Abstract
An apparatus for manufacturing a component of an aerosol-generating article is provided, the apparatus including: a conveyor configured to convey a band of material through the apparatus along a first path; and a device disposed along the first path, the device including: one or more nozzles configured to apply additive to the band of material, when the band of material passes the device, and a device body including a contact surface configured to contact the conveyed band of material as the band of material passes the device, the contact surface having a convex profile as viewed in a direction of the first path at the device; and a funnel having a first open end configured to receive the band of material and a second open end providing an exit point for the band of material, the first open end being positioned downstream of the device.
Claims
1.-14. (canceled)
15. An apparatus for manufacturing a component of an aerosol-generating article, the apparatus comprising: a conveyor configured to convey a band of material through the apparatus along a first path; and a device disposed along the first path, the device comprising: one or more nozzles configured to apply additive to the band of material, when the band of material passes the device, and a device body comprising a contact surface configured to contact the conveyed band of material as the band of material passes the device, wherein the contact surface has a convex profile as viewed in a direction of the first path at the device; and a funnel having a first open end configured to receive the band of material and a second open end providing an exit point for the band of material, the first open end being positioned downstream of the device.
16. The apparatus according to claim 15, wherein each of the one or more nozzles has an outlet defined by the contact surface.
17. The apparatus according to claim 15, wherein the one or more nozzles are a plurality of nozzles having outlets distributed along the convex profile of the contact surface.
18. The apparatus according to claim 15, wherein the device body is in the form of an at least partial disc having a rim, and wherein the convex profile is defined by the rim of the at least partial disc.
19. The apparatus according to claim 15, wherein the device body further comprises a central element and a plurality of spaced apart walls radially extending outwardly from the central element and following one another in a circumferential direction around the central element, and wherein the contact surface comprises an end surface of each of the plurality of spaced apart walls.
20. The apparatus according to claim 15, wherein the device body has one or both of: a hole extending through the device body from a first end of the device body to a second end of the device body, and a recessed portion in the device body.
21. The apparatus according to claim 15, wherein the one or more nozzles are attached to an external portion of the device body.
22. The apparatus according to claim 15, wherein the contact surface also has a convex profile as viewed in a direction perpendicular a first axis of the body of the device.
23. The apparatus according to claim 15, wherein the device body further comprises a first part configured to be held in a fixed position in the apparatus, and a second part configured to be attachable to and removable from the first part.
24. The apparatus according to claim 15, further comprising a crimping device positioned upstream of the device, the crimping device being configured to crimp the band of material.
25. The apparatus according to claim 15, further comprising a second conveyor configured to convey a band of susceptor material through the apparatus.
26. The apparatus according to claim 15, wherein the device is a first device, and wherein the apparatus further comprises a second device configured to apply additive to the conveyed band of material.
27. The apparatus according to claim 26, wherein the first device is configured to apply additive to a first portion of the conveyed band of material, wherein the second device is further configured to apply additive to a second portion of the conveyed band of material, and wherein the first portion is different from the second portion.
28. A method of applying additive to a conveyed band of material in an apparatus for manufacturing a component of an aerosol-generating article, the method comprising: providing a device comprising one or more nozzles for applying additive to a band of material; providing a funnel having a first open end configured to receive the band of material and a second open end providing an exit point for the band of material, the first open end being positioned downstream of the device; conveying the band of material through the apparatus and past the device, such that the band of material comes into contact with a convex contact surface of the device; transferring additive from the one or more nozzles of the device to the band of material as the band of material is conveyed past the device; and conveying the band of material with the transferred additive through the first open end of the funnel and out of the second open end of the funnel.
Description
[0113] The invention will now be further described, by way of example only, with reference to the accompanying drawings in which:
[0114] FIG. 1 shows a perspective view of a device for use in an apparatus in accordance with a first embodiment of the invention;
[0115] FIG. 2 shows a schematic comparative illustration of the device of FIG. 1 and a device not in accordance with the invention;
[0116] FIG. 3 shows a schematic side view of an apparatus in accordance in accordance with a first embodiment of the invention;
[0117] FIG. 4 shows a schematic side view of an apparatus in accordance in accordance with a second embodiment of the invention;
[0118] FIG. 5 shows a perspective view of a device for use in an apparatus in accordance with a third embodiment of the invention;
[0119] FIG. 6 shows a perspective view of a device for use in an apparatus in accordance with a fourth embodiment of the invention;
[0120] FIG. 7 shows a side view of a second part of the device of FIG. 6;
[0121] FIG. 8 shows a cross-sectional view of the second part of the device of FIG. 6;
[0122] FIG. 9 shows a front perspective view of a device for use in an apparatus in accordance with a second embodiment of the invention;
[0123] FIG. 10 shows a rear perspective view of the device of FIG. 9;
[0124] FIG. 11 shows a front view of the device of FIG. 9; and
[0125] FIG. 12 shows a rear view of the device of FIG. 9.
[0126] FIG. 1 shows device 1 for use in an apparatus for manufacturing a component of an aerosol-generating article. In particular, as discussed in more detail below, the device is configured to contact a conveyed band of material in the apparatus and apply an additive to the conveyed band of material.
[0127] The device 1 comprises a device body 10, which is substantially disc shaped. The device body has a first side 11 configured to face in a downstream direction of the conveyed band of material in the apparatus. The device also has an opposed second side (not shown) configured to face in an upstream direction of the conveyed band of material in the apparatus. The device body 10 also comprises a contact surface 15 positioned between the first side 11 of the device body 10 and the second side of the device body 10. The contact surface extends around at least part of the rim of the disc shaped body 10. The contact surface 15 is configured to contact the conveyed band of material as the conveyed band of material passes the device 1 in the apparatus. Because the contact surface 15 is a rim of a substantially disc shaped body 10, the contact surface 15 forms a convex profile as viewed in the direction of conveyance of the band of material at the device, when the device is provided in the apparatus.
[0128] The contact surface 15 contains a plurality of holes, which form outlets 22 for a plurality of nozzles of the device 1. The plurality of nozzles are disposed within the device body 10 and not visible in FIG. 1. The nozzles are configured to eject an additive from the device body 10 through the outlets 22, so that the additive can be applied to the conveyed band of material when the band of material passes and comes into contact with the contact surface 15 of the device 1.
[0129] The device of FIG. 1 also has an additive inlet 24 for enabling additive to be pumped into the device body 10. Although not visible in FIG. 1, the additive may pass from the additive inlet 24 to the nozzles and then out of the outlets 22.
[0130] The device of FIG. 1 also has a hole 55 in the device body 10. The hole 55 extends through the device body 10 from the first side 11 of the device body 10 to the second side of the device body 10. As will be described in more detail below with reference to FIG. 3, the hole is included so that a band of susceptor material may pass through the device body 10 without interacting with the contact surface 15 or one or more nozzles of the device 1.
[0131] FIG. 2 shows a schematic comparative illustration of the device 1 of FIG. 1 and a device 200 not in accordance with the invention. The device 200 not in accordance with the invention is cube shaped and provides a flat contact surface 215 for engaging with the conveyed band of material. As illustrated in FIG. 2, the conveyed band of material is a crimped sheet of material 40. The crimped sheet has a plurality of substantially parallel ridges or corrugations, which extend in the direction of conveyance of the crimped sheet 40.
[0132] In the device 200 not in accordance with the invention, the crimped sheet 40 is unaffected by the flat contact surface 215 of the device. Consequently the ridges or corrugations of the crimped sheet 40 are reasonably pronounced. This results in portions of the crimped sheet being not readily available for receipt of additive from the nozzles 220 of the device 200.
[0133] In contrast, the convex contact surface 15 of device 1 in FIG. 2 imposes a reaction force on the crimped sheet 40 as the crimped sheet 40 comes into contact with the convex contact surface 15. This force acts to spread the crimped sheet 40 in a transverse direction around the device 1 as the crimped sheet 40 passes the device 1. This has the effect of reducing the severity of the crimping or corrugation in the crimped sheet 40 and thus helps to increase the surface area of the crimped sheet 40 which is readily available for additive application.
[0134] FIG. 3 shows a schematic side view of an apparatus 2 in accordance in accordance with a first embodiment of the invention. Arrows are used in FIG. 3 to indicate movement of components of the apparatus. The apparatus comprises the device 1 of FIG. 1. The apparatus 2 also comprises a sheet of crimped aerosol-forming substrate 40, which is conveyed through the apparatus 2 along a first path 42 by a first conveyor comprising a first rotating roller 54. The apparatus 2 also comprises a band of susceptor material 50, which is conveyed through the apparatus 2 along a second path 52 by a second conveyor comprising a second rotating roller 54. The apparatus also comprises a funnel 60 disposed downstream of the first device 1. The funnel 60 comprises an open upstream end 62 and an open downstream end 64, through which the sheet of crimped aerosol-forming substrate 40 and band of susceptor material 50 are fed. The open upstream end 62 is the larger end of the funnel 60, so that as the sheet of crimped aerosol-forming substrate 40 and band of susceptor material 50 are fed through the funnel 60 they are gathered into a rod 70, which is conveyed out of the funnel 60 and conveyed for downstream in the apparatus 2. The open upstream end 62 of the funnel 1 is positioned downstream of the first device 1, such that the entirety of the funnel 60 resides downstream of the device 1.
[0135] As shown in FIG. 3, when the sheet of crimped aerosol-forming substrate 40 passes the device 1 along the first path 42, the sheet of crimped aerosol-forming substrate 40 comes into contact with the contact surface 15 of the first device 1. Due to the shape and position of the first device 1 and its convex contact surface 15, the sheet of crimped aerosol-forming substrate 40 is pulled and spread over the convex contact surface 15 during such conveyance. This is indicated by the two dotted lines in FIG. 3 at the first device 1. Furthermore, when the sheet 40 is passing over and in contact with the contact surface 15, nozzles in the body of the device 1 apply additive to the surface of the sheet 40. Shortly thereafter, the shaped and additive containing crimped sheet of aerosol-forming substrate 40 is fed into the funnel 60 where it is gathered into a rod 70 in combination with the band of susceptor material 50.
[0136] Providing the device 1 having such a shape, position and orientation in the apparatus 2 has at least two notable effects on the function of the apparatus 2. Firstly, the device 1 shapes the sheet of crimped aerosol-forming substrate 40 into a form more suitable for receiving additive, by reducing the severity of the crimping of the sheet 40 when at the device 1. Secondly, the device 1 shapes the sheet of crimped aerosol-forming substrate 40 into a form more suitable for being received by the downstream funnel 60, by pre-shaping the sheet 40 into a convex curved profile. In doing so, the sheet 40 may be more suitable for being received into the funnel 60. This can reduce the likelihood of jamming occurring when the sheet 40 is fed into the funnel 60. Furthermore, by applying additive to the underside of the sheet 40 in the manner shown in FIG. 3, the additive is not on a surface of the sheet 40 which would come into direct contact with the inner surface of the funnel 60. This can reduce the likelihood of the funnel 60 impacting one or both of the amount or the location of the additive carried by the sheet 40. This can also reduce the likelihood of the additive impacting the performance of the funnel 60.
[0137] FIG. 4 shows a schematic side view of an apparatus 402 in accordance in accordance with a second embodiment of the invention. The apparatus 402 of FIG. 4 is similar to the apparatus 2 of FIG. 3 in that it also comprises the crimped sheet of aerosol-forming substrate band of susceptor material 50, gathered rod 70, funnel 60, device 1, first roller 44 and second roller 54. However, in the apparatus 402 of FIG. 4 the device 1 is a first device 1, and the apparatus 402 further includes a second device 401. The apparatus 402 of FIG. 4 also further comprises a first pump 91 for supplying additive to the first device 1, and a second pump 92 for supplying additive to the second device 401.
[0138] The second device 401 is positioned upstream of the first device 1. The second device 401 comprises a contact surface 415, which contacts the crimped sheet 40 as the crimped sheet passes the second device 415. The contact surface 415 of the second device 401 has a convex profile as viewed in the direction of the first path 42 at the second device 415. Consequently, when the crimped sheet 40 is conveyed past the second device 401, the crimped sheet 40 is spread in a curved shape around the second device 401. Although not shown in the schematic illustration of FIG. 4, the second device 401 also comprises a plurality of nozzles, which apply additive to the crimped sheet 40 as the crimped sheet 40 passes the second device 401. The additive applied by the second device 401 may be a different type of additive to that which is applied by the first device 1. Alternatively or additionally, the additive applied by the second device 401 may be applied to a different portion or portions of the crimped sheet 40 to the portion or portions on which additive from the first device 1 is applied.
[0139] FIG. 5 shows a perspective view of a device 501 for use in an apparatus in accordance with a third embodiment of the invention. The device 501 is similar to the device 1 of FIG. 1 in that it has a device body 510 which is generally disc shaped. However, in FIG. 5, the device body 510 only forms the shape of a partial disc. That is, the curved rim of the device body 510 does not extend around the entire periphery of the disc. Furthermore, the device body 510 does not comprise a hole 55 extending therethrough for the passage of a band of susceptor material. Instead, the device body comprises a recessed portion 555, which is spaced away from the contact surface 15 and nozzle outlets 22 of the device body 510. When the device 501 is placed in an apparatus, such as the apparatus of FIG. 3 or 4, the recessed portion 555 may enable a band of susceptor material to pass the device 501 without interacting with the contact surface 15 or one or more nozzles of the device 501.
[0140] FIG. 6 shows a perspective view of a device 601 for use in an apparatus in accordance with a fourth embodiment of the invention. The device 601 of FIG. 6 is similar to the device 501 of FIG. 5 in that it has a device body 610 which is partially disc shaped. However, in FIG. 6, the device body 610 is formed of two parts. In particular, the device body 610 comprises a first part 611 configured to be held in a fixed position in the apparatus, and a second part 612 configured to be removable from and attachable to the first part 611. The second part 612 may be interchange with other second parts. This may allow for simple modification of one or more properties of the device 601. The second part 612 comprises the contact surface 15 of the device 601 and a groove 16 extending along the curvature of the rim 17 of the device body 610. Disposed within the groove 16 are the outlets of the plurality of nozzles of the device (not visible in FIG. 6). The groove 16 is delimited by the contact surface 15.
[0141] FIG. 7 shows a side view of the second part 612 of the device of FIG. 6 in partial cross-section. FIG. 8 shows a cross-sectional view of the second part 612 of the device of FIG. 6. As can be seen from FIGS. 7 and 8, the second part 612 of the device body 610 comprises a plurality of recesses 613 for receiving complementary attachment pins from the first part 611 of the device body 610. These provide an attachment mechanism for allowing the second part 612 to be attachable to and removable from the first part 611. The second part 612 also comprises an internal additive chamber 626 for housing the additive with the plurality of nozzles 620 being in fluid communication with the additive chamber 626. The plurality of nozzles 620 are evenly spaced along the rim 17 of the second part 612, with the outlet 622 of each nozzle being disposed in the base of a groove 16, which also extends along the rim 17 of the second part 612.
[0142] As best seen from FIG. 7, the rim 17 of the second part 612 of the device body is rounded. In particular, the rim curves when moving in a direction from the first side 11 of the device body 610 to the second side 612 of the device body 610. This results in the contact surface also having a convex profile as viewed in a direction perpendicular the direction of direction of the first path at the device, namely the view shown in FIG. 7.
[0143] FIG. 9 shows a front perspective view of a device 900 for use in an apparatus in accordance with a second embodiment of the invention. The device 900 of FIG. 9 may be used in one or both of the apparatus of FIG. 3 and the apparatus of FIG. 4 instead of or in addition to devices 1 and 401.
[0144] As shown in FIG. 9, the device 900 comprises a device body comprising central element 982 and a plurality of spaced apart walls 984 radially extending outwardly from the central element 982 and following one another in a circumferential direction around the central element 982. In this embodiment, the contact surface 915 comprises an end surface of each of the plurality of spaced apart walls 984, with the outlets 922 being disposed on the end surfaces of each wall 984. The convex profile of the contact surface 915 is therefore defined by the manner in which the end surfaces of the plurality of spaced apart walls 984 are distributed around the central element 982 of the device body. Consequently, in the embodiment of FIG. 9, the contact surface 915 is formed by a plurality of surfaces rather than a single surface. In such an embodiment, as the band of material reaches the device, the band of material passes into contact with the end surface of at least some of the spaced apart walls. Since these end surfaces are distributed in a convex profile around the central element, the band of material may therefore be subjected to similar forces as would be produced if the band of material were passed over a single continuous convex surface. That is, the spaced apart walls 984, and in particular their end surfaces 915, can help to stretch or otherwise spread the band of material in a curved shaped around the device 900 as the band of material passes the device 900.
[0145] By providing a plurality of spaced apart walls 984 radially extending outwardly from the central element 982, an empty space is formed between two adjacent spaced-apart walls 984.
[0146] In FIG. 9, the central element 982 is substantially cylindrical shaped. A longitudinal axis of the central element 982 is arranged to extend in substantially the same direction as the first path of the band of material at the device 900. The longitudinal axis of the central element 982 is therefore substantially aligned with the direction of the first path of the band of material at the device 900.
[0147] FIG. 9 depicts a front perspective view of the device 900 and thus shows the front or downstream end face 911 of the device 900. FIG. 10 depicts a rear perspective view of the device 900 and thus shows the rear or upstream end face 914 of the device 900. A hole 955 is also provided in the central element 982. The hole 955 extends through the central element 982 from the downstream end face 911 of the central element 982 to the upstream end face 914 of the device body 10. These features can also be appreciated from FIGS. 11 and 12 which respectively depict a front view and a rear view of the device 900.
[0148] For ease of viewing not all of the walls in FIGS. 9 to 12 have been labelled with reference numeral 984. Similarly, not all of the end surfaces of these walls have been labelled with reference numeral 915. It will be appreciated that the contact surface 915 may be formed by any combination of the walls 984 of the device 900, provided they form a convex profile as viewed in the direction of the first path at the device 900.
