Aerosol-Generating Material Rod Segment

Abstract

A method for manufacturing an aerosol-generating material rod segment 126 is provided. The method includes longitudinally cutting a sheet of aerosol-generating material to produce a plurality of strands of aerosol-generating material, collecting the strands to form a rod of aerosol-generating material, each of the plurality of strands being substantially unwound, and cutting the rod of aerosol-generating material into segments to produce rod segments. Apparatus for producing the rod of aerosol-generating material and products comprising the rod of aerosol-generating material are also disclosed.

Description

[Technical field]

[0001] The present invention relates to a method and apparatus for producing aerosol-forming material rod segments. [Background technology]

[0002] In a known process for producing cigarettes, tobacco leaves are shredded into short strips, also known as cut rag tobacco. The shredded tobacco is then strewn onto a continuous web of cigarette paper. A machine, also known as a cigarette maker, wraps the paper around the shredded tobacco to form a continuous rod. The rod is cut into segments of a desired length. A filter is added to each tobacco rod to produce a cigarette.

[0003] Smoking articles, such as cigarettes, cigars, etc., are burned during use to produce tobacco smoke. Attempts have been made to provide alternatives to these articles by producing products that release compounds from tobacco or other materials without combustion. Examples of such products include so-called "heat not burn" products, or tobacco heating devices or products, or aerosol generating devices or products, which release compounds by heating, rather than burning, materials such as tobacco. Summary of the Invention

[0004] According to a first aspect of the present invention, there is provided a method of producing aerosol-generating material rod segments, comprising: longitudinally cutting a sheet of aerosol-generating material to produce a plurality of strands of aerosol-generating material; collecting the strands to form a rod of aerosol-generating material, each of the plurality of strands of aerosol-generating material being substantially uncoiled; and cutting the rod of aerosol-generating material into segments to produce the aerosol-generating material rod segments.

[0005] Collecting can include collecting the strands to form a rod of aerosol-generating material, in which the strands of aerosol-generating material are substantially parallel to one another.

[0006] Collecting can include collecting the strands to form a rod of aerosol-generating material, wherein each of the plurality of strands of aerosol-generating material is substantially straight.

[0007] The sheet of aerosol-forming material may be a tobacco sheet.

[0008] The tobacco sheet may be a reconstituted tobacco sheet.

[0009] The sheet of aerosol-generating material may include glycerol.

[0010] The sheet of aerosol-generating material may have a substantially constant mass per unit length.

[0011] The method can include obtaining a sheet of aerosol-generating material from a bobbin of aerosol-generating material.

[0012] The method can include providing a mother reel of aerosol-generating sheet material and slitting the mother reel to produce bobbins.

[0013] The method may include selecting a mass per unit length of a rod segment of aerosol-generating material, determining a bobbin width based on the mass per unit area of ​​the sheet of aerosol-generating material and based on the selected mass per unit length of the rod segment of aerosol-generating material, and scoring a mother reel to produce a bobbin having the determined bobbin width.

[0014] The method may include selecting a number of strands and / or a strand width for the rod segment of aerosol generating material and determining a number of cuts and / or a cutting spacing based on the selected number of strands and / or strand width, and cutting the sheet of aerosol generating material may include cutting the sheet of aerosol generating material according to the determined number of cuts and / or cutting spacing.

[0015] The method may include feeding a sheet of aerosol-generating material in a sheet-in-feed direction, and cutting the sheet of aerosol-generating material may include cutting the sheet of aerosol-generating material substantially parallel to the sheet-in-feed direction.

[0016] The collecting can include collecting each of the strands with an axis that lies in a plane, the plane including the feed direction and perpendicular to a plane defined by the plurality of strands before being collected.

[0017] The collecting can include collecting each of the strands toward a central axis of the plurality of strands.

[0018] The gathering can include gathering each of the strands substantially laterally to form a rod.

[0019] Collecting can include forcing the strands through a funnel to collect the strands.

[0020] The method may include, prior to said cutting the sheet of aerosol-forming material, feeding the sheet of aerosol-forming material through a funnel to form a rod of non-shredded tobacco sheet aerosol-forming material.

[0021] The width of each of the plurality of strands is substantially within the range of 0.25 to 3 mm, or substantially within the range of 0.5 to 1.5 mm.

[0022] The method can include coating a rod of aerosol-forming material with a coating material.

[0023] The covering material may be or may include one or both of paper and aluminum foil.

[0024] Each aerosol-forming material rod segment may have an outer diameter substantially within the range of 5.4-7.8 mm, or substantially within the range of 6.7-7.8 mm.

[0025] The aerosol-generating material rod segment may be a consumable item of the aerosol generating device.

[0026] According to a second aspect of the present invention, there is provided an apparatus for producing aerosol-generating material rod segments, the apparatus comprising: a first cutter configured to longitudinally cut a sheet of aerosol-generating material to produce a plurality of strands of aerosol-generating material; a collector configured to collect the strands to form a rod of aerosol-generating material, each of the plurality of strands of aerosol-generating material being substantially uncoiled; and a second cutter configured to cut the rod of aerosol-generating material into segments to produce the aerosol-generating material rod segments.

[0027] The collector can be configured to collect the strands to form a rod of aerosol-forming material, in which the strands of aerosol-forming material are substantially parallel to one another.

[0028] The collector may be configured to collect the strands to form a rod of aerosol-forming material, wherein each of the plurality of strands of aerosol-forming material is substantially straight.

[0029] The apparatus may be arranged to obtain the sheet of aerosol-forming material from a bobbin of the sheet of aerosol-forming material.

[0030] The first cutter may be adjustable to adjust the number and / or width of the strands.

[0031] A first cutter can be adjustable to cut the sheet of aerosol-generating material to produce the plurality of strands of aerosol-generating material, or to not cut the sheet of aerosol-generating material.

[0032] The apparatus can be configured to feed a sheet of aerosol-generating material in a sheet-in-feed direction, and the first cutter can be configured to cut the sheet of aerosol-generating material substantially parallel to the sheet-in-feed direction.

[0033] The collector can be configured to collect each of the strands along an axis that lies in a first plane, the first plane including the feed direction and perpendicular to a second plane defined by the plurality of strands before they are collected.

[0034] The collector may be arranged to collect each of the strands toward a central axis of the plurality of strands.

[0035] The collector may be arranged to collect each of the strands substantially laterally to form a rod.

[0036] The collector may comprise a funnel.

[0037] The first cutter can be configured to longitudinally cut the sheet of aerosol-generating material to produce a plurality of strands of aerosol-generating material, each strand having a width substantially within the range of 0.25-3 mm, or substantially within the range of 0.5-1.5 mm.

[0038] The apparatus may include a coating device configured to coat the rod of aerosol-generating material with a coating material.

[0039] The covering material may be or may include one or both of paper and aluminum foil.

[0040] The apparatus may be configured to produce aerosol-forming material rod segments having outer diameters substantially within the range of 5.4-7.8 mm, or substantially within the range of 6.7-7.8 mm.

[0041] The aerosol-generating material rod segment may be a consumable item of the aerosol generating device.

[0042] According to a third aspect of the present invention, there is provided an article of manufacture comprising a rod of aerosol-generating material, the rod of aerosol-generating material being formed from a plurality of longitudinal strands of aerosol-generating material, each of the plurality of longitudinal strands of aerosol-generating material being substantially uncoiled.

[0043] The strands may be substantially parallel to one another.

[0044] Each of the plurality of strands may be substantially straight.

[0045] Each of the plurality of strands may have a width substantially within the range of 0.25 to 3 mm, or substantially within the range of 0.5 to 1.5 mm.

[0046] One or more of the strands may be or include tobacco.

[0047] One or more of the strands may be or include reconstituted tobacco.

[0048] One or more of the strands may include glycerol.

[0049] The article of manufacture may include a coating wrapped around a rod of aerosol-forming material.

[0050] The covering material may be or may include one or both of paper and aluminum foil.

[0051] The product may have an outer diameter substantially within the range of 5.4 to 7.8 mm, or substantially within the range of 6.7 to 7.8 mm.

[0052] The product may be a consumable product for an aerosol generating device.

[0053] Further features and advantages of the present invention will become apparent from the following description of preferred embodiments of the invention, given by way of example only, which proceeds with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0054] [Figure 1] FIG. 1 is a perspective view that shows diagrammatically an apparatus for manufacturing tobacco rod segments according to a first example. [Diagram 2] FIG. 2 is a side view that shows, in schematic form, an apparatus for producing tobacco rod segments according to a second example. [Diagram 3] FIG. 2 is a schematic perspective view of a mother reel of a tobacco sheet according to one example. [Figure 4] 1 is a flow chart that generally illustrates a process for producing tobacco rod segments, according to one example. [Figure 5a] 1A-1C are schematic diagrams illustrating the insertion of a blade heater into a tobacco rod segment, according to one example. [Figure 5b] 1A-1C are schematic diagrams illustrating the insertion of a blade heater into a tobacco rod segment, according to one example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0055] 1 , an exemplary apparatus 100 for producing tobacco rod segments 126 includes a first cutter 106, a collector 114, and a second cutter 124. The first cutter 106 is configured to longitudinally cut the tobacco sheet 104 to produce a plurality of tobacco strands 112. The collector 114 is configured to collect the strands 112 to form a tobacco rod 120, each of the plurality of tobacco strands 112 being substantially unwound. The second cutter 124 is configured to cut the tobacco rod 120 into segments to produce the tobacco rod segments 126.

[0056] As described in more detail below, the collector 114 is configured to collect the strands 112 to form a tobacco rod 120 in which each of the multiple tobacco strands 112 is substantially unwound, allowing for the production of a number of tobacco rod segments 126 into which, in use, a blade-type heater of an aerosol generating device can be easily inserted (see, for example, Figures 5a and 5b), which facilitates the passage of volatile material therethrough, thereby reducing loss of volatile material when the tobacco rod segments 126 are heated.

[0057] Returning to FIG. 1, the first cutter 106 is configured to cut the tobacco sheet 104 .

[0058] The tobacco sheet 104 may be a sheet or web of reconstituted tobacco. The reconstituted tobacco sheet may be produced, for example, by a paper-making process, band casting, or extrusion. For example, the reconstituted tobacco sheet may be paper reconstituted tobacco. Paper reconstituted tobacco refers to tobacco material formed by a process in which tobacco raw material is extracted with a solvent to obtain an extract of soluble substances and a residue containing fibrous material, and then (usually after concentration and optionally after further processing) the extract is recombined with fibrous material from the residue by depositing the extract on the fibrous material (usually after purification of the fibrous material and optionally with the addition of a portion of non-tobacco fibers). The recombination process is similar to the process of making paper. The raw material may include or consist of one or more of tobacco shreds, tobacco stems, and / or whole tobacco leaves. Fragments, fines, and culls may alternatively or additionally be used as raw materials. It is understood that reconstituted tobacco sheet 104 formed by any process may be used.

[0059] The reconstituted tobacco sheet 104 is malleable.

[0060] The tobacco sheet 104 may be provided from a bobbin 102 of tobacco sheet 104. The bobbin 102 comprises a spindle 102a on which a continuous tobacco sheet 104 is wound. The bobbin 102 is arranged to rotate to feed the tobacco sheet 104 from the bobbin 102 to a first cutter 106 along a sheet-feed direction (arrow A). In some examples, the apparatus 100 may be arranged to drive the bobbin 102 to rotate. In other examples, the bobbin 102 may be allowed to rotate freely and the tobacco sheet 104 may be drawn from the bobbin 102 by a downstream apparatus component, for example a roller or drive belt (not shown in FIG. 1 ) may rotate the bobbin.

[0061] The tobacco sheet 104 may include glycerol. For example, the reconstituted tobacco sheet 104 may be impregnated with or otherwise formed with glycerol. When heated, the glycerol may volatilize to form an aerosol, which may enhance the user experience of an aerosol generating device or any suitable "heat-not-burn" device in which the tobacco rod segment 126 may be used.

[0062] The tobacco sheet 104 is of known dimensions. For example, the tobacco sheet 104 fed from the bobbin 102 may have a constant and known width and thickness. For example, the tobacco sheet 104 may be of a given, constant mass per unit length. This can ensure that the tobacco rod segments 126 produced have a constant weight per unit length. Thus, the use of a tobacco sheet 104 of known (and constant) dimensions allows for weight control of the resulting tobacco rod segments 126 without the need for a weighing system to weigh the tobacco rod 120 or tobacco rod segments 126.

[0063] The first cutter 106 is arranged to longitudinally cut the tobacco sheet 104 to produce a plurality of tobacco strands 112. The produced tobacco strands 112 are elongated. The first cutter 106 comprises a cutter array 106a. The cutter array 106a comprises a plurality of circular disks 108 arranged along an axis 110. Each disk 108 has a sharpened blade. The axis 110 is arranged substantially perpendicular to the sheet infeed direction (arrow A), and each disk 108 is arranged such that the cutting blade of the disk 108 runs substantially parallel to the sheet infeed direction (arrow A). Each disk 108 is arranged to longitudinally cut the tobacco sheet 104, i.e. to cut the tobacco sheet 104 along its length, as the tobacco sheet 104 is fed through the first cutter 106. For example, the cutter array 106a may cut the tobacco sheet 104 against a support surface (not shown) disposed on an opposite side of the tobacco sheet 104 from the cutter array 106a. The plurality of disks 108 function to cut the tobacco sheet 104 into a plurality of substantially parallel elongated tobacco strands 112.

[0064] The number of tobacco strands 112 produced depends on the number of cutting disks 108 included in the cutter array 106a. For example, a cutter array 106a with eight cutting disks 108 will produce a total of nine tobacco strands. In general, a cutter array 106a with n cutting disks 108 will produce n+1 tobacco strands 112.

[0065] The strand width of the tobacco strands 112 is determined by the spacing between successive cutting disks 108. The disks 108 are equally spaced along the length of the shaft 110 and along the width of the tobacco sheet 104, such that each of the elongated tobacco strands 112 is of substantially equal width. This arrangement may help ensure consistency of the tobacco rod segments 126 produced. The cutter array 106a may be arranged such that each of the plurality of elongated tobacco strands 112 has a width substantially within the range of 0.25-3 mm, or substantially within the range of 0.5-1.5 mm. This arrangement would correspond, for example, to cutting disks 108 spaced apart by substantially 0.25-3 mm, or substantially 0.5-1.5 mm.

[0066] The first cutter 106 is adjustable to adjust the number and / or width of the strands 112 into which the tobacco sheet 104 is cut. For example, the cutting disks 108 may be adjustable on the axis 110 to adjust the number of disks 108 on the axis and / or to adjust the spacing between each disk 108 along the axis 110. As another example, the cutter array 106a may be replaceable with another cutter array 106a having a different number of disks 108 and / or different spacing between the disks 108. This allows flexibility in the number and / or width of the strands 112 of the tobacco rod segments 126 produced, and therefore the properties of those tobacco rod segments 126.

[0067] The collector 114 is configured to collect a plurality of tobacco strands 112 to form a tobacco rod 120. The collector 114 is a funnel 114. The funnel 114 includes a funnel portion 116 and a stem portion 118. The funnel portion 116 and the stem portion 118 are circular in cross section and coaxial. The funnel 114 is symmetrical about its axis. The funnel portion 116 tapers from a relatively wide mouth 116a to a relatively narrow stem portion 118. The tobacco strands 112 pass through the funnel 114 from the funnel portion 116 to the stem portion 118. As the tobacco strands 112 pass through the funnel 114, the narrowing diameter of the funnel portion 116 collects the strands 112 to form a tobacco rod 120.

[0068] The funnel 114 is aligned with the center of the plurality of tobacco strands 112. As such, the funnel 114 collects each strand 112 substantially laterally to form a rod 120. Specifically, the funnel 114 collects each strand 112 toward an axis that is central to the plurality of strands 112. The funnel 114 aligned with the tobacco strands 112 in this manner may enable the strands 112 to be collected evenly and centrally within the funnel 114.

[0069] The funnel 114 is aligned with the center of the tobacco sheet 104. Specifically, the axis along which the strand 112 is collected by the funnel 114 lies in a first plane that contains the feed direction (arrow A) and is perpendicular to a second plane defined by the strands 112 before they are collected. This orientation may help ensure uniform tension between the strands 112 as they are collected by the funnel 114.

[0070] The funnel 114 exerts a substantially lateral force on the strands 112 as they pass through the funnel 114, the lateral force being substantially directed toward a center of the plurality of strands 112. The tobacco strands 112 are unwound when collected, i.e., remain substantially unwound when collected (i.e., during collection), i.e., when passing through the funnel 114. For example, the tobacco strands 112 are not twisted, spiraled, wound, or entangled with one another when collected, e.g., do not form a twisted, spiraled, or helical structure or shape when collected. Thus, the funnel 114 collects the strands 112 to form a tobacco rod 120 in which each of the plurality of tobacco strands 112 is substantially unwound. The tobacco strands 112 remain substantially parallel to one another as they are collected, i.e., when passing through the funnel 114. Thus, the funnel 114 collects the strands 112 to form a tobacco rod 120 in which the plurality of tobacco strands 112 are substantially parallel to one another. The tobacco strands 112 are not substantially bent, corrugated, pleated, deformed, etc. as they are collected, and remain substantially straight as they are collected, i.e., as they pass through the funnel 114. Thus, the funnel 114 collects the strands 112 to form a tobacco rod 120 in which each of the plurality of tobacco strands 112 is substantially straight.

[0071] The apparatus 100 includes a coating apparatus 122 configured to coat the tobacco rod 120 with a coating material 128. The coating apparatus 122 may be the same as or similar to the coating apparatus 222 described below with reference to, for example, FIG. 2. Briefly, the coating apparatus 122 wraps a continuous sheet of coating material 128 around the continuous tobacco rod 120 and applies an adhesive to the coating material 128 to seal the coating material 128 in place around the rod 120. The coating material may be, or may include, for example, one or both of paper and aluminum foil. For example, the coating material may be a laminate of aluminum foil and paper. This laminate may help prevent ignition of the tobacco rod segment 126, and may be useful, for example, when the tobacco rod segment 126 is to be used as a consumable in a "heat-not-burn" device, or a tobacco heating product device, or an aerosol generating device.

[0072] The outer diameter of the tobacco rod 120 once rolled may depend, for example, on the mass per unit length of the tobacco sheet 104 used, the thickness and width of the tobacco sheet 104 used, the level of compression of the garniture during rod formation, and / or the characteristics of, for example, the coating apparatus 122 and / or coating material 128 used. The outer diameter of the coated tobacco rod 120 may be constant during a given operating cycle of the apparatus 100. The outer diameter may be, for example, substantially within the range of 5.4-7.8 mm, or substantially within the range of 6.7-7.8 mm.

[0073] The second cutter 124 is configured to cut the tobacco rod 120 (e.g., after being coated with the coating material 128 by the coating device 122) into segments 126 to produce the tobacco rod segments 126. The second cutter 124 cuts the tobacco rod 120 transversely to produce several lengths of the tobacco rod 120 (i.e., the tobacco rod segments 126). The second cutter 124 can, for example, comprise a blade (not shown) whose cutting surface (not shown) is disposed perpendicular to the length of the tobacco rod 120 and can be controlled to slice the tobacco rod 120. The tobacco sheet 104, the tobacco strands 112, and the tobacco rod 120 can pass through the device 100 at a constant speed. The second cutter 124 can be configured to cut the continuous tobacco rod 120 at regular time intervals to produce the tobacco rod segments 126 of equal length. The tobacco rod segments 126 can, for example, have a length in the range of 12 to 60 mm. For example, the tobacco rod segment 126 can be 12 mm in length, or can be 42 mm in length, or can be 60 mm in length. Other lengths can be obtained, for example, by varying the spacing between successive cuts.

[0074] In use, the first cutter 106 cuts the tobacco sheet 104 longitudinally to produce a plurality of tobacco strands 112. The collector 114 collects the strands 112 to form a tobacco rod 120, each of the plurality of tobacco strands 112 being substantially unwound, e.g., substantially straight. The second cutter 124 cuts the tobacco rod 120 into segments to produce tobacco rod segments 126.

[0075] The apparatus 100 thereby produces tobacco rod segments 126, each of which includes a tobacco rod 130 formed from a plurality of longitudinal strands of tobacco (not shown), i.e., strands of tobacco extending along the length of the tobacco rod 130, each of the plurality of longitudinal strands (not shown) being substantially unwound.

[0076] The first cutter 106 may be adjustable to cut the tobacco sheet 104 into a plurality of strands 112, or to not cut the tobacco sheet 104 at all. In use, when the apparatus 100 is first used with a given tobacco sheet 104, the first cutter 106 may be adjusted to not cut the tobacco sheet 104 into a plurality of strands 112. The uncut tobacco sheet 104 may then be fed through a funnel 114 to form a tobacco rod (not shown) of uncut tobacco sheet 104, and the resulting rod (not shown) of uncut tobacco sheet 104 may be fed through a coating apparatus 122 and a second cutter 124 to form segments (not shown) of the rod (not shown) of uncut tobacco sheet 104. After the formation of the rod (not shown) of uncut tobacco sheet 104 has stabilized, for example after several segments (not shown) of the rod (not shown) of uncut tobacco sheet 104 have been produced, the first cutter 106 may be adjusted to cut the tobacco sheet 104 into a plurality of strands 112 as described above to produce tobacco rod segments 126 each including a tobacco rod 130 formed from the plurality of strands 112 of tobacco, each of which is substantially unwound. The several segments (not shown) of the rod (not shown) of uncut tobacco sheet 104 produced before the tobacco rod segment 126 including the plurality of strands 112 of tobacco is produced may be discarded. This may allow for easier and more consistent setup of the apparatus 100 when installing or replacing the tobacco sheet 104 (e.g., the bobbin 102 of the tobacco sheet 104).

[0077] Referring now to Figure 2, there is shown diagrammatically another example of an apparatus 200 for producing tobacco rod segments 226. Components of the apparatus 200 shown in Figure 2 that are the same as or similar to components already described with reference to Figure 1 will not be described again in detail, but these components are given the same reference numerals as in Figure 1, but increased by 100.

[0078] The apparatus 200 includes a first cutter 206, a collector 214, and a second cutter 224. The first cutter 206 is configured to longitudinally cut the tobacco sheet 204 to produce a plurality of tobacco strands 212. The collector 214 is configured to collect the strands 212 to form a tobacco rod 220, each of the plurality of tobacco strands 212 being substantially unwound, e.g., substantially straight. The second cutter 224 is configured to cut the tobacco rod 220 into segments 226 to produce the tobacco rod segments 226.

[0079] The apparatus 200 includes a bobbin 202 of tobacco sheet 204. The tobacco sheet 204 is fed from the bobbin 202 of tobacco sheet 204 towards a first cutter 226.

[0080] The apparatus 200 comprises a tensioning device 205 including a plurality (four in this example) of tensioning rollers 205a, 205b, 205c, 205d. The tobacco sheet 104 is fed from the bobbin 202 and over the tensioning rollers 205a, 205b, 205c, 205d, before being fed in a sheet-feed direction (arrow A) to a first cutter 206. This may help to ensure that the tobacco sheet 204 is under sufficient tension (e.g. longitudinal tension) to be effectively cut by the first cutter 206. This may also help to stretch the tobacco sheet 104, for example to remove any wrinkles that may be present in the tobacco sheet 104.

[0081] The first cutter 206 comprises two cutting arrays 206a, 206b arranged to contact opposing major surfaces of the tobacco sheet 204. Each cutting array 206a, 206b may be the same as or similar to the cutting array 106a described above with reference to FIG. 1. The cutting arrays 206a, 206b are arranged to press against each other against the tobacco sheet to longitudinally cut the tobacco sheet 204 into a plurality of tobacco strands 112 (the plurality of tobacco strands 112 are distributed along a plane extending into the page in FIG. 2). For example, the cutting arrays 206a, 206b may be offset from each other in a direction perpendicular to the feeding direction of the tobacco sheet (i.e., offset in the direction extending into the page in FIG. 2).

[0082] The collector 214 comprises a funnel 214 including a funnel portion 216 and a stem portion 218. The axis of the funnel 114 is at the center of the plurality of tobacco strands 112 and lies in the plane in which the plurality of tobacco strands are distributed. The plurality of tobacco strands 112 are collected as they pass through the funnel 214 to form a tobacco rod 220.

[0083] The apparatus 200 includes a coating apparatus 222 configured to coat the tobacco rod 220 with a coating material 228. The coating apparatus 222 may be or include, for example, a rod making machine known in the art, such as a KDF (moving flow medium) filter rod making machine, for controlling the orientation and tension of the coating material 228.

[0084] The coating apparatus 222 includes a drive belt 246 , a coating material bobbin 252 , a garniture 240 , a bonding section 242 , and a heater section 244 .

[0085] The drive belt 246 is a continuous strip of flexible material looped around and supported by two rollers 248a, 248b. The drive belt 246 is held taut between the rollers 248a, 248b to define a generally flat drive belt top surface 246a. The rollers 248a, 248b are arranged to rotate about their respective axes such that the drive belt surface 246a can translate between the two rollers 248a, 248b. One or both of the rollers 248a, 248b are driven to rotate about their axes (clockwise in FIG. 2) to translate the drive belt top surface 246a (from left to right in FIG. 2).

[0086] The covering material bobbin 252 supplies a continuous sheet or web of covering material 228 to the drive belt upper surface 246a. The covering material 228 can be fed onto the drive belt upper surface 246a by friction of the moving drive belt upper surface 246a against the sheet of covering material 228. In response, the sheet of covering material 228 moves on the drive belt upper surface 246a (from left to right in FIG. 2 ). The tobacco rod 220 is fed onto the sheet of covering material 228 on the drive belt upper surface 246a. At least in part, friction between the moving covering material 228 and the tobacco rod 220 can cause the tobacco rod 220 to be fed onto the covering material 228 and therefore to move with the covering material 228. Alternatively, or in addition, the tobacco rod 220 can be fed onto the moving covering material 228 by another means, such as one or more infeed rollers. In either case, the tobacco rod 220 is fed over the covering material 228 so that the tobacco rod 220 moves together (i.e., at the same speed) with the covering material 228, which in turn moves together (i.e., at the same speed) with the drive belt upper surface 246a.

[0087] A garniture 240, known per se, wraps the covering material 228 around the tobacco rod 220 as they pass through the garniture 240. The garniture 240 wraps the covering material 228 around the tobacco rod 220. The garniture wraps the covering material 228 around the tobacco rod 220 such that the covering material 228 overlaps itself (not shown) and covers slightly more than the circumference of the tobacco rod 120.

[0088] In the bonding section 242, adhesive is applied to the covering material 228 to secure the covering material 228 in place around the tobacco rod 220. Specifically, in the bonding section 242, adhesive is applied where the covering material 228 overlaps itself to secure the covering material 228 to itself around the tobacco rod 220.

[0089] The heater section 244 heats the tobacco rod 220 to aid in drying and / or curing the adhesive. This helps ensure that the adhesive is sufficiently dried / cured before the tobacco rod is cut into the tobacco rod segments 226.

[0090] The second cutter 224 is configured to cut the tobacco rod 220 into segments to produce tobacco rod segments 226. The second cutter 224 may be the same as or similar to the second cutter 124 described above with reference to FIG.

[0091] In use, the second cutter 206 cuts the tobacco sheet 204 longitudinally to produce a plurality of tobacco strands 212. The collector 214 collects the strands 212 to form a substantially unwound tobacco rod 220, each of the plurality of tobacco strands 212. The second cutter 224 cuts the tobacco rod 220 into segments to produce tobacco rod segments 226.

[0092] The apparatus 200 thereby produces tobacco rod segments 226, each of which includes a tobacco rod 230 formed from a plurality of longitudinal strands of tobacco (not shown), i.e., strands of tobacco extending along the length of the tobacco rod 230, each of the plurality of longitudinal strands (not shown) being substantially unwound, e.g., substantially straight.

[0093] Similar to what was described with reference to the apparatus 100 of Figure 1, the first cutter 206 of the apparatus 200 of Figure 2 may be adjustable to cut the tobacco sheet 104 into a plurality of longitudinal strands 112, or to not cut the tobacco sheet 104 at all. As discussed above, this may allow for easier and more consistent set-up of the apparatus 200 when installing or replacing the tobacco sheet 204 (e.g., the bobbin 202 of tobacco sheet 204).

[0094] As mentioned above, in some examples, the tobacco sheet 104,204 is provided from a bobbin 102,202 of tobacco sheet 104,204.

[0095] 3, a bobbin 302a of tobacco sheet 304, which may be used, for example, as the bobbin 102, 202 described above with reference to Figures 1 and 2, may be obtained from a mother reel 370 of tobacco sheet 304. The mother reel 370 may be transversely scored (see dashed line 372) to produce the bobbin 302a of tobacco sheet 304.

[0096] The mother reel 307 can be scored to produce bobbins 302a having a particular width W. This allows the tobacco sheet 304 of the bobbins 302a to have a particular mass per unit length, and therefore the produced tobacco rod segments (not shown in FIG. 3 ) to have a particular mass per unit length. Thus, at the start of the production process, a desired mass per unit length of the tobacco rod segments (not shown in FIG. 3 ) can be selected. The bobbin width W can then be determined based on the selected mass per unit length of the tobacco rod segments (not shown) and based on the known mass per unit length of the tobacco sheet 304 of the mother reel 370. For example, the mass per unit area (also called basis weight) of the tobacco sheet 304 can be 100 g / m 2 The mother reel 370 may then be slit to produce bobbins 302a having the determined bobbin width W. The bobbins 302a may then be used, for example, in the apparatus 100, 200 described above with reference to Figures 1 and 2 to produce tobacco rod segments (not shown in Figure 3) having a desired mass per unit length. The mother reel 370 may then be slit several times to produce bobbins 302b, 302c, 302d, 302e, for example, with the same or different bobbin widths W, as desired. This may allow for convenient and less expensive control of the mass per unit length of the tobacco rod segments (not shown in Figure 3) produced.

[0097] Figure 4 shows a schematic flow chart of a process for producing tobacco rod segments, according to one example. For example, the process can be carried out using the apparatus 100, 200 described above with reference to Figures 1 and 2, respectively. Accordingly, the reference numerals used in Figures 1 and 2 will be used below where appropriate.

[0098] In step S402, the process includes longitudinally cutting the tobacco sheet 104,204 to produce a plurality of tobacco strands 112,212.

[0099] The tobacco sheet 104, 204 may have a substantially constant mass per unit length, may be a reconstituted tobacco sheet, and / or may include glycerol.

[0100] The process may include, prior to step S402, providing a tobacco sheet 104, 204 from a bobbin 102, 202 of tobacco sheet 104, 204. The process may also include providing a mother reel 307 of tobacco sheet 104, 204, 304, and slitting the mother reel to produce bobbins 102, 202, 302a. The process may itself include selecting a mass per unit length of the tobacco rod segment 126, 226, determining a bobbin width W based on the mass per unit area of ​​the tobacco sheet 104, 204, 304 and based on the selected mass per unit length of the tobacco rod segment, and slitting the mother reel 307 to produce bobbins 102, 202, 302a having the determined bobbin width W.

[0101] The process may include, prior to step S402, feeding the tobacco sheet 104, 204 in the sheet-feed direction A. In this case, cutting the tobacco sheet 104, 204, 304 in S402 may include cutting the tobacco sheet 104, 204, 304 substantially parallel to the sheet-feed direction A.

[0102] Step S402 may include cutting the tobacco sheet 104, 204 at a determined number of cuts and / or cut spacing. The number of cuts and / or cut spacing may be determined by selecting a number of strands 112, 212 and / or a width of the strands 112, 212 of the tobacco rod segment 126, 226 and determining the number of cuts and / or cut spacing based on the selected number of strands and / or strand width. Each of the plurality of strands may have a width substantially within the range of 0.25-3 mm, or substantially within the range of 0.5-1.5 mm.

[0103] In step S404, the process includes collecting the strands 112, 212 to form a tobacco rod 112, 212 in which each of the plurality of tobacco strands 112, 212 is substantially unwound. Step S404 includes collecting the strands 112, 212 to form a tobacco rod 120, 220 in which the plurality of tobacco strands 112, 212 are substantially parallel to one another and / or substantially straight. Step S404 may include collecting each of the elongated strands 112, 212 substantially transversely toward an axis central to the plurality of strands 112, 212 to form the rod 120. The axis along which the strands 112, 212 are collected lies in a plane that includes the feed direction A and is perpendicular to a plane defined by the plurality of strands 112, 212 prior to collection. Step S404 may include feeding the strands 112, 212 through a funnel 114, 214 to collect the strands 112, 212.

[0104] The process may include feeding the tobacco sheet 104, 204 through a funnel 114, 214 to form a tobacco rod (not shown) of the uncut tobacco sheet 114, 214 before said cutting of the tobacco sheet 104, 204 is applied in step S402.

[0105] In step S406, the process includes cutting the tobacco rod 120 (of the tobacco strands 112, 212) into segments to produce said tobacco rod segments 126, 226.

[0106] The process may include coating the tobacco rod 120, 220 with a coating material 128, 228 prior to S406. The coating material 128, 228 may be or include one or both of paper and aluminum foil. For example, the coating material 128, 228 may be a laminate of paper and aluminum foil. The tobacco rod segments 126, 226 (which are coated) may each have an outer diameter substantially within the range of 5.4-7.8 mm, or substantially within the range of 6.7-7.8 mm. The tobacco rod segments 126, 226 may be consumables for the aerosol generating device.

[0107] Figure 5a illustrates a schematic representation of an example tobacco rod segment 526 mounted on a blade heater 580 of an aerosol generating device (not shown). Specifically, Figure 5a illustrates the tobacco rod segment 526 before it is mounted on the blade heater 580, and Figure 5b illustrates the tobacco rod segment 526 after it is mounted on the blade heater 580.

[0108] The tobacco rod segment 526 may be the same as or similar to the tobacco rod segments 126, 226 described above with reference to Figures 1 and 2, respectively, for example. The tobacco rod segment 526 may be manufactured, for example, by the apparatus 100, 200 described above with reference to Figures 1 and 2, respectively, and / or by the process described above with reference to Figure 4.

[0109] 5a and 5b, the tobacco rod segment 526 includes a tobacco rod 530 formed from a plurality of longitudinal tobacco strands 512 (i.e., a plurality of tobacco strands 512 extending along the length of the tobacco rod 530), each of the plurality of longitudinal strands 512 being substantially unwound. The plurality of strands 512 are substantially parallel to one another, substantially straight, and each extend substantially along the entire length of the tobacco rod segment 526. The tobacco rod segment 526 includes a covering material 528 wrapped around the tobacco rod 530.

[0110] The blade heater 580 may take the form of an elongated rectangular parallelepiped that is relatively thin compared to its width or length. The width of the blade heater 580 is less than the outer diameter of the tobacco rod segment 526. The blade heater 538 may comprise a resistive heater (not shown) that is powered by a battery (not shown) of a handheld aerosol generating device (not shown) and is controllable by a user to heat. In some examples, the blade heater 580 may have a pointed end (not shown) to facilitate insertion of the blade heater into the tobacco rod segment 526.

[0111] The blade heater 580 can be inserted into the tobacco rod segment 526 (arrow B in FIG. 5a), or similarly, the tobacco rod segment 526 can be pushed over the blade heater 580, such that the blade heater 580 extends longitudinally into the tobacco rod segment 526 (as shown in FIG. 5b).

[0112] The plurality of longitudinal strands 512 of the tobacco rod segment 526 are substantially unwound, which allows for easy insertion of the blade heater 580 into the tobacco rod segment 526, since the unwound longitudinal strands 512 offer relatively little resistance to the longitudinal insertion of the blade heater 580. This allows for easy installation or replacement of the tobacco rod segment 528 onto the blade heater 580, which may be a consumable part of the overall aerosol generating device (not shown). This reduces damage to the tobacco rod segment 526 when inserting the blade heater 580, and allows for more consistent and proper positioning of the tobacco rod segment 526 relative to the blade heater 580. For example, this tobacco rod segment can be contrasted with a virtual tobacco rod segment that includes wound longitudinal strands, e.g., configured in a helical configuration, in which case insertion of a blade heater would be limited by the strands intersecting the insertion path, and the blade heater may deform and compress a portion of the tobacco, making installation of the virtual tobacco rod segment relatively difficult and inconsistent, and potentially resulting in an increased risk of damaging the virtual tobacco rod segment.

[0113] The multiple longitudinal strands 512 of the tobacco rod segment 526 are similarly parallel to one another and / or straight, allowing for easier insertion of the blade heater 580 into the tobacco rod segment 526. In this case, the axis of insertion of the blade heater 580 is parallel to the axes of each of the longitudinal strands 512, and the tip of the blade heater 580 is presented with only a small surface area of ​​tobacco when it is inserted. As described above, easy installation or replacement of the tobacco rod segment 526 may be achieved and / or damage to the tobacco rod segment 526 may be reduced, and / or more consistent and proper positioning of the tobacco rod segment 526 relative to the blade heater 580 may be possible. This tobacco rod segment can be contrasted with a virtual tobacco rod segment that includes, for example, randomly oriented strips of cut rag tobacco, or that includes a sheet of crinkled or corrugated tobacco, where insertion of a blade heater may deform and compress portions of the cut rag tobacco, or edges of the crinkled or corrugated sheet of tobacco, thereby making installation of the virtual tobacco rod segment relatively difficult and inconsistent, and may result in an increased risk of damage to the virtual tobacco rod segment.

[0114] After the tobacco rod segment 526 is inserted onto a blade heater 580 of the overall aerosol generating device (not shown), the blade heater 580 can be controlled to heat (e.g., by resistive heating internal to the blade heater 580) to heat (but not burn) the tobacco strands 512. This can release components (e.g., volatile components) from the tobacco strands 512. As discussed above, the tobacco strands 512 can contain glycerol, which can be volatilized when heated by the blade heater 580 to form an aerosol.

[0115] The plurality of substantially unwrapped longitudinal strands 512 of the tobacco rod segment 526 establish a corresponding plurality of substantially unwrapped longitudinal passages 513 therethrough between the plurality of longitudinal strands 512. These passages 513 facilitate the transport of volatile materials (e.g., volatile components of the tobacco itself or volatile glycerol, or both) released from the tobacco strands 512 upon heating through the tobacco rod segment 526. This may reduce losses of such materials as they pass through the tobacco rod segment 526, e.g., the relatively short continuous passages 513 may reduce condensation of volatile materials on portions of the tobacco rod segment 526. This tobacco rod segment may be contrasted with a hypothetical tobacco rod segment that includes, e.g., randomly oriented strips of cut rag tobacco (as in a standard cigarette), in which the path length of volatile materials to exit the hypothetical tobacco rod is relatively long. This tobacco rod segment may also be contrasted with a hypothetical tobacco rod segment comprising a plurality of wrapped longitudinal strands, in which the path length of volatilized material to exit the hypothetical tobacco rod is also relatively long.

[0116] As discussed above, the covering material 528 may be or include, for example, paper and / or aluminum foil, such as a laminate of paper and aluminum foil, which may be useful in preventing ignition of the tobacco rod segment 526 by the blade heater 580.

[0117] Each of the plurality of strands 512 may have a width substantially within the range of 0.25-3 mm, or substantially within the range of 0.5-1.5 mm. The tobacco rod segment 526 may have an outer diameter substantially within the range of 5.4-7.8 mm, or substantially within the range of 6.7-7.8 mm. This may allow a relatively larger blade heater 580 to be used, thereby increasing the heating surface area of ​​the blade heater 580 and therefore the rate at which tobacco can be heated and / or the amount of tobacco that can be heated by the blade heater 580.

[0118] The above examples should be understood as illustrative examples of the present invention.

[0119] For example, although in the above examples the tobacco sheets 104, 204, 304 are described as being sheets of reconstituted tobacco, this need not be the case and in other examples the tobacco sheets 104, 204, 304 may be made from other materials. The tobacco sheets 104 may or may not include glycerol and may include other materials, such as additives or enhancers, in place of or in addition to glycerol.

[0120] In some of the above examples, the tobacco sheet 104, 204, 304 is described as being supplied from a bobbin 102, 202, 302, but this does not necessarily have to be the case and may, for example, be supplied from a separate device or source (not shown), which does not necessarily form part of the apparatus 100, 200.

[0121] In the above examples, the first cutter 106, 206 is described as comprising an array of circular discs 108, however this is not necessarily the case and in other examples the first cutter 106, 206 may be any suitable cutter or cutting means for longitudinally cutting the tobacco sheet 104 to form a plurality of tobacco strands 112, 212.

[0122] Although in the above examples the collector 114, 214 is described as a funnel 114, 214 having a circular cross section, this need not be the case and in other examples the collector 114, 214 may take another shape. For example, the collector 114, 214 may be or include a so-called stuffer jet (not shown) arranged to feed and collect the plurality of strands 112, 212 by using air pressure. As another example, the funnel 114, 214 need not be circular in cross section but may have another cross section, such as rectangular or square, for example. In fact, the collector may be any suitable means for collecting the strands 112, 212 to form a tobacco rod 120, 220 in which each of the plurality of tobacco strands 112, 212 is substantially unwound.

[0123] Although in the above examples the apparatus 100, 200 comprises a coating device 122, 222 arranged to coat the tobacco rod 120, 220 with a coating material 128, 228 before the tobacco rod is cut by the second cutter 124 into segments 126, 226 to produce the tobacco rod segments 126, 226, this does not necessarily have to be the case and in other examples the apparatus 100, 200 may not comprise a coating device 122, 222 and the (uncoated) tobacco rod 120, 220 may be cut by the second cutter 124, 224 into segments 126, 226 to produce the tobacco rod segments 126, 226. In this example, the tobacco rod segments 126, 226 produced do not necessarily have to comprise a coating material 128, 228.

[0124] It should be understood that Figures 1 and 2 illustrate generally an example of an apparatus for producing tobacco rod segments 126, 226 according to one example, and that in other examples, the apparatus 100, 200 may include additional (or fewer) components, such as one or more feed rollers for feeding the tobacco sheet 104, 204 and / or the multiple strands 112, 212, one or more tension rollers for tensioning the tobacco sheet 104, 204 and / or the multiple strands 112, 212, and / or one or more drive belts for transporting the tobacco sheet 104, 204 and / or the multiple strands 112, 212 and / or the tobacco rod 120, 220 and / or segments of the tobacco rod 120, 220.

[0125] While in the above examples the tobacco strands 112, 212 are described as being straight and parallel to one another, this need not necessarily be the case and in other examples the tobacco strands 112, 212 may not be substantially straight and / or may not be substantially parallel to one another. For example, the tobacco strands 112, 212 may be subjected to processing to include longitudinal waves or wrinkles or zigzags, etc., or indeed the tobacco sheet 104 may essentially include longitudinal waves or wrinkles or zigzags, etc., or may be processed to have such a shape or form. Indeed the tobacco rod segment 126, 226 may include any tobacco rod 130, 530 formed from a plurality of longitudinal strands 112, 212 of tobacco, each of which is substantially unwound.

[0126] In the above examples, the tobacco rod segment 126, 226, 526 is described as being produced by the apparatus 100, 200 and / or by the process described with reference to FIG. 3, however this need not necessarily be the case and in other examples any suitable method or apparatus may be used for producing the tobacco rod segment 126, 226, 526 including a tobacco rod 130, 530 formed from a plurality of longitudinal strands 112, 212, 512 of tobacco, each of the plurality of longitudinal strands 112, 212, 512 being substantially unwound.

[0127] While in some of the above examples the tobacco rod segment 126, 226, 526 is described as a consumable, such as a "non-combustion heating" device that includes a blade heater 580, this need not be the case and in other examples the tobacco rod segment 126, 226, 526 may be used in other devices and / or for other purposes. For example, the tobacco rod segment 126, 226, 526 may be a consumable in any aerosol generating device (e.g., a tobacco heating product or device that does not necessarily include a blade heater 580).

[0128] Although in the above examples the tobacco sheet 102, 204, 304 is described as being or including tobacco (e.g. reconstituted tobacco), this need not necessarily be the case, and in other examples the sheet 104, 204, 304 may be or include a sheet of any aerosol-generating material. The aerosol-generating material may be a material that generates an aerosol when heated, for example by the blade heater 580 of the overall aerosol generating device. For example, the sheet 104, 204, 304 of aerosol-generating material may be or include a flavoring base. The flavoring base 104, 204, 304 may include a flavoring, such as a tobacco flavoring or other flavoring, and / or may include glycerol or other additives or enhancers instead of or in addition to glycerol. The flavoring base with or without glycerol or other additives may be heated to generate an aerosol.

[0129] It may be noted that, in general, an aerosol is a colloid of fine solid particles or liquid droplets in air or other gas, and a colloid is a state of matter in which microscopically dispersed insoluble particles are suspended throughout another substance. Vapor, on the other hand, is a substance in the gas phase at a temperature below a critical temperature, which means, for example, that a vapor can be condensed into a liquid by increasing its pressure without lowering the temperature. It is to be understood that, as used herein, the term aerosol includes aerosol and / or vapor.

[0130] It will be appreciated that in some examples, the aerosol-generating material rod segments 126, 226, 526 can be produced from a sheet of aerosol-generating material 102, 204, 304 as described above for the sheet of reconstituted tobacco 102, 204, 304, for example, by longitudinally cutting the sheet of aerosol-generating material 102, 204, 304 to produce a plurality of strands 112, 212, 512 of aerosol-generating material; by collecting the strands 112, 212, 512 to form a rod 130, 530 of aerosol-generating material in which the plurality of strands 112, 212, 512 of aerosol-generating material are substantially unwound; and by cutting the rod 130, 530 of aerosol-generating material into segments 126, 226, 526 to produce the aerosol-generating material rod segments 126, 226, 526.

[0131] Similarly, it will be appreciated that a product can include a rod 130, 530 of aerosol-generating material, the rod 130, 530 of aerosol-generating material being formed from a plurality of longitudinal strands 112, 212, 512 of aerosol-generating material, each of the plurality of longitudinal strands 112, 212, 512 of aerosol-generating material being substantially uncoiled.

[0132] It is to be understood that any feature described with respect to any one of the examples can be used alone or in combination with other features described, and can also be used with one or more features of any other of the examples, or in any combination of any other of the other examples. Moreover, equivalents and modifications not described above may also be used without departing from the scope of the invention as defined in the appended claims.

Claims

1. 1. A method of making a rod segment of aerosol-forming material, comprising the steps of: longitudinally cutting a sheet of aerosol-generating material to produce a plurality of strands of aerosol-generating material; collecting the plurality of strands of aerosol-forming material to form a rod of aerosol-forming material, each of the plurality of strands of aerosol-forming material being substantially unwound; coating the rod of aerosol-forming material with a coating material, the coating material being or including one or both of paper and aluminum foil; cutting the rod of aerosol-generating material into segments to produce the rod segments of aerosol-generating material, each of the rod segments of aerosol-generating material having a length of substantially 12 mm and an outer diameter substantially within the range of 5.4-7.8 mm, or substantially within the range of 6.7-7.8 mm; A method comprising:

2. 2. The method of claim 1, wherein the collecting step comprises collecting the plurality of strands of aerosol-forming material to form the rod of aerosol-forming material, the plurality of strands of aerosol-forming material being substantially parallel to one another.

3. 3. The method of claim 1 or 2, wherein the collecting step includes collecting the plurality of strands of aerosol-forming material to form the rod of aerosol-forming material, each of the plurality of strands of aerosol-forming material being substantially straight.

4. A method according to any one of claims 1 to 3, wherein the sheet of aerosol-forming material is a tobacco sheet.

5. The method of claim 4, wherein the tobacco sheet is a reconstituted tobacco sheet.

6. The method of any one of claims 1 to 5, wherein the sheet of aerosol-generating material comprises glycerol.

7. A method according to any preceding claim, wherein the sheet of aerosol-forming material has a substantially constant mass per unit length.

8. The method of any one of claims 1 to 7, comprising obtaining the sheet of aerosol-generating material from a bobbin of sheets of aerosol-generating material.

9. Providing a mother reel of sheets of aerosol-generating material; making the bobbin by cutting the mother reel; The method of claim 8 , comprising:

10. selecting a mass per unit length of the aerosol-forming material rod segment; determining a bobbin width based on a mass per unit area of ​​the sheet of aerosol-generating material and based on the selected mass per unit length of the rod segment of aerosol-generating material; slitting the mother reel to produce a bobbin having the determined bobbin width; 10. The method of claim 9, comprising:

11. The method comprises: selecting a number of strands and / or a strand width for the aerosol-forming material rod segment; determining a number of cuts and / or a cut spacing based on the selected number of strands and / or strand width; Including, 11. The method of claim 1, wherein the step of cutting the sheet of aerosol-generating material comprises cutting the sheet of aerosol-generating material according to the determined number of cuts and / or cutting intervals.

12. The method includes feeding a sheet of the aerosol-generating material in a sheet-feed direction; The method of any one of claims 1 to 11, wherein the step of cutting the sheet of aerosol-generating material comprises cutting the sheet of aerosol-generating material substantially parallel to the sheet-feed direction.

13. the collecting step includes collecting each of the plurality of strands of aerosol-forming material along an axis that lies in a plane; 13. The method of claim 12, wherein the plane contains the feed direction and is perpendicular to a plane defined by the plurality of strands of aerosol-forming material before collection.

14. 14. The method of claim 1, wherein the collecting step comprises collecting each of the plurality of strands of aerosol-forming material toward an axis at a center of the plurality of strands of aerosol-forming material.

15. 15. The method of any one of claims 1 to 14, wherein the collecting step comprises collecting each of the plurality of strands of aerosol-forming material substantially laterally to form the rod.

16. 16. The method of any one of claims 1 to 15, wherein the collecting step comprises directing the plurality of strands of aerosol-forming material through a funnel to collect the plurality of strands of aerosol-forming material.

17. 17. The method of claim 16, comprising, prior to said step of cutting the sheet of aerosol-forming material, feeding the sheet of aerosol-forming material through a funnel to form a rod of non-cut tobacco sheet aerosol-forming material.

18. 18. The method of any one of the preceding claims, wherein the width of each of the plurality of strands of aerosol-forming material is substantially in the range of 0.25 to 3 mm, or substantially in the range of 0.5 to 1.5 mm.

19. The method of any one of claims 1 to 18, wherein the rod segment of aerosol-generating material is a consumable part of an aerosol generating device.

20. 1. An apparatus for producing an aerosol-forming material rod segment, comprising: a first cutter configured to longitudinally cut the sheet of aerosol-generating material to produce a plurality of strands of aerosol-generating material; a collector configured to collect the plurality of strands of aerosol-forming material, each of the plurality of strands of aerosol-forming material forming a substantially unwound rod of aerosol-forming material; a second cutter configured to cut the rod of aerosol-generating material into segments to produce the rod segments of aerosol-generating material; Equipped with the apparatus comprises a coating device configured to coat the rod of aerosol-forming material with a coating material, the coating material being or including one or both of paper and aluminum foil; the second cutter is configured to cut the rod of aerosol-generating material into rod segments having a length of substantially 12 mm and an outer diameter substantially within the range of 5.4 to 7.8 mm, or substantially within the range of 6.7 to 7.8 mm.

21. 21. The apparatus of claim 20, wherein the collector is configured to collect the plurality of strands of aerosol-forming material to form the rod of aerosol-forming material, the plurality of strands of aerosol-forming material being substantially parallel to one another.

22. 22. The apparatus of claim 20 or 21, wherein the collector is configured to collect the plurality of strands of aerosol-forming material to form the rod of aerosol-forming material, each of the plurality of strands of aerosol-forming material being substantially straight.

23. Apparatus according to any one of claims 20 to 22, arranged to obtain the sheet of aerosol-generating material from a bobbin of sheets of aerosol-generating material.

24. 24. The apparatus of any one of claims 20 to 23, wherein the first cutter is adjustable to adjust the number and / or width of the plurality of strands of aerosol-forming material.

25. 25. The apparatus of claim 20, wherein the first cutter is adjustable to cut the sheet of aerosol-generating material to produce the plurality of strands of aerosol-generating material or to not cut the sheet of aerosol-generating material.

26. 26. The apparatus of claim 20, wherein the apparatus is configured to feed the sheet of aerosol-generating material in a sheet-infeed direction, and the first cutter is configured to cut the sheet of aerosol-generating material substantially parallel to the sheet-infeed direction.

27. 27. The apparatus of claim 26, wherein the collector is configured to collect each of the plurality of strands of aerosol-forming material toward an axis that lies in a first plane, the first plane including the feed direction and perpendicular to a second plane defined by the plurality of strands of aerosol-forming material before they are collected.

28. 28. The apparatus of claim 20, wherein the collector is configured to collect each of the plurality of strands of aerosol-forming material toward an axis at the center of the plurality of strands of aerosol-forming material.

29. 29. The apparatus of any one of claims 20 to 28, wherein the collector is configured to collect each of the plurality of strands of aerosol-forming material substantially laterally to form the rod.

30. Apparatus according to any one of claims 20 to 29, wherein the collector comprises a funnel.

31. 31. The apparatus of claim 20, wherein the first cutter is configured to longitudinally cut the sheet of aerosol-generating material to produce the plurality of strands of aerosol-generating material, each strand having a width substantially within the range of 0.25 to 3 mm, or substantially within the range of 0.5 to 1.5 mm.

32. 32. The apparatus of any one of claims 20 to 31, wherein the aerosol-generating material rod segment is a consumable part of an aerosol generating device.

33. 1. An article of manufacture comprising a rod of aerosol-generating material, the rod of aerosol-generating material being formed from a plurality of longitudinal strands of aerosol-generating material, each of the plurality of longitudinal strands of aerosol-generating material being substantially unwound; the article comprises a covering wrapped around the rod of aerosol-forming material, the covering being or including one or both of paper and aluminum foil; The rod of aerosol-forming material has a length of substantially 12 mm and an outer diameter substantially within the range of 5.4 to 7.8 mm, or substantially within the range of 6.7 to 7.8 mm.

34. 34. The article of claim 33, wherein the plurality of longitudinal strands of aerosol-forming material are substantially parallel to one another.

35. 35. The article of claim 33 or 34, wherein each of the plurality of longitudinal strands of aerosol-forming material is substantially straight.

36. 36. A product according to any one of claims 33 to 35, wherein each of the plurality of longitudinal strands of aerosol-forming material has a width substantially within the range of 0.25 to 3 mm, or substantially within the range of 0.5 to 1.5 mm.

37. 37. The product of any one of claims 33 to 36, wherein one or more of the plurality of longitudinal strands of aerosol-forming material is or comprises tobacco.

38. 40. The product of claim 37, wherein one or more of the plurality of longitudinal strands of aerosol-forming material is or includes reconstituted tobacco.

39. 39. The article of manufacture of any one of claims 33 to 38, wherein one or more of the plurality of longitudinal strands of aerosol-forming material comprises glycerol.

40. 40. A product according to any one of claims 33 to 39 which is a consumable for an aerosol generating device.

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