Method and assembly for processing a continuous sheet of material - Patents.com

Abstract

A method for processing a continuous sheet of material in the manufacture of a consumable component for use in or with an aerosol delivery system. The method includes drawing the sheet material through a groove in a prefolding unit so that the sheet material at least partially adopts the contours of the groove, the groove extending along a spiral path. Also disclosed is an assembly including a prefolding unit for processing a continuous sheet of material in the manufacture of a consumable component for use in or with an aerosol delivery system. The prefolding unit includes at least one groove in a surface of the prefolding unit, the at least one groove extending along a spiral path. Also disclosed is a consumable component for use in or with an aerosol delivery system.

Description

[Technical Field]

[0001] The present invention relates to methods of processing continuous sheet material in the manufacture of consumable components for use in or with aerosol delivery systems and assemblies for doing so. The present invention also relates to components formed using the assemblies and associated methods. [Background technology]

[0002] Aerosol delivery systems include traditional systems such as cigarettes, as well as more modern systems such as electronic aerosol generating devices and their associated consumables. These systems are complex and have many components, many of which may be made of non-biodegradable materials. Therefore, there is a need to design new components that have the same or better functionality and performance, but with improved biodegradability to reduce environmental impact.

[0003] [Summary of the Invention] In a first aspect of the present invention there is provided a method of processing a continuous sheet material in the manufacture of a consumable component for use in or with an aerosol delivery system, the method comprising: drawing the sheet material through a groove in the prefolding unit such that the sheet material at least partially adopts the contour of the groove, the groove extending along a spiral path; A method is provided.

[0004] The groove may be part of a series of grooves. The groove may be formed in a convex side of the curved wall of the pre-fold unit. The groove may be formed in a concave side of the curved wall of the pre-fold unit.

[0005] The helical path may form at least one complete helical turn.

[0006] The upstream end of the curved wall may have a first radius and the downstream end may have a second radius, the first radius being greater than the second radius.

[0007] The pitch of the at least one groove at the downstream end may be between 3 mm and 20 mm.

[0008] The sheet of material may comprise paper. The sheet material may comprise a nonwoven material.

[0009] The method may include applying a crimping pattern to the sheet material before drawing the sheet material over the edge.

[0010] The crimping pattern may have a crimp amplitude of about 0.1 mm to 0.2 mm.

[0011] The method may further include feeding the sheet material into a channel of a conveying jet that includes a funnel and a mandrel.

[0012] The method may further include applying a binder to the material.

[0013] The binder may comprise about 6 wt% pectin.

[0014] The mandrel may be disposed within the funnel such that an outer surface of the mandrel is spaced from an inner surface of the funnel to define a channel between the outer surface of the mandrel and the inner surface of the funnel, the mandrel may include an internal conduit, an aperture in a wall of the mandrel may connect the conduit with the channel, and applying the binder to the material may include applying the binder through the aperture in the mandrel.

[0015] The method may further include dividing the sheet material into individual strands of sheet material upstream of the prefold unit.

[0016] In a second aspect of the present invention, there is provided an assembly comprising a prefolding unit for processing a continuous sheet of material in the manufacture of a consumable component for use in or with an aerosol delivery system, wherein the prefolding unit comprises at least one groove in a surface of the prefolding unit, the at least one groove extending along a spiral path.

[0017] The groove may be formed in the convex side of the curved wall.

[0018] The groove may be formed in the concave side of the curved wall.

[0019] The helical path may form at least one complete helical turn.

[0020] The upstream end of the curved wall may have a first radius and the downstream end may have a second radius, the first radius being greater than the second radius.

[0021] At least one groove in the series of grooves at the downstream end may have a pitch of between 3 mm and 20 mm.

[0022] In a third aspect of the present invention, there is provided a consumable component for use in or with an aerosol delivery system, the component comprising a hollow tube formed from a gathered sheet of material, the gathered sheet of material extending along a helical path about a longitudinal axis of the component.

[0023] Consumable components for use in or with an aerosol delivery system may include sheets of material processed as described above.

[0024] The gathered sheet of material may include individual strands of sheet material that each extend along a helical path.

[0025] The gathered sheet of material may include a crimped gathered sheet of material.

[0026] The component may have an axial length of 4 mm to 12 mm, and optionally an inner diameter of 2.5 mm to 5.5 mm, and optionally a wall thickness of 1 mm to 1.5 mm.

[0027] The helical path of the or each strand may have a pitch of 50 mm to 550 mm.

[0028] The helical path may have a twist angle of 0.7 degrees per cm of axial length of the component.

[0029] The sheet of material may comprise any one of paper, lyocell, viscose, silk, cotton, linen, jute, or tobacco paper.

[0030] The sheet material may include an aerosol-forming material.

[0031] Also disclosed is a consumable configured to generate an aerosol when used with an electronic aerosol generating device, the consumable comprising the components described above.

[0032] The component may form part of a filter assembly, an aerosol-generating section, or any other section of the consumable through which the aerosol is drawn in use.

[0033] Also disclosed is an aerosol delivery system comprising the above-described components.

[0034] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0035] [Figure 1] The consumables are shown in cross section. [Figure 2]1 shows a schematic representation of a portion of a manufacturing line for consumable components. [Figure 3] 1 shows a cross section of the sheet material after passing through a crimping station. [Figure 4] 1 shows a cross section of the sheet material after passing through a prefold unit. [Figure 5] 1 shows a crimping pattern imprinted into the sheet material by the crimping station. [Figure 6] 1 shows a first example of a pre-folding unit. [Figure 7] 1 shows a second example of a pre-folding unit. [Figure 8] 1 shows a cross-sectional view of a transport jet. [Figure 9a] 10A and 10B show schematic diagrams of tapered portions of the mandrel of the transport jet; [Figure 9b] 10 shows a schematic of a converging section of a funnel of a conveying jet; [Figure 10] 1 is a flow chart of a method for manufacturing a consumable component. [Figure 11] 1 is a flow chart of a method of processing sheet material in the manufacture of consumable components. [Figure 12] 1 illustrates a component formed in accordance with the methods and apparatus described herein. DETAILED DESCRIPTION OF THE INVENTION

[0036] According to the present disclosure, a "combustion-based" aerosol delivery system is one in which the constituent aerosol-generating materials (or components thereof) of the aerosol delivery system are combusted or burned during use to facilitate delivery of at least one substance to a user.

[0037] In some embodiments, the delivery system is a combustion aerosol delivery system, such as a system selected from the group consisting of a cigarette, a cigarillo, and a cigar.

[0038] In some embodiments, the present disclosure relates to aerosol modifier-releasing components such as filters, filter rods, filter segments, tobacco rods, spills, capsules, threads, or beads, or papers such as plug wrap, tipping paper, or cigarette paper, for use in combustion-based aerosol delivery systems.

[0039] According to the present disclosure, a "non-combustion" aerosol delivery system is one in which the constituent aerosol-generating materials (or components thereof) of the aerosol delivery system are not combusted or burned to facilitate delivery of at least one substance to a user.

[0040] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0041] In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0042] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system.

[0043] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, where one or more aerosol-generating materials can be heated. Each of the aerosol-generating materials can be, for example, in solid, liquid, or gel form and can contain nicotine or not. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material can include, for example, tobacco or a non-tobacco product.

[0044] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable item for use with the non-combustion aerosol delivery device.

[0045] In some embodiments, the present disclosure relates to consumables, sometimes referred to as articles throughout this disclosure, that include aerosol-generating materials and are configured for use with non-combustion aerosol delivery devices.

[0046] In some embodiments, a non-combustion aerosol delivery system, such as a non-combustion aerosol delivery device, can include a power source and a controller. The power source can be, for example, a power source or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon substrate that can be energized to deliver power in the form of heat to an aerosol-generating material or a heat-transfer material proximate the heat-generating power source.

[0047] In some embodiments, the non-combustion aerosol delivery system may include an area for receiving consumables, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0048] In some embodiments, consumables for use with non-combustion aerosol delivery devices may include aerosol-generating materials, aerosol-generating material storage areas, aerosol-generating material transfer components, aerosol generators, aerosol-generating areas, housings, packaging, filters, mouthpieces, and / or aerosol modifiers.

[0049] FIG. 1 illustrates an aerosol delivery system 10 in the form of a rod-shaped consumable 10 for use with an electronic aerosol generating device. FIG. 1 is shown as a cross section along the longitudinal axis of the system. As illustrated, the system includes a hollow component 11. By "hollow," we mean that the component includes a central passageway 12 along which the aerosol can travel during use of the system 10. In this example, the hollow component 11 is a tube 11 formed from crimped paper sheets assembled into a tube according to the methods outlined herein. Other components of the system may vary depending on the specific application of the system but are readily selected by those skilled in the art and may include an aerosol-generating section, a filter, and, optionally, a section containing other additives or active substances. In other examples, the tube 11 itself may be provided with aerosol-generating material. In the illustrated example, the hollow component 11 is attached to the rod-shaped aerosol-generating section 13 by an overlapping packaging material 14 that surrounds both the hollow component 11 and the rod-shaped aerosol-generating section 13. The wrapper 14 may be tipping paper, cigarette paper, plug wrap, or any other suitable bonded overwrap that would be available to one skilled in the art.

[0050] FIG. 2 schematically illustrates a portion of a manufacturing line 20 for component 11. Line 20 includes a supply 21 of continuous sheet material 22 at an upstream end "U" of line 20 and an endless garniture belt 27 at a downstream end "D" of line 20. The direction of travel of continuous sheet material 22 during operation of line 20 is referred to herein as the "machine direction" and is indicated by arrow "MD." From the upstream end to the downstream end, manufacturing line 20 further includes a crimping station 23, an optional cutting station 24, a pre-folding unit 25, a conveying jet 26, a pressure chamber 28, and a drying chamber 29. During operation, continuous sheet material 22 is output from conveying jet 26 and processed to form a continuous hollow rod 30. The endless garniture belt 27 transports the continuous hollow rod 30 before it is cut into individual components for transport to further assembly stations to form consumable products. The cutting of the continuous hollow rod 30 and the subsequent formation of the individual components 11 into the consumable 10 may be performed in any manner apparent to one skilled in the art and is beyond the scope of this disclosure. However, it will be understood that forming consumables 10 from rod-like components 11 is well understood in the tobacco industry, and omissions from this description would not pose any difficulty to one skilled in the art in forming the consumable 10 as shown in FIG. 1 .

[0051] The continuous sheet material supply 21 includes a reel 211 around which a continuous sheet material 22 (also referred to herein simply as "sheet material 22" for brevity) is wound. During operation of the line 20, the sheet material 22 is unwound from the reel 211 and conveyed in the machine direction. The sheet material may include a nonwoven material. The sheet material 22 is preferably a cellulose fiber paper having a paper weight of 30 gsm to 70 gsm, although other biodegradable materials having any suitable thickness may be used. For example, the sheet material 22 may be any of paper, lyocell, viscose, silk, cotton, linen (1.0 to 5.0 denier), jute, or tobacco paper. The sheet material 22 may also include an aerosol-generating material. The width of the sheet material 22 is preferably 70 mm to 160 mm, and in a particular example, 90 mm. The thickness of the sheet material 22 may be 60 μm to 100 μm, and in a particular example, 85 μm.

[0052] The crimping station 23 includes a pair of crimping rollers 231, 231'. Each roller 231, 231' is a cylinder configured to rotate about its own axis. The rollers 231, 231' are positioned such that their axes are parallel and their peripheries are closely spaced apart so that, during use, the rollers 231, 231' rotate to grip the sheet material 22 therebetween. The crimping rollers 231, 231' may be driven to assist in drawing the sheet material from the reel 21, or may be passive and rotate as a result of the sheet material 22 being drawn between the crimping rollers 231, 231'. For example, the sheet material may be drawn in the machine direction solely by an endless garniture belt 27 at the downstream end of the line 20.

[0053] One or both of the rollers 231, 231′ have an embossed pattern on the periphery of the roller or rollers 231, 231′ to impress the pattern into the sheet material 22 as it passes between the rollers 231, 231′. The pattern includes a series of ridges and grooves, as shown in FIGS. 3 and 5, and is referred to herein as a “crimp pattern” or “crimping pattern.” FIG. 3 shows a cross-section of the sheet material 22 as it emerges from the crimping station 23. The grooves imprinted into the sheet material extend in the longitudinal direction LD, or machine direction MD, of the sheet material 22.

[0054] FIG. 5 illustrates the crimping pattern in more detail. The crimping pattern has a crimp amplitude A (also known as a “crimping factor”), which refers to the depth of the grooves that the crimping pattern forms in the sheet material 22. That is, crimping the sheet material 22 creates a plurality of peaks 221 and valleys 222 in the sheet material 22, and the crimp amplitude “A” is the depth of the valleys 222 measured from the peaks 221. The crimping factor affects the hardness and roundness of the component 11 produced. That is, increasing the crimping factor has been found to increase the hardness and roundness of the component 11, with associated benefits in terms of component integrity and quality. Furthermore, increasing the crimping factor has been found to increase the pressure drop across the component 11 as aerosol is drawn through the component 11 during use. This can be beneficial for controlling and achieving consistency in the pressure drop across the component 11 and, therefore, within a consumable product 10 including such a component 11. The crimping may form a “zigzag” or another shape. Adjacent grooves in the crimped sheet material are spaced a distance apart, i.e., having a pitch "P." The pitch is preferably in the range of 100 μm to 1000 μm, more preferably in the range of 100 μm to 500 μm. The crimp amplitude is preferably in the range of 50 μm to 250 μm, or more preferably in the range of 100 μm to 200 μm. In a specific example, the crimped sheet material has a pitch of 300 μm and a crimp amplitude of 150 μm.

[0055] Following crimping, the sheet material may optionally be fed to a cutting station 24, where, as shown in FIG. 2 , the sheet material 22 is slit into individual strands 22′, 22″, 22′″ of the sheet material 22. If the cutting station 24 is omitted, the sheet material 22 instead advances directly to the prefolding unit 25 without being divided into strands and remains there. Preferably, slitting the sheet material 22 into individual strands 22′, 22″, 22′″ results in a more uniform distribution of the sheet material 22 when it is gathered into the shape of the component 11 within the conveying jet 25, as will be further described below. The cutting station 24 includes an arrangement of blades 241 that extend into the path of the sheet material 22 to slice the sheet material 22 into individual strands 22′, 22″, 22′″ as it is drawn over the blades 241. Obviously, the number of blades will depend on the number of individual strands desired. Blade 241 may have a straight edge, or alternatively, blade 241 may be a disk that cuts the sheet material against an anvil roller or other cutting surface. If cutting station 24 is employed, sheet material 22 may be cut into two, three, four, or five strands, as desired.

[0056] Following cutting, the sheet material 22 is pulled onto or through the prefold unit 25, depending on the design of the prefold unit, as described below. Regardless of the design, the prefold unit 25 includes a series of grooves 251 extending along a spiral path. FIG. 6 shows a first exemplary prefold unit 25 in which the grooves 251 are formed in the convex side of the curved wall 252 of the prefold unit 25. In this example, the curved wall 252 is the curved outer surface 252 of a solid, frusto-conical, single-piece component 25′. The component 25′ includes an upstream end U configured to face the direction of the incoming sheet material 22 and a downstream end D opposite the upstream end. The upstream end is the larger diameter end of the frusto-conical component. In the illustrated example, the component 25′ includes five grooves 251, each following a spiral path around the outer surface 252 of the component 25′, although any number of grooves may be employed as desired. During operation of manufacturing line 20, sheet material 22 is drawn over upstream end U, component 25′, and into conveying jet 26. The entrance to conveying jet 26 has a diameter equal to or less than the diameter of downstream end D of pre-component 25′, such that sheet material 22 is drawn tightly over curved surface 252 and into grooves 251 of pre-component 25′, causing sheet material 22 to adopt the contours of grooves 251. In this manner, sheet material 22 is pre-folded such that sheet material 22 retains the shape imparted by grooves 251 as it leaves component 25′.

[0057] A second exemplary pre-fold unit 25 is shown in FIG. 7 , with like features retaining the same reference numerals. In this example, grooves 251 are formed in the concave side 253 of the curved wall 254 of the pre-fold unit 25. The curved wall 254 forms a hollow, frusto-conical, single-piece component 25″ with grooves 251 disposed in the inner surface 253 of the hollow component 25″ in a manner similar to rifling. Like the solid component 25′, the hollow component 25″ has an upstream end U configured to face the incoming sheet material 22 and a downstream end D opposite the upstream end, the upstream end being the larger diameter end of the truncated cone. In the illustrated example, the component 25″ includes eight grooves 251, each following a spiral path around the inner surface 253 of the component 25″, although any number of grooves 251 may be employed as desired. During operation of the production line 20, sheet material is drawn into the upstream end and exits through the downstream end before being fed into the conveying jet 26. Between the upstream and downstream ends, the diameter of the inner surface 253 decreases so that the sheet material 22 closely conforms to the inner surface 253 of the component 25'' and adopts the contours of the grooves 251. In this manner, the sheet material is pre-folded similarly to the solid component 25'.

[0058] 4 shows a cross-section of the sheet material exiting the pre-folding unit 25. As shown, the sheet material 22 includes macro- and micro-fold patterns. The macro-fold pattern refers to the shape imparted by the grooves 251 in the pre-folding unit 25 and includes a series of ridges and grooves that are sinusoidal in appearance. The micro-fold pattern refers to the much finer series of peaks 221 and valleys 222 imparted by the crimping roller 23 as described above.

[0059] One advantage of the spiral path of the grooves of the prefold unit 25 described above is that the continuous sheet material 22 itself begins to follow a spiral path as it leaves the prefold unit 25 and enters the conveying jet 26. If multiple strands of sheet material 22 are provided to the prefold unit 25, each individual strand will follow a spiral path as it enters the conveying jet 26. As will be explained further below, the sheet material 22 is gathered into the conveying jet 26 to form a continuous hollow rod 30, with each strand of gathered sheet material 22 following a spiral path about the axis of the continuous hollow rod 30. The advantage of this is that the continuous hollow rod 30 will have a more uniform distribution of gathered sheet material 22 along its length than would be the case if the individual strands did not follow a spiral-shaped path.

[0060] The grooves 251 of the prefolding unit 25 described herein may have a pitch of 50 mm to 550 mm, such as 200 mm to 400 mm, at the downstream end D of the prefolding unit 25. "Pitch" refers to the axial distance it takes for the helical path to complete one complete turn (i.e., a 360-degree turn). The pitch at the downstream end D refers to the pitch of the helical path at the diameter of the downstream end D of the prefolding unit 25. The pitch at the downstream end will be substantially equal to the pitch of the individual strands of sheet material 22 as they enter the conveying jet 26. It will be understood that the pitch need not be constant over the length of the prefolding unit 25. For example, the grooves 251 may have a smaller pitch at the downstream end D of the prefolding unit 25 than at the upstream end U of the prefolding unit 25. In this manner, the helical path traced by the grooves 251 may gradually become tighter between the upstream and downstream ends U, D. In one example, the helical path may trace a conical spiral.

[0061] The illustrated pre-fold unit 25 is machined from aluminum, steel, or any other suitable material, a detailed description of which is omitted as it is within the understanding of one skilled in the art. The pre-fold unit 25 may be mounted to the bed of the production line 20 by a bracket (not shown) or any other suitable method. Importantly, the axis XX of the pre-fold unit 25 is parallel to the machine direction MD, with the upstream end U pointing toward the incoming sheet material 22. The pre-fold unit 25 should be positioned in the path of the sheet of material 22 so that the sheet material follows the grooves 251 of the pre-fold unit 25 in the manner described above.

[0062] The grooves 251 of the illustrated pre-folding unit 25 may have a width between 3 mm and 20 mm. The narrower the width of each groove 251, the more tightly the sheet material 22 is pre-folded.

[0063] 8 shows the transport jet 26 in cross section along the longitudinal axis of the transport jet 26. The transport jet 26 comprises a funnel 261 and a mandrel 262. The mandrel 262 is an elongated rod positioned within the funnel 261 such that an outer surface 263 of the mandrel 262 is spaced from an inner surface 264 of the funnel 261 to form an annular channel 265.

[0064] Mandrel 262 comprises a tapered portion 266 and a uniform portion 267. "Tapered" means that the overall diameter of mandrel 262 decreases between upstream end 2610 of mandrel 262 and uniform portion 267. "Uniform" means that the overall diameter of uniform portion 267 remains constant along the length of uniform portion 267 to downstream end 2611 of mandrel 262.

[0065] Funnel 261 comprises a converging section 268 and a uniform section 269 downstream of converging section 268. The inner diameter of funnel 261 at converging section 268 decreases between the upstream end 2612 of the funnel and uniform section 269, from which the inner diameter remains constant the length of uniform section 269 to the downstream end 2613 of funnel 261.

[0066] Mandrel 262 is positioned within funnel 261 such that tapered portion 266 of mandrel 262 resides within converging portion 268 of funnel 261 and uniform portion 267 of mandrel 262 resides within uniform section 269 of funnel 261 .

[0067] The taper angle of tapered portion 266 of mandrel 262 is less than the convergence angle of converging section 268 of funnel 261. Thus, channel 265 comprises a section 2614 (referred to herein as the "upstream section 2614") where outer surface 263 of mandrel 262 and inner surface 264 of funnel 261 converge. In other words, the cross-sectional area of ​​upstream section 2614 of channel 265 decreases between an entrance 2616 of channel 265 and a midpoint 2617 of channel 265. Midpoint 2617 of channel 265 is the location along the length of channel 265 where upstream section 2614 intersects with downstream section 2615, and is represented graphically in FIG. 8 by a dashed line. Downstream section 2615 is defined as the portion of the channel where the cross-sectional area of ​​channel 265 is constant. In other words, it is the section of channel 265 defined between uniform portion 267 of mandrel 262 and uniform section 269 of funnel 261. In the illustrated example, downstream section 2615 extends from midpoint 2617 to outlet 2618 of channel 265.

[0068] Mandrel taper angle A T is expressed by the following formula:

[0069]

number

[0070] During the ceremony, A T is the taper angle, D SM is the small diameter end of the tapered section of the mandrel, D LM is the large diameter end of the tapered portion of the mandrel, L Mis the length of the tapered portion of the mandrel.

[0071] These features are illustrated in FIG. 9 a , which shows a schematic representation of tapered section 266 of mandrel 262 .

[0072] Similarly, the convergence angle A of the convergent section 268 of the funnel 261 C is expressed by:

[0073]

number

[0074] During the ceremony, A C is the convergence angle, D SF is the small diameter end of the upstream section of the funnel, D LF is the large diameter end of the upstream section of the funnel, L F is the length of the upstream section of the funnel.

[0075] These features are illustrated in Figure 9b, which shows a schematic of the converging section 268 of the funnel 261. The depicted diameter D of the funnel 261 SF , D LF It should be understood that is the inner diameter of the funnel 261. Therefore, the cross-sectional area of ​​the inlet (C IN ) is expressed by the following formula:

[0076]

number

[0077] Similarly, the cross-sectional area at the midpoint (C IP ) is represented by:

[0078]

number

[0079] In the example shown in Figure 8, regardless of the actual value, C IN >C IP A so that T C This ensures a smooth and gradual gathering of the sheet material 22 as it progresses through the upstream section of the funnel.

[0080] ​The mandrel 262 includes an internal conduit 2619 and an aperture 2620 that connects the internal conduit 2619 to the channel 265. The internal conduit 2619 is connected to a source of binder 210, which is pumped through the internal conduit 2619 and through the aperture 2620 into the channel 265 during operation of the conveying jet 26. The internal conduit 2619 and the aperture 2620 are located within the tapered portion 266 of the mandrel 262 such that the aperture 2620 is in communication with the upstream section 2614 of the channel 265. Thus, the binder is introduced into the upstream section 2614 of the channel 265 as the sheet material 22 is gathered around the mandrel 262. The apertures 2620 are regularly spaced along the length of the tapered portion 266 of the mandrel 262, thereby allowing the binder to be evenly distributed within the sheet material 22 in the upstream section 2614 of the channel 265. Another advantage of regular aperture 2620 spacing is that it allows for continuous application of binder as the sheet material 22 moves over the apertures 2620. For viscous agents, such as those discussed below, the required amount of binder must be applied to the sheet material 22. However, it will be appreciated that other aperture spacings may be employed. For example, the apertures 2620 may be spaced closer together as they approach the midpoint 2617 of the channel 265. The apertures may be provided as groups of apertures 2620 extending radially from the conduit 2619 at locations along the length of the tapered portion 266 of the mandrel 262. In this way, the binder is evenly distributed around the circumference of the mandrel 262. Alternatively, the apertures may be grouped into a spiral extending along the length of the tapered portion 266 of the mandrel 262. The spiral of apertures 2620 is a group of apertures 2620 spaced along the length of the mandrel 262, with each aperture 2620 extending along a radius that is angularly offset from adjacent apertures 2620 in the group. During operation of the conveying jet, each spiral of apertures 2620 may be positioned to align with the helical direction that the individual strands of sheet material 22 take as they exit the prefold unit 25.

[0081] The downstream section 2615 of the channel 265 has a cross-sectional area equal in size and shape to the cross-section of the completed component 11. Thus, after gathering the sheet material 22 within the upstream section 2614 of the channel 265, the gathered sheet material 22 takes the dimensions of the channel 265 in the downstream section 2615 and emerges from the outlet 2618 as a continuous hollow rod 30 for cutting into individual components 11. With reference to FIG. 12 , it will be seen that use of the pre-folding unit 25 described above results in a component 11 that includes a hollow tube formed from the gathered sheet of material, the gathered sheet of material comprising individual strands 22′, 22″, 22′″ of material extending along a helical path about the longitudinal axis XX of the component 11.

[0082] To aid in setting the binder, the downstream section 2615 of the mandrel 262 may be heated. This may be accomplished by either heating the outer surface 263 of the mandrel 262 or by heating the inner surface 264 of the funnel 261. The funnel 261 and / or mandrel 262 may be heated in any suitable manner. For example, an electric filament (not shown) may be embedded within the heated surfaces 263, 264. The filament is heated by electrical resistance such that application of a voltage to the filament causes it to heat. The surface in which the filament is embedded, i.e., the outer surface 263 of the mandrel 262 or the inner surface 264 of the funnel 261, may be made of a thermally conductive material such as metal. In one example, the mandrel 262 and funnel 261 are machined from machining-grade aluminum or stainless steel. A track (not shown) may be machined into the outer surface 263 of the mandrel 262 or the inner surface 264 of the funnel 261, along which the filament may be laid. When the filament is heated, heat is conducted to the funnel 261 or mandrel 262, heating the gathered sheet material 22 passing through the channel 265. In one example, the inner surface 264 of the funnel 261 and / or the outer surface of the mandrel 262 are heated to a temperature between 150°C and 250°C, or greater than about 200°C.

[0083] A pressurizing mechanism 2621 may be provided in the upstream section 2614 of the channel 265 to assist in gathering the sheet material 20 within the conveying jet 26. The pressurizing mechanism 2621 includes a nozzle 2622 configured to direct an airflow toward the inlet 2616 of the channel 265, thereby increasing the static pressure at the inlet 2616. The pressurizing mechanism may be configured to increase the static pressure at the inlet 2616 to between 4 bar and 8 bar. In one example, the pressurizing mechanism is configured to increase the static pressure at the inlet 2616 to 6 bar.

[0084] Alternatively or additionally, a pressure chamber 28 and a drying chamber 29 may be employed downstream of the conveying jet 26. These chambers 28, 29 are enclosures with openings that allow the continuous hollow rod 30 to pass through. The pressure in the pressure chamber 28 is greater than ambient, which aids in setting the binder and hardening the continuous hollow rod 30. The temperature in the drying chamber 29 is greater than ambient, which further aids in setting the binder and hardening the continuous hollow rod 30.

[0085] The conveying jet 26 may be attached to the bed of the manufacturing line 20 by a bracket (not shown) or in any other suitable manner. For example, the outer surface of the funnel 261 may be attached to the bed by a bracket. The mandrel 262 may be supported within the funnel 261 either by attaching the mandrel 262 to the inner surface 264 of the funnel 261 by its own bracket or by attaching it to the bed of the manufacturing line 20. In one example, the tapered portion 266 of the mandrel 262 protrudes beyond the funnel 261 from the inlet 2616, and a bracket (not shown) secures the protruding portion of the tapered portion 266 to the bed of the manufacturing line 20. The bracket should be configured to minimize obstruction to the inlet 2616. For example, the bracket may be a fin-shaped support extending radially from the mandrel 262 to the bed. In this way, the bracket does not interfere with the helical path of the sheet material 22 as it progresses through the channel 265. The bracket may include a line for supplying bonding agent to the conduit 2619 of the mandrel 262 .

[0086] 10 , a method 40 of manufacturing a hollow component 11 of a consumable 10 is described. The method 40 includes using 41 a conveying jet 26 to gather a continuous sheet material 20 into the shape of the hollow component 11. According to the method, using 41 the conveying jet 26 includes feeding 42 the sheet material 20 into a channel 265 of the conveying jet 26, gathering 43 the sheet material 20 into the channel 265, and applying 44 a binder to the gathered sheet material 20 through an aperture 2620 of a mandrel 262.

[0087] In an example, providing 42 material 20 includes providing a fibrous material. In an example, the fibrous material is a continuous sheet of paper. In an example, the continuous sheet of paper is a continuous sheet of crimped paper. In an example, the crimped paper has a crimp amplitude of about 0.1 mm to 0.2 mm.

[0088] In an example, applying a binder 44 includes applying a binder comprising about 6 wt% food-grade pectin. In one example, the binder can be 4 wt% food-grade pectin. In other examples, binders other than pectin may be used, such as starch-based binders, clay-based binders, BioWax, cellulose acetate (in one example, 5% cellulose acetate dissolved in triacetin), and resin-based binders.

[0089] In an example, the method may further include setting 45 the binder by heating the surface of the conveying jet 26 to a temperature between 150°C and 250°C, or greater than about 200°C.

[0090] In an example, gathering 43 the sheet material may further include pressurizing 46 the conveying jet 26 to increase the static pressure within the channel 265 of the conveying jet 26 to 6 bar.

[0091] 11, a method 50 for processing sheet material in the manufacture of hollow components 11 of consumable product 10 will now be described. Method 50 includes drawing 51 sheet material 20 through grooves 251 of pre-folding unit 25 such that sheet material 20 at least partially adopts the contours of grooves 251.

[0092] In examples, the method of processing sheet material may further include dividing 52 the sheet material into individual strands 22 , 22 ″, 22 ′″ of sheet material 22 upstream of the prefolding unit 25 .

[0093] Figure 12 illustrates an exemplary hollow component 11 formed using the methods and apparatus outlined above, particularly the exemplary apparatus employing the prefold unit 25 shown in Figures 6 and 7. The gathered sheet material of the component of Figure 12 comprises individual strands 22', 22'', 22''', each extending along a helical path about the longitudinal axis of the component. However, it will be understood that the component may alternatively comprise any number of strands, including a single strand.

[0094] The helical path of the or each strand has a twist angle of 5 to 45 degrees for an exemplary component having an axial length of 7 cm. By "twist angle" is meant the angle at which the radius advances along the helical path as it travels a given distance (7 cm in this example) along the longitudinal axis. Thus, the twist angle per cm of axial length of the component 11 is 0.7 to 6.5 degrees. This corresponds to a pitch of 50 to 550 mm. Thus, the pitch of the helical path of the or each strand of gathered sheet material 22 is in a similar range to the pitch of the helical path of the grooves 251 of the prefolding unit 25, although they need not be exactly the same in any given example. A pitch of 50 to 550 mm adds stability to the component 11. However, a pitch greater than 550 mm risks jamming the prefolding unit 25.

[0095] In examples, the component has an axial length of 4 mm to 12 mm, and optionally an inner diameter of 2.5 mm to 5.5 mm, and optionally a wall thickness of 1 mm to 1.5 mm.

[0096] Component 11 may be used as part of a filter assembly, an aerosol-generating section, or any other section of consumable 10 from which a user will inhale aerosol when using consumable 10.

[0097] 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. A method of processing a continuous sheet material in the manufacture of a consumable component for use in or with an aerosol delivery system, the method comprising: drawing the sheet material through a groove in a prefolding unit so that the sheet material at least partially adopts the contour of the groove, the groove extending along a spiral path; method.

2. The method of claim 1 , wherein the groove is part of a series of grooves.

3. The method of claim 2 , wherein the groove is formed in a convex side of a curved wall of the prefold unit.

4. The method of claim 2 , wherein the groove is formed in a concave side of a curved wall of the prefold unit.

5. The method of any one of claims 1 to 4, wherein the helical path forms at least one complete helical turn.

6. 6. The method of claim 3, wherein the upstream end of the curved wall has a first radius and the downstream end has a second radius, the first radius being greater than the second radius.

7. The method of claim 6, wherein the pitch of the at least one groove at the downstream end is between 3 mm and 20 mm.

8. The method of any one of claims 1 to 7, wherein the sheet of material comprises paper.

9. 9. The method of claim 8, further comprising applying a crimping pattern to the sheet material before drawing the sheet material over the edge.

10. The method of claim 9, wherein the crimping pattern has a crimp amplitude of about 0.1 mm to 0.2 mm.

11. The method of any one of claims 1 to 10, further comprising feeding the sheet material into a channel of a conveying jet comprising a funnel and a mandrel.

12. The method of claim 11 further comprising applying a binder to the material.

13. 13. The method of claim 12, wherein the binder comprises about 6 wt% pectin.

14. 14. The method of claim 12 or 13, wherein the mandrel is disposed within the funnel such that an outer surface of the mandrel is spaced from an inner surface of the funnel to define the channel between the outer surface of the mandrel and the inner surface of the funnel, the mandrel including an internal conduit, an aperture in a wall of the mandrel connecting the conduit with the channel, and the step of applying the binder to the material includes applying the binder through the aperture in the mandrel.

15. A method according to any preceding claim, further comprising the step of dividing the sheet material into individual strands of sheet material upstream of the prefolding unit.

16. 1. An assembly comprising a prefolding unit for processing a continuous sheet of material in the manufacture of a consumable component for use in or with an aerosol delivery system, the prefolding unit comprising at least one groove in a surface of the prefolding unit, the at least one groove extending along a spiral path.

17. The assembly of claim 16 , wherein the groove is formed in a convex side of the curved wall.

18. The assembly of claim 16 , wherein the groove is formed in the concave side of the curved wall.

19. 19. The assembly of claim 17 or 18, wherein the helical path forms at least one complete helical turn.

20. 20. The assembly of any one of claims 16 to 19, wherein the upstream end of the curved wall has a first radius and the downstream end has a second radius, the first radius being greater than the second radius.

21. 21. The assembly of claim 20, wherein the pitch of at least one groove in the series of grooves at the downstream end is between 3 mm and 20 mm.

22. 16. A consumable component for use in or with an aerosol delivery system, the component comprising a sheet of material processed according to the method of any one of claims 1 to 15.

23. 1. A consumable component for use in or with an aerosol delivery system, the component comprising a hollow tube formed from a gathered sheet of material, the gathered sheet of material extending along a helical path about a longitudinal axis of the component.

24. 24. The component of claim 23, wherein the gathered sheet of material comprises individual strands of sheet material each extending along a helical path.

25. 25. The component of claim 23 or 24, wherein the gathered sheet of material comprises a crimped gathered sheet of material.

26. 26. The component of any one of claims 23 to 25, wherein the component has an axial length of 4 mm to 12 mm, and optionally an internal diameter of 2.5 mm to 5.5 mm, and optionally a wall thickness of 1 mm to 1.5 mm.

27. A component according to any one of claims 23 to 26, wherein the helical path of the or each strand has a pitch of between 50mm and 550mm.

28. 28. A component according to any one of claims 23 to 27, wherein the helical path has a twist angle of 0.7 degrees per cm of axial length of the component.

29. 29. The component of any one of claims 23 to 28, wherein the sheet of material comprises any one of paper, lyocell, viscose, silk, cotton, linen, jute, or tobacco paper.

30. 30. The component of any one of claims 23 to 29, wherein the sheet material comprises an aerosol-forming material.

31. A consumable configured to generate an aerosol when used with an electronic aerosol generating device, said consumable comprising a component according to any one of claims 23 to 30.

32. 32. The consumable product of claim 31, wherein the component forms part of a filter assembly, an aerosol-generation section, or any other section of the consumable product through which aerosol is drawn in use.

33. An aerosol delivery system comprising a component according to any one of claims 23 to 30.

Images