Method and apparatus for assembling smoking articles or aerosol generating articles

Abstract

A method of assembling smoking articles or aerosol generating articles, comprises: providing a plurality of rods; arranging the rods in rod groups and conveying in sequence said rod groups along a conveying direction; positioning the rods of each rod group in a staggered configuration in which the rods of each rod group are transverse to the conveying direction, placed one after the other along the conveying direction and staggered one with respect to another of an axial offset at least half a length of each rod; cutting each rod of each rod group in two halves through a respective knife.

Description

[0001] The present disclosure relates to a method and an apparatus for assembling smoking articles or aerosol generating articles.

[0002] The smoking articles herein referred to include traditional burning cigarettes in which a sensorial medium is combusted or heated to provide flavour to the user. A traditional burning cigarette is a narrow cylinder containing a combustible material, typically tobacco such as a mixture of tobacco cut filler, that is rolled into paper for smoking. The cigarette is ignited at one end, causing it to smoulder, and the resulting smoke is inhaled via the opposite end. The cigarette may be provided with a filter attached to the rolled combustible material.

[0003] An aerosol-generating article or heat-not-burn product comprises an aerosol-generating substrate that is heated rather than combusted. The aerosol-generating substrate is, for instance, a tobacco-free herbaceous or plant-based cast sheet or a biodegradable fibre-based material. Typically, in such heated aerosol-generating articles, an aerosol is generated by the transfer of heat from a heat source to a physically separate aerosol-generating substrate or material, which may be located in contact with, within, around or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are entrained in air drawn through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol.

[0004] Document EP3457872B1 discloses a method for assembling a tobacco industry product (smoking article) in which an endless rod is cut in a plurality of four length rods, wherein a four-length rod is made of four single length rods each destined to be part of a single smoking article. Each four-length rod is cut into first and second double-length rods. The first and second double-length rods are moved from a first configuration, in which they are axially aligned, to a second configuration, in which the first and second double-length rods are out of axial alignment and the axes of the first and second double-length rods are parallel and spaced apart and remote ends of the first and second double-length rods are substantially aligned with each other. The first and second double-length rods are cut into single-length rods through a knife. Then one further component is joined to the single-length rods so as to form a tobacco industry product assembly. The tobacco industry product assembly is cut at a mid-point of the further component through a knife so as to form two single tobacco industry products.

[0005] It would be particularly desirable to have a method and an apparatus which allow to mitigate wear of the knives which are employed to cut the rods through different steps of the process.

[0006] It would be also desirable to have a method and an apparatus for assembling smoking articles or aerosol generating articles capable of reducing the amount of machine downtime which is required to replace or service the knives.

[0007] It would be also desirable to have a method and an apparatus which allow to achieve the above stated goals while preserving as much as possible the benefit of using less knives.

[0008] It would be also desirable to have a method and an apparatus for assembling smoking articles or aerosol generating articles which allow to improve the quality of said smoking or aerosol generating articles without compromising the manufacturing rate of these articles.

[0009] The present disclosure relates to a method of assembling smoking articles or aerosol generating articles. The method comprises: providing a plurality of rods, arranging the rods in rod groups and conveying in sequence said rod groups along a conveying direction. The method further comprises: positioning the rods of each rod group in a staggered configuration in which said rods of each rod group are transverse to the conveying direction, placed one after the other along said conveying direction and staggered one with respect to another of an axial offset at least half a length of each rod. The rods of each rod group may be perpendicular to the conveying direction. The method may also further comprise: cutting each rod of each rod group in two halves through a respective knife.

[0010] The present disclosure relates to a method of assembling smoking articles or aerosol generating articles. The method is carried out through an apparatus for assembling smoking articles or aerosol generating articles. The apparatus comprises: a groups conveyor configured to convey rod groups in sequence. The apparatus further comprises: a positioning device arranged downstream of the groups conveyor and configured to position the rods of each rod group in a staggered configuration in which said rods of each rod group are transverse to a conveying direction, placed one after the other along said conveying direction and staggered one with respect to another of an axial offset at least half a length of each rod. Said rods of each rod group may be perpendicular to the conveying direction. The apparatus may also comprise a cutting device arranged downstream of the positioning device and comprising a plurality of knives, the cutting device being configured to cut each rod of each rod group in two halves through a respective knife of said plurality of knives.

[0011] The present disclosure relates to an apparatus for assembling smoking articles or aerosol generating articles. The apparatus is configured to carry out a method of assembling smoking articles or aerosol generating articles. The method comprises: providing a plurality of rods, arranging the rods in rod groups and conveying in sequence said rod groups along a conveying direction. The method further comprises: positioning the rods of each rod group in a staggered configuration in which said rods of each rod group are transverse to the conveying direction, placed one after the other along said conveying direction and staggered one with respect to another of an axial offset at least half a length of each rod. The rods of each rod group may be perpendicular to the conveying direction. The method may also further comprise: cutting each rod of each rod group in two halves through a respective knife. The apparatus may also comprise a cutting device arranged downstream of the positioning device and comprising a plurality of knives, the cutting device being configured to cut each rod of each rod group in two halves through a respective knife of said plurality of knives.

[0012] The present disclosure relates to an apparatus for assembling smoking articles or aerosol generating articles. The apparatus comprises: a groups conveyor configured to convey rod groups in sequence. The apparatus further comprises: a positioning device arranged downstream of the groups conveyor and configured to position the rods of each rod group in a staggered configuration in which said rods of each rod group are transverse to a conveying direction, placed one after the other along said conveying direction and staggered one with respect to another of an axial offset at least half a length of each rod. Said rods of each rod group may be perpendicular to the conveying direction. The apparatus may also comprise a cutting device arranged downstream of the positioning device and comprising a plurality of knives, the cutting device being configured to cut each rod of each rod group in two halves through a respective knife of said plurality of knives.

[0013] The present disclosure relates to an aerosol generating article assembled through said method of assembling smoking articles or aerosol generating articles and / or by said apparatus for assembling smoking articles or aerosol generating articles.

[0014] The present disclosure relates to a smoking article or to an aerosol generating article or to a rod assembly assembled through said method of assembling smoking articles or aerosol generating articles and / or by said apparatus for assembling smoking articles or aerosol generating articles. The rod assembly is a rod shaped semi-finished product intended for making the smoking articles or the aerosol generating articles.

[0015] The inventor found that the disclosed method and apparatus allow to reduce wear and tear of the knives since the cutting is shared among two or more knives instead of being performed by one knife only as disclosed in prior art document EP3457872B1. Indeed, according to EP3457872B1, remote ends of the first and second double-length rods are aligned with each other and the first and second double-length rods are cut in two to form single-length rods through a single knife. Differently, according to the disclosed method and apparatus, due to the staggered configuration of the rods of each rod group, the cutting is carried out by more than one knife and thus the wear is shared among a plurality of knives.

[0016] The inventor found that the machine downtime is reduced because each knife is subjected to reduced wear.

[0017] The inventor found that, due to the potential reduction of wear of each knife, the disclosed apparatus and method allow to cut abrasive materials, as the material of the filters.

[0018] The inventor found that the staggered configuration allows to place the knives closer to each other than knives used to cut axially aligned rods and this allows for small footprint of dedicated devices and conveyors.

[0019] The inventor also found that the staggered configuration according to the disclosure may be implemented in different steps of assembling smoking articles or aerosol generating articles.

[0020] According to embodiments, providing the plurality of rods comprises: manufacturing an endless rod and cutting said endless rod in the plurality of rods.

[0021] According to embodiments, each rod group comprises N rods and the rods of each rod group are cut through N knives. N may be two or three.

[0022] The inventor also found that two or three knives are a very good compromise between wear reduction, high production rate and small footprint.

[0023] According to embodiments, the rods of each rod group are offset all in a same versus. According to embodiments, the axial offsets in one rod group or in all the rod groups are the same. According to embodiments, the axial offset is equal to half the length of each rod. According to embodiments, the axial offset is equal to half the length of each rod plus a tolerance gap. The tolerance gap may be greater than 1 mm, optionally from 1 mm to 3 mm, optionally greater than 3 mm.

[0024] The inventor found that the tolerance gap avoids interference of the knives with terminal ends of adjacent rods.

[0025] According to embodiments, arranging the rods in rod groups comprises: arranging the rods of each rod group axially aligned one to the other and transverse to the conveying direction. Said rods of each rod group may be perpendicular to the conveying direction. Positioning the rods of each rod group comprises: moving the rods of each rod group to the staggered configuration. Moving the rods of each rod group to the staggered configuration may comprise: rotating at least one of the rods of each rod group about a pivot axis. A rotation angle of at least one of the rods of each rod group about the pivot axis may be 180°.

[0026] According to embodiments, arranging the rods in rod groups comprises: arranging the rods of each rod group one after the other along the conveying direction and transverse to the conveying direction, wherein terminal ends of the rods of each rod group are aligned along said conveying direction. Said rods of each rod group may be perpendicular to the conveying direction. Positioning the rods of each rod group comprises: moving the rods of each rod group to the staggered configuration. Moving the rods of each rod group to the staggered configuration may comprise: translating at least one of the rods of each rod group along an axial direction.

[0027] According to embodiments, the positioning device comprises: a positioning conveyor having seat groups for the rod groups moving along the conveying direction. According to embodiments, each seat group comprises N seats and the plurality of knives comprises N knives. N may be two or three.

[0028] The positioning device may also comprise a displacement device part of the positioning conveyor or operatively active on the positioning conveyor and configured to move the seats of each seat group with the rods of each rod group to the staggered configuration through a rotation or a through translation of at least one of said seats. In the staggered configuration the seats of each seat group may be offset all in a same versus. According to embodiments, the positioning conveyor is a positioning drum and the seat groups are placed on a circumferential conveyance surface of the positioning drum.

[0029] According to embodiments, the displacement device comprises a turning mechanism configured to rotate at least one of said seats of each seat group to the staggered configuration. The turning mechanism is configured to move the seats of each seat group from an aligned configuration, in which the seats of each seat group are axially aligned one to the other and transverse to the conveying direction, to said staggered configuration. Said seats of each seat group may be perpendicular to the conveying direction.

[0030] According to embodiments, the displacement device comprises moving sectors configured to translate at least one of said seats of each seat group to the staggered configuration. The moving sectors are configured to move the seats of each seat group from a sequential configuration, in which the seats of each seat group are placed one after the other along the conveying direction and transverse to the conveying direction with terminal ends of the seats of each seat group aligned along said conveying direction, to said staggered configuration. Said seats of each seat group are perpendicular to the conveying direction.

[0031] The inventor found that, depending on the initial arrangement of the rods in the rod groups, rotation or translation may be adopted.

[0032] According to embodiments, the cutting device comprises: a cutting conveyor having seats for the rods of each group arranged in the staggered configuration. The knives may be operatively coupled to the seats. The knives may be staggered from each other transverse to the conveying direction. According to embodiments, the cutting conveyor is a cutting drum. The seats are placed on a circumferential conveyance surface of the cutting drum. The knives are operatively coupled to the circumferential conveyance surface of the cutting drum. The cut of each rod may be carried out while advancing the rod group along the conveying direction.

[0033] According to embodiments, the two halves of each rod are then axially spaced from each other. The two halves of each rod are axially spaced to delimit a void therebetween. According to embodiments, a separating device is operatively placed downstream of the cutting device and configured to axially space the two halves of each rod from each other.

[0034] According to embodiments, the separating device comprises a separating conveyor provided with a plurality of seats, each seat extending along a respective axis, the axes of the seats being parallel to each other. Each seat may be sized to accommodate the two halves of each rod. The separating conveyor may comprise sections axially movable to space the two halves of each rod from each other. According to embodiments, the separating device is a separating drum.

[0035] According to embodiments, a double length second rod is inserted between the two halves. According to embodiments, the double length second rod is joined to the two halves to form a double length rod assembly. The double length second rod may be cut in two so as to form two single length rod assemblies. The rod assembly may be a rod shaped semi-finished product intended for making smoking articles or aerosol generating articles.

[0036] According to embodiments, each smoking article or aerosol generating article comprises a first rod of single length, a second rod of single length and a tipping paper applied around and joining together the first rod and the second rod. Each rod of the plurality of rods may be a M-length first rod or a M-length second rod, where M is even. M may be equal to 2, 4, 6 or 8.

[0037] According to embodiments, M = 2 and the half of each rod is a first rod of single length. According to embodiments, after axially spacing, the method further comprises: inserting a double length second rod between the two first rods of single length; wrapping a double length tipping paper around the double length second rod and at least partially around the two first rods of single length to form a double-length smoking article or a double-length aerosol generating article; cutting the double length second rod in two so as to form two smoking articles or two aerosol generating articles. The first rod of single length may comprise a plurality of different plugs wrapped in a wrapping paper. One of the plugs may comprise an aerosol generating substrate. The different plugs in each first rod of single length may be ordered according to a sequence. The M-length first rod may be formed by M first rods of single length in which one first rod of single length may be oriented according to the sequence and may be followed and / or preceded by another first rod of single length oriented according to a mirrored sequence.

[0038] According to embodiments, each smoking article or aerosol generating article comprises a first rod of single length, a second rod of single length and a tipping paper applied around and joining together the first rod and the second rod. Each rod of the plurality of rods is a M-length smoking article or a M-length aerosol generating article, where M is even. M may be equal to 2, 4, 6 or 8.

[0039] According to embodiments, M = 2 and the half of each rod is a smoking article or an aerosol generating article. According to embodiments, the method further comprises: cutting the double length second rod in two so as to form two smoking articles or two aerosol generating articles.

[0040] According to embodiments, an inserting device is operatively placed downstream of the separating device and is configured to insert a double length second rod between the two halves. According to embodiments, the inserting device comprises: an inserting conveyor provided with a plurality of seats, each seat extending along a respective axis, the axes of the seats being parallel to each other. Each seat may be sized to accommodate the two spaced halves of each rod. The inserting device may also comprise a double length second rods conveyor operatively coupled to the inserting conveyor and configured to feed double length second rods to the inserting conveyor. The inserting conveyor may be an inserting drum. The double length second rods conveyor may be a double length second rods drum.

[0041] According to embodiments, an application device is placed downstream of the inserting device and is configured to attach an extremity of a double length tipping paper on a side of each double length second rod and of the two spaced halves.

[0042] According to embodiments, the application device comprises: an application conveyor provided with a plurality of seats, each seat extending along a respective axis, the axes of the seats being parallel to each other. Each seat may be sized to accommodate one double length second rod placed between the two spaced halves. The application device may also comprise a double length tipping papers conveyor operatively coupled to the application conveyor and configured to feed double length tipping papers to the application conveyor. The application conveyor may be an application drum. The double length tipping papers conveyor may be a double length tipping papers drum.

[0043] According to embodiments, a wrapping device is operatively placed downstream of the application device and is configured to wrap each double length tipping paper around one double length second rod and at least partially around the respective two spaced halves.

[0044] According to embodiments, the wrapping device comprises: a wrapping conveyor provided with a plurality of seats, each seat extending along a respective axis and the axes of the seats being parallel to each other. Each seat may be sized to accommodate one double length second rod between the respective two spaced halves and provided with the double length tipping paper. A steady element having a steady surface may be arranged close to the wrapping conveyor so that the double length second rod between the respective two spaced halves and provided with the double length tipping paper carried by the wrapping conveyor roll against the steady surface. The wrapping conveyor may be a wrapping drum rotating about an own main axis. A circumferential conveyance surface of the wrapping drum may face the steady surface.

[0045] As used in the present description, the term "single length" is referred to the length of a respective element (e.g. first rod, second rod, tipping paper) in one single final smoking article or aerosol generating article. Therefore, "double length" and "N-length" means an element having an overall length that is, respectively, two times or N-times its length in the single final smoking article or aerosol generating article.

[0046] As used in the present description, the "first rod" is a semi-finished product that may be a combined rod made of one or more plugs or segments.

[0047] As used in the present description, the "second rod" is a semi-finished product that may be a combined rod made of one or more plugs or segments and that is different from the "first rod".

[0048] As used in the present description, the "tipping paper" is a paper used to join the "first rod" to the "second rod", that encircles the "first rod" and the "second rod" and that may extend partially or totally along a length of the "first rod" and of the "second rod".

[0049] As used in the present description, the term "transverse" referred to a rod or a seat and the conveying direction means that the rod or the seat and the conveying direction delimit an angle other than 0° between them, optionally and angle of 90° + / - 10°, optionally of 90°.

[0050] The invention is defined in the claims. However, below there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0051] EX1. A method of assembling smoking articles or aerosol generating articles, comprising: providing a plurality of rods; arranging the rods in rod groups and conveying in sequence said rod groups along a conveying direction; positioning the rods of each rod group in a staggered configuration in which said rods of each rod group are transverse to the conveying direction, placed one after the other along said conveying direction and staggered one with respect to another of an axial offset at least half a length of each rod; optionally said rods of each rod group are perpendicular to the conveying direction; cutting each rod of each rod group in two halves through a respective knife.

[0052] EX2. The method according to EX1, wherein the rods of each rod group are offset all in a same versus.

[0053] EX3. The method according to EX1 or EX2, wherein the axial offsets in one rod group or in all the rod groups are the same.

[0054] EX4. The method according to any of EX1 to EX3, wherein each rod group comprises N rods and the rods of each rod group are cut through N knives.

[0055] EX5. The method according to EX4, wherein N is two or three.

[0056] EX6. The method according to any of EX1 to EX5, wherein the axial offset is equal to half the length of each rod.

[0057] EX7. The method according to any of EX1 to EX5, wherein the axial offset is equal to half the length of each rod plus a tolerance gap.

[0058] EX8. The method according to EX7, wherein the tolerance gap greater than 1 mm, optionally from 1 mm to 3 mm, optionally greater than 3 mm.

[0059] EX9. The method according to any of EX1 to EX8, wherein cutting each rod is caried out while advancing the rod group along the conveying direction.

[0060] EX10. The method according to any of EX1 to EX9, wherein arranging the rods in rod groups comprises: arranging the rods of each rod group axially aligned one to the other and transverse to the conveying direction; wherein positioning the rods of each rod group comprises: moving the rods of each rod group to the staggered configuration; wherein optionally said rods of each rod group are perpendicular to the conveying direction.

[0061] EX11. The method according to EX10, wherein moving the rods of each rod group to the staggered configuration comprises: rotating at least one of the rods of each rod group about a pivot axis.

[0062] EX12. The method according to EX11, wherein a rotation angle of at least one of the rods of each rod group about the pivot axis is 180°.

[0063] EX13. The method according to any of EX1 to EX9, wherein arranging the rods in rod groups comprises: arranging the rods of each rod group one after the other along the conveying direction and transverse to the conveying direction, wherein terminal ends of the rods of each rod group are aligned along said conveying direction; wherein positioning the rods of each rod group comprises: moving the rods of each rod group to the staggered configuration; wherein optionally said rods of each rod group are perpendicular to the conveying direction.

[0064] EX14. The method according to EX13, wherein moving the rods of each rod group to the staggered configuration comprises: translating at least one of the rods of each rod group along an axial direction.

[0065] EX15. The method according to any of EX1 to EX14, further comprising: axially spacing the two halves of each rod from each other.

[0066] EX16. The method according to EX15, wherein the two halves of each rod are axially spaced to delimit a void therebetween.

[0067] EX17. The method according to EX15 or EX16, comprising: inserting a double length second rod between the two halves.

[0068] EX18. The method according to EX17, comprising: joining the double length second rod to the two halves to form a double length rod assembly, the rod assembly being a rod shaped semi-finished product intended for making smoking articles or aerosol generating articles.

[0069] EX19. The method according to EX18, comprising: cutting the double length second rod in two so as to form two single length rod assemblies.

[0070] EX20. The method according to any of EX1 to EX16, wherein each smoking article or aerosol generating article comprises a first rod of single length, a second rod of single length and a tipping paper applied around and joining together the first rod and the second rod; wherein each rod of the plurality of rods is a M-length first rod or a M-length second rod, where M is even; wherein optionally M = 2, 4, 6 or 8.

[0071] EX21. The method according to EX20 when according to EX15 or EX16, wherein M = 2 and the half of each rod is a first rod of single length.

[0072] EX22. The method according to EX21, wherein, after axially spacing, the method further comprises: inserting a double length second rod between the two first rods of single length; wrapping a double length tipping paper around the double length second rod and at least partially around the two first rods of single length to form a double-length smoking article or a double-length aerosol generating article; cutting the double length second rod in two so as to form two smoking articles or two aerosol generating articles.

[0073] EX23. The method according to any of EX20 to EX22, wherein the first rod of single length comprises a plurality of different plugs wrapped in a wrapping paper, wherein one of the plugs comprises an aerosol generating substrate.

[0074] EX24. The method according to EX23, wherein the different plugs in each first rod of single length are ordered according to a sequence and wherein the M-length first rod is formed by M first rods of single length in which one first rod of single length is oriented according to the sequence and is followed and / or preceded by another first rod of single length oriented according to a mirrored sequence.

[0075] EX25. The method according to any of EX1 to EX16, wherein each smoking article or aerosol generating article comprises a first rod of single length, a second rod of single length and a tipping paper applied around and joining together the first rod and the second rod; wherein each rod of the plurality of rods is a M-length smoking article or a M-length aerosol generating article, where M is even; wherein optionally M = 2, 4, 6 or 8.

[0076] EX26. The method according to EX25 when according to EX15 or EX16, wherein M = 2 and the half of each rod is a smoking article or an aerosol generating article; wherein the method further comprises: cutting the double length second rod in two so as to form two smoking articles or two aerosol generating articles.

[0077] EX27. The method according to any of EX1 to EX26, wherein providing the plurality of rods comprises: manufacturing an endless rod and cutting said endless rod in the plurality of rods.

[0078] EX28. An apparatus for assembling smoking articles or aerosol generating articles.

[0079] EX29. The apparatus according to EX28, wherein said apparatus is configured to carry out the method according to any of EX1 to EX27.

[0080] EX30. The apparatus according to EX28 or EX29, comprising: a groups conveyor configured to convey rod groups in sequence; a positioning device arranged downstream of the groups conveyor and configured to position the rods of each rod group in a staggered configuration in which said rods of each rod group are transverse to a conveying direction, placed one after the other along said conveying direction and staggered one with respect to another of an axial offset at least half a length of each rod; wherein optionally said rods of each rod group are perpendicular to the conveying direction; a cutting device arranged downstream of the positioning device and comprising a plurality of knives, the cutting device being configured to cut each rod of each rod group in two halves through a respective knife of said plurality of knives.

[0081] EX31. The apparatus according to EX30, wherein the positioning device comprises: a positioning conveyor having seat groups for the rod groups moving along the conveying direction; a displacement device part of the positioning conveyor or operatively active on the positioning conveyor and configured to move the seats of each seat group with the rods of each rod group to the staggered configuration through a rotation or a through translation of at least one of said seats.

[0082] EX32. The apparatus according to EX31, wherein in the staggered configuration the seats of each seat group are offset all in a same versus.

[0083] EX33. The apparatus according to EX31 or EX32, wherein each seat group comprises N seats and the plurality of knives comprises N knives; optionally N being two or three.

[0084] EX34. The apparatus according to any of EX31 to EX33, wherein the positioning conveyor is a positioning drum and the seat groups are placed on a circumferential conveyance surface of the positioning drum.

[0085] EX35. The apparatus according to any of EX31 to EX34, wherein the displacement device comprises a turning mechanism configured to rotate at least one of said seats of each seat group to the staggered configuration.

[0086] EX36. The apparatus according to EX35, wherein the turning mechanism is configured to move the seats of each seat group from an aligned configuration, in which the seats of each seat group are axially aligned one to the other and transverse to the conveying direction, to said staggered configuration; wherein optionally said seats of each seat group are perpendicular to the conveying direction.

[0087] EX37. The apparatus according to any of EX31 to EX34, wherein the displacement device comprises moving sectors configured to translate at least one of said seats of each seat group to the staggered configuration.

[0088] EX38. The apparatus according to EX37, wherein the moving sectors are configured to move the seats of each seat group from a sequential configuration, in which the seats of each seat group are placed one after the other along the conveying direction and transverse to the conveying direction with terminal ends of the seats of each seat group aligned along said conveying direction, to said staggered configuration; wherein optionally said seats of each seat group are perpendicular to the conveying direction.

[0089] EX39. The apparatus according to any of EX28 to EX38, wherein the cutting device comprises: a cutting conveyor having seats for the rods of each group arranged in the staggered configuration; wherein the knives are operatively coupled to the seats.

[0090] EX40. The apparatus according to EX39, wherein the knives are staggered from each other transverse to the conveying direction.

[0091] EX41. The apparatus according to EX39 or EX40, wherein the cutting conveyor is a cutting drum, the seats are placed on a circumferential conveyance surface of the cutting drum and the knives are operatively coupled to the circumferential conveyance surface of the cutting drum.

[0092] EX42. The apparatus according to any of EX28 to EX41, comprising a separating device operatively placed downstream of the cutting device and configured to axially space the two halves of each rod from each other.

[0093] EX43. The apparatus according to EX42, wherein the separating device comprises a separating conveyor provided with a plurality of seats, each seat extending along a respective axis, the axes of the seats being parallel to each other, each seat being sized to accommodate the two halves of each rod; the separating conveyor comprising sections axially movable to space the two halves of each rod from each other.

[0094] EX44. The apparatus according to EX43, wherein the separating device is a separating drum.

[0095] EX45. The apparatus according to any of EX42 to EX44, comprising an inserting device operatively placed downstream of the separating device and configured to insert a double length second rod between the two halves.

[0096] EX46. The apparatus according to EX45, wherein the inserting device comprises: an inserting conveyor provided with a plurality of seats, each seat extending along a respective axis, the axes of the seats being parallel to each other; each seat being sized to accommodate the two spaced halves of each rod; a double length second rods conveyor operatively coupled to the inserting conveyor and configured to feed double length second rods to the inserting conveyor.

[0097] EX47. The apparatus according to EX46, wherein the inserting conveyor is an inserting drum and the double length second rods conveyor is a double length second rods drum.

[0098] EX48. The apparatus according to any of EX45 to EX47, comprising an application device placed downstream of the inserting device and configured to attach an extremity of a double length tipping paper on a side of each double length second rod and of the two spaced halves.

[0099] EX49. The apparatus according to EX48, wherein the application device comprises: an application conveyor provided with a plurality of seats, each seat extending along a respective axis, the axes of the seats being parallel to each other; each seat being sized to accommodate one double length second rod placed between the two spaced halves; a double length tipping papers conveyor operatively coupled to the application conveyor and configured to feed double length tipping papers to the application conveyor.

[0100] EX50. The apparatus according to EX49, wherein the application conveyor is an application drum and the double length tipping papers conveyor is a double length tipping papers drum.

[0101] EX51. The apparatus according to any of EX48 to EX50, comprising a wrapping device operatively placed downstream of the application device and configured to wrap each double length tipping paper around one double length second rod and at least partially around the respective two spaced halves.

[0102] EX52. The apparatus according to EX51, wherein the wrapping device comprises: a wrapping conveyor provided with a plurality of seats, each seat extending along a respective axis and the axes of the seats being parallel to each other, each seat being sized to accommodate one double length second rod between the respective two spaced halves and provided with the double length tipping paper; a steady element having a steady surface and arranged close to the wrapping conveyor so that the double length second rod between the respective two spaced halves and provided with the double length tipping paper carried by the wrapping conveyor roll against the steady surface.

[0103] EX53. The apparatus according to EX52, wherein the wrapping conveyor is a wrapping drum rotating about an own main axis, wherein a circumferential conveyance surface of the wrapping drum faces the steady surface.

[0104] EX54. A smoking article or an aerosol generating article or a rod assembly assembled through the method according to any of EX1 to EX27 and / or by the apparatus according to any of EX28 to EX53, wherein the rod assembly is a rod shaped semi-finished product intended for making smoking articles or aerosol generating articles.

[0105] Examples will now be further described with reference to the figures in which: Figure 1 shows an exploded view of an aerosol generating article; Figure 2 shows a longitudinal cross section of the aerosol generating article of figure 1; Figure 3 is a schematic representation of the aerosol generating article of figures 1 and 2; Figure 4 shows a combiner part of an apparatus for making aerosol generating articles; Figure 5 is a cross section of a continuous rod made through the combiner of figure 4; Figures 6 to 19 show subsequent steps of a method of assembling smoking articles or aerosol generating articles; Figures 20 to 23 show devices configured to carry out some of the steps of figures 6 to 19; Figures 24 to 34 show subsequent steps of a variant method of assembling smoking articles or aerosol generating articles; Figure 35 is a flowchart representing the method of assembling smoking articles or aerosol generating articles.

[0106] One example of aerosol-generating article 1 is depicted in the exploded view of Figure 1 and comprises (from left to right in Figure 1): an aerosol-generating plug 2, a tubular plug 3 (hollow plug, for instance of cellulose acetate), a cooler plug 4 (for instance of poly lactic acid) and a filter plug 5 (mouthpiece filter usually made of filter material like tow). Each plug has a wrapping of its own (not detailed Figure 1) helping to contain properly their content. The aerosol-generating plug 2, a tubular plug 3 and a cooler plug 4 are wrapped in a wrapping paper 6 to form a first rod (A) of single length. The filter plug 5 in this example is made of a single element forming a second rod (B) of single length. A tipping paper (C) encircles and connects together the first rod (A) of single length and the second rod (B) of single length.

[0107] The aerosol-generating plug 2 comprises, for instance, an aerosol-generating substrate made of a sheet of material gathered in a continuous rod shape and wrapped in a wrapper. The material of the aerosol-generating substrate may comprise reconstituted tobacco or tobacco-free herbaceous or plant-based material or a biodegradable fibre-based material.

[0108] In figure 3, the first rod (A) of single length, the second rod (B) of single length and the tipping paper (C) are schematically represented and the tipping paper (C) is shown as a flat element not yet wrapped for better clarification. The first rod (A) of single length, the second rod (B) of single length and the tipping paper (C) may also be part of a traditional smoking article, in which the first rod (A) is made of tobacco or reconstituted tobacco wrapped in a paper and the second rod (B) is a filter.

[0109] The aerosol-generating articles 1 are manufactured by an apparatus for making aerosol generating articles and through a method for making aerosol generating articles as described in the following. Part of the method is shown in the flow chart of Figure 35.

[0110] A first endless rod 7 made of a plurality of first rods (A) is manufactured in a combiner 100 as the one schematically shown in Figure 4. The combiner 100 comprises a conveyor 200 having a surface moving along a conveying direction "F1". A cooler plugs feeder 300, a tubular plugs feeder 400 and an aerosol-generating plugs feeder 500 are located one after the other above the conveying surface. The cooler plugs feeder 300 feeds one at a time a plurality of cooler plugs 4' having a double length (which is double with respect to the single length of the cooler plug 4). The tubular plugs feeder 400 feeds one at a time a plurality of tubular plugs 3 (of single length). The aerosol-generating plugs feeder 500 feeds one at a time a plurality of aerosol-generating plugs 2' having a double length (which is double with respect to the single length of the aerosol-generating plug 2). The cited plugs 4', 2, 3' are fed such to align them along the conveying direction "F 1" according to the following sequence: double length aerosol-generating plug 2' - tubular plug 3 - double length cooler plug 4' - tubular plug 3. This sequence is repeated a plurality of times. The cited aligned plugs 4', 2, 3' are wrapped in the wrapping paper 6 while advanced along the conveying direction "F1" to form the first endless rod 7.

[0111] The first endless rod 7 is therefore made of the plurality of first rods (A) of single length. One first rod (A) of single length comprises the aerosol-generating plug 2, the tubular plug 3 and the cooler plug 4 ordered form left to right and said one first rod (A) of single length is followed and preceded by two other first rods (A) of single length, in which the aerosol-generating plug 2, the tubular plug 3 and the cooler plug 4 are ordered from right to left, i.e. mirrored (figure 5).

[0112] The combiner 100 comprises a cutter 600 (for instance a rotating knife) configured to cut the first endless rod 7 in a plurality of double-length first rods (2A), i.e. a rod made of two first rods (A) of single length. The double-length first rods (2A) are then advanced along a direction "F2" perpendicular to the conveying direction "F1" (figure 4) and loaded on a groups conveyor 700.

[0113] A first example of groups conveyor 700 is depicted in Figure 20 and is a conveyor drum having a circumferential conveyance surface carrying a plurality of groups of double-length first rods (2A). Each group (encircled in dashed line) comprises two double-length first rods (2A) arranged in sequence one after the other along a respective conveying direction "F3" and transverse to the conveying direction "F3". The conveying direction "F3" is the direction of the circumferential conveyance surface rotating about a main axis "Y-Y" of the conveyor drum. Terminal ends of the two double-length first rods (2A) of each rod group are aligned along said conveying direction "F3".

[0114] A second example of groups conveyor 700 is depicted in Figure 21 and is a conveyor drum having a circumferential conveyance surface carrying a plurality of groups of double-length first rods (2A). Differently from Figure 20, the two double-length first rods (2A) of each rod group are axially aligned one to the other and transverse to the conveying direction. The two axially aligned double-length first rods (2A) of one rod group are also represented in figure 6.

[0115] The groups conveyors 700 of Figure 20 and of Figure 21 are provided with seats and suction devices to retain the double-length first rods (2A) on the circumferential conveyance surface.

[0116] The groups of double-length first rods (2A) are then transferred to a positioning device 800 which comprises a positioning conveyor 801 arranged downstream of the groups conveyor 700. The positioning conveyor 801 of Figure 22 is a positioning drum rotating about an own main axis "X-X". A circumferential conveyance surface of the positioning conveyor 801 presents seat groups for the rod groups moving along a respective conveying direction "F4". The conveying direction "F4" is the direction of the circumferential conveyance surface rotating about the own main axis "X-X" of the positioning drum.

[0117] The positioning device 800 is configured to move the two double-length first rods (2A) of each rod group from the axially aligned configuration of Figures 6 and 21 to a staggered configuration. In the staggered configuration, depicted in Figure 22 and also in Figure 9, the two double-length first rods (2A) of each group are perpendicular to the respective conveying direction "F4", placed one after the other along said conveying direction "F4" and staggered one with respect to another of an axial offset "O" which is half a length of each double-length first rods (2A) plus a tolerance gap "G". The axial offsets "O" in all the rod groups are the same. The tolerance gap is for instance from 1 mm to 3 mm.

[0118] The positioning device 800 illustrated in Figures 7, 8 and 9 comprises a displacement device 802 which is operatively active on the positioning conveyor and is configured to move one of the two double-length first rod (2A) of each rod group to the staggered configuration through a rotation. For sake of clarity, Figures 7, 8 and 9 show the positioning drum of the positioning device 800 showing subsequent rotation steps of one rod group comprising two double-length first rod (2A).

[0119] Each seat group on the positioning conveyor 801 comprises a steady seat 803 and a movable seat 804. The movable seat 804 is part of the displacement device 802 and is pivoted about a hinge 805 placed on a side of the respective movable seat 804. A turning mechanism, not shown, is connected to the movable seat 804 and is configured to rotate the movable seat 804 with the respective double-length first rod (2A) about a pivot axis of the hinge 805 while the positioning conveyor 801 rotates about the own main axis "X-X". The movable seat 804 is rotated of a rotation angle of 180° to the staggered configuration (figures 7 to 9).

[0120] If the two double-length first rods (2A) are arranged in sequence one after the other along the conveying direction "F3" as in Figure 20, a variant embodiment of the positioning device 800, not illustrated, comprises moving sectors configured to translate one or both the seats of each seat group to the staggered configuration. For instance, every other seat with the respective double-length first rod (2A) is axially shifted apart.

[0121] The groups of staggered double-length first rods (2A) are then transferred to a cutting device 900 which comprises a cutting conveyor 901 arranged downstream of the positioning device 800.

[0122] The cutting conveyor 901 of figure 23 is a cutting drum rotating about an own main axis "Z-Z". A circumferential conveyance surface of the cutting conveyor 901 presents seat groups each comprising two staggered seats 902 (shown in figure 10) for the staggered rod groups moving along a respective conveying direction "F". The conveying direction "F" is the direction of the circumferential conveyance surface rotating about the own main axis "Z-Z" of the cutting drum.

[0123] The cutting device 900 is configured to cut each double-length first rod (2A) of each rod group in two halves through a respective knife 903 while advancing the rod group along the conveying direction "F". The cutting device 900 of figure 23 comprises two rotating knives 902 each having an edge operatively coupled to the circumferential conveyance surface of the cutting drum 901 and operatively coupled to the seats 902 to cut the double-length first rods (2A) in the seats. The two knives 903 are staggered from each other transverse to the conveying direction "F4" of the above cited axial offset "O". Each double-length first rods (2A) is cut along a cutting line "C" schematically represented in figure 10.

[0124] The groups of staggered and cut double-length first rods (2A) are then transferred to a separating device placed downstream of the cutting device 900 and configured to axially space the two halves of each rod from each other. The separating device, which is not shown as a whole in the attached figures, is provided with a plurality of seats 1001, each seat 1001 extending along a respective axis, the axes of the seats 1001 being parallel to each other, each seat 1001 being sized to accommodate the two halves of each double-length first rod (2A). The separating conveyor is a separating drum comprising sections axially movable to space the two halves of each double-length first rod (2A) from each other. In some embodiments, the axially movable sections are part of the same conveyor 901 and the two halves of each double-length first rod (2A) are spaced from each other on the conveyor 901.

[0125] Figure 11 shows the seats 1001 of one group which, due to the motion of the movable sections, are each parted in two half-seats 1001A, 1001B axially spaced from each other to delimit a void therebetween. Each half-seat 1001A, 1001B holds a respective half of the double-length first rod (2A), i.e. a first rod (A) of single length.

[0126] An inserting device operatively placed downstream of the separating device is configured to insert a double length second rod (2B) between the two halves (figure 12). The inserting device is not shown as a whole in the attached figures. According to embodiments, the inserting device comprises an inserting conveyor, for instance an inserting drum, provided with a plurality of seats. Each seat extends along a respective axis and each seat is sized to accommodate the two spaced first rods (A) of single length and the double length second rod (2B) which is to be inserted therebetween. The inserting device further comprises a double length second rods conveyor, for instance a double length second rods drum, operatively coupled to the inserting conveyor and configured to feed the double length second rods (2B) to the inserting conveyor and to place the double length second rod (2B) between the two first rods (A) of single length.

[0127] An application device is placed downstream of the inserting device and is configured to attach an extremity of a double length tipping paper (2C) on a side of each double length second rod (2B) and of the two spaced first rods (A) of single length. The application device, which is not shown in the attached figures, comprises: an application conveyor, for instance an application drum, provided with a plurality of seats. Each seat extends along a respective axis and the axes of the seats are parallel to each other. Each seat is sized to accommodate one double length second rod (2B) placed between the two spaced first rods (A) of single length. A double length tipping papers conveyor, for instance a double length tipping papers drum, is operatively coupled to the application conveyor and is configured to feed double length tipping papers (2C) to the application conveyor and to attach said double length tipping papers (2C) to each double length second rod (2B) and to the two spaced first rods (A) of single length.

[0128] A wrapping device is operatively placed downstream of the application device and is configured to wrap each double length tipping paper (2C) around one double length second rod (2B) and at least partially around the respective two spaced first rods (A) of single length. This way, each double length second rod (2B) is joined to the respective two first rods (A) of single length to form a double length rod assembly 8. The double length rod assembly 8 is a rod shaped semi-finished product intended for making the aerosol generating articles 1.

[0129] The wrapping device, which is not shown in the attached figures, comprises: a wrapping conveyor, for instance a wrapping drum, provided with a plurality of seats. Each seat extends along a respective axis and the axes of the seats are parallel to each other. Each seat is sized to accommodate one double length second rod (2B) between the respective two first rods (A) of single length and provided with the double length tipping paper (2C). The wrapping device further comprises a steady element having a steady surface. The steady surface is arranged close to the wrapping conveyor so that the double length second rod (2B) between the respective two spaced first rods (A) of single length and provided with the double length tipping paper (2C) carried by the wrapping conveyor roll against the steady surface such that the double length tipping paper (2C) wraps around the assembly. The double length tipping paper (2C) is also provided with adhesive extremities which join to each other once wrapped to form the double length rod assembly 8.

[0130] According to one embodiment of the method (figures 14 and 15), each double length second rod (2B) of each double length rod assembly 8 is cut in two so as to form two aerosol generating articles 1. To this aim, the plurality of double length rod assemblies 8 are carried on a circumferential conveyance surface of a cutting drum similar to the one shown in Figure 23 but cooperating with one single rotating knife. Indeed, the double length rod assemblies 8 are arranged one after the other with terminal ends of the double length rod assemblies 8 aligned along a conveying direction of the circumferential conveyance surface and the rotating knife cuts in sequence the double length rod assemblies 8.

[0131] According to another embodiment of the method (figures 16 to 20), the double length rod assemblies are arranged in rod groups, each comprising two double length rod assemblies 8. The double length rod assemblies 8 may be arranged one after the other with terminal ends of the rod assemblies 8 aligned along a conveying direction (figure 16), like the double-length first rods (2A) of Figure 20.

[0132] Then, the double length rod assemblies 8 of each group are moved to a staggered configuration (figure 17). In the staggered configuration, which is similar to the staggered configuration of the two double-length first rods (2A) depicted in Figures 22 and 9, the two double length rod assemblies 8 of each group are perpendicular to a respective conveying direction "F6", placed one after the other along said conveying direction "F6" and staggered one with respect to another of an axial offset "O" which is half a length of each double-length first rods (2A) plus a tolerance gap "G".

[0133] The staggered double length rod assemblies 8 are then cut in two (Figure 18) through two rotating knives, for instance through a cutting drum similar to the one shown in figure 22, to form a plurality of aerosol generating articles 1 (figure 19).

[0134] Figures 24 to 34 show a variant embodiment of the method in which each rod group comprises three double-length first rods (2A) axially aligned, as in Figure 24, or placed one after another in the conveying direction "F3", as in Figure 25.

[0135] The three double-length first rods (2A) are moved to the staggered configuration of Figure 26 by rotation about the hinges 805 or by translation. In the staggered configuration, the double-length first rods (2A) of each rod group are offset all in a same versus with the offset "O".

[0136] Each of the three double-length first rods (2A) is cut in two through a respective knife (Figure 27) and the two halves are spaced apart (Figure 28). Each half is a first rod (A) of single length.

[0137] Three double length second rods (2B) for each rod group are prepared (Figure 29) and each inserted between the two first rods (A) of single length (Figure 30).

[0138] Three double length tipping papers (2C) are prepared, each applied to one double length second rod (2B) and partially around the adjacent first rods (A) of single length and wrapped around to form three double length rod assemblies 8 (Figures 31 and 32).

[0139] Then, the three double length rod assemblies 8 are moved to the staggered configuration of Figure 33 by rotation or by translation. In the staggered configuration, the double length rod assemblies 8 of each rod group are offset all in a same versus with the offset "O'".

[0140] The three staggered double length rod assemblies 8 are cut through three knives and spaced apart to obtain six aerosol generating articles 1 (Figure 34).

[0141] In other embodiments, not shown in the attached drawings, each rod group comprises N rods and the rods of each rod group are cut through N knives and each rod of the plurality of rods is a M-length first rod or a M-length second rod, where M is even. For instance, M = 2, 4, 6 or 8.

[0142] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A ± 5 percent of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

1. A method of assembling smoking articles or aerosol generating articles, comprising: - providing a plurality of rods; - arranging the rods in rod groups and conveying in sequence said rod groups along a conveying direction; - positioning the rods of each rod group in a staggered configuration in which said rods of each rod group are transverse to the conveying direction, placed one after the other along said conveying direction and staggered one with respect to another of an axial offset at least half a length of each rod; - cutting each rod of each rod group in two halves through a respective knife.

2. Method according to claim 1, wherein each rod group comprises N rods and the rods of each rod group are cut through N knives.

3. Method according to claim 2, wherein N is two or three.

4. Method according to claim 1 or 2 or 3, wherein the axial offset is equal to half the length of each rod plus a tolerance gap.

5. Method according to any of claims 1 to 4, wherein arranging the rods in rod groups comprises: arranging the rods of each rod group axially aligned one to the other and transverse to the conveying direction; wherein positioning the rods of each rod group comprises: moving the rods of each rod group to the staggered configuration.

6. Method according to any of claims 1 to 4, wherein arranging the rods in rod groups comprises: arranging the rods of each rod group one after the other along the conveying direction and transverse to the conveying direction, wherein terminal ends of the rods of each rod group are aligned along said conveying direction; wherein positioning the rods of each rod group comprises: moving the rods of each rod group to the staggered configuration.

7. Method according to any of claims 1 to 6, wherein providing the plurality of rods comprises: manufacturing an endless rod and cutting said endless rod in the plurality of rods.

8. Method according to any of claims 1 to 7, further comprising: axially spacing the two halves of each rod from each other.

9. Method according to any of claims 1 to 8, wherein each smoking article or aerosol generating article comprises a first rod (A) of single length, a second rod (B) of single length and a tipping paper (C) applied around and joining together the first rod (A) and the second rod (B); wherein each rod of the plurality of rods is a M-length first rod or a M-length second rod, where M is even.

10. Method according to claim 9 when according to claim 8, wherein M = 2 and the half of each rod is a first rod (A) of single length; wherein, after axially spacing, the method further comprises: - inserting a double length second rod (2B) between the two first rods (A) of single length; - wrapping a double length tipping paper (2C) around the double length second rod (2B) and at least partially around the two first rods (A) of single length to form a double-length smoking article or a double-length aerosol generating article; - cutting the double length second rod (2B) in two so as to form two smoking articles or two aerosol generating articles.

11. Method according to any of claims 1 to 8, wherein each smoking article or aerosol generating article comprising a first rod (A) of single length, a second rod (B) of single length and a tipping paper (C) applied around and joining together the first rod (A) and the second rod (B); wherein each rod of the plurality of rods is a M-length smoking article or a M-length aerosol generating article, where M is even.

12. Method according to claim 11 when according to claim 8, wherein M = 2 and the half of each rod is a smoking article or an aerosol generating article; wherein the method further comprises: cutting the double length second rod (2B) in two so as to form two smoking articles or two aerosol generating articles.

13. An apparatus for assembling smoking articles or aerosol generating articles, comprising: a groups conveyor configured to convey rod groups in sequence; a positioning device arranged downstream of the groups conveyor and configured to position the rods of each rod group in a staggered configuration in which said rods of each rod group are transverse to a conveying direction (F4), placed one after the other along said conveying direction (F4) and staggered one with respect to another of an axial offset (O) at least half a length of each rod; a cutting device arranged downstream of the positioning device and comprising a plurality of knives, the cutting device being configured to cut each rod of each rod group in two halves through a respective knife of said plurality of knives.

14. Apparatus according to claim 13, wherein the positioning device comprises: a positioning conveyor having seat groups for the rod groups moving along the conveying direction (F4); a displacement device part of the positioning conveyor or operatively active on the positioning conveyor and configured to move the seats of each seat group with the rods of each rod group to the staggered configuration through a rotation or through a translation of at least one of said seats; wherein the cutting device comprises: a cutting conveyor having seats for the rods of each rod group arranged in the staggered configuration; wherein the knives are operatively coupled to the seats and are staggered from each other transverse to the conveying direction (F5).

15. Apparatus according to claim 14, wherein the positioning conveyor is a positioning drum and the seat groups are placed on a circumferential conveyance surface of the positioning drum, wherein the displacement device comprises a turning mechanism configured to rotate at least one of said seats to the staggered configuration or wherein the displacement device comprises moving sectors configured to translate at least one of said seats to the staggered configuration; wherein the cutting conveyor is a cutting drum and the seats are placed on a circumferential conveyance surface of the cutting drum, wherein the knives are operatively coupled to the circumferential conveyance surface of the cutting drum.

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