Note: Descriptions are shown in the official language in which they were submitted.
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AEROSOL-GENERATING MATERIAL ROD SEGMENT
Technical Field
The present invention relates to a process and apparatus for producing aerosol-
generating material rod segments.
Background
In a known process of manufacturing cigarettes, tobacco leaves are shredded
into short fine strips, also referred to as cut rag tobacco. The shredded
tobacco is then
dispersed over a continuous web of cigarette paper. A machine, also known as a
cigarette maker, folds the paper around the shredded tobacco to form a
continuous rod.
The rod is cut into segments of desired length. A filter is added to each
tobacco rod
segment to produce the cigarette.
Smoking articles such as cigarettes, cigars and the like burn tobacco during
use
to create tobacco smoke. Attempts have been made to provide alternatives to
these
articles by creating products that release compounds from tobacco or other
materials
without combusting. Examples of such products are so-called "heat not burn"
products
or tobacco heating devices or products or aerosol-generating devices or
products, which
release compounds by heating, but not burning, material, such as tobacco.
Summary
According to a first aspect of the present invention, there is provided a
process
of producing aerosol-generating material rod segments, comprising: cutting a
sheet of
aerosol-generating material longitudinally to produce a plurality of aerosol-
generating
material strands; gathering the strands together to form an aerosol-generating
material
rod in which each of the plurality of aerosol-generating material strands is
substantially
non-coiled; and cutting the aerosol-generating material rod into segments to
produce
said aerosol-generating material rod segments.
The gathering may comprise: gathering the strands together to form the aerosol-
generating material rod in which the plurality of aerosol-generating material
strands are
substantially parallel to one another.
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The gathering may comprise: gathering the strands together to form the aerosol-
generating material rod in which each of the aerosol-generating material
strands is
substantially straight.
The sheet of aerosol-generating material may be a tobacco sheet.
The tobacco sheet may be a reconstituted tobacco sheet.
The sheet of aerosol-generating material may comprise glycerol.
The sheet of aerosol-generating material may have a substantially constant
mass
per unit length.
The process may comprise: providing the sheet of aerosol-generating material
from a bobbin of aerosol-generating material sheet.
The process may comprise: providing a mother reel of aerosol-generating
material sheet; and slitting the mother reel to produce the bobbin.
The process may comprise: selecting a mass per unit length for the aerosol-
generating material rod segments; determining, based on a mass per unit area
of the
sheet of aerosol-generating material, and based on the selected mass per unit
length for
the aerosol-generating material rod segments, a bobbin width; and slitting the
mother
reel to produce a bobbin having the determined bobbin width.
The process may comprise: selecting a strand number and/or a strand width for
the aerosol-generating material rod segments; and determining, based on the
selected
strand number and/or strand width, a cut number and/or a cut spacing; and the
cutting
the sheet of aerosol-generating material may comprise cutting the sheet of
aerosol-
generating material with the determined cut number and/or cut spacing.
The process may comprise: feeding the sheet of aerosol-generating material in
a sheet feed direction; and the cutting the sheet of aerosol-generating
material may
comprises cutting the sheet of aerosol-generating material substantially
parallel to the
sheet feed direction.
The gathering may comprise: gathering each of the strands towards an axis that
lies in a plane, the plane including the feed direction and being
perpendicular to a plane
defined by the plurality of strands before they are gathered.
The gathering may comprise: gathering each of the strands towards an axis that
lies centrally of the plurality of strands.
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The gathering may comprise: gathering each of the strands substantially
transversely to form the rod.
The gathering may comprise: feeding the strands through a funnel to gather the
strands.
The process may comprise, before said cutting the sheet of aerosol-generating
material: feeding the sheet of aerosol-generating material through the funnel
to form an
aerosol-generating material rod of non-cut tobacco sheet.
Each of the plurality of strands may have a width substantially in the range
0.25
mm to 3 mm, or substantially in the range 0.5 mm to 1.5 mm.
The process may comprise: wrapping the aerosol-generating material rod in a
wrapping material.
The wrapping material may be or comprise one or both of paper and aluminium
foil.
The aerosol-generating material rod segments may each have an outer diameter
substantially in the range 5.4 mm to 7.8 mm, or substantially in the range 6.7
mm to 7.8
mm.
The aerosol-generating material rod segments may be consumables for an
aerosol-generating device.
According to a second aspect of the present invention, there is provided
apparatus for producing aerosol-generating material rod segments, the
apparatus
comprising: a first cutter arranged to cut a sheet of aerosol-generating
material
longitudinally to produce a plurality of aerosol-generating material strands;
a gatherer
arranged to gather the strands together to form an aerosol-generating material
rod in
which each of the plurality of aerosol-generating material strands is
substantially non-
coiled; and a second cutter arranged to cut the aerosol-generating material
rod into
segments to produce said aerosol-generating material rod segments.
The gatherer may be arranged to gather the strands together to form the
aerosol-
generating material rod in which the plurality of aerosol-generating material
strands are
substantially parallel to one another.
The gatherer may be arranged to gather the strands together to form the
aerosol-
generating material rod in which each of the aerosol-generating material
strands is
substantially straight.
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The apparatus may be arranged to provide the sheet of aerosol-generating
material from a bobbin of aerosol-generating material sheet.
The first cutter may be adjustable so as to adjust the number and/or width of
the
strands.
The first cutter may be adjustable to either cut said sheet of aerosol-
generating
material to produce said plurality of aerosol-generating material strands or
to not cut
said sheet of aerosol-generating material.
The apparatus may be arranged to feed the sheet of aerosol-generating material
to the first cutter in a sheet feed direction; and the first cutter may be
arranged to cut
the sheet of aerosol-generating material substantially parallel to the sheet
feed direction.
The gatherer may be arranged to gather each of the strands towards an axis
that
lies in a first plane, the first plane including the feed direction and being
perpendicular
to a second plane defined by the plurality of strands before they are
gathered.
The gatherer may be arranged to gather each of the strands towards an axis
that
lies centrally of the plurality of strands.
The gatherer may be arranged to gather each of the strands substantially
transversely to form the rod.
The gatherer may comprise a funnel.
The first cutter may be arranged to cut the sheet of aerosol-generating
material
longitudinally so as to produce the plurality of aerosol-generating material
strands each
having a width substantially in the range 0.25 mm to 3 mm, or substantially in
the range
0.5 mm to 1.5 mm.
The apparatus may comprise a wrapper arranged to wrap the aerosol-generating
material rod in a wrapping material.
The wrapping material may be or comprise one or both of paper and aluminium
foil.
The apparatus may be arranged to produce aerosol-generating material rod
segments having an outer diameter substantially in the range 5.4 mm to 7.8 mm,
or
substantially in the range 6.7 mm to 7.8 mm.
The aerosol-generating material rod segments may be consumables for an
aerosol-generating device.
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According to a third aspect of the present invention, there is provided a
product
comprising an aerosol-generating material rod, wherein the aerosol-generating
material
rod is formed of a plurality of longitudinal strands of aerosol-generating
material,
wherein each of the plurality of longitudinal strands of aerosol-generating
material is
substantially non-coiled.
The plurality of strands may be substantially parallel to one another.
Each of the plurality of strands may be substantially straight.
Each of the plurality of strands may have a width substantially in the range
0.25
mm to 3 mm, or substantially in the range 0.5 mm to 1.5 mm.
One or more of the strands may be or comprise tobacco.
One or more of the strands may be or comprise reconstituted tobacco.
One or more of the strands may comprise glycerol.
The product may comprise a wrapping material wrapped around the aerosol-
generating material rod.
The wrapping material may be or comprises one or both ofpaper and aluminium
foil.
The product may have an outer diameter substantially in the range 5.4 mm to
7.8 mm, or substantially in the range 6.7 mm to 7.8 mm.
The product may be a consumable for an aerosol-generating device.
Further features and advantages of the invention will become apparent from the
following description of preferred embodiments of the invention, given by way
of
example only, which is made with reference to the accompanying drawings.
Brief Description of the Drawings
Figure 1 illustrates schematically a perspective view of an apparatus for
producing tobacco rod segments, according to a first example;
Figure 2 illustrates schematically a side view of an apparatus for producing
tobacco rod segments, according to a second example;
Figure 3 illustrates schematically a perspective view of a mother reel of
tobacco
sheet, according to an example;
Figure 4 illustrates schematically a flow diagram of a process of producing
tobacco rod segments, according to an example; and
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Figures 5a and 5b illustrate schematically insertion of a blade heater into a
tobacco rod segment, according to an example.
Detailed Description
Referring to Figure 1, in broad overview, an example apparatus 100 for
producing tobacco rod segments 126 comprises a first cutter 106, a gatherer
114, and a
second cutter 124. The first cutter 106 is arranged to cut a tobacco sheet 104
longitudinally to produce a plurality of tobacco strands 112. The gatherer 114
is
arranged to gather the strands 112 together to form a tobacco rod 120 in which
each of
the plurality of tobacco strands 112 is substantially non-coiled. The second
cutter 124
is arranged to cut the tobacco rod 120 into segments to produce tobacco rod
segments
126.
As is explained in more detail below, the gatherer 114 being arranged to
gather
the strands 112 together to form a tobacco rod 120 in which each of the
plurality of
tobacco strands 112 is substantially non-coiled allows for the production of a
number
of tobacco rod segments 126 into which a blade type heater of an aerosol
generating
device may be readily inserted (see e.g. Figures 5a and 5b), in use, and which
facilitates
transport of volatile materials therethrough thereby reducing losses of
volatile materials
when the tobacco rod segment 126 is heated.
Returning to Figure 1, the first cutter 106 is arranged to cut the tobacco
sheet
104.
The tobacco sheet 104 may be a sheet or web of reconstituted tobacco.
Reconstituted tobacco sheets may be produced, for example, by a paper making
process, band casting or extrusion. For example, the reconstituted tobacco
sheet may
be paper reconstituted tobacco. Paper reconstituted tobacco refers to tobacco
material
formed by a process in which tobacco feedstock is extracted with a solvent to
afford an
extract of solubles and a residue comprising fibrous material, and then the
extract
(usually after concentration, and optionally after further processing) is
recombined with
fibrous material from the residue (usually after refining of the fibrous
material, and
optionally with the addition of a portion of non-tobacco fibres) by deposition
of the
extract onto the fibrous material. The process of recombination resembles the
process
for making paper. The feedstock may comprise or consist of one or more of
tobacco
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strips, tobacco stems, and/or whole leaf tobacco. Scraps, fines and winnowings
may
alternatively or additionally be employed in the feedstock. It will be
appreciated that
reconstituted tobacco sheet 104 formed by any process may be used. t
The reconstituted tobacco sheet 104 is malleable.
The tobacco sheet 104 may be provided from a bobbin 102 of tobacco sheet
104. The bobbin 102 comprises a spindle 102a around which continuous tobacco
sheet
104 is wound. The bobbin 102 is arranged to rotate to feed the tobacco sheet
104 from
the bobbin 102 to the first cutter 106 along a sheet feed direction (arrow A).
In some
examples, the apparatus 100 may be arranged to drive the bobbin 102 to rotate.
In other
examples, the bobbin 102 may be free to rotate, and the tobacco sheet 104
being pulled
from the bobbin 102 by a downstream component of the apparatus, for example a
roller
or drive belt (not shown in Figure 1) may cause the bobbin to rotate.
The tobacco sheet 104 may comprise glycerol. For example, the reconstituted
tobacco sheet 104 may be impregnated or otherwise formed with glycerol. When
heated, the glycerol may be volatilised to form an aerosol, which may enhance
user
experience of an aerosol-generating device, or any suitable "heat not burn"
device, with
which the tobacco rod segment 126 may be used.
The tobacco sheet 104 is of known dimensions. For example, the width and
thickness of the tobacco sheet 104 fed from the bobbin 102 may be constant and
known.
For example, the tobacco sheet 104 may be of a given and constant mass per
unit length.
This may ensure that the tobacco rod segments 126 produced are of consistent
weight
per unit length. Using a tobacco sheet 104 of known (and constant) dimensions
therefore allows weight control of the resulting tobacco rod segments 126
without the
need for weighing systems for weighing the tobacco rod 120 or tobacco rod
segments
126.
The first cutter 106 is arranged to cut the tobacco sheet 104 longitudinally
to
produce a plurality of tobacco strands 112. The tobacco strands 112 produced
are
elongate. The first cutter 106 comprises a cutter array 106a. The cutter array
106a
comprises a plurality of circular discs 108 arranged along an axle 110. The
discs 108
each have sharpened edges. The axle 110 is arranged substantially
perpendicularly to
the sheet feed direction (arrow A), and each disc 108 is arranged such that
the cutting
edge of the disc 108 runs substantially parallel to the sheet feed direction
(arrow A).
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Each disc 108 is arranged to cut the tobacco sheet 104 longitudinally i.e. to
cut the
tobacco sheet 104 along its length, as the tobacco sheet 104 is fed through
the first cutter
106. For example, the cutter array 106a may cut the tobacco sheet 104 against
a support
surface (not shown) arranged on an opposite side of the tobacco sheet 104 to
the cutter
array 106a. The plurality of discs 108 act to cut the tobacco sheet 104 into a
plurality
of substantially parallel elongate tobacco strands 112.
The number of tobacco strands 112 produced depends on the number of cutting
discs 108 the cutter array 106a comprises. For example, a cutter array 106a
comprising
eight cutting discs 108 will produce a total of nine tobacco strands. In
general, a cutter
array 106a comprising n cutting discs 108 will produce n+1 tobacco strands
112.
The strand width of the tobacco strands 112 depends on the spacing between
consecutive ones of the cutting discs 108. The discs 108 are equally spaced
along the
length of the axle 110, and along the width of the tobacco sheet 104, so that
each of the
elongate tobacco strands 112 is of substantially equal width. This arrangement
may help
to ensure consistency of the tobacco rod segments 126 produced. The cutter
array 106a
may be arranged such that each of the plurality of elongate tobacco strands
112 has a
width substantially in the range 0.25 mm to 3 mm, or substantially in the
range 0.5 mm
to 1.5 mm. This would correspond, for example, to the cutting discs 108 being
spaced
apart by substantially 0.25 mm to 3 mm, or substantially 0.5 mm to 1.5 mm,
respectively.
The first cutter 106 may be adjustable so as to adjust the number and/or width
of the strands 112 into which the tobacco sheet 104 is cut. For example, the
cutting
discs 108 may be adjustable on the axle 110 to adjust the number of discs 108
on the
axle and/or to adjust the spacing between each disc 108 along the axle 110. As
another
example, the cutter array 106a may be replaceable by another cutter array 106a
having
a different number of discs 108 and/or different spacing between the discs
108. This
allows flexibility in the number and/or width of the strands 112 in the
tobacco rod
segments 126 produced, and hence flexibility in the characteristics of those
tobacco rod
segments 126.
The gatherer 114 is arranged to gather the plurality of tobacco strands 112
together to form a tobacco rod 120. The gatherer 114 is a funnel 114. The
funnel 114
comprises a funnel portion 116 and a stem portion 118. The funnel portion 116
and the
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stem portion 118 are circular in cross-section, and are coaxial. The funnel
114 is
symmetric about its axis. The funnel portion 116 narrows from a relatively
wide mouth
116a to the relatively narrow stem portion 118. The tobacco strands 112 travel
through
the funnel 114 from the funnel portion 116 to the stem portion 118. As the
tobacco
strands 112 travel through the funnel 114, the narrowing diameter of the
funnel portion
116 gathers the strands 112 together to form the tobacco rod 120.
The funnel 114 is aligned with and positioned centrally of the plurality of
tobacco strands 112. The funnel 114 therefore gathers each of the strands 112
substantially transversely to form the rod 120. Specifically, the funnel 114
gathers each
of the strands 112 towards an axis that lies centrally of the plurality of
strands 112. The
funnel 114 being aligned with the tobacco strands 112 in this way may allow
the strands
112 to be gathered evenly and centrally of the funnel 114.
The funnel 114 is aligned with and positioned centrally ofthe tobacco sheet
104.
Specifically, the axis towards which the strands 112 are gathered by the
funnel 114 lies
in a first plane, the first plane including the feed direction (arrow A) and
being
perpendicular to a second plane defined by the plurality of strands 112 before
they are
gathered. This alignment may help ensure an even tension across the plurality
of strands
112 as they are gathered by the funnel 114.
The funnel 114 applies substantially transverse forces to the strands 112 as
they
pass through the funnel 114, which transverse forces are directed
substantially centrally
of the plurality of strands 112. The tobacco strands 112 are not coiled as
they are
gathered, i.e. remain substantially non-coiled as they are gathered (i.e.
during the
gathering), i.e. as they pass through the funnel 114. For example, the tobacco
strands
112 are not twisted, spiralled, rolled or intertwined relative to one another
as they are
gathered, for example they do not form a twisted or spiralled or helical
structure or
shape as they are gathered. The funnel 114 therefore gathers the strands 112
together to
form the tobacco rod 120 in which each of the plurality of tobacco strands 112
are
substantially non-coiled. The tobacco strands 112 remain substantially
parallel to one
another as they are gathered, i.e. as they pass through the funnel 114. The
funnel 114
therefore gathers the strands 112 together to form the tobacco rod 120 in
which the
plurality of tobacco strands 112 are substantially parallel to one another.
The tobacco
strands 112 are not substantially bent, corrugated, crimped or deformed or the
like as
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they are gathered, and remain substantially straight as they are gathered,
i.e. as they
pass through the funnel 114. The funnel 114 therefore gathers the strands 112
together
to form the tobacco rod 120 in which each of the plurality of tobacco strands
112 is
substantially straight.
The apparatus 100 comprises a wrapper 122 arranged to wrap the tobacco rod
120 in a wrapping material 128. The wrapper 122 may be, for example, the same
as or
similar to the wrapper 222 described below with reference to Figure 2. In
brief, the
wrapper 122 wraps a continuous sheet of wrapping material 128 around a
circumference
of the continuous tobacco rod 120, and applies adhesive to the wrapping
material 128
to seal the wrapping material 128 in place around the rod 120. The wrapping
material
may be or comprise, for example, one or both ofpaper and aluminium foil. For
example,
the wrapping material may be a laminate of aluminium foil and paper. This
laminate
may help prevent ignition of the tobacco rod segment 126, which may be useful
for
example where the tobacco rod segment 126 is for use as a consumable in a
"heat not
burn" device, or a tobacco heating product device, or an aerosol-generating
device.
The outer diameter of the tobacco rod 120 once wrapped may depend, for
example, on the mass per unit length of the tobacco sheet 104 used, the
thickness and
width of the tobacco sheet 104 used, the level of compression in the garniture
during
rod forming, and/or for example properties ofthe wrapper 122 and/or wrapping
material
128 used. The outer diameter of the wrapped tobacco rod 120 may be constant
during
a given operational cycle of the apparatus 100. The outer diameter may be
substantially
in the range 5.4 mm to 7.8 mm, or substantially in the range 6.7 mm to 7.8 mm,
for
example.
The second cutter 124 is arranged to cut the tobacco rod 120 (for example
after
it has been wrapped in wrapping material 128 by the wrapper 122) into segments
126
to produce the tobacco rod segments 126. The second cutter 124 cuts through
the
tobacco rod 120 transversely, so as to produce lengths of tobacco rod 120
(i.e. the
tobacco rod segments 126. The second cutter 124 may comprise, for example, a
blade
(not shown) whose cutting surface (not shown) is arranged perpendicularly to
the length
of the tobacco rod 120, and is controllable to slice through the tobacco rod
120. The
tobacco sheet 104, tobacco strands 112, and tobacco 120 rod may progress
through the
apparatus 100 at a constant rate. The second cutter 124 may be arranged to cut
through
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the continuous tobacco rod 120 at regular intervals of time, thereby to
produce tobacco
rod segments 126 of equal length. The tobacco rod segments 126 may have, for
example, a length in the range of 12 mm to 60 mm. For example, the tobacco rod
segments 126 may be 12 mm in length, or may be 42 mm in length, or may be 60
mm
in length. Other lengths may be obtained, for example, by changing the
interval between
consecutive cuts.
In use, the first cutter 106 cuts the tobacco sheet 104 longitudinally to
produce
the plurality of tobacco strands 112. The gatherer 114 gathers the strands 112
together
to form the tobacco rod 120 in which each of the plurality of tobacco strands
112 is
substantially non-coiled, for example substantially straight. The second
cutter 124 cuts
the tobacco rod 120 into segments to produce the tobacco rod segments 126.
The apparatus 100 thereby produces tobacco rod segments 126 each comprising
a tobacco rod 130 formed of a plurality of longitudinal strands of tobacco
(not shown),
i.e. strands of tobacco extending along a direction of the length of the
tobacco rod 130,
wherein each of the plurality of longitudinal strands (not shown) are
substantially non-
coiled.
The first cutter 106 may be adjustable to either cut the tobacco sheet 104
into a
plurality of stands 112, or to not cut the tobacco sheet 104 at all. In use,
when the
apparatus 100 is first used for a given tobacco sheet 104, the first cutter
106 may be
adjusted so as to not cut the tobacco sheet 104 into the plurality of strands
112. The
non-cut tobacco sheet 104 may then be fed through the funnel 114 to form a
tobacco
rod (not shown) of non-cut tobacco sheet 104, and the resulting rod (not
shown) of non-
cut tobacco sheet 104 may be fed through the wrapper 122 and the second cutter
124 to
form segments (not shown) of the rod (not shown) of non-cut tobacco sheet 104.
Once
the formation of the rod (not shown) ofnon-cut tobacco sheet 104 is stable,
for example,
once a few segments (not shown) of the rod (not shown) of non-cut tobacco
sheet 104
have been produced, the first cutter 106 may be adjusted to cut the tobacco
sheet 104
into a plurality of strands 112 as described above, thereby to produce tobacco
rod
segments 126 each comprising a tobacco rod 130 formed of a plurality of
strands of
tobacco 112 wherein each of the plurality of strands 112 are substantially non-
coiled.
The few segments (not shown) of the rod (not shown) of non-cut tobacco sheet
104
produced before the tobacco rod segments 126 comprising a plurality of strands
of
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tobacco 112 are produced, may be discarded. This may allow for simpler and
more
consistent setup of the apparatus 100 on installation or replacement of
tobacco sheet
104, for example a bobbin 102 of tobacco sheet 104.
Referring now to Figure 2, there is illustrated schematically an apparatus 200
for producing tobacco rod segments 226 according to another example.
Components of
the apparatus 200 illustrated in Figure 2 that are the same or similar to the
components
already described with reference to Figure 1 will not be described again in
detail, but
are given the same reference signs to as in Figure 1 except increased by 100.
The apparatus 200 comprises a first cutter 206, a gatherer 214, and a second
cutter 224. The first cutter 206 is arranged to cut a tobacco sheet 204
longitudinally to
produce a plurality of tobacco strands 212. The gatherer 214 is arranged to
gather the
strands 212 together to form a tobacco rod 220 in which each of the plurality
of tobacco
strands 212 is substantially non-coiled, for example substantially straight.
The second
cutter 224 is arranged to cut the tobacco rod 220 into segments 226 to produce
the
tobacco rod segments 226.
The apparatus 200 comprises a bobbin 202 of tobacco sheet 204. The tobacco
sheet 204 is fed towards the first cutter 226 from the bobbin 202 of tobacco
sheet 204.
The apparatus 200 comprises a tensioning arrangement 205 comprising a
plurality (in this example four) tension rollers 205a, 205b, 205c, 205d. The
tobacco
sheet 104 is fed from the bobbin 202 over the tension rollers 205a, 205b,
205c, 205d,
before being fed to the first cutter 206 in a sheet feed direction (arrow A).
This may
help ensure that the tobacco sheet 204 has sufficient tension, for example
longitudinal
tension, to be cut effectively by the first cutter 206. This may also help to
smooth out
the tobacco sheet 104, for example to remove any creases that may be in the
tobacco
sheet 104.
The first cutter 206 comprises two cutting arrays 206a, 206b arranged to
contact
opposite major surfaces of the tobacco sheet 204. Each cutting array 206a,
206b may
be the same or similar to the cutting array 106a described above with
reference to Figure
1. The cutting arrays 206a, 206b are arranged to press towards one another
against the
tobacco sheet, thereby to cut the tobacco sheet 204 longitudinally into a
plurality of
tobacco strands 112 (the plurality of tobacco strands 112 are distributed
along a plane
running into the page of Figure 2). For example, the cutting arrays 206a, 206b
may be
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offset from one another in a direction perpendicular to the feed direction of
the tobacco
sheet (i.e. offset in a direction running into the page of Figure 2).
The gatherer 214 comprises a funnel 214 comprising a funnel portion 216 and
a stem portion 218. The axis of the funnel 114 lies centrally of the plurality
of tobacco
strands 112 and lies in the plane along which the plurality of tobacco strands
is
distributed. The plurality of tobacco strands 112 are gathered together as
they travel
through funnel 214, to form a tobacco rod 220.
The apparatus 200 comprises a wrapper 222 arranged to wrap the tobacco rod
220 in a wrapping material 228. The wrapper 222 may be or comprise for
example, a
rod maker as known in the art, for example a KDF (kinetic fluxion media)
filter rod
maker to control the orientation and tension wrapping material 228.
The wrapper 222 comprises a drive belt 246, a wrapper material bobbin 252, a
garniture 240, an adhesive section 242, and a heater section 244.
The drive belt 246 is a continuous strip of flexible material looped around
and
supported by two rollers 248a, 248b. The drive belt 246 is held taut between
the rollers
248a, 248b so as to define a generally flat upper drive belt surface 246a. The
rollers
248a, 248b are arranged to rotate about their respective axes, so that the
drive belt
surface 246a may translate between the two rollers 248a, 248b. One or both of
the
rollers 248a, 248b is driven to rotate (clockwise in the sense of Figure 2)
about its axis,
so as to cause the upper drive belt surface 246a to translate (from left to
right in the
sense of Figure 2).
The wrapping material bobbin 252 supplies a continuous sheet or web of
wrapping material 228 to the upper drive belt surface 246a. The wrapping
material 228
may be fed onto the upper drive belt surface 246a by the friction of the
moving upper
drive belt surface 246a against the sheet of wrapping material 228.
Accordingly, the
sheet of wrapping material 228 travels on top of the upper drive belt surface
246a (from
left to right in the sense of Figure 2). The tobacco rod 220 is fed onto the
sheet of
wrapping material 228 on the upper drive belt surface 246a. Friction between
the
moving wrapping material 228 and the tobacco rod 220 may at least in part
cause the
tobacco rod 220 to be fed onto the wrapping material 228 and so to move with
the
wrapping material 228. Alternatively or additionally, the tobacco rod 220 may
be fed
onto the moving wrapping material 228 by other means, such as one or more feed
rollers
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or the like. In either case, the tobacco rod 220 is fed onto the wrapping
material 228 so
that the tobacco rod 220 moves with (i.e. at the same rate as) the wrapping
material 228,
which in turn moves with (i.e. at the same rate as) the upper drive belt
surface 246a.
The garniture 240, as is known per se, folds the wrapping material 228 around
the tobacco rod 220 as they move through the garniture 240. The garniture 240
wraps
the wrapping material 228 around the circumference of the tobacco rod 220. The
garniture wraps the wrapping material 228 around the tobacco rod 220 over
slightly
more than the circumference of the tobacco rod 120 so that there is a portion
where the
wrapping material 228 overlaps with itself (not shown).
The adhesive section 242 applies adhesive to the wrapping material 228 so as
to secure the wrapping material 228 in place around the tobacco rod 220.
Specifically,
the adhesive section 242 applies adhesive to the portion where the wrapping
material
228 overlaps with itself, so as to secure the wrapping material 228 to itself
around the
tobacco rod 220.
The heater section 244 heats the tobacco rod 220 so as to assist the drying
and/or
curing of the adhesive. This helps to ensure the adhesive is sufficiently
dry/cured before
the tobacco rod is cut into tobacco rod segments 226.
The second cutter 224 is arranged to cut the tobacco rod 220 into segments to
produce the tobacco rod segments 226. The second cutter 224 may be the same or
similar to the second cutter 124 described above with reference to Figure 1.
In use, the first cutter 206 cuts the tobacco sheet 204 longitudinally to
produce
the plurality of tobacco strands 212. The gatherer 214 gathers the strands 212
together
to form the tobacco rod 220 in which each of the plurality of tobacco strands
212 is
substantially non-coiled. The second cutter 224 cuts the tobacco rod 220 into
segments
to produce the tobacco rod segments 226.
The apparatus 200 thereby produces tobacco rod segments 226 each comprising
a tobacco rod 230 formed of a plurality of longitudinal strands of tobacco
(not shown),
i.e. strands of tobacco extending along a direction of the length of the
tobacco rod 230,
wherein each of the plurality of longitudinal strands (not shown) are
substantially non-
coiled, for example substantially straight.
Similarly to as described with reference to the apparatus 100 of Figure 1, the
first cutter 206 of the apparatus 200 of Figure 2 may be adjustable to either
cut the
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tobacco sheet 104 into a plurality of longitudinal stands 112, or to not cut
the tobacco
sheet 104 at all. As described above, this may allow for simpler and more
consistent
setup of the apparatus 200 on installation or replacement of tobacco sheet
204, for
example a bobbin 202 of tobacco sheet 204.
As mentioned above, in some examples the tobacco sheet 104, 204 is provided
from a bobbin 102, 202 of tobacco sheet 104, 204.
Referring to Figure 3, a bobbin 302a of tobacco sheet 304, which may for
example used as the bobbin 102, 202 as described above with reference to
Figures 1
and 2, may be provided from a mother reel 370 of tobacco sheet 304. The mother
reel
370 may be slit transversely (see dashed line 372) to produce the bobbin 302a
of tobacco
sheet 304.
The mother reel 307 may be slit so as to produce a bobbin 302a having a
certain
width W. This provides that the tobacco sheet 304 of the bobbin 302a has a
certain mass
per unit length, and hence that the tobacco rod segments (not shown in Figure
3)
produced have a certain mass per unit length. Accordingly, at the beginning of
a
manufacturing process, a desired mass per unit length of the tobacco rod
segments (not
shown in Figure 3) may be selected. A bobbin width W may then be determined
based
on the selected mass per unit length for the tobacco rod segment (not shown),
and based
on the known mass per unit area of the tobacco sheet 304 of the mother reel
370. For
example, the mass per unit area (also referred to as grammage) of the tobacco
sheet 304
may be 100 g/m2. The mother reel 370 may then be slit to produce a bobbin 302a
having
the determined bobbin width W. The bobbin 302a may then be used, for example
in the
apparatus 100, 200 described above with reference to Figures 1 and 2, to
produce
tobacco rod segments (not shown in Figure 3) having the desired mass per unit
length.
The mother reel 370 may be slit a number of times to produce bobbins 302b,
302c,
302d, 302e as desired, for example with the same or different bobbin widths W.
This
may allow convenient and inexpensive control over the mass per unit length of
the
tobacco rod segments (not shown in Figure 3) produced.
Figure 4 illustrates schematically a flow diagram of a process of producing
tobacco rod segments 126, 226 according to an example. For example, the
process may
be performed using the apparatus 100, 200 described above with reference to
Figures 1
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and 2, respectively. Reference signs used in Figures 1 and 2 are therefore
also used in
the below as appropriate.
In step S402, the process comprises cutting a tobacco sheet 104, 204
longitudinally to produce a plurality of tobacco strands 112, 212.
The tobacco sheet 104, 204 may have a substantially constant mass per unit
length, may be a reconstituted tobacco sheet and/or may comprise glycerol.
The process may comprise, prior to step S402, providing the tobacco sheet 104,
204 from a bobbin 102, 202 of tobacco sheet 104, 204. This may comprise
providing a
mother reel 307 of tobacco sheet 104, 204, 304, and slitting the mother reel
to produce
the bobbin 102, 202, 302a. This in itself may comprise selecting a mass per
unit length
for the tobacco rod segments 126, 226, determining, based on a mass per unit
area of
the tobacco sheet 104, 204, 304, and based on the selected mass per unit
length for the
tobacco rod segments, a bobbin width W, and slitting the mother reel 307 to
produce a
bobbin 102, 202, 302a having the determined bobbin width W.
The process may comprise, prior to step S402, feeding the tobacco sheet 104,
204, in a sheet feed direction A. The cutting the tobacco sheet 104, 204, 304
in S402
may then comprise cutting the tobacco sheet 104, 204, 304 substantially
parallel to the
sheet feed direction A.
Step S402 may comprise cutting the tobacco sheet 104, 204 with a determined
cut number and/or cut spacing. The cut number and/or cut spacing may be
determined
by selecting a strand 112, 212 number and/or a strand 112, 212 width for the
tobacco
rod segments 126, 226, and determining, based on the selected strand number
and/or
strand width, the cut number and/or a cut spacing. Each of the plurality of
strands may
have a width substantially in the range 0.25 mm to 3 mm, or substantially in
the range
0.5 mm to 1.5 mm.
In step S404, the process comprises gathering the strands 112, 212 together to
form a tobacco rod 112, 212 in which each of the plurality of tobacco strands
112, 212
is substantially non-coiled. Step S404 may comprise gathering the strands 112,
212
together to form the tobacco rod 120, 220 in which the plurality of tobacco
strands 112,
212 are substantially parallel to one another and/or are each substantially
straight. Step
S204 may comprise gathering each of the elongate strands 112, 212
substantially
transversely, towards an axis that lies centrally of the plurality of strands
112, 212, to
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form the rod 120. The axis towards which the strands 112, 212 are gathered may
lie in
a plane, the plane including the feed direction A and being perpendicular to a
plane
defined by the plurality of strands 112, 212 before they are gathered. Step
S204 may
comprise feeding the strands 112, 212 through a funnel 114, 214 to gather the
strands
112, 212.
The process may comprise, before said cutting the tobacco sheet 104, 204 in
step S402 is applied, feeding the tobacco sheet 104, 204 through the funnel
114, 214 to
form a tobacco rod (not shown) of non-cut tobacco sheet 114, 214.
In step S406, the process comprises cutting the tobacco rod 120 (of tobacco
strands 112, 212) into segments to produce said tobacco rod segments 126, 226.
The process may comprise, prior to step S406, wrapping the tobacco rod 120,
220 in a wrapping material 128, 228. The wrapping material 128, 228 may be or
comprise one or both of paper and aluminium foil. For example, the wrapping
material
128, 228 may be a laminate of paper and aluminium foil. The tobacco rod
segments
126, 226 (being wrapped) may each have an outer diameter substantially in the
range
5.4 mm to 7.8 mm, or substantially in the range 6.7 mm to 7.8 mm. The tobacco
rod
segments 126, 226 may be consumables for an aerosol generating device.
Figure 5a illustrates schematically a tobacco rod segment 526 according to an
example being placed on a blade heater 580 of an aerosol-generating device
(not
shown). Specifically, Figure 5a illustrates the tobacco rod segment 526 before
being
installed over the blade heater 580, and Figure 5b illustrates the tobacco rod
segment
526 after it has been installed over the blade heater 580.
The tobacco rod segment 526 may be, for example, the same or similar to the
tobacco rod segment 126, 226 described above with reference to Figures 1 and
2,
respectively. The tobacco rod segment 526 may be produced, for example, by the
apparatus 100, 200 described above with respect to Figures 1 and 2,
respectively and/or
by the process described above with respect to Figure 4.
Referring to Figures 5a and 5b, the tobacco rod segment 526 comprises a
tobacco rod 530 formed of a plurality of longitudinal strands 512 of tobacco,
i.e. a
plurality of strands 512 of tobacco extending in a direction of a length of
the tobacco
rod 530, wherein each of the plurality of longitudinal strands 512 are
substantially non-
coiled. The plurality of strands 512 are substantially parallel to one
another,
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substantially straight, and each extend along substantially the entire length
of the
tobacco rod segment 526. The tobacco rod segment 526 comprises a wrapping
material
528 wrapped around the tobacco rod 530.
The blade heater 580 can take the form of an elongate cuboid that is
significantly
thinner than it is wide or long. The width of the blade heater 580 is less
than the outer
diameter of the tobacco rod segment 526. The blade heater 538 may comprise a
resistive
heater (not shown) powered by a battery (not shown) of a hand-held aerosol
generating
device (not shown) and which is controllable by a user to heat up. In some
examples,
the blade heater 580 may have a pointed end (not shown) so as to facilitate
insertion of
the blade heater into the tobacco rod segment 526.
The blade heater 580 may be inserted into the tobacco rod segment 526 (arrow
B in Figure 5a), or equally the tobacco rod segment 526 may be pushed over the
blade
heater 580, so that the blade heater 580 extends longitudinally into the
tobacco rod
segment 526 (as shown in Figure 5b).
The plurality of longitudinal strands 512 of the tobacco rod segment 526 being
substantially non-coiled allow the blade heater 580 to be easily inserted into
the tobacco
rod segment 526. This is because the non-coiled longitudinal strands 512
present
relatively little resistance to longitudinal insertion of the blade heater
580. This may
provide for convenient installation or replacement of the tobacco rod segment
528 onto
the blade heater 580, which tobacco rod segment 526 may be a consumable of the
overall aerosol generating device (not shown). This may reduce damage to the
tobacco
rod segment 526 on insertion of the blade heater 580, and allow for more
consistent and
correct placement of the tobacco rod segment 526 relative to the blade heater
580. This
may be contrasted, for example, with a hypothetical tobacco rod segment
comprising
longitudinal strands that are coiled, for example arranged in a helical
structure: in this
case insertion of the blade heater would be restricted by strands crossing the
insertion
path, and the blade heater may deform and compress portions of the tobacco,
which
may lead to relatively difficult and inconsistent placement of the
hypothetical tobacco
rod segment, and may result in an increased risk of damaging the hypothetical
tobacco
rod segment.
The plurality of longitudinal strands 512 of the tobacco rod segment 526 being
parallel to one another and/or straight similarly allows the blade heater 580
to be easily
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inserted into the tobacco rod segment 526. In this case, the axis of insertion
of the blade
heater 580 is parallel to the axis of each of the longitudinal strands 512,
and only a small
surface area of tobacco is presented to the leading edge of the blade heater
580 as it is
inserted. Similarly to as mentioned above, this may provide for convenient
installation
or replacement of the tobacco rod segment 526 and/or reduce damage to the
tobacco
rod segment 526, and/or provide for more consistent and correct placement of
the
tobacco rod segment 526 relative to the blade heater 580. This may be
contrasted, for
example, with a hypothetical tobacco rod segment comprising randomly oriented
shreds
of cut rag tobacco, or comprising crimped or corrugated sheets of tobacco: in
this case
insertion of a blade heater may deform and compress portions of the cut rag
tobacco or
edges of the crimped or corrugated sheets of tobacco, which may lead to
relatively
difficult and inconsistent placement of the hypothetical tobacco rod segment,
and may
result in an increased risk of damaging the hypothetical tobacco rod segment.
Once the tobacco rod segment 526 is inserted over the blade heater 580 of the
overall aerosol generating device (not shown), the blade heater 580 may be
controlled
to heat up (for example via resistive heating internal of the blade heater
580), and
thereby to heat, but not burn, the tobacco strands 512. This may release
constituents,
for example volatile constituents, from the tobacco strands 512. As mentioned
above,
the tobacco strands 512 may comprise glycerol, which may be volatilised when
heated
by the blade heater 580 to form an aerosol.
The plurality of substantially non-coiled longitudinal strands 512 of the
tobacco
rod segment 526 establish a corresponding plurality of substantially non-
coiled
longitudinal pathways 513 through the tobacco rod segment 526, in between the
plurality of longitudinal strands 512. These pathways 513 facilitate the
transport of
volatile materials released from the tobacco strands 512 on heating (for
example volatile
constituents of the tobacco itself or volatilised glycerol or both) through
the tobacco rod
segment 526. This may reduce the losses of such materials as they pass through
the
tobacco rod segment 526, for example the relatively short and uninterrupted
pathways
513 may reduce occurrences of condensation of the volatile materials back onto
portions of the tobacco rod segment 526. This may be contrasted for example,
with a
hypothetical tobacco rod segment comprising randomly oriented shreds of cut
rag
tobacco (such as in standard cigarettes), in which the path length for
volatilised
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materials to exit the hypothetical tobacco rod is relatively long. This may
also be
contrasted with a hypothetical tobacco rod segment comprising a plurality of
coiled
longitudinal strands, in which the path length for volatilised materials to
exit the
hypothetical tobacco rod is also relatively long.
As mentioned above, the wrapping material 528 may, for example, be or
comprise one or both of paper and aluminium foil, for example a laminate of
paper and
aluminium foil. The laminate of paper and aluminium foil may be useful to
prevent the
tobacco rod segment 526 from being ignited by the blade heater 580.
Each of the plurality of strands 512 may have a width substantially in the
range
0.25 mm to 3 mm, or substantially in the range 0.5 mm to 1.5 mm. The tobacco
rod
segment 526 may have an outer diameter substantially in the range 5.4 mm to
7.8 mm,
or substantially in the range 6.7 mm to 7.8 mm. This may allow the use of a
relatively
large blade heater 580, hence increasing the heating surface area of the blade
heater
580, hence increasing the rate at which the tobacco may be heated and/or the
amount
of tobacco that may be heated by the blade heater 580.
The above examples are to be understood as illustrative examples of the
invention.
For example, although in the above examples the tobacco sheet 104, 204, 304
is described as being a sheet of reconstituted tobacco, this need not
necessarily be the
case, and in other examples, the tobacco sheet 104, 204, 304 may be made of
other
materials. The tobacco sheet 104 may or may not comprise glycerol, and may
comprise
other materials, such as additives or enhancers, alternatively or additionally
to glycerol.
Although in some of the above examples the tobacco sheet 104, 204, 304 is
described as being provided from a bobbin 102, 202, 302, this need not
necessarily be
the case and may for example be supplied from another device or source (not
shown),
said device or source not necessarily forming part of the apparatus 100, 200.
Although in the above examples the first cutter 106, 206 is described as
comprising an array of circular discs 108, this need not necessarily be the
case and in
other examples the first cutter 106, 206 may be any suitable cutter or cutting
means to
cut the tobacco sheet 104 longitudinally to form a plurality of tobacco
strands 112, 212.
Although in the above examples the gatherer 114, 214 was described as a funnel
114, 214 having a circular cross-section, this need not necessarily be the
case, and in
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other examples the gatherer 114, 214 may take different forms. For example,
the
gatherer 114, 214 may be or comprise a so-called stuffer jet (not shown)
arranged to
feed and gather the plurality of strands 112, 212 by using air pressure. As
another
example, the funnel 114, 214 need not be circular in cross section, and may,
for
example, have another cross-section such as rectangular or square. Indeed, the
gatherer
may be any suitable means for gathering the strands 112, 212 together to form
a tobacco
rod 120, 220 in which each of the plurality of tobacco strands 112, 212 is
substantially
non-coiled.
Although in the above examples the apparatus 100, 200 comprises a wrapper
122, 222 arranged to wrap the tobacco rod 120, 220 in a wrapping material 128,
228,
before the tobacco rod is cut by the second cutter 124 into segments 126, 226
to produce
the tobacco rod segments 126, 226, this need not necessarily be the case and
in other
examples the apparatus 100, 200 may not comprise a wrapper 122, 222, and the
(non-
wrapped) tobacco rod 120, 220 may be cut by the second cutter 124, 224 into
segments
126, 226 to produce the tobacco rod segments 126, 226. In this example, the
tobacco
rod segments 126, 226 produced need not necessarily comprise wrapping material
128,
228.
It will be appreciated that Figures 1 and 2 illustrate schematically examples
of
an apparatus for producing tobacco rod segments 126, 226 according to an
example,
and that in other examples, the apparatus 100, 200 may include additional (or
fewer)
components, for example one or more feed rollers for feeding the tobacco sheet
104
204 and/or plurality of strands 112, 212, one or more tension rollers for
tensioning the
tobacco sheet 104 204 and/or plurality of strands 112, 212, and/or one or more
drive
belts for conveying the tobacco sheet 104, 204 and/or the plurality of strands
112, 212
and/or the tobacco rod 120, 220 and/or the segments of tobacco rod 120, 220.
Although in the above examples the tobacco strands 112, 212 are described as
being straight and parallel to one another, this need not necessarily be the
case, and in
other examples the tobacco strands 112, 212 may not be substantially straight
and/or
may not be substantially parallel to one another. For example, the tobacco
strands 112,
212 may undergo processing so as to comprise a longitudinal wave or
corrugation or
zig-zag shape or the like, or indeed the tobacco sheet 104 may inherently
comprise a
longitudinal wave or corrugation or zig-zag shape or the like or be processed
so as to
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have such a shape or configuration. Indeed, the tobacco rod segment 126, 226,
may
comprise any tobacco rod 130, 530 formed of a plurality of longitudinal
strands of
tobacco 112, 212, wherein each of the plurality of longitudinal strands 112,
212 are
substantially non-coiled.
Although in the above examples the tobacco rod segments 126, 226, 526 are
described as being produced by the apparatus 100, 200 and/or by the process as
described with reference to Figure 3, this need not necessarily be the case
and in other
examples any suitable method or apparatus for producing a tobacco rod segment
126,
226, 526 comprising a tobacco rod 130, 530 formed of a plurality of
longitudinal strands
of tobacco 112, 212, 512 wherein each of the plurality of longitudinal strands
112, 212,
512 are substantially non-coiled, may be used.
Although in some of the above examples the tobacco rod segment 126, 226, 526
is described as being a consumable for a "heat-not-burn" device or the like
comprising
a blade heater 580, this need not necessarily be the case, and in other
examples the
tobacco rod segment 126, 226, 526 may be used in other devices and/or for
other
purposes. For example, the tobacco rod segment 126, 226, 526 may be a
consumable
of any aerosol generating device, for example tobacco heating products or
devices not
necessarily comprising a blade heater 580.
Although in the above examples the tobacco sheet 102, 204, 304 is described as
being or comprising tobacco, for example reconstituted tobacco, this need not
necessarily be the case and in other examples the sheet 104, 204, 304 may be
or
comprise a sheet of any aerosol-generating material. The aerosol-generating
material
may be a material which when heated, for example by the blade heater 580 of an
overall
aerosol generating device, produces an aerosol. For example, the sheet of
aerosol-
generating material 104, 204, 304 may be or comprise a flavour substrate. The
flavour
substrate 104, 204, 304 may comprise flavour, such as tobacco flavour or other
flavour
and/or may comprise glycerol or other additives or enhancers alternatively or
additionally to glycerol. The flavour substrate, with or without glycerol or
other
additives, may be heated to produce an aerosol.
It may be noted that, in general, an aerosol is a colloid of fine solid
particles or
liquid droplets, in air or another gas, where a colloid is a substance in
which
microscopically dispersed insoluble particles are suspended throughout another
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substance. On the other hand, a vapour is a substance in the gas phase at a
temperature
lower than its critical temperature, which means that for example the vapour
can be
condensed to a liquid by increasing its pressure without reducing the
temperature. It is
to be understood that as used herein the term aerosol includes aerosol and/or
vapour.
It will be appreciated that in some examples, aerosol-generating material rod
segments 126, 226, 526 may be made from a sheet of aerosol-generating material
102,
204, 304, as described above for a sheet of reconstituted tobacco 102, 204,
304, for
example by cutting the sheet of aerosol-generating material 102, 204, 304
longitudinally to produce a plurality of aerosol-generating material strands
112, 212,
512; gathering the strands 112, 212, 512 together to form an aerosol-
generating material
rod 130, 530 in which each of the plurality of aerosol-generating material
strands 112,
212, 512 is substantially non-coiled; and cutting the aerosol-generating
material rod
130, 530 into segments 126, 226, 526 to produce the aerosol-generating
material rod
segments 126, 226, 526.
Similarly, it will be appreciated that a product may comprise a rod 130, 530
of
aerosol-generating material, wherein the rod 130, 530 of aerosol-generating
material is
formed of a plurality of longitudinal strands 112, 212, 512 of aerosol-
generating
material, wherein each of the plurality of longitudinal strands 112, 212, 512
of aerosol-
generating material is substantially non-coiled.
It is to be understood that any feature described in relation to any one
example
may be used alone, or in combination with other features described, and may
also be
used in combination with one or more features of any other of the examples, or
any
combination of any other of the other examples. Furthermore, equivalents and
modifications not described above may also be employed without departing from
the
scope of the invention, which is defined in the accompanying claims.
