25a, 25b. The tobacco removal wheel 37 acts to knock away tobacco material 4 as it is trimmed by the trimming disks 25a, 25b. The tobacco removal wheel is shown in isolation in FIG. 10. As shown in FIG. 10, the tobacco removal wheel 37 comprises a plurality of paddles 38 that extend radially from the tobacco removal wheel 37 (only one paddle 38 is shown in FIG. 9). The tobacco removal wheel 37 has a stepped radius. In particular, the wheel 37 has at least one segment with a radius that is different to the radius of the remaining part of the tobacco removal wheel 37. In the embodiment shown in Figure 10, the tobacco removal wheel 37 has two segments 37a that have a different (greater) radius than the remaining portion of the wheel 37. Paddles 38 extend radially from the periphery of the segments 37a and, preferably from the remaining portion of the wheel 37 as well. The tobacco removal wheel 37 is rotated synchronously with the trimming disks 25a, 25b so that the paddles 38 extending from the segments 37a are aligned with the tobacco removal regions 33. In this way, the paddles 38 are always close to the bottom of the trimming disks 25a, 25b as the tobacco material 4 is trimmed from the suction band 11, as shown in FIG. 9. As the tobacco material 4 comes between the tobacco removal regions 33 (and optionally the recessed regions 34) the paddles 38 knock the tobacco material 4 away.

The tobacco removal wheel 37 is arranged at an angle to the direction of the suction band, so that the tobacco material 4 is knocked sideways, away from the suction conveyor 11, as the tobacco material 4 is removed.

As shown in FIG. 9, the paddles 38, extending from the segments 37a of the tobacco removal wheel 37, synchronously align with the thin peripheral edges 32a, 32b of the trimming disks 25a, 25b as they rotate, so that the paddles 38 are always acting close to the underside of the trimming disks 25a, 25b to remove as much tobacco material 4 as possible.

A guide (not shown) may be arranged to catch the tobacco material 4 that is removed from the suction band 11. The guide may be provided with vacuum to pull the tobacco material 4 away from the suction band 11. Removed tobacco material 4 may be recycled or re-used.

As explained earlier with reference to FIG. 3, after the first trimming unit 24 the suction band 11 is provided with a second tobacco material 5 in the spaces between the spaced regions of first tobacco material 4 created by the first trimming unit 24. The combined first and second tobacco materials 4, 5 are transferred to a garniture for wrapping to form tobacco rods 3 such as those shown in FIGS. lA and lB. Advantageously, the suction conveyor 10 and the first and second vertical feeders 19, 20 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 suction conveyor arrangement, commonly known as a ‘V.E’. This machine can be modified to be used as the apparatus described with reference to the examples. For example, modification might include installation of the first trimming unit 24, replacement of the suction bands, and/or addition of a second vertical tobacco feeder 20.

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.

A tobacco industry product refers to any item made in, or sold by the tobacco industry, typically including a) cigarettes, cigarillos, cigars, tobacco for pipes or for roll-your-own cigarettes, (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes); b) non-smoking products incorporating tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes such as snuff, snus, hard tobacco, and heat-not-burn (HnB) products; and c) other nicotine-delivery systems such as inhalers, aerosol generation devices including e-cigarettes, lozenges and gum. This list is not intended to be exclusive, but merely illustrates a range of products which are made and sold in the tobacco industry. In one example, tobacco industry product is not a conventional cigarette.

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) may be 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 maybe utilised and modifications maybe 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

1. Apparatus for manufacturing a rod of aerosolisable material, the apparatus comprising:

a suction band arranged to convey an aerosolisable material, and

2. The apparatus of claim l, wherein the suction band is arranged to convey the aerosolisable material on an underside of the suction band.

3. The apparatus of claim 2, wherein the pair of rotatable trimming disks are arranged underneath the suction band to remove aerosolisable material from the suction band during operation of the apparatus.

4. The apparatus of any preceding claim, wherein the rotatable trimming disks are parallel to the suction band.

5. The apparatus of any preceding claim, wherein the pair of rotatable trimming disks are arranged to act against the suction band to remove the aerosolisable material from the suction band.

6. The apparatus of any of claims l to 4, wherein the rotatable trimming disks are disposed proximate to the suction band.

7. The apparatus of claim 6, wherein the rotatable trimming disks are spaced from the suction band by a distance of less than 5 millimetres, or by a distance of less than 2 millimetres, or by a distance of less than 1 millimetre, or by a distance of less than 0.5 millimetres, or by a distance of less than 0.05mm.

Claims

8. The apparatus of any preceding claim, wherein a surface of each material removal region that faces the suction band is planar.

9. The apparatus of any preceding claim, wherein the peripheral edge at each material removal region comprises a chamfer, and wherein the chamfer is disposed on a side of the peripheral edge that faces away from the suction band.

10. The apparatus of any preceding claim, wherein the peripheral edge of each trimming disk comprises a recessed region.

11. The apparatus of claim 10, wherein the recessed region is configured to remove no aerosolisable material from the suction band, or wherein the recessed region is configured to remove less aerosolisable material from the suction band than the material removal region.

12. The apparatus of claim 10 or claim 11, wherein the peripheral edge of each trimming disk comprises a plurality of material removal regions and plurality of recessed regions arranged alternately about the peripheral edge of each trimming disk. 13. The apparatus of any preceding claim, wherein the material removal region of one trimming disk is configured to be aligned to the material removal region of the other trimming disk as the trimming disks rotate during operation of the apparatus.

14. The apparatus of any preceding claim, further comprising a material removal wheel arranged adjacent to the pair of trimming disks, opposite to the suction band, the material removal wheel being arranged to rotate and remove aerosolisable material as it is removed from the suction band by the pair of trimming disks.

15. The apparatus of claim 14, wherein the material removal wheel comprises a plurality of paddles extending radially from the material removal wheel. i6. The apparatus of claim 14 or claim 15, wherein the radius of the material removal wheel varies about the circumference of the material removal wheel.

17. The apparatus of any preceding claim, further comprising a first feeder arranged to provide the aerosolisable material to the suction band upstream of the pair of rotatable trimming disks. 18. The apparatus of any preceding claim, further comprising a second feeder arranged to provide a second aerosolisable material to the suction band downstream of the pair of rotatable trimming disks to combine the second aerosolisable material with the aerosolisable material on the suction band. 19. The apparatus of claim 18, further comprising a second trimming unit arranged downstream of the second feeder, the second trimming unit being arranged to trim the combined aerosolisable material and second aerosolisable material.

20. The apparatus of any preceding claim, further comprising a garniture arranged to receive the aerosolisable material from the suction conveyor and to wrap the suction conveyor in a wrapper to form a rod of aerosolisable material.

21. A method of manufacturing a rod of aerosolisable material, the method comprising conveying an aerosolisable material on a suction band, and removing substantially all of the aerosolisable material from the suction band at regular intervals along the suction band.

22. The method of claim 21, further comprising providing a second aerosolisable material to the suction band after removing aerosolisable material from the suction band at regular intervals along the suction band.

23. The method of claim 22, further comprising wrapping the aerosolisable material and second aerosolisable material in a wrapper to form a rod of aerosolisable material. 24. 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 21 to 23, and further comprising combining the rod of aerosolisable material with a further component. 25. The method of claim 24, wherein the tobacco industry product is a cigarette.

26. The method of any of claims 21 to 25, wherein the aerosolisable material is a tobacco material.

27. A trimming disk for apparatus for manufacturing a rod of aerosolisable material, the trimming disk comprising a peripheral edge having a material removal portion and a recessed portion, and wherein a surface of the material removal portion is planar such that the trimming disk is positionable proximate to, or against, a suction band of the apparatus for manufacturing a rod of aerosolisable material to remove substantially all of the aerosolisable material from the suction band during use.