Apparatus and method for manufacturing rods made of aerosol-generating material

Abstract

To provide an apparatus for producing a rod of aerosol-generating material.SOLUTION: The apparatus comprises a first feed device adapted to supply a first web 34 of aerosol-generating material to a processing unit, a second feed device adapted to supply a second web 33 of aerosol-generating material, and a web changeover unit 35 arranged such that the supply of aerosol-generating material to the processing unit is changed from the first web of aerosol-generating material to the second web of aerosol-generating material. The web changeover unit is configured to position a leading edge of the second web of aerosol-generating material adjacently to a trailing edge of the first web of aerosol-generating material upstream of the processing unit during changeover from the first web of aerosol-generating material to the second web of aerosol-generating material.SELECTED DRAWING: Figure 2

Description

[Technical field]

[0001] The present invention relates to an apparatus and method for producing rods of aerosol-generating material, such as tobacco rods. [Background technology]

[0002] In the traditional method of cigarette manufacturing, tobacco leaves are shredded into short, fine pieces, also known as shredded tobacco. The shredded tobacco is then spread onto a continuous web of cigarette paper. A machine, also known as a cigarette maker, shreds the paper and folds it around the tobacco to form a continuous rod. The rod is cut into segments of the desired length. A filter is added to each tobacco rod and cigarettes are made.

[0003] Smoking articles, such as cigarettes and cigars, burn tobacco and produce smoke when used. Attempts have been made to provide alternatives to these smoking articles by creating products that generate compounds from tobacco or other materials without combustion. Such products include "non-combustion heating" products or tobacco heating devices or products or aerosol generating devices or products, which release compounds by heating materials such as tobacco without burning them. Summary of the Invention

[0004] According to the present invention there is provided an apparatus for producing a rod of aerosol-generating material, the apparatus comprising: a first supply device adapted to supply a first web of aerosol-generating material to the treatment unit; a second supply device adapted to supply a second web of aerosol-generating material; a web switching unit configured to switch a supply of aerosol-generating material to the treatment unit from a first web of aerosol-generating material to a second web of aerosol-generating material; The web switching unit is configured to position a leading edge of the second web of aerosol-generating material adjacent to the trailing edge of the first web of aerosol-generating material upstream of the treatment unit when switching from the first web of aerosol-generating material to the second web of aerosol-generating material.

[0005] The web switching unit may be configured to position a leading edge of a second web of aerosol-generating material into abutment with a trailing edge of the first web of aerosol-generating material.

[0006] The web switching unit may be configured to position the leading edge of the second web of aerosol-generating material relative to the trailing edge of the first web of aerosol-generating material such that a space is defined between the leading edge of the second web of aerosol-generating material and the trailing edge of the first web of aerosol-generating material.

[0007] The space may be less than 20mm, preferably less than 10mm, more preferably less than 5mm.

[0008] The web switching unit may be configured to position the first web of aerosol-generating material and the second web of aerosol-generating material adjacent to a trailing edge of the first web of aerosol-generating material without overlapping.

[0009] The web changer unit does not have to attach the second web of aerosol-generating material to the first web of aerosol-generating material.

[0010] The apparatus of the invention may further include a support configured to convey the leading edge of the second web of aerosol-generating material to the treatment unit.

[0011] The leading edge of the second web of aerosol-generating material and the trailing edge of the second web of aerosol-generating material may be complementary.

[0012] The leading edge of the second web of aerosol-generating material and the trailing edge of the first web of aerosol-generating material may be oblique to the direction of movement of the leading edges of the first web of aerosol-generating material and the second web of aerosol-generating material.

[0013] The apparatus of the present invention may further include a cutting unit arranged to cut the first web of aerosol-generating material to define the trailing edge.

[0014] The apparatus of the present invention may further include a cutting unit arranged to cut the second web of aerosol-generating material to define the leading edge.

[0015] The cutting unit may further be arranged to cut the second web of aerosol-generating material to define the leading edge.

[0016] The cutting unit may include a blade extending diagonally across the web of aerosol-generating material.

[0017] The web switching unit may include a nip drive roller configured to feed a second web of aerosol-generating material.

[0018] The web switching unit may further include sensors for detecting the position of the leading edge of the second web of aerosol-generating material and the trailing edge of the first web of aerosol-generating material.

[0019] The apparatus of the invention may further include a controller configured to adjust the nip drive rollers to position the leading edge of the second web of aerosol-generating material adjacent to the trailing edge of the first web of aerosol-generating material.

[0020] The apparatus of the present invention may further include an additional web supply unit for providing an additional web of aerosol-generating material to the treatment unit, the additional web of aerosol-generating material being positioned so as to overlap the web of aerosol-generating material in the treatment unit.

[0021] Additional web supply units are a first supply device adapted to supply a first web of aerosol-generating material to the treatment unit; a second supply device adapted to supply a second web of aerosol-generating material; a web switching unit configured to switch the supply of aerosol-generating material to the treatment unit from the first web to the second web; The web switching unit is configured to position a leading edge of a second web of aerosol-generating material adjacent to the trailing edge of the first web of aerosol-generating material upstream of the treatment unit.

[0022] The apparatus of the present invention may further include an embossing unit configured to emboss the second web of aerosol-generating material onto the additional web of aerosol-generating material.

[0023] The embossing unit may be configured to emboss a portion of the second web of aerosol-generating material adjacent the leading edge of the additional web of aerosol-generating material.

[0024] The processing unit may be a slitting unit that slits the web of aerosol-generating material into a plurality of strands of aerosol-generating material.

[0025] The apparatus of the present invention may further include a conveyor configured to gather together the strands of aerosol-generating material.

[0026] The apparatus of the present invention may further include a suction conveyor positioned to receive the strand of aerosol-generating material.

[0027] The device of the present invention may further include a garniture configured to wrap the strand of aerosol-generating material to form a continuous rod.

[0028] The apparatus of the present invention may further include a cutter positioned to cut the continuous rod into individual rod segments.

[0029] The aerosol-generating material may include tobacco.

[0030] The aerosol-generating material may include reconstituted tobacco sheets.

[0031] The present invention also provides a method of making a rod of aerosol-generating material, the method comprising: providing a first web of aerosol-generating material to a processing unit; providing a second web of aerosol-generating material; and redirecting a supply of aerosol-generating material to the treatment unit from a first web of aerosol-generating material to a second web of aerosol-generating material; Varying the supply of aerosol-generating material includes positioning a leading edge of a second web of aerosol-generating material adjacent the trailing edge of the first web of aerosol-generating material upstream of the treatment unit.

[0032] The method may include positioning a leading edge of a second web of aerosol-generating material in abutting contact with the trailing edge of the first web of aerosol-generating material.

[0033] The method may include positioning a leading edge of a second web of aerosol-generating material against a trailing edge of a first web of aerosol-generating material such that a space is defined between the leading edge of the second web of aerosol-generating material and the trailing edge of the first web of aerosol-generating material.

[0034] The space may be less than 20mm, preferably less than 10mm, more preferably less than 5mm.

[0035] The method may include positioning a leading edge of the second web of aerosol-generating material adjacent to the trailing edge of the first web of aerosol-generating material without overlapping the first web of aerosol-generating material and the second web of aerosol-generating material.

[0036] The step of switching the supply of aerosol-generating material may not include applying a second web of aerosol-generating material to the first web of aerosol-generating material.

[0037] The method may further comprise cutting the first web of aerosol-generating material to define a trailing edge.

[0038] The method may further comprise cutting the second web of aerosol-generating material to define a leading edge.

[0039] The trailing edge of the first web of aerosol-generating material and the leading edge of the second web of aerosol-generating material may be cut to have complementary shapes.

[0040] The trailing edge of the first web of aerosol-generating material and the leading edge of the second web of aerosol-generating material may be beveled.

[0041] The method of the present invention may include supplying an additional web of aerosol-generating material to the treatment unit.

[0042] The method of the present invention may include embossing a second web of aerosol-generating material into an additional web of aerosol-generating material.

[0043] The processing unit may be a slitting unit and the method may further comprise slitting the web of aerosol-generating material into a plurality of strands of aerosol-generating material.

[0044] The method of the present invention may further comprise gathering together the strands of aerosol-generating material.

[0045] The method of the present invention may further comprise conveying the strand of aerosol-generating material on a suction conveyor.

[0046] The method of the present invention may further comprise wrapping the strands of aerosol-generating material to form a continuous rod.

[0047] The method of the present invention may further comprise cutting the continuous rod into individual rod segments.

[0048] The aerosol-generating material may include tobacco.

[0049] The aerosol-generating material may include reconstituted tobacco sheets.

[0050] Several embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0051] [Figure 1A] 1 shows a tobacco rod segment and a portion of an aerosol generating device, particularly a heating blade. [Figure 1B] 1 shows a tobacco rod segment and a portion of an aerosol generating device, particularly a heating blade. [Diagram 2] 1 is a schematic diagram of an apparatus for producing tobacco rod segments. [Diagram 3] 2 shows a schematic diagram of a further example of an apparatus for producing tobacco rod segments. [Figure 4] 4 shows a conveyor of the apparatus of FIGS. 2 and 3; [Figure 5A] 1 shows the process of changing the web from the first reel to the second reel. [Figure 5B] 1 shows the process of changing the web from the first reel to the second reel. [Figure 5C] 1 shows the process of changing the web from the first reel to the second reel. [Figure 5D] 1 shows the process of changing the web from the first reel to the second reel. [Figure 5E] 1 shows the process of changing the web from the first reel to the second reel. [Figure 6A] 5B shows an apparatus including a web switching unit for carrying out the process of FIG. 5A. [Figure 6B] 5C shows an apparatus including a web switching unit for carrying out the process of FIG. 5B. [Figure 6C] 5D shows an apparatus including a web switching unit for carrying out the process of FIG. 5C. [Figure 6D] 5D shows an apparatus including a web switching unit for carrying out the process of FIG. 5D. [Figure 6E] 5C shows an apparatus including a web switching unit for carrying out the steps of FIG. 5E. [Figure 7] The apparatus has two sets of web supply units and two switching units. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0052] The apparatus described herein is for producing a rod of aerosol-generating material. In some examples, the rod of aerosol-generating material is a tobacco rod segment 1, as shown in Figures 1A and 1B. The tobacco rod segment 1 is formed of a plurality of tobacco strands 2 extending longitudinally along a tobacco rod 3 of the tobacco rod segment 1. The tobacco rod segment 1 also includes a wrapper 4 surrounding the tobacco rod 3.

[0053] The tobacco strand 2 is preferably formed from a sheet of tobacco material, for example a sheet of reconstituted tobacco. The reconstituted tobacco sheet can be slit into a plurality of tobacco strands 2 for incorporation into the tobacco rod 3. The reconstituted tobacco sheet may be produced, for example, by a papermaking process, band casting or extrusion. For example, the reconstituted tobacco sheet may be a paper reconstituted tobacco. By paper reconstituted tobacco is meant tobacco material formed by a process in which a tobacco raw material is extracted with a solvent to a residue comprising a soluble extract and fibrous material, and then the extract (usually after concentration, and optionally after further processing) is recombined with the fibrous material from the residue (usually after removal of impurities from the fibrous material, and optionally with the addition of small amounts of non-tobacco fiber) by depositing the extract on the fibrous material. The recombination process is similar to a papermaking process. The raw material may comprise or consist of one or more of tobacco strips, tobacco stems and / or whole tobacco. Trash, fines and rice husk may alternatively or additionally be employed in the raw material. Of course, reconstituted tobacco sheet formed by any method may be used. Reconstituted tobacco sheets are malleable.

[0054] 1A and 1B, the tobacco strands 2 of the tobacco rod 3 extend along the length of the tobacco rod 3, and each of the plurality of strands 2 is substantially uncoiled. The plurality of tobacco strands 2 are substantially parallel to one another, substantially straight, and each extend substantially along the entire length of the tobacco rod segment 1.

[0055] The wrapper 4 surrounding the tobacco strand 2 is preferably made of paper. The wrapper 5 may, for example, comprise one or both of paper and aluminum foil, such as a laminate of paper and aluminum foil. The wrapper 4 may have a glued seam that secures the wrapper 4 around the tobacco rod 3.

[0056] As described in more detail below, the steps of producing the tobacco rod segments 1 may include slitting a reconstituted tobacco sheet into tobacco strands 2, consolidating the tobacco strands 2, wrapping the tobacco strands 2 in a wrapper 4 to form a reconstituted tobacco rod, and then cutting the continuous tobacco rod into individual tobacco rod segments 1. The step of consolidating the tobacco strands 2 occurs on a conveyor, such as is described in more detail below.

[0057] The tobacco strands 2 can be heated to release an aerosol that is inhaled by a user. The tobacco rod segment 1 can be used with an aerosol generating device that includes a heating blade 5. The heating blade 5 is inserted within an end 6 of the tobacco rod segment 1 between the tobacco strands 2 as shown in Figures 1A and 1B.

[0058] The reconstituted tobacco sheet used to make the tobacco strands 2 may include glycerin. For example, the reconstituted tobacco sheet may be soaked in or formed with glycerin. When heated, the glycerin volatilizes and forms an aerosol, which may enhance the sensation of a user of an aerosol generating device or any suitable "non-combustion heating" device with which the tobacco rod segment 1 is used.

[0059] The blade heater 5 may take the form of an elongated rectangular parallelepiped that is significantly thinner than its width or length. The width of the blade heater 5 is less than the outer diameter of the tobacco rod segment 1. The blade heater 5 may include a resistive heater that is powered by a battery (not shown) of a portable aerosol generating device (not shown) and adjusted by a user to provide heating. In some examples, the blade heater 5 may have a pointed end (not shown) that facilitates insertion of the blade heater 5 into the tobacco rod segment 1.

[0060] The blade heater 5 may be inserted into the tobacco rod segment 1 so that the blade heater 5 extends longitudinally within the tobacco rod segment 1 as shown in FIG. 1B, or the tobacco rod segment 1 may be pressed onto the blade heater 5 in the same manner.

[0061] The substantially uncoiled, longitudinally extending tobacco strands 2 of the tobacco rod segment 1 allow the blade heater 5 to be easily inserted into the tobacco rod segment 1 because the uncoiled tobacco strands 2 offer relatively little resistance to the longitudinal insertion of the blade heater 5. This is convenient when inserting or positioning the tobacco rod segment 1, which is a consumable part of a typical aerosol generating device (not shown), into the blade heater 5. This reduces damage to the tobacco rod segment 1 upon insertion of the blade heater 5 and allows for consistent and correct positioning of the tobacco rod segment 1 relative to the blade heater 5. For example, this is in contrast to a hypothetical tobacco rod segment including longitudinally extending strands arranged in a coiled, e.g., helical, configuration, in which the insertion of the blade heater is restricted by the strands intersecting the insertion path, and the blade heater deforms and compresses portions of the tobacco, which makes positioning of the hypothetical tobacco rod segment relatively difficult and uncertain, and increases the risk of damage to the hypothetical tobacco rod segment.

[0062] The parallel and / or straight longitudinal tobacco strands 2 of the tobacco rod segment 1 similarly facilitate the insertion of the blade heater 5 into the tobacco rod segment 1, where the insertion axis of the blade heater 5 is parallel to the respective axes of the longitudinal strands 2, and where only a small surface area of ​​the tobacco impinges on the leading edge of the blade heater 5 as it is inserted. As above, this may facilitate installation or replacement of the tobacco rod segment 1, and / or reduce damage to the tobacco rod segment 1, and / or allow for consistent and correct installation of the tobacco rod segment 1 relative to the blade heater 5. This is in contrast to a hypothetical tobacco strand that includes, for example, randomly oriented pieces of shredded tobacco or a sheet of crimped or wrinkled tobacco, where insertion of the blade heater may deform and compress some portions of the shredded tobacco or the sheet of crimped or wrinkled tobacco, which may result in relatively difficult and inconsistent installation of the hypothetical tobacco rod segment and increased risk of damage to the hypothetical tobacco rod segment.

[0063] When the tobacco rod segment 1 is inserted into a blade heater 5 of an overall aerosol generating device (not shown), the blade heater 5 is adjusted to heat (e.g., via a resistively heated interior of the blade heater), thereby heating, without burning, the tobacco strand 2, thereby releasing components, such as volatile components, from the tobacco strand 2. As discussed above, the tobacco strand 2 may include glycerin, which is volatilized when heated by the blade heater 5 to form an aerosol.

[0064] The plurality of substantially non-coiled longitudinally extending tobacco strands 2 of the tobacco rod segment 1 establish corresponding substantially non-coiled longitudinally extending passages 7 between the plurality of tobacco strands 2 and through the tobacco rod segment 1. These passages 7 facilitate the migration of volatilized material (e.g., volatile components such as tobacco itself and / or volatilized glycerin) from the tobacco strands 2 through the tobacco rod segment 1 upon heating. This reduces the loss of such material as it passes through the tobacco rod segment 1, e.g., the relatively short and unobstructed path reduces the tendency of volatilized material to return and agglomerate at some point in the tobacco rod segment 1. This is in contrast to, for example, a hypothetical tobacco rod segment that includes randomly oriented shredded tobacco pieces (as in a standard cigarette) that provide a relatively long path length for volatilized material to exit the hypothetical tobacco rod. This is also in contrast to a hypothetical tobacco rod segment that includes a plurality of coiled longitudinally extending strands that provide a relatively long path length for volatilized material to exit the hypothetical tobacco rod.

[0065] As discussed above, the wrapper 5 may comprise, for example, one or both of paper and aluminum foil, such as a laminate of paper and aluminum foil. The laminate of paper and aluminum foil serves to prevent the tobacco rod segment 1 from being ignited by the blade heater 5. The aluminum foil serves to prevent a consumer from igniting the tobacco rod segment 1 as with a conventional cigarette when the tobacco rod segment 1 is intended for use in a heating device.

[0066] Each of the plurality of tobacco strands 2 has a width substantially in the range of 0.25 mm to 3 mm, or substantially in the range of 0.5 mm to 1.5 mm. The tobacco rod segment 1 has an outer diameter substantially in the range of 5.4 mm to 7.8 mm, or substantially in the range of 6.7 mm to 7.8 mm. This allows a relatively large blade heater 5 to be used, thereby increasing the heating surface area of ​​the blade heater 5 and increasing the rate at which the tobacco strand 2 is heated and / or the amount of the tobacco strand 2 heated by the blade heater 5.

[0067] FIG. 2 illustrates diagrammatically an apparatus 8 for producing rods of aerosol-generating material, and in particular the tobacco rod segments 1 described with reference to FIGS. 1A and 1B.

[0068] The reconstituted tobacco sheet used to produce the tobacco strand 2 is provided to the apparatus 8 in the form of a tobacco web 11. The apparatus 8 includes a tobacco web supply unit 9 which supplies the tobacco web 11 into the apparatus 8. The tobacco web supply unit 9 includes a first reel support 30 which supports a first reel 10. A first tobacco web 34 is provided from the first reel 10. The tobacco web supply unit 9 also includes a second reel support 31 which supports a second reel. The tobacco web supply unit 9 also includes a web switching unit 35 which receives the first tobacco web 34 and the second tobacco web 33. In the configuration shown in Figure 2, the first tobacco web 34 passes through the web switching unit 35 and is supplied to the remainder of the apparatus as the tobacco web 11. Then, when the first reel 10 is empty or nearly empty, the web switching unit 35 changes the supply of tobacco web 11 from the first tobacco web 34 to the second tobacco web 33 so that the apparatus 8 can continue to operate. A replacement first reel 10 can be loaded and when the second reel 32 becomes empty or nearly empty, a web switching unit 35 can change the supply of tobacco web 11 from the second tobacco web 33 to the first tobacco web 34.

[0069] The first reel support 30 and the second reel support 31 both include a spindle on which the reel 10, 32 of reconstituted tobacco is supported. The first and second reel supports 30, 31 preferably each include a drive, e.g. a motor, to rotate the spindle and feed the tobacco web 34, 33 into the apparatus 8. Alternatively or additionally, a drive roller may engage an outer surface of the reel 10, 32 to rotate the reel 10, 32 and thereby feed the tobacco web 33, 34 into the apparatus 8. Alternatively, the spindle may be freely rotatable such that the tobacco web 33, 34 is unwound by pulling the tobacco web 33, 34 from the reel 10, 32 of reconstituted tobacco. The tobacco web 33, 34 may be pulled by a portion of the apparatus 8 located downstream of the first and second reel supports 30, 31. The spindle generates tension in the tobacco web 33, 34 and may be braked to adjust it.

[0070] The dimensions of the tobacco web 11 are conventional. For example, the width and thickness of the tobacco web 11 provided from the tobacco web supply unit 9 are constant and of conventional width and thickness. For example, the tobacco web 11 may be of a predetermined and constant mass per unit length. This ensures that the tobacco rod segments 1 produced have a constant weight per unit length. Thus, by using a tobacco web 11 of conventional (and constant) dimensions, no weighing system is required to weigh the tobacco rod or tobacco rod segments 1, and the weight of the resulting tobacco rod segments 1 can be controlled.

[0071] The tobacco web 11 is fed into a slitting unit 13 which slits the tobacco web 11 into a plurality of tobacco strands 14. The slitting unit 13 slits the tobacco web 11 longitudinally to produce longitudinally extending tobacco strands 14.

[0072] In one example, the slitting unit 13 includes a cutting roller 15 and an anvil roller 16. The cutting roller 15 includes an array of circumferentially extending cutting blades that sever the tobacco web 11 as it passes between the cutting roller 15 and the anvil roller 16. Alternatively, the slitting unit 13 may include a first cutting roller 15 and a second cutting roller 17, each having an array of circumferentially extending cutting blades that cooperate to slit the tobacco web 11. For example, the circumferentially extending cutting blades of the first cutting roller 15 closely overlap the circumferentially extending cutting blades of the second cutting roller 17 to shear the tobacco web 11 into tobacco strands 14.

[0073] The row of circumferentially extending cutting blades on the or each cutting roller 15, 17 determines the number of tobacco strands 14 and the size of the tobacco strands 14. Preferably, the tobacco strands 14 are all of equal width. The row of circumferentially extending cutting blades on the or each cutting roller 15, 17 is arranged so that the width of each tobacco strand 14 is in the range substantially 0.25mm to 3mm or substantially 0.5mm to 1.5mm. This could, for example, be such that the circumferentially extending cutting blades are substantially 0.25mm to 3mm or substantially 0 This corresponds to a distance of .5mm to 1.5mm.

[0074] The distance between the cutting roller 15 and the anvil roller 16 or between the first cutting roller 15 and the second cutting roller 17 may be fixed. Alternatively, one of the cutting roller 15 and the anvil roller 16 or one of the first cutting roller 15 and the second cutting roller 17 may be slidably mounted and an actuator may be arranged to apply hydraulic or pneumatic pressure between the cutting roller 15 and the anvil roller 16 or between the first cutting roller 15 and the second cutting roller 17.

[0075] On exiting the slitting unit 13, the tobacco strands 14 are fed onto a conveyor 18, which will be described in more detail with reference to Figures 3 to 7. The conveyor 18 is configured to transport the tobacco strands 14. Preferably, the tobacco strands 14 are consolidated as they are transported along the conveyor 18.

[0076] Figure 4 illustrates an example of a conveyor 18. As shown, the conveyor includes a guide 39. In this example, the conveyor 18 includes a set of rails 40 angled towards each other to bring the tobacco strands 14 together. The set of rails 40 are arranged as a funnel with a wide entrance 41 located towards the slit unit 13 and a narrow exit 42 located towards the suction conveyor 19. The set of rails 40 move the outer tobacco strands 14 towards the centre of the conveyor 18 to bring the strands together. The angle of the set of rails 40 with respect to the direction of travel of the tobacco strands 14 is selected to allow for an acceptable force on the tobacco strands 14, with a smaller angle of the rails 40 resulting in a smaller force on the tobacco strands 14.

[0077] The conveyor 18 may be a belt conveyor that transports the tobacco strands 14 from the slitting unit 13 to the suction conveyor 19. Alternatively, the conveyor may be a surface over which the tobacco strands 14 are pushed and / or pulled. The conveyor 18 supports the tobacco strands 14 as they move from the slitting unit 13 to the suction conveyor 19.

[0078] Referring again to Figure 2, upon exiting the conveyor 18, the consolidated tobacco strands 14 are fed to a suction conveyor 19, also shown in Figure 2. The suction conveyor 19 includes a suction band 20 which moves along an upper run 21 and a lower run 22. A suction chamber 23 is provided between the upper run 21 and the lower run 22, and the suction force applied to the suction chamber 23 acts through suction holes formed in the suction band 20. The suction force acts through the suction holes in the suction band 20 only on the lower run 22, as the suction chamber 23 is closed to the upper run 21.

[0079] The suction conveyor 19 is positioned to hold the tobacco strand 14 in a runway 22 below the suction band 20. The suction conveyor 19 transports the tobacco strand 14 through a garniture 24 as shown.

[0080] A wrapper web 25 is fed into the garniture 24 from a wrapper reel 26 supported on a wrapper reel support 27 .

[0081] The garniture 24 receives the tobacco strands 14 and the wrapper web 25, and the garniture 24 wraps the wrapper web 25 around the tobacco strands 14 as they are transported along the suction conveyor 19. An adhesive unit is applied along one edge of the wrapper web 25 to form a longitudinal seam joining one edge of the wrapper web 25 to the other edge of the wrapper web 25. In this manner, a continuous tobacco rod 28 is produced. The continuous tobacco rod 28 has a group of longitudinally extending tobacco strands 14 surrounded by a wrapper.

[0082] The suction conveyor 19 and garniture 24 are similar to the equipment used in the manufacture of tobacco rods for use in cigarettes, and therefore those skilled in the art will be familiar with the details of the suction conveyor 19 and garniture 24 and will not be described further.

[0083] A cutting unit 29 is disposed downstream of the suction conveyor 19 and the garniture 24 and cuts the continuous tobacco rod 28 into individual tobacco rod segments 1, each of which is as described with reference to Figures 1A and 1B.

[0084] In some instances, the cutting unit 29 cuts the continuous tobacco rod 28 into two separate tobacco rod lengths 1, i.e., two separate tobacco rods 1 joined end to end. For example, the two separate tobacco rod lengths 1 are then sent to a subsequent device where the two separate tobacco rod lengths 1 are combined with other components, such as a filter and / or a mouthpiece. The subsequent device cuts the two separate tobacco rod lengths 1 into single length separate tobacco rods 1 as described with reference to Figures 1A and 1B.

[0085] Alternatively or additionally, the individual tobacco rod segments 1 are conveyed outwardly to a packaging device which packages the tobacco rod segments 1 for sale, distribution and / or storage.

[0086] FIG. 3 shows another example of an apparatus 8 for producing the tobacco rod segments 1 described with particular reference to FIGS. 1A and 1B.

[0087] As shown, the apparatus 8 of FIG. 3 includes the same components as the apparatus 8 of the example of FIG. 2, and further includes a second tobacco web supply unit 9B (in addition to the first tobacco web supply unit 9A). The second tobacco web supply unit supplies an additional tobacco web 36 for input to the slitting unit 13. The additional tobacco web 36 is arranged to overlap the tobacco web 11 from the first tobacco web supply unit 9A, thereby providing a double thickness of tobacco web 11, 36 to the slitting unit 13. The double thickness of tobacco web 11, 36 means that the slitting unit 13 produces tobacco strands with a higher density. This configuration is preferred when it is desired that the individual tobacco strands 14 are particularly thin or of low density when the individual tobacco strands 14 are provided to each tobacco rod segment 1 so as to have twice the number of tobacco strands 14. Furthermore, for the same number of tobacco strands 14, the combined width of the tobacco web 11 and the additional tobacco web 32 is narrower than the width of a single tobacco web 11 of the same thickness. Thus, the tobacco strands 14 formed from the overlapping tobacco webs 11, 32 have less lateral movement as they are assembled into the tobacco rod 3, which is preferred.

[0088] Furthermore, providing the additional tobacco web 36 means that it is possible to provide two different types of tobacco strands 14 in the tobacco rod segment 1. For example, one type (e.g., the tobacco web 11) may be high in glycerin to generate significant aerosol or vapor, while the other (e.g., the additional tobacco web 36) may contain flavorants that are delivered with the aerosol or vapor. In this way, different tobacco rod segments 1 can be made with different reel combinations.

[0089] The second web supply unit 9 includes a first reel 10, a second reel 32 and a reel changeover unit 35 to switch the supply of additional tobacco web 36 to ensure a continuous supply.

[0090] Typically, the slitting unit 13 has a fixed distance between the cutting rollers 15, 16, 17, and any significant changes in the thickness of the tobacco web 11 can damage and / or jam the slitting unit 13. Additionally, any adhesive or tape or other material passing through the slitting unit 13 can also jam or impair the operation of the slitting unit 13. It is therefore advantageous to avoid overlapping or tape or adhesive splicing when switching from the first tobacco web 34 to the second tobacco web 33. While a typical splicing unit will splice the second tobacco web 33 to the first tobacco web 34 in the overlapping area, it is preferred to avoid such devices in the present invention.

[0091] Additionally, it is preferable to avoid significant variations in the weight of the material along the length of the tobacco strands 14 as the tobacco web 11, and then the tobacco strands 14, are transported to be presented to the garniture 24 for wrapping to form the tobacco rod 1, as this could cause the garniture 24 to clog or impair its function (the wrapper 25 would not be wide enough to enclose an increased number of tobacco strands 14).

[0092] The web switching unit 35 of the present invention is configured to position the leading edge of the second tobacco web 33 adjacent to the trailing edge of the first tobacco web 34 at a location upstream of the slitting unit 13 during switching. The first tobacco web 34 and the second tobacco web 33 do not overlap, nor are the first tobacco web 34 and the second tobacco web 33 attached to each other.

[0093] 5A-5E briefly explain the operation of the web switching unit 35. FIG.

[0094] Figure 5A shows the initial state of the web switching unit 35, where the first tobacco web 34 moves intact through the web switching unit 35 towards the slitting unit (13, see Figure 2). As illustrated in Figure 5B, the first operation of the web switching unit 35 involves cutting the first tobacco web 34. The first tobacco web 34 is cut along a line 43, which is oblique to the direction of movement of the first tobacco web 34. As shown in Figure 5B, after cutting, the cut portion of the first tobacco web 34 continues to be pulled through the apparatus (8, see Figure 2) and the remainder, which is attached to the first reel 10, is pulled back towards the reel 32 for removal from the apparatus 8. The second tobacco web 33 is then accelerated towards the slitting unit (13, see Figure 2).

[0095] The web switching unit 35 then cuts the second tobacco web 33 along a line 44 which coincides with the cut line 43 of the first tobacco web 34. The severed portion 45 is removed. The second tobacco web 33 is thus provided with a leading edge 46 which is complementary to the trailing edge 47 of the first tobacco web 34.

[0096] The second tobacco web 33 is then positioned such that the leading edge 46 of the second tobacco web 33 is adjacent to the trailing edge 47 of the first tobacco web 34. The leading edge 46 of the second tobacco web 33 is located adjacent to the trailing edge 47 of the first tobacco web 34 but does not overlap it. In particular, there is no overlap between the first tobacco web 34 and the second tobacco web 33.

[0097] The leading edge 46 of the second tobacco web 33 may be positioned in abutment with the trailing edge 47 of the first tobacco web 34. Alternatively, the leading edge 46 of the second tobacco web 33 may be spaced apart from the trailing edge 47 of the first tobacco web 34. The leading edge 46 of the second tobacco web 33 may be spaced apart from the trailing edge 47 of the first tobacco web 34 by less than 20 mm, preferably less than 10 mm, and more preferably less than 5 mm.

[0098] In some examples, the first tobacco web 34 and the second tobacco web 33 are cut with the same cutter. The first tobacco web 34 and the second tobacco web 33 may be cut with the same cutter at the same time. Advantageously, the leading edge 46 of the second tobacco web 33, located away from the trailing edge 47 of the first tobacco web 34, is positioned adjacent to one another by cutting the first and second tobacco webs 34, 33 simultaneously. In other examples, the first tobacco web 34 and the second tobacco web 33 may be cut with separate cutters.

[0099] In the position shown in Figure 5D, where the leading edge 46 of the second tobacco web 33 is adjacent to but not overlapping the trailing edge 47 of the first tobacco web 34, the first and second tobacco webs 34, 33 move through an apparatus (8, see Figure 2) for the production of a rod of aerosolizable material as described above. As shown in Figure 5E, the diagonal cut lines 43, 44 and the resulting diagonal leading and trailing edges 46, 47 mean that the slitting unit 13 can grip both the first tobacco web 34 and the second tobacco web 33 simultaneously, thereby maintaining the position of the leading edge 46 of the second tobacco web 33 and the trailing edge 47 of the first tobacco web 34.

[0100] Furthermore, by positioning the leading edge 46 of the second tobacco web 33 adjacent to but not overlapping the trailing edge 47 of the first tobacco web 34, the tobacco web 11 passing through the slit unit 13 is prevented from becoming thicker.

[0101] Figures 6A-6E show an arrangement of a web switching unit 35 for carrying out the method described in Figures 5A-5E. As shown, the web switching unit 35 includes a support 51 and a cutter 50, which cuts the first tobacco web 34 and the second tobacco web 33 on the support.

[0102] In the illustrated example, the web switching unit 35 includes a single cutter 50 for cutting both the first tobacco web 34 and the second tobacco web 33. However, as discussed above, the web switching unit 35 may alternatively have two cutters, one for each of the first tobacco web 34 and the second tobacco web 33.

[0103] The web switching unit 35 also includes a first nip drive 48 for feeding the first tobacco web 34 and a second nip drive 49 for feeding the second tobacco web 33. The first nip drive 48 and the second nip drive 49 each include two rollers between which the first and second tobacco webs 34, 33, respectively, are fed. The first and second nip drives 48, 49 are independently driven and can also change their driving direction, which allows the first tobacco web 34 and the second tobacco web 33 to be advanced and retracted independently in the manner described with reference to Figures 5A-5E.

[0104] An output nip drive 52 is provided at the downstream end of the cutter 50 as shown, and also includes two rollers between which the tobacco web 11 is fed. In this example, once a portion of the tobacco web 11 has passed the output nip drive 52, the web is no longer forced to retract.

[0105] A support 53 is provided between the output nip drive 52 and the slitting unit 13. The support 53 conveys the leading edge of the cut tobacco web 34, 33 to the slitting unit 13. The support 53 may be a surface over which the tobacco web 34, 33 slides or it may be a conveyor, for example a belt conveyor.

[0106] As shown in Figure 6A, a first tobacco web 34 is unwound from a first reel 10 and fed into a web switching unit 35. From there, the first tobacco web 34 exits the web switching unit 35 as tobacco web 11 and travels to a slitting unit 13 and through the remainder of the apparatus (8, see Figure 2).

[0107] Specifically, the first tobacco web 34 passes between the first nip drive 48, cutter 50 and support 51, over the output nip drive 52, support 53 and into the slitting unit 13. In the state shown in Figure 6A, the first tobacco web 34 is the tobacco web 11, which will be used to produce individual tobacco rods as described above.

[0108] In preparation for the changeover, the second tobacco web 33 from the second reel 32 is placed in a web switching unit 35. The web switching unit 35 switches from the first tobacco web 34 to the second tobacco web 33 when the first reel 10 is empty or nearly empty.

[0109] Specifically, the second tobacco web 33 passes through the second nip drive 49 such that a leading portion of the second tobacco web 33 is positioned between a cutter 50 and a support 51 .

[0110] In the situation illustrated in FIG. 6A, the web switching unit 35 is about to switch over when the first reel 10 is empty or almost empty.

[0111] Figure 6B shows a first step of the switching process performed by the web switching unit 35. As shown, a cutter 50 has cut the first tobacco web 34 and the second tobacco web 33. As mentioned above, in alternative examples the first tobacco web 34 and the second tobacco web 33 may be cut by two separate cutters.

[0112] The first nip drive 48 and / or the first reel support 30 pulls the remainder of the first tobacco web 34 towards the first reel 10. The trimmed off portion 45 of the second tobacco web 33 is removed, for example by suction.

[0113] At this stage, the leading edge 46 of the second tobacco web 33 is adjacent to the trailing edge 47 of the first tobacco web 34. If the cutter 50 cuts both the first tobacco web 34 and the second tobacco web 33 simultaneously, the leading edge 46 of the second tobacco web 33 and the trailing edge 47 of the first tobacco web 34 are already adjacent to each other. In instances where the second tobacco web 33 and the first tobacco web 34 are cut separately, the second nip drive 49 can be used to position the second tobacco web 33 such that the leading edge 46 of the second tobacco web 33 is adjacent to the trailing edge 47 of the first tobacco web 34.

[0114] In some examples a sensor, for example a camera, may be positioned to detect the relative position of the leading edge 46 of the second tobacco web 33 and the trailing edge 47 of the first tobacco web 34. If an adjustment is required, the second nip drive 49 may move the second tobacco web 33 accordingly.

[0115] As the trailing edge 47 of the first tobacco web 34 and the leading edge 46 of the second tobacco web 33 pass the output nip drive 52, their relative positions are fixed, as shown in Figure 6C. The output nip drive 52 can simultaneously grip the first tobacco web 34 and the second tobacco web 33 by their diagonal cuts, as shown in Figure 5E. The support 53 transports the leading edge of the second tobacco web 33 to the slitting unit. The second tobacco web 33 is then pulled through the rest of the apparatus (8, see Figure 2) as the tobacco web 11, as shown in Figure 6D.

[0116] As shown in Figure 6E, the first reel 10 can be replaced and a new first tobacco web 34 can be placed in the web switching unit 35. When the second reel 32 is empty or nearly empty, the web switching unit 35 switches the supply from the second tobacco web 33 to the first tobacco web 34.

[0117] In some cases it may be preferable to stop the movement of the first and second tobacco webs 34, 33 at the web switching unit 35 when switching from one to the other. This can be achieved by providing a buffer, e.g. a floating arm, downstream of the web switching unit 35. As will be appreciated by those skilled in the art, a floating arm is a form of web buffer in which one or more rollers can be moved relative to one or more other rollers to provide web paths of different lengths. The floating arm is complete when the rollers are maximally separated, and moving the rollers towards each other allows the output of the web from the floating arm to continue while the input of the web into the floating arm stops. Such a buffer allows the first and second tobacco webs 34, 33 to be stationary within the web switching user for a short period while the tobacco web is retracted from the buffer. Such configurations are known to those skilled in the art.

[0118] Figure 7 shows an example of an apparatus 8 similar to that of Figure 3. The apparatus 8 has first and second tobacco web supply units 9A, 9B and second web switching units 35A, 35B, respectively, as described above. This configuration provides an additional tobacco web 36 which overlaps the tobacco web 11 as shown. The double thickness of the tobacco webs 11, 36 means that the slitting unit 13 produces a denser tobacco strand.

[0119] 7, a support 54 is provided for transporting the leading edge of the additional tobacco web 36 from the second changer unit 35B to where the tobacco web 11 and the additional tobacco web 36 are combined. The support 55 may be a surface over which the additional tobacco web 36 is pressed or may be a conveyor, for example a belt conveyor.

[0120] In the example of Figure 7, the apparatus 8 optionally further comprises an embossing unit 55. The embossing unit is arranged downstream of where the tobacco web 11 and the additional tobacco web 36 are combined. When one of the tobacco web 11 and the additional tobacco web 36 is exchanged (by one of the first and second web change units 35A, 35B), the embossing unit 55 is operated to emboss the leading edge of the new tobacco web 11 or 36 into the other additional tobacco web 11 or 36. In this way, the new tobacco web 11 or 36 is transported to the slitting unit by the other tobacco web 11 or 36. In this way, the support 53 described with reference to Figures 6A-6E is not required.

[0121] The embossing unit 55 may be configured to emboss the tobacco web 11 and the additional tobacco web 36 against one another only in the area where one of the tobacco webs 11, 36 is switched. Alternatively, the embossing unit 55 may be configured to emboss the tobacco web 11 and the additional tobacco web 36 against one another along the length of the tobacco web 11 and the additional tobacco web 36.

[0122] Naturally, in the example of FIG. 7 in which the tobacco web 11 and the additional tobacco web 36 are embossed against each other, the reels 10A, 32A, 10B, 32B are arranged in such a way that they are not used up simultaneously so that one of the tobacco webs 11, 36 can carry the leading portion of the other tobacco web 11, 36 after a changeover.

[0123] Significantly, the web switching unit 35 or units 35A, 35B do not attach the first tobacco web 34 to the second tobacco web 33 during switching between the first and second tobacco webs 34, 33. Instead, the leading edge 46 of the second tobacco web 33 is located adjacent to the trailing edge 47 of the first tobacco web 34, as described with reference to Figures 5A-5E. The leading edge 46 of the second tobacco web 33 may abut the trailing edge 47 of the first tobacco web 34, or the leading edge 46 of the second tobacco web 33 may be spaced apart from the trailing edge 47 of the first tobacco web 34. Because there is no overlap or connection between the first tobacco web 34 and the second tobacco web 33, there is no local thickening and no change in material, allowing the tobacco web 11 to pass through the slitting unit 13 and other parts of the apparatus 8.

[0124] The above examples should be understood as illustrative examples of the present invention.

[0125] For example, although the above examples describe tobacco web 11 as a sheet of reconstituted tobacco, this need not be the case and tobacco web 11 may be made of other materials. Tobacco web 11 may or may not contain glycerin and may contain other materials, such as additives or enhancers, instead of or in addition to glycerin.

[0126] While in the above examples the tobacco strands 14 are described as being straight and parallel to one another, this need not be the case and in other examples the tobacco strands 14 may not be substantially straight and / or may not be substantially parallel to one another. For example, the tobacco strands 14 may be processed to include longitudinal corrugations or pleats or zigzag configurations, etc., and it is understood that the tobacco web 11 may naturally include longitudinal corrugations or pleats or zigzag configurations or may be processed to have such configurations or configurations. It is understood that the tobacco rod segment 1 may include any tobacco rod 3 formed of a plurality of longitudinally extending tobacco strands 14, each of the plurality of longitudinally extending tobacco strands 14 being substantially non-coiled.

[0127] While in some of the above examples the tobacco rod segment 1 is described as a consumable item, such as a "non-combustion heating" device that includes a blade heater 5, this need not be the case and in other examples the tobacco rod segment 1 may be used in other devices and / or for other purposes. For example, the tobacco rod segment 1 may be a consumable item in any aerosol generating device, such as a tobacco heating product or device that does not necessarily include a blade heater 15.

[0128] Although in the above examples the tobacco web 1 is described as being or including tobacco, e.g. reconstituted tobacco, this need not necessarily be the case and in other examples the sheet may be or include a sheet of any aerosol-generating material. The aerosol-generating material may be a material that produces an aerosol when heated, e.g. by the blade heater 15 of the overall aerosol generating device. For example the sheet of aerosol-generating material may be or may include a flavour base. The flavour base may include a flavourant, such as a tobacco flavourant or other flavourant, and / or may include glycerin or other additives or enhancers instead of or in addition to glycerin. The flavour base, with or without glycerin or other additives, is heated to generate an aerosol.

[0129] It should be noted that in general, an aerosol is a colloid of fine solid particles or liquid droplets in air or other gas, a colloid being a substance in which microscopically dispersed insoluble particles are suspended throughout another substance, whereas a vapor is a substance in the gas phase below its critical temperature, meaning that, for example, a vapor can be condensed into a liquid by increasing the pressure without decreasing the temperature. Of course, the term aerosol as used herein includes aerosols and / or vapors.

[0130] It will be appreciated that in some cases the rod segments of aerosol-generating material may be produced from a web of aerosol-generating material, for example, by longitudinally cutting a sheet of aerosol-generating material to create a plurality of strands of aerosol-generating material, gathering the strands together to form a rod of aerosol-generating material, each of the plurality of strands of aerosol-generating material being substantially non-coiled, as described above for reconstituted tobacco, and then cutting the rod of aerosol-generating material into segments to create rod segments of aerosol-generating material.

[0131] It will also be appreciated that the article may include a rod of aerosol-generating material, the rod of aerosol-generating material being formed from a plurality of longitudinally extending strands of aerosol-generating material, the plurality of longitudinally extending strands of aerosol-generating material being substantially non-coiled.

[0132] As used herein, the terms "upstream" and "downstream" refer to locations within the apparatus relative to the direction in which the aerosol-generating material moves through the apparatus. Thus, as shown in Figure 2, "upstream" refers to locations in the direction of the reel of the tobacco web, and "downstream" refers to locations in the direction of the cutting unit.

[0133] To address various problems and advance the technology, the entire disclosure exemplarily illustrates various embodiments in which the claimed invention may be practiced to provide an apparatus for manufacturing a rod of an aerosol-generating material. The advantages and features of the disclosure are merely representative examples of the embodiments, and are not exhaustive or exclusive. They are provided merely to aid in the understanding and teaching of the claimed features. It is to be understood that the advantages, embodiments, examples, features, features, structures, and / or other aspects of the disclosure should not be construed as limiting the disclosure to the exact scope of the claims or to the equivalents of the claims, and that other embodiments may be utilized or modified without departing from the scope and / or spirit of the disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of the disclosed elements, components, features, parts, steps, means, or other combinations. The disclosure also includes other inventions not currently claimed but which may be claimed in the future.

Claims

1. 1. An apparatus for producing rods of aerosol-generating material, the apparatus comprising: a first supply device adapted to supply a first web of aerosol-generating material to a processing unit including a slitting unit for slitting the web of aerosol-generating material into a plurality of strands of aerosol-generating material; a second supply device adapted to supply a second web of aerosol-generating material; a web switching unit configured to switch a supply of aerosol-generating material to the treatment unit from a first web of aerosol-generating material to a second web of aerosol-generating material; the web switching unit is configured to position a leading edge of the second web of aerosol-generating material adjacent a trailing edge of the first web of aerosol-generating material upstream of the processing unit when switching from the first web of aerosol-generating material to the second web of aerosol-generating material; The web switching unit does not attach the leading edge to the trailing edge.

2. 2. The apparatus of claim 1, wherein the web switching unit is configured to position the leading edge against the trailing edge of the aerosol-generating material passing through the web switching unit.

3. 2. The manufacturing apparatus of claim 1, wherein the web switching unit is configured to position the leading edge relative to the trailing edge of the aerosol-generating material passing through the web switching unit such that a space is defined between the leading edge and the trailing edge.

4. 4. The manufacturing apparatus of claim 3, wherein the space is less than 20 mm, or less than 10 mm, or less than 5 mm.

5. 5. The manufacturing apparatus of claim 1, further comprising a support arranged to carry the leading edge to the processing unit.

6. 6. The manufacturing apparatus of claim 1, wherein the leading edge and the trailing edge are complementary in shape.

7. 7. The apparatus of claim 6, wherein the leading edge and the trailing edge are oblique to a direction of travel of the adjacent aerosol-generating material into the treatment unit.

8. 8. The apparatus of claim 1, further comprising a cutting unit arranged to cut the aerosol-generating material to define the trailing edge.

9. 9. The apparatus of claim 1, further comprising a cutting unit arranged to cut the aerosol-generating material to define the leading edge.

10. 10. The apparatus of claim 8 or 9, wherein the cutting unit includes a blade extending diagonally across the web of aerosol-generating material.

11. 11. The apparatus of claim 1, wherein the web switching unit includes a nip drive roller configured to drive the web of aerosol-generating material.

12. 12. The manufacturing apparatus of claim 1, wherein the web switching unit further comprises sensors for detecting the positions of the leading edge and the trailing edge.

13. The manufacturing apparatus of claim 11 further comprising a controller configured to control the nip drive rollers to position the leading edge adjacent to the trailing edge.

14. 14. The apparatus of claim 1, further comprising a conveyor configured to gather together a plurality of strands of the aerosol-generating material.

15. 15. The apparatus of claim 1, further comprising a suction conveyor positioned to receive the plurality of strands of aerosol-generating material.

16. 16. The apparatus of claim 1, further comprising a garniture configured to wrap a plurality of strands of the aerosol-generating material to form a continuous rod.

17. 17. The manufacturing apparatus of claim 16, further comprising a cutter positioned to cut the continuous rod into individual rod segments.

18. 1. A method for producing a rod of aerosol-generating material, the method comprising: providing a first web of aerosol-generating material to a treatment unit; providing a second web of aerosol-generating material; switching a supply of aerosol-generating material to the treatment unit from the first web of aerosol-generating material to the second web of aerosol-generating material; and The step of switching the supply of aerosol-generating material includes positioning a leading edge of a second web of aerosol-generating material adjacent a trailing edge of a first web of aerosol-generating material upstream of the treatment unit; and The method of manufacturing, wherein switching the supply of aerosol generating material comprises unattaching the leading edge and the trailing edge to one another.

19. The method of claim 18 including the step of positioning the leading edge against the trailing edge.

20. The method of claim 18 including positioning the leading edge relative to the trailing edge such that a space is defined between the leading edge and the trailing edge.

21. 21. The method of claim 20, wherein the space is less than 20 mm, or less than 10 mm, or less than 5 mm.

22. 22. The method of claim 18, further comprising cutting the web of aerosol-generating material to define the trailing edge.

23. 23. A method according to any one of claims 18 to 22, further comprising cutting the web of aerosol-generating material to define the leading edge.

24. 24. A method according to claim 22 or 23, wherein the leading edge and the trailing edge are cut to have complementary shapes.

25. 25. The method of claim 22, 23 or 24, wherein the leading edge and the trailing edge are beveled.

26. 26. The method of any one of claims 18 to 25, wherein the processing unit comprises a slitting unit, and further comprising the step of slitting the web of aerosol-generating material into a plurality of strands of aerosol-generating material.

27. 27. The method of claim 26, further comprising the step of gathering together the plurality of strands of aerosol-generating material.

28. 28. The method of claim 26 or 27, further comprising the step of conveying the plurality of strands of aerosol-generating material on a suction conveyor.

29. 29. The method of any one of claims 26 to 28, further comprising wrapping a plurality of strands of the aerosol-generating material to form a continuous rod.

30. 30. The method of claim 29, further comprising cutting the continuous rod into individual rod segments.

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