Assembled Assembly

Abstract

A collection assembly (220) for use in the manufacture of aerosol-generating articles is described. The collection assembly comprises a collection element (230) for receiving and collecting material on a support. The collection element comprises an inlet (232) for receiving the material, an outlet (234) for outward passage of the material, and a converging portion (236) configured to receive the material from the inlet and collect the material on the support as it passes between the inlet and outlet of the collection element. The collection assembly further comprises a support assembly (240) comprising a first portion (242) having a fixed position relative to the support, a second portion (244) movable relative to the first portion, the second portion being coupled to the collection element and movable with the collection element, and a sacrificial member (248) configured to couple the first portion and the second portion, the sacrificial member configured to break when a force applied to the collection element by the material exceeds a predetermined level.

Description

[Technical Field]

[0001] The present disclosure relates to an assembly for use in the manufacture of aerosol-generating articles. The assembly may be part of a larger system, for example, a system for use in the manufacture of aerosol-generating articles or in a rod-making machine. [Background technology]

[0002] Aerosol-generating articles are often a combination of different types of plugs, each made of material formed into a rod shape and rolled up within a packaging material.

[0003] For example, for a heat-and-burn consumable product, one of these plugs may include a collection of sheets of a sensate, which may be a substrate that generates an aerosol when heated, such as a sheet of cast leaf tobacco.

[0004] In known systems, material is typically unwound from a bobbin and then passed through a converging funnel, which gradually gathers the material into a rod shape.

[0005] The converging device is located upstream of the inlet of the rod-forming means. As the gathered material approaches the outlet of the converging funnel, it is dispensed onto the packaging material. The packaging material is pulled or driven by the garniture tape through the gathering element, from the outlet of the converging funnel, and into the rod-forming means.

[0006] The collecting element typically has a half-funnel shape, i.e., it comprises a funnel separated into two parts along its length, with the half-funnel shape above the sheet of material and the packaging material at the bottom.

[0007] As the material passes through the collecting element, it is progressively collected by the collecting element, i.e., the collecting element exerts a force on the material. Upon exiting the collecting element, the material is formed into a rod of a predetermined diameter.

[0008] The longitudinal ends of the packaging material are overlapped and glued to form a continuous cylindrical rod, which is then cut into individual sticks to create the desired components to be used in the aerosol-generating article. Summary of the Invention [Problem to be solved by the invention]

[0009] Sometimes, a band of material passing through a collection element may have an unexpected increase in thickness or resistance to compression (or an increase in both thickness and resistance to compression). The increase in thickness or resistance to compression may be only temporary. For example, the increase may occur at the transition between material received from one bobbin and material received from a subsequent bobbin. The increase in thickness or resistance to compression may also occur due to other factors, such as the randomness associated with the use of natural materials.

[0010] As material passes through the collecting element, this "spike" in thickness or resistance to compression can result in the force exerted on the collecting element by the material exceeding the material resistance of the collecting element. As a result, the collecting element can deform or break under unexpectedly high forces. Removal and replacement of collecting elements can result in significant manufacturing downtime, as the replaced collecting element must be secured and fine-tuned for correct positioning.

[0011] It would be desirable to provide an assembly element and method of assembling materials that overcomes the above problems. [Brief explanation of the drawings]

[0012] [Figure 1] FIG. 1 illustrates a schematic perspective view of a typical system used in the manufacture of rod components for aerosol-generating articles. [Figure 2] FIG. 1 illustrates a schematic perspective view of a cluster assembly in an operational configuration. [Figure 3]FIG. 3 illustrates a schematic perspective view of the cluster assembly of FIG. 2 in a non-operational configuration. [Figure 4] FIG. 3 illustrates a perspective view of the cluster assembly of FIG. 2 in an operational configuration. [Figure 5] FIG. 3 illustrates a perspective view of the cluster assembly of FIG. 2 in a non-operational configuration. [Figure 6] 10A and 10B illustrate adjustment means for the cluster assembly. [Figure 7] FIG. 3 illustrates a top cross-sectional view of the cluster assembly of FIG. 2. [Figure 8] 10A-10C illustrate sacrificial members for the assembly. DETAILED DESCRIPTION OF THE INVENTION

[0013] According to a first aspect, there is provided a collection assembly for use in the manufacture of an aerosol-generating article, the collection assembly comprising a collection element and a support assembly; The collection element is configured to receive and collect material on the support assembly, the collection element comprising: an inlet for receiving the material; an outlet for the outward passage of material; a converging portion configured to receive material from the inlet and to converge the material on the support assembly as the material passes between the inlet and the outlet of the convergence element; and The support assembly includes: a first portion having a fixed position relative to the support assembly; a second portion movable relative to the first portion, the collection element being coupled to the second portion and movable with the second portion; a sacrificial member configured to connect the positions of the first and second portions, the sacrificial member configured to break when a force applied by the material to the collection element exceeds a predetermined level.

[0014] The use of a sacrificial member prevents the collection elements from becoming damaged during use. If the force exerted on the collection elements by the material increases beyond a predetermined level, the sacrificial member breaks. Breaking the sacrificial member relieves the force on the collection elements. By ensuring that the collection elements avoid damage, a more reliable system is provided with reduced manufacturing downtime. As a result, there is a beneficial impact on efficiency. Additionally, only a simple part (the sacrificial member) needs to be replaced, rather than a relatively expensive component (the entire collection element). Replacing a sacrificial member is faster than replacing an entire collection element because less fine-tuning is required.

[0015] In some embodiments, the material is a web of sheet material.

[0016] In some embodiments, the material may include a susceptor. Problems with known systems are of particular concern when producing rods that include incompressible susceptors.

[0017] In some embodiments, the second portion is rotatably coupled to the first portion. Rotational coupling provides a simple yet effective way to allow the second portion to move relative to the first portion. Furthermore, by rotatably coupling the first and second portions, only a single fixation point (i.e., a single sacrificial element) is required to securely couple or fix the relative positions of the first and second portions.

[0018] In some embodiments, the support assembly further comprises a limiter element configured to limit rotation of the second portion relative to the first portion, which may prevent collision between the second portion and other components in the system.

[0019] In some embodiments, the second portion is biased away from the support assembly. In some embodiments, the second portion is biased away from the first portion. Biasing the second portion away from the support assembly or away from the first portion ensures that the force on the collecting element is significantly reduced after the sacrificial element breaks. That is, the second portion actively moves away from the support assembly or away from the first portion upon fracture of the sacrificial element.

[0020] In some embodiments, the fracture of the sacrificial member allows the collection element to move away from the operating position. Specifically, the fracture of the sacrificial member removes the constraint on the relative position of the first and second portions. In this manner, the second portion can move away from the support assembly or away from the first portion, thus reducing the force exerted by the material on the collection element.

[0021] In some embodiments, the sacrificial member is configured to break when the force applied by the material to the collection element's outlet exceeds a predetermined level. The diameter of the collection element is generally smallest at its outlet. Therefore, the force applied to the collection element by the band of material is highest at the collection element's outlet. As a result, deformation or fracture of the collection element is most likely to occur at the collection element's outlet. By linking the fracture of the sacrificial member to the force applied to the collection element's outlet, the risk of fracture of the collection element is reduced.

[0022] In some embodiments, the sacrificial member is configured to fail when the force applied by the material to the outlet of the collecting element exceeds a predetermined level that is less than a normal failure load at the outlet of the collecting element. The material generally applies a normal load to the outlet of the collecting element. By taking this normal load into account, the sacrificial member is configured to fail at a precise predetermined load.

[0023] In some embodiments, the sacrificial member is configured to fail when the force applied by the material to the outlet of the collection element exceeds a predetermined level, i.e., the normal failure load at the outlet of the collection element divided by a safety factor, e.g., 1.5, 2, or more. The safety factor provides a balance between continued operation and protection of the collection element.

[0024] In some embodiments, the sacrificial member includes a shear pin.

[0025] In some embodiments, the first portion and the second portion each include a recess for receiving a portion of the sacrificial member.

[0026] In some embodiments, the support assembly further comprises an intermediary member positioned within the recess of the first portion or the second portion for interfacing between the sacrificial member and the recess.

[0027] In some embodiments, the interface member is a bushing or vibration isolator. The interface member, particularly the bushing or vibration isolator, ensures that there is little or no damage to the first and second portions when the sacrificial member breaks.

[0028] In some embodiments, the sacrificial member comprises hard or tempered steel. Using such a hard material for the sacrificial member ensures that the relative position between the first and second portions is properly maintained during use. That is, the sacrificial member undergoes little deformation before failure, so that the assembly element remains stable during use.

[0029] In some embodiments, the support assembly further comprises positioning means for adjusting the position of the collecting element relative to the second portion, the positioning means allowing the collecting element to be aligned with an upstream component from which material passes or a downstream component to which material passes.

[0030] According to a second aspect, there is provided a system for use in the manufacture of an aerosol-generating article, the system comprising: a group assembly according to the first aspect; a support, on which, in use, the gathering elements of the gathering assembly gather material.

[0031] In some embodiments, the system comprises: a funnel upstream of the collective assembly; and a rod forming means downstream of the gathering assembly.

[0032] According to a third aspect, a method of constructing an assembly for use in the manufacture of an aerosol-generating article is disclosed, the method comprising: providing a collection element and a support assembly, the collection element for receiving and collecting material on the support assembly; The set elements are an inlet for receiving the material; an outlet for the outward passage of material; a converging portion configured to receive material from the inlet and to collect the material on the support assembly as the material passes between the inlet and the outlet of the collecting element; and The support assembly includes: a first portion having a fixed position relative to the support assembly; a second portion movable relative to the first portion, the collection element being coupled to the second portion and movable with the second portion; a sacrificial member configured to connect the positions of the first and second portions, the sacrificial member configured to break when a force applied by the material to the collection element exceeds a predetermined level.

[0033] In some embodiments, the cluster assembly is a cluster assembly of the first aspect of the cluster assembly of the present invention.

[0034] In some embodiments, the method comprises: Further comprising removing the broken sacrificial member from the support assembly when the force exerted by the material on the collection element exceeds a predetermined level at which the sacrificial member is configured to break.

[0035] The method may further include providing a further sacrificial member configured to connect the positions of the first and second portions and configured to break when the force exerted by the material on the collection element exceeds a predetermined level.

[0036] In some embodiments, both the sacrificial member and the further sacrificial member are configured to break when the force exerted on the collection element by the material then exceeds the same predetermined level.

[0037] In some embodiments, the method comprises: determining a failure load at the exit of the assembly element; Further comprising selecting properties for and locations for the sacrificial member such that the sacrificial member breaks before the collecting elements break.

[0038] As used herein, the term "collecting element" is used to describe a channel or channel-like component for collecting material, i.e., a component that forms material from a substantially two-dimensional entity, e.g., a web of sheet material, into a three-dimensional entity, e.g., a rod or rod precursor. Specifically, the interior surfaces of the collecting element collect material as it moves through the collecting element. The material is collected in a direction transverse to the longitudinal direction of the collecting element. As used herein, the term converging portion is used to describe the portion of the collecting element that collects material.

[0039] As used herein, the term "failure" is used to describe the failure of a component at or subject to a failure load or force. Failure may refer to fracture, separation into two or more pieces, yielding, or another threshold.

[0040] As used herein, the terms "breaking load" or "breaking force" refer to the maximum load or force, respectively, that a component can sustain without breaking.

[0041] As used herein, the term "sacrificial member" refers to a component that is designed to break at a predetermined limit in order to protect another component or to allow an additional action or function to occur. In the described embodiment, the additional action permitted by the breakage of the sacrificial member is movement of a second portion relative to a first portion.

[0042] As used herein, the term "predetermined limit" refers to a generally known or contemplated limit, for example, a calculated load.

[0043] The present invention is defined in the claims. However, the following provides 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 any other example, embodiment, or aspect described herein.

[0044] [Example] Example 1. A mass assembly for use in the manufacture of an aerosol-generating article, comprising: A collection element for receiving and collecting material on a support, comprising: an inlet for receiving the material; an outlet for the outward passage of material; a collecting element comprising a converging portion configured to receive material from an inlet and to collect the material on a support as the material passes between an inlet and an outlet of the collecting element; A support assembly comprising: a first portion having a fixed position relative to the support; a second portion movable relative to the first portion, the collection element being coupled to the second portion and movable with the second portion; a support assembly comprising a sacrificial member configured to connect the positions of the first portion and the second portion, the sacrificial member being configured to break when a force applied by the material to the assembly element exceeds a predetermined level.

[0045] Example 2. An assembly according to Example 1, wherein the material is a web of sheet material.

[0046] Example 3. The assembly according to example 1, wherein the second part is rotatably coupled to the first part.

[0047] Example 4. The assembly according to example 3, wherein the support assembly further comprises a limiter element configured to limit rotation of the second portion relative to the first portion.

[0048] Example 5. The assembly according to any preceding example, wherein the second portion is biased away from the support.

[0049] Example 6. A cluster assembly according to any preceding example, wherein destruction of the sacrificial member allows the cluster elements to move away from the operating position.

[0050] Example 7. The cluster assembly according to any preceding example, wherein the sacrificial member is configured to break when a force applied by the material to the cluster element outlet exceeds a predetermined level.

[0051] Example 8. The cluster assembly according to example 7, wherein the sacrificial member is configured to fail when a force applied by the material to the exit of the cluster element exceeds a predetermined level that is less than a normal failure load at the exit of the cluster element.

[0052] Example 9. A cluster assembly according to example 8, wherein the sacrificial member is configured to fail when the force applied by the material to the cluster element outlet exceeds a predetermined level, i.e., the normal failure load at the cluster element outlet divided by a safety factor, e.g., 1.5, 2, or more.

[0053] Example 10. The assembly according to any preceding example, wherein the sacrificial member comprises a shear pin.

[0054] Example 11. The assembly according to any preceding example, wherein the first portion and the second portion each include a recess for receiving a portion of the sacrificial member.

[0055] Example 12. The assembly assembly according to example 11, wherein the support assembly further comprises an intermediary member positioned within the recess of the first part or the second part for interfacing between the sacrificial member and the recess.

[0056] Example 13. The assembly according to Example 12, wherein the intermediate member is a bushing or vibration isolator.

[0057] Example 14. The assembly according to any preceding example, wherein the sacrificial member comprises hardened or tempered steel.

[0058] Example 15. The cluster assembly according to any preceding example, wherein the support assembly further comprises position adjustment means for adjusting the position of the cluster element relative to the second portion.

[0059] Example 16. A system for use in the manufacture of an aerosol-generating article, comprising: a group assembly according to any preceding embodiment; and A system comprising: a support, wherein in use, a gathering element of the gathering assembly gathers material on the support.

[0060] Example 17. a funnel upstream of the collective assembly; 17. The system according to example 16, further comprising a rod forming means downstream of the gathering assembly.

[0061] Example 18. A method of constructing a collective assembly for use in the manufacture of an aerosol-generating article, comprising: A collection element for receiving and collecting material on a support, comprising: an inlet for receiving the material; an outlet for the outward passage of material; providing a collecting element comprising a converging portion configured to receive material from an inlet and to concentrating the material on a support as the material passes between an inlet and an outlet of the collecting element; A support assembly comprising: a first portion having a fixed position relative to the support; a second portion movable relative to the first portion, the collection element being coupled to the second portion and movable with the second portion; providing a support assembly comprising: a sacrificial member configured to connect the positions of the first portion and the second portion, the sacrificial member configured to break when a force applied by the material to the collection element exceeds a predetermined level.

[0062] Example 19. A method comprising: The method according to example 18, further comprising removing the broken sacrificial member from the support assembly when the force exerted by the material on the collection element exceeds a predetermined level at which the sacrificial member is configured to break.

[0063] Example 20. The method according to example 19, further comprising providing an additional sacrificial member configured to connect the positions of the first and second portions and configured to break when a force applied by the material to the assembly element exceeds a predetermined level.

[0064] Example 21. The method according to example 20, wherein the sacrificial member and the further sacrificial member are both configured to break when the force exerted by the material on the collection element then exceeds the same predetermined level.

[0065] Example 22. determining a failure load at the exit of the assembly element; 19. The method according to example 18, further comprising: selecting a property for the sacrificial member and a location for the sacrificial member such that the sacrificial member breaks before the collecting element breaks.

[0066] The embodiments will now be further described with reference to the figures.

[0067] 1 illustrates a system 100 for use in the manufacture of aerosol-generating articles. System 100 includes a converging funnel 102 for receiving material to be formed into a rod or plug. In use, material is received in the direction of arrow 10. Converging funnel 102 gradually collects the material into a rod shape.

[0068] Typically, the material is provided as a web of sheet material (not shown), e.g., a tobacco compound such as cast leaf tobacco. The web of sheet material may have a width of 5 cm to 25 cm. The web of sheet material may be subjected to various pretreatments, including, for example, crimping.

[0069] As the collected material approaches the outlet of the converging funnel 102, it is deposited on a packaging material 104. The packaging material 104 is pulled or driven by a support from the outlet of the converging funnel 102 to downstream components (described below). In this example, the support is a garniture tape 110, although in other examples, the support may be a garniture tongue.

[0070] The system 100 further includes a collecting element 230 for receiving and collecting material on a support. The collecting element 230 is positioned downstream of the converging funnel 102. The collecting element 230 receives the material from the converging funnel 102 and then further collects the material into a rod of a predetermined diameter.

[0071] The material may be assembled around a metal strip, such as a susceptor, that is capable of converting electromagnetic energy into heat sufficient to generate an aerosol from the aerosol-forming substrate, the susceptor being present in the final rod.

[0072] System 100 further includes a rod-forming means 108 downstream of collection element 230. As the material passes through rod-forming means 108, the longitudinal ends of packaging material 104 overlap and are glued together to form a continuous cylindrical rod. Rod-forming means 108 has an opening at the top to allow for closure and gluing of packaging material 104 around the moving, compressed band of material to be achieved. This continuous rod is then cut into individual sticks to create the desired components to be used in the aerosol-generating article.

[0073] The collection element 230 is part of the collection assembly 220. For clarity, only the collection element 230 of the collection assembly 220 is shown in Figure 1. The collection assembly 220 is shown in Figures 2-8.

[0074] The collecting element 230 includes an inlet 232 for receiving the material. The collecting element 230 further includes an outlet 234 for the outward passage of the material. The collecting element 230 further includes a converging portion 236 configured to receive the material from the inlet 232 and collect the material on the support as it passes between the inlet 232 and the outlet 234 of the collecting element 230. The direction of transport of the material as driven by the garniture tape 238 is indicated in FIG. 2 by arrow 238.

[0075] The converging portion 236 of the collecting element 230 has a generally "half-funnel" shape, i.e., the shape of the converging portion 236 of the collecting element 230 corresponds to a funnel separated into two parts along its length.

[0076] The cluster assembly 220 further includes a support assembly 240. Generally, the support assembly 240 provides support to which the cluster elements 230 are attached or coupled.

[0077] Support assembly 240 includes a first portion 242 that has a fixed position relative to the support. In this embodiment, when the support is garniture tape 110, first portion 242 has a fixed position relative to the stationary position of garniture tape 110. That is, first portion 242 is static within the system.

[0078] The support assembly 240 further includes a second portion 244. The second portion 244 is movable relative to the first portion 242. In this embodiment, the second portion 244 is movable relative to the first portion 242 by rotation. That is, the second portion 244 is rotatably coupled to the first portion 242.

[0079] In this embodiment, first portion 242 and second portion 244 are rotatably coupled by shaft assembly 246. As shown in FIG. 7 , in this embodiment, shaft assembly 246 includes a shaft 2461 that extends through first portion 242 and into second portion 244. First portion 242 is fixed relative to, or attached to, shaft 2461. Second portion 244 is free to rotate about shaft 2461 as its axis of rotation. In this embodiment, shaft assembly 246 includes a housing 2462 that is attached within second portion 244. Second portion 244 is fixed relative to housing 2462 via a fixing element 2463. In this embodiment, fixing element 2463 extends into a hollow end of shaft 2461 and is free to rotate within shaft 2461. Shaft 2461 is received within housing 2462 such that shaft 2461 can freely rotate within housing 2462. In some embodiments, additional bearings or lubricants may be included between the housing 2462 and the shaft 2461 to reduce friction.

[0080] In other embodiments, other suitable rotatable connections may be used to rotatably connect first portion 242 and second portion 244. For example, shaft assembly 246 may include a single shaft that passes through both first portion 242 and second portion 244. First portion 242 may be attached to the shaft, while second portion 244 is free to rotate about the shaft as an axis of rotation. That is, the shaft is freely received within a recess in second portion 244.

[0081] The collecting element 230 is coupled to the second portion 244 and is movable with the second portion 244. That is, rotation of the second portion 244 relative to the first portion 242 also rotates the collecting element 230 relative to the first portion 242.

[0082] In this embodiment, the collecting element 230 is oriented perpendicular to the axis of rotation of the second portion 244. That is, the collecting element 230 is oriented perpendicular to the shaft assembly 246. The distance between the outlet 234 of the collecting element 230 and the shaft assembly 246 is greater than the distance between the inlet 232 of the collecting element 230 and the shaft assembly 246. In this manner, as the second portion 244 rotates relative to the first portion 242, the outlet 234 of the collecting element 230 moves away from the support compared to the inlet 232 of the collecting element 230.

[0083] Support assembly 240 further includes a sacrificial member 248 configured to couple the positions of first portion 242 and second portion 244. In this embodiment, sacrificial member 248 prevents relative rotation between first portion 242 and second portion 244. That is, sacrificial member 248 substantially fixes the position of second portion 244 relative to first portion 242.

[0084] In this example, the sacrificial member 248 comprises an elongated pin. The first portion 242 and the second portion 244 each include a recess for receiving a portion of the sacrificial member 248. Generally, as shown in FIG. 7 , the recess extends inward from the corresponding surface of the first portion 242 and the second portion 244 in a direction parallel to the axis of rotation. The recess is located on the side of each of the first portion 242 and the second portion 244. In use, the side of the first portion 242 having the recess faces the side of the second portion 244 having the recess. In this manner, when the recesses are aligned, the sacrificial member 248 can extend into both the first portion 242 and the second portion 244 simultaneously. Therefore, the sacrificial member 248 can prevent relative rotation between the first portion 242 and the second portion 244.

[0085] 2 and 4 illustrate cluster assembly 220 in an operational configuration. First portion 242 and second portion 244 are positioned with corresponding recesses aligned. Sacrificial member 248 extends into the recesses of both first portion 242 and second portion 244. Thus, the positions of second portion 244 and cluster element 230 are fixed relative to first portion 242. In this manner, cluster assembly 220 can be positioned such that cluster element 230 is in its operational position adjacent to and parallel to the support.

[0086] The support assembly 240 may include a position adjustment means 250 for adjusting the position of the collecting element 230 relative to the second portion 244. In this manner, the operational position of the collecting element 230 can be adjusted to ensure that the collecting element 230 aligns with upstream and downstream components, such as, for example, a rod forming means and a funnel device.

[0087] 4-6, in this embodiment, the position adjustment means 250 includes at least one screw 252 mounted on the second portion 244. In use, advancement of the screw 252 pushes the collecting element 230 to adjust its position relative to the second portion 244. There may be multiple screws to adjust the position of the collecting element 230 relative to the second portion 244 in multiple dimensions.

[0088] In use, as material passes through collecting element 230, the material is increasingly concentrated onto the underlying support by converging portion 236 as the cross-sectional dimension of converging portion 236 decreases. As the material is concentrated onto the support, a reaction force is exerted by the material on collecting element 230. This generally normal force increases as the material approaches outlet 234 of collecting element 230 and is typically at its greatest at outlet 234.

[0089] Sacrificial member 248 is configured to break when the force exerted by the material on collection element 230 exceeds a predetermined level. That is, sacrificial member 248 is configured to have a failure load that corresponds to a force on collection element 236 exceeding a predetermined level.

[0090] In this embodiment, sacrificial member 248 is configured to fail when the force applied by the material to outlet 248 of collection element 230 exceeds a predetermined level. The predetermined level is less than the normal failure load at outlet 234 of collection element 230. That is, sacrificial member 248 is configured to fail before the normal load applied by the material to outlet 234 of collection element 230 reaches a failure limit, such as a maximum allowable normal force at outlet 234.

[0091] Using the above arrangement, an upward force from the material onto collecting element 230 creates a moment that forces collecting element 230 to rotate. That moment results in a shear load 239 on sacrificial member 248. In this embodiment, sacrificial member 248 is a shear pin configured to break when the shear load reaches a predetermined shear load.

[0092] FIG. 8 illustrates an example shear pin (shown in FIG. 7). Shear pin 248 includes outer portions 2481 and a central portion or notch 2482 located between outer portions 2481. Notch 2482 has a smaller diameter than outer portions 2481 and is generally the breaking point of the shear pin. In use, shear pin 248 can be positioned within recesses in first portion 242 and second portion 244 such that notch 2482 is located at the interface between first portion 242 and second portion 244, as shown in FIG. 7. Locating the notch at the interface between first portion 242 and second portion 244 ensures that breaking of the shear pin allows relative movement between first portion 242 and second portion 244.

[0093] 3 illustrates cluster assembly 220 in a non-operating configuration. Specifically, sacrificial member 248 has broken, allowing rotation of second portion 244 relative to first portion 242 (as indicated by the arrow). Similarly, cluster element 230 has been allowed to move away from its operating position. This eliminates, or at least significantly reduces, the force exerted by the material on cluster element 230.

[0094] The method for selecting a suitable sacrificial member 248 for the support assembly 240 is as follows: - determining the failure load at the outlet 234 of the collecting element 230; selecting appropriate properties for and locations for the sacrificial members 248 so that the sacrificial members 248 break before the collecting elements 230 break.

[0095] For example, the failure load at outlet 234 and the distance of outlet 234 from the axis of rotation can be used to determine the failure torque or moment on collection element 230. The torque applied by the material to sacrificial member 248 is substantially equal to the torque applied by the material to outlet 234 of collection element 230. Thus, the location, material, and dimensions of sacrificial member 248 can be selected such that the failure torque or moment of sacrificial member 248 is less than the failure torque or moment of collection element 230.

[0096] A factor of safety may be included at any stage in the above example calculations. That is, the predetermined level of force exerted by the material on collection element 230 at which sacrificial member 248 is configured to fail may be the failure load of collection element 230 divided by a factor of safety, e.g., 1.5.

[0097] In this embodiment, the sacrificial member 248 comprises hardened or tempered steel. Using a hard material that is less likely to deform allows the relative position between the first portion 242 and the second portion 244 to be maintained. This holds the gathering element 230 in the correct position to gather the material to the correct diameter.

[0098] A non-limiting example calculation may be as follows: Lt = distance between outlet 234 of collecting element 230 and axis of rotation Ft = normal force exerted by the material onto the outlet 234 of the collection element 230 Ls = distance between sacrificial member 248 and the axis of rotation Fs = normal force applied to sacrificial member 248 via collection element 230 and second portion 244 Equalize the torque at the sacrificial member 248 to the torque at the collection element outlet 234: Ft×Lt=Fs×Ls The failure load at the outlet 234 of the collecting element 230 may be calculated theoretically, for example, from the geometry and material of the collecting element 230. The failure load at the outlet 234 of the collecting element 230 may also be determined using known experimental methods (or both). For a maximum normal force supported by outlet 234 of 4000N, Ft=4000N. Including a safety factor of 2, Ft may be reduced to 2000N, i.e., the collection element 230 should only experience a maximum of 2000N in use. Fs = 2000 × Lt / Ls (1) In addition, the sacrificial member Shear stress = Fs / surface of cross section Fs = shear stress x surface of cross section Fs = shear stress x Pi x (radius) 2 When using D3 hardened steel, the ultimate shear strength is about 1220 MPa, which is about 60 percent of its ultimate tensile strength. For a D3 hardened steel shear pin to break, the shear stress must equal its ultimate shear strength. Therefore, Fs=1220MPa×Pi×(radius) 2 (2) As an example, if Lt=195 mm and Ls=125 mm, then by equating equations (1) and (2) above, it can be calculated that the notch radius of sacrificial member 248 should be 9 mm.

[0099] In this embodiment, an interface member 249 is positioned within a recess in the first portion 242 or the second portion 244 (as shown in FIG. 7 ). The interface member 249 provides an interface between the sacrificial member 248 and the recess. For example, the interface member 249 may be a bushing or a vibration isolator. By providing the interface member 249 to interface between the sacrificial member 248 and either or both of the first portion 242 and the second portion 244, the first portion 242 and the second portion 244 may be protected from the sacrificial member 248 upon fracture. That is, the bushing or vibration isolator may absorb or damp the mechanical energy of the fractured sacrificial member 248. This allows for repeated replacement of the sacrificial member 248 without damage to the main body of the support assembly 240.

[0100] The support assembly 240 may further include a limiter element configured to limit rotation of the second portion 244 relative to the first portion 242. For example, the limiter element may prevent excessive rotation of the second portion 244 that would risk causing the second portion 244 to collide with components of the system, such as the convergent funnel 102.

[0101] Any suitable limiter element may be used. In this embodiment (as shown in FIG. 7 ), the limiter element is a protrusion 247 that protrudes from the second portion 244. The protrusion 247 extends into a corresponding recess in the first portion 242. The boundaries of the recess define the extent of movement of the second portion 244. For example, the recess may be disposed in an arc having a radius about the axis of rotation, thereby allowing the second portion 244 to rotate relative to the first portion 242 until the protrusion 247 is interrupted by the edge of the groove. In this manner, the limiter defines the maximum angle of rotation of the second portion 244.

[0102] In some embodiments, cluster assembly 220 may be biased toward its inoperative configuration. Specifically, second portion 244 may be biased away from the support. In this manner, sacrificial member 248 ensures that the force exerted by the material on cluster element 230 is removed as second portion 244 breaks and cluster element 230 moves away from the support. Any suitable biasing means may be used. For example, second portion 244 may be spring-mounted relative to first portion 242.

[0103] As noted above, various modifications of the detailed arrangement are possible. For example, first portion 242 and second portion 244 may not be rotationally coupled. Instead, second portion 244 may translate relative to first portion 242 as cluster assembly 220 moves to its non-operating configuration. That is, the entire cluster element 230 may move away from the support upon destruction of sacrificial member 248.

[0104] It should also be understood by those skilled in the art that combinations of any number of the features set forth above or illustrated in the accompanying drawings offer distinct advantages over the prior art and, therefore, are within the scope of the invention as described herein.

[0105] The schematic drawings are not necessarily to scale and are presented for purposes of illustration, not limitation. The drawings depict one or more aspects described in the present disclosure. However, it will be understood that other aspects not shown in the drawings are within the scope of the present disclosure.

[0106] For purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like are understood to be modified in all instances by the term "about." Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein. Thus, in this context, the number A is understood as A ± 25 percent of A. Within this context, the number A may be considered to include values ​​that are within the common standard error of measurement for the property that it modifies. In some cases, as used in the appended claims, the number A may deviate by the percentages recited above, provided that the amount by which A deviates does not materially affect the basic and novel property(ies) of the claimed invention. Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein.

Claims

1. An assembly for use in the manufacture of aerosol-generating articles, comprising an assembly element and a support assembly, the assembly element being configured to receive and assemble material on the support assembly, the assembly element comprising an inlet for receiving the material, an outlet for the outward passage of the material, a converging portion configured to receive the material from the inlet and to assemble the material on the support assembly as the material passes between the inlet and the outlet of the assembly element, and the support assembly comprising a first portion having a fixed position relative to the support assembly, a second portion movable relative to the first portion, to which the assembly element is connected and which is movable with the second portion, and a sacrificial member configured to connect the positions of the first portion and the second portion and to break when a force applied to the assembly element by the material exceeds a predetermined level.

2. The assembly according to claim 1, wherein the material is a web of sheet material.

3. The assembly according to claim 1, wherein the second portion is rotatably connected to the first portion.

4. The assembly according to claim 3, wherein the support assembly further comprises a limiter element configured to limit rotation of the second portion relative to the first portion.

5. The assembly according to any one of claims 1 to 4, wherein the second portion is biased away from the support assembly.

6. The assembly according to any one of claims 1 to 4, wherein breakage of the sacrificial member enables the assembly element to move away from the operating position.

7. The assembly according to any one of claims 1 to 4, wherein the sacrificial member is configured to break when a force applied to the outlet of the assembly element by the material exceeds a predetermined level.

8. The assembly according to claim 7, wherein the sacrificial member is configured to break when a force applied to the outlet of the assembly element by the material exceeds a predetermined level that is less than the vertical breaking load at the outlet of the assembly element.

9. The assembly according to any one of claims 1 to 4, wherein the sacrificial member comprises a shear pin.

10. The assembly according to any one of claims 1 to 4, wherein the first part and the second part each comprise a recess for receiving a part of the sacrificial member.

11. The assembly according to claim 10, wherein the support assembly further comprises an intermediate member positioned within the recess of the first part or the second part for mediation between the sacrificial member and the recess.

12. The assembly according to claim 11, wherein the intermediate member is a bushing or a vibration isolation device.

13. The assembly according to any one of claims 1 to 4, wherein the sacrificial member comprises hardened steel or tempered steel.

14. The assembly according to any one of claims 1 to 4, wherein the support assembly further comprises position adjustment means for adjusting the position of the assembly element relative to the second part.

15. A system for use in the manufacture of an aerosol generating article, the assembly according to any one of claims 1 to 4, and a support, which, in use, allows the assembly element of the assembly to assemble material on the support.

16. a funnel upstream of the assembly, and rod forming means downstream of the assembly.

17. A method of constructing an assembly for use in the manufacture of an aerosol generating article, comprising providing an assembly element and a support assembly, the assembly element being for receiving and assembling material on the support assembly, wherein the assembly element comprises an inlet for receiving the material, an outlet for outward passage of the material, and a converging portion configured to receive the material from the inlet and to assemble the material on the support assembly as the material passes between the inlet and the outlet of the assembly element, and wherein the support assembly comprises a first part having a fixed position relative to the support assembly, and a second part movable relative to the first part, the assembly element being connected to the second part and being movable with the second part, and a sacrificial member configured to connect the positions of the first part and the second part and configured to break when the force applied to the assembly element by the material exceeds a predetermined level.

Images