Apparatus for manufacturing a rod of aerosol generating material, methods of manufacturing a rod of aerosol generating material and methods of manufacturing an article for an aerosol provision system

Abstract

Apparatus for Manufacturing a Rod of Aerosol Generating Material, Methods of Manufacturing a Rod of Aerosol Generating Material and Methods of Manufacturing an Article for an Aerosol Provision System The present disclosure relates to an apparatus (9) for manufacturing a rod of aerosol generating material (3). The apparatus (9) comprises a suction belt (11) for conveying aerosol generating material, the suction belt (11) comprising suction holes (16) to retain aerosol generating material on the suction belt (11), and wherein the apparatus (9) is arranged such that the suction belt (11) receives a first aerosol generating material (4) at a first supply zone (17). The apparatus (9) further comprises a blocking member (19) configured to block some of the suction holes (16) in CA the suction belt (11) at the first supply zone (17) such that the first aerosol generating material (4) is arranged in a profile comprising a plurality of first regions of the first aerosol generating material (4), with no or a reduced amount of first aerosol generating material provided between the first regions. The apparatus (9) further comprises a first feeding device (30) configured to supply at least one of beads, pellets or granules of a second aerosol generating material (5) between said first regions. The present disclosure also relates to methods of manufacturing a rod of aerosol generating material, and to methods of manufacturing an article for an aerosol provision system. The present disclosure also relates to an article for use in an aerosol provision system.

1 . An apparatus for manufacturing a rod of aerosol generating material, the apparatus comprising:
 a suction belt for conveying aerosol generating material, the suction belt comprising suction holes to retain aerosol generating material on the suction belt, and wherein the apparatus is arranged such that the suction belt receives a first aerosol generating material at a first supply zone; and,   a blocking member configured to block some of the suction holes in the suction belt at the first supply zone such that the first aerosol generating material is arranged in a profile comprising a plurality of first regions of the first aerosol generating material, with no or a reduced amount of first aerosol generating material provided between the first regions; and,   a first feeding device configured to supply at least one of beads, pellets or granules of a second aerosol generating material between said first regions.   
     
     
         2 . The apparatus of  claim 1 , wherein the profile is arranged such that substantially no first aerosol generating material is disposed between the first regions such that the first regions are discrete and spaced apart from each other. 
     
     
         3 . The apparatus of  claim 1 , wherein the profile is arranged such that a connection region is provided between each first region, wherein each connection region comprises a reduced amount of the first aerosol generating material than the first region. 
     
     
         4 . The apparatus of  claim 1 , wherein the first feeding device comprises a drum comprising a plurality of receiving spaces configured to receive the beads, pellets and/or granules and transfer the beads, pellets and/or granules between said first regions. 
     
     
         5 . The apparatus of  claim 4 , configured such that the beads, pellets and/or granules are blown and/or sucked from the receiving spaces. 
     
     
         6 . The apparatus of  claim 4 , comprising a plurality of mesh sections that define the receiving spaces. 
     
     
         7 . The apparatus of  claim 1 , wherein the feeding device is configured to supply the beads, pellets and/or granules to the suction belt. 
     
     
         8 . The apparatus of  claim 1 , wherein the feeding device is configured to supply the beads, pellets and/or granules downstream of the suction belt. 
     
     
         9 . The apparatus of  claim 1 , further comprising a garniture arranged to receive the profile of first aerosol generating material from the suction belt. 
     
     
         10 . The apparatus of  claim 9 , wherein the feeding device is configured to supply the beads, pellets and/or granules downstream of the suction belt, and wherein the feeding device is configured to supply the beads, pellets and/or granules to the profile on the garniture. 
     
     
         11 . The apparatus of  claim 9 , wherein the garniture is adapted to wrap a ribbon of paper about the first aerosol generating material and the beads, pellets and/or granules to form a continuous rod of aerosol generating material. 
     
     
         12 . The apparatus of  claim 11 , further comprising a cutter adapted to cut the continuous rod of aerosol generating material. 
     
     
         13 . The apparatus of  claim 1 , wherein the first feeding device is configured to supply at least one of extruded beads, pellets or granules and, preferably, at least one of beads, pellets or granules that have been extruded and subject to spheronisation. 
     
     
         14 . The apparatus of  claim 1 , wherein the first feeding device is configured to supply beads, pellets and/or granules having a density from at least about 0.4 g/cm 3  and, preferably, from at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g/cm 3 . 
     
     
         15 . The apparatus of  claim 1 , wherein the first feeding device is configured to supply beads, pellets and/or granules having a particle size in the range of 0.5 to 3 mm and, preferably, in the range of 1 to 2 mm. 
     
     
         16 . The apparatus of  claim 1 , wherein the first and/or second aerosol generating materials comprise, consist of, or essentially consist of tobacco material. 
     
     
         17 . The apparatus of  claim 1 , wherein the suction belt is arranged to retain the first aerosol generating material on an underside of the suction belt. 
     
     
         18 . The apparatus of  claim 1 , further comprising a second feeding device arranged to feed the first aerosol generating material onto the suction belt in the first supply zone and, preferably, the second feeding device is disposed below the suction belt. 
     
     
         19 . The apparatus of  claim 1 , wherein the first feeding device is disposed below the suction belt. 
     
     
         20 . The apparatus of  claim 1 , wherein the blocking member comprises a profile belt arranged to overlap the suction belt in the first region, the profile belt being configured to block some of the suction holes in the suction belt such that the first aerosol generating material is retained on the suction belt in the profile. 
     
     
         21 . The apparatus of  claim 20 , wherein the profile belt comprises a plurality of suction regions and a plurality of blocking regions arranged along the length of the profile belt. 
     
     
         22 . The apparatus of  claim 21 , wherein the profile belt further comprises connecting suction regions disposed between the suction regions, each of the connecting suction regions being smaller than the suction regions such that less aerosol generating material is retained on the suction belt in each connecting suction region than in each suction region. 
     
     
         23 . The apparatus of  claim 20 , wherein the suction belt has a first width and the profile belt has a second width, and wherein the second width is less than the first width. 
     
     
         24 . A method of manufacturing a rod of aerosol generating material, the method comprising:
 applying suction to a suction belt having suction holes to retain a first aerosol generating material on the suction belt in a first supply zone;   blocking some suction holes of the suction belt in the first region such that the first aerosol generating material is retained on the suction belt in a profile comprising a plurality of first regions of the first aerosol generating material, with no or a reduced amount of first aerosol generating material provided between the first regions; and,   supplying at least one of beads, pellets or granules of a second aerosol generating material between said first regions.   
     
     
         25 . The method of  claim 24 , wherein the beads, pellets and/or granules are supplied to the suction belt. 
     
     
         26 . The method of  claim 24 , wherein the beads, pellets and/or granules are supplied downstream of the suction belt. 
     
     
         27 . The method of  claim 24 , further comprising transferring the first aerosol generating material to a garniture. 
     
     
         28 . The method of  claim 27 , wherein the beads, pellets and/or granules are supplied downstream of the suction belt, and wherein the beads, pellets and/or granules are supplied to the garniture. 
     
     
         29 . The method of  claim 27 , further comprising wrapping the aerosol generating material in a ribbon of paper to form a continuous rod of aerosol generating material. 
     
     
         30 . The method of  claim 29 , further comprising cutting the continuous rod of aerosol generating material. 
     
     
         31 . The method of  claim 24 , wherein the first feeding device is configured to supply extruded beads, pellets and/or granules and, preferably, beads, pellets and/or granules that have been extruded and subject to spheronisation. 
     
     
         32 . The method of  claim 24 , wherein the first feeding device is configured to supply beads, pellets and/or granules having a density from at least about 0.4 g/cm 3  and, preferably, from at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g/cm 3 . 
     
     
         33 . The method of  claim 24 , wherein the first feeding device is configured to supply beads, pellets and/or granules having a particle size in the range of 0.5 to 3 mm and, preferably, in the range of 1 to 2 mm. 
     
     
         34 . The method of  claim 24 , wherein the first aerosol generating material and/or the beads, pellets and/or granules comprise, consist of, or essentially consist of tobacco material. 
     
     
         35 . A method of manufacturing an article for an aerosol provision system, the method comprising manufacturing a rod of aerosol generating material comprising:
 applying suction to a suction belt having suction holes to retain a first aerosol generating material on the suction belt in a first supply zone;   blocking some suction holes of the suction belt in the first region such that the first aerosol generating material is retained on the suction belt in a profile comprising a plurality of first regions of the first aerosol generating material, with no or a reduced amount of first aerosol generating material provided between the first regions; and,   supplying at least one of beads, pellets or granules of a second aerosol generating material between said first regions,   wherein first and second ends of the rod of aerosol generating material comprises first and second ends of the article.   
     
     
         36 . A method of manufacturing rods of aerosol generating material, the method comprising:
 providing at least one of beads, pellets or granules of tobacco material;   entraining the beads, pellets and/or granules in a continuous pressurised fluid stream; and   feeding the stream into a first aerosol generating material.   
     
     
         37 . The method according to  claim 36 , wherein entraining the beads, pellets and/or granules in a continuous pressurised fluid stream comprises using a venturi device to entrain the beads, pellets and/or granules. 
     
     
         38 . The method according to  claim 36 , wherein entraining the beads, pellets and/or granules in a continuous pressurised fluid stream comprises propelling the beads, pellets and/or granules in a high pressure jet. 
     
     
         39 . The method according to any of  claim 36 , wherein entraining the beads, pellets and/or granules in a continuous pressurised fluid stream comprises using a vacuum pump to propel the beads, pellets and/or granules. 
     
     
         40 . The method according to  claim 36 , wherein feeding the stream into a first aerosol generating material comprising feeding the stream into a body or rod of first aerosol generating material. 
     
     
         41 . The method according to  claim 30 , wherein feeding the stream comprises positioning the stream substantially parallel to a longitudinal axis of the body or rod. 
     
     
         42 . The method according to  claim 36 , wherein providing the beads, pellets and/or granules of tobacco material comprises storing beads, pellets and/or granules of tobacco material in a storage unit and receiving the beads, pellets and/or granules from the storage unit. 
     
     
         43 . The method according to  claim 42 , wherein storing the beads, pellets and/or granules comprises storing the beads, pellets and/or granules in a conical hopper. 
     
     
         44 . The method according to  claim 36 , wherein the beads, pellets and/or granules are extruded and, preferably, beads, pellets and/or granules have been extruded and subject to spheronisation. 
     
     
         45 . The method according to  claim 36 , wherein the beads, pellets and/or granules have a density from at least about 0.4 g/cm 3  and, preferably, from at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g/cm 3 . 
     
     
         46 . The method according to  claim 36 , wherein the beads, pellets and/or granules have a particle size in the range of 0.5 to 3 mm and, preferably, in the range of about 1 to 2 mm. 
     
     
         47 . The method according to  claim 36 , wherein the first aerosol generating material comprise, consist of, or essentially consist of tobacco material. 
     
     
         48 . A method of manufacturing an article for an aerosol provision system, the method comprising manufacturing a rod of aerosol generating material comprising:
 providing at least one of beads, pellets or granules of tobacco material;   entraining the beads, pellets and/or granules in a continuous pressurised fluid stream; and   feeding the stream into a first aerosol generating material,   wherein first and second ends of the rod of material comprises first and second ends of the article.   
     
     
         49 . (canceled) 
     
     
         50 . (canceled) 
     
     
         51 . An article for an aerosol provision system comprising a rod of aerosol generating material, wherein the rod of aerosol generating material comprises a first region of a first aerosol generating material and a second region of a second aerosol generating material comprising at least one of beads, pellets and/or granules. 
     
     
         52 . The article according to  claim 51 , wherein the beads, pellets or granules are inserted into the first aerosol generating material. 
     
     
         53 . (canceled) 
     
     
         54 . (canceled) 
     
     
         55 . The article according to  claim 51 , wherein first and second ends of the rod of aerosol generating material comprise first and second ends of the article. 
     
     
         56 . The article according to  claim 51 , wherein the beads, pellets and/or granules have a density from at least about 0.4 g/cm 3  and, preferably, from at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g/cm 3 .