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

Background

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

Summary

According to the present invention, there is provided a suction belt of a suction conveyor for use in manufacturing a rod of aerosolisable material, the suction belt comprising a plurality of suction regions and a plurality of non-suction regions arranged in a profile along the suction belt, each suction region comprising a plurality of suction holes for retaining aerosolisable material on the suction belt in the suction regions such that during use aerosolisable material is retained on the suction belt in a profile according to the profile of the suction regions. In examples, there are no suction holes in the non-suction regions. No suction is provided to retain aerosolisable material in the non-suction regions, such that aerosolisable material is only retained on the suction belt in the suction regions.

The suction regions maybe spaced along the suction belt. In examples, the suction regions and non-suction regions may be alternately arranged along the suction belt.

Each non-suction region may extend across a width of the suction belt between adjacent suction regions. Alternatively, each non-suction region may extend only partially across a width of the suction belt. The suction belt may further comprise connecting suction regions disposed between adjacent suction regions on the suction belt. Each connecting suction region may comprise one or more suction holes for retaining aerosolisable material on the suction belt during use. In this example, each connecting suction region may be smaller than the suction regions such that less aerosolisable material is retained in the connecting suction regions than in the suction regions.

Each connecting suction region may extend between one suction region and an adjacent suction region.

According to a further aspect of the present invention, there is also provided a suction conveyor for use in manufacturing a rod of aerosolisable material, the suction conveyor comprising the suction belt described above. The suction belt may be arranged to rotate about rollers to convey aerosolisable material that is retained on the suction belt.

The suction conveyor may be arranged above a feeder, the feeder being configured to feed aerosolisable material onto the suction belt such that said aerosolisable material is retained on an underside of the suction belt. In examples, the feeder is a vertical feeder.

Alternatively, the suction conveyor may be arranged to receive said aerosolisable material on an upper side of the suction belt. The suction conveyor may further comprise a suction chamber arranged to provide suction to the suction holes.

According to a further aspect of the present invention, there is also provided apparatus for manufacturing a rod of aerosolisable material, the apparatus comprising the suction conveyor described above.

The apparatus may further comprise a feeder disposed below the suction conveyor, the feeder may be configured to feed aerosolisable material onto the suction belt such that said aerosolisable material is retained on an underside of the suction belt. The apparatus may further comprise a transfer conveyor, and the apparatus may be arranged to transfer said aerosolisable material from the suction conveyor to the transfer conveyor. The transfer conveyor may comprise a suction conveyor as described above.

The apparatus may further comprise a second suction conveyor, and the apparatus may be arranged to transfer said aerosolisable material from the transfer conveyor to the second suction conveyor.

The apparatus may further comprise a second feeder disposed below the second suction conveyor. The second feeder may be adapted to feed a second aerosolisable material onto the second suction conveyor to create a combined stream of aerosolisable material and second aerosolisable material. The second feeder may be a vertical feeder.

The second suction conveyor may comprise a second suction belt having suction holes arranged in a continuous pattern along the length of the second suction belt.

The apparatus may further comprise a garniture arranged to receive the combined stream of aerosolisable material and second aerosolisable material from the second suction conveyor.

The garniture may be adapted to wrap a ribbon of paper about the combined aerosolisable material and second aerosolisable material to form a continuous rod of aerosolisable material and second aerosolisable material.

The apparatus may further comprise a cutter adapted to cut the continuous rod of aerosolisable material and second 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:

feeding an aerosolisable material

retaining the aerosolisable material on a suction belt, and

conveying the aerosolisable material to a garniture; and wherein the step of retaining the aerosolisable material on the suction belt comprises retaining the aerosolisable material in a profile having varying amounts of aerosolisable material along the suction belt. The method may further comprise combining the aerosolisable material with a second aerosolisable material.

The method may further comprise transferring said aerosolisable material from a first suction conveyor to a second suction conveyor.

The method may further comprise wrapping a paper ribbon about the aerosolisable material to form a continuous rod of aerosolisable material.

The method may further comprise cutting the continuous rod of aerosolisable material.

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

In various examples, the rod of aerosolisable material comprises a tobacco material.

Brief Description of the Drawings

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

FIGS. lA to lD show examples of tobacco industry products that include two different types of tobacco material;

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

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

FIG. 4 shows a part of apparatus for manufacturing the example wrapped tobacco rods of FIGS. 2A and 2B, including the first suction conveyor of FIG. 3;

FIG. 5 shows a more detailed view of the removal drum of the apparatus of FIG. 4; FIG. 6 shows a more detailed view of the transfer point from the intermediate suction belt to the second suction belt of the apparatus of FIG. 4;

FIGS. 7A and 7B show example profiled suction belts of the apparatus of FIG. 3; and, FIG. 7C shows an example suction belt for the second suction conveyor.

Detailed Description

FIGS. lA to lD show different examples of tobacco industry products 1. The tobacco industry products 1 include a rod of aerosolisable material. In the described

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

aerosolisable material is a tobacco rod 3.

As illustrated, each of the tobacco industry products 1 includes a filter 2 and a tobacco rod 3. The filter 2 may comprise a filtering material and a wrapper, and the tobacco rod

3 comprises tobacco material and a paper wrapper. The filter 2 and the tobacco rod 3 may be joined together by a joining wrapper that circumscribes and at least partially overlaps the filter 2 and the tobacco rod 3. For clarity, these details are omitted from FIGS. lA to lD, which schematically illustrate the arrangement of first and second tobacco materials 4, 5 in the tobacco rod 3. As illustrated, in these examples the tobacco rods 3 include a first tobacco material 4 and a second tobacco material 5. The first and second tobacco materials 4, 5 are different. The first and second tobacco materials 4, 5 are arranged in distinct areas of the tobacco rod 3, such that a boundary is formed between the first tobacco material 4 and the second tobacco material 5 in the tobacco rod 3, as illustrated.

In the example of FIG. lA, the first tobacco material 4 extends from the end of the tobacco rod 3 adjacent to the filter 2, and the second tobacco material 5 extends from the open end 6 of the tobacco rod 3. The boundary between the first and second tobacco materials 4, 5 is angled with respect to the axial direction of the tobacco industry product 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.

The example of FIG. lB is similar to that of FIG. lA, although the first tobacco material

4 extends alongside the second tobacco material 5 to the open end 6 of the tobacco rod 3. In this example, the first tobacco material 4 extends from the filter 2 to the open end

length of the tobacco rod 3.

The examples of FIGS. lC and lD are similar to those of FIGS. lA and lB, but the first tobacco material 4 and the second tobacco material 5 are oppositely arranged with respect to the filter 2 and the open end 6 of the tobacco rod 3. In these examples, the second tobacco material 5 is located at the end of the tobacco rod 3 abutting the filter 2, and the first tobacco material 4 is extends to the open end 6 of the tobacco rod 3. In other examples, the boundary between the first tobacco material 4 and the 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. lAto lD.

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

FIGS. 2A and 2B are schematic drawings showing the arrangement of the first and second tobacco materials 4, 5 along the length of the continuous tobacco rods 7, and the lengths and widths illustrated are not dimensionally representative of the actual continuous tobacco rod 7. In particular, the length dimension is compressed and the width dimension is exaggerated to provide a clear illustration of the arrangement of the first and second tobacco materials 4, 5 along the continuous tobacco rod 7. As shown, the first tobacco material 4 and second tobacco material 5 are arranged in an alternating pattern along the continuous tobacco rods 7. In particular, the first and second tobacco materials 4, 5 are arranged such that it can be cut at regular intervals to form the tobacco rods 3 for the tobacco industry products 1 of FIGS. lA to lD. The first and second tobacco materials 4, 5 are arranged such that after the continuous tobacco rod 7 is cut at lines 8 the individual tobacco rods are arranged in an opposing back-to- back manner (i.e. they are mirror-images of each other about the cut line). Cigarette assembly apparatus can then attach the filters 2 in the manner shown in FIGS. lAto lD. 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 diagram of part of an apparatus 9 for manufacturing a continuous rod of aerosolisable material, for example a continuous tobacco rod, for example the continuous tobacco rods 7 of FIGS. 2A and 2B. The apparatus 9 includes a first suction conveyor 12. The first suction conveyor 12 receives a first aerosolisable material, in this example a first tobacco material 4, and that first tobacco material 4 is transferred to an intermediate suction conveyor 14. Specifically, the first tobacco material 4 is formed into a profile on the first suction conveyor 12. The profiled first tobacco material 4 is then transferred, in profile, to the second suction conveyor 13. A first vertical feeder 10 provides the first tobacco material 4 to a first suction conveyor 12. The first vertical feeder 10 has a vertical chimney 15 that receives first tobacco material 4. The first tobacco material 4 is fed into the bottom of the vertical chimney 15 and is urged upwards towards the first suction conveyor 12. As explained further below, the first suction conveyor 12 includes a first suction belt 16 that has suction holes that draw the first tobacco material 4 onto the first suction conveyor 12. Optionally, air flow is induced within the vertical chimney 15 to urge the first tobacco material 4 vertically upwards towards the first suction conveyor 12. The first suction belt 16 is driven on rollers 19 such that the first suction belt 16 has an upper run 17 and a lower run 18, the lower run 18 moving to the left as illustrated in FIG. 3. The first vertical feeder 10 is disposed beneath the lower run 18 of the first suction belt 16.

The first suction conveyor 12 also has a suction chamber 20 located between the upper and lower runs 17, 18 of the first suction belt 16. The suction chamber 20 is a closed box (or similar) defining a closed area within the first suction conveyor 12, and has one or more openings on its lower side, adjacent to the lower run 18 of the first suction belt 16. The suction chamber 20 is connected to a vacuum pump via an outlet 21. The first suction belt 16 includes suction holes formed through the first suction belt 16. Therefore, a suction air flow is induced by the vacuum pump from the chimney 15 of the first vertical feeder 10, through the suction holes in the first suction belt 16, into the suction chamber 20 and outlet 21. This suction air flow urges the first tobacco material 4 onto the underside of the lower run 18 of the first suction belt 16. The suction holes are sized such that the first tobacco material 4 is retained on the underside of the lower run 18 of the first suction belt 16 by the suction. In this way, the first tobacco material 4 is entrained on the first suction conveyor 12. Guides may be provided to guide the first tobacco material 4 along the first suction conveyor 12 as the first suction belt 16 moves. The first suction belt 16 is driven to rotate about rollers 19 to carry first tobacco material 4 towards the intermediate suction conveyor 14 on the underside of the lower run 18 of the first suction belt 16. As explained hereinafter, the first tobacco material 4 is then transferred from the first suction conveyor 12 to the intermediate suction conveyor 14.

FIGS. 7A and 7B illustrate two examples of the first suction belt 16. The first suction belt 16 is adapted to create a profiled stream of first tobacco material 4 on the first suction belt 16. FIG. 7A illustrates an example first suction belt 16a. The first suction belt 16a has suction regions 47 and non-suction regions 48. Each suction region 47 has a plurality of suction holes 46. Each non-suction region 48 has no suction holes 46.

As illustrated, on the first suction belt 16a there are suction regions 47 extending across the width of the first suction belt 16a that include suction holes 46, and there are non- suction regions 48 extending across the width of the first suction belt 16a that have no suction holes 46. The suction regions 47 and non-suction regions 48 are alternately arranged along the first suction belt 16a.

Referring also to FIG. 3, during use the first tobacco material 4 from the first vertical feeder 10 is retained on the first suction belt 16a only in the suction regions 47 because of the suction holes 46. This creates a profiled stream of first tobacco material 4 on the first suction belt 16a as the first suction belt 16a rotates about the rollers 19.

FIG. 7B shows another example of the first suction belt 16b. As shown, the suction holes 46 are arranged in suction regions 47 spaced along the suction belt 16b. Non-suction regions 50 are disposed between the suction regions 47. In this example, connecting suction regions 59 are disposed between the suction regions 47. The connecting suction regions 59 include suction holes 46 arranged to extend between two adjacent suction regions 47. In the connecting suction regions 59 there are fewer suction holes 46 than in the suction regions 47, such that less tobacco material 4 is retained in the connecting suction regions 59 than in the suction regions 47. The suction regions 47 and connecting suction regions 50 are alternately arranged along the length of the first suction belt 16b. In this example, the non-suction regions 50 are arranged either side of the connecting suction regions 59. No tobacco material 4 is retained by the non-suction regions 50 as there are no suction holes.

The first suction belt 16b of FIG. 7B might be used, for example, in the production of the continuous tobacco rod 7 of FIG. 2B, where the first tobacco material 4 extends along the length of the continuous tobacco rod 7, but in varying amounts.

It will be appreciated that the suction regions 47, 59 on the first suction belt 16, in particular the suction holes 46, can be arranged such that the first tobacco material 4 is arranged in various profiles along the first suction conveyor 12. As illustrated in FIG. 3 and in FIG. 4, an intermediate suction conveyor 14 is disposed at an end of the first suction conveyor 12. The intermediate suction conveyor 14 includes an intermediate suction belt 22 that is driven on rollers 23 such that the intermediate suction belt 22 has an upper run 24 and a lower run 25. The intermediate suction conveyor 14 also has a suction chamber 26 located between the upper and lower runs 24, 25 of the intermediate suction belt 22. The suction chamber 26 is a closed box (or similar) defining a closed area within the intermediate suction conveyor 14, and has one or more openings on its upper side, adjacent to the upper run 24 of the first suction belt 16. The suction chamber 26 is connected to a vacuum pump via an outlet 27.

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

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

intermediate suction belt 22 in the first transfer region 28. In this way, the first tobacco material 4 is transferred from the first suction belt 16 to the intermediate suction belt 22 in the first transfer region 28. The intermediate suction belt 22 rotates about rollers 23 to carry first tobacco material 4 towards a second suction conveyor, as illustrated in FIG. 4.

In some examples, the intermediate suction belt 22 comprises a suction belt 22a, 22b having a profile of suction holes 46, for example the suction belts 22a, 22b illustrated in FIGS. 7A and 7B. Specifically, the intermediate suction belt 22 may have suction regions 47 and non-suction regions 48, 50 arranged along the length of the intermediate suction belt 22. In addition, the intermediate suction belt 22 may have connecting suction regions 59, as described with reference to FIG. 7B.

As illustrated in FIG. 3, the intermediate suction belt 22a of this example comprises the suction belt 22a of FIG. 7A, with suction regions 47 spaced along the suction belt 22a.

In this example, the first suction belt 16a and intermediate suction belt 22a are rotated in registration such that the suction regions 47 of the first suction belt ia6 and intermediate suction belt 22a are aligned to each other in the first transfer region 28, for transfer of the spaced areas of first tobacco material 4 from the first suction conveyor 12 to the intermediate suction conveyor 14.

In a further example, the intermediate suction belt 22 comprises the suction belt 22b of FIG. 7B, with suction regions 47 and connecting suction regions 59 extending between the suction regions 47. The connecting suction regions 59 have few suction holes 46 than the suction regions 47. In this example, the first suction belt 16b and intermediate suction belt 22b are rotated in registration such that the suction regions 47 of the first suction belt 16b and the intermediate suction belt 22b are aligned to each other in the first transfer region 28, for transfer of the spaced areas of first tobacco material 4 from the first suction conveyor 12 to the intermediate suction conveyor 14.

Use of a profiled intermediate suction belt 22a, 22b on the intermediate suction conveyor 14 advantageously helps to keep the first tobacco material 4 in the desired profile. In addition, it can prevent waste of energy as there are no (or fewer) exposed suction holes 46 that are not engaged in retaining the first tobacco material 4. However, it will be appreciated that the intermediate suction belt 22 may not have a profile of suction regions 47. For example, the suction belt 29 illustrated in FIG. 7C and described further hereinafter may be used as the intermediate suction belt 22 c.

FIG. 4 is a schematic diagram of part of an apparatus 9 for manufacturing a continuous tobacco rod 7, for example the continuous tobacco rods 7 of FIGS. 2A and 2B. The apparatus 9 includes the first suction conveyor 12 and intermediate suction conveyor 14 described with reference to FIG. 3. As shown, the apparatus 9 of FIG. 4 also includes a second suction conveyor 13. As previously described, the first suction conveyor 12 receives a first tobacco material 4, and that first tobacco material 4 is transferred to the intermediate suction conveyor 14. The intermediate suction conveyor 14 then transfers the first tobacco material 4 to the second suction conveyor 13. A second tobacco material 5 is added to the second suction conveyor 13 to create a stream of tobacco material comprising the first and second tobacco materials 4, 5.

As explained above, the first suction belt 16 includes suction holes 46 arranged in a profile to create a profiled stream of first tobacco material 4 on the first suction conveyor 12. That profiled stream of first tobacco material 4 is then transferred to the second suction conveyor 14 via the intermediate suction conveyor 14. The second tobacco material 5 is then provided to form a stream of first and second tobacco materials 4, 5 suitable for forming a continuous tobacco rod 7, for example the continuous tobacco rod 7 of FIG. 2A or 2B.

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

The second suction conveyor 13 has a second suction belt 29 that is driven on rollers 30 such that the second suction belt 29 has an upper run 31 and a lower run 32. The second vertical feeder 11 is disposed beneath the lower run 32 of the second suction belt 29. The second suction belt 29 has suction holes 51 formed along the length of the second suction belt 29.

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

The profiled first tobacco 4 is transferred from the intermediate suction belt 22 onto the second suction belt 29 in a second transfer region 35.

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

FIG. 6 schematically illustrates the second transfer region 35, where the first tobacco material 4 is transferred from the intermediate suction belt 22 to the second suction belt 29.

As explained above and illustrated in FIG. 6, the first tobacco material 4 is arranged in a profile on the intermediate suction belt 22, in the illustrated example the profile is a series of spaced groups of first tobacco material 4. As illustrated in FIG. 7C, the second suction belt 29 has suction holes 51 arranged in a continuous pattern along the length of the second suction belt 29.

The suction chamber 26 of the intermediate suction conveyor 14 has an end wall approximately aligned with the roller 30 of the second suction conveyor 13, at the start of the second transfer region 35. The end wall 37 defines the extent of the suction chamber 26, such that after the intermediate suction belt 22 has passed the end wall 37 no (or very little) suction is provided to the suction holes on the intermediate suction belt 22. In this way, the first tobacco material 4 is released from the intermediate suction belt 22 in the second transfer region 35. Preferably, an outlet 38 is provided within the intermediate suction conveyor 14. The outlet 38 can be vented to atmosphere, so that any residual vacuum from the suction chamber 26 is released. Alternatively, the outlet 38 may be provided with a positive air flow to counteract any residual suction from the suction chamber 26 and/or to push the first tobacco material 4 off of the intermediate suction belt 22, towards the second suction belt 29. As illustrated, in the second transfer region 35 the second suction belt 29 is disposed above the intermediate suction belt 22. The suction chamber 33 extends over the second transfer region 35. Therefore, as the first tobacco material 4 is released from the intermediate suction conveyor 22 it is drawn onto the second suction conveyor 13.

Thereafter, the second suction belt 29 with the first tobacco material 4 moves across the top of a second vertical feeder 11, as illustrated in FIG. 4, and the second tobacco material 5 is added to the second suction belt 29. A second vertical feeder 11 provides the second tobacco material 5 to a second suction conveyor 13. The second vertical feeder 11 has a vertical chimney 15 that receives second tobacco material 5. The second tobacco material 5 is fed into the bottom of the vertical chimney 15 and is urged upwards towards the second suction conveyor 13. As shown in FIG. 7C, the second suction conveyor 13 includes suction holes 51 that draw the second tobacco material 5 onto the second suction conveyor 13. Optionally, air flow is induced within the vertical chimneys 15 to urge the second tobacco material 5 vertically upwards towards the second suction conveyor 13. As the second suction belt 22 has suction holes 51 arranged in a continuous pattern along the length of the second suction belt 22, second tobacco material 5 is drawn onto the second suction belt 29 in areas where there is no first tobacco material 4, or in areas where the amount of first tobacco material 4 is reduced due to the profile of the first tobacco material 4 created by the profile of suction holes 46 on the first suction belt 16.

Suction air flow induced by the vacuum pump creates air flow from the chimney 15 of the second vertical feeder 11, through the suction holes 51 in the second suction belt 29, into the suction chamber 33 and outlet 34. This suction air flow draws the second tobacco material 5 onto the underside of the lower run 32 of the second suction belt 29, where the first tobacco material 4 provided from the intermediate suction conveyer 14 is also retained. The suction holes 51 are sized such that the first and second tobacco materials 4, 5 are retained on the underside of the lower run 32 of the second suction belt 29 by the suction. In this way, the second tobacco material 5 is added to the first tobacco material 4 and together they are entrained on the second suction conveyor 13. Guides may be provided to guide the first tobacco material 4 and second tobacco material 5 along the second suction conveyor 13 as the second suction belt 29 moves. In this way, the second suction belt 29 is adapted to create a combined stream of first tobacco material 4 and second tobacco material 5. The second suction belt 29 rotates about rollers 30 to carry the stream of first and second tobacco materials 4, 5 towards the garniture 36.

In some examples, as illustrated in FIG. 4, a removal drum 39 may be provided on the intermediate suction conveyor 14. The removal drum 39 is configured to remove parts of the first tobacco material 4 from the intermediate suction belt 22 such that the first tobacco material 4 is arranged in a profile on the intermediate suction belt 22. The removal drum 39 may be used in addition to the profiled first suction belt 16 and the profiled intermediate suction belt 22. The removal drum 39 can remove any excess first tobacco material 4 to ensure an accurate profile of first tobacco material 4 on the intermediate suction conveyor 14. The profiled first tobacco material 4 is then transferred onto the second suction conveyor 13 in that profile, as previously described.

The removal drum 39 is shown in more detail in FIG. 5. The removal drum 39 includes a rotor 40 that rotates above the upper run 24 of the intermediate suction belt 22, such that the circumferential surface 41 of the rotor rolls over the intermediate suction belt 22 as the intermediate suction belt 22 moves.

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

Tobacco that is not aligned with a removal passage 42 remains on the intermediate suction belt 22. Therefore, the arrangement of the removal passages 42 about the rotor 40 determines the profile of the first tobacco material 4 on the intermediate suction belt 22

downstream of the removal drum 39.

In some examples, the rotor 40 may contact the intermediate suction belt 22 as the rotor 40 rotates. In other examples, the rotor 40 may be spaced from the intermediate suction belt 22. In the example illustrated in FIG. 5, the removal passages 42 are configured to remove all of the first tobacco material 4 from the intermediate suction belt 22 in the region that they align with during rotation. However, in other examples the removal passages 42 may be configured to remove only part of the first tobacco material 4, so that some is left on the intermediate suction belt 22, creating a profile of first tobacco material 4 having varying thickness along the intermediate suction belt 22.

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

Preferably, the suction extraction tube 43 is adapted to recycle the removed first tobacco material 4 into the first vertical tobacco material feeder 10.

In an alternative example, the removal drum 39 is adapted to remove first tobacco material 4 from the intermediate suction belt 22 by pushing parts of the first tobacco material 4 off of the intermediate suction belt 22. For example, the rotor may include a series of angled blades that push first tobacco material 4 off of the side of the intermediate suction belt 22. In this example, the removal drum may rotate about an axis that is rotated in the plane of the intermediate suction belt 22 such that the angled blades push the first tobacco material 4 off of the intermediate suction belt 22. The removed first tobacco material 4 can be collected and recycled to the first vertical feeder 10.

Preferably, as illustrated in FIG. 5, a suction break chamber 44 is disposed below the intermediate suction belt 22. The suction break chamber 44 is aligned with the position at which the removal passages 42 (or removal blades) are closest to the intermediate suction belt 22 - i.e. the location where first tobacco material 4 is removed.

In one example, the suction break chamber 44 is sealed from the suction chamber 26, so that no suction is applied to the first tobacco material 4 as it is removed from the intermediate suction belt 22. Alternatively, the suction break chamber 44 may not be sealed from the suction chamber 26, but maybe provide with an air jet 45 that intermittently directs air flow onto the underside of the intermediate suction belt 22 to counteract the suction of the suction chamber 26 while first tobacco material 4 is removed. The air jet 45 is timed to coincide with the removal passages 42 (or removal blades). In another example, the suction break chamber 44 is sealed from the suction chamber 26 and it may also include an air jet 45 that intermittently directs air flow onto the underside of the intermediate suction belt 22. The air jet 45 is timed to coincide with the removal passages 42 (or removal blades). As illustrated in FIG. 4, the first, second and intermediate suction conveyors 12, 13, 14 are angled at a downwards slope towards the garniture 36. The suction belts 16, 22, 29 are parallel to each other and angled downwards in the direction that the tobacco materials 4, 5 move during use. As described above, the first tobacco material 4 is arranged in a profile on the first suction conveyor 12 by the first suction belt 16. In examples, the first tobacco material 4 may have variable thickness on the intermediate suction belt 22. For example, the first tobacco material 4 maybe arranged in spaced groups along the first suction belt 16. In another example, the first tobacco material 4 may be arranged along the first suction belt 16 with spaced thicker parts and intermediate thinner parts. In these examples, the second tobacco material 5 will fill in the gaps between the spaced areas of first tobacco material 4, thereby creating an arrangement of the tobacco materials 4, 5 suitable for forming the continuous tobacco rods 7 of FIGS. 2A and 2B. In one example, providing stronger suction to the suction chamber 33 of the second suction conveyor 13 may draw second tobacco material 5 onto the second suction belt 29 on top of the first tobacco material 4, thereby creating an overlapping profile of first and second tobacco materials 4, 5-

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

In further examples, the combined first and second tobacco materials 4, 5 on the second suction belt 29 may be trimmed by a trimming unit 54. The trimming unit 54 can include a pair of counter-rotating blades 55 that are spaced from the second suction belt 29 so that they trim the first and/or second tobacco materials 4, 5 to an

appropriate thickness. Alternatively or additionally, the trimming unit 54 can include a paddle wheel that rotates and knocks first tobacco material off of the second suction belt 29. Depending on the arrangement of the first and second tobacco materials 4, 5 on the second suction belt 29, one or both of the first and second tobacco materials 4, 5 may be trimmed. The trimming unit 54 is arranged downstream of the second vertical feeder 11, before the tobacco materials 4, 5 are transferred onto the garniture 36. The trimming unit 54 may include a recycling device 53 arranged to collect tobacco material that is trimmed by the trimming unit 54. If only one type of the first and second tobacco materials 4, 5 is trimmed from the second suction belt 29, then that trimmed tobacco material can be recycled to the first or second vertical tobacco 10, 11, as appropriate. If the trimmed tobacco is a mix of first and second tobacco materials 4, 5, then the trimming tobacco material can be recycled for alternative uses, for example in different tobacco industry products.

The arrangement described above and illustrated in FIG. 4 creates a tobacco stream having two different tobacco materials 4, 5. However, one or more additional vertical feeders, suction conveyors, and intermediate suction conveyors (along with appropriate suction belts / removal drums) could be arranged in series to create a stream of tobacco material having three or more different types of tobacco material arranged in a profile.

Moreover, by placing the same type of tobacco material in the first and second vertical feeders 10, 11 the apparatus could be used to produce a tobacco rod having a single type of tobacco material. This is advantageous as it gives flexibility in the manufacturing process - i.e. the apparatus can be employed to produce various formats of tobacco rod, having one or more different types of tobacco material. As described above, the combined stream of first and second tobacco materials 4, 5 is transferred from the second suction conveyor 13 into a garniture 36. The skilled person will be aware of suitable existing garnitures 36, but a brief description of the garniture 36 is provided below.

The garniture comprises a continuous garniture belt 57 that drives a ribbon of paper 58 through the garniture 36. The garniture belt 57 is disposed below the ribbon of paper 58, and the tobacco material 4, 5 is transferred from the second suction conveyor 13 onto the top of the ribbon of paper 58. In this way, the tobacco material 4, 5 is arranged on the ribbon of paper 58, which is moved through the garniture 36 by the garniture belt 57.

An adhesive applicator (not illustrated) applies adhesive to the top of the ribbon of paper 58 along one side. The garniture includes a wrapping unit (not illustrated) through which the ribbon of paper 58 with tobacco material 4, 5 is conveyed. The wrapping unit wraps the ribbon of paper 28 about the tobacco material 4, 5 and the adhesive glues the ribbon of paper 58 in place to form a continuous tobacco rod 7, for example a continuous tobacco rod as illustrated in one of FIGS. 2A and 2B.

The continuous tobacco rod is then cut to the appropriate length for forming tobacco industry products, for example the tobacco industry products 1 shown in FIGS. lA to lD. In various examples, the continuous tobacco rod is cut on the tobacco rod making machine and/or on subsequent assembly apparatus. In various examples, the continuous tobacco rod can be cut into double-length rods, quadruple-length rods, and so on, and transferred to an assembly machine for further cutting and combining with a filter to produce complete tobacco industry products. In examples, this can be referred to as a‘two-up’ or‘four-up’ manufacturing process.

Advantageously, the first and second vertical feeders 10, 11 and first and second suction conveyors 12, 13 can be produced by modification of conventional apparatuses already used in the tobacco product industry. For example, the Hauni Protos cigarette making machine includes a vertical feeder and suction rod conveyor arrangement, commonly known as a‘V.E’. This machine can be adapted to be used as the first vertical feeder 10 and first suction conveyor 12 described with reference to the examples. This machine can also be adapted to be used as the second vertical feeder 11 and second suction conveyor 13 described with reference to the examples. For example, modification might include replacement of the suction belts, modification of the suction chambers, and/or addition of trimming units. Two of the modified machines can be combined in the described manner by provision of the intermediate suction conveyor 14 and/or addition of the removal drum 39.

The term“profile” means that the aerosolisable material is retained in a varying thickness along the length of the profiled suction belt. In contrast, a non-profiled belt, such as that shown in FIG. 7C, would retain the aerosolisable material in a constant stream having substantially uniform thickness along the length of the non-profiled belt.

As used herein, the term‘aerosolisable material’ includes materials that provide volatilised components upon heating, typically in the form of vapour or an aerosol. In some examples, as described above, the aerosolisable material includes a tobacco material. In other examples, the aerosolisable material consists of a tobacco material, or a blend of different tobacco materials. In other examples, the aerosolisable material is free from tobacco material. The apparatus described herein maybe used to manufacture a rod of any aerosolisable material.

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

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

In one embodiment, the tobacco industry product is a non-combustible smoking article.

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

In another embodiment the tobacco industry product is a hybrid system to generate aerosol by heating, but not burning, a combination of aerosolisable substrate materials. The aerosolisable substrate materials may comprise for example solid, liquid or gel which may or may not contain nicotine. In one embodiment, the hybrid system comprises a liquid or gel substrate and a solid substrate. The solid substrate may be for example tobacco or other non-tobacco products, which may or may not contain nicotine. In one embodiment the hybrid system comprises a liquid or gel substrate and tobacco.

In order to address various issues and advance the art, the entirety of this disclosure shows by way of illustration various embodiments in which the claimed invention(s) maybe practiced and provide for superior apparatus for manufacturing a rod of aerosolisable material, and a superior method of manufacturing a rod of aerosolisable material. The advantages and features of the disclosure are of a representative sample of embodiments only, and are not exhaustive and/or exclusive. They are presented only to assist in understanding and teach the claimed features. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects of the disclosure are not to be considered limitations on the disclosure as defined by the claims or limitations on equivalents to the claims, and that other embodiments 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.