Reconfigurable wrapping mechanism

This application is a U.S. National Stage Application of International Application No. PCT/EP2019/070676 filed Jul. 31, 2019, which was published in English on Feb. 6, 2020 as International Publication No. WO 2020/025699 A1. International Application No. PCT/EP2019/070676 claims priority to European Application No. 18187364.7 filed Aug. 3, 2018.

The present invention relates to a reconfigurable wrapping mechanism, a method of reconfiguration of a wrapping mechanism and a method of use of a reconfigurable wrapping mechanism, and more particularly to manufacturing rods for aerosol-generating articles.

The present specification relates to equipment for the manufacture of an aerosol-generating article, which may comprise an aerosol-forming substrate for generating an inhalable aerosol when heated by a heating element of an aerosol-generating device. The specification also relates to methods of using and reconfiguring equipment for the manufacture of an aerosol-generating article.

Wrapped rods are formed in the manufacture of aerosol-generating articles, for example being any of an aerosol-forming substrate, a support element, an aerosol-cooling element, and a mouthpiece.

A wrapped rod may be formed by passing a web of wrapping material and a core through an assembly known as a ‘garniture’, in which the web is wrapped and sealed around the core. The garniture assembly has an elongate formation channel with an open side extending along its length, and a shoe positioned close to at least part of the open side, and a belt that is driven through the formation channel, along the concave surface of the formation channel. The web is entrained onto the belt and drawn through the formation channel, with the core positioned onto the belt. The formation channel and shoe cooperate to wrap the web around the core, with at least part of the garniture forming a generally cylindrical channel between the shoe, belt and formation channel. A heating element may be provided in part of the shoe to thermoset an adhesive between overlapping portions of the wrapped web.

In use, the belt and the formation channel each become worn, which undesirably increases the size of the manufactured wrapped rods. To maintain manufacturing quality, it is necessary to replace the worn belts and worn formation channel assemblies, introducing additional costs into the manufacturing process and reducing manufacturing efficiency.

According to a first aspect, there is provided a reconfigurable wrapping mechanism for forming a substantially cylindrical wrapped element by wrapping a core within a web material, comprising a reconfigurable garniture bed having an elongate formation channel for supporting a conveying belt extending along the length of the elongate formation channel for entraining the web material, and wherein the elongate formation channel has an elongate open side.

According to a second aspect, there is provided a method of reconfiguring a garniture bed in a wrapping mechanism for forming a substantially cylindrical wrapped element by wrapping a core within a web material, the wrapping mechanism comprising a reconfigurable garniture bed having an elongate formation channel for supporting a conveying belt extending along the length of the elongate formation channel for entraining the web material, and wherein the elongate formation channel has an elongate open side,

wherein the garniture bed comprises a base member and a replaceable formation channel liner provided with the elongate formation channel and detachably connected to the base member, and the method comprises detaching and replacing the formation channel liner.

In preferred embodiments, the replaceable formation channel liner at least partly supports the conveying belt.

According to a third aspect, there is provided a method of manufacturing a substantially cylindrical wrapped element with a wrapping mechanism comprising:

- a reconfigurable garniture bed having an elongate formation channel for supporting a conveying belt extending along the length of the elongate formation channel for entraining the web material, and wherein the elongate formation channel has an elongate open side;
- a conveying belt extending along the length of the elongate formation channel; and
- a drive mechanism for driving the conveying belt along the length of the elongate formation channel,

the method comprising:

- driving the conveying belt and an entrained web material along the elongate formation channel with the drive mechanism;
- receiving a core onto the entrained web material; and
- wrapping the core within a web material.

The garniture bed may comprise:

- a base member; and
- a replaceable formation channel liner provided with the elongate formation channel and detachably connected to the base member.

The wrapping mechanism may comprise an elongate shoe provided adjacent and extending along the elongate open side of the elongate formation channel for slideably contacting at least one of the wrapped core, core and web material.

The wrapping mechanism may comprise one or both:

- the elongate shoe is configured for movement towards the garniture bed transverse to the length of elongate formation channel; and
- the garniture bed is configured for movement towards the elongate shoe transverse to the length of elongate formation channel.

The wrapping mechanism may comprise a conveying belt extending along the length of the elongate formation channel for entraining the web material.

The wrapping mechanism may comprise a drive mechanism for driving a conveying belt along the length of the elongate formation channel.

The wrapping mechanism may comprise:

- an elongate shoe provided adjacent and extending along the elongate open side of the elongate formation channel for slideably contacting at least one of the wrapped core, core and web material, and

the method may comprise one or both:

- the elongate shoe is configured for movement towards the garniture bed transverse to the length of elongate formation channel; and
- the garniture bed is configured for movement towards the elongate shoe transverse to the length of elongate formation channel.

The method may comprise reconfiguration of garniture bed to provide a narrower formation channel.

The wrapping mechanism may comprise a conveying belt extending along the length of the elongate formation channel for entraining the web material, and the method may comprise reconfiguration of garniture bed to provide a wider formation channel, and the method further comprises replacement of the conveying belt.

As used herein, the term ‘aerosol-generating device’ is used to describe a device that interacts with an aerosol-forming substrate of an aerosol-generating article to generate an aerosol. Preferably, the aerosol-generating device is a smoking device that interacts with an aerosol-forming substrate of an aerosol-generating article to generate an aerosol that is directly inhalable into a user's lungs thorough the user's mouth. The aerosol-generating device may be a holder for a smoking article.

Preferably, the aerosol-generating article is a smoking article that generates an aerosol that is directly inhalable into a user's lungs through the user's mouth. More, preferably, the aerosol-generating article is a smoking article that generates a nicotine-containing aerosol that is directly inhalable into a user's lungs through the user's mouth.

As used herein, the term ‘aerosol-forming substrate’ is used to describe a substrate capable of releasing upon heating volatile compounds, which can form an aerosol. The aerosol generated from aerosol-forming substrates of aerosol-generating articles described herein may be visible or invisible and may include vapours (for example, fine particles of substances, which are in a gaseous state, that are ordinarily liquid or solid at room temperature) as well as gases and liquid droplets of condensed vapours.

The aerosol-forming substrate may be formed as a folded web (also referred to as a pleated web). The folded web may be, but is not limited to a homogenized tobacco material, for example TCL (tobacco cast leaf), and is wrapped within a wrapping paper.

As used herein, the term ‘aerosol-cooling element’ is used to describe an element having a large surface area and a low resistance to draw. In use, an aerosol formed by volatile compounds released from the aerosol-forming substrate passes over and is cooled by the aerosol-cooling element before being inhaled by a user. In contrast to high resistance to draw filters and other mouthpieces, aerosol-cooling elements have a low resistance to draw. Chambers and cavities within an aerosol-generating article are also not considered to be aerosol cooling elements.

The wrapper may be a wrapper of filter paper. Preferably, the outer wrapper is a cigarette paper. However, this is not essential, and elements of aerosol-generating articles may be circumscribed by other outer wrappers.

As used herein, the term ‘formation channel’ is used to describe a channel for wrapping a web material around a core as the web material and core pass along the channel. At least an inlet portion of the formation channel, in which the web material is progressively wrapped around the core, in use, has a radius of curvature that decreases towards the downstream end. At the upstream end, in use, the channel may be substantially flat or have a large radius of curvature, where unwrapped materials are introduced into the formation channel. At least an outlet portion of the formation channel opens-out towards the downstream end, for example, having a radius of curvature that increases towards the downstream end, and may become flat at the downstream end.

As used herein, the term ‘reconfigurable garniture bed’ is used to describe a composite structure providing the formation channel or a portion of the length of the formation channel, which may be modified to compensate for wear, replacement of other parts, or both. One of the parts of the composite structure may provide the full surface of the formation channel, perpendicular to the length of the formation channel. Alternatively, a plurality of parts may each provide part of the full surface of the formation channel, perpendicular to the length of the formation channel.

As used herein, ‘reconfiguration’ is used to describe a modification that may be performed rapidly. Removal of the replaceable formation channel liner for reconfiguration of the garniture bed may require the release of no more than two securing screws or securing bolts.

Reconfiguration of the garniture bed may include changing the size of the formation channel, for example, changing the garniture bed to provide a formation channel that is narrower or wider.

The replaceable formation channel liner is substantially smaller than the complete garniture bed. Perpendicular to the length of the formation channel, and at the location along the length of the formation channel at which the cross-sectional area of the formation channel is smallest (or at which the radius of curvature of the formation channel is smallest), the cross-sectional area of the replaceable formation channel liner may by less than the cross-sectional area of the garniture bed by a ratio of at least 10:1, at least 5:1, or at least 2:1.

As used herein, the term ‘formation channel liner’ is used to describe a replaceable element that provides the formation channel or a portion of the length of the formation channel, and is detachably connected to a base member that is retained when the formation channel liner is replaced. In use the “conveying belt” is likely to rest on the replaceable formation channel liner(s) causing friction and wear to the replaceable formation channel liner(s).

As used herein, the term ‘conveying belt’ is a strip of material that is laid along the length of the formation channel, and is driven along the formation channel in use, to entrain the web of wrapping material and the core. The conveying belt is also known as a garniture belt or a garniture. As used herein, the term ‘drive mechanism’ is a motorised mechanism for driving the conveying belt along the formation channel. The conveying belt may be an endless loop.

As used herein, the term ‘shoe’ has been used to describe a member that provides a surface that is complementary to the formation channel of the garniture bed, for cooperating with the formation channel to wrap the wrapping material around the core material, in use.

In cross-section, perpendicular to the length of the formation channel, the replaceable formation channel liner is smaller than the base member, which may enable the replaceable formation channel liner to be replaced without detaching the conveying belt from the remainder of the garniture bed (which comprises at least the base member).

In use, the conveying belt may be held under tension by a belt tensioning mechanism, for example, a tensioning pulley, which may be a pulley rotatably mounted on a biased arm. To replace the garniture bed the tensioning mechanism may be released, to relax the conveying belt, enabling the conveying belt to be lifted from the formation channel, whilst the garniture bed is reconfigured, after which the conveying belt is replaced into the formation channel and re-tensioned by re-engaging the belt tensioning mechanism.

Advantageously, the garniture bed may be reconfigured without requiring complete removal of one or more of the garniture bed, the conveying belt, and the shoe (where present). Reconfiguration of the garniture bed without complete removal of one or more of the garniture bed, the conveying belt, and the shoe, may enable periodic servicing of the wrapping mechanism to be undertaken much more rapidly than would otherwise be the case, reducing downtime of the wrapping mechanism, and increasing manufacturing efficiency. Advantageously, reconfiguration of the wrapping mechanism without complete removal of the garniture bed or shoe, may avoid or reduce the requirement for skilled reassembly and re-alignment.

Commonly, the conveying belt is replaced more frequently than the known garniture bed. To reduce wear of the known formation channel, it is known to form garniture beds from wear resistant material, for example, stainless steel, which may additionally be provided with a hardened coating, for example, a diamond-like carbon coating. Enabling convenient reconfiguration of the garniture bed by replacement of the replaceable formation channel liner may enable the formation channel to be provided in a less wear-resistant material (for example, a plastics material), with increased wear to the garniture bed being compensated for by reconfiguration of the garniture bed. Advantageously, provision of the formation channel in a less wear-resistant material may reduce wear of the conveying belt, enabling a reduction of the frequency of periodic servicing, and reducing overall downtime of the wrapping mechanism.

Advantageously, reconfiguration of the garniture bed may enable continued use of one or both of a conveying belt and a garniture bed even when one or both have become worn, which may increase the time for which the wrapping mechanism may be run before it becomes necessary to replace the conveying belt. Prolonging the running time of parts may increase operational efficiency and reduce operational costs.

Advantageously, by reconfiguration of the garniture bed, both the substantially cylindrical shape and the cross-sectional area of the wrapped core may be maintained within narrower tolerances.

Examples are further described hereinafter with reference to the accompanying drawings, in which:

FIG. 1A shows a perspective view of a first reconfigurable wrapping mechanism;

FIG. 1B shows a cross-sectional view through the reconfigurable wrapping mechanism of FIG. 1A; and

FIG. 2 shows a cross-sectional view through a second reconfigurable wrapping mechanism in an unworn condition.

Like reference numerals refer to like elements throughout. In the described examples, like features have been identified with like numerals, albeit in some cases having one or more of increments of integer multiples of 100. For example, in different figures, 100 and 200 have been used to indicate a reconfigurable wrapping mechanism.

FIG. 1A shows a perspective view of a first reconfigurable wrapping mechanism 100, and FIG. 1B shows a cross-sectional view of the wrapping mechanism in use.

The reconfigurable wrapping mechanism 100 has a garniture bed 110 with a formation channel 112 extending along its length. A conveying belt 120 extends along the surface of the formation channel 112, and both are open along the length of the formation channel, with the open side facing towards an elongate shoe 150.

In the illustrated garniture bed 110, the formation channel 112 has an inlet section 112A, a middle section 112B, and an outlet section 112C. The middle section 112B has a constant radius of curvature along its length. The inlet section 112A narrows-down, away from the inlet of the formation channel 112, and towards the middle section 112B. The outlet section 112C broadens-out, towards the outlet, and away from the middle section 112C.

The conveying belt 120 may be an endless belt, and only part of the conveying belt is illustrated in FIG. 1A, being the portion within the middle section 112B of the formation channel 112. A belt drive mechanism (not shown) is provided to drive the conveying belt 120 along the formation channel 112, in the transport direction T. The shoe 150 has a concave face 152, in cross-section perpendicular to the length of the formation channel 112, which faces towards the open side of the formation channel 112. The formation channel 112, conveying belt 120 and the concave face 152 of the shoe 150 are arranged and complementarily shaped for receiving a substantially cylindrical member, for example, a generally cylindrical core 160 wrapped within a wrapping paper 162. Although present in the wrapping mechanism 100 of FIG. 1B, the elongate shoe 150 is optional, and may be omitted (for example, as shown in FIG. 2).

The first garniture bed 110 is of a composite construction, having a base 110A and a replaceable formation channel liner 110B, which is detachably connected to the base. The elongate formation channel 112 may be provided entirely in the replaceable formation channel liner 110B, as shown in FIG. 1A, enabling the full length of the formation channel to be replaced by replacing only the replaceable formation channel liner.

The formation channel 112, conveying belt 120 and the concave face 152 of the shoe 150 (where present) are arranged and complementarily shaped for forming and transporting a substantially cylindrical member, entrained on the conveying belt, for example, a generally cylindrical core 160 wrapped within a wrapping paper 162. In use, the belt drive mechanism drives the conveying belt 120 along the formation channel 112 in the transport direction T (indicated in FIG. 1A), the wrapping paper 162 is received onto and extends along the conveying belt 120, the core 160 is received onto the wrapping paper, and the wrapping paper is wrapped around the core. As the conveying belt 120 draws the wrapping paper 162 and the core 160 along the inlet section 112A and the middle section 1128 of the formation channel 112, the wrapping paper is progressively wrapped around the core, before the wrapped core exits the formation channel along the outlet section 112C. Whilst passing along the formation channel 112 (for example, in the middle section 112B), the wrapping paper 162 is sealed around the core 160.

In the illustrated reconfigurable wrapping assembly 100, the illustrated shoe 150 has a constant cross-sectional shape along its length, and extends along the middle section 1128 of the formation channel 112. However, to enhance wrapping performance, the shoe 150 may have a shape that varies along the length of the formation channel 112. However, the shoe 150 may extend part or all of the length of the inlet section 112A, part or all of the length of the middle section 112B, part or all of the length of the outlet section 112C, or may extend along part or all of a combination adjacent sections 112A, 112B, 112C of the formation channel 112. Preferably, all sections 112A, 112B and 112C of the formation channel 112 support the conveying belt 120. The formation channel 112 may support the conveying belt 120 directly, or indirectly.

During manufacturing, when the wrapping paper 162 has been wrapped around the core 160, a double layered region 162D may pass along the concave surface 152 of the shoe 150 (or similarly, the double layered region 262B may pass along a concave surface of the formation channel 112, as shown in FIG. 2).

A contact adhesive may be provided between the layers in the double layered region 162D, and adhesion may be facilitated by contact between the double layered region and one or both of the conveying belt 120 and the formation channel 112. Alternatively, or additionally, a thermosetting adhesive may be provided between the layers in the double layered region 162D. At least part of the concave surface 152 of the shoe 150 (or the surface of the formation channel 212, in the arrangement of FIG. 2) may be provided with a heating region (not shown) that heats the double layered region 162D to dry or melt an adhesive between the layers, and the concave surface 152 of the shoe 150 (or the surface of the formation channel 212, in the arrangement of FIG. 2) may optionally also be provided with a cooling region (not shown) to cool the adhesive.

With continued use, the conveying belt 120 may be worn thinner, for example, being worn back to the dashed line indicated by 120W. Alternatively, or additionally, the replaceable formation channel liner 1108 may be worn away by the conveying belts 120, for example, being worn back to the dashed line indicated by 110W. This may be due to the friction caused, in use, by the moving conveying belt 120, supported by, and contacting the replaceable formation channel liners 1108. In some embodiments the conveying belt is supported by the replaceable formation channel liner(s). In some embodiments the conveying belt is directly supported by the replaceable formation channel liner(s).

When the user or an automated monitoring mechanism (not shown) detects wear of one or both of the replaceable formation channel liner 110B and the conveying belt 120, the formation channel liner 110B may be detached from the base 110A, and replaced with a further formation channel liner. The formation channel liner, or replaceable formation channel liner, may support the conveying belt 120. The formation channel liner, or replaceable formation channel liner, may support the conveying belt 120, directly or indirectly. Preferably the formation channel liner, or replaceable formation channel liner, is configured to support the conveying belt 120. Preferably the formation channel liner, or replaceable formation channel liner, directly supports the conveying belt 120.

Where wear of the conveying belt 120 is detected and the conveying belt may be used further, the replaceable formation channel liner 110B may be replaced with another replaceable formation channel liner that is shaped to compensate for the worn conveying belt, having a smaller diameter formation channel, for example, having a smaller diameter in the middle section 112B.

Where wear of the replaceable formation channel liner 110B is detected and the conveying belt 120 may be used further, the replaceable formation channel liner may be replaced with another replaceable formation channel liner that is shaped to correct for the worn replaceable formation channel liner, for example, having the shape of the preceding replaceable formation channel liner, when new, or having a shape that compensates for a conveying belt that is worn, but is not sufficiently worn to merit replacement.

Where both the replaceable formation channel liner 110B and the conveying belt 120 require to be replaced, they may be replaced with a replaceable formation channel liner having a shape that complements a new conveying belt.

Additionally, the height of the shoe 150 (where present) above the base of the formation channel 112 (for example, in the middle section 112B) may be adjusted, H, in correspondence with reconfiguration of the garniture bed 110, and in correspondence with wear of the conveying belt 120.

The reconfigurable wrapping mechanism 100 illustrated in FIGS. 1A and 1B comprises an elongate shoe 150. However, alternatively, the elongate shoe may be omitted from the reconfigurable wrapping mechanisms.

FIG. 2 shows a cross-sectional view through a second reconfigurable wrapping mechanism 200 in an unworn condition, which is generally similar to the first reconfigurable wrapping mechanism 100 of FIG. 1B.

The second reconfigurable wrapping mechanism 200 differs from the first reconfigurable wrapping mechanism 100 by omitting the elongate shoe 150.

The reconfigurable wrapping mechanism 200 has a garniture bed 210 with a formation channel 212 extending along its length. A conveying belt 220 extends along the surface of the formation channel 212, and both are open along the length of the formation channel. The conveying belt 220 may be an endless belt, and only part of the conveying belt is illustrated in FIG. 2. A belt drive mechanism (not shown) is provided to drive the conveying belt 220 along the formation channel 212, in the transport direction (T, shown in FIG. 1A).

The second garniture bed 210 is of a composite construction, having a base 210A and a replaceable formation channel liner 210B, which is detachably connected to the base, with the elongate formation channel 212 being provided in the formation channel liner.

The formation channel 212 and conveying belt 220 are shaped for forming and transporting a substantially cylindrical member, entrained on the conveying belt, for example, a generally cylindrical core 260 wrapped within a wrapping paper 262. In use, the belt drive mechanism drives the conveying belt 220 along the formation channel 212 (for example, in the transport direction T, as indicated in FIG. 1A), the wrapping paper 262 is received onto and extends along the conveying belt 220, the core 260 is received onto the wrapping paper, and the wrapping paper is wrapped around the core. For ease of representation, the formation channel 212 has been shown with a uniform cross-sectional shape (perpendicular to the length of the formation channel). However, to enhance wrapping performance, the formation channel 212 may have a shape that varies along the length of the formation channel.

During manufacturing, when the wrapping paper 262 has been wrapped around the core 260, a double layered region 262D may pass along the concave surface of the formation channel 212. A contact adhesive may be provided between the layers in the double layered region 262D, and adhesion may be facilitated by contact between the double layered region and one or both of the conveying belt 220 and the formation channel 212. Alternatively, or additionally, a thermosetting adhesive may be provided between the layers in the double layered region 262D. At least part of the concave surface of the formation channel 212 may be provided with a heating region (not shown) that heats the double layered region 262D to dry or melt the adhesive, and the formation channel 212 may optionally also be provided with a cooling region (not shown) to cool the double layered region.

With continued use, the conveying belt 220 may be worn thinner, for example, being worn back to the dashed line indicated by 220W. Alternatively, or additionally, the replaceable formation channel liner 2108 may be worn away by the conveying belts 220, for example, being worn back to the dashed line indicated by 210W.

When the user or an automated monitoring mechanism (not shown) detects wear of one or both of the replaceable formation channel liner 210B and the conveying belt 220, the formation channel liner may be detached from the base 210A, and replaced with a further formation channel liner that is shaped to compensate for the worn conveying belt (for example, having a smaller diameter formation channel), that is shaped to correct for the worn formation channel liner (for example, having the original shape of the preceding formation channel liner), or is shaped to compensate and correct for both forms of wear.

Reconfiguration of the garniture bed can enable continued use of one or both of a conveying belt and a garniture bed even when one or both have become worn, which may increase the time for which the wrapping mechanism may be run before it becomes necessary to replace the conveying belt or formation channel. Prolonging the running time of parts may increase operational efficiency and reduce operational costs.

By reconfiguration, both the substantially cylindrical shape and the cross-sectional area of the wrapped core may be maintained within narrower tolerances.

The figures provided herein are schematic and not to scale.

Throughout the description and claims of this specification, the words “comprise” and “contain” and variations of them mean “including but not limited to”, and they are not intended to (and do not) exclude other moieties, additives, components, integers or steps. Throughout the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

Features, integers, characteristics, compounds, chemical moieties or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

The reader's attention is directed to all papers and documents which are filed concurrently with or previous to this specification in connection with this application and which are open to public inspection with this specification, and the contents of all such papers and documents are incorporated herein by reference.

Number	Name	Date	Kind
2327020	Clausen	Aug 1943	A
2850019	Sosa	Sep 1958	A
20170013872	Williams	Jan 2017	A1

Number	Date	Country
102010051894	May 2012	DE
3 320 788	May 2018	EP
574861	Jan 1946	GB

Reconfigurable wrapping mechanism

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Entry
Search Report and Written Opinion for PCT/EP2019/070676 dated Oct. 22, 2019 (11 pages).
Extended European Search Report for Application No. 18187364.7 dated Feb. 18, 2019 (7 pages).