WO2025003137A1

WO2025003137A1 - Method and apparatus for forming a heated-tobacco-product consumable having a generally planar form

Info

Publication number: WO2025003137A1
Application number: PCT/EP2024/067813
Authority: WO
Inventors: Sandra SPIELES; Markus Cremer
Original assignee: JT International SA
Current assignee: JT International SA
Priority date: 2023-06-26
Filing date: 2024-06-25
Publication date: 2025-01-02
Anticipated expiration: 2025-12-26

Abstract

A method of forming a heated-tobacco-product consumable (200) having a generally planar form, comprising: forming a wrapper material (202) into a U- shape having a flat base and two upstanding sides, each upstanding side forming an angle (α) with the flat base; providing a first adhesive on a first portion of the flat base between the two upstanding sides; providing a support element (204) on the adhesive to attach the support element to the first portion of the flat base; providing a tobacco substrate (206) on a second portion of the flat base adjacent to the support element, preferably the tobacco substrate and the support element having substantially the same height dimension from the flat base; folding a portion of a first one of the upstanding sides over the support element and the tobacco substrate so as to be in parallel relationship with the flat base; providing a second adhesive on at least one of the upstanding sides; and folding a portion of the second one of the upstanding sides over the portion of the first one of the upstanding sides so as to be in parallel relationship therewith, thereby to attach the upstanding sides together to enclose the support element and the tobacco substrate in the wrapper material.

Description

METHOD AND APPARATUS FOR FORMING A HEATED-TOBACCOPRODUCT CONSUMABLE HAVING A GENERALLY PLANAR FORM

FIELD OF THE INVENTION

The present invention relates to heated-tobacco products, in particular a method and apparatus for forming a heated-tobacco-product consumable having a generally planar form.

BACKGROUND

It is conventional to produce heated-tobacco-product consumables having a flat, generally planar shape, for convenient insertion into a slot of a heating device for use by a consumer. The finished consumable typically comprises a tobacco substrate and a support (or cooling) element which are both enclosed by a wrapper, for example a high-density paper wrapper. The production process may include manipulating the wrapper and fixing the wrapper in place using an adhesive. This can be problematic, for the following reasons.

When wrapping the soft tobacco substrate with a high-density paper wrapper, it is difficult to ensure correct final dimensions because the surfaces of the soft tobacco substrate tend to yield under the applied pressure. This makes it challenging to ensure a precise, rectangular shape with sharp comers and crease lines. These difficulties can lead to undesirable variability in finished consumables as well as a slow rate of production.

The present invention aims to alleviate at least to some extent the problems of the prior art.

SUMMARY OF INVENTION

According to an aspect of the invention, there is provided a method of forming a heated-tobacco-product consumable having a generally planar form, comprising: forming a wrapper material into a U-shape having a flat base and two upstanding sides, each upstanding side forming an angle a with the flat base; providing a first adhesive on a first portion of the flat base between the two upstanding sides; providing a support (or cooling) element on the adhesive to attach the support element to the first portion of the flat base; providing a tobacco substrate on a second portion of the flat base adjacent to the support element, preferably the tobacco substrate and the support element having substantially the same height dimension from the flat base; folding a portion of a first one of the upstanding sides over the support element and the tobacco substrate so as to be in parallel relationship with the flat base; providing a second adhesive on at least one of the upstanding sides; and folding a portion of the second one of the upstanding sides over the portion of the first one of the upstanding sides so as to be in parallel relationship therewith, thereby to attach the upstanding sides together to enclose the support element and the tobacco substrate in the wrapper material.

The initial formation of the wrapper material, into a U-shape having a flat base and upstanding walls, advantageously defines the maximum width of the consumable and further ensures that the lower part of the consumable has the desired sharp comers and crease lines. The upper part of the consumable is also endowed with sharp comers and crease lines by the subsequent folding of the upstanding sides.

Forming the wrapper material into a U-shape may comprise stamping the wrapper material to conform to a channel of a carriage, the channel having a channel flat base and two channel upstanding sides each forming an angle of between 90 and 170 degrees with the channel flat base.

The wrapper material may be stamped directly into the channel of the carriage. Alternatively, the wrapper material may be stamped into the channel of a separate die block, the channel of the die block being geometrically similar to the channel of the carriage, and then transferred to the channel of the carriage.

The formed, U-shaped wrapper material may be located in the channel of the carriage for receiving the tobacco substrate. Once added to the wrapper material, the tobacco substrate may exert an outward force on the upstanding sides of the wrapper material. The rigid, upstanding walls of the carriage channel will resist this force to prevent outward deflection of the upstanding sides of the wrapper material, thereby helping to ensure correct dimensions of the consumable. The rigid, upstanding walls of the carriage channel will also provide a useful guide for the placement of the support element on the wrapper material.

The wrapper material may comprise paper or card, optionally wherein the wrapper material comprises a metallic foil layer.

The support element may comprise a corrugated material, for example corrugated paper.

Providing the tobacco substrate on the second portion of the flat base may comprise applying an adjustable pressure to a top of the tobacco substrate to compress the tobacco substrate.

Compressing the soft tobacco substrate helps to keep the tobacco substrate in place in the consumable and also enhances the structural rigidity of the consumable.

Providing the second adhesive on one of the upstanding sides may comprise providing the second adhesive on an inner surface of the unfolded said portion of the second one of the upstanding sides.

Folding said portion of the first one of the upstanding sides and folding said portion of the second one of the upstanding sides may comprise: moving a first flat blade laterally toward the U-shape wrapper material to cause an edge of the first flat blade to engage and fold said portion of the first one of the upstanding sides; providing the second adhesive on the second one of the upstanding sides; moving the first blade laterally in an opposite direction away from the U-shape wrapper material, or moving the U-shape wrapper material away from the first blade; and moving a second flat blade laterally in the second direction toward the U-shape wrapper material to cause an edge of the second flat blade to engage and fold said portion of the second one of the upstanding sides. The edge of the second flat blade, and optionally the edge of the first flat blade, may comprise a curved profile to reduce friction between the moving blade and the U-shape wrapper material.

The method may comprise placing the consumable in a curing and shaping chamber having an interior shape which is complementary to the exterior shape of the consumable, in order to allow one or both of the first and second adhesives to cure while maintaining the exterior shape of the consumable.

The angle a may be between 90 and 170 degrees, optionally between 90 and 160 degrees, optionally between 100 and 150 degrees, optionally between 100 and 140 degrees.

According to another aspect of the invention, there is provided apparatus for forming a heated-tobacco-product consumable having a generally planar form, comprising: a carriage comprising a channel having a channel flat base and two upstanding sides each forming an angle of between 90 and 170 degrees with the channel flat base, the carriage being arranged to be guided to move between processing stations of the apparatus; a die stamp station arranged to stamp a wrapper material to conform to the channel of the carriage so as to form the wrapper material into a U-shape having a flat base and two upstanding sides, each upstanding side forming an angle a with the flat base; an adhesive station located downstream of the die stamp station and arranged to apply a first adhesive to a first portion of the flat base of the U-shape wrapper material between the sides thereof; a support element station located at or downstream of the adhesive station and arranged to place a support element on the adhesive to attach the support element to the first portion of the flat base of the U-shape wrapper material; a tobacco substrate station located downstream of the support element station and arranged to place a tobacco substrate on a second portion of the flat base of the U-shape wrapper adjacent to the support element, preferably so that the tobacco substrate and the support element have substantially the same height dimension from the flat base of the U-shape wrapper; and one or more folding and adhesive stations located downstream of the tobacco substrate station and arranged to: fold a portion of a first one of the sides of the U-shape wrapper material over the support element and the tobacco substrate so as to be in parallel relationship with the flat base of the U-shape wrapper material; provide a second adhesive on at least one of the sides; and fold a portion of the second one of the sides of the U-shape wrapper material over the portion of the first one of the sides of the U-shape wrapper material so as to be in parallel relationship therewith, thereby to attach the sides of the wrapper material together to enclose the support element and the tobacco substrate in the wrapper material.

The tobacco substrate station may comprise a stamp arranged to apply an adjustable pressure to the top of the tobacco substrate to compress the tobacco substrate.

The one or more folding and adhesive stations may be arranged to provide the second adhesive on the second one of the sides of the U-shape wrapper material and comprise: a first flat blade arranged to be moved laterally toward the U-shape wrapper material to cause an edge of the first flat blade to engage and fold said portion of the first one of the upstanding sides of the U-shape wrapper material, and optionally further arranged to be moved in an opposite direction away from the U-shape wrapper material; and a second flat blade arranged to be moved laterally to cause an edge of the second flat blade to engage and fold said portion of the second one of the upstanding sides of the U-shape wrapper material, and optionally further arranged to be moved in an opposite direction away from the U- shape wrapper material.

The edge of the second flat blade, and optionally the edge of the first flat blade, may comprise a curved profile to reduce friction between the moving blade and the U-shape wrapper material.

The apparatus may comprise a curing and shaping chamber located downstream of the one or more folding and adhesive stations, the curing and shaping chamber having an interior shape which is complementary to the exterior shape of the consumable, for receiving the consumable and allowing one or both of the first and second adhesives to cure while maintaining the exterior shape of the consumable. The apparatus may comprise a wrapper material hopper arranged to hold a plurality of the wrapper materials and to dispense individual wrapper materials to the carriage.

The apparatus may comprise a support element hopper arranged to hold a plurality of the support elements and to dispense individual support elements to the support element station.

The apparatus may comprise a tobacco substrate hopper arranged to hold a plurality of the tobacco substrates and to dispense individual tobacco substrates to the tobacco substrate station.

BRIEF DESCRIPTION OF DRAWINGS

Examples will now be described with reference to the accompanying figures, in which:

Figures 1A and 1 B show views of an apparatus for forming a heated-tobacco- product consumable;

Figure 2 shows a perspective view of a portion of the apparatus of Figures 1 A and 1 B;

Figures 3A to 3D show a heated-tobacco-product consumable, including a paper wrapper, a support element and a tobacco substrate, that may be produced using the apparatus;

Figures 4A and 4B relate to the placement of the paper wrapper on a carriage of the apparatus;

Figures 5A and 5B relate to the placement of the support element on the paper wrapper;

Figure 6 relates to the placement of the tobacco substrate on the paper wrapper;

Figure 7 shows a first flat blade of the apparatus for folding the paper wrapper; Figure 8 shows movements of the first flat blade and a second flat blade of the apparatus; and

Figure 9 shows a curing and shaping chamber of the apparatus for curing an adhesive and shaping the heated-tobacco-product consumable.

DETAILED DESCRIPTION

Referring in particular to Figures 2, 4A, 5A and 6, an apparatus 100 for forming a heated-tobacco-product consumable comprises a carriage 102 which is arranged to be movable between a plurality of processing stations, including: a die stamp station 104 including a die stamp 104a and a die block 104b; an adhesive station 106 located downstream of the die stamp station 104; a support element station 108 located downstream of the adhesive station 106 and including a support element carrier 108a; a tobacco substrate station 110 located downstream of the support element station 108 and including a tobacco substrate carrier 110a; a first folding and adhesive station 112 located downstream of the tobacco substrate station 110 and including a first flat blade 112a; and a second folding and adhesive station 114 located downstream of the first folding and adhesive station 112 and including a second flat blade 114a. In this example, the carriage 102 is slidably mounted on a guide rail 102a so as to be movable between the processing stations in a linear fashion. In this example, the carriage 102 is constructed from stainless steel.

As can be seen in Figure 5A, for example, an upper surface of the carnage 102 comprises a recessed channel 102b having a channel flat base and two upstanding sides each forming an angle a with the channel flat base. In this example, the angle a is chosen from a range of options to be substantially about 90 degrees.

Referring again to Figure 2, in this example the apparatus 100 further comprises: a paper wrapper vertical hopper 116 for providing a supply of paper wrappers; a support element vertical hopper 118 located downstream of the paper wrapper vertical hopper 116 and for providing a supply of support elements; a tobacco substrate vertical hopper 120 located downstream of the support element vertical hopper 118 and for providing a supply of tobacco substrates; a curing and shaping chamber 122 located downstream of the second folding and adhesive station 114; and an outfeed chute 124 located downstream of the curing and shaping chamber 122.

Still referring to Figure 2, the die block 104b of the die stamp station 104 is located laterally of the guide rail 102a. As shown in the Figure, in an initial position the carriage 102 is located on the guide rail 102a adjacent to the die block 104b. An upper surface of the die block 104b comprises a channel (not visible in the Figures) which is geometrically similar to the above-mentioned channel 102b of the carriage 102.

Turning now to Figure 3A, a heated-tobacco-product consumable 200 (hereinafter “consumable”) comprises a paper wrapper 202 that surrounds a support (or cooling) element 204 and a tobacco substrate 206 which are arranged adjacent to each other in an end-end-to-end fashion as shown in Figure 3B. As can be seen in Figures 3C and 3D, in this example each one of the support element 204 and the tobacco substrate 206 has a corrugated form. The corrugations may advantageously enable cooling of vapours in use and may add structural strength to the generally planar consumable 200. The support element 204 may comprise paper. The consumable 200 may have a length ranging from 18.0 to 34.0 mm, preferably a length of 27.5 mm and a width ranging from 5.0 to 15.0 mm, preferably a width of 10 mm, for example.

An exemplary method of formation or assembly of the consumable 200 using the apparatus 100 will now be described.

Referring again to Figure 2, the carriage 102 is initially positioned on the guide rail 102a at the die stamp station 104. A flat paper wrapper 202 is dispensed from the paper wrapper vertical hopper 116 to the die stamp 104a and is held thereto by means of vacuum suction. The die stamp 104a is lowered vertically toward the die block 104b so that the paper wrapper 202 is pressed into the channel of the die block 104b by the die stamp 104a. A downward force exerted by the die stamp 104a deforms the paper wrapper 202 so that the paper wrapper 202 conforms to the shape of the channel.

As has been mentioned herein above, the channel of the die block 104b is geometrically similar to the channel 102b of the carriage 102. Accordingly, two upstanding sides of the channel of the die block 104b form an angle a of substantially about 90 degrees with a flat base of the channel of the die block 104b. Thus, the deformed paper wrapper 202 assumes a flat (horizontal) base and two upstanding (vertical) sides which are substantially perpendicular with the flat base. That is, the deformed paper wrapper 202 is generally U-shaped in crosssection. The die stamp 104a is then raised upward so as to lift the paper wrapper 202 vertically away from the die block 104b under the vacuum suction.

Referring next to Figure 4A, the die stamp 104a is moved laterally so as to overlie the carriage 102. The die stamp 104a is lowered vertically toward the carriage 102 so that the paper wrapper 202 is pressed into the channel 102b of the carriage 102 by the die stamp 104a, causing the paper wrapper 202 to conform to the shape of the channel 102b. Thus, the deformed paper wrapper 202 is transferred from the channel of the die block 104b to the channel 102b of the carriage 102 by the die stamp 104a. Since the channel 102b of the carriage 102 has substantially the same geometry as the channel of the die block 104b, the shape of the deformed paper wrapper 202 is substantially the same at the conclusion of the transfer as at the beginning of the transfer.

Referring now to Figure 4B, the vacuum suction is released and the die stamp 104a is raised vertically away from the paper wrapper 202 and the carriage 102. Vacuum suction is applied to the carriage 102 to maintain the paper wrapper 202 in position on the carriage 102. A portion of the paper wrapper 202 remains located in the channel 102b and is in conformance with the shape of the channel 102b. As may be understood from Figure 4B, portions of the upstanding sides of the paper wrapper 202, which are in contact with the upstanding sides of the channel 102b, will be substantially vertical, while other portions of the upstanding sides of the paper wrapper 202, which project upwardly and outwardly from the channel 102b and which are unrestrained by the upstanding sides of the channel 102b, may tend to bend slightly under their own weight so as to be located outside of the vertical plane.

Referring again to Figure 2, the carriage 102 is moved along the guide rail 102a to be positioned at the adhesive station 106. The paper wrapper 202 remains in place on the carriage 102 while the carriage is in transit, preferably without movement of the paper wrapper 202 relative to the carriage 102, due the vacuum suction applied to the paper wrapper 202 by the carriage 102. A small amount of a first adhesive, for example a single drop, is provided on a first portion of the flat base of the paper wrapper 202 between the upstanding sides thereof. The first adhesive may be any suitable conventional adhesive and may be provided by any conventional means, for example using a nozzle, a roller, or a spray.

Referring next to Figures 2 and 5A, the carriage 102 is moved along the guide rail 102a to be positioned at the support element station 108. The paper wrapper 202 remains in place on the carriage 102 while the carriage is in transit, preferably without movement of the paper wrapper 202 relative to the carriage 102, due the vacuum suction applied to the paper wrapper 202 by the carriage 102. A support element 204 (of the kind shown in Figure 3C and not visible in Figures 2 and 5A) is dispensed from the support element vertical hopper 118 to the support element carrier 108a and is held thereto by means of vacuum suction. The support element carrier 108a is positioned over the carriage 102b and is lowered vertically toward the carriage 102 so that the support element 204 is placed into contact with the first adhesive that was provided on the first portion of the flat base of the paper wrapper 202.

Referring now to Figure 5B, the vacuum suction is released and the support element carrier 108a is raised vertically away from the paper wrapper 202 and the carriage 102. The support element 204 remains located on the first adhesive on the first portion of the flat base of the paper wrapper 202. Thus, the support element 204 is fixedly attached to the first portion of the flat base of the paper wrapper 202. Referring next to Figures 2 and 6, the carriage 102 is moved along the guide rail 102a to be positioned at the tobacco substrate station 110. The paper wrapper 202 remains in place on the carriage 102 while the carriage is in transit, preferably without movement of the paper wrapper 202 relative to the carriage 102, due the vacuum suction applied to the paper wrapper 202 by the carriage 102. A tobacco substrate 206 (of the kind shown in Figure 3D and not visible in Figures 2 and 6) is dispensed from the tobacco substrate vertical hopper 120 to the tobacco substrate carrier 110a and is held thereto by means of vacuum suction. The tobacco substrate carrier 110a is positioned over the carriage 102 and is lowered vertically toward the carriage 102 so that the tobacco substrate 206 is placed on a second portion of the flat base of the paper wrapper 202 which is immediately adjacent to the first portion of the flat base of the paper wrapper 202.

The tobacco substrate carrier 110a may be configured to apply a variable downward pressure on the tobacco substrate 206 to compress the tobacco substrate 206 to any desired height or thickness. For example, the tobacco substrate 206 may be compressed so that the tobacco substrate 206 and the support element 204 have substantially the same height as measured from the flat base of the paper wrapper 202.

The vacuum suction is released and the tobacco substrate carrier 110a is raised vertically away from the paper wrapper 202 and the carriage 102. Thus, the tobacco substrate 206 is located immediately alongside the support element 204 (as shown in Figure 3B). In combination, the tobacco substrate 206 and the support element 204 may extend substantially the entire length of the paper wrapper 202.

It will be recalled that portions of the upstanding sides of the paper wrapper 202 project upwardly and outwardly from the channel 102b of the carriage 102 and are unrestrained by the upstanding sides of the channel 102b. These projecting portions of the paper wrapper 202 are folded and attached to each other at the first and second folding and adhesive stations 112, 114, as follows. Referring to Figures 2 and 7, the carriage 102 is moved along the guide rail 102a to be positioned at the first folding and adhesive station 112. The paper wrapper 202 remains in place on the carriage 102 while the carriage is in transit, preferably without movement of the paper wrapper 202 relative to the carriage 102, due the vacuum suction applied to the paper wrapper 202 by the carriage 102. The first flat blade 112a is moved laterally (horizontally) toward the paper wrapper 202 to cause a leading edge 112ai of the first flat blade 112a to engage the projecting portion of a first one of the upstanding sides of the paper wrapper 202. It will be understood that the lateral movement of the first flat blade 112a is in a deployment direction which is substantially perpendicular to both the direction of travel of the carnage 102 along the guide rail 102a and to a length axis of the paper wrapper 202. In this example, the leading edge 112ai of the first flat blade 112a comprises a curved profile to reduce friction between the moving blade and the paper wrapper 202. Continued movement of the first flat blade 112a in this direction causes the first one of the upstanding sides of the paper wrapper 202 to be folded at an angle of about 90 degrees, so that the folded first side of the paper wrapper 202 overlies (at least part of) the support element 204 and the tobacco substrate 206 and is in parallel relationship with the flat base of the paper wrapper 202.

Referring now also to Figure 8, in this example the first flat blade 112a is moved far enough in the deployment direction to also contact the inside part of the (still) upwardly projecting portion of the second one of the upstanding sides of the paper wrapper 202, thereby to deflect the upwardly projecting portion of the second one of the upstanding sides outwardly so as to form an angle a’ of, for example, 150 to 170 degrees from the folded (horizontal) first side of the paper wrapper 202.

A second adhesive is then provided on the inside part of the deflected projecting portion of the second one of the upstanding sides of the paper wrapper 202. It will be understood that the application of the second adhesive is made easier by the prior deflection of the projecting portion of the second one of the upstanding sides by the first flat blade 112a, which remains in place while the adhesive is applied. The second adhesive may be any suitable conventional adhesive and may be provided by any conventional means, for example using a nozzle, a roller, or a spray. The adhesive is not allowed to cure at this stage.

In an alternative example, the first flat blade 112a is retracted away from the paper wrapper 202 (i.e. in a direction which is opposite to the deployment direction of the first flat blade 112a), thereby to expose an upper surface of the folded first side of the paper wrapper 202, and then the second adhesive is provided on the exposed upper surface of the folded first side of the paper wrapper 202.

In a further alternative example, the second adhesive is provided on both the exposed upper surface of the folded first side of the paper wrapper 202 and the (still) upwardly projecting portion of the second upstanding side.

Referring again to Figure 2, the carriage 102 is moved along the guide rail 102a to be positioned at the second folding and adhesive station 114. The paper wrapper 202 remains in place on the carriage 102 while the carriage is in transit, preferably without movement of the paper wrapper 202 relative to the carriage 102, due the vacuum suction applied to the paper wrapper 202 by the carriage 102. In this example, the first flat blade 112a remains in place in the folding position while the carriage 102 is moved to the second folding and adhesive station 114, and is then retracted away from the paper wrapper 202 (i.e. in a direction which is opposite to the deployment direction of the first flat blade 112a), thereby to expose an upper surface of the folded first side of the paper wrapper 202.

The second flat blade 114a is moved laterally (horizontally) toward the paper wrapper 202 to cause a leading edge 114ai of the second flat blade 114a to engage the projecting portion of the second one of the upstanding sides of the paper wrapper 202. It will be understood that the lateral movement of the second flat blade 114a is in a deployment direction which is substantially perpendicular to both the direction of travel of the carriage 102 along the guide rail 102a and to the length axis of the paper wrapper 202. Furthermore, the lateral movement of the second flat blade 114a is in a deployment direction which is opposite to the deployment direction of the lateral movement of the first flat blade 112a. In this example, the leading edge 114ai of the second flat blade 114a comprises a curved profile to reduce friction between the moving blade and the paper wrapper 202. Continued movement of the second flat blade 114a in this direction causes the second one of the upstanding sides of the paper wrapper 202 to be foldedso as to overlie (at least part of) the folded first side to be in parallel relationship with the folded first side and with the flat base of the paper wrapper 202. Referring to Figure 8, it will be understood that this folding of the second side of the paper wrapper 202 causes the angle a’ (which was previously about 150 to 170 degrees, as mentioned above) to be reduced to substantially zero degrees. Furthermore, a lower surface of the folded second side of the paper wrapper 202 is in resting contact with the second adhesive that was provided on the exposed upper surface of the folded first side.

Thus, the folded first and second sides of the paper wrapper 202 are fixedly attached to each other. Furthermore, the paper wrapper 202 surrounds or encloses the support element 204 and the tobacco substrate 206 to form the generally planar consumable 200 as depicted in Figure 3A. Referring now to Figures 2 and 9, the vacuum suction is removed from the carriage 102 and the consumable 200 is loaded into the curing and shaping chamber 122, e.g. by any conventional means such as a mechanical arm or the like. The carriage 102 is thus free of the consumable 200 and may be returned to the die stamp station 104 using the guide rail 102a.

In this example, the second flat blade 114a is retracted away from the paper wrapper 202 (i.e. in a direction which is opposite to the deployment direction of the second flat blade 114a) before the consumable 200 is loaded into the curing and shaping chamber 122. In another example, the second flat blade 114a is not retracted away from the paper wrapper 202 until after the consumable 200 has been loaded into the curing and shaping chamber 122.

The curing and shaping chamber 122 has an interior shape which is complementary to the exterior shape of the consumable 200. The consumable 200 may remain inside the curing and shaping chamber 122 for a period of time to ensure that the integrity of the exterior shape of the consumable 200 is maintained while the second adhesive is fully cured.

The completed consumable 200 is unloaded from the curing and shaping chamber 122, e.g. by the above-mentioned mechanical arm, and is dispensed from the apparatus 100 via the outfeed chute 124. The forming process may be repeated to produce further consumables 200.

In the example described herein above, the paper wrapper 202 is stamped into the channel of the die block 104b of the die stamp station 104 and is then transferred to the channel 102b of the carriage 102. In another example, the die block 104b of the die stamp station 104 is omitted and the paper wrapper 202 is stamped directly into the channel 102b of the carriage 102 by the die stamp 104a.

In the example described herein above, the support element station 108 is located downstream of the adhesive station 106. In another example, the support element station 108 is located at the adhesive station 106. That is, the support element station and the adhesive station 106 are co-located or combined.

In the example described herein above, the apparatus 100 comprises both of a first folding and adhesive station 112 including a first flat blade 112a and a second folding and adhesive station 114 located downstream of the first folding and adhesive station 112 and including a second flat blade 114a. In another example, the apparatus comprises a single folding and adhesive station including a single flat blade. In this example, the single flat blade comprises a first leading edge on a first side of the blade and a second leading edge on a second and opposite side of the blade. The single flat blade is located at a start position laterally of the paper wrapper 202. The single flat blade is arranged to move from the start position in a first deployment direction to cause the first leading edge to engage and fold the first upstanding side of the paper wrapper 202 by 90 degrees, as has been described herein above, and further to continue movement in the first deployment direction so as to pass over the paper wrapper 202 to a resting position at the other side of the paper wrapper 202, thereby to expose the upper surface of the folded first side for the application of the second adhesive. The single flat blade is further arranged move in a second deployment direction, which is opposite to the first deployment direction, to cause the second leading edge to engage and fold the second upstanding side of the paper wrapper 202 by 90 degrees, as has been described herein above, and further to continue movement in the second deployment direction so as to pass over the paper wrapper 202 back to the start position, thereby allowing curing of the second adhesive as required.

While in the above-described example the consumable 200 comprises a paper wrapper 202, it will be understood that a wide variety of different kinds of wrapper may be used, including, but not limited to, high GSM paper wrappers, card, and aluminium-coated wrappers.

It should be understood that the invention has been described in relation to its preferred embodiments and may be modified in many different ways without departing from the scope of the invention as defined by the accompanying claims.

Claims

1 . A method of forming a heated-tobacco-product consumable (200) having a generally planar form, comprising: forming a wrapper material (202) into a U-shape having a flat base and two upstanding sides, each upstanding side forming an angle (a) with the flat base; providing a first adhesive on a first portion of the flat base between the two upstanding sides; providing a support element (204) on the adhesive to attach the support element to the first portion of the flat base; providing a tobacco substrate (206) on a second portion of the flat base adjacent to the support element, preferably the tobacco substrate and the support element having substantially the same height dimension from the flat base; folding a portion of a first one of the upstanding sides over the support element and the tobacco substrate so as to be in parallel relationship with the flat base; providing a second adhesive on at least one of the upstanding sides; and folding a portion of the second one of the upstanding sides over the portion of the first one of the upstanding sides so as to be in parallel relationship therewith, thereby to attach the upstanding sides together to enclose the support element and the tobacco substrate in the wrapper material.

2. A method of forming a heated-tobacco-product consumable (200) according to claim 1 , wherein forming the wrapper material (202) into a U-shape comprises stamping the wrapper material to conform to a channel (102b) of a carriage (102), the channel having a channel flat base and two channel upstanding sides each forming an angle of between 90 and 170 degrees with the channel flat base.

3. A method of forming a heated-tobacco-product consumable (200) according to claim 1 or 2, wherein the wrapper material (202) comprises paper or card, optionally wherein the wrapper material comprises a metallic foil layer.

4. A method of forming a heated-tobacco-product consumable (200) according to any preceding claim, wherein the support element (204) comprises a corrugated material, for example corrugated paper.

5. A method of forming a heated-tobacco-product consumable (200) according to any preceding claim, wherein providing the tobacco substrate (206) on the second portion of the flat base comprises applying an adjustable pressure to a top of the tobacco substrate to compress the tobacco substrate.

6. A method of forming a heated-tobacco-product consumable (200) according to any preceding claim, wherein providing the second adhesive on one of the upstanding sides comprises providing the second adhesive on an inner surface of the unfolded said portion of the second one of the upstanding sides.

7. A method of forming a heated-tobacco-product consumable (200) according to any preceding claim, wherein folding said portion of the first one of the upstanding sides and folding said portion of the second one of the upstanding sides comprises: moving a first flat blade (112a) laterally toward the U-shape wrapper material (202) to cause an edge (112ai) of the first flat blade to engage and fold said portion of the first one of the upstanding sides; providing the second adhesive on the second one of the upstanding sides; moving the first blade laterally in an opposite direction away from the U- shape wrapper material, or moving the U-shape wrapper material away from the first blade; and moving a second flat blade (114a) laterally in the second direction toward the U-shape wrapper material to cause an edge (114ai) of the second flat blade to engage and fold said portion of the second one of the upstanding sides.

8. A method of forming a heated-tobacco-product consumable (200) according to claim 7, wherein the edge (114ai) of the second flat blade (114a), and optionally the edge (112ai) of the first flat blade (112a), comprises a curved profile to reduce friction between the moving blade and the U-shape wrapper material (202).

9. A method of forming a heated-tobacco-product consumable (200) according to any preceding claim, comprising placing the consumable in a curing and shaping chamber (122) having an interior shape which is complementary to the exterior shape of the consumable, in order to allow one or both of the first and second adhesives to cure while maintaining the exterior shape of the consumable.

10. A method of forming a heated-tobacco-product consumable (200) according to any preceding claim, wherein the angle a is between 90 and 170 degrees, optionally between 90 and 160 degrees, optionally between 100 and 150 degrees, optionally between 100 and 140 degrees.

11 . Apparatus (100) for forming a heated-tobacco-product consumable (200) having a generally planar form, comprising: a carriage (102) comprising a channel (102b) having a channel flat base and two upstanding sides each forming an angle of between 90 and 170 degrees with the channel flat base, the carriage being arranged to be guided to move between processing stations of the apparatus; a die stamp station (104) arranged to stamp a wrapper material (202) to conform to the channel of the carriage so as to form the wrapper material into a U-shape having a flat base and two upstanding sides, each upstanding side forming an angle a with the flat base; an adhesive station (106) located downstream of the die stamp station and arranged to apply a first adhesive to a first portion of the flat base of the U- shape wrapper material between the sides thereof; a support element station (108) located at or downstream of the adhesive station and arranged to place a support element (204) on the adhesive to attach the support element to the first portion of the flat base of the U-shape wrapper material; a tobacco substrate station (110) located downstream of the support element station and arranged to place a tobacco substrate (206) on a second portion of the flat base of the U-shape wrapper adjacent to the support element, preferably so that the tobacco substrate and the support element have substantially the same height dimension from the flat base of the U-shape wrapper; and one or more folding and adhesive stations (112, 114) located downstream of the tobacco substrate station and arranged to: fold a portion of a first one of the sides of the U-shape wrapper material over the support element and the tobacco substrate so as to be in parallel relationship with the flat base of the U-shape wrapper material; provide a second adhesive on at least one of the sides; and fold a portion of the second one of the sides of the U-shape wrapper material over the portion of the first one of the sides of the U- shape wrapper material so as to be in parallel relationship therewith, thereby to attach the sides of the wrapper material together to enclose the support element and the tobacco substrate in the wrapper material.

12. Apparatus (100) for forming a heated-tobacco-product consumable (200) according to claim 11 , wherein the tobacco substrate station (110) comprises a stamp (110a) arranged to apply an adjustable pressure to the top of the tobacco substrate (206) to compress the tobacco substrate.

13. Apparatus (100) for forming a heated-tobacco-product consumable (200) according to claim 11 or 12, wherein the one or more folding and adhesive stations (112, 114) are arranged to provide the second adhesive on the second one of the sides of the U-shape wrapper material (202) and comprise: a first flat blade (112a) arranged to be moved laterally toward the U-shape wrapper material to cause an edge (112ai) of the first flat blade to engage and fold said portion of the first one of the upstanding sides of the U-shape wrapper material, and optionally further arranged to be moved in an opposite direction away from the U-shape wrapper material; and a second flat blade (114a) arranged to be moved laterally to cause an edge (114ai) of the second flat blade to engage and fold said portion of the second one of the upstanding sides of the U-shape wrapper material, and optionally further arranged to be moved in an opposite direction away from the U-shape wrapper material.

14. Apparatus (100) for forming a heated-tobacco-product consumable (200) according to claim 13, wherein the edge (114ai) of the second flat blade (114a), and optionally the edge (112ai) of the first flat blade (112a), comprises a curved profile to reduce friction between the moving blade and the U-shape wrapper material (202).

15. Apparatus (100) for forming a heated-tobacco-product consumable (200) according to any one of claims 11 to 14, comprising a curing and shaping chamber (122) located downstream of the one or more folding and adhesive stations, the curing and shaping chamber having an interior shape which is complementary to the exterior shape of the consumable, for receiving the consumable and allowing one or both of the first and second adhesives to cure while maintaining the exterior shape of the consumable.