Method and apparatus for separating susceptors from aerosol-generating articles

Abstract

A method of processing waste rod-shaped aerosol-generating articles (30) each comprising an aerosol-generating substrate portion including a substantially planar metallic susceptor (32) disposed longitudinally within the aerosol-generating substrate portion, together with other plug components, all wrapped in at least one wrapper (3), wherein: i) the rod-shaped aerosol-generating articles are fed onto a conveyor (41) travelling in a first direction; ii) the rod-shaped aerosol-generating articles on the conveyor are subjected to a magnetic field so as to cause the rod-shaped aerosol-generating articles to be disposed such that planes of the substantially planar metallic susceptors are aligned in substantially the same direction; and iii) the rod-shaped aerosol-generating articles with their substantially planar metallic susceptors aligned in substantially the same direction are compressed in a second direction substantially perpendicular to the first direction so as to deform the rod-shapes aerosol-generating articles and to loosen the at least one wrapper (3) from the aerosol¬ generating substrate portions and the other plug components.

Description

[0001] METHOD AND APPARATUS FOR SEPARATING SUSCEPTORS FROM AEROSOLGENERATING ARTICLES

[0002] The present disclosure relates to the recycling of aerosol-generating articles, in particular to the separation of metallic susceptor elements that are embedded in such aerosol-generating articles.

[0003] It is known to process defective or waste conventional cigarettes, comprising a rod of loose tobacco wrapped in a paper wrapper and abutted to rod-shaped mouthpiece filter by way of a tipping paper. The mouthpiece filter is usually made of a cellulose acetate tow plasticized with triacetin. The defective or waste conventional cigarettes, or even used conventional cigarettes, may be processed by shredding so as to release internal components from the paper wrappers. The shredded waste can be screened, for example by way of an inclined rotary drum sieve or “trommel screen”, where smaller bits of waste (typically comprising tobacco) fall through holes in the rotary drum sieve, and larger bits of waste (typically parts of mouthpiece filters and bits of paper) remain within the rotary drum sieve and are driven by the slope of the rotary drum sieve towards a drum exit. The larger bits of waste may then be passed to a tank of water, where they are stirred so as to promote separation of paper components from the mouthpiece filter components by way of a “float and sink” process. The paper components will tend to absorb water and sink, while the cellulose acetate tow of the mouthpiece filter components contains trapped air and will tend to float. In this way, it is possible to separate tobacco waste, paper waste and mouthpiece filter waste. The separated waste can then be recycled or disposed of an in environmentally-responsible manner as appropriate.

[0004] However, the shredding process can generate a very large volume of waste, particularly when the cellulose acetate tow of the mouthpiece filters is expanded by the shredding process. Moreover, shredding processes are unsuitable for aerosol-generating articles comprising metallic susceptor elements, since there is a risk of shredding the metallic susceptor elements and contaminating the waste stream with small metal particles that cannot easily be recovered.

[0005] In the manufacture of aerosol-generating articles, for example heat-not-burn heated tobacco products, heat-not-burn nicotine-containing products, and hybrids thereof, various elements are combined to make the aerosol-generating articles. Typically, these articles comprise an aerosol-generating substrate, or “sensorial medium”, for example tobacco cast leaf, other agricultural products, such as clove, menthol and guar gum, glycerine, one or more filter elements, for example comprising a cellulosic material, an aerosol-cooling element, for example comprising a polylactic acid material or an acetate material, and a metallic susceptor element that, when heated, causes the aerosol-generating substrate to heat up and release an aerosol. The various elements are arranged in a desired configuration and assembled as rod-shaped articles wrapped in an outer wrapper, which may be made of paper or other material.There are many different designs of aerosol-generating article, and the present disclosure is directed specifically at waste streams generated during the manufacture of aerosol-generating articles comprising rod-shaped articles with internal metallic susceptor elements, or to waste streams comprising used aerosol-generating articles comprising rod-shaped articles with internal metallic susceptor elements.

[0006] With reference to the manufacture of aerosol-generating articles, a production line may be set up to manufacture thousands or tens of thousands or even more aerosol-generating articles per hour. The aerosol-generating articles are subject to quality checks, and those that do not meet quality standards will be rejected and sent to a waste stream. The waste stream may comprise complete aerosol-generating articles that do not meet quality standards and partially complete aerosol-generating articles that have been rejected before completion. It would be desirable to separate the metallic susceptor elements of the aerosol-generating articles and optionally other components of the aerosol-generating articles in the waste stream for recycling or environmentally-responsible disposal.

[0007] It would also be desirable to separate components when processing used aerosolgenerating articles, which may have been collected from end users or testing machines.

[0008] Aerosol-generating articles in the form of consumable products for use with aerosolgenerating devices are known in the marketplace. Such aerosol-generating articles consist of multiple components arranged into a rod-like structure. Aerosol-generating articles designed for induction heating often incorporate an elongated, substantially planar, metallic susceptor element that is positioned longitudinally within an aerosol-generating substrate or sensorial medium. The metallic susceptor element may be heated by applying an external varying electromagnetic field, which will induce eddy currents and consequent Joule heating in the metallic susceptor element. The varying electromagnetic field may be generated by induction coils that form part of an aerosolgenerating device into which the aerosol-generating article is inserted for consumption.

[0009] Moreover, such aerosol-generating articles often feature additional components such as filtering and air management segments, arranged in a sequential manner, often composed of cellulose-based materials. During the assembly process, the various components are first aligned in the desired order and then encased within an outer paper wrapper, which is applied tightly to maintain the integrity and shape of the article.

[0010] An exemplary aerosol-generating article 30 is shown in exploded form in Figure 1, with the various components partially unwrapped. Figure 2 is a longitudinal cross-section through an assembled aerosol-generating article 30.

[0011] The aerosol-generating article 30 comprises a rod-shaped plug of sensorial medium 31 wrapped in a plug wrap 37 made of thin paper. The sensorial medium 31 may be formed by crimping or pleating a flat sheet and subsequently gathering the crimped or pleated sheet througha funnel to form a rod. A planar metallic susceptor element 32 is disposed longitudinally along a central part of the plug of sensorial medium 31.

[0012] The plug of sensorial medium 31 is protected at the front of the aerosol-generating article assembly 30 by a front plug 33, usually made of porous cellulose acetate tow, and also provided with a plug wrap 37. Behind the plug of sensorial medium 31, there is provided a hollow acetate tune (HAT) plug 34 with a relatively narrow central bore, and a fine hollow acetate tube (FHAT) plug 35 with a relatively wide central bore. The HAT plug 34 and FHAT plug 35 are made of compressed plasticized cellulose acetate having an empty and airtight central bore, and serve to cool and condition aerosol released from the plug of sensorial medium 31 when the metallic susceptor element 32 is inductively heated. The HAT plug 34 and FHAT plug 35 may also be provided with a plug wrap 37. Finally, there is provided a mouth piece filter (MPF) 36, mostly made of plasticized cellulose acetate tow, and provided with a plug wrap 37. The front plug 33, plug of sensorial medium 31, HAT plug 34 and FHAT plug 35 may be wrapped together in a wrapping paper 3, and the MPF 36 may be joined to the assembly of wrapped plugs by way of a tipping paper 5.

[0013] Figure 2 is a longitudinal cross-section through the aerosol-generating article 30 with the arrows indicating a direction of air flow when a user sucks or inhales at the MPF 36.

[0014] The different plugs making up such an aerosol-generating article 30 are usually just abutted to each other, rather than glued to each other.

[0015] It will be appreciated that different combinations of plugs may be used to assemble an aerosol-generating article 30. For example, one or both of the HAT plug 34 and FHAT plug 35 may be replaced by one or more hollow paperboard or polylactic acid tubes.

[0016] Existing processes for separating components of waste or used conventional cigarettes do not work well with these aerosol-generating articles 30 for a number of reasons. Firstly, the shredding step may damage the metallic susceptor elements 32, creating small particles of metallic waste that will contaminate the recycling stream and be very hard to separate from the other components. Secondly, the screening process using an inclined rotary drum sieve is not particularly effective, since most of the components making up an aerosol-generating article 30 are of a similar size, and there is no loose tobacco that can easily be separated. Thirdly, the float and sink process does not work well to separate the paper plug wraps, wrapping papers and tipping papers from the more valuable sheets of sensorial medium 31, since all of these components have similar densities and interactions with water.

[0017] According to a first aspect of the present invention, there is provided a method of processing waste rod-shaped aerosol-generating articles each comprising an aerosol-generating substrate portion including a substantially planar metallic susceptor disposed longitudinally within the aerosol-generating substrate portion, together with other plug components, all wrapped in at least one wrapper, wherein:i) the rod-shaped aerosol-generating articles are fed onto a conveyor travelling in a first direction;

[0018] ii) the rod-shaped aerosol-generating articles on the conveyor are subjected to a magnetic field so as to cause the rod-shaped aerosol-generating articles to be disposed such that planes of the substantially planar metallic susceptors are aligned in substantially the same direction; and

[0019] iii) the rod-shaped aerosol-generating articles with their substantially planar metallic susceptors aligned in substantially the same direction are compressed in a second direction substantially perpendicular to the first direction so as to deform the rod-shapes aerosol-generating articles and to loosen the at least one wrapper from the aerosol-generating substrate portions and the other plug components.

[0020] By compressing the rod-shaped aerosol-generating articles in the second direction, it is possible to loosen the at least one wrapper from the aerosol-generating substrate portions and the other plug components without damaging the metallic susceptors. This is in contrast to known processes that use blades or toothed wheels or cylinders to shred aerosol-generating articles.

[0021] Moreover, the compression force can be carefully controlled and adjusted so as to take into account different aerosol-generating article constructions. A controlled compression force can gently loosen and separate the other plug components and the at least one wrapper from each other and from the aerosol-generating substrate portions with their substantially planar metallic susceptors.

[0022] The use of a magnetic field to align the substantially planar metallic susceptors in substantially the same direction means that the action of the compression force in the second direction gives a consistent result that is not affected by differing planar metallic susceptor orientations.

[0023] In step ii), the magnetic field may cause the rod-shaped aerosol-generating articles to be disposed such that the planes of the substantially planar metallic susceptors are aligned in a direction substantially perpendicular to the second direction. In such embodiments, the planes of the substantially planar metallic susceptors are aligned in a direction substantially perpendicular to the direction of the compression force, and the compression force, while loosening the at least one wrapper from the aerosol-generating substrate portions and the other plug components, may tend to strengthen a connection between the aerosol-generating substrate portions and their substantially planar metallic susceptors. This is because parts of the aerosol-generating substrate portions will tend to be pressed against the opposed major surfaces of the substantially planar metallic susceptors, strengthening a bond therebetween. This may be advantageous in a subsequent processing step, where the aerosol-generating substrate portions with attached substantially planar metallic susceptors are separated from the at least one wrapper and from the other plug components. By flattening the rod-shaped aerosol-generating articles using acompression force, an outer circumference of the rod-shaped aerosol-generating articles will tend to stretch and increase, causing tearing or breaking of the at least one outer wrapper, or pulling the at least one outer wrapper apart along a glue seam. In this embodiment, it is currently believed that a relatively large compression force is advantageous in order to deform the outer circumferences of the rod-shaped aerosol-generating articles sufficiently to tear or break the at least one outer wrapper. For example, it has been found that compressing the rod-shaped aerosol-generating articles so that a thickness of the rod-shaped aerosol-generating articles in a direction parallel to the second direction (the compression force direction) is decreased by around 64 percent from an original, uncompressed diameter of the rod-shaped aerosol-generating articles results in reliable tearing or breaking of the at least one outer wrapper.

[0024] Alternatively, in step ii), the magnetic field may cause the rod-shaped aerosol-generating articles to be disposed such that the planes of the substantially planar metallic susceptors are aligned in a direction substantially parallel to the second direction. In such embodiments, the planes of the substantially planar metallic susceptors are aligned in a direction substantially parallel to the direction of the compression force, and the compression force may cause edges of the substantially planar metallic susceptors to burst through the at least one wrapper. This is because the compressive force may cause the at least one outer wrapper to press against a sharp edge of the substantially planar metallic susceptor, causing a cut or tear in the at least one outer wrapper. Preferably, the compression force is controlled so as not to push the substantially planar metallic susceptors completely out of the aerosol-generating substrate portions, since it is preferred in a subsequent processing step for these respective components to remain attached to each other. It may not be necessary to apply as great a compression force in this embodiment is in the previous embodiment in order to break or tear the at least one outer wrapper. For example, it has been found that compressing the rod-shaped aerosol-generating articles so that a thickness of the rod-shaped aerosol-generating articles in a direction parallel to the second direction (the compression force direction) is decreased by around 30 percent from an original, uncompressed diameter of the rod-shaped aerosol-generating articles results in reliable tearing or breaking of the at least one outer wrapper, albeit at the cost of potentially loosening a bond between the substantially planar metallic susceptor and the aerosol-generating substrate portion.

[0025] By using a magnetic field to rotate the rod-shaped aerosol-generating articles in such a way that the planes of the substantially planar metallic susceptors are aligned in substantially the same direction, namely either substantially perpendicular to the second direction (for example, in a substantially horizontal direction), or substantially parallel to the second direction (for example, in a substantially vertical direction), the compression force applied in the second direction to the aerosol-generating articles has a more consistent effect on loosening and separating the other plug components and the at least one wrapper from each other and from the aerosol-generating substrate portions with their substantially planar metallic susceptors.It will be understood that the application of the magnetic field might not always ensure that every single rod-shaped aerosol-generating article is fully rotated such that all of the substantially planar metallic separators are perfectly aligned in exactly the same direction. Some of the rodshaped aerosol-generating articles may not fully rotate to the correct position due to frictional forces between respective rod-shaped aerosol-generating articles, especially when several layers of rod-shaped aerosol-generating articles are disposed on top of each other on the conveyor.

[0026] Accordingly, the term “such that the planes of the substantially planar metallic susceptors are aligned in a direction” is to be interpreted in a statistical manner, meaning that at least 50 percent, preferably 75 percent, more preferably at least at least 90 percent of the rod-shaped aerosol-generating articles are disposed such that the planes of the substantially planar metallic susceptors are aligned within plus or minus 10 degrees, preferably within plus or minus 5 degrees, of the respective perpendicular or parallel direction.

[0027] In order to facilitate alignment of the planes of the substantially planar metallic susceptors by the magnetic field, the rod-shaped aerosol-generating articles on the conveyor may be shaken or vibrated. This can help to fluidize the flow of rod-shaped aerosol-generating articles along the conveyor, especially when there are multiple layers, and this can overcome frictional forces that might otherwise prevent the rod-shaped aerosol-generating articles from rotating to the correct orientation in the magnetic field.

[0028] In step i), the rod-shaped aerosol-generating articles may be aligned substantially parallel to each other on the conveyor. For example, in step i), the rod-shaped aerosol-generating articles may be aligned substantially perpendicular to the first direction on the conveyor.

[0029] The rod-shaped aerosol-generating articles may be fed onto the conveyor from a hopper. The hopper may be configured so as to promote alignment of the rod-shaped aerosol-generating articles with each other before the rod-shaped aerosol-generating articles are fed onto the conveyor.

[0030] The rod-shaped aerosol-generating articles may be disposed on the conveyor in a single layer. By arranging a single layer of rod-shaped aerosol-generating articles on the conveyor, it becomes easier to ensure that all or nearly all or most of the rod-shaped aerosol-generating articles are correctly aligned and rotated by the magnetic field, and also means that application of the compression force gives a consistent result, since the compression force will only be applied to a single layer of rod-shaped aerosol-generating articles. However, processing only a single layer of rod-shaped aerosol-generating articles may limit the processing efficiency.

[0031] Accordingly, in some embodiments, the rod-shaped aerosol-generating articles may be disposed on the conveyor in multiple layers. Preferably, the rod-shaped aerosol-generating articles are disposed on the conveyor in no more than five layers. This may increase the throughput of rod-shaped aerosol-generating articles, leading to improved process efficiency, while still allowing relatively free rotation of the rod-shaped aerosol-generating articles such thatthe planes of the substantially planar metallic susceptors are aligned in the respective direction by the magnetic field, and such that the compression force still gives consistent results. Where multiple layers of rod-shaped aerosol-generating articles are present, the compression force may be applied to an upper layer and transmitted through the underlying layers to a surface of the conveyor. Provided that there are not too many layers of rod-shaped aerosol-generating articles, the compression force will tend to be relatively uniformly transmitted, and each rod-shaped aerosol-generating article within the several layers will experience substantially the same compression force.

[0032] The magnetic field may be applied by a permanent magnet.

[0033] The magnetic field may be applied by an electromagnet. Using an electromagnet may be advantageous since a strength of the magnetic field may be varied so as to take into account different shapes of, or materials used for, the rod-shaped aerosol-generating articles or the substantially planar metallic susceptors.

[0034] The rod-shaped aerosol-generating articles may be subjected to vibration or shaking on the conveyor during application of the magnetic field. As noted above, this may help to fluidize the stream of rod-shaped aerosol-generating articles on the conveyor, facilitating their rotation and alignment in the magnetic field.

[0035] In step iii), the rod-shaped aerosol-generating articles may be compressed in the second direction by a pressing roller operable to exert a compression force in a direction towards the conveyor. Using a pressing roller may facilitate a continuous process, since a stream of rodshaped aerosol-generating articles may pass continuously between the pressing roller and the surface of the conveyor. A pressing roller may be more effective when processing the rod-shaped aerosol-generating articles in a single layer rather than in multiple layers, since it may be difficult to control a compression force and prevent rolling of rod-shaped aerosol-generating articles relative to each other when compressing multiple layers with a pressing roller.

[0036] Alternatively, in step iii), the rod-shaped aerosol-generating articles may be compressed in the second direction by a pressing block operable to exert a compression force in a direction towards the conveyor. Using a pressing block may allow for more precise application of the compression force, since the rod-shaped aerosol-generating articles may be substantially stationary relative to the pressing block, at least in the first direction, during application of the compression force. However, this may require that the conveyor does not operate continuously, but instead operates on a stop-start basis, with the conveyor being stopped during application of the compression force by the pressing block. Moreover, it is easier to adjust or vary the compression force when applying the compression force with a pressing block instead of a pressing roller, since there may be fewer degrees of freedom of movement of the rod-shaped aerosol-generating articles relative to the pressing block and the surface of the conveyor, especially when compressing multiple layers of rod-shaped aerosol-generating articles.The rod-shaped aerosol-generating articles may be wetted prior to or while being compressed. For example, the rod-shaped aerosol-generating articles may be sprayed with water prior to or while being compressed. For example, the rod-shaped aerosol-generating articles may be sprinkled with water prior to or while being compressed. Wetting the rod-shaped aerosol-generating articles may help to loosen the at least one wrapper from the aerosolgenerating substrate portions and the other plug components, for example by at least partially dissolving a glue seam or weakening the paper of the at least one wrapper.

[0037] The rod-shaped aerosol-generating articles, after compression in step iii), may be agitated so as to promote separation of the aerosol-generating substrate portions containing metallic susceptors from the other plug components and from the wrappers. For example, the rod-shaped aerosol-generating articles may be agitated in a tubular rotating cylinder. The tubular rotating cylinder may be downwardly-inclined along an axis of rotation so as to encourage a flow of rodshaped aerosol-generating articles, with their at least one outer wrappers opened, from an upper end of the tubular rotating cylinder towards a lower end of the tubular rotating cylinder. The tubular rotating cylinder may comprise circumferential perforations so as to allow small pieces of waste to fall through the perforations for collection. The tubular rotating cylinder may be vibrated. This may help to promote separation of small pieces of waste and may help to promote separation of the aerosol-generating substrate portions containing metallic susceptors from the other plug components and from the wrappers

[0038] The aerosol-generating substrate portions containing metallic susceptors, the other plug components, and the wrappers may passed along a further conveyor and subjected to a magnetic separation process. This may be in addition to or instead of the previous step of agitating the rod-shaped aerosol-generating articles after compression. The magnetic separation process may comprise applying a magnetic field so as to separate the aerosol-generating substrate portions containing metallic susceptors from the other plug components and from the wrappers. For example, the further conveyor may comprise a conveyor belt, and the magnetic field may be applied at an end of the conveyor belt, such that the aerosol-generating substrate portions containing metallic susceptors will tend to remain attracted to an underside of the conveyor belt for a period of time before falling into a first collection vessel, while the other plug components and the wrappers will tend to fall directly from the end of the conveyor belt into a second collection vessel.

[0039] The separated aerosol-generating substrate portions containing metallic susceptors may be subjected to further agitation to promote unfurling of the aerosol-generating substrate portions. The separated aerosol-generating substrate portions containing metallic susceptors may have been collected in the first collection vessel of the previous step prior to being subjected to further agitation. For example, the separated aerosol-generating substrate portions containing metallicsusceptors may be agitated in a further tubular rotating cylinder. The further tubular rotating cylinder may be downwardly-inclined along an axis of rotation.

[0040] The aerosol-generating substrate portions and metallic susceptors may be subjected to at least one air current so as to separate the aerosol-generating substrate portions from the metallic susceptors. This may be particularly efficacious when the aerosol-generating substrate portions have been at least partly unfurled, since the at least one air current will tend to interact more with the larger surface area of the partly unfurled aerosol-generating substrate portions than with the smaller surface area of the metallic susceptors. For example, the aerosol-generating substrate portions and metallic susceptors may be caused to fall under gravity past at least one transverse air jet that causes the aerosol-generating substrate portions to be deflected into a third collection vessel, while the metallic susceptors fall without substantial deflection into a fourth collection vessel. A prior step of vigorous agitation to promote unfurling of the aerosol-generating substrate portions and separation of the aerosol-generating substrate portions from the metallic susceptors may be advantageous.

[0041] While the use of a transverse air jet is relatively simple and effective, there are potential drawbacks in the event that metallic susceptors are too firmly attached to the aerosol-generating substrate portions and do not separate cleanly therefrom without damaging the aerosolgenerating substrate portions. It is also possible that the compression step may damage the aerosol-generating substrate portions, giving rise to small pieces of aerosol-generating substrate portion debris. These small pieces of debris may not be deflected by the transverse air jet as much as the larger unfurled sheets of aerosol-generating substrate portions, and may thus contaminate the collection of metallic susceptors in the fourth collection vessel, leading to non-optimal separation.

[0042] Accordingly, the aerosol-generating substrate portions and metallic susceptors may alternatively be passed through a cyclonic separator so as to separate the aerosol-generating substrate portions from the metallic susceptors. A fluid vortex may be generated in the cyclonic separator, the fluid flow path describing a descending, spiral helical path around an inner peripheral surface of the cyclonic separator. This is defined as the outer vortex. The fluid flow path is partially reflected upwardly at a narrow lower end of the cyclonic separator and passes upwardly through a central part of the cyclonic separator. This is defined as the inner vortex. Fluid may be injected in a tangential manner at a top part of the cyclonic separator and swirl around an inner surface of the cyclonic separator in an overall downward direction, with a part of the flow exiting at a lower end of the cyclonic separator, and a part of the flow returning upwardly through a centre of the cyclonic flow path. Heavier elements within the cyclonic separator, such as aerosol-generating substrate portions without metallic susceptors, will tend to be flung outwardly the most by centrifugal acceleration into the outer vortex, and will tend to collect at a bottom of the cyclonic separator where they can be separated and removed. Lighter elementswithin the cyclonic separator, such as metallic susceptors, will tend to accumulate in the central part of the cyclonic separator and be lifted upwardly by the rising fluid current of the inner vortex to a top of the cyclonic separator, where they can be separated and removed. The cyclonic separator may have an inverted frustoconical shape.

[0043] The cyclonic separator may use a vortex of air to separate the aerosol-generating substrate portions from the metallic susceptors.

[0044] Alternatively, the cyclonic separator may use a vortex of water to separate the aerosolgenerating substrate portions from the metallic susceptors. When using a vortex of water, the aerosol-generating substrate portions without metallic susceptors will tend to absorb water and become heavier, and this can accentuate the outward movement of the aerosol-generating substrate portions in the vortex due to centrifugal forces. The metallic susceptors will be the lighter elements in the vortex, because the metallic susceptors do not absorb water. Accordingly, in a cyclonic separator using a vortex of water, which may be termed a hydrocyclonic separator, the metallic susceptors (being the lighter elements) may collect in the central part of the hydrocyclonic separator, while the aerosol-generating substrate portions (being the heavier elements) may tend to be flung outwardly by centrifugal force.

[0045] In some embodiments, the cyclonic separator may comprise an axial shaft comprising or containing a magnet that attracts the metallic susceptors. The metallic susceptors attracted to the axial shaft may thus be caught up in the ascending fluid flow path of the inner vortex and move to the top of the cyclonic separator. It is also possible, due to the thinness of the metallic susceptors, that they become magnetically attached to the axial shaft without being caught up in the ascending fluid flow, and are not transported upwardly by the inner vortex. In this case, the axial shaft may periodically be removed from the cyclonic separator in order to allow the metallic susceptors to be scraped or pulled off the axial shaft. Alternatively, in embodiments where the axial shaft comprises or contains an electromagnet rather than a permanent magnet, the electromagnet may periodically be switched off so as to release the metallic susceptors magnetically attached to the axial shaft and to allow the released metallic susceptors to be carried upwardly by the ascending inner vortex.

[0046] The axial shaft may be provided with an external helical member that is coaxial with and rotatable relative to the axial shaft. The external helical member may snugly but rotatably receive the axial shaft so that rotation of the external helical member about the axial shaft will tend to push the metallic susceptors on the axial shaft along a length of the axial shaft, for example upwardly to the top of the cyclonic separator or downwardly to the bottom of the cyclonic separator. The axial shaft may be kept stationary while the external helical member is rotated. The axial shaft may be rotated while the external helical member is rotated. The axial shaft and the external helical member may be rotated at different speeds or in opposite directions. Theexternal helical member may thus enable a continuous removal of metallic susceptors magnetically attracted to the axial shaft from the cyclonic separator.

[0047] It has been found that these embodiments, with an axial shaft comprising or containing a magnet, work best when the cyclonic separator uses a vortex of water to separate the aerosolgenerating substrate portions from the metallic susceptors, since the vortex of water will exert a greater force than a vortex of air in order to help unfurl the aerosol-generating substrate portions and to separate the aerosol-generating substrate portions from the metallic susceptors.

[0048] According to a second aspect of the present invention, there is provided an apparatus for processing waste rod-shaped aerosol-generating articles each comprising an aerosol-generating substrate portion including a substantially planar metallic susceptor disposed longitudinally within the aerosol-generating substrate portion, together with other plug components, all wrapped in at least one wrapper, the apparatus comprising:

[0049] i) a conveyor configured to travel in a first direction;

[0050] ii) a feeder configured to feed the rod-shaped aerosol-generating articles onto the conveyor;

[0051] iii) a magnetic field generator to generate a magnetic field to cause the rod-shaped aerosol-generating articles on the conveyor to be disposed such that planes of the substantially planar metallic susceptors are aligned in substantially the same direction; and

[0052] iv) a compressor configured to compress the rod-shaped aerosol-generating articles in a second direction substantially perpendicular to the first direction so as to deform the rod-shapes aerosol-generating articles and to loosen the at least one wrapper from the aerosol-generating substrate portions and the other plug components.

[0053] The various advantageous technical features of the first aspect apply equally to the second aspect where the context allows.

[0054] The magnetic field generator may be configured to cause the rod-shaped aerosolgenerating articles to be disposed such that the planes of the substantially planar metallic susceptors are aligned in a direction substantially perpendicular to the second direction.

[0055] The magnetic field generator may be configured to cause the rod-shaped aerosolgenerating articles to be disposed such that the planes of the substantially planar metallic susceptors are aligned in a direction substantially parallel to the second direction.

[0056] The feeder may be configured to feed the rod-shaped aerosol-generating onto the conveyor such that the rod-shaped aerosol-generating articles are aligned substantially parallel to each other on the conveyor.

[0057] The feeder may be configured to feed the rod-shaped aerosol-generating onto the conveyor such that the rod-shaped aerosol-generating articles are aligned substantially perpendicular to the first direction on the conveyor.

[0058] The feeder may comprise a hopper.The feeder may be configured to feed the rod-shaped aerosol-generating articles onto the conveyor as a single layer.

[0059] The feeder may be configured to feed the rod-shaped aerosol-generating articles onto the conveyor as multiple layers. The feeder may be configured to feed the rod-shaped aerosolgenerating articles onto the conveyor in no more than five layers.

[0060] The magnetic field generator may comprise a permanent magnet.

[0061] The magnetic field generator may comprise an electromagnet.

[0062] The magnetic field generator may be incorporated in the conveyor, for example between upper and lower belts of a belt conveyor. Alternatively, the magnetic field generator may be disposed under the conveyor or above the conveyor.

[0063] The apparatus may further comprise a vibrator or shaker configured to subject the rodshaped aerosol-generating articles to vibration or shaking on the conveyor during application of the magnetic field.

[0064] The compressor may be a pressing roller operable to exert a compression force in a direction towards the conveyor.

[0065] The compressor may be a pressing block operable to exert a compression force in a direction towards the conveyor.

[0066] The apparatus may further comprise a liquid applicator configured to wet the rod-shaped aerosol-generating articles prior to or while being compressed. The liquid applicator may be a spray applicator or a sprinkler applicator. The liquid may be water.

[0067] The apparatus may further comprise an agitator configured to receive and agitate the rodshaped aerosol-generating articles, after compression, so as to promote separation of the aerosol-generating substrate portions containing metallic susceptors from the other plug components and from the wrappers. The agitator may comprise a tubular rotating cylinder. The tubular rotating cylinder may be downwardly-inclined along an axis of rotation. The tubular rotating cylinder may comprise circumferential perforations so as to allow small pieces of waste to fall through the perforations for collection. The apparatus may further comprise a vibrator configured to vibrate the tubular rotating cylinder.

[0068] The apparatus may comprise a further conveyor, and may be configured such that the aerosol-generating substrate portions containing metallic susceptors, the other plug components, and the wrappers are passed along the further conveyor. The apparatus may comprise a further magnetic field generator configured to apply a magnetic field to the further conveyor to separate the aerosol-generating substrate portions containing metallic susceptors from the other plug components and from the wrappers. The further conveyor may be a conveyor belt, and the further magnetic field generator may be disposed at an end of the conveyor belt, configured such that the aerosol-generating substrate portions containing metallic susceptors will tend to remain attracted to an underside of the conveyor belt for a period of time before falling into a first collectionvessel, while the other plug components and the wrappers will tend to fall directly from the end of the conveyor belt into a second collection vessel. The apparatus may comprise a further agitator configured to receive the separated aerosol-generating substrate portions containing metallic susceptors from the first collection vessel and to agitate the separated aerosol-generating substrate portions containing metallic susceptors to promote unfurling of the aerosol-generating substrate portions. The further agitator may comprise a further tubular rotating cylinder. The further tubular rotating cylinder may be downwardly-inclined along an axis of rotation.

[0069] The apparatus may further comprise an air current generator configured to subject the aerosol-generating substrate portions and metallic susceptors to at least one air current so as to separate the aerosol-generating substrate portions from the metallic susceptors. The air current generator may comprise at least one transverse air jet, and the aerosol-generating substrate portions and metallic susceptors may be caused to fall under gravity past at least one transverse air jet operable to deflect the aerosol-generating substrate portions into a third collection vessel, while the metallic susceptors fall into a fourth collection vessel.

[0070] The apparatus may further comprise a cyclonic separator configured to receive the aerosolgenerating substrate portions and metallic susceptors and to separate the aerosol-generating substrate portions from the metallic susceptors. The cyclonic separator may be configured to generate an air vortex to separate the aerosol-generating substrate portions from the metallic susceptors. The cyclonic separator may be configured to generate a water vortex to separate the aerosol-generating substrate portions from the metallic susceptors. The cyclonic separator may comprises an axial shaft comprising or containing a magnet that attracts the metallic susceptors. The axial shaft may be provided with an external helical member that is coaxial with and rotatable relative to the axial shaft the axial shaft. Rotation of the external helical member relative to the axial shaft may cause metallic susceptors on the axial shaft to travel along a length of the axial shaft.

[0071] As used herein, the term “aerosol-generating article” refers to an article comprising an aerosol-generating substrate that is configured to be used with an aerosol-generating device. The aerosol-generating substrate may comprise a nicotine-containing substance, e.g. tobacco. The article may comprise additional components such as a mouthpiece, an aerosol mixing portion, a filter portion, a flavour portion and so forth. An aerosol-generating article preferably has a rodlike or cylindrical form factor.

[0072] As used herein, the term “aerosol-generating substrate portion” refers to a sheet of material that releases an aerosol when heated. The sheet of material may be crimped and gathered around a metallic susceptor so as to form a rod shape that may subsequently be wrapped with a plug wrap. Examples of aerosol-generating substrates include tobacco cast leaf formed from a slurry of ground tobacco leaves and suitable binders, and also mixtures of nicotine with one ormore of glycerine, guar gum, menthol, cloves, other flavourings, other agricultural products, or high retention material with nicotine content.

[0073] As used herein, the terms “agitate” refers to a deliberate application of a shaking or vibrating movement to components within a stream of components, the shaking or vibrating movement being sufficient to promote at least partial opening or decomposition of the components.

[0074] As used herein, the term “plug component” refers to an individual rod-shaped component of an aerosol-generating article, usually provided with a wrapper that is referred to as a “plug wrapper”.

[0075] As used herein, the term “substantially planar metallic susceptor” refers to a metallic component of a shape having an overall major plane. This includes metallic susceptors that may be crimped or corrugated, but still with an overall major plane that may be aligned with the major planes of other metallic susceptors. A metallic susceptor is an electrically conductive component that can be heated by resistive or inductive heating so as to cause an aerosol-generating substrate portion to generate an aerosol.

[0076] As used herein, the term “such that the planes of the substantially planar metallic susceptors are aligned in a direction” is to be interpreted in a statistical manner, meaning that at least 50 percent, preferably 75 percent, more preferably at least at least 90 percent of the rod-shaped aerosol-generating articles are disposed such that the planes of the substantially planar metallic susceptors are aligned within plus or minus 10 degrees, preferably within plus or minus 5 degrees, of the respective perpendicular or parallel direction.

[0077] As used herein, the term “wrapper” refers to a sheet of material, preferably paper or a paperbased material, that is used to wrap one or more components of an aerosol-generating article in a rod-like shape. Opposing edges of a wrapper may be secured to each other with an adhesive so as to hold the wrapper in place around its contents. The term “tipping paper” refers to a special wrapper that is more resistant to saliva than other wrappers, since a tipping paper is used to wrap a mouth piece filter plug component that will be in contact with a user’s mouth.

[0078] The invention is defined in the claims. However, below there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0079] Example Ex1: A method of processing waste rod-shaped aerosol-generating articles each comprising an aerosol-generating substrate portion including a substantially planar metallic susceptor disposed longitudinally within the aerosol-generating substrate portion, together with other plug components, all wrapped in at least one wrapper, wherein:

[0080] i) the rod-shaped aerosol-generating articles are fed onto a conveyor travelling in a first direction;

[0081] ii) the rod-shaped aerosol-generating articles on the conveyor are subjected to a magnetic field so as to cause the rod-shaped aerosol-generating articles to be disposed such thatplanes of the substantially planar metallic susceptors are aligned in substantially the same direction; and

[0082] iii) the rod-shaped aerosol-generating articles with their substantially planar metallic susceptors aligned in substantially the same direction are compressed in a second direction substantially perpendicular to the first direction so as to deform the rod-shapes aerosol-generating articles and to loosen the at least one wrapper from the aerosol-generating substrate portions and the other plug components.

[0083] Example Ex2: The method according to Example Ex1, wherein, in step ii), the magnetic field causes the rod-shaped aerosol-generating articles to be disposed such that the planes of the substantially planar metallic susceptors are aligned in a direction substantially perpendicular to the second direction.

[0084] Example Ex3: The method according to Example Ex1, wherein, in step ii), the magnetic field causes the rod-shaped aerosol-generating articles to be disposed such that the planes of the substantially planar metallic susceptors are aligned in a direction substantially parallel to the second direction.

[0085] Example Ex4: The method according to any preceding Example, wherein in step i), the rodshaped aerosol-generating articles are aligned substantially parallel to each other on the conveyor.

[0086] Example Ex5: The method according to Example Ex4, wherein in step i), the rod-shaped aerosol-generating articles are aligned substantially perpendicular to the first direction on the conveyor.

[0087] Example Ex6: The method according to any preceding Example, wherein the rod-shaped aerosol-generating articles are fed onto the conveyor from a hopper.

[0088] Example Ex7: The method according to any preceding Example, wherein the rod-shaped aerosol-generating articles are disposed on the conveyor in a single layer.

[0089] Example Ex8: The method according to any one of Examples Ex1 to Ex6, wherein the rodshaped aerosol-generating articles are disposed on the conveyor in multiple layers.

[0090] Example Ex9: The method according to Example Ex8, wherein the rod-shaped aerosolgenerating articles are disposed on the conveyor in no more than five layers.

[0091] Example Ex10: The method according to any preceding Example, wherein the magnetic field is applied by a permanent magnet.

[0092] Example Ex11 : The method according to any one of Examples Ex1 to Ex9, wherein the magnetic field is applied by an electromagnet.

[0093] Example Ex12: The method according to any preceding Example, wherein the rod-shaped aerosol-generating articles are subjected to vibration or shaking on the conveyor during application of the magnetic field.Example Ex13: The method according to any preceding Example, wherein in step iii), the rod-shaped aerosol-generating articles are compressed in the second direction by a pressing roller operable to exert a compression force in a direction towards the conveyor.

[0094] Example Ex14: The method according to any one of Examples Ex1 to Ex12, wherein in step iii), the rod-shaped aerosol-generating articles are compressed in the second direction by a pressing block operable to exert a compression force in a direction towards the conveyor.

[0095] Example Ex15: The method according to any preceding Example, wherein the rod-shaped aerosol-generating articles are wetted prior to or while being compressed.

[0096] Example Ex16: The method according to any preceding Example, wherein the rod-shaped aerosol-generating articles, after compression in step iii), are agitated so as to promote separation of the aerosol-generating substrate portions containing metallic susceptors from the other plug components and from the wrappers.

[0097] Example Ex17: The method according to Example Ex16, wherein the rod-shaped aerosolgenerating articles are agitated in a tubular rotating cylinder.

[0098] Example Ex18: The method according to Example Ex17, wherein the tubular rotating cylinder is downwardly-inclined along an axis of rotation.

[0099] Example Ex19: The method according to Example Ex17 or Ex18, wherein the tubular rotating cylinder comprises circumferential perforations so as to allow small pieces of waste to fall through the perforations for collection.

[0100] Example Ex20: The method according to any one of Examples Ex17 to Ex19, wherein the tubular rotating cylinder is vibrated.

[0101] Example Ex21: The method according to any one of Examples Ex16 to Ex20, wherein the aerosol-generating substrate portions containing metallic susceptors, the other plug components, and the wrappers are passed along a further conveyor and subjected to a magnetic separation process.

[0102] Example Ex22: The method according to Example Ex21, wherein the magnetic separation process comprises applying a magnetic field so as to separate the aerosol-generating substrate portions containing metallic susceptors from the other plug components and from the wrappers.

[0103] Example Ex23: The method according to Example Ex22, wherein the further conveyor is a conveyor belt, and wherein the magnetic field is applied at an end of the conveyor belt, such that the aerosol-generating substrate portions containing metallic susceptors will tend to remain attracted to an underside of the conveyor belt for a period of time before falling into a first collection vessel, while the other plug components and the wrappers will tend to fall directly from the end of the conveyor belt into a second collection vessel.

[0104] Example Ex24: The method according to any one of Examples Ex21 to Ex23, wherein the separated aerosol-generating substrate portions containing metallic susceptors are subjected to further agitation to promote unfurling of the aerosol-generating substrate portions.Example Ex25: The method according to Example Ex24, wherein the separated aerosolgenerating substrate portions containing metallic susceptors are agitated in a further tubular rotating cylinder.

[0105] Example Ex26: The method according to Example Ex25, wherein the further tubular rotating cylinder is downwardly-inclined along an axis of rotation.

[0106] Example Ex27: The method according to any one of Examples Ex21 to Ex26, wherein the aerosol-generating substrate portions and metallic susceptors are subjected to at least one air current so as to separate the aerosol-generating substrate portions from the metallic susceptors.

[0107] Example Ex28: The method according to Example Ex27, wherein the aerosol-generating substrate portions and metallic susceptors are caused to fall under gravity past at least one transverse air jet that causes the aerosol-generating substrate portions to be deflected into a third collection vessel, while the metallic susceptors fall into a fourth collection vessel.

[0108] Example Ex29: The method according to any one of Examples Ex21 to Ex26, wherein the aerosol-generating substrate portions and metallic susceptors are passed through a cyclonic separator so as to separate the aerosol-generating substrate portions from the metallic susceptors.

[0109] Example Ex30: The method according to Example Ex29, wherein the cyclonic separator uses a vortex of air to separate the aerosol-generating substrate portions from the metallic susceptors.

[0110] Example Ex31: The method according to Example Ex29, wherein the cyclonic separator uses a vortex of water to separate the aerosol-generating substrate portions from the metallic susceptors.

[0111] Example Ex32: The method according to any one of Examples Ex29 to Ex31, wherein the cyclonic separator comprises an axial shaft comprising or containing a magnet that attracts the metallic susceptors.

[0112] Example Ex33: The method according to Example Ex32, wherein the axial shaft is provided with an external helical member that is coaxial with and rotatable relative to the axial shaft so that metallic susceptors on the axial shaft will travel along a length of the axial shaft when the external helical member is rotated relative to the axial shaft.

[0113] Example Ex34: An apparatus for processing waste rod-shaped aerosol-generating articles each comprising an aerosol-generating substrate portion including a substantially planar metallic susceptor disposed longitudinally within the aerosol-generating substrate portion, together with other plug components, all wrapped in at least one wrapper, the apparatus comprising:

[0114] i) a conveyor configured to travel in a first direction;

[0115] ii) a feeder configured to feed the rod-shaped aerosol-generating articles onto the conveyor;iii) a magnetic field generator to generate a magnetic field to cause the rod-shaped aerosol-generating articles on the conveyor to be disposed such that planes of the substantially planar metallic susceptors are aligned in substantially the same direction; and

[0116] iv) a compressor configured to compress the rod-shaped aerosol-generating articles in a second direction substantially perpendicular to the first direction so as to deform the rod-shapes aerosol-generating articles and to loosen the at least one wrapper from the aerosol-generating substrate portions and the other plug components.

[0117] Example Ex35: The apparatus according to Example Ex34, wherein the magnetic field generator is configured to cause the rod-shaped aerosol-generating articles to be disposed such that the planes of the substantially planar metallic susceptors are aligned in a direction substantially perpendicular to the second direction.

[0118] Example Ex36: The apparatus according to Example Ex34, wherein the magnetic field generator is configured to cause the rod-shaped aerosol-generating articles to be disposed such that the planes of the substantially planar metallic susceptors are aligned in a direction substantially parallel to the second direction.

[0119] Example Ex37: The apparatus according to any one of Examples Ex34 to Ex36, wherein the feeder is configured to feed the rod-shaped aerosol-generating onto the conveyor such that the rod-shaped aerosol-generating articles are aligned substantially parallel to each other on the conveyor.

[0120] Example Ex38: The apparatus according to Example Ex37, wherein the feeder is configured to feed the rod-shaped aerosol-generating onto the conveyor such that the rod-shaped aerosolgenerating articles are aligned substantially perpendicular to the first direction on the conveyor.

[0121] Example Ex39: The apparatus according to any one of Examples Ex34 to Ex38, wherein the feeder comprises a hopper.

[0122] Example Ex40: The apparatus according to any one of Examples Ex34 to Ex39, wherein the feeder is configured to feed the rod-shaped aerosol-generating articles onto the conveyor as a single layer.

[0123] Example Ex41: The apparatus according to any one of Examples Ex34 to Ex39, wherein the feeder is configured to feed the rod-shaped aerosol-generating articles onto the conveyor as multiple layers.

[0124] Example Ex42: The apparatus according to Example Ex41, wherein feeder is configured to feed the rod-shaped aerosol-generating articles onto the conveyor in no more than five layers.

[0125] Example Ex43: The apparatus according to any one of Examples Ex34 to Ex42, wherein the magnetic field generator comprises a permanent magnet.

[0126] Example Ex44: The apparatus according to any one of Examples Ex34 to Ex42, wherein the magnetic field generator comprises an electromagnet.Example Ex45: The apparatus according to any one of Examples Ex34 to Ex44, further comprising a vibrator or shaker configured to subject the rod-shaped aerosol-generating articles to vibration or shaking on the conveyor during application of the magnetic field.

[0127] Example Ex46: The apparatus according to any one of Examples Ex34 to Ex45, wherein the compressor is a pressing roller operable to exert a compression force in a direction towards the conveyor.

[0128] Example Ex47: The apparatus according to any one of Examples Ex34 to Ex45, wherein the compressor is a pressing block operable to exert a compression force in a direction towards the conveyor.

[0129] Example Ex48: The apparatus according to any one of Examples Ex34 to Ex47, comprising a liquid applicator configured to wet the rod-shaped aerosol-generating articles prior to or while being compressed.

[0130] Example Ex49: The apparatus according to any one of Examples Ex34 to Ex48, further comprising an agitator configured to receive and agitate the rod-shaped aerosol-generating articles, after compression, so as to promote separation of the aerosol-generating substrate portions containing metallic susceptors from the other plug components and from the wrappers.

[0131] Example Ex50: The apparatus according to Example Ex49, wherein the agitator comprises a tubular rotating cylinder.

[0132] Example Ex51: The apparatus according to Example Ex50, wherein the tubular rotating cylinder is downwardly-inclined along an axis of rotation.

[0133] Example Ex52: The apparatus according to Example Ex50 or Ex51, wherein the tubular rotating cylinder comprises circumferential perforations so as to allow small pieces of waste to fall through the perforations for collection.

[0134] Example Ex53: The apparatus according to any one of Examples Ex50 to Ex52, further comprising a vibrator configured to vibrate the tubular rotating cylinder.

[0135] Example Ex54: The apparatus according to any one of Examples Ex49 to Ex53, comprising a further conveyor, and configured such that the aerosol-generating substrate portions containing metallic susceptors, the other plug components, and the wrappers are passed along the further conveyor.

[0136] Example Ex55: The apparatus according to Example Ex54, comprising a further magnetic field generator configured to apply a magnetic field to the further conveyor to separate the aerosolgenerating substrate portions containing metallic susceptors from the other plug components and from the wrappers.

[0137] Example Ex56: The apparatus according to Example Ex55, wherein the further conveyor is a conveyor belt, and wherein the further magnetic field generator is disposed at an end of the conveyor belt, configured such that the aerosol-generating substrate portions containing metallic susceptors will tend to remain attracted to an underside of the conveyor belt for a period of timebefore falling into a first collection vessel, while the other plug components and the wrappers will tend to fall directly from the end of the conveyor belt into a second collection vessel.

[0138] Example Ex57: The apparatus according to any one of Examples Ex54 to Ex56, comprising a further agitator configured to receive the separated aerosol-generating substrate portions containing metallic susceptors from the first collection vessel and to agitate the separated aerosolgenerating substrate portions containing metallic susceptors to promote unfurling of the aerosolgenerating substrate portions.

[0139] Example Ex58: The apparatus according to Example Ex57, wherein the further agitator comprises a further tubular rotating cylinder.

[0140] Example Ex59: The apparatus according to Example Ex58, wherein the further tubular rotating cylinder is downwardly-inclined along an axis of rotation.

[0141] Example Ex60: The apparatus according to any one of Examples Ex54 to Ex59, further comprising an air current generator configured to subject the aerosol-generating substrate portions and metallic susceptors to at least one air current so as to separate the aerosolgenerating substrate portions from the metallic susceptors.

[0142] Example Ex61: The apparatus according to Example Ex60, wherein the air current generator comprises at least one transverse air jet, and wherein the aerosol-generating substrate portions and metallic susceptors are caused to fall under gravity past at least one transverse air jet operable to deflect the aerosol-generating substrate portions into a third collection vessel, while the metallic susceptors fall into a fourth collection vessel.

[0143] Example Ex62: The apparatus according to any one of Examples Ex54 to Ex59, further comprising a cyclonic separator configured to receive the aerosol-generating substrate portions and metallic susceptors and to separate the aerosol-generating substrate portions from the metallic susceptors.

[0144] Example Ex63: The apparatus according to Example Ex62, wherein the cyclonic separator is configured to generate an air vortex to separate the aerosol-generating substrate portions from the metallic susceptors.

[0145] Example Ex64: The apparatus according to Example Ex62, wherein the cyclonic separator is configured to generate a water vortex to separate the aerosol-generating substrate portions from the metallic susceptors.

[0146] Example Ex65: The apparatus according to any one of Examples Ex62 to Ex64, wherein the cyclonic separator comprises an axial shaft comprising or containing a magnet that attracts the metallic susceptors.

[0147] Example Ex66: The apparatus according to Example Ex65, wherein the axial shaft is provided with an external helical member that is coaxial with and rotatable relative to the axial shaft.

[0148] Examples will now be further described with reference to the figures in which:Figure 1 shows an exemplary aerosol-generating article in exploded view, partially unwrapped;

[0149] Figure 2 shows the aerosol-generating article of Figure 1 in assembled longitudinal cross-sectional view;

[0150] Figure 3 shows a substantially planar metallic susceptor;

[0151] Figure 4 shows a schematic side view of an apparatus comprising a conveyor, a feeder for feeding aerosol-generating articles to the conveyor, and a magnetic field generator for aligning the substantially planar metallic susceptors of the aerosol-generating articles in a desired direction;

[0152] Figure 5 shows a close-up view of the magnetic field generator of Figure 4, with the conveyor omitted for clarity, showing how the metallic susceptors are aligned by the magnetic field;

[0153] Figure 6 shows the apparatus of Figure 4, with the feeder omitted for clarity, and further comprising a compressor in the form of a pressing roller;

[0154] Figure 7 shows a transverse cross-section through an aerosol-generating substrate portion of an aerosol-generating article, including the metallic susceptor;

[0155] Figure 8 illustrates the compression of an aerosol-generating article in a direction substantially perpendicular to an orientation of the substantially planar metallic susceptor;

[0156] Figure 9 is a graph showing a relationship between a cross-sectional height and a cross-sectional width of the aerosol-generating article of Figures 7 and 8 during compression;

[0157] Figure 10 illustrates the compression of an aerosol-generating article in a direction substantially parallel to an orientation of the substantially planar metallic susceptor, with the aerosol-generating article being disposed on top of one or more further layers of aerosolgenerating articles;

[0158] Figure 11 illustrates the compression of an aerosol-generating article in a direction substantially parallel to an orientation of the substantially planar metallic susceptor, with the aerosol-generating article being disposed on top of the conveyor and under one or more further layers of aerosol-generating articles;

[0159] Figure 12 shows a side elevation of a magnetic separator comprising an inclined tubular rotating cylinder, a belt conveyor and a magnet;

[0160] Figure 13 shows a vertical cross-section through an air flow separator comprising an inclined tubular rotating cylinder and a vessel across which an air current is directed;

[0161] Figure 14 shows a vertical cross-section through a cyclonic separator;

[0162] Figure 15 shows a vertical cross-section through a cyclonic separator with an axial shaft comprising or containing a magnet; andFigure 16 shows a close-up vertical cross-sectional view through the axial shaft of the cyclonic separator of Figure 15, additionally provided with an external helical member that is coaxial with and rotatable relative to the axial shaft.

[0163] Figure 3 illustrates a substantially planar metallic susceptor 32. In the embodiment of Figure 3, the metallic susceptor 32 takes the form of a substantially flat rectangle, with two opposed major surfaces 320 and two pairs of opposed edges 321 , 322. In some embodiments, the metallic susceptor 32 may be considered to be a parallelepiped with two opposed major surfaces 320 each having an area significantly greater than the areas of the remaining opposed minor surfaces 321, 322. While the metallic susceptor 32 of Figure 3 is shown with substantially flat major surfaces 320, it is possible that the metallic susceptor may be corrugated or have other surface striations that may increase a surface area of the major surfaces 320, which may increase heat transfer from the metallic susceptor 32 to an aerosol-generating substrate portion 31 (see Figures 1 and 2), provided always that the metallic susceptor 32 has an overall substantially planar shape. In one example, the metallic susceptor may have a length of around 12 millimetres, a width of around 5 millimetres, and a height of around 60 micrometres. The length of the metallic susceptor 32 may be substantially the same as the length of the plug of sensorial medium 31 (see Figures 1 and 2), and the width of the metallic susceptor 32 may be slightly less than the diameter of the plug of sensorial medium 31 so that the edges 321 do not touch the wrapper 37 of the plug of sensorial medium 31. The height of the metallic susceptor 32 may be between about 100 and 200 times smaller than the length or the width of the metallic susceptor 32. The height of the metallic susceptor 32 may be between about two to three orders of magnitude smaller than the length or the width of the metallic susceptor 32. The metallic susceptor 32 may take the form of a metallic foil. The metallic susceptor 32 may, for example, be made of a magnetic stainless steel alloy. Alternatively, the metallic susceptor 32 may be made of a non-magnetic metallic material, such as 304 stainless steel alloy, provided with a thin nickel coating in order to impart magnetic properties and to allow the metallic susceptor 32 to interact with a magnetic field.

[0164] Figure 4 shows a schematic side view of an apparatus comprising a conveyor 41 in the form of a conveyor belt, a feeder 42 for feeding aerosol-generating articles 38 to the conveyor 41 , and a magnetic field generator 44 to generate a magnetic field 45 that acts so as to align the substantially planar metallic susceptors 32 of the aerosol-generating articles 38 in a desired direction. The aerosol-generating articles 38 may be supplied to the feeder 42 as a mass 40 of generally parallel aerosol-generating articles 38. The feeder 42 may have a face that slopes downwardly towards the conveyor 41 and acts as a barrier that controls a total height of the aerosol-generating articles 38 fed onto the conveyor 41. Although many aerosol-generating articles 38 have been omitted from Figure 4 in the interests of clarity, it can be seen that the feeder 42 limits the total height to around three layers of aerosol-generating articles 38. It has beenfound that with more than around 5 layers of aerosol-generating articles 38, it becomes difficult to ensure that the planes of the substantially planar metallic susceptors 32 are correctly aligned in the desired direction by the magnetic field 45 generated by the magnetic field generator 44, since the weight of upper layers of aerosol-generating articles 38 pressing down on the lower layers of aerosol-generating articles 38 means that the aerosol-generating articles 38 in the lower layers are not sufficiently free to rotate in the magnetic field 45.

[0165] The magnetic field generator 44, which may be a permanent magnet or an electromagnet, is preferably located under the conveyor 41 , for example between the upper and lower belts of the conveyor 41 when the conveyor 41 is a conveyor belt. It is preferred to use an electromagnet as the magnetic field generator 44 since an electromagnet allows for adjustable control of a magnetic field strength and, in some instances, direction. In addition, an electromagnet can be switched on and off or pulsed in order to impart an agitation to the aerosol-generating articles 38, which may help loosen any packing of the aerosol-generating articles 38 on the conveyor 41 and allow for freer rotation and alignment of the substantially planar metallic susceptors 32.

[0166] Figure 5 shows a close-up view of the magnetic field generator 44 of Figure 4, with the conveyor 41 omitted for clarity, showing how the aerosol-generating articles 38 are rotated by the magnetic field 45 so as to align the substantially planar metallic susceptors 32, in this case substantially in a horizontal direction. It will be understood that the magnetic field generator 44 may be configured to generate a magnetic field 45 having a different orientation, and thus the substantially planar metallic susceptors 32 may be aligned in a different orientation, for example substantially in a vertical direction.

[0167] In order to assist the rotation of the aerosol-generating articles 38 in the magnetic field 45, the conveyor 41 may be shaken or vibrated so as at least partially to fluidize the layer or layers of aerosol-generating articles 38 on the conveyor 41. In some embodiments, the natural mechanical shaking or vibration of the conveyor 41 during operation may be sufficient.

[0168] In the illustrated embodiments, the aerosol-generating articles 38 are arranged substantially parallel to each other and transverse to a direction of travel of the conveyor 41. This is facilitated because aerosol-generating articles 38 of the type shown, for example, in Figures 1 and 2 do not have to be stubbed out after consumption (in contrast to conventional cigarettes), and thus tend to retain their cylindrical shape even after consumption.

[0169] Figure 6 shows the apparatus of Figure 4, with the feeder 42 omitted for clarity, and further comprising a compressor 46 in the form of a pressing roller. The compressor 46 is mounted above the conveyor 41 , and is configured to apply a downward compression force to the aerosolgenerating articles 38 in a direction substantially perpendicular to a direction of travel of the conveyor 41. The compression force deforms the aerosol-generating articles 38 to form flattened aerosol-generating articles 47. In Figure 6, the aerosol-generating articles 38 have been rotated by the magnetic field 45 so that the substantially planar metallic susceptors are alignedhorizontally, substantially parallel to the direction of travel of the conveyor 41, and substantially perpendicular to the direction of the compression force applied by the pressing roller. Only a single layer of aerosol-generating articles 38 is shown in Figure 6 for the sake of clarity, but multiple layers may be present.

[0170] The provision of a pressing roller as the compressor 46 enables continuous processing, since the pressing roller can rotate about its axis as the aerosol-generating articles 38 pass underneath on the conveyor 41.

[0171] Alternatively, the compressor may be configured as a non-rotating pressing block, and the aerosol-generating articles 38 may be compressed batchwise. This may have the advantage of enabling more precise control of the compression force, and may avoid unwanted rotation of the aerosol-generating articles 38 by rotation of a pressing roller.

[0172] Compression and flattening of the aerosol-generating articles 38 in this way can break or loosen the wrapping papers 37, 3, 5 (see Figures 1 and 2) because the flattened aerosolgenerating articles 47 are deformed to such an extent that their perimeters are greater than the circumference of the non-deformed aerosol-generating articles 38, and this will tend to break or rupture the paper wrappers 37, 3, 5, especially along edges sealed with adhesive. This can be facilitated by spraying or sprinkling the aerosol-generating articles 38 with water prior to or during compression so as to weaken the paper wrappers 37, 3, 5 or so as at least partially to dissolve any adhesive used for sealing.

[0173] Figure 7 shows a transverse cross-section through an aerosol-generating substrate portion 31 of an aerosol-generating article 38, including the metallic susceptor 32. The aerosolgenerating substrate portion 31 may be formed from a crimped sheet of sensorial medium that has been gathered around the metallic susceptor 32, leaving air gaps 310 to allow for passage of aerosol along a length of the aerosol-generating substrate portion 31 , and provided with a plug wrap 37, made for example from paper, to form a generally cylindrical plug component. Also shown is the outer wrapper 3, made for example from paper, that is used to join several plug components together to form the aerosol-generating article 38 (see Figures 1 and 2).

[0174] Figure 8 illustrates the compression of an aerosol-generating article 38 of diameter D in a direction substantially perpendicular to an orientation of the substantially planar metallic susceptor 32 so as to form a flattened aerosol-generating article 47 of height H and width W.

[0175] The perimeter P of the aerosol-generating article 38 can be defined by a diameter D (which is usually about 7.2 millimetres).

[0176] P = TID

[0177] The elasticity of the wrapping material or materials and the sealing adhesive means that the circumferential length of the wrapping material around the aerosol-generating article 38 can beslightly extended by a value p, so the maximum circumferential length L of the wrapping material before tearing or unsealing can be defined as:

[0178] L = \iP = \inD, with > 7.

[0179] For instance, if p = 1.1, this means that the initial perimeter can be stretched by 10 percent before the wrapping material breaks.

[0180] It may be supposed that the value of p is the maximum value once all the wrapping materials of an aerosol-generating article 38 (cigarette paper, tipping paper, plug wraps) have been taken into account.

[0181] The breaking propensity of the wrapping when the aerosol-generating article 38 is flattened is related to the inability of the wrapping to contain the flattened solid content of the aerosolgenerating article 38 in a defined perimeter, and so is related to the dimensions of the section of the flattened aerosol-generating article 47 solid content in relation to the maximum perimeter, i.e., the circumferential length L, that can sustain the wrapping.

[0182] Assuming that the resistance to compression of the solid content is far superior to the resistance to break (or to be unsealed) of the wrappings, the conservation of the dimensions of the section as defined by the compression force will, if necessary, be to the detriment of the conservation of the perimeter, i.e., will lead to the breaking of the wrappings.

[0183] With regard to the aerosol-generating substrate portion 31 plug component, the solid content is mainly the sheet of aerosol-generating substate portion 31 and the metallic susceptor 32. The sheet of aerosol-generating substrate portion 31 is usually dispensed from a bobbin in the form of a crimped band and is gathered and folded around the metallic susceptor 32 by way of a funnel so as to form a rod. The crimped band may have a width of around 12.5 centimetres and a thickness of around 200 micrometres. Accordingly, for the section illustrated in Figure 7, the sheet of aerosol-generating substrate portion 31 has a cross-sectional surface area Sm:

[0184] Sm = 125 x 0.2 mm2= 25 mm2.

[0185] The dimensions of the metallic susceptor 32 cross-section are much smaller, usually about 5 millimetres width for a thickness of 60 micrometres, thus giving a cross-sectional surface area Sc:

[0186] Sc = 5 x 0.06 mm2= 0.3 mm2.

[0187] The global cross-sectional area Sg of an aerosol-generating article 38 of 7.2 mm diameter is:

[0188]

[0189] The thickness of the wrapping materials, which is about 0.1 millimetres of the external diameter of the aerosol-generating article 38 (twice the thicknesses of the average cigarette paper and plug wrap) is deemed to be negligible in these calculations.

[0190] Accordingly, the aerosol-generating substrate portion 31 plug has about 25.3 / 40.7 « 62% of its content that can be considered to be solid or “incompressible” content and which, with regard to the sheet of aerosol-generating substrate portion 31, will expend in a direction perpendicular to the compression force rather than being compressed.

[0191] Accordingly, when compressed vertically, the aerosol-generating substrate portion 31 plug will first lose some of the surface of its cross-section (~38 percent representing the empty parts of the crimped and gathered sheet of aerosol-generating substrate 31 defining the air paths 310), and will then extend laterally when the as the aerosol-generating substrate 31 starts to be compressed.

[0192] It will be noted that the horizontal orientation of the largest planar surfaces of the metallic susceptor 32 helps to reorient the vertical compression force laterally (as well as to reorient the symmetrical vertical reaction force coming from the conveyor 41), and this redirects the aerosolgenerating substrate 31 to apply a lateral pushing force toward the lateral sides of the wrappings.

[0193] A coefficient p may be defined as the proportion “incompressible” solid content in the aerosol-generating substrate portion 31 plug (in the previous calculation, « 62%), then the “incompressible” cross-section Si of an aerosol-generating article 38 plug of diameter D is:

[0194]

[0195] A wrapping perimeter (maximum length) L can be defined as:

[0196] L = [inD

[0197] When compressed, the aerosol-generating article 47 can be approximated as a rectangle of width W and height H (see Figure 8).

[0198] The perimeter of the “rectangle” made by the flattened aerosol-generating article 47, namely 2(H+W), should at most be L, so:

[0199] H + W < - (E1)The surface of the cross-section Sr of the same “rectangle”, HW, should contain Si, so:

[0200] HW > Si (E2)

[0201] The curves (E1) and (E2) are plotted graphically in Figure 9, where the hatched zone represents the values of H and W where the section of the rectangle contains the “incompressible” solid cross-section, and where the perimeter is at most L, i.e., where both constraints (E1) and (E2) are satisfied.

[0202] When compressing the aerosol-generating article 38 so that the height H of the flattened aerosol-generating article 47 becomes less than HO (as seen in Figure 9), then both constraints (E1) and (E2) are no longer satisfied, and the constraint (E2) on the cross-section will dominate over the constraint (E1) on the perimeter, and thus the width W will go beyond the maximum value for the perimeter, i.e., beyond the line (E1), leading to the tearing of the wrapping material of the aerosol-generating substrate portion 31 plug.

[0203] To give a numerical example, using the above values:

[0204] L = \inD = 1.1 x n x 7.2 = 24.9 mm

[0205] nD2(7.2)2

[0206] Si = B - = 0.62 x n x - = 25.24 mm2

[0207] 4 4

[0208] The two couples (W, H) solutions of (E’1) H+W = L / 2 and (E’2) HW = Si are the points at the intersection of the two curves in Figure 9.

[0209] From H = Si / W, (E’1) becomes Si / W + W = L / 2.

[0210] This second degree equation may be solved for the lowest H value, i.e., HO:

[0211] L [L2L

[0212] H0 = — — - Si = -(1 —

[0213]

[0214] ) « 2.55 mm

[0215] 4 J 16 4 J L2

[0216] with

[0217] L L

[0218] WO = — — HO = — +

[0219]

[0220] « 9.9 mm

[0221] 2 4 16

[0222] Accordingly, when compressing an aerosol-generating article 38 (having the metallic susceptor 32 arranged perpendicular to the compression force) so that the height decreases from 7.2 millimetres to less than 2.55 millimetres (i.e. a 4.65 / 7.2 « 64% decrease in diameter), andusing the previous numerical values regarding the elasticity of the wrapping material and the sealing adhesive, then the wrapping materials (the cigarette paper and the plug wrap) of the aerosol-generating substrate portion 31 plug can be expected to break.

[0223] For example, using the above numerical values, if a pressing roller is used to flatten aerosolgenerating articles 38 stacked in three layers, then the minimum distance between the outside surface of the pressing roller and the conveyor 41 required to break the wrappings of the aerosolgenerating substrate portion 31 plugs should be less than 2.55 millimetres x 3 = 7.65 millimetres.

[0224] In addition to opening the wrapping materials, an advantage obtained by a compression step with the metallic susceptors 32 oriented perpendicular to the compression force is that an attachment between the aerosol-generating substrate portion 31 and the metallic susceptor 32 may be strengthened. This is because the aerosol-generating substrate portion 31 is firmly pressed onto the major planar surfaces 320 of the metallic susceptor 32 during compression, and this may be helpful in subsequent processing steps, when it is desired to separate the aerosolgenerating substrate portions 31 and attached metallic susceptors 32 from other components of the aerosol-generating articles 38.

[0225] Figures 10 and 11 show an alternative compression process, in which the aerosolgenerating articles 38 are rotated by the magnetic field 45 so that the substantially planar metallic susceptors 32 are aligned substantially perpendicular to the first direction, and thus substantially parallel to the second direction in which the compression force is applied. The substantially planar metallic susceptors 32 may be aligned substantially in a vertical direction. This may be achieved by appropriate configuration of the magnetic field generator 44 so that the magnetic field 45 has field lines substantially parallel to the second direction, at least in a location through which the metallic susceptors 32 pass when travelling on the conveyor 41. Although not shown in Figures 10 and 11, the other features of the embodiments of Figures 4 to 6 are present, including the feeder 40, the conveyor 41 , the magnetic field generator 44 and the compressor 46.

[0226] Figure 10 illustrates the compression of an aerosol-generating article 38 in a direction substantially parallel to an orientation of the substantially planar metallic susceptor 32, with the aerosol-generating article 38 being disposed on top of one or more further layers 49 of aerosolgenerating articles 38. In this arrangement, the metallic susceptor 32 is disposed with one of the thin opposed edges 321 facing downwardly towards the conveyor 41. When a downward compression force 48 is applied by the compressor 46 in the second direction substantially parallel to the orientation of the metallic susceptor 32, the downwardly-facing edge 321 of the metallic susceptor 32 will be pushed through and burst the downwardly-facing part of the wrapper as shown at 300. This is because the upwardly-facing edge of the metallic susceptor 32 is pushed downwardly by the compressor 46, and due to an inherent structural rigidity of the metallic susceptor 32 and a reaction force applied upwardly by the underlying one or more further layers 49 of aerosol-generating articles 38.Figure 11 illustrates the compression of an aerosol-generating article 38 in a direction substantially parallel to an orientation of the substantially planar metallic susceptor 32, with the aerosol-generating article 38 being disposed on the conveyor 41 and under one or more further layers 49 of aerosol-generating articles 38. In this arrangement, the metallic susceptor 32 is disposed with one of the thin opposed edges 321 facing upwardly away from the conveyor 41. When a downward compression force 48 is applied to an upper layer of the one or more further layers 49 of aerosol-generating articles 38 by the compressor 46 in the second direction substantially parallel to the orientation of the metallic susceptor 32, the downward compression force 48 will be transmitted 480 through the one or more further layers 49 of aerosol-generating articles 38. The upwardly-facing edge 321 of the metallic susceptor 32 will be pushed through and burst the upwardly-facing part of the wrapper as shown at 301. This is because the downwardly-facing edge of the metallic susceptor 32 experiences an upward reaction force from the conveyor 41, and the inherent structural rigidity of the metallic susceptor 32 causes the upwardly-facing edge 321 of the metallic susceptor 32 to burst the wrapper at an upwardly-facing part thereof.

[0227] During application of the compression force 48, the aerosol-generating articles 38 may become more closely packed together, and this may reduce or prevent unwanted rotation, keeping the substantially planar metallic susceptors 32 correctly aligned. This may apply also in Figures 4 to 6.

[0228] When using the previously-indicated exemplary dimensions for a metallic susceptor (width of about 5 millimetres, thickness of about 60 micrometres, and a length about the same as that of the aerosol-generating substrate portion 31) in an aerosol-generating article 38 of diameter about 7.2 millimetres, then it appears that by applying a compression force 48 to decrease the diameter of the aerosol-generating article 38 by only around 2.2 millimetres (thus decreasing the diameter by 2.2 / 7.2 « 30 percent instead of 64 percent as in the embodiment of Figures 4 to 6) is sufficient to cause the thin edge 321 of the metallic susceptor 32 to contact and start to push through the wrapping materials.

[0229] In the embodiments of Figures 10 and 11, where the compression force 48 is applied in a direction substantially parallel to an orientation of the substantially planar metallic susceptors 32, it is preferred that the amount of compression is limited so as not to cause complete separation of the metallic susceptors 32 from the aerosol-generating substrate, since subsequent processing steps may be facilitated by maintaining a connection between the metallic susceptors 32 and their surrounding aerosol-generating substrate. Accordingly, the compression force 48 and a compression distance should be calculated to push the metallic susceptors 32 sufficiently to cut the wrapping materials but not to push the metallic susceptors 32 completely out of the aerosolgenerating substrate portions 31.When comparing the two alternative arrangements discussed above, it is currently believed that the embodiment of Figures 4 to 6, where the metallic susceptors 32 are oriented substantially perpendicular to the compression force 48, may have the advantage of promoting a strong bonding between the aerosol-generating substrate and the metallic susceptors 32, which may be of benefit in subsequent magnetic separation processing steps. In contrast, it is currently believed that the embodiment of Figures 10 and 11, where the metallic susceptors 32 are oriented substantially parallel to the compression force 48, may have the advantage of breaking the wrapping materials with a smaller amount of compression (in the illustrated example, a compression by only around 30 percent is needed to break the wrapping materials, as opposed to around 64 percent). Moreover, where the this arrangement may be more beneficial where the metallic susceptors 32 have good structural rigidity in the direction of the compression force 48 (i.e. across their widths). This will more likely be the case when the metallic susceptors 32 are not corrugated along their lengths, since in this case the metallic susceptors 32 may be more prone to crumple under width-wise compression, rather than breaking the wrapping materials.

[0230] In some embodiments, the aerosol-generating articles 38 may be wetted prior to or during compression. For example, a sprayer or sprinkler may be provided so as to spray or sprinkle water onto the aerosol-generating articles 38 on the conveyor 41 , preferably after the metallic susceptors 32 have been aligned by the magnetic field 45 (since wetted aerosol-generating articles 38 may not rotate as freely as dry aerosol-generating articles 38 due to increased friction or adhesion between wetted aerosol-generating articles 38). Wetting the aerosol-generating articles 38 may help to weaken the wrapping materials (especially if the wrapping materials are paper-based), and may help to weaken or partially dissolve water-soluble adhesives used to hold the wrapping materials in place, and this may facilitate cutting or tearing of the wrapping materials during compression of the aerosol-generating articles 38.

[0231] The compression step is primarily intended to help open up the wrapping materials used to wrap the aerosol-generating substrate portion 31 plugs, since these plug portions will tend to have the highest incompressible solids content of the various plug components due to the presence of the metallic susceptor 32 that is surrounded by a relatively well-packed aerosol-generating substrate. This is in contrast to the MPF, HAT and FHAT plugs, which include relatively large, sometimes hollow, compressible volumes, and which do not generally comprise metallic susceptors 32.

[0232] It will be appreciated that even if only the aerosol-generating substrate portion 31 plugs are opened up by the compression step, and not the MPF, HAT and FHAT plugs, embodiments of the present invention remain effective for separating the content of the aerosol-generating substrate portion 31 plugs from their wrappers without damaging or breaking the metallic susceptors 32, since this is a primary objective of embodiments of the present invention, and distinguishes over prior art processes that involve shredding of the aerosol-generating articles 38.It will also be appreciated that breaking or tearing open the outer wrapper 3 (e.g. cigarette paper) around the aerosol-generating substrate portion 31 plug will tend also to help release the other plug components 33, 34 and 35 from the outer wrapper 3.

[0233] After the compression step, the aerosol-generating articles 38 may be shaken or vibrated in order to promote separation of at least some of the various components making up the aerosolgenerating articles 38. In particular, it is desirable to separate the aerosol-generating substrate portions 31 containing metallic susceptors 32 from the outer wrapper 3, the plug wrap 37 and the other plug components of the aerosol-generating articles 38.

[0234] Figure 12 shows an arrangement in which compressed aerosol-generating articles 50, with broken or loosened outer wrappers 3 and plug wraps 37, are fed into an upper end of an inclined rotating tubular cylinder 51. The rotating tubular cylinder 51 has an axis of rotation that slopes downwardly, and this promotes movement of the compressed aerosol-generating articles 50 from the upper end towards a lower end of the rotating tubular cylinder 51. In addition to the agitation that is imparted to the compressed aerosol-generating articles 50 by tumbling in the rotating tubular cylinder 51 , additional agitation may be provided by applying vibrations to the rotating tubular cylinder 51 or to a shaft of the rotating tubular cylinder 51.

[0235] In some embodiments, the rotating tubular cylinder 51 may have circumferential perforations, and act as a rotary drum screen. This can help to separate broken pieces or strips of aerosol-generating substrate portion 31 that have been released in the compression and agitation steps. Where the aerosol-generating substrate portion 31 is in the form of a crimped and gathered sheet of tobacco cast leaf, it is possible that crimps present lines of weakness that allow thin strips or pieces of aerosol-generating substrate to fall away, and these can fall through the circumferential perforations in the rotating tubular cylinder 51 for collection and recycling.

[0236] Larger components, such as MPF plugs 36, HAT plugs 34, FHAT plugs 35 and aerosolgenerating substrate portions 31 attached to metallic susceptors 32, as well as wrapping materials 3, 5, 37 (indicated collectively at 52), may fall from the lower end of the rotating tubular cylinder 51 onto a further conveyor 53, which may be a conveyor belt passing over a pair of pulleys 55.

[0237] A magnetic field may be applied by a magnetic field generator 54 located at a downstream end of the further conveyor 53. The magnetic field generator 54 may be a permanent magnet or an electromagnet. As the conveyor belt of the further conveyor 53 passes over the downstream pulley 55, the magnetic field will exert an attractive force on the metallic susceptor 32, with the result that the metallic susceptors 32 and the aerosol-generating substrate portions 31 attached to the metallic susceptors 32 will remain attracted to the conveyor belt as it passes around the downstream pulley 55, until they move sufficiently far from the magnetic field generator 54 so that gravity will cause them to fall from an underside of the conveyor 51 into a first collection vessel 56. Non-magnetic components such as MPF plugs 36, HAT plugs 34, FHAT plugs 35 andwrapping materials 3, 5, 37 (collectively indicated at 39) will tend to fall freely from the end of the conveyor 51 into a second collection vessel 57.

[0238] Magnetic separation to separate ferromagnetic materials from non-ferromagnetic materials is in itself well-known. However, in the context of the present application, attempting to recover only the metallic susceptors 32 at this stage would be challenging. For example, using magnetic separation to separate the metallic susceptors 32 directly from the aerosol-generating substrate portions 31 would require very strong magnetic fields, since the metallic susceptors 32 are still, at this stage, at least partially wrapped in or contained by the aerosol-generating substrate portions 31. Moreover, applying very strong magnetic fields may cause the metallic susceptors 32 to tear or damage the aerosol-generating substrate portions 31, leading to the generation of small particles of aerosol-generating substrate which can be difficult to separate efficiently. Small pieces of aerosol-generating substrate may remain stuck or attached to the metallic susceptors 32, and this may require subsequent cleaning of the metallic susceptors 32 prior to recycling, which may be inefficient. In addition, separating the metallic susceptors 32 from the aerosolgenerating substrates at this stage, using magnetic separation, would mean that aerosolgenerating substrate materials would end up mixed in with wrapping materials and other nonmagnetic components. Since the aerosol-generating substrates are fairly similar to the wrapping materials in terms of density, surface area and material properties, it can be challenging to separate aerosol-generating substrate materials from wrapping materials.

[0239] Accordingly, the magnetic separation step illustrated in Figure 12 is unusual and different from known magnetic separation techniques, since the objective is to use magnetic separation to separate the metallic susceptors 32 while still attached to the aerosol-generating substrates on the one hand, from other non-magnetic components of the aerosol-generating articles 38 on the other hand.

[0240] The metallic susceptors 32 tend to stay attached to the aerosol-generating substrate sheets for a number of reasons.

[0241] Firstly, in the aerosol-generating articles 38, the metallic susceptors 32 are strongly held inside the aerosol-generating substrate portions 31 , which may enclose the metallic susceptors 32 laterally and, in some instances, longitudinally.

[0242] Secondly, aerosol-generating substrate sheets may include aerosol formers and other components (for instance nicotine gel), and these can have adhesive properties, causing the aerosol-generating substrates to stick to the metallic susceptors 32.

[0243] Thirdly, the compression step, especially in embodiments where the metallic susceptors are aligned in a direction perpendicular to the compression force, will press the aerosol-generating substrates onto the major opposed surfaces of the metallic susceptors, thus reinforcing any attachment therebetween.The shaking or vibration step prior to the magnetic separation step may therefore be tuned (by adjusting frequency, or amplitude, or both frequency and amplitude, for example by adjusting a rotational speed of the rotating tubular cylinder 51 or vibrations applied to the rotating tubular cylinder 51) in order to promote separation of the aerosol-generating substrate portions 31 and their attached metallic susceptors 32 from the wrapping materials and other non-magnetic components, but without causing the metallic susceptors 32 to become separated from the aerosol-generating substrate portions 31.

[0244] The magnetic separation process shown in Figure 12 may have a further advantage that the metallic susceptors 32 that are attracted to the further conveyor 53 may trap partially or fully unfurled sheets of aerosol-generating substrate that are located between the metallic susceptors 32 and the further conveyor 53, and this may help to ensure that the sheets of aerosol-generating substrate are released into the first collection vessel 56 together with the metallic susceptors 32.

[0245] To reduce the likelihood of the metallic susceptors 32 trapping components other than the sheets of aerosol-generating substrates, it is preferred that the aerosol-generating article components 52 exiting the rotating tubular cylinder 51 are spread out on the conveyor 53 as a thin layer. This can be achieved by regulating the speed of the conveyor 53, or the slope of the tubular rotating cylinder 51, or both.

[0246] After the magnetic separation step, the aerosol-generating articles 38 will have been disassembled into collections of components: one the one hand, a first collection comprising substantially just aerosol-generating substate portions 31 with metallic susceptors 32, and a second collection comprising the other parts of the aerosol-generating articles 38, predominantly cellulose acetate plug portions, wrapping materials and other non-magnetic components, for example cardboard or polymer tubes where these are present. Although there may be some cross-contamination between the first and second collections, this may be acceptable in terms of the overall process.

[0247] The second collection of components can be subjected to further known separation processes, including shredding (if necessary) to open the plug wrappers (if not already opened by the compression step) and a “float and sink” process, in which cellulose acetate materials are separated from paper materials by immersion in a body of water, with the cellulose acetate plugs tending to float while the paper materials tend to become waterlogged and sink.

[0248] The first collection of components may be subjected to further separation processes as outlined below.

[0249] Figure 13 shows a vertical cross-section through an air flow separator comprising an inclined tubular rotating cylinder 60 and a vessel 61 across which an air current 63 is directed. The second collection of components, comprising aerosol-generating substrate portions 31 attached to metallic susceptors 32, and possibly loose metallic susceptors 32 and loose aerosolgenerating substrate portions 31 , is introduced into an upper end of the inclined tubular rotatingcylinder 60. Rotation of the inclined tubular rotating cylinder 60 may help to unfurl the aerosolgenerating substrate portions 31 so that they revert to a more sheet- or ribbon-like configuration. Rotation of the inclined tubular rotating cylinder 60 may also help to separate the aerosolgenerating substrate portions 31 from the metallic susceptors 32. The inclined tubular rotating cylinder may include internal air jets to help unfurl the aerosol-generating substrate portions 31 and to help separate them from the metallic susceptors 32. The at least partially separated and unfurled aerosol-generating substrate portions 31 and metallic susceptors 32 may then be allowed to fall into the vessel 61, for example through an inlet funnel 62. An air current 63 is directed across an interior of the vessel 61 , for example by way of an air current inlet fan and an air current outlet fan. A mesh 64 may be provided at the air current outlet to prevent solid material from being blown out of the air current outlet. Alternatively, an air current 63 may be applied across the interior of the vessel 61 by one or more air jets. In both cases, the idea is to apply an air current substantially transverse to a direction in which the sheets of aerosol-generating substrate 31 and the metallic susceptors 32 fall under gravity. The air current 63 may also help further to unfurl the sheets of aerosol-generating substrate 31. Because the unfurled sheets of aerosol-generating substrate 31 present a significantly greater surface area to the air current 63 than the metallic susceptors 32, the unfurled sheets of aerosol-generating substrate 31 will tend to be laterally displaced within the vessel 61 more than the metallic susceptors 32. This allows the unfurled sheets of aerosol-generating substrate 31 to be directed to and collected in a third collection vessel 65, while the metallic susceptors 32 fall more directly into and are collected in a fourth collection vessel 66. In a specific example, an unfurled sheet of aerosol-generating substrate 31 may have an area of around 12 millimetres by 125 millimetres, while a metallic susceptor 32 may have an area of around 12 millimetres by 5 millimetres.

[0250] The rotating tubular cylinder 60 is not essential - any other appropriate shaking or agitation device may be used to promote unfurling of the aerosol-generating substrate portions 31 and separation of the aerosol-generating substrate portions 31 from the metallic susceptors 32.

[0251] While the use of an air flow separator as shown in Figure 13 may have the advantage of being relatively simple in implementation, an air flow separator may not always be the most appropriate solution for separating the aerosol-generating substrate portions 31 from the metallic susceptors 32. For example, if the aerosol-generating substrate portions 31 are stuck too firmly to the metallic susceptors 32, it may be difficult to separate the aerosol-generating substrate portions 31 without damage. Moreover, the compression step may damage the aerosolgenerating substrate portions 31, leading to the generation of debris comprising small pieces of aerosol-generating substrate that might not be sufficiently deflected by the air current 63 and might contaminate the metallic susceptors 32 in the fourth collection vessel 66.

[0252] Accordingly, instead of the airflow separator of Figure 13, there may be provided a cyclonic separator as shown in Figure 14.Figure 14 shows a vertical cross-section through a cyclonic separator 74 comprising a frustoconical housing 70 with an upper input feed 700 configured to allow a fluid stream 71 containing aerosol-generating substrate portions 31 attached to metallic susceptors 32 to be introduced into an upper, wider part of the frustoconical housing 70 in a generally tangential direction. The fluid of the fluid stream 71 may be gaseous, for example air, or may be liquid, for example water. The fluid stream 71 follows a descending outer vortex path 72 around the inside of the frustoconical housing 70, towards a lower outlet 73. However, due to the progressive narrowing of the frustoconical housing 70 towards the lower outlet 73, a portion of the fluid stream 71 is reflected upwardly as an ascending central vortex path 75, and travels upwardly to an upper outlet 76 of the frustoconical housing 70.

[0253] Shear forces are generated in the fluid stream 71, the descending vortex path 72 and the ascending vortex path 75, and these shear forces help to unfurl and separate the aerosolgenerating substrate portions 31 from the metallic susceptors 32. The shear forces may be greater than the forces generated by air currents 63 in the air flow separator of Figure 13, resulting in improved separation.

[0254] Heavier elements in the fluid stream 71 tend to be driven outwardly by centrifugal forces in the vortex paths 72, 75, and are thus driven downwardly by the descending outer vortex and out through the lower outlet 73 as shown at 77. The heavier elements comprise the aerosolgenerating substrate portions 31. Conversely, lighter elements in the fluid stream 71 tend to migrate towards a central axis of the frustoconical housing 70 and are thus carried upwardly by the ascending inner vortex and out through the upper outlet 76 as shown at 78. The lighter elements comprise the metallic susceptors 32. For example, metallic susceptors 32 in some aerosol-generating articles may have a mass of around 23 milligrammes.

[0255] In a further development, Figure 15 shows a vertical cross-section through a cyclonic separator 74 comprising a frustoconical housing 70 similar to the arrangement of Figure 14, but with an axial shaft 80 comprising or containing a magnet. The magnet may be a permanent magnet or an electromagnet. The axial shaft 80 extends along a longitudinal central axis of the frustoconical housing 70, from the upper outlet 76 towards the lower outlet 73. Preferably, the cyclonic separator 74 of Figure 15 is configured as a hydrocyclonic separator, using water as a fluid for the fluid stream 71. Similarly to the cyclonic separator of Figure 14, the fluid stream 71 follows a descending outer vortex path 72 around the inside of the frustoconical housing 70, towards the lower outlet 73, with a portion of the fluid stream 71 being reflected upwardly as an ascending central vortex path 75 that travels upwardly, around the axial shaft 80, to an upper outlet 76 of the frustoconical housing 70. The cyclonic separator arrangement of Figure 15, except that the axial shaft 80 comprising or containing a magnet will magnetically attract the metallic susceptors 32, while the aerosol-generating substrate portion 31 and smaller pieces of aerosol-generating substrate will tend to move outwardly and be caught up in the descendingouter vortex path 72 for removal at the lower outlet 73 as indicated at 77. The metallic susceptors 32 magnetically attracted to the axial shaft 80 may be driven upwardly by the ascending inner vortex path 75 for removal at the upper outlet 76 as indicated at 78. In order to remove magnetic susceptors 32 that are magnetically attached to the axial shaft 80 and resist the force of the ascending inner vortex, the axial shaft 80 may periodically be withdrawn from the frustoconical housing 72, for example through the upper outlet 76, and the metallic susceptors 32 scraped off for recovery. Alternatively, where the axial shaft 80 comprises or contains an electromagnet, the electromagnet may periodically be switched off, or a power supply to the electromagnet may be reduced, so as to release metallic susceptors 32 that are magnetically attached to the axial shaft 80 and to allow these metallic susceptors 32 to be carried up and out through the upper outlet 76 by the ascending inner vortex.

[0256] It is relatively simple to separate the metallic susceptors 32 from the fluid, for example water, collected at the upper outlet 76 of the cyclonic separator 74 by using a sieve or filter. Likewise, the aerosol-generating substrate portions 31 and small pieces of aerosol-generating substrate can be separated from water collected at the lower outlet 73 of the cyclonic separator 74 by using a sieve or filter. The separated metallic susceptors 32 and aerosol-generating substrate portions 31 can then be recycled or reprocessed as required.

[0257] Figure 16 shows a close-up vertical cross-sectional view through the axial shaft 80 of the cyclonic separator of Figure 15, additionally provided with an external helical member 82 that is coaxial with and rotatable relative to the axial shaft 80. The external helical member 82 may fit snugly yet rotatably around an external cylindrical casing 81 of the axial shaft 80. Turns of the external helical member 82 may have an upwardly-directed face 86 that pushes the magnetically-attached metallic susceptors 32 upwardly along the external cylindrical casing 81 when the external helical member 82 is rotated about the axial shaft 80 in the appropriate direction. In this way, it is possible to drive any magnetically-attached metallic susceptors 32 upwardly and out of the upper outlet 76. Figure 16 also shows a magnet 84 disposed within the outer cylindrical casing 81 and a magnetic field 85 generated by the magnet 84, the magnetic field 85 attracting metallic susceptors 32 towards the axial shaft 80.

[0258] The cyclonic separator 74 may be preceded by a shaker or agitator, for example a rotating tubular cylinder 60 as shown in Figure 13, to promote separation of the metallic susceptors 32 from the aerosol-generating substrate portions 31.

[0259] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A ± 5% of A. Within this context, a number A may be considered to includenumerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

CLAIMS:

1. A method of processing waste rod-shaped aerosol-generating articles each comprising an aerosol-generating substrate portion including a substantially planar metallic susceptor disposed longitudinally within the aerosol-generating substrate portion, together with other plug components, all wrapped in at least one wrapper, wherein:i) the rod-shaped aerosol-generating articles are fed onto a conveyor travelling in a first direction;ii) the rod-shaped aerosol-generating articles on the conveyor are subjected to a magnetic field so as to cause the rod-shaped aerosol-generating articles to be disposed such that planes of the substantially planar metallic susceptors are aligned in substantially the same direction; andiii) the rod-shaped aerosol-generating articles with their substantially planar metallic susceptors aligned in substantially the same direction are compressed in a second direction substantially perpendicular to the first direction so as to deform the rod-shapes aerosol-generating articles and to loosen the at least one wrapper from the aerosol-generating substrate portions and the other plug components.

2. The method according to claim 1, wherein, in step ii), the magnetic field causes the rodshaped aerosol-generating articles to be disposed such that the planes of the substantially planar metallic susceptors are aligned in a direction substantially perpendicular to the second direction.

3. The method according to claim 1, wherein, in step ii), the magnetic field causes the rodshaped aerosol-generating articles to be disposed such that the planes of the substantially planar metallic susceptors are aligned in a direction substantially parallel to the second direction.

4. The method according to any preceding claim, wherein in step iii), the rod-shaped aerosolgenerating articles are either:compressed in the second direction by a pressing roller operable to exert a compression force in a direction towards the conveyor; orcompressed in the second direction by a pressing block operable to exert a compression force in a direction towards the conveyor.

5. The method according to any preceding claim, wherein the rod-shaped aerosol-generating articles, after compression in step iii), are agitated so as to promote separation of the aerosolgenerating substrate portions containing metallic susceptors from the other plug components and from the wrappers, and wherein the aerosol-generating substrate portions containing metallicsusceptors, the other plug components, and the wrappers are passed along a further conveyor and subjected to a magnetic separation process.

6. The method according to claim 5, wherein the aerosol-generating substrate portions and metallic susceptors are subjected to at least one air current so as to separate the aerosolgenerating substrate portions from the metallic susceptors.

7. The method according to claim 5, wherein the aerosol-generating substrate portions and metallic susceptors are passed through a cyclonic separator so as to separate the aerosolgenerating substrate portions from the metallic susceptors.

8. The method according to claim 7, wherein the cyclonic separator comprises an axial shaft comprising or containing a magnet that attracts the metallic susceptors.

9. The method according to claim 8, wherein the axial shaft is provided with an external helical member that is coaxial with and rotatable relative to the axial shaft so that metallic susceptors on the axial shaft will travel along a length of the axial shaft when the external helical member is rotated relative to the axial shaft.

10. An apparatus for processing waste rod-shaped aerosol-generating articles each comprising an aerosol-generating substrate portion including a substantially planar metallic susceptor disposed longitudinally within the aerosol-generating substrate portion, together with other plug components, all wrapped in at least one wrapper, the apparatus comprising:i) a conveyor configured to travel in a first direction;ii) a feeder configured to feed the rod-shaped aerosol-generating articles onto the conveyor;iii) a magnetic field generator to generate a magnetic field to cause the rod-shaped aerosol-generating articles on the conveyor to be disposed such that planes of the substantially planar metallic susceptors are aligned in substantially the same direction; andiv) a compressor configured to compress the rod-shaped aerosol-generating articles in a second direction substantially perpendicular to the first direction so as to deform the rod-shapes aerosol-generating articles and to loosen the at least one wrapper from the aerosol-generating substrate portions and the other plug components.

11. The apparatus according to claim 10, wherein the magnetic field generator is configured to cause the rod-shaped aerosol-generating articles to be disposed such that the planes of the40 / 41substantially planar metallic susceptors are aligned in a direction substantially perpendicular to the second direction.

12. The apparatus according to claim 10, wherein the magnetic field generator is configured to cause the rod-shaped aerosol-generating articles to be disposed such that the planes of the substantially planar metallic susceptors are aligned in a direction substantially parallel to the second direction.

13. The apparatus according to any one of claims 10 to 12, further comprising:an agitator configured to receive and agitate the rod-shaped aerosol-generating articles, after compression, so as to promote separation of the aerosol-generating substrate portions containing metallic susceptors from the other plug components and from the wrappers;a further conveyor configured to convey the aerosol-generating substrate portions containing metallic susceptors, the other plug components, and the wrappers; anda further magnetic field generator configured to apply a magnetic field to the further conveyor to separate the aerosol-generating substrate portions containing metallic susceptors from the other plug components and from the wrappers.

14. The apparatus according to claim 13, further comprising a cyclonic separator configured to receive the aerosol-generating substrate portions and metallic susceptors and to separate the aerosol-generating substrate portions from the metallic susceptors.

15. The apparatus according to claim 14, wherein the cyclonic separator comprises an axial shaft comprising or containing a magnet that attracts the metallic susceptors; optionally wherein the axial shaft is provided with an external helical member that is coaxial with and rotatable relative to the axial shaft.

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