Apparatus, components thereof, and method for handling rods of aerosol-forming material - Patent Application 20070122997

Abstract

The apparatus (10) for handling rods of aerosol-generating material includes a rotatable drum (12) having a plurality of elongated longitudinal grooves (23) disposed about the drum's exterior and extending axially along the drum. The rotatable drum (12) includes a circumferential groove in the exterior that intersects the longitudinal grooves (23) and a guide member (235) having a longitudinal arm with a guide surface (38) at a first end. An air flow outlet (236) is disposed in the guide surface (38), and an air passage (238) is in fluid communication with the air flow outlet (236). The air passage (238) is connected to a supply of pressurized gas to provide pressurized gas to the air flow outlet. The guide member (235) is positioned with the guide surface (38) at least partially received within the groove and configured to emit gas from the air flow outlet (236) onto the rod supported within the longitudinal grooves (23). A guide member (235) for use with such an apparatus (10), and a method of using such an apparatus (10) are also provided.

Description

[Technical Field]

[0001] The present invention relates to an apparatus for handling a rod of aerosol-forming material, and components of such an apparatus. The present invention also relates to a method for handling a rod of aerosol-forming material. [Background technology]

[0002] Certain tobacco industry products generate aerosols that are inhaled by the user during use. Such tobacco industry products generally comprise an aerosol-forming material in the form of a cylindrical rod surrounded by an outer wrapper.

[0003] Apparatus for producing, manipulating, transporting, and otherwise handling rods of aerosol-generating material during the manufacture of consumables for use in aerosol generating systems is known. The aerosol-generating material may include tobacco, tobacco derivatives, or other types of aerosol-generating material. Such apparatus may include at least one rotatable drum having elongated grooves disposed about the circumferential surface of the drum for receiving the rods. Such drums may have suction holes communicating with the grooves for retaining the rods within the grooves as the drum rotates.

[0004] A variety of different compositions and types of aerosol-generating materials may be provided within rods intended for transport through such devices. Accordingly, such rods may have varying hardness, elasticity, and deformability. This may result in some types of rods presenting problems when handled by known devices. For example, some rods may become jammed within the grooves of a drum or may be more easily damaged by physical contact with rod guides within known rod-handling devices. Summary of the Invention

[0005] According to a first aspect of the present invention, there is provided an apparatus for handling a rod of aerosol-generating material, the apparatus comprising: a rotatable drum having a plurality of elongated longitudinal grooves disposed about an outer surface of the drum and extending axially of the drum, the rotatable drum having circumferential grooves in its outer surface intersecting the longitudinal grooves; and a guide member having a longitudinal arm with a guide surface at a first end and an air flow path in fluid communication with the air flow path, the air flow path being connected to a supply of pressurized gas to supply pressurized gas to the air flow path, the guide member being arranged with the guide surface at least partially received within the grooves and configured to emit gas from the air flow path onto the rod supported in the longitudinal grooves.

[0006] The guide surface may be inclined at an angle relative to the longitudinal axis of the guide member.

[0007] The angle of the guide surface may be between 30 degrees and 60 degrees, or may be approximately 45 degrees.

[0008] The air outlet may be configured to guide the airflow from the air outlet at a constant angle of 20 to 70 degrees from the direction perpendicular to the guide surface, which may be 30 to 60 degrees, 40 to 50 degrees, or 45 degrees.

[0009] The longitudinal axis of the guide member may be generally horizontal.

[0010] The air flow outlet may be configured to direct the air flow vertically downward from the air flow outlet.

[0011] The guide member may include a plurality of air flow outlets, or may include three air flow outlets.

[0012] The guide member may comprise two plates secured together at their respective opposing faces, and the air flow passage and air outlet(s) may be formed in the opposing face of at least one of the plates.

[0013] The pressure of the pressurized gas supplied to the air flow path may be 0.5 to 2 bar, 0.7 to 1.8 bar, 0.9 to 1.6 bar, or 1 to 1.5 bar.

[0014] Each flute in the rotatable drum may include one or more suction holes extending from a surface of the respective flute that communicate with an associated vacuum duct in the drum, and the apparatus may further include a control flange, wherein the drum rotates in use relative to the control flange, the control flange having a first opening connected to a vacuum source and a second opening connected to a pressurized gas source, and as the drum rotates relative to the control flange, the vacuum duct is in fluid communication with the first opening over a first range of rotation of the drum to apply a negative pressure to the vacuum duct, and the vacuum duct is in fluid communication with the second opening over a second range of rotation of the drum to apply a positive gas pressure to the vacuum duct.

[0015] Each flute may include a plurality of suction holes.

[0016] Each vacuum duct may open at a first end face of the drum.

[0017] The control flange may be disposed adjacent the first end face of the drum.

[0018] The control flange may include a vent cavity open to the atmosphere, and the vacuum duct may be in fluid communication with the vent cavity over a third range of rotation of the drum after being in fluid communication with the first opening over a first range of rotation of the drum and before being in fluid communication with the second opening over a second range of rotation of the drum.

[0019] The vacuum duct may be in fluid communication with the vent cavity over a fourth range of rotation of the drum, after which the vacuum duct is in fluid communication with the second opening over a second range of rotation of the drum before returning to be in fluid communication with the first opening over a first range of rotation of the drum.

[0020] The control flange may include a gas manifold connected to a source of pressurized gas, and the second opening may be formed in the gas manifold.

[0021] A gas manifold may be disposed within the vent cavity.

[0022] The second range of rotation of the drum may extend around a lowermost region of the drum.

[0023] The first range of rotation of the drum may be greater than the second range of rotation of the drum.

[0024] The second rotation range may be 1 to 40 degrees, 5 to 35 degrees, 10 to 30 degrees, or 15 to 25 degrees.

[0025] The control flange may include a circular recess, and the first end face of the drum may be received within the circular recess.

[0026] The second opening may be arcuate.

[0027] The first opening may be arcuate, and the first and second openings may each be circumferentially arranged about a common center point.

[0028] The first and second openings may be positioned at equal radial distances from a common center point.

[0029] Pressurized gas may be supplied to the second opening at 1 to 5 bar, may be 1.2 to 4 bar, may be 1.3 to 3 bar, may be 1.5 to 3 bar, may be 2 to 3 bar, or may be about 3 bar.

[0030] According to a further aspect of the present invention, there is provided a guide member for use with a drum of an apparatus for handling a rod of aerosol-generating material, the guide member comprising a longitudinal arm having a guide surface at a first end thereof, an air flow outlet disposed in the guide surface, and an air flow passage in fluid communication with the air flow outlet.

[0031] The guide member may further comprise any of the features described above with respect to the device.

[0032] The guide member may further include an air inlet at a second end of the longitudinal arm opposite the first end, the air inlet being in fluid communication with the air flow passage.

[0033] According to a further aspect of the present invention, there is provided a method for handling a rod of aerosol-generating material using an apparatus as described above, the method comprising: receiving the rod within a longitudinal groove of a rotatable drum; and supplying pressurized gas to an air flow passage to emit a pressurized air flow from an air flow outlet onto the rod supported within the longitudinal groove to assist in ejection of the rod from the longitudinal groove.

[0034] The method may further include discharging the pressurized gas vertically downward from the air flow outlet.

[0035] The pressurized gas may be supplied to the air flow path at 0.5 to 2 bar, or may be 0.7 to 1.8 bar, or may be 0.9 to 1.6 bar, or may be 1 to 1.5 bar.

[0036] Each flute of the rotatable drum may include one or more suction holes extending from a surface of the respective flute that communicate with an associated vacuum duct in the drum, and the apparatus may further include a control flange that may have a first opening connected to a vacuum source and a second opening connected to a pressurized gas source, and the method may further include rotating the drum relative to the control flange, applying a negative pressure to the one or more suction holes to retain the rod within the flute as the drum rotates relative to the control flange through a first range of rotation, and applying a positive gas pressure to the one or more suction holes to assist in ejection of the rod from the flute as the drum rotates relative to the control flange through a second range of rotation.

[0037] The method may further include opening the one or more suction holes to the atmosphere over a third range of rotation of the drum after the drum has rotated through the first range of rotation and before the drum has rotated through the second range of rotation.

[0038] The method may further include opening the one or more suction holes to the atmosphere over a fourth range of rotation of the drum after the second range of rotation and before the drum returns to the first range of rotation.

[0039] The first range of rotation of the drum may be greater than the second range of rotation of the drum.

[0040] The second rotation range may be 1 to 40 degrees, 5 to 35 degrees, 10 to 30 degrees, or 15 to 25 degrees.

[0041] Pressurized gas may be supplied to the second opening at 1 to 5 bar, may be 1.2 to 4 bar, may be 1.3 to 3 bar, may be 1.5 to 3 bar, may be 2 to 3 bar, or may be about 3 bar.

[0042] The method may include handling a rod of sheet-cut aerosol-forming material. The aerosol-forming material may include material formed from a tobacco sheet or a gel sheet, cut into strips, and formed into a rod.

[0043] The rods or articles handled by the apparatus and method of the present invention include an aerosol-generating material. The aerosol-generating material is, for example, a material that can generate an aerosol when heated, irradiated, or energized in any other manner. The aerosol-generating material may be in the form of a solid, liquid, or semi-solid (such as a gel), which may or may not contain an active substance and / or flavoring.

[0044] The aerosol-generating material may include one or more active agents and / or flavors, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0045] The aerosol-generating material may include plant material / tobacco material which may be in the form of individual strands / strips of reconstituted tobacco, and may include cut rag tobacco, leaf plant material / tobacco, reconstituted plant material / tobacco, extruded plant material / tobacco or expanded plant material / tobacco.

[0046] The aerosol-generating material may include a binder, such as a gelling agent, and an aerosol-forming agent. Optionally, a substance to be delivered and / or a bulking agent may also be present. Optionally, a solvent, such as water, may also be present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free of plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0047] The aerosol-generating material may include or be in the form of an aerosol-generating film. The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness may be within a range of about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm.

[0048] The aerosol-generating film may be continuous. For example, the film may comprise or be a continuous sheet of material. The sheet may be in the form of a wrapper, gathered to form a gathered sheet, or chopped to form a chopped sheet. The chopped sheet may comprise one or more strands or strips of aerosol-generating material.

[0049] The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may include one or more discrete portions or regions of aerosol-generating material, such as dots, stripes, or lines, that may be supported on a substrate. In such embodiments, the substrate may be planar or non-planar.

[0050] The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-forming agent, and one or more other ingredients, such as one or more substances to be delivered, to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent and form the aerosol-generating film.

[0051] The slurry may be heated to remove at least about 60%, 70%, 80%, 85%, or 90% by weight of the solvent.

[0052] The aerosol-generating material may include or be an "amorphous solid." In some embodiments, the aerosol-generating material includes an aerosol-generating film that is an amorphous solid. The amorphous solid may be a "monolithic solid." The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dry gel. The amorphous solid may be a solid material that may retain some fluid, such as a liquid, within the amorphous solid. In some embodiments, the amorphous solid may comprise, for example, about 50 wt%, 60 wt%, or 70 wt% amorphous solid, up to about 90 wt%, 95 wt%, or 100 wt% amorphous solid. The amorphous solid may be substantially free of plant material. The amorphous solid may be substantially free of tobacco.

[0053] The method may include handling a rod having a susceptor material therein. The susceptor is a material that can be heated by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that penetration with the varying magnetic field causes induction heating of the heating material. The heating material may be a magnetic material, such that penetration with the varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, such that the susceptor is heatable by both heating mechanisms.

[0054] The susceptor material within the rod or article may include particulate matter within the rod / article or may include a metal such as iron or aluminum. The susceptor material may include one or more elongated elements disposed within the rod. The susceptor material may include wire, filament, foil, rod, blade, or pin. The susceptor material may be substantially centered about the axis of the rod or offset from the central axis. The susceptor material may be distributed throughout the aerosol-generating material, uniformly distributed, or distributed at various densities or concentrations within the rod. The susceptor material may be more concentrated at the upstream end of the rod and less concentrated at the downstream end of the rod relative to the direction of aerosol flow through the rod during use. Alternatively, the susceptor material may be less concentrated at the upstream end of the rod and more concentrated at the downstream end of the rod. The susceptor material may vary continuously in concentration along the length of the rod between regions of different concentration, or may vary abruptly or non-uniformly between regions of different concentration within the rod. The susceptor material may extend substantially parallel to the central axis of the rod or may extend at an angle to the central axis of the rod. The susceptor material may comprise multiple elements within the rod or a single susceptor element.

[0055] The rods or articles handled by the apparatus and method of the present invention, notwithstanding one or more of the above-described structures, compositions, or materials, may be heavier and / or more fragile than other known types of rods for tobacco industry products. It would therefore be desirable to provide a smoother transition of such rods between drums of an article manufacturing apparatus during production, reducing collisions during the transition between drums to avoid damage and / or deformation of such rods or articles. [Brief explanation of the drawings]

[0056] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Figure 1] 1 is a side view of a portion of a known tobacco industry product manufacturing apparatus. [Figure 2]FIG. 2 is a perspective view of a portion of the apparatus of FIG. 1 with the hopper drum removed to show the control flange and drum shaft. [Figure 3] FIG. 2 is a side view of the control flange of the device of FIG. 1. [Figure 4] FIG. 2 is a perspective view of a hopper drum of the device of FIG. 1. [Figure 5] FIG. 2 is a perspective view of a rod guide of the device of FIG. 1. [Figure 6] FIG. 2 is a perspective view of the grading drum of the apparatus of FIG. 1. [Figure 7] FIG. 2 is an enlarged schematic side view of a region of the apparatus of FIG. 1 illustrating the interaction between the hopper drum and the rod guides, and also showing the grading drum. [Figure 8] FIG. 2 is a perspective view of the apparatus shown in FIG. 1, showing the hopper drum, grading drum, and rod guides, with the hopper omitted for clarity. [Figure 9] 1 is a perspective view of a rod guide of a first embodiment of the present invention for use in a tobacco industry product manufacturing apparatus of the present invention; FIG. [Figure 10] 10 is a cross-sectional view of the rod guide of FIG. 9 taken along line XX. [Figure 11] 1 is an enlarged view of the discharge area of ​​a hopper drum in use of a known tobacco industry product manufacturing apparatus with conventional rod guides; FIG. [Figure 12] 11 is an enlarged view of the discharge area of ​​a hopper drum of a tobacco industry product manufacturing apparatus of the present invention, in use, comprising the rod guide of the first embodiment of the present invention of FIGS. 9 and 10; FIG. [Figure 13] FIG. 10 is a side view of a control flange of a second embodiment of the present invention for use in a tobacco industry product manufacturing apparatus of the present invention. [Figure 14] 14 is a perspective view of the control flange of FIG. 13 in place on a tobacco industry product manufacturing apparatus of the present invention with the hopper drum removed from the drum shaft. [Figure 15] 1 is an enlarged view of the discharge area of ​​a hopper drum in use of a known tobacco industry product manufacturing apparatus; FIG. [Figure 16]14 is an enlarged view of the discharge area of ​​the hopper drum of the tobacco industry product manufacturing apparatus of the present invention, in use, with the control flange of the second embodiment of the present invention of FIG. 13. DETAILED DESCRIPTION OF THE INVENTION

[0057] In the figures described herein, like reference numerals are used to denote equivalent features, items or components.

[0058] FIG. 1 shows a schematic side view of a portion of a known tobacco industry product manufacturing apparatus 10 (hereafter, "apparatus" for brevity). The apparatus 10 includes a hopper 11 configured to receive multi-length rods (hereafter, "rods") of aerosol-generating material Rm. That is, the rods Rm are produced by the manufacturing apparatus and are present in the final assembled aerosol-generating consumable (hereafter, "consumable"), and are multiples of the length of the rods intended for use in the aerosol-generating system. As such, the rods Rm require cutting and placement as part of a process step in the consumable manufacturing process.

[0059] In the portion of apparatus 10 shown in FIG. 1, rods Rm are transported from a hopper 11 by a hopper drum 12 and, while held on the hopper drum, are cut into a plurality of smaller rods Rc by first and second cut-off wheels 13, 14. The cut rods Rc are then transferred to a grading drum 15. The grading drum 15 receives the cut rods Rc from the hopper drum 12 in a staggered manner, allowing for spacing, shuffling, and rearrangement of the cut rods Rc into finished consumables in subsequent manufacturing steps (not shown). The directions of rotation of the hopper drum 12 and grading drum 15 are indicated by respective arrows in FIG. 1.

[0060] The hopper 11 has side walls 16 that define an interior space of the hopper 11 and opens to a transfer area 17 at the bottom region of the hopper 11. The hopper drum 12 is positioned adjacent the hopper 11 and partially within the transfer area 17 and is configured to receive rods Rm from within the hopper 11 and convey them away from the hopper 11 for processing into consumables in subsequent processing steps of the apparatus 10.

[0061] The hopper drum 12, shown in more detail in FIG. 4, is a cylindrical component having a central axis AA and a bore 18 extending axially through the drum 12. The hopper drum 12 is rotatable within the apparatus 10 by being attached to a rotatable shaft 19 (see FIGS. 2 and 4) of the apparatus 10, which extends through the bore 18. The hopper drum 12 has first and second end faces 20, 21 and a circumferential outer surface 22 extending around the hopper drum 12 between the end faces 20, 21. The outer surface 22 includes a plurality of longitudinal grooves 23. The longitudinal grooves 23 are curved recesses or indentations configured to receive the rods Rm from the hopper 11, retain the rods Rm within the longitudinal grooves 23 as the hopper drum 12 rotates, and transport the rods Rm away from the hopper 11 and forward through the apparatus 10 for processing into consumables. The longitudinal grooves 23 are elongated and extend in the axial direction of the hopper drum 12. That is, the longitudinal grooves 23 are positioned with an elongated length extending in a direction aligned parallel to the central axis AA of the hopper drum 12.

[0062] The outer surface 22 of the hopper drum 12 is formed with a plurality of circumferential grooves 24. The grooves 24 extend radially inward such that the grooves extend into and intersect the longitudinal grooves 23. A plurality of vacuum ducts 25 (see FIG. 7) penetrate the body of the hopper drum 12 in a direction parallel to the central axis AA. The vacuum ducts 25 are disposed circumferentially around the hopper drum 12 and radially inward of the longitudinal grooves 23. Each vacuum duct 25 opens at a respective vacuum port 26 in the first end face 20 of the hopper drum 12. The vacuum ports 26 are thus disposed in a circular arrangement on the first end face 20 of the hopper drum 12 at a radial distance rv measured from the central axis AA of the hopper drum 12 / rotatable shaft 19 (see FIG. 7). Each longitudinal groove 23 is provided with a plurality of suction holes 27 that are in fluid communication with an associated respective vacuum duct 25. In one embodiment, each vacuum duct 25 may communicate with the suction holes 27 of two adjacent rows of flutes 23, as shown in Figure 7. In other embodiments, each vacuum duct 25 may communicate with the suction holes 27 of just one row of flutes 23, or with the suction holes 27 of three or more rows of flutes 23. This allows a vacuum to be applied to the suction holes 27 of one or more flutes 23 by applying a vacuum to the vacuum port 26 of the associated vacuum duct 25.

[0063] FIG. 3 illustrates the control flange 30 of the known apparatus 10 shown in FIG. 1. The control flange 30 comprises a generally circular body having a circular recess 31 formed in a surface 32 of the control flange 30 and a central circular opening 33. The control flange 30 comprises an apex 30a and a nadir 30b. When the control flange 30 is installed in the apparatus 10, the apex 30a is the uppermost portion and the nadir 30b is the lowermost portion. When the apparatus 10 is assembled, the first end surface 20 of the hopper drum 12 is received in the circular recess 31, and the rotatable shaft 19 of the apparatus 10 passes through the central circular opening 33. The control flange 30 includes two arcuate openings 34 formed therethrough within the circular recess 31. The arcuate openings 34 are separated by a bridging portion 41, which provides the control flange 30 with structural strength that might otherwise be compromised by a single long arcuate opening. However, in other embodiments, a single arcuate opening, or three or more arcuate openings, may be provided in the control flange 30.

[0064] The arcuate opening 34 extends over only a portion of the circumference of the control flange 30, as indicated by angle V in FIG. 3 . As noted above, the bridging portion 41 may be omitted in some instances to provide a single arcuate opening. The arcuate opening is disposed at a radial distance rv measured from the center point C of the circular recess 31 / circular opening 33, which, in the assembled apparatus 10, is the same radial distance rv from the central axis AA of the hopper drum 12 / rotatable shaft 19. Thus, the arcuate opening 34 may be in fluid communication with one or more vacuum ports 26, depending on the rotational position of the hopper drum 12 relative to the control flange 30. The control flange 30 further includes a vent cavity 42 disposed in a lower region of the control flange 30. The vent cavity 42 extends over a region of the circumference of the control flange 30, as indicated by angle NV in FIG. 3 . The vent cavity 42 is disposed at a radial distance rv measured from the center point C of the circular recess 31 / circular opening 32, which in the assembled apparatus 10 is the same radial distance rv from the central axis AA of the hopper drum 12 / rotatable shaft 19. The vent cavity 42 also extends radially outward to the edge of the control flange 30, opening at a radially outer surface 43 of the control flange 30.

[0065] The apparatus 10 includes a front guide 2828 (and a corresponding rear guide at the opposite end of the hopper drum 12, not referenced in the figures) that extends around a portion of the circumference of the end faces 20, 21 of the hopper drum 12 (as shown in FIG. 1). A lower transfer surface 29 is provided below the hopper drum 12 across the axial length of the hopper drum 12 and extends around a portion of the circumference of the hopper drum 12 within the bottom region of the hopper drum 12. In use, the lower transfer surface 29 assists in the transfer of the cut rods Rc from the hopper drum 12 to the grading drum 15, as described in more detail below.

[0066] Guide members in the form of rod guides 35 are disposed in the bottom region of the hopper drum 12 and comprise elongated arms that are substantially horizontally disposed and extend substantially tangentially relative to the hopper drum 12 (see FIGS. 1 and 7). A known configuration of rod guides 35 is shown in FIG. 5. Each rod guide 35 comprises an elongated arm having a longitudinal axis DD. In use, the longitudinal axis DD lies substantially horizontal. The rod guides 35 include mounting openings 36 for securing the rod guides 35 to the apparatus 10 by attaching bolts 37, as shown in FIG. 1. The rod guides 35 include an inclined guide surface 38 at the end of the rod guide 35 opposite the mounting opening 36. The rod guides 35 are secured within the apparatus 10 such that the guide surfaces 38 are at least partially positioned within the grooves 24 and longitudinal slots 23 of the hopper drum 12.

[0067] The cut-off wheels 13, 14 are mounted adjacent to the hopper drum 12 and are staggered axially and circumferentially about the hopper drum 12. The peripheral cutting edge 39 of each cut-off wheel 13, 14 intersects the outer surface 22 of the hopper drum 12 and extends into a respective cutting groove 40 formed circumferentially around the outer surface 22 of the hopper drum 12 and extending through each longitudinal groove 23. Thus, the rod Rm received in the longitudinal groove 23 can be cut into individual smaller cut rods Rc as it passes through the cut-off wheels 13, 14 as the hopper drum 12 rotates.

[0068] The grading drum 15, shown in perspective view in FIG. 6, comprises a cylindrical component having a central axis BB and a bore 44 extending axially through the drum 15. The grading drum 15 is rotatably mounted below the hopper drum 12, as shown in FIG. 1. The grading drum 15 has a circumferential outer surface 45 extending around the grading drum. The outer surface 45 includes a plurality of rod seats 46 configured to receive cut rods Rc from the hopper drum 12 / lower transfer surface 29 as the hopper drum 12 rotates and transport the cut rods Rc away from the hopper drum 12 and forward through the apparatus 10 for processing into consumables. The lower transfer surface 29 includes slots 47 through which the rod seats 46 of the grading drum 15 rotate as they pass adjacent to the hopper drum 12 to allow the rod seats 46 to collect the cut rods Rc from the hopper drum 12. The rod seats 46 are staggered in the circumferential direction when viewed in the axial direction of the grading drum 15. This allows the rods Rc cut from one axial row on the hopper drum 12 (i.e., axially aligned within one longitudinal groove 23 on the hopper drum 12) to be picked up by the grading drum 15 at staggered intervals, whereby the cut rods are once offset axially on the grading drum 15.

[0069] The operation of the known device shown in FIG. 1 will now be described. Hopper 11 is provided with multiple lengths of rods Rm. The rods Rm are held within hopper 11 with their axes parallel to the axis AA of hopper drum 12. Hopper drum 12 rotates in the direction shown, and as the area of ​​hopper drum 12 passes through transfer area 17 of hopper 11, each longitudinal groove 23 picks up an individual rod Rm and transports it around and out of hopper 11. Control flange 30 remains fixed within device 10 as hopper drum 12 rotates. A vacuum is applied through arcuate openings 34 such that each vacuum port 26 is in fluid communication with arcuate opening 34, thereby providing reduced pressure to vacuum duct 25 when subjected to the applied vacuum. This, in turn, creates a suction force through suction holes 27 of longitudinal grooves 23, which are in fluid communication with vacuum duct 25. This helps to position and retain the individual rods Rm within their respective longitudinal grooves 23 as the hopper drum 12 rotates through the transfer region 17 of the hopper 11 .

[0070] From the shape and circumferential extent of the arcuate openings 34 of the control flange 30 shown in FIG. 3, it can be seen that a vacuum is applied to the vent ports 26, and thereby to the suction holes 27 of the longitudinal grooves 23, over a first range or angle of rotation of the hopper drum 12 relative to the control flange 30, designated V in FIG. 3. For convenience, this corresponds approximately to the arcuate region superimposed on the hopper drum 12 in FIG. 1, designated V. In this region of rotation, the rods Rm are held within the longitudinal grooves 23 by suction. As noted above, the arcuate openings 34 may comprise a single arcuate opening 34 by omitting the bridging portion 41, or three or more arcuate openings 34 may be provided. The vacuum is applied over the circumferential extent of that / all arcuate openings 34 and is substantially unaffected by the presence of any bridging portion 41. Thus, the angle V at which the vacuum is applied through the arcuate openings 34 may be the entire angle V of a single arcuate opening 34 or the angular range of all arcuate openings 34 circumferentially from the start point to the end point, including any angular range in which bridging portions 41 may exist.

[0071] As the rod Rm passes through the cut-off wheels 13, 14, the cut-off wheels 13, 14 cut the rod Rm into smaller individual cut rods Rc as the rod Rm is held within the longitudinal grooves 23.

[0072] When the vacuum port 26 reaches the vent cavity 42 as the hopper drum 12 rotates, the vacuum port 26 is placed in fluid communication with the vent cavity 42. Because the vent cavity 42 is open to the atmosphere at the radially outer surface 43 of the control flange 30, the vacuum port 26 is therefore open to the atmosphere when in communication with the vent cavity 42. This removes the suction force through the suction holes 27 in the longitudinal grooves 23, releasing the cut rods Rc from the longitudinal grooves 23. The lower transfer surface 29 is positioned within an area of ​​the hopper drum 12 corresponding to the location of the vent cavity 42 in the control flange 30. Thus, the cut rods Rc are transported around the lower area of ​​the hopper drum 12 on the lower transfer surface 29 until they are picked up by the grading drum 15 in the upper area of ​​the grading drum. The rod seat 46 of the grading drum 15 passes near the bottom of the hopper drum 12 through the slot 47 in the lower transfer surface 29. As a result, as the cut rods Rc leave the longitudinal grooves 23, they are picked up by the respective rod seats 46 of the grading drum 15 and carried forward within the rod seats 46 as the longitudinal grooves 23 of the hopper drum 12 rotate away from the grading drum 15 and back towards the hopper 11, collecting another plurality of lengths of rod Rm.

[0073] In ideal operation, when the suction force is removed from the suction holes 27, the cut rods Rc fall consistently, quickly, and uniformly from their respective flutes 23 of the hopper drum 12 due to gravity. However, some rods Rm / Rc of a particular composition of aerosol-generating material being processed by the apparatus 10 may have specific material properties, such as hardness, resilience, or elastic / plastic deformability, which can pose challenges to the cut rods Rc leaving the flutes 23. In some cases, the cut rods may become stuck in the flutes even after the suction force is removed. In particular, rods Rc containing aerosol-generating material with softer material properties may be more easily deformed and tend to become trapped within the flutes 23. Alternatively, or additionally, at increased rod production rates, the rods Rc may simply not be able to release from the flutes 23 quickly enough to be transferred from the hopper drum 12 to the grading drum 15 under gravity. This can lead to poor production, jammed machinery, or at least wasted rod material as the rod Rc is lost from the production line or actively removed and disposed of.

[0074] One known feature intended to avoid such problems of inconsistent or insufficient extraction of cut rods Rc from the flutes 23 of the hopper drum 12 is the provision of rod guides 35, as described above and shown in FIG. 5, and in the context of the apparatus 10, in FIGS. 1 and 7. The rod guides 35 function to mechanically push the cut rods Rc out of their respective flutes 23 and / or physically guide the rods Rc so that they pass quickly enough to the grading drum 15. That is, as the hopper drum 12 rotates, jammed cut rods Rc abut against the inclined guide surfaces 38 of the rod guides 35, and as the hopper drum 12 continues to rotate, the cut rods Rc are forced out of the flutes 23 and toward the grading drum 15. Alternatively, if the rod Rc is not stuck within the flute 23, but the apparatus 10 is moving fast enough so that the rod Rc does not fall out of the flute 23 quickly enough under gravity, the released rod Rc will still contact the inclined guide surface 38 and be deflected downward to assist its movement away from the hopper drum 12 and towards the grading drum 15.

[0075] The above-described use of rod guides 35 is effective in removing cut rods Rc from the flutes 23 and / or aiding in the movement of the rods at a velocity toward the grading drum 15. However, problems can arise due to the force with which the rods Rc may abut against the guide surfaces 38 of the rod guides 35. Such a collision can dent or damage the cut rods Rc, which can result in uneven or damaged consumables. Additionally, the cut rods Rc can be deflected unevenly from the flutes 23, which can result in the rods being collected inconsistently by the grading drum 15.

[0076] A first aspect of the present invention relates to an improved rod guide 235, shown in FIGS. 9 and 10. The rod guide 235 of the present invention shares several features with the rod guide 35 shown in FIG. 5; similar features retain the same reference numerals and will not be described in detail again. The rod guide 235 includes an elongated arm having a longitudinal axis DD that is horizontally positioned in use, a mounting opening 36 for securing the rod guide 235 to the apparatus 10 with a mounting bolt 37, and a sloped guide surface 38 at the end of the rod guide 235 opposite the mounting opening 36. The difference with the rod guide 235 of the present invention is that the sloped guide surface 38 includes a plurality of air flow outlets 236. The rod guide 235 includes an air flow inlet 237 fluidly connected to the air flow outlets 236 by an air passage 238 extending through the body of the rod guide 235. This can be clearly seen in the cross-sectional view of FIG. 10. In operation, a supply of pressurized air is connected to air inlet 237 so that air flow is generated through air passage 238 and out air outlet 236. While exemplary embodiments are described and illustrated herein as including a supply of pressurized air, it will be understood that the invention is not limited to the use of pressurized air and any suitable gas or gas mixture may be used. However, for purposes of the following description, the invention will be described with reference to air.

[0077] The operation of the apparatus 10 used with the rod guide 235 of the present invention will now be described. The steps of operation described above will not be repeated in detail. The hopper drum 12 rotates through the transfer area 17 of the hopper 11, and the rods Rm are picked up by the flutes 23, conveyed around the hopper 11, and exit the hopper 11. Vacuum is applied through the arcuate openings 34, the vacuum ports 26, and the vacuum ducts 25, thus creating a suction force through the suction holes 27 in the flutes 23 to position and hold the rods Rm within their respective flutes 23.

[0078] As the rod Rm passes through the cut-off wheels 13, 14, the cut-off wheels 13, 14 cut the rod Rm into smaller individual cut rods Rc as the rod Rm is held within the longitudinal grooves 23.

[0079] As the hopper drum 12 rotates, when the vacuum port 26 reaches the vent cavity 42, the vacuum port 26 is placed in fluid communication with the vent cavity 42 and is open to the atmosphere, thereby eliminating the suction force through the suction holes 27 in the longitudinal grooves 23. This allows the severed rods Rc to be released from the longitudinal grooves 23, as previously described. However, as also previously described, some rods Rc may remain lodged in the longitudinal grooves 23 as the hopper drum 12 rotates, or may not leave the longitudinal grooves quickly enough.

[0080] The difference in operation with the known device 10 occurs as the hopper drum 12 continues to rotate as the rod Rc approaches the guide surface 38 of the rod guide 235. In the known device, the guide surface 38 physically contacts the jammed or insufficiently released rod Rc, slamming the rod downward toward the grading drum 15. However, in the rod guide 235 of the present invention, the pressurized airflow supplied to the air inlet 237 flows through the air passage 238 and exits the air outlet 236. This creates an air cushion in front of the guide surface 38, blowing the rod Rc downward from the guide surface 38 before it actually physically contacts the guide surface 38. Additionally or alternatively, this airflow from the air outlet 236 shields the cut rod Rc as it moves toward the guide surface 38, thereby at least reducing the force with which the cut rod Rc contacts the guide surface 38, if it does contact the guide surface 38 at all. This results in consistent release of the cut rods Rc from the flutes 23. The airflow from the rod guides 235 also directs the cut rods Rc perpendicularly out of the flutes 23, preventing the rods Rc from tilting or moving one end of the rod Rc lower than the other end during transport, which can occur if the rods Rc are physically struck by known rod guides 35. This process also helps reduce damage or deformation of the cut rods Rc during transport from the flutes 23 of the hopper drum 12 to the grading drum, as physical contact with the rod guides 235 is reduced or avoided. The effectively and uniformly released cut rods Rc can then be picked up by the rod seats 46 of the grading drum 15 and transported forward for further processing into consumables, as described above.

[0081] An improvement in the operation of the apparatus 10 using the rod guide 235 of the present invention in place of the previously described known rod guide 35 is shown in Figures 11 and 12. Figure 11 shows an enlarged view of an area of ​​the apparatus 10 in operation, with cut rods Rc being discharged from the hopper drum 12. This apparatus 10 uses the known rod guide 35 (and also the known control flange 30) shown in Figure 5. Figure 12 shows the same area of ​​the apparatus 10 in operation as Figure 11, but with the rod guide 235 of the present invention, and with a pressurized air flow being supplied to the air inlet 237.

[0082] FIG. 11 shows the hopper drum 12, flutes 23, rod guide 35, and guide surface 38. The severed rod Rc is in the lowermost region of the hopper drum 12 where it will be transferred to the grading drum 15. The grading drum 15, rod seat 46, and lower transfer surface 29 are also shown. There is no suction through the suction holes 27 in the flutes 23 in the region of the hopper drum 12 shown in FIG. 11. It can be seen that the severed rod, labeled Rc in FIG. 11, has struck the angled guide surface 38 of the rod guide 35 to encourage the rod to deflect downward toward the grading drum 15. The severed rod Rc has also not completely cleared the flutes 23 or fully contacted the lower transfer surface 29. The severed rod Rc has also been knocked out of its parallel orientation from when it was placed in the flutes 23 of the hopper drum 12. That is, the rod was struck so that its longitudinal axis was angled relative to the horizontal. This can be seen by the position of the cut rod Rc and the adjacent cut rods marked in Figure 11, where the cut rods are already received in the rod seats 46 and are therefore horizontally positioned. This is also indicated by the non-parallel dashed-dotted axes shown in Figure 11, which run through the cut rod marked Rc in Figure 11 and through the adjacent cut rods Rc. This position of the cut rods Rc means that even if they are collected by the rod seats 46 of the grading drum 15, there is a risk that the rods Rc will be missed by the passing rod seats 46 intended to collect them, resulting in loss and manufacturing defects of the rods Rc and / or damage or dents / deformations of the rods Rc.

[0083] Referring to FIG. 12, the difference can be seen in the pressurized airflow supplied to the air inlet 237, which generates a pressurized airflow from the air outlet 236. The airflow aids in the discharge of the cut rods Rc from the longitudinal grooves 23. FIG. 12 was taken in the same operational position of the apparatus 10 as FIG. 11, with respect to the hopper drum 12 and grading drum 15. The difference in effective rod transport can be clearly seen in the cut rods labeled Rc in FIG. 12. Here, the rods Rc leave the longitudinal grooves 23 even more evenly (i.e., the rods Rc in FIG. 12 have no axial tilt). This is also indicated by the parallel dash-dot axes shown in FIG. 12 extending through the cut rods labeled Rc in FIG. 12 and through adjacent cut rods. Furthermore, in the same operational position of the apparatus 10, the rods Rc do not contact the rod guide 235 but are spaced a distance (indicated by arrow J) from the inclined guide surface 38 of the rod guide 235. That is, the air flow from the air flow outlet 236 evenly urged the rod Rc out of the longitudinal groove 23 without the rod Rc having to physically contact the guide surface 38 of the rod guide 235. Thus, the rod Rc was positioned to be reliably extracted from the longitudinal groove 23 and reliably collected by the rod seat 46 of the grading drum 15 with minimal or no impact, denting or damage.

[0084] An additional advantage provided by the rod guide 235 of the present invention relates to the setup and maintenance of the apparatus 10. In known apparatus 10, the rod guide 35 must be precisely installed and adjusted to ensure uniform and horizontal discharge of the rod Rc from the longitudinal groove 23. This is because if the rod guide 35 is not precisely installed within the apparatus 10, the rod Rc can easily be thrown out of horizontal alignment when it strikes the guide surface 38. For example, the tolerance for the installation position of the rod guide 35 may be approximately + / - 0.2 mm within the apparatus 10 to achieve acceptable operation.

[0085] As described above, when using the rod guide 235 of the present invention, the airflow from the air outlet 236 and the resulting air cushion / airflow urging the rod Rec out of the longitudinal groove 23 help achieve a more uniform, level, and consistent discharge of the rod Rec. This also avoids or reduces the impact of the rod Rec on the guide surface 38, thereby reducing the extent to which the rod Rec falls or is thrown out of horizontal alignment during discharge from the longitudinal groove 23 toward the grading drum 15. Therefore, the installation position tolerance of the rod guide 235 within the apparatus can be significantly greater than that of known apparatus 10. For example, the rod guide 235 of the present invention may be installed in the apparatus 10 with an installation position tolerance of approximately + / - 1.5 mm while still achieving acceptable operation. It will be appreciated that this increased tolerance reduces the frequency of apparatus maintenance required to readjust the rod guide position, resulting in fewer production defects or rod losses and helping to reduce production line downtime. These benefits help achieve increased production efficiency and reduced operating costs.

[0086] In one embodiment, the airflow outlet 236 is configured to direct the airflow vertically downward, i.e., at 90 degrees relative to the horizontal. In use, the rod guide 235 is mounted with its longitudinal axis aligned generally horizontally, as shown in FIGS. 1, 7, and 8, so this corresponds substantially to a 90-degree angle from the longitudinal axis DD of the rod guide 235. This is indicated by the airflow arrow F in FIG. 10. The inclined guide surface 38 is disposed at an angle θ relative to the horizontal and the longitudinal axis DD of the rod guide 235, as shown in FIGS. 9 and 10. θ may be between 30 and 60 degrees, or may be approximately 45 degrees. This airflow direction is suitable for urging the cut rods Rc from the longitudinal flutes 23 toward the grading drum 15.

[0087] In one embodiment, the or each air flow outlet 236 is configured to direct air flow F therefrom at an angle N measured relative to the normal to the guide surface 38. Angle N is shown in FIG. 10. Angle N may vary within the scope of the present invention and may be between 20 and 70 degrees from normal to the guide surface, between 30 and 60 degrees, between 40 and 50 degrees, or even 45 degrees. Again, this air flow direction is preferred to optimally bias the cut rods Rc from the flutes 23 toward the grading drum 15.

[0088] A second aspect of the present invention relates to a control flange 130 shown in FIG. 13. The control flange has several features in common with the control flange 30 shown in FIG. 3; similar features retain the same reference numerals and will not be described in detail again. The control flange 130 comprises a generally circular body having a circular recess 31 formed in a surface 32, a central circular opening 33, and two arcuate openings 34 extending over an angle V and separated by a bridging portion 41. The angle V represents a first range or angle of rotation of the hopper drum 12 through which vacuum or suction is applied to the suction holes 27. The arcuate openings 34 are disposed at a radial distance rv measured from a center point C of the circular recess 31 / circular openings 32. The control flange 130 further comprises a vent cavity 42 disposed in a lower region of the control flange 130, also disposed at a radial distance rv measured from the center point C. The vent cavity 42 extends radially outwardly at the edge of the control flange 130 and opens at the radially outer surface 43 of the control flange 130 .

[0089] The difference from the control flange 130 of the present invention is the provision of a gas or air manifold 131 (hereinafter, "air manifold"). In the illustrated exemplary embodiment, the air manifold 131 is provided within the vent cavity 42. The air manifold 131 comprises a body having an air inlet 132 and an air outlet 133 that are fluidly connected by an air channel 134 extending through the body. In the illustrated exemplary embodiment, the air outlet 133 comprises an arcuate opening, although other opening shapes are possible. The air outlet 133 is located at the same radial distance rv from the center point C as the arcuate opening 34. The air manifold 131 is positioned so that the surface of the body on which the air outlet 133 is formed is flush with the surface of the recess 31 on which the arcuate opening 34 is formed. Thus, in the assembled apparatus 10, the first end face 20 of the hopper drum 12 is equally spaced from the surface of the body on which the air outlet 133 is formed and the surface of the recess 31 on which the arcuate opening 34 is formed, when viewed in the axial direction of the hopper drum 12. Such spacing may be, for example, 0.01 mm to 2 mm. As a result, as the hopper drum 12 rotates, each vacuum port 26 is selectively in fluid communication with the arcuate opening 34, the vent cavity 42, and the air outlet 133. The control flange 130 is shown in place on a tobacco industry product manufacturing apparatus 10 according to an embodiment of the present invention in FIG. 14 (with the hopper drum removed). This shows a pressurized air supply line 135 connected to the air inlet 132. This allows pressurized air to be supplied from the air inlet 132 to the air outlet 133 via air channels 134 within the body of the air manifold 131. As discussed above with reference to the rod guide 235, the present invention is not limited to the use of pressurized air; any suitable gas or gas mixture may be supplied to the air outlet 133. However, for purposes of the following discussion, the present invention will be described with reference to air.

[0090] The operation of the apparatus 10 shown in Figure 13 will now be described with reference to the apparatus 10 of Figure 1 and also to features of the apparatus 10 described above. The steps of operation described above will not be repeated in detail. The hopper drum 12 rotates through the transfer area 17 of the hopper 11, and the multiple rods Rm are picked up by the longitudinal grooves 23, conveyed around the hopper 11, and exit the hopper 11. Vacuum is applied through the arcuate openings 34, the vacuum port 26, and the vacuum duct 25, thus creating a suction force through the suction holes 27 in the longitudinal grooves 23 to position and hold the rods Rm within their respective longitudinal grooves 23.

[0091] As the rod Rm passes through the cut-off wheels 13, 14, the cut-off wheels 13, 14 cut the rod Rm into smaller individual cut rods Rc as the rod Rm is held within the longitudinal grooves 23.

[0092] As the hopper drum 12 rotates, when the vacuum port 26 reaches the vent cavity 42, the vacuum port 26 is placed in fluid communication with the vent cavity 42 and is open to the atmosphere, thereby eliminating the suction force through the suction holes 27 in the flutes 23. This allows the severed rods Rc to be released from the flutes 23, as previously described. However, as also previously described, some rods Rc may remain lodged in the flutes 23 as the hopper drum 12 rotates, or may not leave the flutes quickly enough under the force of gravity.

[0093] The difference in operation over the known apparatus 10 occurs when the hopper drum 12 continues to rotate, resulting in the vacuum port 26 aligning with, and therefore in fluid communication with, the air outlet 133. Because the air outlet 133 is connected to a supply of pressurized air, air pressure is then supplied to the vacuum port 26, and thereby to the vacuum duct 25 and the suction holes 27 in the flutes 23. This causes the rods Rc to be pushed out of the flutes 23 by the force of the air pressure. This occurs at the rotation point of the hopper drum 12, when the flutes 23 face the lower transfer surface 29 / grading drum 15. For convenience, this corresponds approximately to the arcuate region superimposed on the hopper drum 12 in FIG. 1, labeled P, and the angle P of the control flange 130 shown in FIG. 13. The angle P represents a second range or angle of rotation of the hopper drum 12. Over this second range of rotation, pressurized air is supplied to the suction holes 27. This results in the consistent ejection of the cut rods Rc from the flutes 23. Angle P may be defined relative to a transfer point where the cut rods Rc are intended to be transferred from the hopper drum 12 to the grading drum 15. Such a transfer point may be the closest point between the hopper drum 12 and the grading drum 15. Such a transfer point may be a point on a line or plane extending between the axis AA of the hopper drum 12 and the axis BB of the grading drum 15. Such a transfer point may be directly below the axis AA of the grading drum 12 and / or directly above the axis BB of the grading drum 15. Angle P may be defined as 20 degrees to 0 degrees of rotation of the hopper drum 12 before the transfer point and 0 degrees to 20 degrees of rotation of the hopper drum 12 after the transfer point. That is, the cut rods Rc may be subjected to positive pressure through the suction holes 27 between 20 degrees before the transfer point and 0 degrees at the transfer point. The positive pressure may then be removed between 0 degrees and 20 degrees after the transfer point.

[0094] Air pressure may be applied uniformly to each rod along its length (when multiple suction holes 27 may be provided in each longitudinal flute). This allows the cut rods Rc to be ejected from the longitudinal flutes 23 at a right angle, preventing them from tilting or one end of the rod Rc from moving lower than the other end during ejection. In other embodiments, or in other areas of the longitudinal flutes 23, air pressure may be applied to each cut rod Rc through only one suction hole 27. This process, which may occur in known apparatus 10, helps reduce damage or deformation of the cut rods Rc during movement from the longitudinal flutes 23 of the hopper drum 12 to the grading drum 15, as described above. This is because physical collision of the cut rods Rc against the guide surface 38 of the rod guide 35 is reduced or avoided. The cut rods Rc that are ejected consistently and uniformly can then be picked up by the rod seat 46 of the grading drum 15 and transported forward for further processing into consumables, as described above.

[0095] An improvement in the operation of the apparatus 10 using the control flange 130 of the present invention in place of the previously described known control flange 30 is shown in Figures 15 and 16. Figure 15 shows an enlarged view of a region of the known apparatus 10 in operation, with severed rods Rc being discharged from the hopper drum 12. This apparatus 10 uses the known control flange 30 shown in Figure 3 (or the control flange 130 of the present invention, but with no air pressure applied to the air inlet 132). Figure 16 shows the same region of the apparatus 10 as Figure 15 in operation, but with the control flange 130 of the present invention and with air pressure applied to the air inlet 132.

[0096] Figure 15 shows the hopper drum 12, the longitudinal grooves 23, the rod guide 35, and the guide surface 38. The cut rod Rc is located in the lowermost region of the hopper drum 12 where it is transferred to the grading drum 15. The grading drum 15, the rod seat 46, and the lower transfer surface 29 are also shown. There is no suction through the suction holes 27 in the longitudinal grooves 23 in the region of the hopper drum 12 shown in Figure 15. It can be seen that the cut rod Rc in Figure 15 is only a short distance from the longitudinal grooves 23, despite having passed through the lower transfer surface, and there is nothing below the cut rod Rc to hold it in the longitudinal grooves 23. Because the cut rod Rc is also spaced from the rod seat 46 of the grading drum 15 below, there is a risk that it will be missed by the passing rod seat 46 intended to collect it, resulting in loss of the cut rod Rc and a production defect. The cut rod Rc also contacted the inclined guide surface 38 of the rod guide 35, indicated by the point indicated by reference character I. This can damage or dent / deform the rod Rc even if it is collected by the rod seat 46 of the grading drum 15.

[0097] Referring to FIG. 16, the difference in the pressurized air supplied to the air manifold 131 can be seen, thereby providing air pressure through the suction holes 27 to assist in the discharge of the cut rods Rc from the flutes 23. FIG. 16 was taken in the same operating position of the apparatus 10 as FIG. 15, relative to the hopper drum 12 and grading drum 15. The difference in effective rod transport can be clearly seen in the cut rods labeled Rc in FIG. 16. Here, the rods Rc leave the flutes 23 more quickly and more uniformly (note that the tilt of the rods Rc in FIG. 12 is less than the rods Rc deflected by the rod guides in FIG. 15). In the same operating position of the apparatus 10, the rods Rc are spaced a constant distance (indicated by arrow G) from the inclined guide surfaces 38 of the rod guides 35. The cut rods Rc are also significantly farther from the flutes 23, as indicated by arrow H in FIG. 12. The rod Rc is therefore positioned so as to be reliably collected by the rod seat 46 of the grading drum 15 .

[0098] Therefore, the apparatus 10 using the control flange 130 of the present invention provides the advantages of consistently ensuring the transfer of cut rods Rc, avoiding production defects, thereby avoiding the waste of damaged consumables or materials during production, reducing production downtime, saving costs, making production more efficient and increasing productivity.

[0099] In order to achieve the above-mentioned advantages, the apparatus 10 of the present invention can apply positive air pressure at different pressures through the air outlet 133 of the control flange 130. In some embodiments, the applied positive air pressure can be 1-5 bar, 1.2-4 bar, 1.3-3 bar, 1.5-3 bar, about 2-3 bar, or 3 bar.

[0100] To achieve the above-mentioned advantages, in the device 10 of the present invention, pressurized airflows may be applied at different pressures through the air inlet 237, the air passage 238, and out the air outlet(s) 236 of the rod guide 235. In some embodiments, the pressurized airflow may be between 0.5 and 2 bar, between 0.7 and 1.8 bar, between 0.9 and 1.6 bar, or between 1 and 1.5 bar.

[0101] In providing apparatus 10 for handling rods of aerosol-generating material with one embodiment of control flange 130, apparatus 10 is provided that can not only retain rods Rm, Rc within flutes 23 during a first range of rotation V of hopper drum 12, but also actively use air (or other gas) pressure to push rods Rc out of flutes 23 over a second range of rotation P of hopper drum 12. Thus, rods Rc do not solely rely on gravity for ejection from flutes 23. This can help overcome problems of rods Rc getting stuck within flutes 23, avoiding deformation or damage due to rod impact with rod guides 35, and / or allowing for faster operating speeds of apparatus 10.

[0102] 13, it can be seen that over a third rotational range, the vacuum duct 25 is open to the atmosphere such that no vacuum or positive pressure is applied to the suction holes 27 of each flute(s) 23. This third rotational range corresponds to the rotational range NV in which the vacuum ports 26 are in fluid communication with the vent cavity 42. In the direction of rotation of the hopper drum 12, this third rotational range occurs after the vacuum ports 26 are in fluid communication with the arcuate openings 34 and before they are in fluid communication with the air outlets 133. This is labeled NV1 in FIG. 13. It can also be seen from FIG. 13 that over a fourth rotational range, the vacuum duct 25 is open to the atmosphere such that no vacuum or positive pressure is applied to the suction holes 27 of each flute(s) 23, which also corresponds to the rotational range NV in which the vacuum ports 26 are in fluid communication with the vent cavity 42. This fourth range of rotation in the direction of rotation of hopper drum 12 occurs after vacuum port 26 is in fluid communication with air outlet 133 and before it is in fluid communication with arcuate opening 34. This is labeled NV2 in FIG.

[0103] In some embodiments, it may be preferred for the vacuum duct 25 to be open to atmosphere between an applied vacuum and an applied positive pressure (i.e., over a third rotational range), and / or to be open to atmosphere between an applied positive pressure and an applied vacuum (i.e., over a fourth rotational range), which can equalize the pressure within the vacuum duct 25 and provide a smoother pressure change profile within the vacuum duct, allowing for greater control over rod handling.

[0104] In some embodiments, there may be a smaller third or fourth rotational range. In yet another embodiment, the control flange 130 may be configured such that the vacuum duct 25 is not open to the atmosphere between the applied vacuum and the applied positive pressure (i.e., the vacuum duct 25 is not in fluid communication with the vent cavity 42 over the third rotational range). Additionally, the vacuum duct 25 may not be open to the atmosphere between the applied positive pressure and the applied vacuum (i.e., the vacuum duct 25 is not in fluid communication with the vent cavity 42 over the fourth rotational range). This may allow for more rapid pressure changes within the vacuum duct 25, which may assist in handling rods at higher machine speeds.

[0105] While the embodiment of the invention comprising the control flange 130 is shown and described above in the context of a hopper drum 12 that handles, conveys, and transfers rods Rc to a grading drum 15, it will be understood that the invention is not limited to this particular application or apparatus and is intended within the scope of the invention to be applicable to any drum in an apparatus intended to accept, convey, and discharge rods within a manufacturing process in which the drum surface includes longitudinal grooves 23 or other features of suction holes for retaining the rods on the drum throughout its range of rotation. Such rods may include rods of aerosol-generating material, filter rods, spacer rods or tubes, or any other rod-shaped article or component for assembly into a consumable product that requires handling and conveyance within the apparatus.

[0106] In providing one embodiment of the rod guide 235 in the apparatus 10 for handling rods of aerosol-generating material, a device is provided that can actively use air (or other gas) pressure to push the rod Rc out of the flutes 23 at a desired rotation point of the hopper drum 12. Thus, rather than relying solely on physical collision of the rod Rc against the guide surface 38 of the rod guide 35, 235 to exit the flutes 23 as needed, such collisions can be reduced or avoided by force. This can help overcome problems of deformation or damage to the rod Rc due to collisions with the rod guide 35 and / or problems with achieving higher operating speeds for the apparatus 10.

[0107] While the embodiment of the invention comprising rod guide 235 is shown and described above in the context of a hopper drum 12 that handles, conveys, and transfers rods Rc to a grading drum 15, it will be understood that the invention is not limited to this particular application or apparatus and is intended within the scope of the invention to be applicable to any drum in an apparatus intended to receive, convey, and discharge rods within a manufacturing process in flutes 23 or other configurations on the drum surface. Such rods may include rods of aerosol-generating material, filter rods, spacer rods or tubes, or any other rod-shaped article or component for assembly into a consumable product, which requires handling and conveying within the apparatus.

[0108] Apparatus 10 has been illustrated and described above as an apparatus for handling rods of aerosol-generating material from hopper 11 to grading drum 15. Such apparatus 10 may comprise part of a larger manufacturing machine that may include additional stations for handling, processing, assembling, and arranging rods into consumables or groups of consumables. Such machines may comprise a single machine, or apparatus 10 may comprise a portion of such a machine. Such machines may comprise modular machines with separate modules assembled and connected to each other to perform desired functions and manufacturing steps, and an apparatus may comprise individual modules of such a modular machine or portions of such modules of such a modular machine. Apparatus 10 may comprise a hopper, hopper drum 12, and grading drum 15 (and related components described above). Alternatively, apparatus 10 may comprise only hopper drum 12, without grading drum 15 or other drums upstream or downstream of hopper drum 12 within the apparatus. As noted above, in such situations, the apparatus may comprise drums other than hopper drum 12 within the scope of the present invention.

[0109] In the illustrated embodiment, the flutes 23 are integrally formed with the hopper drum 12 on the outer surface 22 of the drum 12. However, the flutes 23 may also be provided as one or more separate components attached to the surface of the drum.

[0110] The rod guide 235 may be made or constructed in a variety of ways within the scope of the present invention. The rod guide 235 may be made as a single, integral piece, for example, by molding or additive manufacturing. In an alternative embodiment, the rod guide 235 may be made of two plates joined together. FIGS. 9 and 10 illustrate how such a rod guide 235 may be formed. FIG. 9 illustrates a rod guide comprising two plates 235a, 235b joined together along a centerline 239. The plates 235a, 235b have respective opposing surfaces that contact each other and are joined together. The air flow outlet 236 and the air passage 238 may be formed in one or both of the plates 235a, 235b, such as in one or both of the opposing surfaces of each plate(s) 235a, 235b. The plates 235a, 235b may be secured to each other in any suitable manner, for example, by welding, adhesive bonding, or suitable mechanical fasteners such as screws, bolts, etc. The air inlet 237 may be integrally formed with one or both of the plates 235a, 235b, or may be a separate component connected to one or both of the plates 235a, 235b by any suitable means, such as by welding, adhesive bonding, or suitable mechanical fasteners such as screws, bolts, etc.

[0111] The control flange 130 of the present invention is shown and described as including one air outlet 133 within the manifold 131. However, the present invention is not limited to such a configuration, and the control flange 130 may include two or more air outlets 133. The air outlets 133 are shown as having a generally arcuate shape, which may be suitable for following the rotational path described by the vacuum ports 26 with which the air outlets 133 are intended to communicate. However, the present invention is not limited to such an air outlet 133 configuration, and the air outlets 133, or each air outlet, may have a non-arcuate shape within the scope of the present invention. Similarly, the openings 34 in the control flange 130 for supplying vacuum to the hopper drum 12 are shown and described as having an arcuate shape. Again, this may be suitable for following the rotational path described by the vacuum ports 26 with which the openings 34 are intended to communicate. However, the present invention is not limited to such an opening 34 configuration, and the openings 34, or each opening, may have a non-arcuate shape within the scope of the present invention. In some embodiments, the or each opening 34 and / or the or each air outlet 133 may be arranged substantially circumferentially, or may be arranged substantially circumferentially around a common center point of the control flange 130.

[0112] The angle P (see FIG. 13) through which the air outlet 133 extends, and therefore the rotation angle of the hopper drum 12 to which positive air pressure is applied through the suction holes 27, may vary within the scope of the present invention and may be between 1 degree and 40 degrees, between 5 degrees and 35 degrees, between 10 degrees and 30 degrees, or between 15 degrees and 25 degrees.

[0113] The control flange 130 is described as including a recess 31 formed within the body of the control flange 130, which may be suitable for receiving the first end surface 20 of the hopper drum 12. Such a configuration may also reduce loss of vacuum or positive pressure supplied to the vacuum port 26 during operation. However, the present invention is not limited to such a configuration of the control flange, and in other embodiments of the present invention, the control flange 130 may not include the recess 31. The hopper drum 12 may be positioned with the first end surface 20 flush with or adjacent to the surface 32 of the control flange 130 so that the vacuum port 26 communicates with the opening(s) 34 and the air outlet 133 as the hopper drum 12 rotates. Such a spacing may be, for example, 0.01 mm to 2 mm.

[0114] The exemplary rod guide 235 of the present invention is shown and described as including three air flow outlets 236. However, the present invention is not limited to such a configuration, and the rod guide 235 may include one, two, or even more than two air flow outlets 236. A single air flow outlet may provide a rod guide 235 that is simpler and more cost-effective to manufacture. Providing multiple air flow outlets 236 may be preferred to create a more uniform air cushion at the guide surface 38 of the rod guide 235 from the pressurized air released from the air flow outlets 236.

[0115] Embodiments of the invention described herein include an apparatus in which positive air pressure is applied through suction holes in the drum flutes 23 to assist in the ejection of the rods Rc from the drum flutes, a control flange configured for use with such an apparatus, an apparatus in which a flow of pressurized air is provided through a guide member / rod guide to assist in the ejection of the rods Rc from the drum flutes, and a guide member / rod guide configured for use with such an apparatus. It is contemplated within the scope of the present invention that an apparatus may include either the above-described control flange and rod guide of the present invention, separately or in combination, to achieve the above-described advantages.

[0116] The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be construed as limitations on the scope of the invention as defined by the claims or limitations on the equivalents of the claims, and it should be understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Additionally, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. 1. An apparatus for handling a rod of aerosol-forming material, comprising: a rotatable drum having a plurality of elongated flutes disposed about an outer surface of the drum and extending axially of the drum, the rotatable drum including circumferential grooves in the outer surface that intersect the flutes; a guide member comprising: a longitudinal arm having a guide surface at a first end thereof; an air flow outlet disposed in the guide surface; and an air flow passage in fluid communication with the air flow outlet; Equipped with the air flow passage is connected to a supply of pressurized gas to supply pressurized gas to the air outlet; the guide member is positioned with the guide surface at least partially received within the groove and configured to discharge gas from the air flow outlet onto a rod supported within the longitudinal flute.

2. The apparatus of claim 1 , wherein the guide surface is inclined at an angle relative to a longitudinal axis of the guide member.

3. The apparatus of claim 2, wherein the constant angle of the guide surface is between 30 and 60 degrees, and may be about 45 degrees.

4. 4. The device of claim 1, wherein the air flow outlet is configured to direct the air flow from the air flow outlet at a constant angle of 20 to 70 degrees from a direction perpendicular to the guide surface, and the constant angle may be 30 to 60 degrees, 40 to 50 degrees, or 45 degrees.

5. An apparatus according to any preceding claim, wherein the longitudinal axis of the guide member is substantially horizontal.

6. The apparatus of any preceding claim, wherein the air flow outlet is configured to direct airflow vertically downward from the air flow outlet.

7. An apparatus according to any preceding claim, wherein the guide member comprises a plurality of air flow outlets, and may comprise three air flow outlets.

8. 8. The apparatus of claim 1, wherein the guide member comprises two plates fixed to each other at their respective opposing faces, and wherein the air flow passage and air outlet(s) are formed in the opposing face of at least one of the plates.

9. 9. The apparatus of claim 1, wherein the supply of pressurized gas supplied to the air flow path is between 0.5 and 2 bar, optionally between 0.7 and 1.8 bar, optionally between 0.9 and 1.6 bar, or optionally between 1 and 1.5 bar.

10. each flute of the rotatable drum including one or more suction holes extending from a surface of the respective flute that communicate with an associated vacuum duct in the drum; the apparatus further comprising a control flange; 10. Apparatus according to any one of claims 1 to 9, wherein the drum rotates in use relative to the control flange, the control flange comprising a first opening connected to a vacuum source and a second opening connected to a pressurised gas source, and wherein as the drum rotates relative to the control flange, the vacuum duct is in fluid communication with the first opening over a first range of rotation of the drum to apply a negative gas pressure to the vacuum duct, and the vacuum duct is in fluid communication with the second opening over a second range of rotation of the drum to apply a positive gas pressure to the vacuum duct.

11. The device of claim 10 , wherein each flute comprises a plurality of suction holes.

12. 12. Apparatus according to claim 10 or claim 11, wherein each vacuum duct opens at a first end face of the drum.

13. An apparatus according to any one of claims 10 to 12, wherein the control flange is located adjacent the first end face of the drum.

14. 14. The apparatus of claim 10, wherein the control flange includes a vent cavity open to the atmosphere, and the vacuum duct is in fluid communication with the vent cavity over a third range of rotation of the drum after being in fluid communication with the first opening over the first range of rotation of the drum and before being in fluid communication with the second opening over the second range of rotation of the drum.

15. 15. The apparatus of claim 14, wherein the vacuum duct is in fluid communication with the vent cavity over a fourth range of rotation of the drum after being in fluid communication with the second opening over the second range of rotation of the drum before returning to being in fluid communication with the first opening over the first range of rotation of the drum.

16. The apparatus of any one of claims 10 to 15, wherein the control flange comprises a gas manifold connected to the source of pressurized gas, and wherein the second opening is formed in the gas manifold.

17. The apparatus of claim 16 , wherein the gas manifold is disposed within the vent cavity.

18. Apparatus according to any one of claims 10 to 17, wherein the second range of rotation of the drum extends around a lowermost region of the drum.

19. The apparatus of any one of claims 10 to 18, wherein the first range of rotation of the drum is greater than the second range of rotation of the drum.

20. 20. The apparatus of claim 10, wherein the second range of rotation is between 1 degree and 40 degrees, optionally between 5 degrees and 35 degrees, optionally between 10 degrees and 30 degrees, or optionally between 15 degrees and 25 degrees.

21. An apparatus according to any one of claims 10 to 20, wherein the control flange comprises a circular recess, the first end face of the drum being received within the circular recess.

22. The device of any one of claims 10 to 21, wherein the second opening is arcuate.

23. 23. The device of claim 22, wherein the first opening is arcuate, and the first and second openings are each circumferentially disposed about a common center point.

24. 24. The apparatus of claim 23, wherein the first and second openings are disposed at equal radial distances from the common center point.

25. 25. The apparatus of any one of claims 10 to 24, wherein the pressurized gas supplied to the second opening is at a pressure of 1 to 5 bar, optionally 1.2 to 4 bar, optionally 1.3 to 3 bar, optionally 1.5 to 3 bar, optionally 2 to 3 bar, or optionally about 3 bar.

26. 1. A guide member for use with a drum of an apparatus for handling a rod of aerosol-forming material, comprising: a longitudinal arm having a guide surface at a first end; an air outlet disposed on the guide surface; an air flow path in fluid communication with the air outlet; A guide member comprising:

27. A guide member according to claim 26, further comprising any of the features recited in claims 2 to 8.

28. 28. A guide member according to claim 26 or claim 27, further comprising an air inlet at a second end of the longitudinal arm opposite the first end, the air inlet in fluid communication with the air flow path.

29. A method for handling a rod of aerosol-forming material using an apparatus as recited in any one of claims 1 to 25, comprising the steps of: receiving a rod within a longitudinal groove of the rotatable drum; supplying pressurized gas to the air passage to emit a pressurized air flow from the air outlet onto the rod supported within the flute to assist in ejection of the rod from the flute; A method comprising:

30. 30. The method of claim 29, further comprising discharging the pressurized gas vertically downward from the air flow outlet.

31. 31. A method according to claim 29 or claim 30, wherein pressurised gas is supplied to the air flow path at 0.5 to 2 bar, optionally 0.7 to 1.8 bar, optionally 0.9 to 1.6 bar, or optionally 1 to 1.5 bar.

32. each flute of the rotatable drum includes one or more suction holes extending from a surface of the respective flute that communicate with an associated vacuum duct in the drum; the apparatus further comprising a control flange, the control flange having a first opening connected to a vacuum source and a second opening connected to a pressurized gas source; The method comprises: rotating the drum relative to the control flange; applying a negative pressure to the one or more suction holes to retain the rod within the longitudinal groove as the drum rotates relative to the control flange through a first range of rotation; applying a positive gas pressure to the one or more suction holes to assist in ejection of the rod from the flutes as the drum rotates relative to the control flange through a second range of rotation; The method of any one of claims 29 to 31, further comprising:

33. opening the one or more suction holes to the atmosphere over a third range of rotation of the drum after the drum has rotated through the first range of rotation and before the drum has rotated through the second range of rotation.

35. The method of claim 34, further comprising:

34. opening the one or more suction holes to the atmosphere for a fourth range of rotation of the drum after the second range of rotation and before the drum returns to the first range of rotation.

34. The method of claim 33, further comprising:

35. 35. The method of any one of claims 32 to 34, wherein the first range of rotation of the drum is greater than the second range of rotation of the drum.

36. 36. The method of any one of claims 32 to 35, wherein the second range of rotation is between 1 degree and 40 degrees, optionally between 5 degrees and 35 degrees, optionally between 10 degrees and 30 degrees, optionally between 15 degrees and 25 degrees.

37. 37. A method according to any one of claims 32 to 36, wherein pressurised gas is supplied to the second opening at 1 to 5 bar, optionally 1.2 to 4 bar, optionally 1.3 to 3 bar, optionally 1.5 to 3 bar, optionally 2 to 3 bar, or optionally about 3 bar.

38. 38. The method of any one of claims 32 to 37, wherein the method includes handling a rod of aerosol-forming material that has been cut into sheets.

39. The method of any one of claims 32 to 38, wherein the method includes handling a rod having a susceptor material within the rod.

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