Apparatus and method for manufacturing delivery systems

Abstract

The present disclosure relates to an apparatus (1) for manufacture of delivery systems. The apparatus comprises a rolling unit (9) comprising: a rotatable drum (14) having a plurality of flutes (18) extending in an axial direction of the drum and spaced circumferentially around a curved outer surface (17) of the drum. The flutes being formed in the curved outer surface of the drum to receive axially-aligned components of delivery systems; and a roll hand (15) having a contact surface (34) facing and spaced from the outer surface of the drum (14) to enable components of delivery systems to be rolled, upon rotation of the drum, across the outer surface (17) between the outer surface (17) and the contact surface (34) of the roll hand (15). The roll hand contact surface (34) includes a groove (32) extending in a substantially circumferential direction of the drum and is configured to at least partially receive one or more of the delivery system components as the drum rotates. The roll hand (15) comprises an airflow passage having an outlet in the groove (32) for directing a flow of air towards said one or more of the delivery system components at least partially received in the groove as the drum rotates. A roll hand (15) forming part of a rolling unit (9) of an apparatus for manufacture of delivery systems is also disclosed, as is a delivery system assembly machine and a method of manufacturing delivery systems.

Description

[0001] Apparatus and Method for Manufacturing Delivery Systems

[0002] Technical Field

[0003] The present disclosure relates to an apparatus for manufacturing delivery systems, to a delivery system assembly machine, to a roll hand forming a part of a rolling unit of an apparatus for manufacture of delivery systems, and to a method of manufacturing delivery systems.

[0004] Background

[0005] It is known to provide apparatus for receiving, arranging and assembling components for the manufacture of delivery systems, such as combustible or non-combustible aerosol provision systems. Such apparatus can include a series of drums that convey components along a manufacturing path as the drums rotate. Components are transferred from one drum to the next at a point where the circumferential surfaces of the drums are closest to each other. As the components are conveyed along the path they are subject to several processes, for example cutting, sliding, combining with other components, gluing, and rolling or wrapping with a paper patch. Delivery system components typically include filters, filter components and wrapped aerosol generating material.

[0006] Summary

[0007] According to an aspect of the present disclosure, there is provided an apparatus for manufacture of delivery systems, the apparatus comprising a rolling unit comprising: a rotatable drum having a plurality of flutes extending in an axial direction of the drum and spaced circumferentially around a curved outer surface of the drum, the flutes being formed in the curved outer surface of the drum to receive axially-aligned components of delivery systems; and a roll hand having a contact surface facing and spaced from the outer surface of the drum to enable components of deliveiy systems to be rolled, upon rotation of the drum, across the outer surface between the outer surface and the contact surface of the roll hand; wherein the roll hand contact surface includes a groove extending in a substantially circumferential direction of the drum and configured to at least partially receive one or more of the delivery system components as the drum rotates; and wherein the roll hand comprises an airflow passage having an outlet in the groove for directing a flow of air towards said one or more of the delivery system components at least partially received in the groove as the drum rotates.The apparatus may comprise a plurality of outlets in the groove.

[0008] The plurality of outlets maybe equally spaced along the groove.

[0009] The roll hand may comprise a plurality of grooves, each groove having a plurality of outlets.

[0010] The size and / or number of outlets in one groove may differ from the size and / or number of outlets in at least one other groove.

[0011] The apparatus may comprise a pump to generate a pressurised flow of air through said passage and out of said outlets and a control unit for controlling the pump. The pump may be controlled so that the pressure of air flowing out of the outlets in one groove is different to the pressure of air flowing out of the outlets in at least one other groove.

[0012] The apparatus may further comprise a kicker bar disposed adjacent to the roll hand and having a contact edge facing and spaced from the outer surface of the drum.

[0013] The groove may continue from said roll hand contact surface into the kicker bar contact edge.

[0014] A depthof the groove in the kicker bar contact edge may be the same as a depth of the groove in the roll hand contact surface.

[0015] A depth of the groove in the kicker bar contact edge may be different to a depth of the groove in the roll hand contact surface.

[0016] The kicker bar may be a separate component to the roll hand and is fixedly secured to the roll hand.

[0017] A position of the kicker bar relative to the roll hand can be adjusted.

[0018] According to another aspect of the invention, there is provided a roll hand forming a part of a rolling unit of an apparatus for manufacture of delivery systems, the roll hand having a contact surface positionable facing and spaced from a drum of a rolling unitsuch that components of delivery systems are rolled, upon rotation of the drum, across an outer surface of the drum between the outer surface and the contact surface of the roll hand, wherein the roll hand contact surface includes a groove extending in a substantially circumferential direction of the drum, the groove being configured to at least partially receive one or more of the delivery system components, and wherein the roll hand comprises an airflow passage having an outlet in the groove to enable a flow of air to be directed towards said one or more of the delivery system components at least partially received in the groove.

[0019] According to another aspect of the present disclosure, there is provided a delivery system assembly machine comprising an apparatus according to the present disclosure.

[0020] According to another aspect of the present disclosure, there is provided a method of manufacturing delivery systems, comprising use of apparatus for manufacturing delivery systems, the apparatus comprising a rolling unit having a rotatable drum having a plurality of flutes extending in an axial direction of the drum and spaced circumferentially around a curved outer surface of the drum, the flutes being formed in the curved outer surface of the drum, a roll hand having a contact surface facing and spaced from the outer surface of the drum to enable spaced components of a delivery system to be rolled, upon rotation of the drum, across the outer surface and between the outer surface and the contact surface of the roll hand, wherein the roll hand contact surface includes a groove extending in a substantially circumferential direction of the drum to at least partially receive one or more of the delivery system components as the drum rotates, and wherein the roll hand comprises an airflow passage having an outlet in the groove, wherein the method comprise directing a flow of air towards said one or more of the delivery system components at least partially received in the groove from said outlet as the drum rotates.

[0021] The method may comprise directing a flow of air towards said one or more of the delivery system components at least partially received in the groove through a plurality of outlets in the groove.

[0022] The method may comprise controlling a pump to generate a pressurised flow of air through the passage and out of said outlets.

[0023] The roll hand may comprise a plurality of grooves, each groove having a plurality of outlets. The method may then include controlling the pump so that the pressure of airflowing out of the outlets in one groove is different to the pressure of air flowing out of the outlets in at least one other groove.

[0024] Brief Description of the Drawings

[0025] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:

[0026] Fig. 1 shows a schematic illustration of a delivery system manufacturing apparatus according to an embodiment of the invention;

[0027] Fig. 2 shows a cross section of an example of a delivery system manufactured by the apparatus of Fig. 1;

[0028] Fig. 3 shows a rolling drum of the delivery system manufacturing apparatus of Fig. 1; Fig. 4 shows an enlarged view of a rolling unit of the apparatus of Fig. 1;

[0029] Fig. 5 shows an enlarged view of a roll hand of the rolling unit of Fig. 4;

[0030] Fig. 6 shows an enlarged view of a roll hand and kicker bar operable with the rolling unit of the apparatus of Fig. 1;

[0031] Fig. 7 shows an enlarged view of an alternative embodiment of a roll hand and kicker bar operable with the rolling unit of the apparatus of Fig. 1;

[0032] Figs. 8A - 8E show schematic cross-sectional views through the roll hand and kicker bar of further alternative embodiments of the invention; and

[0033] Fig. 9 shows a flow chart of a method of operation of the delivery system manufacturing apparatus of an embodiment of the invention.

[0034] Detailed Description

[0035] As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes: combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material); and non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials.

[0036] According to the present disclosure, a “combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (orcomponent thereof) is combusted or burned during use in order to facilitate delivery of at least one substance to a user.

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

[0038] In some embodiments, the disclosure relates to a component for use in a combustible aerosol provision system, such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosol-modifying agent release component such as a capsule, a thread, or a bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper.

[0039] According to the present disclosure, a “non-combustible” aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

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

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

[0042] In some embodiments, the non-combustible aerosol provision system is an aerosolgenerating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

[0043] In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.Typically, the non-combustible aerosol provision system may comprise a noncombustible aerosol provision device and a consumable for use with the noncombustible aerosol provision device.

[0044] In some embodiments, the disclosure relates to consumables comprising aerosolgenerating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

[0045] In some embodiments, the non-combustible aerosol provision system, such as a non-combustible aerosol provision device (THP) thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

[0046] In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and / or an aerosol-modifying agent.

[0047] In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol-modifying agent.

[0048] Aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and / or flavourants.

[0049] The aerosol-generating material may comprise one or more active substances and / or flavours, one or more aerosol-former materials, and optionally one or more other functional material. The one or more other functional materials may comprise one ormore of apH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0050] A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and / or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.

[0051] Fig. 1 schematically shows a part of a delivery system manufacturing apparatus 1 comprising a delivery system manufacturing apparatus of one embodiment of the present invention. The apparatus 1 includes an aerosol generating rod feed drum 2 and a filter component feed drum 3. The aerosol generating rod feed drum 2 receives wrapped aerosol generating rods 5 and end plugs P that are travelling in a direction transverse to their length (i.e. sideways) in flutes formed in the peripheral surface of the aerosol generating rod feed drum 2. The term ‘aerosol generating rod’ used herein refers to the combination of the aerosol generating rods 5 and the end plugs P. The filter component feed drum 3 receives filter components 6 from a hopper 4 in flutes formed in the peripheral surface of the filter component feed drum 3. In the apparatus 1 shown, a single filter component feed drum 3 and single hopper 4 is shown. However, the apparatus 1 may include multiple filter component feed drums 3 and / or multiple hoppers 4, in order that different configurations or types of filter components may be combined and assembled into the delivery systems being manufactured. Alternatively, the single hopper 4 maybe configured to provide different configurations of filter components 6 to the filter component feed drum 3.

[0052] The filter component feed drum 3 and the aerosol generating rod feed drum 2 feed filter components 6 and aerosol generating rods 5, respectively, onto a combining drum 7, such that the filter components 6 and aerosol generating rods 5 are axially aligned in flutes on the peripheral surface of the combining drum 7, ready to be wrapped to form an assembled delivery system.As shown in Fig. 1, from the combining drum 7, the aerosol generating rods 5 and filter components 6 are transferred onto a tipping drum 8 where they are provided with a tipping paper patch 22 (see Fig. 2) before being transferred to a rolling unit 9 that rolls the tipping paper patch 22 around the aerosol generating rods 5 and filter components 6 to form two joined and assembled delivery systems 21 in back-to-back arrangement. The tipping paper patch is supplied to the tipping drum 7 by a tipping paper suction drum 10.

[0053] A web 13 of tipping paper passes through an adhesive applicator 11 that applies adhesive to one surface of the tipping paper web 13. The tipping paper web 13 is then received on the tipping paper suction drum 10, which uses suction to hold the web 13 of tipping paper against the peripheral surface of the tipping paper suction drum 10. A cutting unit 12 cuts the web 13 of tipping paper into patches on the tipping paper suction drum 10 and the patches are then transferred to the aerosol generating rods 5 and filter components 6 on the tipping drum 8.

[0054] In one example, the cutting unit 12 comprises a crush cutter. In this case, the cutting unit 12 comprises a rotary blade and the tipping paper suction drum 10 acts as an anvil against which the tipping paper web 13 is cut by the rotary blade, in a transverse direction (i.e. across the web 13), to form patches of tipping paper.

[0055] In an alternative embodiment, the cutting unit 12 uses a shear cutter to cut the web 13. In this case, the tipping paper suction drum 10 comprises edges that act with blades of the cutting unit 12 to shear cut the tipping paper web 13.

[0056] The cutting unit 12 may have several rotary blades which protrude from a shaft in a radial direction so that as the shaft rotates the blades successively engage the tipping paper suction drum 10 and cut the web 13 in a transverse direction (i.e. in the axial direction of the tipping paper suction drum 10 and cutting unit 12).

[0057] The cut patches of tipping paper 22 on the tipping paper suction drum 10 already have adhesive applied to their outwards facing surface, so at the position where the tipping paper suction drum 10 rotates closest to the tipping drum 8 the suction acting on the tipping paper patches 22 is released and the patches are transferred from the tipping paper suction drum 10 to the tipping drum 8, specifically onto the aerosol generatingrods 5 and filter components 6. The adhesive anchors the tipping paper patches to the aerosol generating rods 5 and filter components 6.

[0058] The tipping drum 8 then transfers the aerosol generating rods 5 and filter components 6 and the tipping paper patch 22 into the rolling unit 9 that rolls the tipping paper patch 22 around the aerosol generating rods 5 and filter components 6 to form delivery systems. The rolling unit 9 comprises a rolling drum 14 that receives and carries the aerosol generating rods 5 and filter components 6 and the tipping paper patch 22 past a stationary roll hand 15 and kicker bar 16 (described in more detail below).

[0059] The rolling drum 14 of a first exemplary embodiment is shown in more detail in Fig. 3, and comprises a cylindrical drum 14 having a curved outer surface 17 with a plurality of flutes 18 formed in the curved outer surface 17. The drum 14 is adapted to rotate about an axis 19. The flutes 18 are sized to receive and retain aerosol generating and / or filter components as the drum 14 rotates. The flutes 18 extend in a direction parallel to the axis of rotation 19 of the drum 14.

[0060] Each flute 18 includes at least one suction hole 20 that holds the components in the flute 18 when suction is provided to the suction hole 20. In this example, each flute 18 includes several suction holes 20, so that multiple components can be retained in the flute 18. However, multiple suction holes 20 maybe provided to retain a single elongate component. Turning off the suction applied to the suction holes 20 will allow the components to leave the flute 18.

[0061] A suction manifold (not shown) can be used to provide suction to the suction holes 20 during pre-defined portions of the rotation of the drum 14, and to switch off the suction to the suction holes 20 in other pre-defined portions of the rotation of the drum 14.

[0062] The kicker bar 16 pushes the aerosol generating rods 5 and filter components 6 and the tipping paper patch 22 out of flutes 18 in the rolling drum 14 as the rolling drum 14 rotates them past the kicker bar 16. It is to be appreciated that in some embodiments, the kicker bar 16 is not present and that alternatives to the kicker bar 16, such as an air blast, maybe used to push the components out of the flutes 18. The aerosol generating rods 5 and filter components 6 and the tipping paper patch 22 are then rolled between the curved surface 17 of the rolling drum 14 and the roll hand 15, thereby wrapping thetipping paper patch 22 around the aerosol generating rods 5 and filter components 6 to join them together.

[0063] The rolled delivery systems are then conveyed by further drums for cutting into individual single length delivery systems, aligning, arranging and packaging.

[0064] Referring to Fig. 2, two joined delivery systems 21 are manufactured together, as explained above, by arranging two aerosol generating rods 5 and end plugs P at either end of a double-length filter component 6 on the combining drum 7. The aerosol generating rods 5 and filter component 6 are joined together by wrapping a tipping paper patch 22 about them, and then cutting through the filter component 6 along line 23 to separate the two delivery systems 21.

[0065] As shown in Fig. 4, the roll hand 15 and kicker bar 16 are mounted on a support mechanism 27. The support mechanism 27 is configured to hold the roll hand 15 and kicker bar 16 in a fixed position during operation of the apparatus 1. In the exemplary embodiment shown, the support mechanism 27 comprises a bracket 28 fixedly secured to the roll hand 15 and mounted about a pivot point 29 to a fixed portion of the apparatus 1. A piston 30 is attached at one end to a portion of the bracket 28 and at the other end to a fixed portion of the apparatus 1. The piston 30 is provided to enable the roll hand 15 and kicker bar 16 to be moved away from the rolling drum 14 for servicing or maintenance, but in use of the apparatus 1, holds the roll hand 15 and kicker bar 16 in a fixed operative position (shown in Fig. 4). The roll hand 15 and kicker bar 16 are thereby not moveable away from or towards the rolling drum 14 during operation of the apparatus 1.

[0066] As explained above, filter components 6, aerosol generating rods 5, end plugs P, tipping paper patches 22, and wrapped delivery systems 21, collectively ‘components’, are transferred between successive drums as the components travel through the apparatus 1 to manufacture delivery systems 21. The components 5, 6, 21, 22, P are transferred from one drum to the next at the point where the peripheral surfaces of the drums are closest, and at these transfer points the components 5, 6, 21, 22, P are in contact with the flutes of both drums.

[0067] The drums are arranged such that at each transfer point, the components 5, 6, 21, 22, P are smoothly and reliably transferred. That is, the components 5, 6, 21, 22, P are placedinto the flutes of the downstream drum so that the suction applied in the flute can take effect on the components 5, 6, 21, 22, P before the upstream drum moves away. During transfer, suction acts on the components 5, 6, 21, 22, P from either the upstream drum, the downstream drum, or, for short time, both the upstream and downstream drums.

[0068] In the rolling unit 9, as the aerosol generating rods 5 and filter components 6 pass between the roll hand 15 and kicker bar 16, the kicker bar 16 initially engages the aerosol generating rods 5 and filter components 6, compressing them slightly to ensure they are reliably pushed out of their flute 18 in the rolling drum 14. As described above, as the rolling drum 14 continues to rotate, the aerosol generating rods 5 and filter components 6 are rolled between the rotating rolling drum 14 and the stationary roll hand 15 to become wrapped with the tipping paper patch 22. The spacing between the kicker bar 16 and the roll hand 15 and the curved surface 17 of the rolling drum 14 is accurately set to ensure the correct degree of initial compression of the aerosol generating rods 5 and filter components 6 in the flute 18, and correct contact pressure of the aerosol generating rods 5 and filter components 6 between the curved surface 17 rolling drum 14 and the roll hand 15. The kicker bar 16 and roll hand 15 are fixedly connected, or are formed as one component, and during use, remain in a fixed position whilst the rolling drum 14 rotates. In a conventional apparatus, the roll hand comprises a continuous curved surface and the kicker bar comprises a continuous elongate bar.

[0069] In various examples within the scope of the present disclosure, each filter component 6 may comprise one or more filter segments. For example, the filter rod 6 may be formed of any combination of cellulose acetate segments, plasticised cellulose acetate segments, paper segments, non-wrapped cellulose acetate segments, plastic components, ceramic components, or metallic segments. These filter segments are generally cylindrical and / or tubular, and may have a cylindrical outer surface that fits within the flutes of the drums and can be rolled by the rolling drum 14 to create a wrapped delivery system. The filter segments may each have a wrapper, typically called a plug wrap, which holds the material of the filter segment in the desired shape before the filter segment is provided to the apparatus 1 of Fig. 1.

[0070] The delivery systems shown in Fig. 2 are products which heat aerosol generating material without burning to release a vapour. Yet further, the delivery systems may be products of a device that heats aerosol generating material without burning to release avapour. Alternatively, they may be any other kind of delivery system that is manufactured on apparatus having a series of drums.

[0071] In the exemplary embodiment, the delivery system shown in Fig. 2 comprises a wrapped aerosol generating rod 5 which comprises a tobacco material wrapped in a wrapper, for example a paper wrapper, and an end plug P. The delivery system also comprises a filter component 6. In this example, the filter component 6 comprises a first filter segment 24 being made of plasticized cellulose acetate through which smoke or vapour can pass and which removes constituents from the smoke or vapour. A second segment 25 of the filter component 6 comprises a tubular member made from plastics, the plastics tubular member having passages therethrough to allow smoke or vapour to pass through the filter section. A third filter segment 26 comprises a tubular member made of paper.

[0072] As is apparent from Fig. 2, each filter component 6 supplied to the apparatus of Fig. 1 is symmetrical so that after the filter component 6 is cut along line 23 there are two identical delivery systems 21.

[0073] It will be appreciated that other filter sections have different combinations of components, and it is possible to arrange such components in a multitude of ways using drums that received, move and position components in the same flute so that they can be wrapped to join them into delivery systems.

[0074] The filter component 6 is attached to the end of a aerosol generating rod 5 by a tipping paper patch 22 that circumscribes the join between the filter component 6 and aerosol generating rod 5. The tipping paper patch 22 is adhered to the outer surface of the filter component 6 and the aerosol generating rod 5. The tipping paper patch 22 may extend over the whole of the filter component 6 and partially over the aerosol generating rod 5. Alternatively, the tipping paper patch 22 may extend partially onto the filter component 6 and partially onto the aerosol generating rod 5.

[0075] As explained above, the delivery systems manufactured by the apparatus 1 of Fig. 1 may include components or segments having a high hardness, for example components made of plastic, ceramic or metal. In this case, during the rolling process in the rolling unit 9, such components are placed under pressure, such as by the kicker bar 16 to push them out of the flutes 18 in the rolling drum 14, and between the curved surface of theroll hand 15 and the curved surface 17 of the rolling drum 14. Such pressure maybe accommodated by components which are deformable and / or resilient. However, if components are delicate, fragile, or brittle, then the components maybe damaged, broken, or deformed by the pressure applied to the components. For example, the aerosol generating rod 5 may be cracked or broken by the pressure. Furthermore, if the kicker bar 16 and / or roll hand 15 are set further away from the rolling drum to avoid damaging the harder components, the rolling unit 9 may not exert sufficient force to push the aerosol generating rods 5 and other filter components 6 out of the flutes 18 or roll them between the rolling drum surface 17 and roll hand 15 successfully or reliably. Yet further, passing hard rigid components between a fixed kicker bar 16 / roll hand 15 and the rolling drum 14 of a conventional apparatus may force the roll hand 15 and kicker bar 16 away from the rolling drum 14, enlarging the spacing therebetween. As mentioned above, the clearance between the roll hand 15 and the kicker bar 16 is carefully set, and effective and reliable operation of the apparatus 1 is sensitive to this spacing. Therefore, unintentional enlargement of this spacing can be detrimental to the operation of the apparatus 1, for example, ineffective rolling of the filter component 6 and aerosol generating rod 5 with the tipping paper patch 22, or these components falling out of the gap between the rolling drum 14 and the roll hand 15.

[0076] In order to seek to avoid or mitigate the above problems and to accommodate delivery system components of differing hardnesses, the roll hand 15 and kicker bar 16 comprise grooves configured to relieve the pressure on the components. It will be appreciated that the terms ‘recess’, ‘groove’ and ‘channel’ as used herein all refer to features of the rolling apparatus 9 in which a recessed or indented formation is provided in the kicker bar 16 or roll hand 15 to accommodate less compressible components of the delivery system being manufactured. As such, all such features disclosed herein could be defined as recesses, grooves or channels interchangeably.

[0077] However, in this arrangement there is a possibility that the tipping paper patch 22 may loosen leading to a poor quality wrap. In order to seek to avoid or mitigate this issue and to accommodate delivery system components of differing hardnesses whilst maintaining good tipping paper patch adhesion without damaging the components, the roll hand 15 of an exemplary embodiment of the present disclosure is provided as illustrated in more detail in Fig 5.The roll hand 15 includes a curved contact surface 34 which, in use, faces the rolling drum 14 and presses against the aerosol generating rods 5 and filter components 6 as they are rolled between the roll hand 15 and the rotating rolling drum 14 to become wrapped with the tipping paper patch 22. The curved contact surface 34 of the roll hand 15 includes a groove 32. In particular, a pair of shallow grooves 32. The grooves 32 extend in a circumferential direction of the rolling drum 14. The grooves 32 have a width ‘w2’ which corresponds to the length of the aerosol generating rod 5. The roll hand 15 comprises an airflow inlet 40 and the groove 32 comprises an airflow outlet 41. The outlet 41 comprises a plurality of ventilation holes 42, which in some embodiments, may be equally spaced along the length of the groove 32. Equal spacing of the ventilation holes 42 ensures a constant pressure is applied along the length of the groove 32. Alternatively, in some embodiments, the outlet 41 may comprise a slot extending along the length of the groove 32. A passage extends between the inlet 40 and the outlet 41 to enable air to flow along the passage and out of the outlet 41. A pump is provided to provide a pressurised air flow along the passage between the inlet 40 and the outlet 41. If there are multiple grooves 32, the pressure of the air provided to the outlets 41 of one groove 32 maybe different to the pressure of air provided to the outlet of at least one other groove 32. Furthermore, the outlets 41 of one groove 32 may be of a different size or number to the outlets 41 in another groove 32.

[0078] In another embodiment shown in Figs 6 and 7, the kicker bar 16 is is fixedly secured to the roll hand 15 during use of the apparatus 1. However, the kicker bar 16 may alternatively be formed integrally with the roll hand 15. In the embodiments shown, the kicker bar 16 is secured to the roll hand 15 by mechanical fasteners 35, such as screws or bolts. The kicker bar 16 includes a contact edge 36 which, in use, is the part of the kicker bar 16 disposed closest to the rolling drum 14. The contact edge 36 is disposed closer to the rolling drum 14 than the curved contact surface 34 of the roll hand 15. The distance between the contact edge 36 and the rolling drum 14 affects how the aerosol generating rods 5 and filter components 6 are initially compressed and / or pushed out of the flutes 18. Also in the exemplary embodiment shown, the kicker bar 16 is adjustable relative to the roll hand 15. That is, a projection distance ‘p’ of the contact edge 36 of the kicker bar 16 from the curved contact surface 34 of the roll hand 15 can be adjusted and set. The kicker bar 16 includes adjustments slots 37 through which the mechanical fasteners 35 extend. The mechanical fasteners 35 can therefore be loosened, the kicker bar 16 adjusted by the distance permitted by the adjustment slots 37, and themechanical fasteners 35 tightened to secure the kicker bar 16 with the desired projection distance ‘p’.

[0079] As shown in Fig. 6, the kicker bar 16 may include recesses 31 formed in the contact edge 36. The recesses 31 have a width ‘wi’ which corresponds to the length of the aerosol generating rod 5. The recesses 31 extend in a circumferential direction of the rolling drum 14 and are in alignment with the grooves 32 of the roll hand 15. In some embodiments, the recesses 31 in the kicker bar 16 are a continuation of the grooves 32 in the roll hand 15. Additionally, the airflow passage may extend into the kicker bar 16 and the recesses 31 in the kicker bar 16 may comprise outlets 42 as described in relation to the roll hand 15.

[0080] As shown in Fig. 7, the kicker bar 16 does not include recesses in the contact edge 36. The projection distance ‘p’ maybe set at or close to a minimal amount necessary to ensure the aerosol generating rods 5 and filter components 6 are pushed out of the flute 18, without damaging the aerosol generating rods 5.

[0081] Operation of the rolling unit 9 of the apparatus 1 of the invention will now be described, with additional reference to the flow chart of Fig. 9. The aerosol generating rods 5 and filter components 6, together with the tipping paper patch 22, are transferred from the tipping drum 8 to the rolling drum 14 as described above, at step Si of Fig. 9. The aerosol generating rods 5 and filter components 6 are received in axial alignment in a flute of the 18 of the rolling drum 14, at step S2. The aerosol generating rods 5 and filter components 6 reach and engage the kicker bar 16 as the rolling drum 14 rotates, at step S3. The filter components 6 and aerosol generating rods 5 contact the contact edge 36 of the kicker bar 16 and pressure is exerted on the aerosol generating rod 5 and filter components 6 to compress them and push them out of the flute 18 as described above.

[0082] In embodiments where the kicker bar 16 comprises recesses 31, the aerosol generating rods 5 are at least partially received within the recesses 31, at step S4, as the filter components 6 and aerosol generating rod 5 pass the kicker bar 16 and are pushed out of the flute 18 at step S5. The recesses 31 prevent the kicker bar 16 damaging the aerosol generating rods 5 through excessive compression.

[0083] Thereafter, the aerosol generating rods 5 and filter components 6, together with the tipping paper patch 22, pass the kicker bar 16 and are rolled between the curved outersurface 17 of the rolling drum 14 and the curved contact surface 34 of the roll hand 15 as described previously, at step S6.

[0084] Once past the kicker bar 16, the aerosol generating rods 5 and filter components 6, together with the tipping paper patch 22 are rolled between the curved outer surface 17 of the rolling drum 14 and the curved contact surface 34 of the roll hand 15. However, the aerosol generating rods 5 are at least partially received within the grooves 32 in the roll hand 15. This helps enable a similar pressure be applied on all the components of varying hardnesses during the rolling process to help achieve consistent rolling performance.

[0085] The aerosol generating rods 5 are at least partially received within the grooves 32 as the components are rolled between the curved outer surface 17 of the rolling drum 14 and the curved contact surface 34 of the roll hand 15. The grooves 32 thereby prevent the roll hand 15 damaging the aerosol generating rods 5 through excessive compression. The flow of air from the airflow outlet 41 in the grooves 32 ensures good adhesion of the tipping paper patch 22, . because the airflow appliesa small amount of pressure to the aerosol generating rods 5 within the grooves 32 to ensure good adhesion of the tipping paper patch 22 whilst avoiding potential damage via excessive compression of the components.

[0086] In embodiments where the kicker bar 16 includes recesses 31 and the roll hand 15 includes grooves 32, the recesses 31 and grooves 32 may have a range of difference depths. These various embodiments are shown in Figs. 8A - 8E which show schematic cross-sectional views through the roll hand 15 and kicker bar 16 taken along a line extending through the recess 31 in the kicker bar 16 and groove 32 in the roll hand 15.

[0087] In one embodiment, shown in Fig. 8A, a base surface 38 of the recess 31 in the kicker bar 16 may be off-set from a base surface 39 of the groove 32 in the roll hand 15, so as not to be level therewith. The off-set is shown as dimension ‘d’ in Fig. 8A. In other words, the depth of the recess 31 in the kicker bar 16 is different to the depth of the groove 32 in the roll hand 15. This may advantageously allow sufficient initial contact with aerosol generating rods 5 to push them from the flutes 18, but thereafter a reduced contact pressure with the aerosol generating rods 5 during the subsequent rolling process to enable rolling without damaging the aerosol generating rods 5.In another embodiment, the base surface 38 of the recess 31 in the kicker bar 16 may be level with a base surface 39 of the groove 32 in the roll hand 15. In other words, the depth of the receses 31 in the kicker bar 16 is the same as the depth of the groove 32 in the roll hand 15. This may enable the aerosol generating rods 5 to more smoothly transfer to the roll hand 15 from the kicker bar 16. This arrangement is shown in Fig.

[0088] 8B.

[0089] In a yet further embodiment, the base surface 38 of the recess(es) 31 in the kicker bar 16 maybe inclined, such that the depth of the recess(es) 31 varies from one side of the kicker bar 16 to the other. As such, the base surface 38 of the recess(es) 31 in the kicker bar 16 may be inclined with respect to the curved surface 17 of the rolling drum 14. The depth of the recess(es) 31 may increase from the side of the kicker bar 16 remote from the roll hand 15 to the side of the kicker bar 16 proximate the roll hand 15, or vice versa. In the former case, illustrated in Fig. 8C, the kicker bar 16 may provide an initial contact with the aerosol generating rods 5 to push them from the flute 18, and as the recess depth increases, the pressure on the aerosol generating rods 5 reduces to transition to the roll hand 15. In the latter case, shown in Fig. 8D, the kicker bar 16 may more gently initially contact the aerosol generating rods 5 to avoid damaging the aerosol generating rods 5 and may increase pressure on the aerosol generating rods 5 to push them from the flute 18.

[0090] In a yet further embodiment, the base surface 38 of the recess 31 in the kicker bar 16 maybe off-set from the base surface 39 of the groove 32 in the roll hand 15 at one side of the kicker bar 16, and may be level with the base surface 39 of the groove 32 in the roll hand 15 at the other side of the kicker bar 16. The base surface 38 of the recess(es) 31 may be off-set from the base surface 39 of the groove(s) in the roll hand 15 at the side of the kicker bar 16 remote from the roll hand 15, and may be level with the base surface 39 of the groove(s) in the roll hand 15 at the side of the kicker bar 16 proximate the roll hand 15, or vice versa. An embodiment of the former configuration is shown in Fig. 8E.

[0091] The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and / or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents tothe claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc, other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

Claims1. An apparatus for manufacture of delivery systems, the apparatus comprising a rolling unit comprising:a rotatable drum having a plurality of flutes extending in an axial direction of the drum and spaced circumferentially around a curved outer surface of the drum, the flutes being formed in the curved outer surface of the drum to receive axially-aligned components of delivery systems; anda roll hand having a contact surface facing and spaced from the outer surface of the drum to enable components of delivery systems to be rolled, upon rotation of the drum, between the outer surface of the drum and the contact surface of the roll hand;wherein the roll hand contact surface includes a groove extending in a substantially circumferential direction of the drum and configured to at least partially receive one or more of the delivery system components as the drum rotates; and wherein the roll hand comprises an airflow passage having an outlet in the groove for directing a flow of air towards said one or more of the delivery system components at least partially received in the groove as the drum rotates.

2. An apparatus according to claim 1, comprising a plurality of outlets in the groove.

3. An apparatus according to claim 2, wherein the plurality of outlets are equally spaced along the groove.

4. An apparatus according to claim 2 or 3, comprising a plurality of grooves, each groove having a plurality of outlets.

5. An apparatus according to claim 4, wherein the outlets in at least one groove are of a different size or number to the outlets in another groove.

6. An apparatus according to claim 4 or 5, comprising a pump to generate a pressurised flow of air through said passage and out of said outlets and a control unit for controlling the pump such that the pressure of air flowing out of the outlets in one groove is different to the pressure of air flowing out of the outlets in at least one other groove.

7. An apparatus according to any of claims 1 to 6, further comprising a kicker bar disposed adjacent to the roll hand and having a contact edge facing and spaced from the outer surface of the drum.

8. An apparatus according to claim 7, wherein the groove continues from said roll hand contact surface into the kicker bar contact edge.

9. An apparatus according to claim 8, wherein a depth of the groove in the kicker bar contact edge is the same as the depth of the groove in the roll hand contact surface.

10. An apparatus according to claim 8, wherein a depth of the groove in the kicker bar contact edge is different to a depth of the groove in the roll hand contact surface.

11. An apparatus according to any preceding claim, wherein the kicker bar is a separate component to the roll hand and is fixedly secured to the roll hand.

12. An apparatus according to claim 11, wherein a position of the kicker bar relative to the roll hand can be adjusted.

13. A roll hand forming a part of a rolling unit of an apparatus for manufacture of delivery systems, the roll hand having a contact surface positionable facing and spaced from a drum of a rolling unit such that components of delivery systems are rolled, upon rotation of the drum, across an outer surface of the drum between the outer surface and the contact surface of the roll hand,wherein the roll hand contact surface includes a groove extending in a substantially circumferential direction of the drum, the groove being configured, when the roll hand is in use, to at least partially receive one or more of the delivery system components, andwherein the roll hand comprises an airflow passage having an outlet in the groove to enable a flow of air to be directed towards said one or more of the delivery system components at least partially received in the groove.

14. A delivery system assembly machine comprising an apparatus according to any of claims 1 to 12.15- A method of manufacturing delivery systems, comprising use of apparatus for manufacturing delivery systems, the apparatus comprising a rolling unit having a rotatable drum having a plurality of flutes extending in an axial direction of the drum and spaced circumferentially around a curved outer surface of the drum, the flutes being formed in the curved outer surface of the drum, a roll hand having a contact surface facing and spaced from the outer surface of the drum to enable spaced components of a delivery system to be rolled, upon rotation of the drum, across the outer surface and between the outer surface and the contact surface of the roll hand, wherein the roll hand contact surface includes a groove extending in a substantially circumferential direction of the drum to at least partially receive one or more of the delivery system components as the drum rotates,wherein the roll hand comprises an airflow passage having an outlet in the groove, andwherein the method comprises directing a flow of air towards said one or more of the delivery system components at least partially received in the groove from said outlet as the drum rotates.

16. A method according to claim 15, comprising directing a flow of air towards said one or more of the delivery system components at least partially received in the groove through a plurality of outlets in the groove.

17. A method according to claim 15, comprising controlling a pump to generate a pressurised flow of air through the passage and out of said outlets.

18. A method according to claim 17, wherein the roll hand comprises a plurality of grooves, each groove having a plurality of outlets and the method includes controlling the pump so that the pressure of air flowing out of the outlets in one groove is different to the pressure of air flowing out of the outlets in at least one other groove.

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