Note: Descriptions are shown in the official language in which they were submitted.
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Apparatus and Method for Combining Components for Smoking Articles
The present invention relates to an apparatus and method for combining
components for
the production of smoking articles.
Apparatus and processes for manufacturing smoking articles consisting of a
plurality of
components are known in the art. For example, a rolling process may be used,
in which the
smoking articles and components are substantially perpendicularly aligned with
respect to the
direction of travel. Alternatively, a linear process may be used, in which the
components are
substantially longitudinally aligned along the direction of travel. In some
arrangements, a
combination of the two processes is used, for example, the combining may be
carried out as a
rolling process and the overwrapping may be carried out as a linear process.
However, known
apparatus and manufacturing processes are not suitable for manufacturing
smoking articles
comprising a component made of a material which cannot be cleanly cut with
mechanical
cutting means, such as a conventional knife or blade.
It is an object of the present invention to provide an apparatus and a method
suitable for
making smoking articles comprising one or more components made of a material
which cannot
be cleanly cut with a conventional blade. The apparatus and method of the
present invention is
particularly, but not exclusively, suitable for manufacturing smoking
articles, wherein one of the
components is a combustible heat source or fuel element, for example a
carbonaceous heat
source.
According to a first aspect of the invention, there is provided a method for
combining two
or more different components for the production of smoking articles, wherein
at least one of the
components is non-cleanly-cuttable, the method comprising the steps of:
feeding a stream of
components along a moving delivery path; compacting the stream of components
into groups of
two or more different components, each group corresponding to a discrete
smoking article,
wherein the components within a group abut one another and wherein there is a
predefined
space between a leading group of components and a trailing group of
components; wrapping
the components in a web of material; and cutting the web of material in each
space between
groups of components.
According to the first aspect of the invention, there is also provided a
method for
combining two or more different components for the production of smoking
articles, wherein at
least one of the components is non-cleanly-cuttable, the method comprising the
steps of:
feeding a stream of components along a moving delivery path; compacting the
stream of
components into groups of two or more different components, each group
corresponding to a
discrete un-tipped smoking article, wherein the components within a group abut
one another
and wherein there is a predefined space between a leading group of components
and a trailing
group of components; wrapping the components in a web of material; and cutting
the web of
material in each space between groups of components.
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The non-cleanly-cuttable component is a component which cannot be cleanly cut
with
conventional mechanical cutting means. For example, the component may comprise
a brittle
material or a material having a tendency to splinter, crumble or fragment when
cut with a
conventional blade. Preferably, the non-cleanly-cuttable component is adjacent
the space
between two groups of components. The smoking article may be tipped or un-
tipped. An un-
tipped smoking article comprises all components for a smoking article, that
is, the entire number
and all the types of components for a smoking article, except for a smoking
article tip, such as a
mouthpiece and a wrapper. Preferably, the non-cleanly-cuttable component and
the tip are at
opposite ends of the smoking article. The two or more different components may
comprise a
non-cleanly-cuttable component plus one, two, three, four, five or more
further components.
Preferably, the two or more different components comprise a non-cleanly-
cuttable component
plus two, three or four components. Even more preferably, the two or more
different
components comprise a non-cleanly-cuttable component plus three components,
one
component of a first type and two components of a second type. The terms
"leading group of
components" and "trailing group of components" are used to indicate the
relative positions of the
groups of components on the moving delivery path, and do not necessarily
indicate the
positions of the components in a smoking article.
The method and apparatus of the invention may advantageously be used to
produce
various smoking articles but are particularly useful in the manufacture of
heated smoking
articles such as those described in granted patents US-A-4,714,082, US-A-
5,819,751 and US-
A-5,040,551, distillation-based smoking articles such as those described in
pending patent
application PCT/IB2008/002868, and heated cigarettes such as those marketed by
the R. J.
Reynolds Tobacco Company under the brand names Premier and Eclipse .
The method according to the invention is advantageous since different
components can
easily be substituted, so that the method may readily be adapted to produce
different types of
smoking article, in different production runs. The method is also advantageous
since it can be
used to manufacture smoking articles at high speed. Cutting the web of
material at the spaces,
rather than through the non-cleanly-cuttable component, avoids the risk of
damage to the
cutting means. In the case of a carbonaceous heat source, this also means that
other
components do not get black or dirty.
Preferably, the components on the delivery path have their longitudinal axes
substantially aligned with each other and with the direction of movement of
the delivery path.
Preferably, the components on the delivery path are the cylindrical components
of the smoking
articles. Such a linear combining process is advantageous since it causes
minimal or no
damage to the components within each smoking article.
The step of feeding the stream of components along the moving delivery path
preferably
comprises interleaving each of the two or more different components with
others of the two or
more different components, such that the components on the delivery path are
in a desired and
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predetermined order.
In a preferred embodiment, the order of the components on the moving delivery
path
corresponds to smoking articles all facing the same direction with respect to
the direction of
movement of the delivery path. That is, the components are aligned first
component, second
component, third component, first component, second component, third
component, first
component and so on, or equivalently for the appropriate number of components.
For example,
the components may be aligned heat source, then aerosol-generating substrate,
then elongate
expansion chamber, then heat source, then aerosol-generating substrate, then
elongate
expansion chamber and so on.
In that preferred embodiment, preferably the method further comprises, after
the step of
cutting the web of material in each space between groups of components,
rotating every
alternate smoking article, such that adjacent smoking articles are facing in
the opposite direction
with respect to the direction of travel.
In an alternative embodiment, the order of the components on the moving
delivery path
corresponds to alternate smoking articles facing in opposite directions with
respect to the
direction of movement of the delivery path. That is, the components are
aligned first component,
second component, third component, third component, second component, first
component, first
component, and so on, or equivalently for the appropriate number of
components. For example,
the components may be aligned heat source, then aerosol-generating substrate,
then elongate
expansion chamber, then elongate expansion chamber, then aerosol-generating
substrate, then
heat source and so on.
In one embodiment, the step of compacting the stream of components into groups
of
components comprises: separating the stream of components into groups of two
or more
different components, wherein each group corresponds to a discrete smoking
article;
compacting the components within a group such that they abut one another; and
setting the
pre-defined space between a leading group of components and a trailing group
of components.
The size of the pre-defined space is the size desired between groups of
components
corresponding to discrete smoking articles. The web of material is cut at each
space. Therefore,
the size of each space should be accurate, since an inaccurate space could
result in damage to
the cutting means. The space should be sufficiently large so that the cutting
means is able to
cut the web of material, but sufficiently small so as not to waste the web of
material. In one
embodiment, the pre-defined spaced is 1 mm 0.5. mm, that is, between 0.5 mm
and 1.5 mm.
Even more preferably, the pre-defined space is between 0.8 mm and 1.2 mm.
If each group of components corresponds to a discrete un-tipped smoking
article, the
method of the invention may further comprise, after the step of cutting the
web of material, the
step of tipping un-tipped smoking articles with tips, to form tipped smoking
articles. Preferably,
the tip is a mouthpiece. The mouthpiece may comprise cellulose acetate tow.
Preferably, the
mouthpiece is cylindrical. Preferably, the step of tipping comprises securing
the tip to the un-
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tipped smoking article by tipping paper.
Preferably, the step of wrapping the components in a web of material comprises
wrapping the components in a paper web. Preferably, the web of material
comprises pre-
applied heat-conducting elements, for example patches of aluminium foil,
spaced along the
inside of the web of material. The position of the pre-applied heat-conducting
elements on the
web of material should be precise. The method may further comprise the step of
applying glue
areas or lines or a continuous or intermittent stream of glue to a web or to
patches of heat-
conducting material, for subsequent application to the web of material. The
method may further
comprise the step of applying spaced patches of the heat-conducting material
to the inside of
the web of material.
The method may further comprise the step of applying glue areas or lines or a
continuous or intermittent stream of glue to the inside of the web of material
before the step of
wrapping the components in the web of material. This will allow the web of
material to be
secured to one or more of the components. This may assist in maintaining the
integrity of the
finished smoking articles.
Preferably, the components are substantially cylindrical, with a circular or
elliptical cross
section.
In a preferred embodiment, the non-cleanly-cuttable component is a heat
source. Each
heat source may be a carbon-based heat source. Each heat source may be a non-
compressible
pyrolised carbon-based heat source. Preferably, the heat source is
cylindrical. In that case,
each heat source on the delivery path preferably has its longitudinal axis
substantially aligned
with the direction of movement of the delivery path. The heat source may
include one or more
airflow channels therethrough.
Preferably, the two or more different components include one or more aerosol-
generating substrates. Each substrate may comprise tobacco material.
Preferably, each
substrate is cylindrical. In that case, each substrate on the delivery path
preferably has its
longitudinal axis substantially aligned with the direction of movement of the
delivery path.
Preferably, the two or more different components include one or more elongate
expansion chambers. Preferably, each elongate expansion chamber is
cylindrical. In that case,
each elongate expansion chamber on the delivery path preferably has its
longitudinal axis
substantially aligned with the direction of movement of the delivery path.
Even more preferably,
each elongate expansion chamber may comprise a cylindrical open-ended tube.
The tube may
comprise cardboard.
The components may further include other components, for example a barrier
material
for locating between the heat source and the aerosol-generating substrate.
In a preferred embodiment, the two or more different components comprise non-
cleanly-
cuttable heat sources, aerosol-generating substrates, and elongate expansion
chambers and
each group corresponding to a discrete smoking article comprises one of the
non-cleanly-
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cuttable heat sources, one or more of the aerosol-generating substrates, and
one or more of the
elongate expansion chambers.
According to a second aspect of the invention, there is provided apparatus for
combining
two or more different components for the production of smoking articles,
wherein at least one of
the components is non-cleanly-cuttable, the apparatus comprising: feeding
means for feeding a
stream of components along a moving delivery path; compacting means for
compacting the
stream of components into groups of two or more different components, each
group
corresponding to a discrete smoking article, wherein the components within a
group abut one
another and wherein there is a predefined space between a leading group of
components and a
trailing group of components; wrapping means for wrapping the components in a
web of
material; and cutting means for cutting the web of material in each space
between groups of
components.
According to a second aspect of the invention, there is provided apparatus for
combining
two or more different components for the production of smoking articles,
wherein at least one of
the components is non-cleanly-cuttable, the apparatus comprising: feeding
means for feeding a
stream of components along a moving delivery path; compacting means for
compacting the
stream of components into groups of two or more different components, each
group
corresponding to a discrete un-tipped smoking article, wherein the components
within a group
abut one another and wherein there is a predefined space between a leading
group of
components and a trailing group of components; wrapping means for wrapping the
components
in a web of material; and cutting means for cutting the web of material in
each space between
groups of components.
Preferably, the components on the delivery path have their longitudinal axes
substantially aligned with each other and with the direction of movement of
the delivery path.
Such a linear combining process is advantageous since it causes minimal or no
damage to the
components within each smoking article.
Preferably, the feeding means is arranged to interleave each of the two or
more different
components with others of the two or more different components, such that the
components on
the delivery path are in a desired and predetermined order. Preferably, the
feeding means is
arranged to interleave each of the two or more different components with
others of the two or
more different components with a distance therebetween in accordance with the
desired order
on the delivery path.
In a preferred embodiment, the order of the components on the moving delivery
path
corresponds to smoking articles all facing the same direction with respect to
the direction of
movement of the delivery path.
In that preferred embodiment, preferably the apparatus further comprises a
turning
drum, after the cutting means, for rotating every alternate smoking article,
such that adjacent
smoking articles are facing in the opposite direction with respect to the
direction of travel.
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In an alternative embodiment, the order of the components on the moving
delivery path
corresponds to alternate smoking articles facing in opposite directions with
respect to the
direction of movement of the delivery path.
Preferably, the feeding means comprises at least one indexing wheel for
feeding
components onto the moving delivery path. Preferably, each indexing wheel
comprises a
plurality of fingers around its circumference. Preferably, the separation of
the fingers sets the
distance between the components on the delivery path.
In one embodiment, the feeding means comprises first and second supply drums
for
feeding each component onto a feeding path upstream of the delivery path.
Preferably, the first
supply drum comprises a plurality of longitudinal flutes around its
circumference. Preferably,
each flute on the first drum is arranged to hold a multiple unit length
component, for example a
double length, quadruple length or sextuple length component. In that case,
preferably, each
feeding means further comprises at least one cutter along the first supply
drum, such that the
multiple unit length component on the first supply drum is cut into single
length components for
the second supply drum. Preferably, the second supply drum comprises a
plurality of
longitudinal flutes around its circumference. Preferably, the flutes are
axially and
circumferentially spaced, such that the components are fed, one or more at a
time, onto the
feeding path. Preferably, the feeding means comprises a hopper for feeding
multiple unit length
components onto each first supply drum.
Preferably, the compacting means comprises: a first wheel having
circumferentially
spaced fixed fingers for separating the stream of components into groups of
two or more
different components, wherein each group corresponds to a discrete smoking
article; a second
wheel, downstream of the first wheel, having circumferentially spaced moveable
fingers more
closely spaced than the fixed fingers on the first wheel, for compacting the
components within a
group such that they abut one another; and a third wheel, downstream of the
second wheel,
having circumferentially spaced moveable fingers, for setting the pre-defined
space between a
leading group of components and a trailing group of components.
In one embodiment, the first and second wheels have substantially equal
diameters. The
moveable fingers on the second wheel allow the components to be transferred
between the first
and second wheels, even though the wheels may be rotating at different speeds.
This is
preferably achieved by driving the moveable fingers on the second wheel by
cams.
In one embodiment, the second and third wheels have different diameters and
the
circumferentially spaced moveable fingers on the third wheel are narrower than
the
circumferentially spaced moveable fingers on the second wheel. This allows the
separation
between groups of components to be reduced as the components are transferred
from the
second wheel to the third wheel. The moveable fingers on the third wheel allow
for precision
and accuracy in the size of the space between groups of components. This is
preferably
achieved by driving the moveable fingers on the third wheel by cams.
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The web of material may comprise a web of paper material, for example
cigarette paper.
Preferably, the web of material supplied to the wrapping means comprises pre-
applied heat-
conducting elements spaced along the inside of the web of material. The
apparatus may further
comprise gluing means for applying glue areas or lines or a continuous or
intermittent stream of
glue to a web or to patches of heat-conducting material, for subsequent
application to the web
of material. The apparatus may further comprise applicator means for applying
spaced patches
of the heat-conducting material to the inside of the web of material.
The apparatus may further comprise gluing means for applying glue areas or
lines or a
continuous or intermittent stream of glue to the inside of the web of material
before the wrapping
means for wrapping the components in the web of material.
If each group of components corresponds to a discrete un-tipped smoking
article, the
apparatus may further comprise a tipper downstream of the cutting means, for
tipping un-tipped
smoking articles with tips, to form smoking articles. Preferably, the tip is a
mouthpiece. The
mouthpiece may comprise cellulose acetate tow. Preferably, the mouthpiece is
cylindrical.
Preferably, the tipper secures the tip to the un-tipped smoking article by
tipping paper. The
tipper may comprise any suitable tipper. Examples of suitable tippers are the
Max-S tipper
made by Hauni AG of Germany, and the Max-80 tipper also made by Hauni AG of
Germany.
In a preferred embodiment, the non-cleanly-cuttable component is a heat
source. Each
heat source may be a carbon-based heat source. Each heat source may be a non-
compressible
pyrolised carbon-based heat source. Preferably, the heat source is
cylindrical. In that case,
each heat source on the delivery path preferably has its longitudinal axis
substantially aligned
with the direction of movement of the delivery path. The heat source may
include one or more
airflow channels therethrough.
Preferably, the two or more different components include one or more aerosol-
generating substrates. Each substrate may comprise tobacco material.
Preferably, each
substrate is cylindrical. In that case, each substrate on the delivery path
preferably has its
longitudinal axis substantially aligned with the direction of movement of the
delivery path.
Preferably, the two or more different components include one or more elongate
expansion chambers. Preferably, each elongate expansion chamber is
cylindrical. In that case,
each elongate expansion chamber on the delivery path preferably has its
longitudinal axis
substantially aligned with the direction of movement of the delivery path.
Even more preferably,
each elongate expansion chamber may comprise a cylindrical open-ended tube.
The tube may
comprise cardboard.
The components may further include other components, for example a barrier
material
for locating between the heat source and the aerosol-generating substrate.
In a preferred embodiment, the two or more different components comprise non-
cleanly-
cuttable heat sources, aerosol-generating substrates, and elongate expansion
chambers and
each group corresponding to a discrete smoking article comprises one of the
non-cleanly-
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cuttable heat sources, one or more of the aerosol-generating substrates, and
one or more of the
elongate expansion chambers.
Features described in relation to one aspect of the invention may also be
applicable to
another aspect of the invention.
The invention will be further described, by way of example only, with
reference to the
accompanying drawings in which:
Figure 1 shows a distillation-based smoking article;
Figure 2 is a perspective schematic view of an exemplary embodiment of the
apparatus
according to the invention;
Figure 3 shows a first example of components ordered on a vacuum belt;
Figure 4 shows a second example of components ordered on a vacuum belt;
Figure 5 is a schematic view of an exemplary embodiment of the compacting
means of
Figure 2; and
Figure 6 is a schematic view of one embodiment of apparatus used to apply heat-
conducting elements to a paper web.
One preferred exemplary embodiment of the apparatus and method of the
invention, will
now be described. The apparatus may be used during manufacture of a
distillation-based.
smoking article, for example, the smoking article shown in Figure 1. In Figure
1, the smoking
article 101 comprises a non-cleanly-cuttable combustible heat source 103, an
aerosol-
generating substrate 105, two elongate expansion chambers 107a and 107b and a
mouthpiece
109, in abutting coaxial alignment, which are overwrapped in an outer paper
wrapper 111. In
this embodiment, the non-cleanly-cuttable heat source 103 is cylindrical and
includes a central
airflow channel 113 which extends longitudinally through the heat source 103.
The aerosol-
generating substrate 105 is located immediately downstream of the heat source
103 and, in this
embodiment, comprises a cylindrical plug of homogenised tobacco material 117,
consisting of
longitudinally aligned filaments of extruded tobacco material. A heat-
conducting element 121
consisting, in this embodiment, of aluminium foil, surrounds and is in contact
with a rear portion
of the non-cleanly-cuttable heat source 103 and an abutting front portion of
the aerosol-
generating substrate 105. The elongate expansion chambers 107a and 107b are
located
downstream of the aerosol-generating substrate 105 and, in this embodiment,
comprise
cylindrical open-ended tubes of cardboard 123. The mouthpiece 109 is located
downstream of
the expansion chambers 107a and 107b and, in this embodiment, comprises a
cylindrical plug
of cellulose acetate tow 125. In this embodiment, the outer paper wrapper 111
includes
perforations 129 around its circumference, just upstream of the heat
conducting element 121.
The smoking article 101 is circumscribed by tipping paper 131.
Figure 1 shows one embodiment of a particular distillation-based smoking
article.
Various modifications are possible, however. For example, one or more of the
following
modifications may be made if desired. The heat source may comprise additional
or differently
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arranged airflow channels. The aerosol-generating substrate may comprise any
suitable
material. Additional aerosol-generating substrates may also be included, for
example including
different tobacco material or flavourings. A barrier material may be included
between the heat
source and the aerosol-generating substrate. Instead of two shorter expansion
chambers, a
single long expansion chamber may be provided. Any suitable mouthpiece may be
included, or
the mouthpiece may be omitted completely. Tipping paper may be omitted. The
perforations
may be omitted, or may be positioned adjacent the heat conducting element,
such that a
consumer is able to see the aluminium foil through the perforations.
Figure 2 is a perspective schematic view of one exemplary embodiment of the
apparatus
of the invention. Figure 2 shows an embodiment of apparatus for combining a
plurality of
components for the production of un-tipped smoking articles. The embodiment of
Figure 2 may
be used for manufacture of smoking articles, including a component that is not
cleanly cuttable
with conventional mechanical cutting means, such as the smoking article
described above with
reference to Figure 1. In the embodiment of Figure 2, each smoking article
comprises a non-
cleanly-cuttable heat source 203, an aerosol-generating substrate 205, two
elongate expansion
chambers 207 and a mouthpiece (not shown). The apparatus shown in Figure 2 is
arranged to
combine the heat sources 203, aerosol-generating substrates 205 and expansion
chambers
207 to form un-tipped smoking articles, to which the mouthpieces may be
attached, optionally
using tipping paper, to form finished smoking articles.
Referring to Figure 2, the apparatus 201 comprises first feeding means 203a
for the heat
sources 203, second feeding means 205a for the aerosol-generating substrates
205, and third
feeding means 207a for the expansion chambers 207. In the embodiment of Figure
2, first
feeding means 203a comprises vibrating bowl 203b, belt 203e and indexing wheel
203f. In the
embodiment of Figure 2, second feeding means 205a comprises hopper 205b,
primary supply
drum 205c, secondary supply drum 205d, vacuum belt 205e and second indexing
wheel 205f.
In the embodiment of Figure 2, third feeding means 207a comprises hopper 207b,
primary
supply drum 207c, secondary supply drum 207d, vacuum belt 207e and indexing
wheel 207f.
The apparatus 201 further comprises vacuum belt 209 and compacting means 210
for
compacting the stream of components into groups of components, in the form of
wheels 211,
213, 215, a garniture region 217 using paper web feed 219 and belt 221, and
cutting means in
the form of blade 223. Further details of the compacting means 210 including
wheels 211, 213
and 215 are shown in Figure 5.
The general operation of the Figure 2 apparatus is as follows. The heat
sources 203 are
introduced from vibrating bowl 203b onto belt 203e, then via indexing wheel
203f onto vacuum
belt 209. The aerosol-generating substrates 205 are introduced from hopper
205b, via primary
supply drum 205c and secondary supply drum 205d onto vacuum belt 205e, then
via indexing
wheel 205f onto vacuum belt 209. Similarly, the expansion chambers 207 are
introduced from
hopper 207b, via primary supply drum 207c and secondary supply drum 207d onto
vacuum belt
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207e, then via indexing wheel 207f onto vacuum belt 209. The various
components 203, 205
and 207 are introduced with appropriate spacing and speed such that their
longitudinal axes are
substantially axially aligned with each other and with the direction of
movement of vacuum belt
209 in the required order. Supply of the components is also described in more
detail with
reference to Figures 3 and 4.
The various components pass along the vacuum belt 209 in order, and then pass
into
the compacting means 210. The function of the compacting means 210 is to
compact the
stream of components into groups of components, each group corresponding to a
discrete un-
tipped smoking article, so that the components within a group abut one another
and there is a
predefined space between a leading group of components and a trailing group of
components.
Further, the compacting means registers the position of each space so that the
blade can cut
the web of material in each space between groups of components. The compacting
means 210
will be described in detail with reference to Figure 5.
After the compacting means 210, the components are overwrapped with paper web
in
the garniture region 217. The paper web feed 219 may include pre-applied heat-
conducting
elements (possibly in the form of aluminium foil patches - see 121 in Figure
1), appropriately
spaced, as will be described further with reference to Figure 6. Once the
components have
been overwrapped with the paper web from feed 219, the web is cut at
appropriate junctures, at
blade 223.
Supply of the aerosol-generating substrates and expansion chambers will now be
further
described. Referring once again to Figure 2, supply drums 205c and 205d are
used to supply
the aerosol-generating substrates 205 from hopper 205b onto the vacuum belt
205e. Supply
drums 207c and 207d are used to supply the expansion chambers 207 from hopper
207b onto
the vacuum belt 207e.
Primary drum 205c, for the aerosol-generating substrates 205, includes a
plurality of
longitudinal flutes (not shown) around its circumference, aligned with the
axis of rotation. In this
embodiment, primary drum 205c rotates in a clockwise direction. Secondary drum
205d also
includes a plurality of longitudinal flutes (not shown) around its
circumference. However, each
flute on secondary drum 205d extends along only one sixth of the length of the
drum and is
arranged to hold a single length aerosol-generating substrate. The flutes on
secondary drum
205d are stepped relative to one another around the circumference of the drum.
Along the
primary drum 205c, there are five rotating cutting blades (not shown), which
cut the x6 aerosol-
generating substrate lengths on primary drum 205c into single length aerosol-
generating
substrates for the secondary drum 205d. In this embodiment, secondary drum
205d rotates in
an anti-clockwise direction and individually deposits the single length
aerosol-generating
substrates 205 onto vacuum belt 205e. The vacuum belt 205e may include fixed
fingers to
ensure correct positioning of the components.
Primary drum 207c, for the expansion chambers 207, includes a plurality of
longitudinal
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flutes (not shown) around its circumference, aligned with the axis of
rotation. In this
embodiment, primary drum 207c rotates in a clockwise direction. Primary drum
207c is arranged
to hold 4x length expansion chambers. Secondary drum 207d also includes a
plurality of
longitudinal flutes (not shown) around its circumference. However, each flute
on secondary
drum 207d extends along only half of the length of the drum and is arranged to
hold two single
length expansion chambers. The flutes on secondary drum 207d are stepped
relative to one
another around the circumference of the drum. Along the primary drum 207c,
there are three
rotating cutting blades (not shown), which cut the x4 expansion chambers on
primary drum
207c into single length expansion chambers for the secondary drum 207d. In
this embodiment,
secondary drum 207d rotates in an anti-clockwise direction. Then, the two
single length
expansion chambers are deposited together onto vacuum belt 207e to provide two
expansion
chambers in each finished smoking article. The vacuum belt may include fixed
fingers to ensure
correct positioning of the components.
Typically, suction is used to hold the components to the drums and known
vacuum
transfer techniques are used to transfer the components between drums.
However, other
mechanisms may be used. In the embodiment of Figure 2, primary drum 205c
includes 42
longitudinal flutes and secondary drum 205d includes 72 stepped longitudinal
flutes. In the
embodiment in Figure 2, primary drum 207c includes 42 longitudinal flutes and
secondary drum
207d includes 24 stepped longitudinal flutes. Of course, other numbers of
flutes are possible
and the flutes may or may not be evenly spaced around the drum.
Between vacuum belt 205e and vacuum belt 209, there is an indexing wheel 205f.
The
indexing wheel 205f rotates and supplies the aerosol-generating substrates 205
onto the
vacuum belt 209. In this embodiment, there are four fixed fingers (not shown)
on indexing wheel
205f, which separate the substrates from one another. In this embodiment,
indexing wheel 205f
sets the distance between aerosol-generating substrates as they are
transferred onto vacuum
belt 209. The speed of vacuum belt 205e is set to cooperate with the
rotational speed of
indexing wheel 205f and the speed of vacuum belt 209.
Between vacuum belt 207e and vacuum belt 209, there is an indexing wheel 207f.
The
indexing wheel 207f rotates and supplies the expansion chambers, two at a
time, onto the
vacuum belt 209. In this embodiment, there are four fixed fingers (not shown)
on indexing wheel
207f, which separate the expansion chambers into groups of two, that is, a
fixed finger is
positioned after every second expansion chamber. In this embodiment, indexing
wheel 207f
sets the distance between expansion chamber pairs as they are transferred onto
vacuum belt
209. The speed of vacuum belt 207e is set to cooperate with the rotational
speed of indexing
wheel 207f and the speed of vacuum belt 209.
Supply of the heat sources will now be further described. Referring once again
to Figure
2, vibrating bowl is used to supply the (pre-cut) heat sources onto the belt
203e.
Between belt 203e and vacuum belt 209, there is an indexing wheel 203f. The
indexing
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wheel 203f rotates and supplies the heat sources onto the vacuum belt 209. In
this
embodiment, there are four or six fixed fingers (not shown) on indexing wheel
203f.
The desired spacing and ordering of the various components on vacuum belt 209
and
the number of fixed fingers on indexing wheel 203f will depend on the
structure of the resulting
smoking article and also on the later processes involved in manufacturing. In
some
arrangements (see, for example, Figure 3 discussed below), a regular spacing
between
components will be required. That is, the same space between one component and
the next
component will always be needed. This is set by the indexing wheels 203f,
205f, 207f. In
particular, for the arrangement shown in Figure 3, four fixed fingers are
provided on indexing
wheel 203f. The indexing wheel 203f delivers a controlled number of heat
sources onto vacuum
belt 209 from continuous supply from belt 203e. For the Figure 3 arrangement,
one heat source
is provided onto vacuum belt 209 at a time and there is equal spacing between
heat sources.
In other arrangements however (see, for example, Figure 4 discussed below), a
non
regular spacing between components will be required. That is, the space
between one
component and the next will not always be the same. In one advantageous
arrangement, there
are two different spacings between components of the same type, so that there
is a first space
between first component and second component, a second space between second
component
and third component, the first space again between third component and fourth
component, the
second space again between fourth component and fifth component, and so on.
Again, this is
set by the indexing wheels 203f, 205f, 207f. In particular, for the
arrangement shown in Figure
4, six fixed fingers are provided on indexing wheel 203f. The indexing wheel
203f delivers a
controlled number of heat sources onto vacuum belt 209 from continuous supply
from belt 203e.
For the Figure 4 arrangement, two heat sources are provided onto vacuum belt
209 at a time.
The space between each pair of heat sources is created by a difference in
speed between
indexing wheel 203f and vacuum belt 209. The speed of vacuum belt 209 is three
times higher
than the tangential speed of the indexing wheel 203f. This produces a space
equal to two twice
the heat source length between each pair of heat sources.
Figure 3 shows one possible order for the components on vacuum belt 209. The
components are simply in the order that they will be positioned in the
finished un-tipped
smoking articles. That is: heat source 203, then aerosol-generating substrate
205, then
expansion chambers 207, then another heat source 203, then another aerosol-
generating
substrate 205, then further expansion chambers 207 and so on. This means that
there is equal
spacing between each heat source from first feeding means 203a (as discussed
above), equal
spacing between each aerosol-generating substrate from second feeding means
205a and
equal spacing between each expansion chamber pair from third feeding means
207a. The
scissor symbols in Figure 3 indicate where the paper web will be cut at blade
223 or further
downstream. In Figure 3, the spacing between components of the same type is
indicated at
301.
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The order shown in Figure 3 is advantageous because it allows flexibility of
the heat
conducting element length and position, and it allows for increased accuracy.
However, during
existing manufacturing processes, typically, a double length rod is formed,
which is then cut in
two, has a double length filter mouthpiece inserted between the two single
length rods and a
double length of tipping paper applied. In order to allow for this with the
Figure 3 arrangement, a
turning drum may be provided downstream of the compacting means, before the
tipper. The
turning drum takes a continuous line of un-tipped smoking articles and rotates
alternate un-
tipped smoking articles, thereby allowing a double length filter mouthpiece to
be inserted
between the two single length un-tipped smoking articles, as in existing
processes.
Figure 4 shows another possible order for the components on vacuum belt 209.
The
components are ordered to create two smoking article rods at a time, one
facing forward, one
facing rearward. That is: heat source 203, then aerosol-generating substrate
205, then
expansion chambers 207, then further expansion chambers 207, then another
aerosol-
generating substrate 205, then another heat source 203, then a third heat
source 203 and so
on. Such an arrangement is advantageous because it may be used with existing
tipping
processes, without the need for a turning drum. In order to achieve the non-
uniform spacing in
Figure 4, indexing wheels 203f, 205f and 207f of feeding means 203a, 205a and
207a are
arranged to supply the components onto vacuum belt 209 with two different
spacings between
components of the same type (as discussed above). The first spacing between
heat sources is
shown as 401. The second spacing between heat sources is shown as 403. (There
are
corresponding spaces (not labelled) between other components of the same
type.) The first
spacing 401 is the spacing between heat sources in one double-length un-tipped
smoking
article. The second spacing 403 is the spacing between heat sources in
adjacent double-length
un-tipped smoking article. The vacuum belt 209 moves the components, in their
desired
positions, towards compacting means 210. Suction is applied from underneath
belt 209 which
assists to adhere the components to the belt.
Figure 5 shows one exemplary embodiment of compacting means 210 of Figure 2.
In
Figure 5, the components enter the compacting means at 501 on belt 209 and
exit the
compacting means at 503 on belt 221. In Figure 5, the components are shown in
the order of
Figure 4, that is, to create two un-tipped smoking articles at a time, one
facing forward, one
facing rearward. However, any suitable component ordering is possible.
In this embodiment, compacting means 210 includes three wheels 211, 213 and
215.
First wheel 211 is used to separate the plurality of components into groups of
components. In
this embodiment, first wheel 211 includes seven fixed, circumferentially-
spaced fingers 505a
and is arranged to rotate in a clockwise direction. Second wheel 213 is used
to compact the
components within each group. In this embodiment, second wheel 213 includes
eight
circumferentially-spaced moveable thick fingers 507a and is arranged to rotate
in an anti-
clockwise direction. Each moveable thick finger 507a is driven by a cam 507b,
rather than being
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fixed to wheel 213, so that movement of each thick finger 507a, relative to
wheel 213, is
possible. Third wheel 215 is used to set the spacing between each group of
components. In this
embodiment, third wheel 215 includes eight circumferentially-spaced moveable
thin fingers
509a and is arranged to rotate in a clockwise direction. The desired spacing
between each un-
tipped smoking article is created either by having a moveable thin finger with
the corresponding
dimension, or by adjusting the speed ratio between the compacting means 210
and the belt
221. Each moveable thin finger 509a is driven by a cam 509b, rather than being
fixed to wheel
215, so that movement of each thin finger 509a, relative to wheel 215, is
possible.
The components are fed into the compacting means 210 at 501 on belt 209. They
are
then guided onto wheel 211 by guide 511 and carried by wheel 211 in a
clockwise direction, as
shown by the arrow. Each fixed finger 505a is positioned between components of
one un-tipped
smoking article and the next un-tipped smoking article, each un-tipped smoking
article including
a group of components. Since the components are likely to be fairly well
spaced out on belt 209,
they remain fairly well spaced out on wheel 211.
At the interface between first wheel 211 and second wheel 213, the components
are
transferred to the second wheel 213 and begin to rotate in an anti-clockwise
direction, as shown
by the arrow. The components are guided onto wheel 213 by guide 513. Each
moveable thick
finger 507a takes the place of fixed finger 505a and is positioned between
components of one
un-tipped smoking article and the next un-tipped smoking article. Because
wheel 211 includes
seven fixed fingers 505a, whereas wheel 213 includes eight moveable fingers
507a, in order for
successful transfer of components from wheel 211 to wheel 213, the two wheels
must be
rotating at different speeds. This is because the wheels have the same
diameter so, for each full
rotation of wheel 213, which corresponds to eight smoking article rods, wheel
211 must turn one
and one seventh rotations. In order to accommodate this speed difference at
the interface,
moveable fingers 507a are driven by cams 507b rather than being fixed to wheel
213. This
allows moveable fingers 507a to travel at the same speed as fixed fingers 505a
at the interface,
by moving relative to wheel 213. Then, once the components are transferred,
the cams 507b
allow the moveable fingers 507a to return to rotation at the same speed as
wheel 213. Since
there are eight spaces between moveable fingers on wheel 213, but only seven
spaces
between fixed fingers on wheel 211, the components within a group of
components on wheel
213 are closer together than on wheel 211.
The components are then carried by wheel 213 in an anti-clockwise direction,
as shown
by the arrow. As already mentioned, each moveable thick finger 507a is
positioned between
components of one un-tipped smoking article and the next un-tipped smoking
article.
At the interface between second wheel 213 and third wheel 215, the components
are
transferred to the third wheel 215 and begin to rotate in a clockwise
direction, as shown by the
arrow. The components are guided onto wheel 215 by guide 515. Each moveable
thin finger
509a takes the place of moveable thick finger 507a and is positioned between
components of
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one un-tipped smoking article and the next un-tipped smoking article. Because
wheel 215
includes eight moveable fingers, just like wheel 213, wheels 213 and 215 are
moving at
approximately the same speed at the interface between them. However, moveable
fingers 509a
are thinner than fingers 507a, which results in a smaller separation between
components of one
un-tipped smoking article and the next un-tipped smoking article. In order to
achieve this, wheel
213 has a slightly different diameter from that of wheel 215. Although
moveable fingers 509a
may not require very much movement relative to wheel 215, they are nonetheless
driven by
cams 509b rather than being fixed to wheel 215. This allows the fingers 509a
to move relative to
wheel 215 at the interface between wheel 213 and wheel 215, should this be
needed to
compact the components. Furthermore, the cam mechanism allows for adjustment
of the speed
of the delivery of the components onto belt 221, in order to compact the
components against
each other.
The components are then carried by wheel 215 in a clockwise direction, as
shown by the
arrow. At this stage, the separation between groups of components (optionally
set by moveable
fingers 509a) is the desired space so that, when the components exit the
compacting means
210 at 503 on belt 221, they are ready to be overwrapped with paper web in
garniture region
217. As already discussed, the blade 223 downstream of the compacting means
210 is
arranged to cut the paper web precisely at each gap between un-tipped smoking
article
components. Thus, the size of the gap between each group of components needs
to be
accurate. This is particularly important with the smoking article of Figure 1,
for example, since
the heat sources tend to be hard and difficult to cut. Thus, any incorrect
spacing could lead to
damage to the blade if it attempts to cut through a heat source. In one
embodiment, the gap
between groups of components may be 1 mm 0.5. mm, that is, between 0.5 mm
and 1.5 mm,
or more preferably between 0.8 mm and 1.2 mm.
The components may be adhered to each wheel by suction and transferred between
wheels using known vacuum transfer techniques. Other techniques are possible,
however.
In Figure 5, wheels 213 and 215 are shown with eight moveable fingers, so that
they can
accommodate eight groups of components for eight smoking article rods, but any
number of
moveable fingers greater than one is possible. Wheel 211 is shown with seven
fixed fingers, so
that it can accommodate seven groups of components for seven smoking article
rods, but any
number of fixed fingers is possible. The important feature is that the first
wheel 211 holds fewer
groups of components than the second wheel 213, so that the components are
compacted in
the transfer from the first wheel to the second wheel.
In garniture region 217, the properly-spaced components are overwrapped with
paper
from paper feed 219. This may be performed in a conventional manner. As the
components
move along the belt, on paper from paper feed 219, the channel steadily
becomes more
cylindrical, thereby wrapping the paper around the components.
Referring to the embodiment of Figure 1, each distillation-based smoking
article includes
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a heat-conducting element 121 which may consist of aluminium foil. Preferably,
the aluminium
foil is pre-applied to the paper 111, before being fed into paper feed 219 and
wrapped over the
components. The application of spaced aluminium foil patches to a paper web
may be
performed by apparatus like that described in pending patent application EP
08250842.5. One
embodiment of such apparatus is shown in Figure 6.
Figure 6 shows a schematic view of one embodiment of apparatus used to apply
spaced
heat-conducting elements in the form of aluminium patches to a web of paper.
The apparatus
601 comprises backplate 603, aluminium foil input 605 from aluminium foil feed
bobbin 607,
aluminium foil feed dancing rollers 609 and fixed rollers 611, glue applicator
613, patch cutting
drum 615, paper input 617, paper input roller 619, patch transfer drum 621 and
paper output
623. In this embodiment, the apparatus additionally includes perforation drum
625 and
additional glue applicator 627. In Figure 6, the thick line is used to
indicate the web of aluminium
foil, the thin line is used to indicate the web of paper, and the thin line
with spaced thick portions
is used to indicate the web of paper with applied patches of aluminium foil.
Aluminium foil web is fed from feed bobbin 607 to the input 605. Then, the
aluminium foil
is fed around dancing roller 609 which, as shown by the arrows, can move up
and down to
affect the tension in the foil web. Then, the aluminium foil web is fed in the
direction of the
arrows, via fixed rollers 611, to the further dancing rollers 609. The dancing
rollers 609 set the
speed of the incoming web, according to the required speed at the patch
cutting drum 615 and
the patch transfer drum 621. After the dancing rollers 609, the glue
applicator 613 applies glue
areas or lines or a continuous or an intermittent stream of glue to the web.
Then, the glued
aluminium foil web proceeds towards the patch cutting drum 615 and the patch
transfer drum
621. Preferably, suction is applied at the entry to patch transfer drum and
air is blown outwards
at the exit of the patch transfer drum. As the glued aluminium foil web passes
between the
patch cutting drum 615 and the patch transfer drum 621, the web is cut into
individual
aluminium patches. The individual patches (glue side out) pass in a clockwise
direction around
the patch transfer drum 621. Paper is fed into paper input roller 619. As the
paper comes into
contact with the individual aluminium patches on the patch transfer drum 621,
the patches are
applied to the paper. The glue may then be dried by heaters (not shown).
The apparatus allows the aluminium patches to be non evenly spaced on the
paper web,
if that is required (for example for the component order shown in Figure 4).
In that case, either
electronic driving control or a mechanical cam (not shown) changes the speed
of the incoming
webs so that patch transfer drum 621 applies the patches to the paper web with
two different
spacings.
As will be understood by the skilled reader, the position of the aluminium
patches on the
paper web is critical, as this affects the position of the heat-conducting
elements relative to the
heat source and aerosol-generating substrate in the eventual smoking articles.
This has a great
effect on the heat conducting properties of the smoking article, and hence on
the temperature
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reached at the aerosol-generating substrate and hence on the smoking
experience for the user.
The aluminium patch may optionally be secured to the heat source, for example
via glue from
applicator 627, to prevent the heat source from dropping out of the paper
overwrap.
The perforation drum 625 is used to perforate the paper, so as to form the
perforations
129 in the finished smoking article (see Figure 1). The perforations may
alternatively allow a
user to peel off part of the paper overwrap from the heat source. This
prevents the paper from
burning, when the smoking article is lit. The perforations in Figure 1 are
shown extending
around the circumference of the smoking article. The perforations may,
alternatively extend
along the length of the smoking article. Alternatively, the perforations may
be added
downstream in the tipper.
An additional unit may also be supplied to apply printing or other markings to
the paper
web before input 617 or in the region of glue applicator 627.
Referring once again to Figure 2, the paper web exiting the garniture region
217 is then
cut by blade 223. As already discussed, the blade 223 cuts the web in the
spaces between
groups of components. After cutting, a mouthpiece may be applied to each un-
tipped smoking
article by tipping paper. The tipping of the un-tipped smoking articles may be
carried out by any
suitable tipping machine (tipper).
Thus, in the apparatus shown in Figure 2, firstly the components are fed in a
stream
along the moving vacuum belt 209. Then, in the compacting means 210, the
stream of
components is compacted into groups of components, each group corresponding to
a discrete
un-tipped smoking article. The components within a group abut one another and
there is a
predefined space between a leading group of components and a trailing group of
components.
Then, in garniture region 217, the components are wrapped in a web of
material. Finally, the
web of material is cut at each space between groups of components.
17
