Patent Description:
It is known to provide apparatuses for receiving, arranging and assembling components for the manufacture of tobacco industry products, such as smoking articles. Such apparatuses can include a series of drums that convey components along a manufacturing path as the drums rotate. Components are transferred from one drum to the next at a point where the circumferential surfaces of the drums are closest to each other. As the components are conveyed along the path they are subject to several processes, for example cutting, sliding, combining with other components, gluing, and rolling or wrapping with a paper patch. Cigarette components typically include filters, filter components and wrapped tobacco rods.

<CIT> discloses a conveyor drum for transporting rod shaped articles with pressure sensitive objects comprising receiving troughs with first shaped recess portions and second groove shaped recess portions.

<CIT> discloses a device for uniting groups formed of cigarettes and filter plugs, comprising a travelling rolling surface, a non-moving counter rolling surface. The counter rolling block has rolling surfaces.

<CIT> discloses an apparatus for uniting assemblies of double length filters between two cigarettes. The apparatus comprises a suction cutting drum, a transfer drum, and a rolling drum and a rolling shoe, which is provided with ridges to commence the rolling operation.

<CIT> discloses a device for rolling rod-like tobacco components comprising a front roll surface in a web wheel. A front roll channel is defined between the front roll surface and the roll surface of a roll conveyor.

<CIT> discloses a consolidation roller having a roughened surface to form a series of axial ridges and grooves, and a roughened stationary surface.

In accordance with some embodiments described herein, there is provided an apparatus for use in the manufacture of tobacco industry products, the apparatus comprising a rolling unit comprising:.

In some embodiments, the groove in the kicker bar contact edge may be aligned with the groove in the roll hand contact surface with respect to a circumferential direction of the drum.

The kicker bar contact edge may include a groove and the roll hand contact surface may include a groove, and wherein a base surface of the groove in the kicker bar contact edge may be level with a base surface of the groove in the roll hand contact surface.

Alternatively, the kicker bar contact edge may include a groove and the roll hand contact surface may include a groove, and wherein a base surface of the groove in the kicker bar contact edge may be off-set from a base surface of the groove in the roll hand contact surface.

In some examples the kicker bar contact edge may include a groove, and wherein a depth of the groove in the kicker bar contact edge may vary from a side of the kicker bar remote from the roll hand to a side of the kicker bar proximate the roll hand.

The kicker bar contact edge may include a groove and the roll hand contact surface may include a groove, and wherein a base surface of the groove in the kicker bar contact edge may be level with a base surface of the groove in the roll hand contact surface at the side of the kicker bar proximate the roll hand, and may be off-set from the base surface of the groove in the roll hand contact edge at the side of the kicker bar remote from the roll hand.

In some examples, the kicker bar is a separate component to the roll hand and is fixedly secured to the roll hand.

Additionally, a position of the kicker bar relative to the roll hand may be adjustable.

In accordance with some embodiments described herein, there is provided a smoking article assembly machine comprising the apparatus described above.

In accordance with some embodiments described herein, there is provided a method of manufacturing tobacco industry products using apparatus for manufacturing tobacco industry products, the apparatus comprising a rolling unit having a rotatable drum having a plurality of flutes extending in an axial direction of the drum and spaced circumferentially around a curved outer surface of the drum, the flutes being formed in the curved outer surface of the drum, a roll hand having a contact surface facing and spaced from the outer surface of the drum to define a space between the contact surface and the outer surface within which space components of a tobacco industry product are rollable across the outer surface upon rotation of the drum, and a kicker bar disposed adjacent to the roll hand and having a contact edge facing and spaced from the outer surface of the drum, the roll hand contact surface and the kicker bar contact edge both including a groove extending in a substantially circumferential direction of the drum, the method comprising transferring a plurality of components of tobacco industry products to the drum, receiving the plurality of components in axial alignment in the flutes, rotating the drum relative to the kicker bar and roll hand so that the components of the tobacco industry products engage the kicker bar and roll hand, and at least one of the components of the tobacco industry products being at least partially received in the groove(s) as the drum rotates.

The components of tobacco industry products may comprises a plurality of filter components, one of the plurality of filter components may have a hardness different to another of the plurality of filter components, and the filter components having a greater hardness may be at least partially received in the groove(s) as the drum rotates.

In some embodiments the kicker bar is a separate component to the roll hand and is fixedly secured to the roll hand, the method comprising adjusting the position of the kicker bar relative to the roll hand to adjust an off-set distance between the contact edge of the kicker bar and the contact surface of the roll hand.

<FIG> schematically shows a part of a tobacco industry product manufacturing apparatus <NUM> comprising a tobacco industry product manufacturing apparatus of one embodiment of the present invention. Hereafter, the description will refer to such tobacco industry products as "smoking articles" for brevity. The apparatus <NUM> includes a tobacco rod feed drum <NUM> and a filter component feed drum <NUM>. The tobacco rod feed drum <NUM> receives wrapped tobacco rods <NUM> that are travelling in a direction transverse to their length (i.e. sideways) in flutes formed in the peripheral surface of the tobacco rod feed drum <NUM>. The filter component feed drum <NUM> receives filter components <NUM> from a hopper <NUM> in flutes formed in the peripheral surface of the filter component feed drum <NUM>. In the apparatus <NUM> shown, a single filter component feed drum <NUM> and single hopper <NUM> is shown. However, the apparatus <NUM> may include multiple filter component feed drums <NUM> and/or multiple hoppers <NUM>, in order that different configurations or types of filter components may be combined and assembled into smoking articles being manufactured. Alternatively, the single hopper <NUM> may be configured to provide different configurations of filter components <NUM> to the filter component feed drum <NUM>.

The filter component feed drum <NUM> and the tobacco rod feed drum <NUM> feed filter components <NUM> and tobacco rods <NUM>, respectively, onto a combining drum <NUM>, such that the filter components <NUM> and tobacco rods <NUM> are axially aligned in flutes on the peripheral surface of the combining drum <NUM>, ready to be wrapped to form an assembled smoking article.

As shown in <FIG>, from the combining drum <NUM> the tobacco rods <NUM> and filter components <NUM> are transferred onto a tipping drum <NUM> where they are provided with a tipping paper patch <NUM> (see <FIG>) before being transferred to a rolling unit <NUM> that rolls the tipping paper patch <NUM> around the tobacco rods <NUM> and filter components <NUM> to form two joined and assembled smoking articles <NUM> in back-to-back arrangement. The tipping paper patch is supplied to the tipping drum <NUM> by a tipping paper suction drum <NUM>.

A web <NUM> of tipping paper passes through an adhesive applicator <NUM> that applies adhesive to one surface of the tipping paper web <NUM>. The tipping paper web <NUM> is then received on the tipping paper suction drum <NUM>, which uses suction to hold the web <NUM> of tipping paper against the peripheral surface of the tipping paper suction drum <NUM>. A cutting unit <NUM> cuts the web <NUM> of tipping paper into patches on the tipping paper suction drum <NUM> and the patches are then transferred to the tobacco rods <NUM> and filter components <NUM> on the tipping drum <NUM>.

In one example, the cutting unit <NUM> comprises a crush cutter. In this case, the cutting unit <NUM> comprises a rotary blade and the tipping paper suction drum <NUM> acts as an anvil against which the tipping paper web <NUM> is cut by the rotary blade, in a transverse direction (i.e. across the web <NUM>), to form patches of tipping paper.

In an alternative embodiment, the cutting unit <NUM> uses a shear cutter to cut the web <NUM>. In this case, the tipping paper suction drum <NUM> comprises edges that act with blades of the cutting unit <NUM> to shear cut the tipping paper web <NUM>.

The cutting unit <NUM> may have several rotary blades which protrude from a shaft in a radial direction so that as the shaft rotates the blades successively engage the tipping paper suction drum <NUM> and cut the web <NUM> in a transverse direction (i.e. in the axial direction of the tipping paper suction drum <NUM> and cutting unit <NUM>).

The cut patches of tipping paper <NUM> on the tipping paper suction drum <NUM> already have adhesive applied to their outwards facing surface, so at the position where the tipping paper suction drum <NUM> rotates closest to the tipping drum <NUM> the suction acting on the tipping paper patches <NUM> is released and the patches are transferred from the tipping paper suction drum <NUM> to the tipping drum <NUM>, specifically onto the tobacco rods <NUM> and filter components <NUM>. The adhesive anchors the tipping paper patches to the tobacco rods <NUM> and filter components <NUM>.

The tipping drum <NUM> then transfers the tobacco rods <NUM> and filter components <NUM> and the tipping paper patch <NUM> into the rolling unit <NUM> that rolls the tipping paper patch <NUM> around the tobacco rods <NUM> and filter components <NUM> to form smoking articles. The rolling unit <NUM> comprises a rolling drum <NUM> that receives and carries the tobacco rods <NUM> and filter components <NUM> and the tipping paper patch <NUM> past a stationary roll hand <NUM> and kicker bar <NUM> (described in more detail below).

The rolling drum <NUM> of a first exemplary embodiment is shown in more detail in <FIG>, and comprises a cylindrical drum <NUM> having a curved outer surface <NUM> with a plurality of flutes <NUM> formed in the curved outer surface <NUM>. The drum <NUM> is adapted to rotate about an axis <NUM>. The flutes <NUM> are sized to receive and retain tobacco and/or filter components as the drum <NUM> rotates. The flutes <NUM> extend in a direction parallel to the axis of rotation <NUM> of the drum <NUM>.

Each flute <NUM> includes at least one suction hole <NUM> that holds the components in the flute <NUM> when suction is provided to the suction hole <NUM>. In this example, each flute <NUM> includes several suction holes <NUM>, so that multiple components can be retained in the flute <NUM>. However, multiple suction holes <NUM> may be provided to retain a single elongate component. Turning off the suction applied to the suction holes <NUM> will allow the components to leave the flute <NUM>.

A suction manifold (not shown) can be used to provide suction to the suction holes <NUM> during pre-defined portions of the rotation of the drum <NUM>, and to switch off the suction to the suction holes <NUM> in other pre-defined portions of the rotation of the drum <NUM>.

The kicker bar <NUM> pushes the tobacco rods <NUM> and filter components <NUM> and the tipping paper patch <NUM> out of flutes <NUM> in the rolling drum <NUM> as the rolling drum <NUM> rotates them past the kicker bar <NUM>. The tobacco rods <NUM> and filter components <NUM> and the tipping paper patch <NUM> are then rolled between the curved surface <NUM> of the rolling drum <NUM> and the roll hand <NUM>, thereby wrapping the tipping paper patch <NUM> around the tobacco rods <NUM> and filter components <NUM> to join them together.

The rolled smoking articles are then conveyed by further drums for cutting into individual single length smoking articles, aligning, arranging and packaging.

Referring to <FIG>, two joined smoking articles <NUM> are manufactured together, as explained above, by arranging two tobacco rods <NUM> at either end of a double-length filter component <NUM> on the combining drum <NUM>. The tobacco rods <NUM> and filter component <NUM> are joined together by wrapping a tipping paper patch <NUM> about them, and then cutting through the filter component <NUM> along line <NUM> to separate the two smoking articles <NUM>.

The roll hand <NUM> and kicker bar <NUM> are mounted on a support mechanism <NUM>. The support mechanism <NUM> is configured to hold the roll hand <NUM> and kicker bar <NUM> in a fixed position during operation of the apparatus <NUM>. In the exemplary embodiment shown, the support mechanism <NUM> comprises a bracket <NUM> fixedly secured to the roll hand <NUM> and mounted about a pivot point <NUM> to a fixed portion of the apparatus <NUM>. A piston <NUM> is attached at one end to a portion of the bracket <NUM> and at the other end to a fixed portion of the apparatus <NUM>. The piston <NUM> is provided to enable the roll hand <NUM> and kicker bar <NUM> to be moved away from the rolling drum <NUM> for servicing or maintenance, but in use of the apparatus <NUM>, holds the roll hand <NUM> and kicker bar <NUM> in a fixed operative position (shown in <FIG>). The roll hand <NUM> and kicker bar <NUM> are thereby not moveable away from or towards the rolling drum <NUM> during operation of the apparatus <NUM>.

As explained above, filter components <NUM>, tobacco rods <NUM>, tipping paper patches <NUM>, and wrapped smoking articles <NUM>, collectively 'components', are transferred between successive drums as the components travel through the apparatus <NUM> to manufacture smoking articles <NUM>. The components <NUM>, <NUM>, <NUM>, <NUM> are transferred from one drum to the next at the point where the peripheral surfaces of the drums are closest, and at these transfer points the components <NUM>, <NUM>, <NUM>, <NUM> are in contact with the flutes of both drums.

The drums are arranged such that at each transfer point, the components <NUM>, <NUM>, <NUM>, <NUM> are smoothly and reliably transferred. That is, the components <NUM>, <NUM>, <NUM>, <NUM> are placed into the flutes of the downstream drum so that the suction applied in the flute can take effect on the components <NUM>, <NUM>, <NUM>, <NUM> before the upstream drum moves away. During transfer, suction acts on the components <NUM>, <NUM>, <NUM>, <NUM> from either the upstream drum, the downstream drum, or, for short time, both the upstream and downstream drums.

In the rolling unit <NUM>, as the tobacco rods <NUM> and filter components <NUM> pass between the roll hand <NUM> and kicker bar <NUM>, the kicker bar <NUM> initially engages the tobacco rods <NUM> and filter components <NUM>, compressing them slightly to ensure they are reliably pushed out of their flute <NUM> in the rolling drum <NUM>. As described above, as the rolling drum <NUM> continues to rotate, the tobacco rods <NUM> and filter components <NUM> are rolled between the rotating rolling drum <NUM> and the stationary roll hand <NUM> to become wrapped with the tipping paper patch <NUM>. The spacing between the kicker bar <NUM> and the roll hand <NUM> and the curved surface <NUM> of the rolling drum <NUM> is accurately set to ensure the correct degree of initial compression of the tobacco rods <NUM> and filter components <NUM> in the flute <NUM>, and correct contact pressure of the tobacco rods <NUM> and filter components <NUM> between the curved surface <NUM> rolling drum <NUM> and the roll hand <NUM>. The kicker bar <NUM> and roll hand <NUM> are fixedly connected, or are formed as one component, and during use, remain in a fixed position whilst the rolling drum <NUM> rotates. In a conventional apparatus, the roll hand comprises a continuous curved surface and the kicker bar comprises a continuous elongate bar.

In various examples within the scope of the invention, each filter component <NUM> may comprise one or more filter segments. For example, the filter rod <NUM> may be formed of any combination of cellulose acetate segments, plasticised cellulose acetate segments, paper segments, non-wrapped cellulose acetate segments, plastic components, ceramic components, or metallic segments. These filter segments are generally cylindrical and/or tubular, and may have a cylindrical outer surface that fits within the flutes of the drums and can be rolled by the rolling drum <NUM> to create a wrapped smoking article. The filter segments may each have a wrapper, typically called a plug wrap, which holds the material of the filter segment in the desired shape before the filter segment is provided to the apparatus <NUM> of <FIG>.

The smoking articles shown in <FIG> and made on the apparatus of <FIG> may be cigarettes. Alternatively, the smoking articles may be products which heat tobacco without burning that tobacco to release a vapour. Yet further, the smoking articles may be products of a device that heats tobacco without burning that tobacco to release a vapour. Alternatively, they may be any other kind of smoking article that is manufactured on apparatus having a series of drums.

In the exemplary embodiment, the smoking article shown in <FIG> comprises a wrapped tobacco rod <NUM> which comprises a tobacco material wrapped in a wrapper, for example a paper wrapper. The smoking article also comprises a filter component <NUM>. In this example, the filter component <NUM> comprises a first filter segment <NUM> being made of plasticized cellulose acetate through which smoke or vapour can pass and which removes constituents from the smoke or vapour. A second segment <NUM> of the filter component <NUM> comprises a tubular member made from plastics, the plastics tubular member having passages therethrough to allow smoke or vapour to pass through the filter section. A third filter segment <NUM> comprises a tubular member made of paper.

As is apparent from <FIG>, each filter component <NUM> supplied to the apparatus of <FIG> is symmetrical so that after the filter component <NUM> is cut along line <NUM> there are two identical smoking articles <NUM>.

It will be appreciated that other filter sections have different combinations of components, and it is possible to arrange such components in a multitude of ways using drums that received, move and position components in the same flute so that they can be wrapped to join them into smoking articles.

The filter component <NUM> is attached to the end of a tobacco rod <NUM> by a tipping paper patch <NUM> that circumscribes the join between the filter component <NUM> and tobacco rod <NUM>. The tipping paper patch <NUM> is adhered to the outer surface of the filter component <NUM> and the tobacco rod <NUM>. The tipping paper patch <NUM> may extend over the whole of the filter component <NUM> and partially over the tobacco rod <NUM>. Alternatively, the tipping paper patch <NUM> may extend partially onto the filter component <NUM> and partially onto the tobacco rod <NUM>.

As explained above, the smoking articles manufactured by the apparatus <NUM> of <FIG> may include components or segments having a high hardness, for example components made of plastic, ceramic or metal. In this case, during the rolling process in the rolling unit <NUM>, such components are placed under pressure, such as by the kicker bar <NUM> to push them out of the flutes <NUM> in the rolling drum <NUM>, and between the curved surface of the roll hand <NUM> and the curved surface <NUM> of the rolling drum <NUM>. Such pressure may be accommodated by components which are deformable and/or resilient. However, if components are delicate, fragile, or brittle, then the components may be damaged, broken, or deformed by the pressure applied to the components. For example, a plastic component may be cracked or broken by the pressure. Furthermore, if the kicker bar <NUM> and/or roll hand <NUM> are set further away from the rolling drum to avoid damaging the harder components, the rolling unit <NUM> may not exert sufficient force to push the tobacco rods <NUM> and other filter components <NUM> out of the flutes <NUM> or roll them between the rolling drum surface <NUM> and roll hand <NUM> successfully or reliably. Yet further, passing hard rigid components between a fixed kicker bar <NUM>/roll hand <NUM> and the rolling drum <NUM> of a conventional apparatus may force the roll hand <NUM> and kicker bar <NUM> away from the rolling drum <NUM>, enlarging the spacing therebetween. As mentioned above, the clearance between the roll hand <NUM> and the kicker bar <NUM> is carefully set, and effective and reliable operation of the apparatus <NUM> is sensitive to this spacing. Therefore, unintentional enlargement of this spacing can be detrimental to the operation of the apparatus <NUM>, for example, ineffective rolling of the filter component <NUM> and tobacco rod <NUM> with the tipping paper patch <NUM>, or these components falling out of the gap between the rolling drum <NUM> and the roll hand <NUM>.

In order to seek to avoid or mitigate the above problems and to accommodate smoking article components of differing hardnesses, the roll hand <NUM> and kicker bar <NUM> of an exemplary embodiment of the present invention are provided as illustrated in more detail in <FIG>.

The roll hand <NUM> includes a curved contact surface <NUM> which, in use, faces the rolling drum <NUM> and presses against the tobacco rods <NUM> and filter components <NUM> as they are rolled between the roll hand <NUM> and the rotating rolling drum <NUM> to become wrapped with the tipping paper patch <NUM>. In the exemplary embodiment shown, the kicker bar <NUM> is a separate component which is fixedly secured to the roll hand <NUM> during use of the apparatus <NUM>. However, the kicker bar <NUM> may alternatively be formed integrally with the roll hand <NUM> within the scope of the invention. In the embodiment shown, the kicker bar <NUM> is secured to the roll hand <NUM> by mechanical fasteners <NUM>, such as screws or bolts. The kicker bar <NUM> includes a contact edge <NUM> which, in use, is the part of the kicker bar <NUM> disposed closest to the rolling drum <NUM>. The contact edge <NUM> is disposed closer to the rolling drum <NUM> than the curved contact surface <NUM> of the roll hand <NUM>. The distance between the contact edge <NUM> and the rolling drum <NUM> affects how the tobacco rods <NUM> and filter components <NUM> are initially compressed and/or pushed out of the flutes <NUM>. Also in the exemplary embodiment shown, the kicker bar <NUM> is adjustable relative to the roll hand <NUM>. That is, a projection distance (see distance 'p' in <FIG>) of the contact edge <NUM> of the kicker bar <NUM> from the curved contact surface <NUM> of the roll hand <NUM> can be adjusted and set. The kicker bar <NUM> includes adjustments slots <NUM> through which the mechanical fasteners <NUM> extend. The mechanical fasteners <NUM> can therefore be loosened, the kicker bar <NUM> adjusted by the distance permitted by the adjustment slots <NUM>, and the mechanical fasteners <NUM> tightened to secure the kicker bar <NUM> with the desired projection distance 'p'.

The kicker bar <NUM> includes recesses <NUM> formed in the contact edge <NUM>. The recesses <NUM> have a width 'w1' which corresponds to the length of the second segment <NUM> of the filter components <NUM>, or which is slightly larger than the length of the second segment <NUM>.

Operation of the rolling unit <NUM> of the apparatus <NUM> of the invention will now be described, with additional reference to the flow chart of <FIG>. The tobacco rods <NUM> and filter components <NUM>, together with the tipping paper patch <NUM>, are transferred from the tipping drum <NUM> to the rolling drum <NUM> as described above, at step S1 of <FIG>. The tobacco rods <NUM> and filter components <NUM> are received in axial alignment in a flute of the <NUM> of the rolling drum <NUM>, at step S2. The tobacco rods <NUM> and filter components <NUM> reach and engage the kicker bar <NUM> as the rolling drum <NUM> rotates, at step S3. The filter components <NUM> and tobacco rods <NUM> contact the contact edge <NUM> of the kicker bar <NUM> and pressure is exerted on the tobacco rod <NUM> and filter components <NUM> to compress them and push them out of the flute <NUM> as described above.

The second segment <NUM> comprises a tubular member made from plastic having a higher hardness than the more compressible tobacco rod <NUM>, first filter segment <NUM> made of plasticized cellulose acetate and third filter segment <NUM> made of paper. However, the second segments <NUM> are partially received within the recesses <NUM>, at step S4, as the filter components <NUM> and tobacco rod <NUM> pass the kicker bar <NUM> and are pushed out of the flute <NUM> at step S5. The recesses <NUM> thereby accommodate the hard second segments <NUM> and so prevent the kicker bar <NUM> and roll hand <NUM> being pushed away from the rolling drum <NUM> and disrupting the spacing therebetween. This also prevents the kicker bar <NUM> damaging the second segments <NUM> through excessive compression.

Thereafter, the tobacco rods <NUM> and filter components <NUM>, together with the tipping paper patch <NUM>, pass the kicker bar <NUM> and are rolled between the curved outer surface <NUM> of the rolling drum <NUM> and the curved contact surface <NUM> of the roll hand <NUM> as described previously, at step S6.

A roll hand <NUM> and kicker bar <NUM> of a first alternative exemplary embodiment of the invention are shown in <FIG>, in which like features in common with the previous embodiment retain the same reference numerals. In this first alternative embodiment, the kicker bar <NUM> includes recesses <NUM> formed in the contact edge <NUM> as with the previous embodiment, the recesses <NUM> having a width 'w1' as before. A difference with the first alternative embodiment is that the curved contact surface <NUM> of the roll hand <NUM> includes a pair of shallow grooves <NUM>. The grooves <NUM> extend in a circumferential direction of the rolling drum <NUM> and are positioned in alignment with the recesses <NUM> in the kicker bar <NUM>. The grooves <NUM> have a width 'w2' which corresponds to the length of the second segment <NUM> of the filter components <NUM>, or which is slightly larger than the length of the second segment <NUM>.

Operation of the rolling unit <NUM> of the apparatus <NUM> of the first alternative embodiment of the invention will now be described. The tobacco rods <NUM> and filter components <NUM>, together with the tipping paper patch <NUM>, are transferred from the tipping drum <NUM> to the rolling drum <NUM> and, as the rolling drum <NUM> rotates, the contact edge <NUM> of the kicker bar <NUM> exerts pressure on the tobacco rods <NUM> and filter components <NUM> to compress them and push them out of the flute <NUM>, as described above. The harder second segments <NUM> are partially received within the recesses <NUM> in kicker bar <NUM> and thereby prevent the kicker bar <NUM> and roll hand <NUM> being pushed away from the rolling drum <NUM>, or damaging the second segments <NUM> through excessive compression, as with the previous embodiment of the invention.

Once past the kicker bar <NUM>, the tobacco rods <NUM> and filter components <NUM>, together with the tipping paper patch <NUM> are rolled between the curved outer surface <NUM> of the rolling drum <NUM> and the curved contact surface <NUM> of the roll hand <NUM>. However, the harder second segments <NUM> are partially received within the grooves <NUM> in the roll hand <NUM>. This further accommodation of the hard second segments <NUM> in the curved contact surface <NUM> of the roll hand <NUM> further helps towards preventing the roll hand <NUM> being pushed away from the rolling drum <NUM> and disrupting the spacing therebetween, and/or preventing the rolling hand <NUM> damaging the second segments <NUM> through excessive compression during rolling. It also helps enable a similar pressure be applied on all filter components <NUM> of varying hardnesses during the rolling process to help achieve consistent rolling performance.

A roll hand <NUM> and kicker bar <NUM> of a second alternative exemplary embodiment of the invention are shown in <FIG>, in which like features in common with the previous embodiments retain the same reference numerals. In this second alternative embodiment, the curved contact surface <NUM> of the roll hand <NUM> includes a pair of shallow grooves <NUM> as described previously. The grooves <NUM> extend in a circumferential direction of the rolling drum <NUM> and have a width 'w2' which corresponds to the length of the second segment <NUM> of the filter components <NUM>, or which is slightly larger than the length of the second segment <NUM>. A difference over the previous embodiments is that the kicker bar <NUM> does not include recesses in the contact edge <NUM>. The projection distance 'p' may be set at or close to a minimal amount necessary to ensure the tobacco rods <NUM> and filter components <NUM> are pushed out of the flute <NUM>, without damaging the harder second filter segments <NUM>.

Operation of the rolling unit <NUM> of the apparatus <NUM> of the second alternative embodiment of the invention will now be described. The tobacco rods <NUM> and filter components <NUM>, together with the tipping paper patch <NUM>, are transferred from the tipping drum <NUM> to the rolling drum <NUM> and, as the rolling drum <NUM> rotates, the contact edge <NUM> of the kicker bar <NUM> exerts pressure on the tobacco rods <NUM> and filter components <NUM> to push them out of the flute <NUM>. Once past the kicker bar <NUM>, the tobacco rods <NUM> and filter components <NUM>, together with the tipping paper patch <NUM> are rolled between the curved outer surface <NUM> of the rolling drum <NUM> and the curved contact surface <NUM> of the roll hand <NUM>. The harder second segments <NUM> are partially received within the grooves <NUM> in the roll hand <NUM> to help prevent the roll hand <NUM> being pushed away from the rolling drum <NUM> and disrupting the spacing therebetween, and/or to prevent the roll hand <NUM> damaging the second segments <NUM> through excessive compression during rolling. The grooves <NUM> also help enable a similar pressure be applied on all filter components <NUM> of varying hardnesses during the rolling process to help achieve consistent rolling performance.

A rolling drum <NUM> of a rolling unit <NUM> of a third alternative exemplary embodiment of the invention is shown in <FIG>, in which like features in common with the rolling drum <NUM> shown in <FIG> retain the same reference numerals. In this alternative embodiment of rolling drum <NUM>, the curved outer surface <NUM> includes a pair of spaced channels <NUM>. The channels <NUM> extend in a circumferential direction of the rolling drum <NUM>, substantially perpendicular to the flutes <NUM>. The channels <NUM> extend in plane that lies substantially perpendicular to the axis of rotation <NUM> of the rolling drum <NUM>. The channels <NUM> have a width 'w3' which corresponds to the length of the second segment <NUM> of the filter components <NUM>, or which is slightly larger than the length of the second segment <NUM>.

Operation of the rolling unit <NUM> of the apparatus <NUM> of the third alternative embodiment of the invention will now be described. The tobacco rods <NUM> and filter components <NUM>, together with the tipping paper patch <NUM>, are transferred from the tipping drum <NUM> to the rolling drum <NUM> as the rolling drum <NUM> rotates. The channels <NUM> are positioned on the rolling drum <NUM> to correspond to the position in which the harder second filter segments <NUM> are disposed when transferred onto the rolling drum <NUM>. Therefore, the harder second segments <NUM> are partially received within the channels <NUM>. As the rolling drum <NUM> rotates, the contact edge <NUM> of the kicker bar <NUM> exerts pressure on the tobacco rods <NUM> and filter components <NUM> to push them out of the flute <NUM>. Once past the kicker bar <NUM>, the tobacco rods <NUM> and filter components <NUM>, together with the tipping paper patch <NUM> are rolled between the curved outer surface <NUM> of the rolling drum <NUM> and the curved contact surface <NUM> of the roll hand <NUM>. At both the point where the kicker bar <NUM> pushes the tobacco rods and filter components <NUM> out of the flute, and during rolling between the roll hand <NUM> and the rolling drum <NUM>, the harder second segments <NUM> are partially received within the channels <NUM>. This helps prevent the roll hand <NUM> and kicker bar <NUM> being pushed away from the rolling drum <NUM> and disrupting the spacing therebetween, and/or prevents the roll hand <NUM> and kicker bar <NUM> damaging the second filter segments <NUM> through excessive compression during compression and/or rolling. The channels <NUM> also help enable a similar pressure be applied on all filter components <NUM> of varying hardnesses during the rolling process to help achieve consistent rolling performance.

In an advantageous embodiment, the kicker bar <NUM> and roll hand <NUM> are provided with respective recesses <NUM> and grooves <NUM>, as well as the rolling drum <NUM> having channels <NUM> therein. In such an embodiment, the harder second filter segments <NUM> are partially received in spaces (i.e. recesses <NUM>, grooves <NUM>, channels <NUM>) in both the roll hand <NUM>/kicker bar <NUM> and rolling drum <NUM>. This can reduce the axial distortion or deflection of the aligned tobacco rods <NUM> and filter components <NUM> when being pushed out of the flutes <NUM> and/or when being rolled between the roll hand <NUM> and the rolling drum <NUM>.

In embodiments where the kicker bar <NUM> includes recesses <NUM> and the roll hand <NUM> includes grooves <NUM>, the recesses <NUM> and grooves <NUM> may have a range of difference depths within the scope of the invention. These various embodiments are shown in <FIG> which show schematic cross-sectional views through the roll hand <NUM> and kicker bar <NUM> taken along a line extending through the recess <NUM> in the kicker bar <NUM> and groove <NUM> in the roll hand <NUM>.

In one embodiment, shown in <FIG>, a base surface <NUM> of the recess <NUM> in the kicker bar <NUM> may be off-set from a base surface <NUM> of the groove <NUM> in the roll hand <NUM>, so as not to be level therewith. The off-set is shown as dimension 'd' in <FIG>. This may advantageously allow sufficient initial contact with the second filter segments <NUM> to push them from the flutes <NUM>, but thereafter a reduced contact pressure with the second filter segments <NUM> during the subsequent rolling process to enable rolling without damaging the second filter segments <NUM>.

In another embodiment, the base surface <NUM> of the recess <NUM> in the kicker bar <NUM> may be level with a base surface <NUM> of the groove <NUM> in the roll hand <NUM>. This may enable the second filter segments <NUM> to more smoothly transfer to the roll hand <NUM> from the kicker bar <NUM>. This arrangement is shown in <FIG>.

In a yet further embodiment, the base surface <NUM> of the recess(es) <NUM> in the kicker bar <NUM> may be inclined, such that the depth of the recess(es) <NUM> varies from one side of the kicker bar <NUM> to the other. As such, the base surface <NUM> of the recess(es) <NUM> in the kicker bar <NUM> may be inclined with respect to the curved surface <NUM> of the rolling drum <NUM>. The depth of the recess(es) <NUM> may increase from the side of the kicker bar <NUM> remote from the roll hand <NUM> to the side of the kicker bar <NUM> proximate the roll hand <NUM>, or vice versa. In the former case, illustrated in <FIG>, the kicker bar <NUM> may provide an initial contact with the second filter segments <NUM> to push them from the flute <NUM>, and as the recess depth increases, the pressure on the second filter components <NUM> reduces to transition to the roll hand <NUM>. In the latter case, shown in <FIG>, the kicker bar <NUM> may more gently initially contact the second filter segments <NUM> to avoid damaging the filter segment <NUM>, and may increase pressure on the second filter segments <NUM> to push them from the flute <NUM>.

In a yet further embodiment, the base surface <NUM> of the recess <NUM> in the kicker bar <NUM> may be off-set from the base surface <NUM> of the groove <NUM> in the roll hand <NUM> at one side of the kicker bar <NUM>, and may be level with the base surface <NUM> of the groove <NUM> in the roll hand <NUM> at the other side of the kicker bar <NUM>. The base surface <NUM> of the recess(es) <NUM> may be off-set from the base surface <NUM> of the groove(s) in the roll hand <NUM> at the side of the kicker bar <NUM> remote from the roll hand <NUM>, and may be level with the base surface <NUM> of the groove(s) in the roll hand <NUM> at the side of the kicker bar <NUM> proximate the roll hand <NUM>, or vice versa. An embodiment of the former configuration is shown in <FIG>.

It will be appreciated that the terms 'recess', 'groove' and 'channel' as used herein all refer to features of the rolling apparatus <NUM> in which a recessed or indented formation is provided in the kicker bar <NUM>, roll hand <NUM> and/or rolling drum <NUM> to accommodate less compressible components of the tobacco industry product being manufactured. As such, all such features disclosed herein could be defined as recesses, grooves or channels interchangeably.

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

In one example, the apparatus for manufacture of tobacco industry products described previously is used to make a tobacco industry product that is a smoking article for combustion, selected from the group consisting of a cigarette, a cigarillo and a cigar.

In another example, the apparatus is used to make a tobacco industry product that is a non-combustible smoking article.

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

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

The drawings accompanying the various embodiments of the invention described herein are not necessarily illustrated to scale and the dimensions of certain features may be exaggerated for ease and clarity of illustration.

Claim 1:
An apparatus for manufacture of tobacco industry products, the apparatus comprising a rolling unit (<NUM>) comprising:
a rotatable drum (<NUM>) having a plurality of flutes (<NUM>) extending in an axial direction of the drum and spaced circumferentially around a curved outer surface (<NUM>) of the drum, the flutes being formed in the curved outer surface of the drum to receive axially-aligned components (<NUM>, <NUM>) of a tobacco industry product (<NUM>);
a roll hand (<NUM>) having a contact surface (<NUM>) facing and spaced from the outer surface of the drum (<NUM>) to define a space, between the contact surface and the outer surface (<NUM>), within which space components of a tobacco industry product are rollable across the outer surface upon rotation of the drum; and
a kicker bar (<NUM>) disposed adjacent to the roll hand (<NUM>) and having a contact edge (<NUM>) facing and spaced from the outer surface of the drum (<NUM>);
characterised in that the roll hand contact surface (<NUM>) and kicker bar contact edge (<NUM>) both include a groove (<NUM>, <NUM>) extending in a substantially circumferential direction of the drum (<NUM>) and configured to at least partially receive one or more of the tobacco industry product components as the drum rotates.