Patent Description:
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.

<CIT> discloses apparatus for withdrawing the leaders of webs from reels of convoluted flexible material. The leader of a fresh reel in a cigarette making or other tobacco processing machine is engaged by the tongs on an endless chain and is advanced to a splicing device so that it can be spliced to the trailing portion of a running web which is being paid out by an expiring reel. The tongs can be opened preparatory to introduction of the leader of the fresh web between its jaws by a severing device which serves to cut the protective strip around the outermost convolution of the fresh web as well as to deflect the thus exposed leader of the web on the fresh reel into the open tongs during pivoting of the severing device from its operative to its inoperative position.

<CIT> discloses a manufacturing method for a smoking article which comprises a rod of smokable material disposed within a wrapper having a strip of paper material forming a region having at least two paper layers aligned substantially parallel to the longitudinal axis of the smoking article.

<CIT> discloses an apparatus and method for splicing substantially flat continuous material comprising a transport unit for transporting a first substantially flat continuous material and a second substantially flat continuous material to a splicing location. The transport unit is adapted to transport the first substantially flat continuous material and the second substantially flat continuous material parallel to each other forming an overlap portion of the first substantially flat continuous material and the second substantially flat continuous material in the splicing location. A pressure unit is adapted to apply a mechanical impact onto at least a part of the overlap portion of the first substantially flat continuous material and the second substantially flat continuous material, thereby at least partially merging the first substantially flat continuous material with the second substantially flat continuous material.

<CIT> discloses a method of processing reconstituted tobacco which includes the steps of drying reconstituted tobacco in a pre-dryer, forming sheets of reconstituted tobacco, cutting the sheets to a pre-selected width, transferring the sheets of pre-selected width to a primary processing facility, feeding the sheets of pre-selected width to a tobacco cutting machine, the sheets being cut to a pre-selected size, and blending the pre-selected size cut reconstituted tobacco with conventional cut tobacco.

<CIT> discloses a cigarette making machine for manufacturing of a cigarette. The cigarette maker allows for mounting of a special bobbin of material which is different in size and width of a normal wrapper bobbin and feeds both the outer wrap web of material and narrower inner wrap web of material to the garniture. A slitting device may be utilized to cut the inner wrap web of material into a plurality of individual strips which are placed adjacent the outer wrap web of material in the garniture area of the maker. The inner wrap web of material may derive from a transverse wound bobbin in order to store large linear amounts of inner wrap web material.

<CIT> discloses a machine for the production of a component for an aerosol generating article. The machine includes a buffer station comprising fixed sheet guides, movable sheet guides, an actuator for moving the moveable sheet guides. The fixed and movable sheet guides together define a zig-zag trajectory for the sheet having a variable length for varying the total length of the sheet of material in the buffer station.

<CIT> discloses a method of making a smoking article from reconstituted tobacco, comprising the steps of supplying said tobacco as a substantially endless web having a mass per unit length substantially equal to that of the desired smoking article, feeding said web at a predetermined speed along a predetermined route of travel, working said web as it travels to modify its structure transverse its length, said working being accomplished by cutting said web into a multiplicity of strands, said cutting being discontinuous to ensure that the web remains coherent, forming said worked web as it continues its travel into a continuous uniformly shaped moving rod having an irregular interior transverse its length and a mass per unit length substantially equal to that of said web, applying a wrapping to said moving rod, and cutting said rod into distinct cigarette or cigar length smoking articles.

<CIT> discloses an apparatus for combining tobacco sheets comprising a first shaft for carrying a first bobbin of tobacco sheet and a second shaft for carrying a second bobbin of tobacco sheet. The apparatus also comprises a splicing unit for combining an end portion of tobacco sheet from the first bobbin to a head portion of tobacco sheet from the second bobbin. The splicing unit comprises a cutting device for cutting the tobacco sheets such as to provide complementary cuts to the tobacco sheets from the first bobbin and from the second bobbin, a dispensing device for dispensing water to at least one of the tobacco sheets, and a combining device for applying force onto the tobacco sheets thereby producing a spliced tobacco sheet.

In accordance with the present invention, there is provided apparatus for producing a rod of aerosol-generating material, the apparatus comprising:.

The web changeover unit may be configured to position the leading edge of the second web of aerosol-generating material to abut the trailing edge of the first web of aerosol-generating material.

The web changeover unit may be configured to position the leading edge of the second web of aerosol-generating material relative the trailing edge of the first web of aerosol-generating material such that a space is defined between the leading edge of the second web of aerosol-generating material and the trailing edge of the first web of aerosol-generating material.

The space may be less than <NUM>, preferably less than <NUM>, more preferably less than <NUM>.

The web changeover unit may be configured to position the leading edge of the second web of aerosol-generating material adjacent to the trailing edge of the first web of aerosol-generating material without overlap between the first web of aerosol-generating material and the second web of aerosol-generating material.

The web changeover unit may not attach the second web of aerosol-generating material to the first web of aerosol-generating material.

The apparatus may further comprise a support arranged to carry the leading edge of the second web of aerosol-generating material to the processing unit.

The leading edge of the second web of aerosol-generating material and the trailing edge of the second web of aerosol-generating material may be complementarily shaped.

The leading edge of the second web of aerosol-generating material and the trailing edge of the second web of aerosol-generating material may be diagonal relative to the direction of travel of the first web leading edge of the second web of aerosol-generating material and the second web of aerosol-generating material.

The apparatus may further comprise a cutting unit arranged to cut the first web of aerosol-generating material to define the trailing edge.

The apparatus may further comprise a cutting unit arranged to cut the second web of aerosol-generating material to define the leading edge.

The cutting unit may be further arranged to cut the second web of aerosol-generating material to define the leading edge.

The cutting unit may comprise a blade that extends diagonally across the web of aerosol-generating material.

The web changeover unit may comprise a nip drive roller configured to drive the second web of aerosol-generating material.

The web changeover unit may further comprise a sensor for detecting the positions of the leading edge of the second web of aerosol-generating material and the trailing edge of the first web of aerosol-generating material.

The apparatus of may further comprise a controller configured to control the nip drive roller to position the leading edge of the second web of aerosol-generating material adjacent to the trailing edge of the first web of aerosol-generating material.

The apparatus may further comprise a further web feed unit for providing a further web of aerosol-generating material to the processing unit, the further web of aerosol-generating material being arranged to overlap with the web of aerosol-generating material in the processing unit.

The apparatus may further comprise an embossing unit configured to emboss the second web of aerosol-generating material to the further web of aerosol-generating material.

The embossing unit may be configured to emboss a portion of the second web of aerosol-generating material adjacent to the leading edge to the further web of aerosol-generating material.

The process unit is may be a slitting unit for slitting the web of aerosol-generating material into a plurality of strands of aerosol-generating material.

The aerosol-generating material may comprise reconstituted tobacco sheet.

According to the invention, there is also provided a method of producing a rod of aerosol-generating material, the method comprising:.

The apparatus described herein is for producing rods of aerosol-generating material. In examples, the rods of aerosol-generating material are tobacco rod segments <NUM>, as shown in <FIG>. The tobacco rod segments <NUM> are formed of a plurality of tobacco strands <NUM> that extend longitudinally along a tobacco rod <NUM> of the tobacco rod segment <NUM>. The tobacco rod segment <NUM> also includes a wrapper <NUM> that circumscribes the tobacco rod <NUM>.

The tobacco strands <NUM> are preferably formed from a sheet of tobacco material, for example a sheet of reconstituted tobacco. The sheet of reconstituted tobacco can be slit into a plurality of tobacco strands <NUM> for incorporation into a tobacco rod <NUM>. 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 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 formed by any process may be used. The reconstituted tobacco sheet is malleable.

Referring to <FIG>, the tobacco strands <NUM> in the tobacco rod <NUM> extend in a direction of a length of the tobacco rod <NUM>, wherein each of the plurality of longitudinal strands <NUM> are substantially non-coiled. The plurality of tobacco strands <NUM> are substantially parallel to one another, substantially straight, and each extend along substantially the entire length of the tobacco rod segment <NUM>.

The wrapper <NUM> circumscribing the tobacco strands <NUM> is preferably made of paper. The wrapper <NUM> may, for example, be or comprise one or both of paper and aluminium foil, for example a laminate of paper and aluminium foil. The wrapper <NUM> may have a glued seam that secures the wrapper <NUM> about the tobacco rod <NUM>.

As described in further detail hereinafter, a process for producing the tobacco rod segments <NUM> can include slitting a reconstituted tobacco sheet into tobacco strands <NUM>, grouping together the tobacco strands <NUM>, wrapping the tobacco strands <NUM> in a wrapper <NUM> to form a continuous tobacco rod, and then cutting the continuous tobacco rod into discrete tobacco rod segments <NUM>. The step of grouping together the tobacco strands <NUM> can be performed on a conveyor, and such a conveyor is described in detail hereinafter.

Heating the tobacco strands <NUM> can release an aerosol for inhalation by a user. The tobacco rod segments <NUM> can be used with an aerosol-generating device that includes a heating blade <NUM>. The heating blade <NUM> can be inserted into an end <NUM> of the tobacco rod segment <NUM>, between tobacco strands <NUM>, as shown in <FIG>.

The reconstituted tobacco sheet used to produce the tobacco strands <NUM> may comprise glycerol. For example, the reconstituted tobacco sheet 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 <NUM> may be used.

The blade heater <NUM> can take the form of an elongate cuboid that is significantly thinner than it is wide or long. The width of the blade heater <NUM> is less than the outer diameter of the tobacco rod segment <NUM>. The blade heater <NUM> 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 <NUM> may have a pointed end (not shown) so as to facilitate insertion of the blade heater <NUM> into the tobacco rod segment <NUM>.

The blade heater <NUM> may be inserted into the tobacco rod segment <NUM>, or equally the tobacco rod segment <NUM> may be pushed over the blade heater <NUM>, so that the blade heater <NUM> extends longitudinally into the tobacco rod segment <NUM> as shown in <FIG>.

The plurality of longitudinally extending tobacco strands <NUM> of the tobacco rod segment <NUM> being substantially non-coiled allows the blade heater <NUM> to be easily inserted into the tobacco rod segment <NUM>. This is because the non-coiled tobacco strands <NUM> present relatively little resistance to longitudinal insertion of the blade heater <NUM>. This may provide for convenient installation or replacement of the tobacco rod segment <NUM> onto the blade heater <NUM>, which tobacco rod segment <NUM> may be a consumable of the overall aerosol generating device (not shown). This may reduce damage to the tobacco rod segment <NUM> on insertion of the blade heater <NUM>, and allow for more consistent and correct placement of the tobacco rod segment <NUM> relative to the blade heater <NUM>. 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 longitudinally extending tobacco strands <NUM> of the tobacco rod segment <NUM> being parallel to one another and/or straight similarly allows the blade heater <NUM> to be easily inserted into the tobacco rod segment <NUM>. In this case, the axis of insertion of the blade heater <NUM> is parallel to the axis of each of the longitudinal strands <NUM>, and only a small surface area of tobacco is presented to the leading edge of the blade heater <NUM> as it is inserted. Similarly to as mentioned above, this may provide for convenient installation or replacement of the tobacco rod segment <NUM> and/or reduce damage to the tobacco rod segment <NUM>, and/or provide for more consistent and correct placement of the tobacco rod segment <NUM> relative to the blade heater <NUM>. 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 <NUM> is inserted over the blade heater <NUM> of the overall aerosol generating device (not shown), the blade heater <NUM> may be controlled to heat up (for example via resistive heating internal of the blade heater), and thereby to heat, but not burn, the tobacco strands <NUM>. This may release constituents, for example volatile constituents, from the tobacco strands <NUM>. As mentioned above, the tobacco strands <NUM> may comprise glycerol, which may be volatilised when heated by the blade heater <NUM> to form an aerosol.

The plurality of substantially non-coiled longitudinal tobacco strands <NUM> of the tobacco rod segment <NUM> establish a corresponding plurality of substantially non-coiled longitudinal pathways <NUM> through the tobacco rod segment <NUM>, in between the plurality of tobacco strands <NUM>. These pathways <NUM> facilitate the transport of volatile materials released from the tobacco strands <NUM> on heating (for example volatile constituents of the tobacco itself or volatilised glycerol or both) through the tobacco rod segment <NUM>. This may reduce the losses of such materials as they pass through the tobacco rod segment <NUM>, for example the relatively short and uninterrupted pathways may reduce occurrences of condensation of the volatile materials back onto portions of the tobacco rod segment <NUM>. 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 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 described above, the wrapper <NUM> 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 <NUM> from being ignited by the blade heater <NUM>. The aluminium foil may also be useful to prevent a consumer from igniting a tobacco rod segment <NUM> like a conventional cigarette when the tobacco rod segment <NUM> is intended for use with a heating device.

Each of the plurality of tobacco strands <NUM> may have a width substantially in the range <NUM> to <NUM>, or substantially in the range <NUM> to <NUM>. The tobacco rod segment <NUM> may have an outer diameter substantially in the range <NUM> to <NUM>, or substantially in the range <NUM> to <NUM>. This may allow the use of a relatively large blade heater <NUM>, hence increasing the heating surface area of the blade heater <NUM>, hence increasing the rate at which the tobacco strands <NUM> may be heated and/or the amount of tobacco strands <NUM> that may be heated by the blade heater <NUM>.

<FIG> schematically illustrates apparatus <NUM> for producing rods of aerosol-generating material, in particular the tobacco rod segments <NUM> described with reference to <FIG>.

The reconstituted tobacco sheet used to produce the tobacco strands <NUM> is provided to the apparatus <NUM> in the form of a tobacco web <NUM>. The apparatus <NUM> includes tobacco web feed unit <NUM> that feeds a tobacco web <NUM> into the apparatus <NUM>. The tobacco web feed unit <NUM> includes a first reel support <NUM> that supports a first reel <NUM>. A first tobacco web <NUM> is provided from the first reel <NUM>. The tobacco web feed unit <NUM> also includes a second reel support <NUM> that supports a second reel <NUM>. A second tobacco web <NUM> is provided from the second reel <NUM>. The tobacco web feed unit <NUM> also includes a web changeover unit <NUM> that receives the first tobacco web <NUM> and the second tobacco web <NUM>. In the arrangement illustrated in <FIG>, the first tobacco web <NUM> pass through the web changeover unit <NUM> and is supplied to the remainder of the apparatus <NUM> as the tobacco web <NUM>. Then, when the first reel <NUM> is empty or nearly empty, the web changeover unit <NUM> changes supply of the tobacco web <NUM> from the first tobacco web <NUM> to the second tobacco web <NUM> so that the apparatus <NUM> can continue to run. A replacement first reel <NUM> can be loaded, and once the second reel <NUM> is empty or nearly empty, the web changeover unit <NUM> can change supply of the tobacco web <NUM> from the second tobacco web <NUM> to the first tobacco web <NUM>.

The first reel support <NUM> and the second reel support <NUM> both include a spindle on which the reels <NUM>, <NUM> of reconstituted tobacco are supported. The first and second reel supports <NUM>, <NUM> each preferably include a drive, for example a motor, that rotates the spindle to drive the tobacco web <NUM>, <NUM> into the apparatus <NUM>. Alternatively or additionally, a drive roller may engage an outer surface of the reel <NUM>, <NUM> to rotate the reel <NUM>, <NUM>, thereby feeding the tobacco web <NUM>, <NUM> into the apparatus <NUM>. Alternatively, the spindles may be freely rotatable such that the tobacco web <NUM>, <NUM> can be unwound by pulling the tobacco web <NUM>, <NUM> off of the reel <NUM>, <NUM> of reconstituted tobacco. The tobacco web <NUM>, <NUM> can be pulled by a part of the apparatus <NUM> located downstream of the first and second reel supports <NUM>, <NUM>. The spindles may be braked to create and/or control tension in the tobacco webs <NUM>, <NUM>.

The tobacco web <NUM> is of known dimensions. For example, the width and thickness of the tobacco web <NUM> fed from the tobacco web feed unit <NUM> may be constant and known. For example, the tobacco web <NUM> may be of a given and constant mass per unit length. This may ensure that the tobacco rod segments <NUM> produced are of consistent weight per unit length. Using a tobacco web <NUM> of known (and constant) dimensions therefore allows weight control of the resulting tobacco rod segments <NUM> without the need for weighing systems for weighing the tobacco rod or tobacco rod segments <NUM>.

The tobacco web <NUM> is fed into a slitting unit <NUM> that slits the tobacco web <NUM> into a plurality of tobacco strands <NUM>. The slitting unit <NUM> slits the tobacco web <NUM> longitudinally to produce longitudinally extending tobacco strands <NUM>.

In one example, the slitting unit <NUM> comprises a cutting roller <NUM> and an anvil roller <NUM>. The cutting roller <NUM> includes an array of circumferential cutting blades that cut the tobacco web <NUM> as it is passed between the cutting roller <NUM> and the anvil roller <NUM>. Alternatively, the slitting unit <NUM> may comprises a first cutting roller <NUM> and a second cutting roller <NUM>, each having an array of circumferential cutting blades that cooperate to slit the tobacco web <NUM>. For example, the circumferential cutting blades of the first cutting roller <NUM> may closely overlap with the circumferential cutting blades of the second cutting roller <NUM> to shear cut the tobacco web <NUM> into tobacco strands <NUM>.

The array of circumferential cutting blades on the or each cutting roller <NUM>, <NUM> determines the number of tobacco strands <NUM> and the size of the tobacco strands <NUM>.

The tobacco strands <NUM> are preferably all equal in width. The array of circumferential cutting blades on the or each cutting roller <NUM>, <NUM> may be arranged such that each tobacco strand <NUM> has a width substantially in the range <NUM> to <NUM>, or substantially in the range <NUM> to <NUM>. This would correspond, for example, to the circumferential cutting blades being spaced apart by substantially <NUM> to <NUM>, or substantially <NUM> to <NUM>, respectively.

The distance between the cutting roller <NUM> and the anvil roller <NUM>, or between the first cutting roller <NUM> and the second cutting roller <NUM>, may be fixed. Alternatively, one of the cutting roller <NUM> and the anvil roller <NUM>, or one of the first cutting roller <NUM> and the second cutting roller <NUM>, may be slidably mounted, and an actuator may be arranged to apply hydraulic or pneumatic pressure between the cutting roller <NUM> and the anvil roller <NUM>, or between the first cutting roller <NUM> and the second cutting roller <NUM>.

From the output of the slitting unit <NUM> the tobacco strands <NUM> are passed onto a conveyor <NUM>, which is described in more detail with reference to <FIG>. The conveyor <NUM> is configured to convey the tobacco strands <NUM>. Preferably, the tobacco strands <NUM> are grouped together as they are conveyed along the conveyor <NUM>.

<FIG> illustrates an example of the conveyor <NUM>. As shown, the conveyor includes a guide <NUM>. In this example, the conveyor <NUM> includes a pair of rails <NUM> angled towards each other to group together the tobacco strands <NUM>. The pair of rails <NUM> are arranged as a funnel, with a wider inlet <NUM> disposed towards the slitting unit <NUM> and a narrower outlet <NUM> disposed towards the suction conveyor <NUM>. The pair of rails <NUM> move the outer lying tobacco strands <NUM> towards the middle of the conveyor <NUM> to group them together. The angle of the pair of rails <NUM> relative to the conveying direction of the tobacco strands <NUM> can be selected such that the forces placed on the tobacco strands <NUM> are acceptable - a lower angle of rail <NUM> will result in lower forces being applied to the tobacco strands <NUM>.

The conveyor <NUM> may be a belt conveyor that carries the tobacco strands <NUM> from the slitting unit <NUM> to the suction conveyor <NUM>. Alternatively, the conveyor <NUM> may be a surface over which the tobacco strands <NUM> are pushed and/or pulled. The conveyor <NUM> supports the tobacco strands <NUM> as they move from the slitting unit <NUM> to the suction conveyor <NUM>.

Referring again to <FIG>, the grouped together tobacco strands <NUM> at the output of the conveyor <NUM> are passed onto a suction conveyor <NUM>, illustrated in <FIG>. The suction conveyor <NUM> includes a suction band <NUM>. The suction band <NUM> is driven to move along an upper run <NUM> and a lower run <NUM>. A suction chamber <NUM> is provided between the upper run <NUM> and the lower run <NUM>, and suction applied to the suction chamber <NUM> acts through suction holes formed in the suction band <NUM>. Suction acts through the suction holes in the suction band <NUM> only on the lower run <NUM>, because the suction chamber <NUM> is closed to the upper run <NUM>.

The suction conveyor <NUM> is arranged to retain the tobacco strands <NUM> on the lower run <NUM> of the suction band <NUM>. The suction conveyor <NUM> conveys the tobacco strands <NUM> through a garniture <NUM>, as illustrated.

A wrapper web <NUM> is input into the garniture <NUM> from a reel <NUM> of wrapper that is supported on a wrapper reel support <NUM>.

The garniture <NUM> receives the tobacco strands <NUM> and the wrapper web <NUM>, and as the tobacco strands <NUM> and the wrapper web <NUM> are conveyed along the suction conveyor <NUM> the garniture <NUM> wraps the wrapper web <NUM> about the tobacco strands <NUM>. An adhesive unit is arranged to apply adhesive along one edge of the wrapper web <NUM> to form a longitudinal seam joining one edge of the wrapper web <NUM> to the other. In this way, a continuous tobacco rod <NUM> is produced. The continuous tobacco rod <NUM> has a group of longitudinal tobacco strands <NUM> surrounded by a wrapper.

The suction conveyor <NUM> and the garniture <NUM> are similar to apparatus used in the manufacture of tobacco rods for use in cigarettes, and so the skilled person will be familiar with the details of the suction conveyor <NUM> and the garniture <NUM>, and further description is omitted herefrom.

A cutting unit <NUM> is arranged downstream of the suction conveyor <NUM> and the garniture <NUM> to cut the continuous tobacco rod <NUM> into discrete tobacco rod segments <NUM>, each tobacco rod segment <NUM> being as described with reference to <FIG>.

In some examples, the cutting unit <NUM> cuts the continuous tobacco rod <NUM> into double-length discrete tobacco rods <NUM>, i.e. two discrete tobacco rods <NUM> joined end-to-end. For example, the double-length discrete tobacco rods <NUM> may then be passed onto subsequent apparatus that combines the double-length discrete tobacco rods <NUM> with other components, for example filters and/or mouthpieces. The subsequent apparatus can also cut the double-length discrete tobacco rods <NUM> into single-length discrete tobacco rods <NUM> as described with reference to <FIG>.

Alternatively or additionally, the discrete tobacco rod segments <NUM> can be onwardly conveyed to packaging apparatus that packages the tobacco rod segments <NUM> for sale, distribution and/or storage.

<FIG> shows a further example of the apparatus <NUM> for producing rods of aerosol-generating material, in particular the tobacco rod segments <NUM> described with reference to <FIG>.

As shown, the apparatus <NUM> of <FIG> includes all of the same components as the apparatus <NUM> of the example of <FIG>, and further comprises a second tobacco web feed unit 9B (in addition to the first tobacco web feed unit 9A). The second tobacco web feed unit supplies a further tobacco web <NUM> for input to the slitting unit <NUM>. The further tobacco web <NUM> is arranged to overlap the tobacco web <NUM> from the first tobacco web feed unit 9A, thereby providing a double-thickness tobacco web <NUM>, <NUM> to the slitting unit <NUM>. The double-thickness tobacco web <NUM>, <NUM> means that the slitting unit <NUM> will produce a higher density of tobacco strands <NUM>. This arrangement may be preferable if it desired that the individual tobacco strands <NUM> are particularly thin or low density as it provides for each tobacco rod segment <NUM> to have twice as many tobacco strands <NUM>. In addition, for the same number of tobacco strands <NUM>, the width of the combined tobacco web <NUM> and the further tobacco web <NUM> would be less than the width of a similar thickness single tobacco web <NUM>. Therefore, the tobacco strands <NUM> producing from overlapping tobacco webs <NUM>, <NUM> would need less lateral movement to be grouped into a tobacco rod <NUM>, which may be preferable.

Furthermore, providing a further tobacco web <NUM> means it is possible to provide two different types of tobacco strands <NUM> in a tobacco rod segment <NUM>. For example, one type (e.g. the tobacco web <NUM>) can have a high glycerol content to generate significant aerosol or vapour, and the other type (e.g. the further tobacco web <NUM>) can include a flavour that is delivered with the aerosol or vapour. In this way, different tobacco rod segments <NUM> can be made by combining different reels.

The second web feed unit <NUM> includes a first reel <NUM>, a second reel <NUM>, and a reel changeover over <NUM> so that supply of the further tobacco web <NUM> can be changed over to ensure continued supply.

The slitting unit <NUM> typically has a fixed distance between the cutting rollers <NUM>, <NUM>, <NUM>, and any significant variation in the thickness of the tobacco web <NUM> can damage and/or jam the slitting unit <NUM>. In addition, any adhesive or tape or other material passing through the slitting unit <NUM> may clog or otherwise impair operation of the slitting unit <NUM>. Therefore, when changing over from the first tobacco web <NUM> to the second tobacco web <NUM> it is advantageous to avoid any overlap between them, or any tape or adhesive join. A typical splicing unit would join the second tobacco web <NUM> to the first tobacco web <NUM> in an overlapping area, but it is preferable to avoid such a system in the present invention.

Moreover, as the tobacco web <NUM>, and subsequently the tobacco strands <NUM>, are conveyed provided to the garniture <NUM> for wrapping to form tobacco rods <NUM>, it is advantageous to avoid significant variations in material weight along the length of the tobacco strands <NUM> as this would jam or impair function of the garniture <NUM> (the wrapper <NUM> would not be wide enough to circumscribe an increased number of tobacco strands <NUM>).

The web changeover unit <NUM> of the present inventive is configured to position a leading edge of the second tobacco web <NUM> adjacent to a trailing edge of the first tobacco web <NUM> at a position upstream of the slitting unit <NUM> during changeover. The first tobacco web <NUM> and second tobacco web <NUM> do not overlap, and there is no attachment between the first tobacco web <NUM> and second tobacco web <NUM>.

<FIG> schematically illustrate operation of the web changeover unit <NUM>.

<FIG> shows an initial condition of the web changeover unit <NUM>, in which the first tobacco web <NUM> is intact and passes through the web changeover unit <NUM> to the slitting unit (<NUM>, see <FIG>). As illustrated in <FIG>, a first operation of the web changeover unit <NUM> comprises cutting the first tobacco web <NUM>. The first tobacco web <NUM> is cut along line <NUM>. Line <NUM> is diagonal with respect to the direction of travel of the first tobacco web <NUM>. As shown in <FIG>, after cutting the cut off part of the first tobacco web <NUM> continues to be drawn into the apparatus (<NUM>, see <FIG>), and the remainder, attached to the first reel <NUM>, is pulled back towards the reel <NUM> for removal from the apparatus <NUM>. The second tobacco web <NUM> is then accelerated in the direction of the slitting unit (<NUM>, see <FIG>).

The web changeover unit <NUM> then cuts the second tobacco web <NUM> along line <NUM>, which matches the cut line <NUM> in the first tobacco web <NUM>. Cut off part <NUM> is removed. In this way, the second tobacco web <NUM> is provided with a leading edge <NUM> that complements the trailing edge <NUM> of the first tobacco web <NUM>.

The second tobacco web <NUM> is then positioned such that the leading edge <NUM> of the second tobacco web <NUM> is adjacent to the trailing edge <NUM> of the first tobacco web <NUM>. The leading edge <NUM> of the second tobacco web <NUM> is positioned adjacent to, and not overlapping, the trailing edge <NUM> of the first tobacco web <NUM>. In particular, there is no overlap between the first tobacco web <NUM> and the second tobacco web <NUM>.

The leading edge <NUM> of the second tobacco web <NUM> may be positioned to abut the trailing edge <NUM> of the first tobacco web <NUM>. Alternatively, the leading edge <NUM> of the second tobacco web <NUM> may be spaced from the trailing edge <NUM> of the first tobacco web <NUM>. The leading edge <NUM> of the second tobacco web <NUM> may be spaced from the trailing edge <NUM> of the first tobacco web <NUM> by a distance of less than <NUM>, preferably less than <NUM>, more preferably less than <NUM>.

In some examples, the first tobacco web <NUM> and the second tobacco web <NUM> are cut by the same cutter. The first tobacco web <NUM> and the second tobacco web <NUM> may be simultaneously cut by the same cutter. Advantageously, the leading edge <NUM> of the second tobacco web <NUM> may be spaced from the trailing edge <NUM> of the first tobacco web <NUM> would be positioned adjacent to each other by cutting the first and second tobacco webs <NUM>, <NUM> simultaneously. In other examples, the first tobacco web <NUM> and the second tobacco web <NUM> can be cut by separate cutters.

In the position shown in <FIG>, in which the leading edge <NUM> of the second tobacco web <NUM> is positioned adjacent to, and not overlapping, the trailing edge <NUM> of the first tobacco web <NUM>, the first and second tobacco webs <NUM>, <NUM> move through the apparatus (<NUM>, see <FIG>) for production of rods of aerosolisable material, as previously described. As shown in <FIG>, the diagonal cut lines <NUM>, <NUM>, and the resultant diagonal leading edge <NUM> and trailing edge <NUM>, means that the slitting unit <NUM> can grip both the first tobacco web <NUM> and the second tobacco web <NUM> simultaneously, thereby maintaining the positions of the leading edge <NUM> of the second tobacco web <NUM> and the trailing edge <NUM> of the first tobacco web <NUM>.

In addition, by positioning the leading edge <NUM> of the second tobacco web <NUM> adjacent to, and not overlapping, the trailing edge <NUM> of the first tobacco web <NUM>, there is no increase in the thickness of the tobacco web <NUM> passing through the slitting unit <NUM>.

<FIG> illustrate the apparatus of the web changeover unit <NUM> for performing the method illustrated in <FIG>. As shown, the web changeover unit <NUM> includes a support <NUM> and a cutter <NUM>. The cutter <NUM> cuts the first tobacco web <NUM> and the second tobacco web <NUM> on the support.

In the illustrated example, the web changeover unit <NUM> includes a single cutter <NUM> that cuts both of the first tobacco web <NUM> and the second tobacco web <NUM>. However, as described above, the web changeover unit <NUM> may alternatively have two cutters, one for each of the first tobacco web <NUM> and the second tobacco web <NUM>.

The web changeover unit <NUM> also includes a first nip drive <NUM> that drives the first tobacco web <NUM>, and a second nip drive <NUM> that drives the second tobacco web <NUM>. The first nip drive <NUM> and the second nip drive <NUM> each comprise two rollers between which the first and second tobacco webs <NUM>, <NUM>, respectively, are driven. The first and second nip drives <NUM>, <NUM> are independently driven and can the direction of drive can also be changed. This allows the first tobacco web <NUM> and the second tobacco web <NUM> to be independently advanced and retracted, as per the method described with reference to <FIG>.

An output nip drive <NUM> is provided at the downstream end of the cutter <NUM>, as shown. The output nip drive <NUM> also includes two rollers between which the tobacco web <NUM> is driven. In this example, once a portion of tobacco web <NUM> passes the output nip drive <NUM> it can no longer be retracted.

A support <NUM> is provided between the output nip drive <NUM> and the slitting unit <NUM>. The support <NUM> carries the leading edge of a cut tobacco web <NUM>, <NUM> to the slitting unit <NUM>. The support <NUM> may be a surface across which the tobacco web <NUM>, <NUM> slides, or it may be a conveyor, for example a belt conveyor.

As shown in <FIG>, the first tobacco web <NUM> is unreeled from the first reel <NUM> and fed into the web changeover unit <NUM>. From there, the first tobacco web <NUM> exits the web changeover unit <NUM> as tobacco web <NUM> and passes to the slitting unit <NUM> and on through the remainder of the apparatus (<NUM>, see <FIG>).

Specifically, the first tobacco web <NUM> passes through the first nip drive <NUM>, between the cutter <NUM> and support <NUM>, through the output nip drive <NUM>, over the support <NUM>, and into the slitting unit <NUM>. In the condition illustrated in <FIG>, the first tobacco web <NUM> is the tobacco web <NUM> and is used to produce discrete tobacco rods, as described previously.

In preparation for changeover, the second tobacco web <NUM> from the second reel <NUM> is positioned in the web changeover unit <NUM>. The web changeover unit <NUM> changes from the first tobacco web <NUM> to the second tobacco web <NUM> when the first reel <NUM> is empty or nearly empty.

Specifically, the second tobacco web <NUM> passes through the second nip drive <NUM>, and a leading part of the second tobacco web <NUM> is positioned between the cutter <NUM> and support <NUM>.

In the condition illustrated in <FIG>, the web changeover unit <NUM> is primed for changeover when the first reel <NUM> is empty or nearly empty.

<FIG> illustrates a first step of the changeover process performed by the web changeover unit <NUM>. As shown, the cutter <NUM> has cut the first tobacco web <NUM> and the second tobacco web <NUM>. As described previously, in an alternative example the first tobacco web <NUM> and the second tobacco web <NUM> may have been cut by two separate cutters.

The first nip drive <NUM> and/or the first reel support <NUM> has withdrawn the remainder of the first tobacco web <NUM> towards the first reel <NUM>. The cut-off part <NUM> of the second tobacco web <NUM> is removed, for example by suction.

At this stage, the leading edge <NUM> of the second tobacco web <NUM> is positioned adjacent to the trailing edge <NUM> of the first tobacco web <NUM>. If the cutter <NUM> has cut both of the first tobacco web <NUM> and the second tobacco web <NUM> simultaneously then the leading edge <NUM> of the second tobacco web <NUM> and the trailing edge <NUM> of the first tobacco web <NUM> are already positioned adjacent to each other. In examples in which the second tobacco web <NUM> and the first tobacco web <NUM> are cut separately, then the second nip drive <NUM> can be used to position the second tobacco web <NUM> such that the leading edge <NUM> of the second tobacco web <NUM> is positioned adjacent to the trailing edge <NUM> of the first tobacco web <NUM>.

In some examples, a sensor, for example a camera, can be arranged to inspect the relative positions of the leading edge <NUM> of the second tobacco web <NUM> and the trailing edge <NUM> of the first tobacco web <NUM>. If adjustments are needed, the second nip drive <NUM> can move the second tobacco web <NUM> accordingly.

As shown in <FIG>, once the trailing edge <NUM> of the first tobacco web <NUM> and the leading edge <NUM> of the second tobacco web <NUM> have passed the output nip drive <NUM>, their relative positions are fixed. The output nip drive <NUM> can grip both the first tobacco web <NUM> and the second tobacco web <NUM> simultaneously due to the diagonal cut, as shown in <FIG>. The support <NUM> carries the leading edge of the second tobacco web <NUM> to the slitting unit. As shown in <FIG>, thereafter the second tobacco web <NUM> is drawn through the remainder of the apparatus (<NUM>, see <FIG>) as the tobacco web <NUM>.

As shown in <FIG>, the first reel <NUM> can be replaced and a new first tobacco web <NUM> can be positioned in the web changeover unit <NUM>. Once the second reel <NUM> is empty or close to empty, the web changeover unit <NUM> can change supply from the second tobacco web <NUM> to the first tobacco web <NUM>.

<FIG> shows an example apparatus <NUM> similar to the apparatus of <FIG>. The apparatus <NUM> has first and second tobacco web feed units 9A, 9B and first and second web changeover units 35A, 35B, each being as described hereinbefore. This arrangement provides a further tobacco web <NUM> that overlaps the tobacco web <NUM>, as illustrated. The double-thickness tobacco web <NUM>, <NUM> means that the slitting unit <NUM> will produce a higher density of tobacco strands <NUM>.

As illustrated in <FIG>, a support <NUM> is provided to carry the leading edge of the further tobacco web <NUM> from the second web changeover unit 35B to where the tobacco web <NUM> and further tobacco web <NUM> are combined. The support <NUM> may be a surface over which the further tobacco web <NUM> is pushed, or it may be a conveyor, for example a belt conveyor.

In the example of <FIG>, the apparatus <NUM> optionally further includes an embossing unit <NUM>. The embossing unit is disposed downstream of the location where the tobacco web <NUM> and further tobacco web <NUM> are combined. When one of the tobacco web <NUM> and further tobacco web <NUM> are replaced (by one of the first and second web changeover units 35A, 35B), the embossing unit <NUM> acts to emboss the leading part of the new tobacco web <NUM> or <NUM> to other further tobacco web <NUM> or <NUM>. In this way, the new tobacco web <NUM> or <NUM> is carried to the slitting unit by the other tobacco web <NUM> or <NUM>. In this way, the support <NUM> described with reference to <FIG> is not required.

The embossing unit <NUM> may be configured to emboss the tobacco web <NUM> and the further tobacco web <NUM> to each other only in the region where one of the tobacco webs <NUM>, <NUM> has been changed over. Alternatively, the embossing unit <NUM> may be configured to emboss the tobacco web <NUM> and the further tobacco web <NUM> to each other along the length of the tobacco web <NUM> and the further tobacco web <NUM>.

It will be appreciated that in the example of <FIG> in which the tobacco web <NUM> and further tobacco web <NUM> are embossed to each other, the reels 10A, 32A, 10B, 32B are arranged so that they do not expire at the same time, such that one of the tobacco webs <NUM>, <NUM> is able to carry the leading part of the other tobacco web <NUM>, <NUM> after changeover.

Significantly, the web changeover unit <NUM> or units 35A, 35B do not attach the first tobacco web <NUM> to the second tobacco web <NUM> during changeover between the first and second tobacco webs <NUM>, <NUM>. Instead, as described with reference to <FIG>, the leading edge <NUM> of the second tobacco web <NUM> is positioned adjacent to the trailing edge <NUM> of the first tobacco web <NUM>. The leading edge <NUM> of the second tobacco web <NUM> might abut the trailing edge <NUM> of the first tobacco web <NUM>, or leading edge <NUM> of the second tobacco web <NUM> might be spaced from the trailing edge <NUM> of the first tobacco web <NUM>. As there is no overlap or connection between the first tobacco web <NUM> and the second tobacco web <NUM>, there is no localised increase in thickness, and no change in materials, and the tobacco web <NUM> can pass through the slitting unit <NUM> and other parts of the apparatus <NUM>.

The above examples are to be understood as illustrative examples of the invention.

For example, although in the above examples the tobacco web <NUM> is described as being a sheet of reconstituted tobacco, this need not necessarily be the case, and in other examples, the tobacco web <NUM> may be made of other materials. The tobacco web <NUM> may or may not comprise glycerol, and may comprise other materials, such as additives or enhancers, alternatively or additionally to glycerol.

Although in the above examples the tobacco strands <NUM> are described as being straight and parallel to one another, this need not necessarily be the case, and in other examples the tobacco strands <NUM> may not be substantially straight and/or may not be substantially parallel to one another. For example, the tobacco strands <NUM> may undergo processing so as to comprise a longitudinal wave or corrugation or zig-zag shape or the like, or indeed the tobacco web <NUM> may inherently comprise a longitudinal wave or corrugation or zig-zag shape or the like or be processed so as to have such a shape or configuration. Indeed, the tobacco rod segment <NUM> may comprise any tobacco rod <NUM> formed of a plurality of longitudinal tobacco strands <NUM>, wherein each of the plurality of longitudinal tobacco <NUM> strands are substantially non-coiled.

Although in some of the above examples the tobacco rod segment <NUM> is described as being a consumable for a "heat-not-burn" device or the like comprising a blade heater <NUM>, this need not necessarily be the case, and in other examples the tobacco rod segment <NUM> may be used in other devices and/or for other purposes. For example, the tobacco rod segment <NUM> may be a consumable of any aerosol generating device, for example tobacco heating products or devices not necessarily comprising a blade heater <NUM>.

Although in the above examples the tobacco web <NUM> is described as being or comprising tobacco, for example reconstituted tobacco, this need not necessarily be the case and in other examples the sheet 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 <NUM> of an overall aerosol generating device, produces an aerosol. For example, the sheet of aerosol generating material may be or comprise a flavour substrate. The flavour substrate 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 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 may be made from a web of aerosol-generating material, as described above for a reconstituted tobacco web, for example by cutting the 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 the aerosol-generating material rod segments.

Similarly, it will be appreciated that a product may comprise a rod of aerosol-generating material, wherein the rod of aerosol-generating material 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.

As used herein, the terms "upstream" and "downstream" refer to a position within the apparatus relative to the direction that the aerosol-generating material moves through the apparatus. Therefore, "upstream" refers to a position in the direction of the reel of tobacco web, and "downstream" refers to a position in the direction of the cutting unit, as illustrated in <FIG>.

Claim 1:
Apparatus (<NUM>) for producing a rod of aerosol-generating material (<NUM>), the apparatus comprising:
a first feed device (<NUM>) adapted to supply a first web of aerosol-generating material (<NUM>) to a processing unit;
a second feed device (<NUM>) adapted to supply a second web of aerosol-generating material (<NUM>); and
a web changeover unit (<NUM>) arranged to change supply of aerosol-generating material to the processing unit from the first web of aerosol-generating material to the second web of aerosol-generating material;
wherein the web changeover unit is configured to position a leading edge (<NUM>) of the second web of aerosol-generating material adjacent to a trailing edge (<NUM>) of the first web of aerosol-generating material upstream of the processing unit such that said leading and trailing edges do not overlap, during changeover from the first web of aerosol-generating material to the second web of aerosol-generating material, and such that said leading and trailing edges remain in a non-overlapping relationship after changeover and when the first web of aerosol-generating material and second web of aerosol-generating material are supplied to the processing unit.