Nicotine gum forming apparatus and method

Abstract

The present invention provides an apparatus and method for forming nicotine gum. [Solution] An apparatus for forming nicotine gum may include a first pair of drums configured to receive a nicotine gum mixture and press it to a first thickness to form a first pressed sheet, and a second pair of drums configured to receive the first pressed sheet and engrave it to form an engraved sheet containing a plurality of gum pieces. The second pair of drums may include a first drum having a first die having a first pattern, and a second drum having a second die having a second pattern. The second pattern may be a mirror image of the first pattern. The first and second drums may be spaced apart so that the first and second dies engrave at least the first pressed sheet as the first pressed sheet passes between the first and second drums.

Description

Technical Field

[0001] At least one exemplary embodiment relates to an apparatus and method for forming a gum such as nicotine gum.

Background Art

[0002] Oral nicotine products are available in various forms such as chewing gum, sprays, lozenges, dissolving tablets, non-dissolving chewing gum, films, gels, capsules, pouches (e.g., containing fibers or granules). Oral products may have nicotine concentrations that provide a familiar experience for adult tobacco consumers.

Summary of the Invention

Means for Solving the Problems

[0003] At least some exemplary embodiments relate to an apparatus for forming nicotine gum.

[0004] In at least one exemplary embodiment, the apparatus may include a first pair of drums and a second pair of drums. The first pair of drums may be configured to receive a nicotine gum mixture and press it to a first thickness to form a first pressed sheet. The second pair of drums may be configured to receive the first pressed sheet and score it to form a scored sheet including a plurality of gum pieces. The second pair of drums may include a first drum and a second drum. The first drum may include a first die having a first pattern, and the second drum may include a second die having a second pattern. The second pattern may be a mirror image of the first pattern. The first drum and the second drum may be spaced apart such that the first die and the second die score at least the first pressed sheet as the first pressed sheet passes between the first drum and the second drum.

[0005] In at least one exemplary embodiment, the first die may define a first plurality of recesses.

[0006] In at least one exemplary embodiment, the second die may define a second plurality of recesses corresponding to the first plurality of recesses.

[0007] In at least one exemplary embodiment, a second pair of drums may be configured to align a first plurality of non-recesses on the first die with a second plurality of non-recesses on the second die, so as to engrave at least a first pressed sheet into a plurality of gum pieces.

[0008] In at least one exemplary embodiment, the first drum of a second pair of drums may be configured to rotate at a first speed. The second drum of the second pair of drums may be configured to rotate at a second speed. The first and second speeds may be established to facilitate consistent material transfer. When the first plurality of non-recesses on the first die are aligned with the second plurality of non-recesses on the second die, the non-recesses make notches in at least the first pressed sheet.

[0009] In at least one exemplary embodiment, each of the first plurality of recesses may have a triangular cross-section along the upper surface of the non-recessed surface of the first die.

[0010] In at least one exemplary embodiment, a first segment of a non-recess on the first die can define one side of each of a pair of adjacent recesses.

[0011] In at least one exemplary embodiment, a second pair of drums may be located downstream of the first pair of drums.

[0012] In at least one exemplary embodiment, a third pair of drums may be located between the second pair of drums and the first pair of drums. The third pair of drums may be configured to receive the first pressed sheet and press it to a second uniform thickness.

[0013] In at least one exemplary embodiment, the heater may be configured to heat the first drum of a second pair of drums, the second drum of a second pair of drums, or a combination thereof, to heat the first pressed sheet.

[0014] At least some exemplary embodiments relate to methods for forming nicotine gum.

[0015] In at least one exemplary embodiment, a method for forming nicotine gum may include passing a sheet of gum mixture through a first pair of drums; pressing the sheet to a first thickness between the first pair of drums to form a first pressed sheet; and passing the first pressed sheet through a second pair of drums. The first drum of the second pair of drums may include a first die, and the second drum of the second pair of drums may include a second die. The first die may include a first recess pattern, and the second die may include a second recess pattern. The first recess pattern may be a mirror image of the second recess pattern, thereby enabling at least notching of the first pressed sheet to form a scored sheet containing a plurality of gum pieces.

[0016] In at least one exemplary embodiment, a second pair of drums may be located downstream of the first pair of drums.

[0017] In at least one exemplary embodiment, the method may further include passing a first pressed sheet through a third pair of drums. The third pair of drums may be located between a second pair of drums and a first pair of drums to press the first pressed sheet to a second uniform thickness.

[0018] In at least one exemplary embodiment, the second uniform thickness can range from 2 mm to 18 mm.

[0019] In at least one exemplary embodiment, the method may further include adjusting the temperatures of a first pair of drums and a second pair of drums.

[0020] In at least one exemplary embodiment, adjusting the temperatures of the first pair of drums and the second pair of drums may include heating the second pair of drums to raise the temperature of the first pressed sheet.

[0021] In at least one exemplary embodiment, adjusting the temperatures of the first pair of drums and the second pair of drums may include cooling the second pair of drums to lower the temperature of the first pressed sheet.

[0022] In at least one exemplary embodiment, passing a first pressed sheet through a second pair of drums may include aligning a first non-recess on the first die with a second non-recess on the second die so as to make at least a notch in the first pressed sheet.

[0023] In at least one exemplary embodiment, the first thickness can range from 4 mm to 20 mm.

[0024] In at least one exemplary embodiment, passing a first pressed sheet through a second pair of drums may include: rotating the first drum of the second pair of drums at a first speed; rotating the second drum of the second pair of drums at a second speed, where the first speed is the same as the second speed; and aligning the non-recesses of a first recess pattern on the first die with the non-recesses of a second recess pattern on the second die to etch at least the first pressed sheet and form a plurality of gum pieces.

[0025] At least some exemplary embodiments relate to an apparatus for forming nicotine gum.

[0026] In at least one exemplary embodiment, an apparatus for forming nicotine gum includes a first pair of drums and a second pair of drums. The first pair of drums may be configured to receive a nicotine gum mixture and press it to a first thickness to form a first pressed sheet. The second pair of drums may be configured to receive the first pressed sheet and cut it to form a plurality of gum pieces. The second pair of drums can include the first drum and the second drum. The first drum may include a first die having a first pattern. The second drum can include a second die having a second pattern. The second pattern may be a mirror image of the first pattern. The first drum and the second drum may be spaced apart such that the first die and the second die cut the plurality of gum pieces as the first pressed sheet passes between the first drum and the second drum.

Brief Description of the Drawings

[0027] The various features and advantages of the non-limiting embodiments herein will become more apparent upon consideration of the detailed description in conjunction with the accompanying drawings. The accompanying drawings are provided for illustrative purposes only and are not to be construed as limiting the claims. The accompanying drawings are not considered to be drawn to scale unless explicitly noted. For clarity, the various dimensions in the drawings may be exaggerated.

[0028] [Figure 1] FIG. 1 is a perspective view of a first side of an apparatus for forming nicotine gum according to at least one exemplary embodiment.

[0029] [Figure 2] FIG. 2 is a perspective view of a second side of an apparatus for forming nicotine gum according to at least one exemplary embodiment.

[0030] [Figure 3] Figure 3 is a schematic diagram of an apparatus for forming nicotine gum according to at least one exemplary embodiment.

[0031] [Figure 4] Figure 4 is an end view perspective of an apparatus for forming nicotine gum according to at least one exemplary embodiment.

[0032] [Figure 5] Figure 5 is a perspective view of a die used in an apparatus for forming nicotine gum according to at least one exemplary embodiment.

[0033] [Figure 6] Figure 6 is a front view of a die used in an apparatus for forming nicotine gum according to at least one exemplary embodiment.

[0034] [Figure 7] Figure 7 is a side view of a die used in an apparatus for forming nicotine gum according to at least one exemplary embodiment.

[0035] [Figure 8A] Figure 8A is a top view of a first pressed sheet according to at least one exemplary embodiment.

[0036] [Figure 8B] Figure 8B is a side view of a first pressed sheet according to at least one exemplary embodiment.

[0037] [Figure 9A] Figure 9A is a top view of a second pressed sheet according to at least one exemplary embodiment.

[0038] [Figure 9B]Figure 9B is a side view of a second pressed sheet according to at least one exemplary embodiment.

[0039] [Figure 10A] Figure 10A is a top view of an engraved sheet according to at least one exemplary embodiment.

[0040] [Figure 10B] Figure 10B is a side view of an engraved sheet according to at least one exemplary embodiment.

[0041] [Figure 11A] Figure 11A is a cross-sectional view of a recess of a die for forming a gum piece having a triangular cross-section along the upper surface of a non-recess, according to at least one exemplary embodiment.

[0042] [Figure 11B] Figure 11B is a cross-sectional view of a recess in a die for forming a gum piece having a cross-section that passes through the thickness and bisects the vertex, according to at least one exemplary embodiment.

[0043] [Figure 11C] Figure 11C is a cross-sectional view of a die according to at least one exemplary embodiment, having a recess cut along the longitudinal axis of the die and bisected through its vertex.

[0044] [Figure 11D] Figure 11D is a cross-sectional view of a die having a recess, cut along an axis perpendicular to the longitudinal axis of the die, according to at least one exemplary embodiment.

[0045] [Figure 12A] Figure 12A is a cross-sectional view of a recess in a die along the upper surface of a non-recess for forming a gum piece having a square cross-section, according to at least one exemplary embodiment.

[0046] [Figure 12B]Figure 12B is a cross-sectional view of a recess in a die for gum pieces having a cross-section through the thickness, according to at least one exemplary embodiment.

[0047] [Figure 13A] Figure 13A is a cross-sectional view of a recess in a die along the upper surface of a non-recess for forming a gum piece having a rectangular cross-section, according to at least one exemplary embodiment.

[0048] [Figure 13B] Figure 13B is a cross-sectional view of a recess in a die for forming a gum piece having a cross-section through the thickness, according to at least one exemplary embodiment.

[0049] [Figure 14A] Figure 14A is a cross-sectional view of a recess in a die along the upper surface of a non-recess for forming gum pieces having a circular cross-section, according to at least one exemplary embodiment.

[0050] [Figure 14B] Figure 14B is a cross-sectional view of a recess in a die for forming a gum piece having a cross-section through the thickness, according to at least one exemplary embodiment.

[0051] [Figure 15A] Figure 15A is a cross-sectional view of a recess in a die along the upper surface of a non-recess for forming a gum piece having a trapezoidal cross-section, according to at least one exemplary embodiment.

[0052] [Figure 15B] Figure 15B is a cross-sectional view of a recess in a die for forming a gum piece having a cross-section through the thickness, according to at least one exemplary embodiment.

[0053] [Figure 16A] Figure 16A is a cross-sectional view of a recess in a die along the upper surface of a non-recess for forming a gum piece having a stadium cross-section, according to at least one exemplary embodiment.

[0054] [Figure 16B] Figure 16B is a cross-sectional view of a recess in a die for forming a gum piece having a cross-section through the thickness, according to at least one exemplary embodiment.

[0055] [Figure 17] Figure 17 is a perspective view of a die used in an apparatus for forming nicotine gum according to at least one exemplary embodiment.

[0056] [Figure 18] Figure 18 is a front view of a die used in an apparatus for forming nicotine gum according to at least one exemplary embodiment.

[0057] [Figure 19] Figure 19 is a schematic diagram of an apparatus for forming nicotine gum according to at least one exemplary embodiment.

[0058] [Figure 20] Figure 20 is a schematic diagram of a control system for an apparatus for forming nicotine gum, according to at least one exemplary embodiment.

[0059] [Figure 21] Figure 21 is a flowchart of a method for forming nicotine gum according to at least one exemplary embodiment. [Modes for carrying out the invention]

[0060] Several detailed exemplary embodiments are disclosed herein. However, the specific structural and functional details disclosed herein are merely representative for the purpose of illustrating the exemplary embodiments. However, the exemplary embodiments may be embodied in many alternative forms and should not be construed as being limited only to the exemplary embodiments described herein.

[0061] Therefore, while exemplary embodiments are subject to various modifications and alternative forms, they are illustrated in the drawings and described in detail herein. However, it should be understood that exemplary embodiments are not intended to limit themselves to any particular form disclosed, but rather to cover all modifications, equivalents, and alternatives that fall within the scope of the exemplary embodiments. Similar numbers refer to similar elements throughout the description of the figures.

[0062] When an element or layer is said to be “on,” “connected to,” “coupled to,” “attached to,” “adjacent to,” or “covering” another element or layer, it should be understood that it may be directly connected to, coupled to, attached to, adjacent to, or covering the other element or layer, or there may be an intervening element or layer. On the other hand, when an element is said to be “directly on,” “directly connected to,” or “directly coupled to” another element or layer, there is no intervening element or layer. In this specification, the same number means the same element. In this specification, the term “and / or” includes any and all combinations or subcombinations of one or more of the related listed items.

[0063] In this specification, terms such as first, second, third, etc., may be used to describe various elements, regions, layers, and / or sections, but it should be understood that these elements, regions, layers, and / or sections should not be limited by these terms. These terms are used solely to distinguish one element, region, layer, or section from another. Thus, the first element, region, layer, or section described below may be referred to as the second element, region, layer, or section without departing from the teaching of the exemplary embodiments.

[0064] In this specification, for the sake of clarity, spatially relative terms (e.g., "beneath," "below," "lower," "above," "upper," etc.) may be used to describe the relationship between one element or function and another, as shown in the diagrams. It should be understood that spatially relative terms are intended to encompass different orientations of the device during use or operation, in addition to the orientation depicted in the diagrams. For example, if the device in the diagram is turned over, elements described as "below" or "beneath" of other elements or features will be oriented "above" of those elements or features. Therefore, the term "below" may encompass both up and down orientations. Furthermore, the device may be oriented in other directions (it may be rotated 90 degrees or oriented in other directions), and the spatially relative descriptors used herein will be interpreted accordingly.

[0065] The terms used herein are for illustrative purposes only and are not intended to limit the exemplary embodiments. The singular forms “a,” “an,” and “the” as used herein are intended to include the plural form unless the context clearly indicates otherwise. It will be further understood that the terms “includes,” “including,” “comprises,” and / or “comprising” as used herein identify the presence of the described features, integers, steps, operations, and / or elements, but do not exclude the presence or addition of one or more other features, integers, steps, operations, elements, and / or groups thereof.

[0066] Where the terms “about” and “substantially” are used in relation to numerical values ​​in this specification, unless otherwise expressly defined, the numerical values ​​are intended to include a tolerance of ±10% around the stated numerical value. Furthermore, where the terms “generally” or “substantially” are used in relation to geometric shapes, precision of the geometric shape is not required, but tolerances of the shape are intended to be within the scope of this disclosure. Moreover, regardless of whether numerical values ​​or shapes are modified as “about,” “generally,” or “substantially,” it will be understood that these numerical values ​​and shapes should be interpreted as including a manufacturing or operational tolerance (e.g., ±10%) around the stated numerical value or shape.

[0067] Unless otherwise defined, all terms used herein (including technical and scientific terms) have the same meaning as commonly understood by those skilled in the art in the field to which the exemplary embodiments belong. Furthermore, terms including those defined in commonly used dictionaries should be interpreted as having the meaning consistent with their meaning in the context of the relevant art, and it will be understood that they should not be interpreted in an idealized or overly formal sense unless expressly defined herein.

[0068] Figure 1 is a first side perspective view of an apparatus for forming nicotine gum according to at least one exemplary embodiment, and Figure 2 is a second side perspective view of an apparatus for forming nicotine gum according to at least one exemplary embodiment.

[0069] In at least one exemplary embodiment, the apparatus 100 configured to form nicotine gum includes a first section 110, a second section 114, and a third section 118. In at least one exemplary embodiment, the first section 110, the second section 114, and the third section 118 process a gum mixture to form a plurality of gum pieces.

[0070] In at least one exemplary embodiment, the gum mixture is a nicotine gum mixture comprising a gum base polymer, an oil, and nicotine or a nicotine derivative. In at least one exemplary embodiment, the gum base polymer comprises polyvinyl acetate (PVA), and the oil comprises a triglyceride. In at least one exemplary embodiment, the nicotine gum mixture may be the nicotine gum mixture described in U.S. Patent Application No. 1, Attorney Docket No. 24000NV-000733-US, entitled "CONTROLLED-RELEASE NICOTINE CHEWING GUM," filed concurrently with this specification on April 6, 2021, the disclosure of which is incorporated herein by reference in its entirety. While nicotine gum mixtures are described, it is understood that this disclosure is not limited thereto. In at least one alternative embodiment, the gum mixture is a cannabinoid gum mixture, a non-nicotine gum mixture, or any suitable gum mixture.

[0071] In at least one exemplary embodiment, the apparatus 100 can process a gum mixture (hereinafter described with respect to, but not limited to, a nicotine gum mixture) to form at least partially a plurality of gum pieces, each of which has a size and shape that is accepted as a whole in the oral cavity of an adult tobacco consumer.

[0072] Referring to Figures 1 and 2, in at least one exemplary embodiment, the first section 110 includes a first tower having a first housing 120, a first pair of gear assemblies 122, and a first pair of drums 124. The first pair of drums includes a first upper drum 126 and a first lower drum 208 (see Figure 2). The first housing 120 at least partially encloses the first upper drum 126 and the first lower drum 208. The first upper drum 126 is adjacent to the first lower drum 208 and positioned vertically above the first lower drum 208. In at least one exemplary embodiment, the first upper drum 126 and the first lower drum 208 are cylindrical drums. The first upper drum 126 and the first lower drum 208 may rotate within the first housing 120 to process a gum mixture.

[0073] In at least one exemplary embodiment, the first pair of gear assemblies 122 includes a first upper gear assembly 130 and a first lower gear assembly 132. The first upper drum 126 is rotated by the first upper gear assembly 130, which is located outside the first housing 120. The first upper gear assembly 130 includes one or more wheels. Each of the one or more wheels includes teeth that mesh to transmit motion from one wheel to another.

[0074] In at least one exemplary embodiment, the first upper gear assembly 130 is connected to the first upper drum 126 by a first upper shaft 134, fixing the first upper drum 126 for rotation by the first upper gear assembly 130. In at least one exemplary embodiment, the first upper gear assembly 130 is rotated manually or by a motor as described below in order to rotate the first upper drum 126.

[0075] In at least one exemplary embodiment, the first lower drum 208 is rotated by a first lower gear assembly 132 located outside the first housing 120. The first lower gear assembly 132 may include one or more wheels having meshing teeth to transmit motion from one wheel to another.

[0076] The first lower gear assembly 132 is connected to the first lower drum 208 by the first lower shaft 212 (see Figure 2), fixing the first lower drum 208 for rotation by the first lower gear assembly 132. In at least one exemplary embodiment, the first upper gear assembly 130 meshes with the first lower gear assembly 132 to drive the rotation of the first lower gear assembly 132, or is driven by the rotation of the first lower gear assembly 132. The first upper gear assembly 130 and the first lower gear assembly 132 determine the velocity relationship between the first upper drum 126 and the first lower drum 208.

[0077] In at least one exemplary embodiment, the first upper drum 126 and the first lower drum 208 constitute the first press drum. In at least one exemplary embodiment, the first upper drum 126 includes a smooth outer surface 138, and the first lower drum 208 includes a smooth outer surface 216 for contact with the gum mixture. In other exemplary embodiments, the outer surface 138 of the first upper drum 126 and the outer surface 216 of the first lower drum 208 may be textured (not shown). In other exemplary embodiments, the outer surfaces 138 and 216 may each include a non-stick coating (not shown). The first pair of drums 124 may receive the gum mixture, and as the first upper drum 126 and the first lower drum 208 rotate, the first upper drum 126 presses the gum mixture against the first lower drum 208 to form the gum mixture into a pressed sheet of first thickness, as further described below.

[0078] In at least one exemplary embodiment, the second section 114 includes a second tower having a second housing 140, a second pair of gear assemblies 142, and a second pair of drums 144. The second pair of drums 144 includes a second upper drum 146 and a second lower drum 228 (see Figure 2). The second housing 140 can at least partially enclose the second upper drum 146 and the second lower drum 228. The second upper drum 146 is adjacent to the second lower drum 228 and positioned vertically above the second lower drum 228. In at least one exemplary embodiment, the second upper drum 146 and the second lower drum 228 are cylindrical drums. The second upper drum 146 and the second lower drum 228 can rotate within the second housing 140 to collectively process the first pressed sheet.

[0079] In at least one exemplary embodiment, the second pair of gear assemblies 142 includes a second upper gear assembly 150 and a second lower gear assembly 152. The second upper drum 146 is rotated by the second upper gear assembly 150, which is located outside the second housing 140. The second upper gear assembly 150 may include one or more wheels having meshing teeth to transmit movement from one wheel to another.

[0080] In at least one exemplary embodiment, the second upper gear assembly 150 is connected to the second upper drum 146 by a second shaft 154, fixing the second upper drum 146 for rotation by the second upper gear assembly 150. In at least one exemplary embodiment, the second upper gear assembly 150 is rotated manually or by a motor, as described below, in order to rotate the second upper drum 146.

[0081] In at least one exemplary embodiment, the second lower drum 228 is rotated by a second lower gear assembly 152 located outside the second housing 140. The second lower gear assembly 152 may include one or more wheels having teeth that mesh to transmit motion from one wheel to another.

[0082] In at least one exemplary embodiment, the second lower gear assembly 152 is connected to the second lower drum 228 by a shaft 232, fixing the second lower drum 228 for rotation by the second lower gear assembly 152. In at least one exemplary embodiment, the second lower gear assembly 152 meshes with the second upper gear assembly 150 to drive the second upper gear assembly 150, or is driven by the rotation of the second upper gear assembly 150. The second upper gear assembly 150 and the second lower gear assembly 152 determine the velocity relationship between the second upper drum 146 and the second lower drum 228.

[0083] In at least one exemplary embodiment, the second upper drum 146 and the second lower drum 228 are second press drums. In at least one exemplary embodiment, the second upper drum 146 includes a smooth outer surface 158, and the second lower drum includes a smooth outer surface 236 for contacting the pressed sheet. However, in other exemplary embodiments, the outer surfaces 158 and 236 may each have a textured surface. In other exemplary embodiments, the outer surfaces 158 and 236 may each include a non-stick coating (not shown). The second pair of drums 144 may receive the pressed sheet, and as the second upper drum 146 and the second lower drum 228 rotate, the second upper drum 146 presses the first pressed sheet against the second lower drum 228 to form the first pressed sheet into a second pressed sheet having a second thickness, as will be further described below.

[0084] In at least one exemplary embodiment, the third section 118 includes a third tower having a third housing 160, a third pair of gear assemblies 162, and a third pair of drums 164. The third pair of drums 164 includes a third upper drum 166 and a third lower drum 316 (further described later with reference to Figure 3). The third housing 160 at least partially encloses the third upper drum 166 and the third lower drum 316. The third upper drum 166 is adjacent to the third lower drum 316 and positioned vertically above the third lower drum 316. In at least one exemplary embodiment, the third upper drum 166 and the third lower drum 316 are cylindrical drums. The third upper drum 166 and the third lower drum 316 can rotate within the third housing 160 to collectively process the second pressed sheet.

[0085] In at least one exemplary embodiment, the third pair of gear assemblies 162 includes a third upper gear assembly 170 and a third lower gear assembly 172. The third upper drum 166 is rotated by the third upper gear assembly 170, which is located outside the third housing 160. In at least one exemplary embodiment, the third upper gear assembly 170 includes one or more wheels having teeth. The teeth of each wheel mesh to transmit motion from one wheel to another.

[0086] In at least one exemplary embodiment, the third upper gear assembly 170 is connected to the third upper drum 166 by a shaft 174, fixing the third upper drum 166 for rotation by the third upper gear assembly 170. In at least one exemplary embodiment, the third upper gear assembly 170 is rotated manually or by a motor, as described below, in order to rotate the third upper drum 166.

[0087] In at least one exemplary embodiment, the third lower drum 316 is rotated by a third lower gear assembly 172 located outside the third housing 160 (see Figure 3). In at least one exemplary embodiment, the third lower gear assembly 172 includes one or more wheels having teeth. The teeth of each wheel mesh to transmit motion from one wheel to another.

[0088] In at least one exemplary embodiment, the third lower gear assembly 172 is connected to the third lower drum 316 by a shaft 324, fixing the third lower drum 316 for rotation by the third lower gear assembly 172. In at least one exemplary embodiment, the third lower gear assembly 172 meshes with the third upper gear assembly 170 to drive the third upper gear assembly 170, or is driven by the rotation of the third upper gear assembly 170. The third upper gear assembly 170 and the third lower gear assembly 172 determine the velocity relationship between the third upper drum 166 and the third lower drum 316.

[0089] In at least one exemplary embodiment, the third upper drum 166 and the third lower drum 316 are forming drums. The third pair of drums 164 receive the second pressed sheet and form the second pressed sheet into a plurality of gum pieces, as will be described later.

[0090] In at least one exemplary embodiment, the third upper drum 166 includes a die 178 having a pattern of recesses 182 on its outer surface 184. In at least one exemplary embodiment, the third lower drum 316 includes a die 328 having a pattern of recesses 400 on its outer surface 332 (see Figure 4). The die 328 is similar to the die 178. The pattern of recesses 182 and the pattern of recesses 400 may be formed from a sheet pressed together into a scored sheet containing multiple pieces of gum.

[0091] In at least one exemplary embodiment, a third pair of drums 164 receive a second pressed sheet, and a third upper drum 166 and a third lower drum 316 rotate the second pressed sheet to form a plurality of gum pieces, or a scribing sheet containing a plurality of gum pieces. In at least one exemplary embodiment, the third pair of drums 164 cooperate to score the plurality of gum pieces into a scribing sheet, as will be further described below. The scribing sheet contains a plurality of gum pieces formed and attached in a single sheet. In at least one alternative exemplary embodiment, the third pair of drums 164 cooperate to cut the plurality of gum pieces into individual distinct pieces, as will be further described below.

[0092] In at least one exemplary embodiment, the first plate 240 extends between the first section 110 and the second section 114, more specifically between the first pair of drums 124 of the first section 110 and the second pair of drums 144 of the second section 114. In at least one exemplary embodiment, the first plate 240 is arranged so that the first pressed sheet is deposited onto the first plate 240 from the first pair of drums 124 of the first section 110, supported by the first plate 240, and fed to the second pair of drums 144 of the second section 114.

[0093] In at least one exemplary embodiment, the first plate 240 includes a first surface 244 that contacts the first pressed sheet as the first pressed sheet moves within the apparatus 100. The first surface 244 is a substantially flat plane extending along the top surface 248 of the first plate 240. In at least one exemplary embodiment, the first surface 244 is a smooth surface to facilitate the transport of the first pressed sheet from the first pair of drums 124 to the second pair of drums 144.

[0094] In at least one exemplary embodiment, the second plate 252 extends between the second section 114 and the third section 118, more specifically between the second pair of drums 144 in the second section 114 and the third pair of drums 164 in the third section 118. In at least one exemplary embodiment, the second plate 252 is positioned so that the second pressed sheet is deposited onto the second plate 252 from the second pair of drums 144 in the second section 114. The second pressed sheet is supported by the second plate 252 and supplied to the third pair of drums 164 in the third section 118.

[0095] In at least one exemplary embodiment, the second plate 252 includes a second surface 256 that contacts the second pressed sheet as the second pressed sheet moves within the apparatus 100. The second surface 256 is a flat plane extending along the upper surface 260 of the second plate 252. In at least one exemplary embodiment, the second surface 256 is a smooth surface to facilitate the transport of the second pressed sheet from the second pair of drums 144 to the third pair of drums 164.

[0096] In at least one exemplary embodiment, the first section 110, the second section 114, and the third section 118 are supported on a frame 186. The frame 186 may include a planar support 190, such as a table or plate, that supports the first section 110, the second section 114, and the third section 118.

[0097] Figure 3 is a schematic diagram of an apparatus for forming nicotine gum according to at least one exemplary embodiment.

[0098] In at least one exemplary embodiment, the apparatus 100 includes a first section 110 having a first pair of drums 124, a second section 114 having a second pair of drums 144, and a third section 118 having a third pair of drums 164. The first upper drum 126 and the first lower drum 208 of the first pair of drums 124 are aligned vertically, with the first upper drum 126 positioned above the first lower drum 208. The first upper drum 126 is spaced a first distance D1 from the first lower drum 208, forming a gap 304 between them. In at least one exemplary embodiment, the distance D1 between the first upper drum 126 and the first lower drum 208 ranges from about 4 millimeters (mm) to about 20 mm (e.g., about 8 mm to about 11 mm or about 9.5 mm to about 10 mm). While an exemplary range is provided, it is understood that the disclosure is not limited thereto. Distance D1 may depend on the desired (or alternatively, specified) nicotine gum product and may vary for different products, different target weights, or different desired (or alternatively, specified) thicknesses.

[0099] In at least one exemplary embodiment, a first upper drum 126 and a first lower drum 208 are press drums that cooperate to press the gum mixture together to produce a first pressed sheet. In at least one exemplary embodiment, the first pressed sheet has a thickness corresponding to the distance D1 of the gap 304 between the first upper drum 126 and the first lower drum 208. Thus, in at least one exemplary embodiment, the first pressed sheet has a thickness in the range of about 4 mm to about 20 mm (e.g., about 8 mm to about 11 mm or about 9.5 mm to about 10 mm).

[0100] In at least one exemplary embodiment, the second upper drum 146 and the second lower drum 228 of the second pair of drums 144 are vertically aligned, with the second upper drum 146 positioned above the second lower drum 228. The second upper drum 146 is spaced a second distance D2 from the second lower drum 228, forming a gap 308 between them. In at least one exemplary embodiment, the distance D2 between the second upper drum 146 and the second lower drum 228 is in the range of about 2 mm to about 18 mm (e.g., about 6 mm to about 9 mm or about 7.5 mm to about 8 mm). While an exemplary range is provided, it is understood that the disclosure is not limited thereto. The distance D2 may depend on the desired (or alternatively, predetermined) nicotine gum product and may vary for different products, different target weights, or different desired (or alternatively, predetermined) thicknesses.

[0101] In at least one exemplary embodiment, the second upper drum 146 and the second lower drum 228 are press drums that cooperate to further press the first pressed sheet together to produce a second pressed sheet. In at least one exemplary embodiment, the second pressed sheet has a thickness corresponding to the distance D2 of the gap 308 between the second upper drum 146 and the second lower drum 228. Thus, in at least one exemplary embodiment, the second pressed sheet has a thickness in the range of about 2 mm to about 18 mm (e.g., about 6 mm to about 9 mm, or about 7.5 mm to about 8 mm).

[0102] In at least one exemplary embodiment, the third upper drum 166 and the third lower drum 316 are vertically aligned, with the third upper drum 166 positioned above the third lower drum 316. The third upper drum 166 is spaced a third distance D3 from the third lower drum 316, forming a gap 336 between them. In at least one exemplary embodiment, the distance D3 between the third upper drum 166 and the third lower drum 316 is in the range of about 0 mm to about 0.2 mm (e.g., about 0.1 mm). While an exemplary range is provided, it is understood that the disclosure is not limited thereto. The distance D3 may depend on the desired (or alternatively, a given) nicotine gum product and may vary for different products. In at least one exemplary embodiment, the distance D3 is in the range of about 0.1 mm to about 0.2 mm, and the second pressed sheet is etched to become an etched sheet. In at least one alternative exemplary embodiment, the distance D3 is approximately 0 mm, or the third upper drum 166 contacts the third lower drum 316 to cut the second pressed sheet into individual gum pieces.

[0103] In at least one exemplary embodiment, the supply plate 340 extends upstream of the first section 110, more specifically, upstream of the first pair of drums 124 of the first section 110. In at least one exemplary embodiment, the supply plate 340 is positioned so that the gum mixture is deposited on the supply plate 340, supported by the supply plate 340, and supplied to the first pair of drums 124 of the first section 110.

[0104] In at least one exemplary embodiment, the feed plate 340 includes a surface 344 that comes into contact with the gum mixture. The surface 344 is a flat plane extending along the top 348 of the feed plate 340. In at least one exemplary embodiment, the surface 344 is a smooth surface to facilitate the transfer of the gum mixture to the first pair of drums 124.

[0105] In at least one exemplary embodiment, the discharge plate 352 extends downstream of the third section 118, more specifically, downstream of the third pair of drums 164 of the third section 118. In at least one exemplary embodiment, the discharge plate 352 is positioned so that the etched sheets or individual pieces of gum accumulate on the discharge plate 352, are supported by the discharge plate 352, and are transported away from the third pair of drums 164 of the third section 118.

[0106] In at least one exemplary embodiment, the discharge plate 352 includes a surface 356 that contacts the etched sheet or individual pieces of gum. The surface 356 is a flat plane extending along the top 360 of the discharge plate 352. In at least one exemplary embodiment, the surface 356 is a smooth surface to facilitate the transport of the etched sheet or individual pieces of gum away from the third pair of drums 164.

[0107] In at least one exemplary embodiment, during operation, the gum mixture is deposited on the feed plate 340. The first upper drum 126 and the first lower drum 208 begin to rotate. In at least one exemplary embodiment, the first upper drum 126 rotates counterclockwise and the first lower drum 208 rotates clockwise.

[0108] In at least one exemplary embodiment, the first upper drum 126 rotates at a first speed and the first lower drum 208 rotates at a second speed. The first and second speeds are set so that there is consistent material transfer through the first upper drum 126 and the first lower drum 208. In at least one exemplary embodiment, the first speed is the same as the second speed and ranges from about 0 revolutions per minute (RPM) to about 20 RPM. In at least one alternative exemplary embodiment, the first speed is different from the second speed. The first upper drum 126 may rotate at a speed in the range of about 0 RPM to about 20 RPM, and the first lower drum 208 may rotate at a speed in the range of about 0 RPM to about 20 RPM. Having different first and second speeds may allow for the relief of imposed strain in the gum mixture as the mixture passes through the apparatus 100. In at least one exemplary embodiment, the first and second speeds are determined based on the speed at which the plurality of gum pieces are removed from the third pair of drums 300 (e.g., the speed at which the operator removes the plurality of gum pieces from the third pair of drums 300). In at least one exemplary embodiment, the speed at which the plurality of gum pieces are removed from the third pair of drums 300 is related to the components and proportions of the gum material, environmental conditions, temperature, coating effect of the gum material, shape of the recesses 182, 400, or a combination thereof.

[0109] In at least one exemplary embodiment, the first upper drum 126 is rotated by the first upper gear assembly 130, and the first lower drum 208 is rotated by the first lower gear assembly 132. The first upper gear assembly 130 and the first lower gear assembly 132 determine the speed relationship between the first upper drum 126 and the first lower drum 208. In at least one exemplary embodiment, for each of the first upper gear assembly 130 and the first lower gear assembly 132, the number of teeth on each gear, the size of each gear, and the number of gears determine the speed relationship.

[0110] In at least one exemplary embodiment, the first upper gear assembly 130, the first lower gear assembly 132, or a combination thereof, is rotated manually. The crank 368 includes a crank gear 372 that meshes with the first lower gear assembly 132 to drive the rotation of the first lower gear assembly 132. The rotation of the first lower gear assembly 132 rotates the first lower drum 208, which in turn drives the rotation of the first upper gear assembly 130. The rotation of the first upper gear assembly 130 rotates the first upper drum 126. In at least one alternative embodiment, the crank 368 engages with the first upper gear assembly 130 and has the opposite effect.

[0111] In at least one exemplary embodiment, the gum mixture is supplied to a gap 304 that separates the first upper drum 126 from the first lower drum 208. The rotation of the first upper drum 126 and the first lower drum 208 draws the gum mixture through the gap 304. The gum mixture is pressed between the first upper drum 126 and the first lower drum 208 to form a first pressed sheet. As described above, in at least one exemplary embodiment, the first pressed sheet has a thickness ranging from about 4 mm to about 20 mm (e.g., about 8 mm to about 11 mm or about 9.5 mm to about 10 mm). The first pressed sheet exits the gap 304 and the first pair of drums 124 onto the first plate 240.

[0112] In at least one exemplary embodiment, the first pressed sheet is transferred along the first plate 240 from the first pair of drums 124 to the second pair of drums 144. The second upper drum 146 and the second lower drum 228 of the second pair of drums 144 begin to rotate. In at least one exemplary embodiment, the second upper drum 146 rotates counterclockwise and the second lower drum 228 rotates clockwise.

[0113] In at least one exemplary embodiment, the first pair of drums 124 may be spaced about 100 mm to about 1500 mm (e.g., about 200 mm to about 400 mm, or about 305 mm) away from the second pair of drums 144. In at least one exemplary embodiment, the first pressed sheet may be completely out of the first pair of drums 124 before being supplied to the second pair of drums 144. In at least one alternative embodiment, the first pressed sheet may be pressed in the first pair of drums 124 in a first portion and simultaneously pressed in the second pair of drums 144 in a second portion. Thus, the material of the first pressed sheet may extend between multiple pairs of drums, including the first pair of drums 124, the second pair of drums 144, and the third pair of drums 164.

[0114] In at least one exemplary embodiment, the second upper drum 146 rotates at a first speed and the second lower drum 228 rotates at a second speed. The first and second speeds are set to ensure consistent material transfer through the second upper drum 146 and the second lower drum 228. In at least one exemplary embodiment, the first speed is the same as the second speed and ranges from about 0 RPM to about 20 RPM. In at least one alternative exemplary embodiment, the first speed is different from the second speed. The speed of the second upper drum 146 may range from about 0 RPM to about 20 RPM, and the speed of the second lower drum 228 may range from about 0 RPM to about 20 RPM. Having different first and second speeds may allow for the relief of strain imposed on the material of the first pressed sheet as it passes through the apparatus 100. In at least one exemplary embodiment, the first and second speeds are determined based on the speed at which the plurality of gum pieces are removed from the third pair of drums 300 (e.g., the speed at which the operator removes the plurality of gum pieces from the third pair of drums 300). In at least one exemplary embodiment, the speed at which the plurality of gum pieces are removed from the third pair of drums 300 is related to the components and proportions of the gum material, environmental conditions, temperature, coating effect of the gum material, shape of the recesses 182, 400, or a combination thereof.

[0115] In at least one exemplary embodiment, the first speed of the second upper drum 146 and the second speed of the second lower drum 228 are the same as the first speed of the first upper drum 126 and the second speed of the first lower drum 208, respectively. In at least one alternative exemplary embodiment, the first speed of the second upper drum 146 and the second speed of the second lower drum 228 are different from the first speed of the first upper drum 126 and the second speed of the first lower drum 208.

[0116] In at least one exemplary embodiment, the second upper drum 146 is rotated by the second upper gear assembly 150, and the second lower drum 228 is rotated by the second lower gear assembly 152. The second upper gear assembly 150 and the second lower gear assembly 152 determine the speed relationship between the second upper drum 146 and the second lower drum 228. In at least one exemplary embodiment, for each of the second upper gear assembly 150 and the second lower gear assembly 152, the number of teeth on each gear, the size of each gear, and the number of gears determine the speed relationship.

[0117] In at least one exemplary embodiment, the second upper gear assembly 150, the second lower gear assembly 152, or a combination thereof, is rotated manually. The crank 380 includes a crank gear assembly 384 that engages with the second lower gear assembly 152 to drive the rotation of the second lower gear assembly 152. The rotation of the second lower gear assembly 152 rotates the second lower drum 228, which in turn drives the rotation of the second upper gear assembly 150. The rotation of the second upper gear assembly 150 rotates the second upper drum 146. In at least one alternative embodiment, the crank 380 may engage with the second upper gear assembly 150 and have the opposite effect.

[0118] In at least one exemplary alternative embodiment, a second upper gear assembly 150, a second lower gear assembly 152, or a combination thereof engages with, or is driven by, a first upper gear assembly 130, a first lower gear assembly 132, or a combination thereof of the first section 110.

[0119] In at least one exemplary embodiment, a first pressed sheet is fed into a gap 308 separating a second upper drum 146 and a second lower drum 228. The rotation of the second upper drum 146 and the second lower drum 228 pulls the first pressed sheet through the gap 308. The first pressed sheet is further pressed between the second upper drum 146 and the second lower drum 228 to become a second pressed sheet. As previously stated, in at least one exemplary embodiment, the second pressed sheet has a thickness ranging from about 2 mm to about 18 mm (e.g., about 6 mm to about 9 mm or about 7.5 mm to about 8 mm). The second pressed sheet exits the gap 308 and the second pair of drums 142 onto the second plate 252.

[0120] In at least one exemplary embodiment, the second pressed sheet is transferred along the second plate 252 from the second pair of drums 144 to the third pair of drums 164. The third upper drum 166 and the third lower drum 316 of the third pair of drums 164 begin to rotate. In at least one exemplary embodiment, the third upper drum 166 rotates counterclockwise and the third lower drum 316 rotates clockwise.

[0121] In at least one exemplary embodiment, the third upper drum 166 rotates at a first speed and the third lower drum 316 rotates at a second speed. The first and second speeds are set to ensure consistent material transfer through the third upper drum 166 and the third lower drum 316. In at least one exemplary embodiment, the first speed is the same as the second speed and ranges from about 0 RPM to about 20 RPM. In at least one alternative exemplary embodiment, the first speed is different from the second speed. The speed of the third upper drum 166 may range from about 0 RPM to about 20 RPM, and the speed of the third lower drum 316 may range from about 0 RPM to about 20 RPM. Having different first and second speeds may allow for the relief of strain imposed on the material of the second pressed sheet as it passes through the apparatus 100. In at least one exemplary embodiment, the first and second speeds are determined based on the speed at which the plurality of gum pieces are removed from the third pair of drums 300 (e.g., the speed at which the operator removes the plurality of gum pieces from the third pair of drums 300). In at least one exemplary embodiment, the speed at which the plurality of gum pieces are removed from the third pair of drums 300 is related to the components and proportions of the gum material, environmental conditions, temperature, coating effect of the gum material, shape of the recesses 182, 400, or a combination thereof.

[0122] In at least one exemplary embodiment, the first speed of the third upper drum 166 and the second speed of the third lower drum 316 are the same as the first speed of the first upper drum 126 and the second speed of the first lower drum 208, respectively. In at least one exemplary embodiment, the first speed of the third upper drum 166 and the second speed of the third lower drum 316 are the same as the first speed of the second upper drum 146 and the second speed of the second lower drum 228, respectively. In at least one alternative exemplary embodiment, the first speed of the third upper drum 166 and the second speed of the third lower drum 316 are different from the first speed of the first upper drum 126, the second speed of the first lower drum 208, the first speed of the second upper drum 146, and the second speed of the second lower drum 228.

[0123] In at least one exemplary embodiment, the third upper drum 166 is rotated by a third upper gear assembly 170, and the third lower drum 316 is rotated by a third lower gear assembly 172. The third upper gear assembly 170 and the third lower gear assembly 172 determine the speed relationship between the third upper drum 166 and the third lower drum 316. In at least one exemplary embodiment, for each of the third upper gear assembly 170 and the third lower gear assembly 172, the number of teeth on each gear, the size of each gear, and the number of gears determine the speed relationship.

[0124] In at least one exemplary embodiment, the third upper gear assembly 170, the third lower gear assembly 172, or a combination thereof, is rotated manually. The crank 388 includes a crank gear 392 that engages with the third lower gear assembly 172 to drive the rotation of the third lower gear assembly 172. The rotation of the third lower gear assembly 172 rotates the third lower drum 316, which in turn drives the rotation of the third upper gear assembly 170. The rotation of the third upper gear assembly 170 rotates the third upper drum 166. In at least one alternative embodiment, the crank 388 engages with the third upper gear assembly 170, having the opposite effect.

[0125] In at least one exemplary alternative embodiment, a third upper gear assembly 170, a third lower gear assembly 172, or a combination thereof engages with a first upper gear assembly 130, a first lower gear assembly 132, a second upper gear assembly 150, a second lower gear assembly 152, or a combination thereof, and drives, or is driven by, the first upper gear assembly 130, the first lower gear assembly 132, the second upper gear assembly 150, the second lower gear assembly 152, or a combination thereof. In at least one exemplary embodiment, a second pressed sheet is supplied to a gap 336 that separates the third upper drum 166 from the third lower drum 316. The rotation of the third upper drum 166 and the third lower drum 316 pulls the second pressed sheet through the gap 336. The second pressed sheet is formed between the third upper drum 166 and the third lower drum 316. In at least one exemplary embodiment, a second pressed sheet is etched by a third upper drum 166 and a third lower drum 316 to form an etched sheet. The etched sheet defines a plurality of gum pieces. In at least one exemplary embodiment, the plurality of gum pieces remain connected in the etched sheet. In at least one alternative exemplary embodiment, the second pressed sheet is cut into a plurality of individual, separate gum pieces by the third upper drum 166 and the third lower drum 316. The plurality of gum pieces exit onto the discharge plate 352 through a gap 336 and a third pair of drums 164.

[0126] In at least one exemplary embodiment, multiple pieces of gum are transported along the discharge plate 352 away from the third pair of drums 164.

[0127] Figure 4 is an end view perspective of an apparatus for forming nicotine gum according to at least one exemplary embodiment.

[0128] In at least one exemplary embodiment, the die 178 on the third upper drum 166 includes a pattern of recesses 182 and non-recesses 404. The die 328 on the third lower drum 316 also includes a pattern of recesses 400 and non-recesses 408. The recesses 400 correspond to the recesses 182. The non-recesses 408 correspond to the non-recesses 404. As the third upper drum 166 and the third lower drum 316 rotate, the recesses 182 align with the recesses 400 and the non-recesses 404 align with the non-recesses 408.

[0129] In at least one exemplary embodiment, the non-recessed 404 defines the boundary of recess 182, and the non-recessed 408 defines the boundary of recess 400. As the third upper drum 166 and the third lower drum 316 rotate, the non-recessed 404 aligns with the non-recessed 408, making incisions or cuts into the second pressed sheet and defining a plurality of gum pieces.

[0130] Figure 5 is a perspective view of a die used in an apparatus for forming nicotine gum according to at least one exemplary embodiment.

[0131] In at least one exemplary embodiment, the die 178 is a cylindrical or tubular die having an opening 504 extending along the longitudinal axis 508 of the die 500. The opening 504 is defined by the inner wall 512 of the die 500.

[0132] In at least one exemplary embodiment, the die 178 is formed from a polymer such as plastic, a metal such as aluminum or stainless steel, or any other suitable material. In at least one exemplary embodiment, the die 178 is formed by three-dimensional (3-D) printing, stamping, bending, or any other suitable process.

[0133] In at least one exemplary embodiment, the die 178 includes a width corresponding to the width of the third upper drum 164 in the range of about 5 mm to about 480 mm (e.g., about 44 mm to about 175 mm, or about 88 mm to about 132 mm). In at least one alternative exemplary embodiment, the width of the die 178 is smaller than the width of the third upper drum 164. The die 178 further includes an inner diameter d1 corresponding to the diameter of the third upper drum, in the range of about 100 mm to about 300 mm or more (e.g., about 130 mm to about 140 mm), and an outer diameter d2 in the range of about 100 mm to about 400 mm or more (e.g., about 135 mm to about 145 mm).

[0134] In at least one exemplary embodiment, the die 178 is configured to be positioned on a third upper drum 166 or a third lower drum 316 within a third section 118. In at least one exemplary embodiment, the die 178 includes a channel 516 in the inner wall 512 of the die 178 (see Figure 7). The channel 516 extends parallel to the longitudinal axis 508 along at least a portion of the length of the die 178. The channel 516 is configured to align the die 178 on the third upper drum 166 or the third lower drum 316. In at least one exemplary embodiment, the channel 516 engages with rails (not shown) on the surface of the third upper drum 166 or the third lower drum 316 to align the die 178 on the third upper drum 166 or the third lower drum 316.

[0135] In at least one exemplary embodiment, the die 178 includes a plurality of recesses 182 and a plurality of non-recesses 404. In at least one exemplary embodiment, the plurality of non-recesses 404 define the boundaries of each of the plurality of recesses 182. In at least one exemplary embodiment, the plurality of non-recesses include a plurality of segments 528 connected to each other. Each segment 528 of the plurality of segments 528 defines the boundaries of two different recesses 182, reducing waste material between slicing or cutting of multiple gum pieces.

[0136] In at least one exemplary embodiment, die 328 is identical to die 178, except that die 328 is positioned on a third lower drum 316.

[0137] Figure 6 is a front view of a die used in an apparatus for forming nicotine gum according to at least one exemplary embodiment.

[0138] In at least one exemplary embodiment, the die 500 is formed of a plurality of rings 532. In at least one exemplary embodiment, each ring 532 may have a width ranging from about 5 mm to about 40 mm (e.g., about 15 mm to about 30 mm, or about 22 mm). The die 500 may include a plurality of rings 532 ranging from about 1 ring to about 12 rings (e.g., about 2 rings to about 6 rings, or about 4 rings).

[0139] Each ring 532 includes a row of recesses 520. In at least one exemplary embodiment, the recesses 520 are arranged alternately to make more efficient use of space. As shown in Figure 6, each of the recesses 520 may include a triangular cross-sectional shape along the upper surface of the non-recessed 404 adjacent to the recess 520. In at least one exemplary embodiment, each of the recesses 520 includes a vertex 536 opposite to the vertex 536 of the adjacent recess 520, so as to alternately point along the row of recesses 520 for each ring 532. Furthermore, the rings 532 are arranged such that the vertices 526 of adjacent recesses 520 on different rings 532 alternately point in the same direction. Thus, the vertices 526 of a recess 520 on one ring 532 are adjacent to or opposite the vertex 526 of a recess 420 on another ring 532.

[0140] In at least one exemplary embodiment, the plurality of recesses 520 are molded to produce one of a variety of different sizes and shapes (as described in more detail below and shown in Figures 8A–8F). In at least one exemplary embodiment, the plurality of recesses 520 are molded to form half of each of the plurality of gum pieces (e.g., the upper half or the lower half), such that a die on the third upper drum 166 cooperates with a die on the third lower drum 316 to form the whole of each of the plurality of gum pieces (i.e., the upper half and the lower half).

[0141] In at least one exemplary embodiment, each of the plurality of recesses 520 has a size and / or shape that forms half (e.g., the upper half or the lower half) of the nicotine gum piece. Thus, complementary pairs of recesses 520 aligned on opposing sides of the second pressed sheet during operation define the size and shape of the nicotine gum piece. The size and shape of the nicotine gum piece facilitate the desired (or alternatively, predetermined) positioning of the nicotine gum piece in the mouth and / or within the package. In at least one exemplary embodiment, each of the plurality of recesses 520 has dimensions ranging from about 1 mm to about 25 mm (e.g., about 1 mm to about 10 mm, about 1 mm to about 5 mm, about 5 mm to about 25 mm, about 5 mm to about 10 mm, about 10 mm to about 15 mm, about 15 mm to about 20 mm, or about 20 mm to about 25 mm). In at least one exemplary embodiment, each of the plurality of recesses 520 has a first dimension (e.g., minimum dimension or thickness) in the range of about 0.5 mm to about 5 mm (e.g., about 2.5 mm). In at least one exemplary embodiment, each of the plurality of recesses 520 has a maximum dimension (e.g., diameter, height, or width) in the range of about 5 mm to about 25 mm (e.g., about 12 mm). Each of the plurality of recesses 520 forms a nicotine gum piece having a weight in the range of about 1 g to about 10 g (e.g., about 1 g to about 5 g, about 2 g to about 4 g, or about 5 g to about 10 g).

[0142] In at least one exemplary embodiment, each nicotine gum piece defines a thickness and a cross-sectional shape perpendicular to that thickness. The thickness and cross-sectional shape of the nicotine gum piece correspond to one complementary pair of thicknesses and cross-sectional shapes of the plurality of recesses 520. As used herein, “thickness” refers to the minimum dimension of the nicotine gum piece. In at least one exemplary embodiment, the nicotine gum piece has a thickness that is greatest in the center and tapers towards each apex. In at least one alternative exemplary embodiment, the nicotine gum piece has a substantially uniform thickness. Although not shown, each of the plurality of recesses 520 described herein may include rounded edges to form a plurality of gum pieces having rounded edges.

[0143] Figure 7 is a side view of a die used in an apparatus for forming nicotine gum according to at least one exemplary embodiment.

[0144] In at least one exemplary embodiment, each of the rings 532 includes a channel 516. The channel 516 aligns the rings 532 relative to one another for assembly onto a third upper drum 166 or a third lower drum 316.

[0145] In at least one exemplary embodiment, the multiple rings 532 are not attached. In at least one alternative exemplary embodiment, the multiple rings are fastened together by adhesive, fasteners, or other fastening methods. In at least one alternative exemplary embodiment, the multiple rings 532 are formed as a single, integrated part. In at least one alternative embodiment, the multiple rings 532 are not fastened together.

[0146] In at least one exemplary embodiment, the rings 532 are press-fitted onto the third upper drum 166 or the third lower drum 316. In at least one alternative exemplary embodiment, the rings 532 are secured to the third upper drum 166 or the third lower drum 316 in other ways. In at least one exemplary embodiment, the rings 532 are secured onto the third upper drum 166 or the third lower drum 316 by a pair of tightening nuts on opposing sides of each of the third upper drum 166 or the third lower drum 316.

[0147] Figure 8A is a top view of a first pressed sheet according to at least one exemplary embodiment.

[0148] In at least one exemplary embodiment, a first pressed sheet 800 is pressed by a first pair of drums 124 (as shown in Figure 2). In at least one exemplary embodiment, a gum mixture is fed into the gap 304, pressed by the first pair of drums 124, and exits the gap 304 as a first pressed sheet 800.

[0149] Figure 8B is a side view of a first pressed sheet according to at least one exemplary embodiment.

[0150] In at least one exemplary embodiment, the first pressed sheet 800 includes a thickness in the range of about 4 mm to about 20 mm (e.g., about 8 mm to about 11 mm or about 9.5 mm to about 10 mm). The thickness of the first pressed sheet 800 may be selected to prepare the first pressed sheet for feeding into the second pair of drums 144. Providing the first pressed sheet with a thickness close to the target thickness of the second pressed sheet (e.g., in the range of about 0.5 mm to about 5 mm, or about 1 mm to about 3 mm, or about 2 mm) helps the second pair of drums 144 to provide the third pair of drums 300 with a sheet of uniform target thickness.

[0151] Figure 9A is a top view of a second pressed sheet according to at least one exemplary embodiment.

[0152] In at least one exemplary embodiment, a second pressed sheet 900 is pressed by a second pair of drums 144. In at least one exemplary embodiment, a first pressed sheet 800 is fed into a gap 308 (shown in Figure 3), pressed by the second pair of drums 144, and exits the gap 308 as a second pressed sheet 900.

[0153] Figure 9B is a side view of a second pressed sheet according to at least one exemplary embodiment.

[0154] In at least one exemplary embodiment, the second pressed sheet 900 has a thickness ranging from about 2 mm to about 18 mm (e.g., about 4 mm to about 16 mm, about 6 mm to about 14 mm, about 8 mm to about 12 mm, about 9 mm to about 11 mm, about 6 mm to about 9 mm, or about 7.5 mm to about 8 mm). The thickness of the second pressed sheet 900 can be selected based on the thickness required for the gum material to fill the recess of the die, the amount of gum material required to achieve a target weight per gum piece, or a combination thereof.

[0155] Figure 10A is a top view of an engraved sheet according to at least one exemplary embodiment.

[0156] In at least one exemplary embodiment, a etched sheet 1000 is formed by a third pair of drums 164. In at least one exemplary embodiment, a second pressed sheet 900 is fed into a gap 336 (shown in Figure 3), etched by the third pair of drums 164, and exits the gap 336 as a etched sheet 1000.

[0157] In at least one exemplary embodiment, the engraved sheet 1000 includes a plurality of gum pieces 1004 and connectors 1008 between the plurality of gum pieces 1004, such that the plurality of gum pieces 1004 exit the apparatus 100 as the engraved sheet 1000. The plurality of gum pieces 1004 and connectors 1008 are a single monolithic piece formed from a second pressed sheet 900. Each of the plurality of gum pieces 1004 takes the corresponding shape of one of a plurality of recesses 182, 400. Following the formation of the engraved sheet 1000, the plurality of gum pieces 1004 may be separated to form a plurality of individual separated gum pieces.

[0158] In at least one exemplary embodiment, the multiple gum pieces 1004 can be separated manually or automatically. Manual separation may be performed by a machine operator. During manual separation, the multiple gum pieces 1004 may be pulled apart while destroying the connector 1008. Automatic separation may be performed by a part of the apparatus 100 and may include shaking, cutting, or other separation functions.

[0159] Figure 10B is a side view of an engraved sheet according to at least one exemplary embodiment.

[0160] In at least one exemplary embodiment, the engraved sheet 1000 has a first thickness for each of the plurality of gum pieces 1004 and a second thickness for each of the connectors 1008. The first thickness is defined by the thickness or depth (twice for the top and bottom) of each of the plurality of recesses 182, 400 and ranges from about 4 mm to about 36 mm (e.g., about 6 mm to about 34 mm, about 8 mm to about 32 mm, about 10 mm to about 30 mm, about 12 mm to about 28 mm, about 14 mm to about 26 mm, about 16 mm to about 24 mm, about 18 mm to about 22 mm, about 12 mm to about 18 mm, or about 15 mm to about 16 mm). The second thickness ranges from about 0.1 mm to about 0.2 mm.

[0161] Figure 11A is a cross-sectional view of a recess of a die for forming a gum piece having a triangular cross-section along the upper surface of a non-recess, according to at least one exemplary embodiment.

[0162] In at least one exemplary embodiment, the recesses 1100A of the plurality of recesses 520 have a substantially triangular cross-section. The cross-section of the recess 1100A has reflective symmetry with respect to the central plane. In at least one exemplary embodiment, the recess 1100A includes three rounded corners, i.e., vertices 1104A. In other exemplary embodiments, the corners may not be rounded.

[0163] In at least one exemplary embodiment, the recess 1100A forms a portion (e.g., upper or lower half) of a nicotine gum piece having a shield shape (e.g., the nicotine gum piece has a substantially triangular cross-section perpendicular to its thickness). The nicotine gum piece is symmetrical with respect to its central plane. In at least one exemplary embodiment, the nicotine gum piece formed by the recess 1100A includes three rounded corners. In other exemplary embodiments, the corners may not be rounded.

[0164] Figure 11B is a cross-sectional view of a recess in a die for forming a gum piece having a cross-section that passes through the thickness and bisects the vertex, according to at least one exemplary embodiment.

[0165] In at least one exemplary embodiment, the cross section through the thickness of the recess 1100A tapers from the plateau 1106B to the rounded point at the apex 1104A. In at least one alternative exemplary embodiment, the apex 1104A is not the rounded point.

[0166] In at least one exemplary embodiment, the cross-section through the thickness of the recess 1100A tapers slightly from the plateau 1106B and becomes square at the side 1108B of the cross-section opposite the apex 1104A. The cross-section includes rounded corners where the taper transitions to the square side 1108B.

[0167] In at least one alternative exemplary embodiment, the cross-section through the thickness of the recess 1100A is half the shape of an ellipse. The cross-section through the thickness tapers parabolic, i.e., U-shaped, from the plateau 1106B at vertex 1104A, and also tapers parabolic, i.e., U-shaped, from the plateau 1106B at the side 1108B opposite to vertex 1104A. In at least one exemplary embodiment, the radius of the parabola at vertex 1104A is approximately the same as the radius of the parabola at the side 1108B opposite to vertex 1104A. In at least one alternative exemplary embodiment, the radius of the parabola at vertex 1104A is smaller than the radius of the parabola at side 1108B.

[0168] In at least one alternative exemplary embodiment, the cross section through the thickness includes a parabolic shape, i.e., a U-shape, at vertex 1104A and a parabolic shape, i.e., a U-shape, at the side 1108B opposite vertex 1104A. The cross section extends transversely and does not taper in thickness, such that the cross section forms half of the capsule shape. In at least one exemplary embodiment, the radius of the parabola at vertex 1104A is approximately the same as the radius of the parabola at the side 1108B opposite vertex 1104A.

[0169] In at least one alternative exemplary embodiment, the cross-section through the thickness of the recess 1100A tapers slightly from the plateau 1106B and becomes square at the vertex 1104A and the side 1108B opposite the vertex 1104A. In at least one exemplary embodiment, the side 1108B has a greater thickness than the thickness of the vertex 1104A. In at least one alternative exemplary embodiment, the thickness of the side 1108B is approximately the same as the thickness of the vertex 1104A.

[0170] In at least one alternative exemplary embodiment, the cross section through the thickness of the recess tapers from plateau 1106B to a rounded point at vertex 1104A, and then tapers again from plateau 1106B to a rounded point at side surface 1108B opposite vertex 1104A. In at least one exemplary embodiment, the radius of the rounded point at vertex 1104A is the same as the radius of the rounded point at side surface 1108B opposite vertex 1104A. In at least one alternative exemplary embodiment, the radius of the rounded point at vertex 1104A is smaller than the radius of the rounded point at side surface 1108B.

[0171] In at least one alternative exemplary embodiment, the cross section through the thickness of the recess tapers from a rounded point midway between the vertex 1104A and the side surface 1108B opposite the vertex 1104A.

[0172] Figure 11C is a cross-sectional view of a die according to at least one exemplary embodiment, having a recess cut along the longitudinal axis of the die and bisected through its vertex.

[0173] In at least one exemplary embodiment, the cross-section through each thickness of the recess 1100A tapers from the plateau 1106B to a rounded point at the apex 1104A. The cross-section through the thickness of the recess 1100A tapers from the plateau 1106B and becomes square at the side surface 1108B of the cross-section opposite the apex 1104A. The cross-section includes a rounded corner where the taper transitions to the square side surface 1108B.

[0174] Figure 11D is a cross-sectional view of a die having a recess, cut along an axis perpendicular to the longitudinal axis of the die, according to at least one exemplary embodiment.

[0175] In at least one exemplary embodiment, the vertex 1104A is rounded, while the side surface 1108B opposite the vertex 1104A is elongated. The three vertices 1104A are each rounded points.

[0176] Figure 12A is a cross-sectional view of a recess in a die along the upper surface of a non-recess for forming a gum piece having a square cross-section, according to at least one exemplary embodiment.

[0177] In at least one exemplary embodiment, the recesses 1200A of the plurality of recesses 520 have a substantially square cross-section. The recesses 1200A are the same as the recesses 1100A except that the recesses 1200A include a substantially square cross-section. The cross-section of the recesses 1200A has reflective symmetry with respect to the central plane. In at least one exemplary embodiment, the recesses 1200A include four rounded corners. In other exemplary embodiments, the corners may not be rounded.

[0178] In at least one exemplary embodiment, the recess 1200A forms a portion (e.g., the upper or lower half) of a nicotine gum piece that is substantially cubic in shape (e.g., the nicotine gum piece has a substantially square cross-section perpendicular to its thickness). In at least one exemplary embodiment, the square cross-section has rounded corners. In other exemplary embodiments, the corners may not be rounded.

[0179] Figure 12B is a cross-sectional view of a recess in a die for forming a gum piece having a cross-section through the thickness, according to at least one exemplary embodiment.

[0180] In at least one exemplary embodiment, the cross-section through the thickness of the recess 1200a tapers slightly and becomes square at the side surface 1204b of the cross-section, forming half of a substantially cubic nicotine gum piece. In at least one alternative exemplary embodiment, the recess 1200 does not taper and includes rounded or pointed corners.

[0181] Figure 13A is a cross-sectional view of a recess in a die along the upper surface of a non-recess for forming a gum piece having a rectangular cross-section, according to at least one exemplary embodiment.

[0182] In at least one exemplary embodiment, the recesses 1300A of the plurality of recesses 520 have a substantially rectangular cross-section. The recesses 1300A are the same as the recesses 1100A, except that the recesses 1300A include a substantially rectangular cross-section. The cross-section of the recesses 1300A has reflective symmetry with respect to the central plane. In at least one exemplary embodiment, the recesses 1300A include four rounded corners. In other exemplary embodiments, the corners may not be rounded.

[0183] In at least one exemplary embodiment, the recess 1300A forms a portion of the nicotine gum piece (e.g., the upper or lower half) that is substantially rectangular prism-shaped (e.g., the nicotine gum piece has a substantially rectangular cross-section perpendicular to its thickness). In at least one exemplary embodiment, the rectangular cross-section has rounded corners. In other exemplary embodiments, the corners may not be rounded.

[0184] Figure 13B is a cross-sectional view of a recess in a die for forming a gum piece having a cross-section through the thickness, according to at least one exemplary embodiment.

[0185] In at least one exemplary embodiment, the cross section through the thickness of the recess 1300A tapers slightly at the side surface 1304B of the cross section, becoming square and forming half of a rectangular prism-shaped piece of nicotine gum.

[0186] In at least one alternative exemplary embodiment, the cross section tapers to a rounded point (similar to point 1104A in Figure 11B) on each side 1304B of the cross section. In at least one alternative embodiment, the point is not a rounded point.

[0187] Figure 14A is a cross-sectional view of a recess in a die along the upper surface of a non-recess for forming gum pieces having a circular cross-section, according to at least one exemplary embodiment.

[0188] In at least one exemplary embodiment, the recesses 1400A of the plurality of recesses 520 have a substantially circular cross-section. The recesses 1400A are the same as the recesses 1100A, except that the recesses 1400A include a substantially circular cross-section. The cross-section of the recesses 1400A has reflection symmetry with respect to the central plane.

[0189] In at least one exemplary embodiment, the recess 1400A forms a portion of a nicotine gum piece (e.g., an upper or lower half) that is substantially disc-shaped (e.g., the nicotine gum piece has a substantially circular cross-section perpendicular to its thickness).

[0190] Figure 14B is a cross-sectional view of a recess in a die for forming a gum piece having a cross-section through the thickness, according to at least one exemplary embodiment.

[0191] In at least one exemplary embodiment, the cross section through the thickness of the recess 1300A tapers slightly at the side surface 1404B of the cross section, becoming square and forming half of a disc-shaped nicotine gum piece.

[0192] In at least one alternative exemplary embodiment, the cross section tapers to a rounded point (similar to point 1104A in Figure 11B) on each side 1404B of the cross section. In at least one alternative embodiment, the point is not a rounded point.

[0193] Figure 15A is a cross-sectional view of a recess in a die along the upper surface of a non-recess for forming a gum piece having a trapezoidal cross-section, according to at least one exemplary embodiment.

[0194] In at least one exemplary embodiment, the recesses 1500A of the plurality of recesses 520 have a substantially trapezoidal cross-section. The recess 1500A is the same as the recess 1100A except that the recess 1500A includes a substantially trapezoidal cross-section. The cross-section of the recess 1500A has reflective symmetry with respect to the central plane. In at least one exemplary embodiment, the recess 1500A includes four rounded corners. In other exemplary embodiments, the corners may not be rounded.

[0195] Figure 15B is a cross-sectional view of a recess in a die for forming a gum piece having a cross-section through the thickness, according to at least one exemplary embodiment.

[0196] In at least one exemplary embodiment, the cross section through the thickness of the recess 1500A tapers slightly on the side surface 1504B of the cross section, becoming square and forming half (e.g., the upper or lower half) of a trapezoidal prism-shaped nicotine gum piece.

[0197] In at least one alternative exemplary embodiment, the cross section tapers to a rounded point (similar to point 1104A in Figure 11B) on each side 1504B of the cross section. In at least one alternative embodiment, the point is not a rounded point.

[0198] Figure 16A is a cross-sectional view of a recess in a die along the upper surface of a non-recess for forming a gum piece having a stadium or oval cross-section, according to at least one exemplary embodiment.

[0199] In at least one exemplary embodiment, recess 1600A of the plurality of recesses 520 has a substantially stadium shape, i.e., an elliptical cross-section. Recess 1600A is identical to recess 1100A except that recess 1600A includes a substantially stadium-shaped cross-section. The cross-section of recess 1600A has reflection symmetry with respect to the central plane.

[0200] In at least one exemplary embodiment, the recess 1600A forms a portion (e.g., the upper or lower half) of a nicotine gum piece that is substantially capsule-shaped (e.g., the nicotine gum piece has a substantially stadium-shaped or elliptical cross-section perpendicular to its thickness).

[0201] Figure 16B is a cross-sectional view of a recess in a die for forming a gum piece having a cross-section through the thickness, according to at least one exemplary embodiment.

[0202] In at least one exemplary embodiment, the cross section through the thickness of the recess 1600A tapers slightly at the side of the cross section 1604B, becoming square and forming half of a capsule-shaped nicotine gum piece.

[0203] In at least one alternative exemplary embodiment, the cross section tapers to a rounded point on each side 1604B of the cross section (similar to point 1104A in Figure 11B). In at least one alternative embodiment, the point is not a rounded point.

[0204] In at least another exemplary embodiment, the recesses of the plurality of recesses 520 define a different cross-sectional shape. In at least one exemplary embodiment, the recesses have a semicircular cross-sectional shape, a boomerang cross-sectional shape, a comma cross-sectional shape, a bowtie cross-sectional shape, or a bean / kidney cross-sectional shape, or any other cross-sectional shape.

[0205] In at least one exemplary embodiment, the recesses of the plurality of recesses 520 have non-uniform thickness (e.g., pillow shape). In at least one alternative exemplary embodiment, the recesses of the plurality of recesses 520 have uniform thickness. In at least one exemplary embodiment, the recessed portion does not have a single minimum dimension or a single thickness dimension (e.g., wedge shape or pillow shape).

[0206] Figure 17 is a perspective view of a die used in an apparatus for forming nicotine gum according to at least one exemplary embodiment.

[0207] In at least one exemplary embodiment, the die 178 includes a plurality of recesses 182 and a plurality of non-recesses 404. In at least one exemplary embodiment, the die 178 is the same as the die 178 of Figures 5-7, except that one segment 1712 of the plurality of non-recesses 404 does not define the boundary between two different recesses 182. Instead, one segment 1712 of the plurality of non-recesses 404 defines the boundary of one recess 182, and another segment 1712 of the plurality of non-recesses 404 defines the boundary between adjacent recesses 182. In at least one exemplary embodiment, a gap recess 1716 separates one segment 1712 from the other segment 1712.

[0208] Figure 18 is a front view of a die used in an apparatus for forming nicotine gum according to at least one exemplary embodiment.

[0209] In at least one exemplary embodiment, the gap recess 1716 extends in the longitudinal direction of the die 178 and separates the adjacent recess 182 in the circumferential direction of the die 178.

[0210] Figure 19 is a schematic diagram of an apparatus for forming nicotine gum according to at least one exemplary embodiment.

[0211] In at least one exemplary embodiment, the gum forming system 1900 includes apparatus 100. The gum forming system 1900 further includes a gum mixture supply system 1904 and a packaging assembly 1908.

[0212] In at least one exemplary embodiment, the gum mixture supply system 1904 includes a mixer 1912 and a material feeder 1916. The mixer 1912 and the material feeder 1916 are arranged along a vertical axis, with the mixer 1912 positioned vertically above the material feeder 1916.

[0213] In at least one exemplary embodiment, the mixer 1912 is configured to combine and mix the components for the gum mixture. In at least one exemplary embodiment, the mixer 1912 is the mixing system described in U.S. Publication No. 2019 / 0321793, published on October 24, 2019, the disclosure of which is incorporated herein by reference in its entirety. The mixed gum mixture is transferred to the material feeder 1916. In at least one exemplary embodiment, the material feeder 1916 is a nozzle-shaped housing for dispensing the gum mixture. In at least one exemplary embodiment, the material feeder 1916 includes a hopper. In at least one exemplary embodiment, the material feeder 1916 is the hopper and measuring system described in U.S. Patent No. 10,399,712 (filed December 29, 2014) by Longest et al., the disclosure of which is incorporated herein by reference in its entirety.

[0214] In at least one exemplary embodiment, the packaging assembly 1908 is configured to package gum pieces for distribution and sale. In at least one exemplary embodiment, the packaging assembly 1908 is a device for filling a plurality of containers with product, as described in U.S. Patent Application No. 17 / 179,610 filed February 19, 2021, the disclosure thereof is incorporated herein by reference in its entirety.

[0215] In at least one exemplary embodiment, the packaging assembly 1908 includes an exciter 1918 for separating a plurality of gum pieces from a sieved sheet. The exciter 1918 is configured to vibrate the sieved sheet to break the plurality of gum pieces along the connector 1008 and separate the plurality of gum pieces. In at least one alternative exemplary embodiment, an operator separates the plurality of gum pieces from the sieved sheet. In at least one alternative exemplary embodiment, the packaging assembly 1908 receives individual gum pieces and sorts and packages the plurality of gum pieces.

[0216] In at least one exemplary embodiment, the system 1900 includes a supply conveyor 1920, a discharge conveyor 1924, a first conveyor 1928, and a second conveyor 1932 instead of plates for transporting nicotine gum material, a first pressed sheet, a second pressed sheet, and a plurality of gum pieces. In at least one exemplary embodiment, the conveyors 1920, 1924, 1928, and 1932 are belt and pulley conveyors.

[0217] In at least one exemplary embodiment, the first pair of drums 124 of the first section 110 are driven by a motor 1936. The motor 1936 meshes with the first lower gear assembly 132 and drives the rotation of the first lower gear assembly 132. The rotation of the first lower gear assembly 132 rotates the first lower drum 208 and drives the rotation of the first upper gear assembly 130. The rotation of the first upper gear assembly 130 rotates the first upper drum 126. In at least one alternative embodiment, the motor 1936 engages with the first upper gear assembly 130 and has the opposite effect.

[0218] In at least one exemplary embodiment, the second pair of drums 144 of the second section 114 are driven by a motor 1940. The motor 1940 engages with the second lower gear assembly 152 to drive the rotation of the second lower gear assembly 152. The rotation of the second lower gear assembly 152 rotates the second lower drum 228, which drives the rotation of the second upper gear assembly 150. The rotation of the second upper gear assembly 150 rotates the second upper drum 146. In at least one alternative embodiment, the motor 1940 engages with the second upper gear assembly 150, having the opposite effect.

[0219] In at least one exemplary alternative embodiment, a second upper gear assembly 150, a second lower gear assembly 152, or a combination thereof, engages with and is driven by the first upper gear assembly 130, the first lower gear assembly 132, or a combination thereof of the first section 110. In at least one exemplary embodiment, the second lower gear assembly 152 engages with the first lower gear assembly 132 via a belt, chain, or pulley 1944.

[0220] In at least one exemplary embodiment, the third pair of drums 164 of the third section 118 are driven by a motor 1948. The motor 1948 engages with the third lower gear assembly 172 to drive the rotation of the third lower gear assembly 172. The rotation of the third lower gear assembly 172 rotates the third lower drum 316, which drives the rotation of the third upper gear assembly 170. The rotation of the third upper gear assembly 170 rotates the third upper drum 166. In at least one alternative embodiment, the motor 1948 engages with the third upper gear assembly 170 and drives the third upper gear assembly 170, having the opposite effect.

[0221] In at least one exemplary alternative embodiment, a third upper gear assembly 170, a third lower gear assembly 172, or a combination thereof, engages with and is driven by or is driven by a first upper gear assembly 130, a first lower gear assembly 132, a second upper gear assembly 150, a second lower gear assembly 152, or a combination thereof. In at least one exemplary embodiment, the third lower gear assembly 172 engages with the first lower gear assembly 132 and the second lower gear assembly 152 via a belt, chain, or pulley 1944.

[0222] In at least one exemplary embodiment, system 1900 includes a control system 1952. In at least one exemplary embodiment, the control system 1952 includes a heater 1956, a cooler 1960, or a combination thereof, a sensor 1964, and a controller 1968. In at least one exemplary embodiment, the control system 1952 is configured to regulate the temperatures of a first pair of drums 124, a second pair of drums 144, and a third pair of drums 164. In at least one exemplary embodiment, the heater 1956, the cooler 1960, or a combination thereof is located on a first upper drum 126, a first lower drum 208, a second upper drum 146, a second lower drum 228, a third upper drum 166, a third lower drum 316, or a combination thereof.

[0223] In at least one exemplary embodiment, the heater 1956 is configured to raise the surface temperature of the drum in which it is placed. The raised surface temperature transfers heat to the gum mixture, the first pressed sheet, or the second pressed sheet. Raising the temperature of the gum mixture, the first pressed sheet, or the second pressed sheet can soften the gum mixture, the first pressed sheet, or the second pressed sheet, making it easier to form the gum mixture, the first pressed sheet, or the second pressed sheet.

[0224] In at least one exemplary embodiment, the cooler 1960 is configured to lower the surface temperature of the drum in which it is placed. The lowered surface temperature transfers heat from the gum mixture, the first pressed sheet, or the second pressed sheet. The gum mixture, the first pressed sheet, or the second pressed sheet may experience temperature increases during pressing, molding, or combination thereof. The temperature of the gum mixture, the first pressed sheet, or the second pressed sheet can be controlled by lowering its temperature. The gum mixture, the first pressed sheet, or the second pressed sheet can be made harder or stiffer by lowering its temperature.

[0225] In at least one exemplary embodiment, the sensor 1964 is positioned on a first conveyor 1928, a second conveyor 1932, a first upper drum 126, a first lower drum 208, a second upper drum 146, a second lower drum 228, a third upper drum 166, a third lower drum 316, or a combination thereof. The sensor 1964 senses the temperature of the gum mixture, a first pressed sheet, or a second pressed sheet.

[0226] Figure 20 is a schematic diagram of a control system for an apparatus for forming nicotine gum, according to at least one exemplary embodiment.

[0227] In at least one exemplary embodiment, the controller 1968 communicates with the heater 1956, the cooler 1960, and the sensor 1964. Based on the output from the sensor 1964, the controller 1968 activates or deactivates the heater 1956 and the cooler 1960.

[0228] In at least one exemplary embodiment, the controller 1968 selectively activates the heater 1956 based on the output of the sensor 1964 indicating that the temperature is below a lower heating temperature threshold. The lower heating temperature threshold may be in the range of about 1°C to about 5°C below the setpoint temperature (for example, the setpoint temperature may be in the range of about 15°C to about 50°C, or about 25°C). The controller 1968 selectively shuts off the heater 1956 based on the output of the sensor 1964 indicating that the temperature is above an upper heating temperature threshold. The upper heating temperature threshold is in the range of about 1°C to about 5°C above the setpoint temperature.

[0229] In at least one alternative exemplary embodiment, the controller 1968 selectively activates and deactivates the heater 1956 based on the running status of one or more of the conveyors 1920, 1924, 1928, and 1932, one or more of the motors 1936, 1940, and 1948, or a combination thereof. The controller 1968 receives a signal to start one of the conveyors 1920, 1924, 1928, and 1932, one of the motors 1936, 1940, and 1948, or a combination thereof, and activates the heater 1956 based on that signal.

[0230] In at least one exemplary embodiment, the controller 1968 sets the temperature or heating level of the heater 1956. The controller 1968 accesses a lookup table (LUT) stored in the controller 1968's memory. The LUT maps inputs to outputs (for example, mapping the output of a sensor to the control value input of the heater). The LUT is derived as design parameters by empirical study. The controller 1968 determines the control value of the heater 1956 based on the output of the sensor 1964.

[0231] In at least one alternative exemplary embodiment, the controller 1968 sets the temperature or heating level of the heater 1956 based on the output of the sensor 1964. In at least one exemplary embodiment, the controller 1968 determines the temperature of the heater 1956 by comparing the output of the sensor 1964 with one or more temperature thresholds. The temperature thresholds indicate an increasing distance from a lower heating temperature threshold. The controller 1968 sets the temperature or heating level to an increased heating position based on the increasing distance from the lower heating temperature threshold.

[0232] In at least one exemplary embodiment, the controller 1968 selectively activates the cooler 1960 based on the output of the sensor 1964 indicating that the temperature is above an upper cooling temperature threshold. The upper cooling temperature may be in the range of about 1°C to about 5°C above the setpoint temperature (for example, the setpoint temperature may be in the range of about 15°C to about 50°C or about 25°C). The controller 1968 selectively shuts off the cooler 1960 based on the output of the sensor 1964 indicating that the temperature is below a lower cooling temperature threshold. The lower cooling temperature threshold is in the range of about 1°C to about 5°C below the setpoint temperature.

[0233] In at least one alternative exemplary embodiment, the controller 1968 selectively activates and deactivates the cooler 1960 based on the running status of one or more of the conveyors 1920, 1924, 1928, and 1932, one or more of the motors 1936, 1940, and 1948, or a combination thereof. The controller 1968 receives a signal to start one of the conveyors 1920, 1924, 1928, and 1932, one of the motors 1936, 1940, and 1948, or a combination thereof, and activates the cooler 1960 based on that signal.

[0234] In at least one exemplary embodiment, the controller 1968 sets the temperature or cooling level of the cooler 1960. The controller 1968 accesses a lookup table (LUT) stored in the controller 1968's memory. The LUT maps inputs to outputs (for example, mapping the output of a sensor to a control value input for the cooler). The LUT is derived as design parameters by empirical study. The controller 1968 determines the control value of the cooler 1960 based on the output of the sensor 1964.

[0235] In at least one alternative exemplary embodiment, the controller 1968 sets the temperature or cooling level of the cooler 1960 based on the output of the sensor 1964. In at least one exemplary embodiment, the controller 1968 determines the temperature or cooling level of the cooler 1960 by comparing the output of the sensor 1964 with one or more temperature thresholds. The temperature thresholds indicate an increasing distance from an upper cooling temperature threshold. Based on the increasing distance from the upper cooling temperature threshold, the controller 1968 sets the temperature or cooling level to an increased cooling position.

[0236] In at least one exemplary embodiment, the controller 1968 communicates with the user control unit 2000, the supply conveyor 1920, the discharge conveyor 1924, the first conveyor 1928, and the second conveyor 1932. Based on output signals from the user control unit 2000, the controller 1968 selectively operates or stops the conveyors 1920, 1924, 1928, and 1932. In at least one exemplary embodiment, the controller 1968 controls one or more speeds of the conveyors 1920, 1924, 1928, and 1932 based on output signals from the user control unit 2000, the speeds of the drums 126, 132, 146, 152, 166, and 172, or a combination thereof. In at least one exemplary embodiment, the speeds of drums 126, 132, 146, 152, 166, and 172 are determined from the speeds of motors 1936, 1940, and 1948.

[0237] In at least one exemplary embodiment, the user control device 2000 provides a signal to start one or more of the conveyors 1920, 1924, 1928, and 1932. In at least one exemplary embodiment, the user control device 2000 is a switch (e.g., a toggle switch), one or more buttons, or a combination thereof. The controller 1968 receives the output from the user control device 2000 and starts the conveyors 1920, 1924, 1928, and 1932 based on that output.

[0238] In at least one exemplary embodiment, conveyors 1920, 1924, 1928, and 1932 are each actuated by motors (not shown). Controller 1968 starts conveyors 1920, 1924, 1928, and 1932 by starting each motor. In at least one alternative embodiment, conveyors 1920, 1924, 1928, and 1932 are actuated by a single motor (not shown). Controller 1968 starts conveyors 1920, 1924, 1928, and 1932 by starting the motor.

[0239] In at least one exemplary embodiment, the controller 1968 communicates with a motor 1936 that rotates a first pair of drums 124, a motor 1940 that rotates a second pair of drums 144, and a motor 1948 that rotates a third pair of drums 164. The controller 1968 selectively starts or stops the rotation of the first pair of drums 124, the second pair of drums 144, and the third pair of drums 164 by selectively starting or stopping the motors 1936, 1940, and 1948, respectively. In at least one exemplary embodiment, the controller 1968 controls the speed of the first pair of drums 124, the second pair of drums 144, and the third pair of drums 164, or any combination thereof, by controlling the speeds of the motors 1936, 1940, and 1948, respectively.

[0240] In at least one exemplary embodiment, a user control device 2000 (e.g., a switch, one or more buttons, or a combination thereof) supplies signals to start a first pair of drums 124, a second pair of drums 144, a third pair of drums 164, or a combination thereof. A controller 1968 receives the output from the user control device 2000 and, based on that output, starts a first motor 1936, a second motor 1940, a third motor 1948, or a combination thereof, and sets the speed.

[0241] The controller 1968 may be implemented using hardware, or a combination of hardware and software, according to one or more exemplary embodiments. The hardware may be implemented using, but is not limited to, one or more processors, one or more central processing units (CPUs), one or more microcontrollers, one or more arithmetic logic units (ALUs), one or more digital signal processors (DSPs), one or more microcomputers, one or more field-programmable gate arrays (FPGAs), one or more system-on-a-chip (SoCs), one or more programmable logic units (PLUs), one or more microprocessors, one or more application-specific integrated circuits (ASICs), or any other device or device capable of performing actions in response to instructions in a defined manner, and such processing or control circuits.

[0242] For example, if the hardware device is a computer processing device (e.g., a processor, central processing unit (CPU), controller, arithmetic logic unit (ALU), digital signal processor, microcomputer, microprocessor, etc.), the computer processing device may be configured to execute the program code by performing arithmetic operations, logical operations, and input / output operations according to the program code. Once the program code is loaded into the computer processing device, the computer processing device may be programmed to execute the program code (e.g., run), thereby transforming the computer processing device into a special-purpose computer processing device. In a more specific example, once the program code is loaded into a processor, the processor is programmed to execute the program code and its corresponding operations, thereby transforming the processor into a special-purpose processor.

[0243] According to one or more exemplary embodiments, a computer processing unit may be described, for clarity of explanation, as comprising various functional units that perform various operations and / or functions. However, the computer processing unit is not intended to be limited to these functional units. For example, in one or more exemplary embodiments, various operations and / or functions of a functional unit may be performed by other functional units. Furthermore, the computer processing unit may perform the operations and / or functions of various functional units without subdividing the operations and / or functions of the computer processing unit into these various functional units.

[0244] A unit and / or apparatus according to one or more exemplary embodiments may also include one or more storage devices. One or more storage devices may be tangible or non-transient computer-readable storage media, such as random access memory (RAM), read-only memory (ROM), permanent mass storage devices (such as disk drives), solid-state (e.g., NAND flash) devices, and / or any other similar data storage mechanisms capable of storing and recording data. One or more storage devices may be configured to store computer programs, program code, instructions, or any combination thereof for one or more operating systems and / or for implementing the exemplary embodiments described herein. Computer programs, program code, instructions, or any combination thereof may also be loaded from a separate computer-readable storage medium into one or more storage devices and / or one or more computer processing devices using a drive mechanism. Such separate computer-readable storage media may include Universal Serial Bus (USB) flash drives, memory sticks, Blu-ray / DVD / CD-ROM drives, memory cards, and / or other similar computer-readable storage media. Computer programs, program code, instructions, or any combination thereof may be loaded from a remote data storage device to one or more storage devices and / or one or more computer processing devices via a network interface, rather than via a locally computer-readable storage medium. Furthermore, computer programs, program code, instructions, or some combination thereof may be loaded from a remote computing system configured to transfer and / or distribute computer programs, program code, instructions, or some combination thereof via a network to one or more storage devices and / or one or more processors.A remote computing system may transfer and / or distribute computer programs, program code, instructions, or any combination thereof via a wired interface, an air interface, and / or any other similar medium.

[0245] One or more hardware devices, one or more storage devices, and / or computer programs, program code, instructions, or any combination thereof may be specifically designed and constructed for the purposes of the exemplary embodiments, or they may be known devices modified and / or altered for the purposes of the exemplary embodiments.

[0246] Hardware devices such as computer processing units can run an operating system (OS) and one or more software applications that run on the OS. Computer processing units can also access, store, manipulate, process, and create data in response to software execution. For simplicity, one or more exemplary embodiments may be illustrated as a single computer processing unit, but those skilled in the art will understand that a hardware device may include multiple processing elements and multiple types of processing elements. For example, a hardware device may include multiple processors, or a processor and a controller. Furthermore, other processing configurations, such as parallel processors, are also possible.

[0247] Software may include computer programs, program code, instructions, or combinations thereof, for independently or collectively instructing or configuring hardware devices to operate as desired. Computer programs and / or program code may include homogeneous entities that can be implemented by one or more hardware devices, such as programs or computer-readable instructions, software modules, data files, data structures, and / or one or more of the hardware devices described above. Examples of program code include both machine code generated by a compiler and high-level program code executed using an interpreter.

[0248] Software and / or data may be permanently or temporarily embodied in any type of device capable of providing instructions and data to or being interpreted by hardware devices, such as machines, elements, physical or virtual devices, or computer storage media and devices. Software may also be distributed across networked computer systems to be stored and executed in a distributed manner. In particular, for example, software and data may be stored on one or more computer-readable recording media, including tangible or non-transient computer-readable recording media or memory.

[0249] Figure 21 is a flowchart of a method for forming nicotine gum according to at least one exemplary embodiment.

[0250] In at least one exemplary embodiment, in S2108, the first pair of drums 124 begin to rotate and the gum mixture is supplied to the first pair of drums 124. In at least one exemplary embodiment, the first upper drum 126 rotates counterclockwise and the first lower drum 208 rotates clockwise. In at least one exemplary embodiment, the first upper drum 126 rotates at a first speed and the first lower drum 208 rotates at a second speed such that there is consistent material movement through the first upper drum 126 and the first lower drum 208. In at least one exemplary embodiment, the first upper drum 126 and the first lower drum 208 are rotated manually, automatically by a motor, or a combination thereof.

[0251] In S2112, the gum mixture is pressed within the first pair of drums 124. In at least one exemplary embodiment, the gum mixture is supplied to a gap 304 that separates the first upper drum 126 from the first lower drum 208. The rotation of the first upper drum 126 and the first lower drum 208 draws the gum mixture through the gap 304. The gum mixture is pressed between the first upper drum 126 and the first lower drum 208 to form a first pressed sheet. As described above, in at least one exemplary embodiment, the first pressed sheet has a thickness ranging from about 4 mm to about 20 mm (e.g., about 8 mm to about 11 mm or about 9.5 mm to about 10 mm). The first pressed sheet exits the gap 304 and the first pair of drums 124 onto the first plate 240 or the first conveyor 1428.

[0252] In S2116, the second pair of drums 144 begins to rotate, and the first pressed sheet is supplied to the second pair of drums 144. In at least one exemplary embodiment, the first pressed sheet is transferred from the first pair of drums 124 to the second pair of drums 144 along the first plate 240, i.e., the first conveyor 1428. The second upper drum 146 and the second lower drum 228 of the second pair of drums 144 rotate. In at least one exemplary embodiment, the second upper drum 146 rotates counterclockwise and the second lower drum 228 rotates clockwise.

[0253] In at least one exemplary embodiment, the second upper drum 146 rotates at a first speed and the second lower drum 228 rotates at a second speed to ensure consistent material transfer through the second upper drum 146 and the second lower drum 228. In at least one exemplary embodiment, the second upper drum 146 and the second lower drum 228 are rotated manually, automatically by a motor, or a combination thereof.

[0254] In S2120, the first pressed sheet is further pressed to a second thickness by the second pair of drums 144. In at least one exemplary embodiment, the first pressed sheet is fed into a gap 308 separating the second upper drum 146 and the second lower drum 228. The rotation of the second upper drum 146 and the second lower drum 228 pulls the first pressed sheet through the gap 308. The first pressed sheet is pressed between the second upper drum 146 and the second lower drum 228 to become the second pressed sheet. As previously stated, in at least one exemplary embodiment, the second pressed sheet has a thickness ranging from about 2 mm to about 18 mm (e.g., about 6 mm to about 9 mm or about 7.5 mm to about 8 mm). The second pressed sheet exits the gap 308 and the pair of the second pair of drums 144 onto the second plate 252.

[0255] In S2124, the third pair of drums 164 begins to rotate, and the second pressed sheet is supplied to the third pair of drums 164. In at least one exemplary embodiment, the second pressed sheet is transported along the second plate 252, i.e., the second conveyor 1432, from the second pair of drums 144 to the third pair of drums 164. The third upper drum 166 and the third lower drum 316 of the third pair of drums 164 rotate. In at least one exemplary embodiment, the third upper drum 166 rotates counterclockwise and the third lower drum 316 rotates clockwise.

[0256] In at least one exemplary embodiment, the third upper drum 166 rotates at a first speed and the third lower drum 316 rotates at a second speed to ensure consistent material transfer through the third upper drum 166 and the third lower drum 316. In at least one exemplary embodiment, the third upper drum 166 and the third lower drum 316 are rotated manually, automatically by a motor, or a combination thereof.

[0257] In S2128, the third pair of drums 164 forms a plurality of gum pieces. In at least one exemplary embodiment, the third pair of drums 164 forms a stenciled sheet having a plurality of gum pieces. In at least one alternative exemplary embodiment, the third pair of drums 164 forms the plurality of gum pieces as individual distinct gum pieces.

[0258] In at least one exemplary embodiment, a second pressed sheet is supplied to a gap 336 separating a third upper drum 166 and a third lower drum 316. The rotation of the third upper drum 166 and the third lower drum 316 pulls the second pressed sheet through the gap 336. The second pressed sheet is formed between the third upper drum 166 and the third lower drum 316.

[0259] In at least one exemplary embodiment, a second pressed sheet is etched by a third upper drum 166 and a third lower drum 316 to form an etched sheet. The etched sheet defines a plurality of gum pieces. In at least one exemplary embodiment, the plurality of gum pieces remain connected in the etched sheet. In at least one alternative exemplary embodiment, the second pressed sheet is cut into a plurality of individual, separate gum pieces by the third upper drum 166 and the third lower drum 316. The plurality of gum pieces exit through a gap 336 and a third pair of drums 164.

[0260] While several exemplary embodiments have been disclosed herein, it should be understood that other modifications are possible. Such modifications will not be considered to deviate from the spirit and scope of this disclosure, and all such modifications that would be obvious to those skilled in the art are intended to be included in the following claims.

Claims

1. A device for forming nicotine gum, It comprises a first pair of drums and a second pair of drums, The first pair of drums is configured to receive the nicotine gum mixture and press it to a first thickness to form a first pressed sheet. The second pair of drums is configured to receive and chop the first pressed sheet to form a scored sheet containing multiple pieces of gum. The aforementioned second pair of drums, It comprises a first drum and a second drum, The first drum comprises a first die including a first pattern, The second drum comprises a second die containing a second pattern, The second pattern is a mirror image of the first pattern, The apparatus is configured such that the first drum and the second drum are spaced apart so that the first die and the second die make notches in at least the first pressed sheet as the first pressed sheet passes between the first drum and the second drum.

2. In the apparatus according to claim 1, An apparatus in which the first die defines a first plurality of recesses.

3. In the apparatus according to claim 2, The apparatus wherein the second die defines a second plurality of recesses corresponding to the first plurality of recesses.

4. In the apparatus described in claim 3, The apparatus, wherein the second pair of drums is configured to align a first plurality of non-recesses on the first die with a second plurality of non-recesses on the second die, so as to engrave at least the first pressed sheet into the plurality of gum pieces.

5. In the apparatus described in claim 3, The first drum of the second pair of drums is configured to rotate at a first speed, The second drum of the second pair of drums is configured to rotate at a second speed, The apparatus is configured such that the first and second speeds facilitate consistent material transfer, such that the non-recesses make notches in at least the first pressed sheet when the first plurality of non-recesses on the first die are aligned with the second plurality of non-recesses on the second die.

6. In the apparatus according to claim 2, The apparatus wherein each of the first plurality of recesses has a triangular cross-section along the upper surface of the non-recessed surface of the first die.

7. In the apparatus according to claim 2, Apparatus in which a first segment of a non-recess on the first die defines one side of each of a pair of adjacent recesses.

8. In the apparatus according to claim 1, The second pair of drums is located downstream of the first pair of drums in the apparatus.

9. In the apparatus according to claim 8, It also features a third pair of drums, The third pair of drums is provided between the second pair of drums and the first pair of drums. The apparatus wherein the third pair of drums are configured to receive the first pressed sheet and press it to a second uniform thickness.

10. In the apparatus according to claim 1, Equipped with an additional heater, The apparatus, wherein the heater is configured to heat the first drum of the second pair of drums, the second drum of the second pair of drums, or a combination thereof, to heat the first pressed sheet.

11. A method for forming nicotine gum, Passing a sheet of gum mixture through a first pair of drums Pressing the sheet to a first thickness between the first pair of drums to form a first pressed sheet This includes passing the first pressed sheet through a second pair of drums, The first drum of the second pair of drums comprises a first die, and the second drum of the second pair of drums comprises a second die. The first die is provided with a first recess pattern, and the second die is provided with a second recess pattern. The first recess pattern is a mirror image of the second recess pattern, and the method involves scoring at least the first pressed sheet to form a scored sheet containing a plurality of gum pieces.

12. In the method according to claim 11, The second pair of drums is located downstream of the first pair of drums.

13. In the method according to claim 12, The process further includes passing the first pressed sheet through a third pair of drums, A method wherein the third pair of drums is located between the second pair of drums and the first pair of drums, and the first pressed sheet is pressed to a second uniform thickness.

14. In the method according to claim 13, The second method wherein the uniform thickness is in the range of 2 mm to 18 mm.

15. In the method according to claim 11, A method further comprising adjusting the temperatures of the first pair of drums and the second pair of drums.

16. In the method according to claim 15, A method comprising adjusting the temperature, which includes heating the second pair of drums to raise the temperature of the first pressed sheet.

17. In the method according to claim 15, A method comprising adjusting the temperature, which includes cooling the second pair of drums to lower the temperature of the first pressed sheet.

18. In the method according to claim 11, A method comprising passing the first pressed sheet through a second pair of drums, wherein the first non-recess on the first die and the second non-recess on the second die are aligned such that at least the first pressed sheet is notched.

19. In the method according to claim 11, A method wherein the first thickness is in the range of 4 mm to 20 mm.

20. In the method according to claim 11, Passing the first pressed sheet through the second pair of drums, Rotating the first drum of the second pair of drums at a first speed, The second drum of the second pair of drums is rotated at a second speed, and the first speed is the same as the second speed. A method comprising aligning the non-recessed portion of the first recess pattern on the first die with the non-recessed portion of the second recess pattern on the second die to make notches in at least the first pressed sheet and form a plurality of gum pieces.

21. A device for forming nicotine gum, It comprises a first pair of drums and a second pair of drums, The first pair of drums is configured to receive the nicotine gum mixture and press it to a first thickness to form a first pressed sheet. The second pair of drums is configured to receive and cut the first pressed sheet to form a plurality of gum pieces. The aforementioned second pair of drums, It comprises a first drum and a second drum, The first drum comprises a first die including a first pattern, The second drum comprises a second die containing a second pattern, The second pattern is a mirror image of the first pattern, The apparatus is such that the first drum and the second drum are spaced apart so that the first die and the second die cut the plurality of gum pieces as the first pressed sheet passes between the first drum and the second drum.

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