EP4637394A1

EP4637394A1 - Apparatus, components thereof and method for handling rods of aerosol-generating material

Info

Publication number: EP4637394A1
Application number: EP23828455.8A
Authority: EP
Inventors: Jeong Hwan Park; Daniel Bray; Richard LEBBON
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2022-12-22
Filing date: 2023-12-15
Publication date: 2025-10-29
Also published as: JP2026503397A; GB202219486D0; WO2024134165A1

Abstract

An apparatus (10) for handling rods of aerosol-generating material. The apparatus (10) comprises a rotatable drum (12) having a plurality of elongate flutes (23) provided around an outer surface of the drum and extending in an axial direction of the drum. Each flute (23) includes one or more suction holes (27) extending from a surface of a respective flute (23) into communication with an associated vacuum duct (25) within the drum (12) and a control flange (30). The drum (12) rotates relative to the control flange (130) in use. The control flange (130) comprises a first aperture (34) connected to a vacuum source, and a second aperture (133) connected to a source of pressurised gas. As the drum (12) rotates relative to the control flange (130), the vacuum ducts (25) are in fluid communication with the first aperture (34) over a first range of rotation of the drum (12) to apply a negative pressure to the vacuum ducts (25), and the vacuum ducts (25) are in fluid communication with the second aperture (133) over a second range of rotation of the drum to apply positive gas pressure to the vacuum ducts (25). Also provided is a control flange (130) for such an apparatus (10) and a method of use of such an apparatus (10).

Description

Apparatus, Components thereof and Method for Handling Rods of Aerosol-Generating Material

Technical Field The present invention relates to an apparatus for handling rods of aerosol-generating material, and components of such apparatus. The invention also relates to methods of handling rods of aerosol-generating material.

Background Certain tobacco industry products produce an aerosol during use, which is inhaled by a user. Such tobacco industry products commonly comprise an aerosol-generating material in the form of a cylindrical rod circumscribed by an outer wrapper.

Apparatuses are known for producing, manipulating, conveying and otherwise handling rods of aerosol-generating material during manufacture of consumables for use in aerosol-generating systems. The aerosol-generating material may include tobacco, tobacco derivatives or other types of aerosol-generating material. Such apparatuses may comprise at least one rotatable drum with elongate flutes provided around a circumferential surface of the drum to receive the rods. Such drums may be provided with suction holes communicating with the flutes to retain the rods within the flutes as the drum rotates.

Various different compositions and types of aerosol-generating material may be provided in rods intended to be conveyed through such apparatuses. Accordingly, such rods can have varying hardness, resilience and deformability. This can result in some types of rods presenting problems when being handled by known apparatuses. For example, some rods may become stuck in the drum flutes, or be more easily damaged by physical contact with rod guides in known rod-handling apparatuses. Summary

According to a first aspect of the present invention, there is provided an apparatus for handling rods of aerosol-generating material, the apparatus comprising a rotatable drum having a plurality of elongate flutes provided around an outer surface of the drum and extending in an axial direction of the drum, wherein each flute includes one or more suction holes extending from a surface of a respective flute into communication with an associated vacuum duct within the drum; and a control flange, wherein the drum rotates relative to the control flange in use, and wherein the control flange comprises a first aperture connected to a vacuum source, and a second aperture connected to a source of pressurised gas, wherein as the drum rotates relative to the control flange, the vacuum ducts are in fluid communication with the first aperture over a first range of rotation of the drum to apply a negative pressure to the vacuum ducts, and the vacuum ducts are in fluid communication with the second aperture over a second range of rotation of the drum to apply positive gas pressure to the vacuum ducts.

Each flute may include a plurality of suction holes. Each vacuum duct maybe open at a first end face of the drum. The control flange maybe disposed adjacent the first end face of the drum. The control flange may include a vent cavity which is open to atmosphere, and the vacuum ducts maybe in fluid communication with the vent cavity over a third range of rotation of the drum which is after being in fluid communication with the first aperture over the first range of rotation of the drum and before being in fluid communication with the second aperture over the second range of rotation of the drum.

The vacuum ducts may be in fluid communication with the vent cavity over a fourth range of rotation of the drum which is after being in fluid communication with the second aperture over the second range of rotation of the drum before returning to being in fluid communication with the first aperture over the first range of rotation of the drum.

The control flange may comprise a gas manifold connected to the source of pressurised gas, and the second aperture may be formed in the gas manifold. The gas manifold may be located within the vent cavity.

The second range of rotation of the drum may extend around a lowermost region of the drum. The first range of rotation of the drum may be greater than the second range of rotation of the drum. The second range of rotation may be between i to 40 degrees, and may be between 5 to 35 degrees, and may be between 10 to 30 degrees, and may be between 15 to 25 degrees.

The control flange may comprise a circular recess and the first end face of the drum maybe received within the circular recess.

The second aperture may be arcuate.

The first aperture may be arcuate and the first and second apertures may each be disposed circumferentially about a common a centre point.

The first and second apertures may be disposed at an equal radial distance from the common centre point.

The rotatable drum may comprise a circumferential groove in the outer surface and intersecting the flutes, and the apparatus may further comprise a guide member comprising a longitudinal arm having a guide surface at a first end thereof, an airflow outlet located at the guide surface and an airflow passage in fluid communication with the airflow outlet; wherein the airflow passage may be connected to a supply of pressurised gas to supply pressurised gas to the airflow outlet; and wherein the guide member may be disposed with the guide surface at least partially received within the groove and configured to expel gas from the airflow outlet onto rods carried in the flutes.

The guide surface may be inclined at an angle relative to a longitudinal axis of the guide member. The angle of the guide surface may be between 30 to 60 degrees, and may be around 45 degrees.

The longitudinal axis of the guide member may be substantially horizontal. The airflow outlet may be configured to direct airflow vertically downwards out of the airflow outlet. The guide member may comprise a plurality of airflow outlets and may comprise three airflow outlets. The guide member may comprise two plates secured together at respective facing surfaces, and the airflow passage and airflow outlet(s) may be formed into a facing surface of at least one of the plates.

The supply of pressurised gas provided to the airflow passage maybe between 0.5 - 2 bar, and may be between 0.7 - 1.8 bar, and may be between 0.9 - 1.6 bar, and may be between 1 - 1.5 bar.

Pressurised gas provided to the second aperture may be between 1 - 5 bar, and may be between 1.2 - 4 bar, and may be between 1.3 - 3 bar, and may be between 1.5 - 3 bar, and may be between 2 - 3 bar, and may be around 3 bar.

According to another aspect of the present invention there is provided a control flange for use with a drum of an apparatus for handling rods of aerosol-generating material, the control flange comprising a plate having a first aperture extending through the plate and around a first circumferential portion of the plate; a gas manifold comprising a second aperture which extends around a second circumferential portion of the plate.

The control flange may further comprise a vent cavity comprising a recessed region formed in the plate.

The control flange may further comprise any of the features described in the above- mentioned apparatus.

According to another aspect of the present invention there is provided a method for handling rods of aerosol-generating material using an apparatus as described above, the method comprising: receiving a rod within a flute of the rotatable drum; applying a negative pressure to the or each suction hole to retain the rod in the flute as the drum rotates relative to the control flange over a first range of rotation; and applying a positive gas pressure to the suction holes to aid discharge of the rod from the flute as the drum rotates relative to the control flange over a second range of rotation. The method may further comprise rendering the or each suction hole open to atmosphere over a third range of rotation of the drum which is after the drum has rotated over the first range of rotation and before the drum has rotated over the second range of rotation.

The method may further comprise rendering the or each suction hole open to atmosphere over a fourth range of rotation of the drum which is after the second range of rotation and before the drum returns to the first range of rotation of the drum. The first range of rotation of the drum may be greater than the second range of rotation of the drum.

The second range of rotation may be between i to 40 degrees, and may be between 5 to 35 degrees, and may be between 10 to 30 degrees, and may be between 15 to 25 degrees.

The drum may comprise a circumferential groove in the outer surface and intersecting the flutes and the apparatus may further comprise a guide member comprising an airflow outlet located at a guide surface disposed within the groove, and the method may further comprise supplying pressurised gas to the airflow outlet to expel gas from the airflow outlet onto rods carried in the flutes.

The method may further comprise expelling the pressurised gas vertically downwards out of the airflow outlet.

The method may comprise pressurised gas being provided to the airflow outlet at between 0.5 - 2 bar, and maybe between 0.7 - 1.8 bar, and maybe between 0.9 - 1.6 bar, and may be between 1 - 1.5 bar. The method may further comprise pressurised gas being provided to the second aperture at between 1 - 5 bar, and may be between 1.2 - 4 bar, and may be between 1.3 - 3 bar, and may be between 1.5 - 3 bar, and may be between 2 - 3 bar, and may be around 3 bar. The method may comprise handling rods of sheet cut aerosol-generating material. The aerosol-generating material may comprise material formed from a tobacco sheet or a gel sheet, cut into strips and formed into the rod. The rods or article handled by the apparatus and methods of the present invention comprises an aerosol-generating material. Aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or semi-solid (such as a gel) which may or may not contain an active substance and/ or flavourants.

The aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material.

The aerosol-generating material may comprise botanical/tobacco material which may be in the form of individual strands/strips of reconstituted tobacco, and may comprise cut rag tobacco, leaf botanical material/tobacco, reconstituted botanical material/tobacco, extruded botanical material/tobacco or expanded botanical material/tobacco.

The aerosol-generating material may comprise a binder, such as a gelling agent, and an aerosol former. Optionally, a substance to be delivered and/or filler may also be present. Optionally, a solvent, such as water, is also present and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free from botanical material. In particular, in some embodiments, the aerosol-generating material is substantially tobacco free. The aerosol-generating material may comprise or be in the form of an aerosolgenerating film. The aerosol-generating film may have a thickness of about 0.015 mm to about 1 mm. For example, the thickness maybe in the range of about 0.05 mm, 0.1 mm or 0.15 mm to about 0.5 mm or 0.3 mm. The aerosol-generating film may be continuous. For example, the film may comprise or be a continuous sheet of material. The sheet maybe in the form of a wrapper, it maybe gathered to form a gathered sheet or it may be shredded to form a shredded sheet. The shredded sheet may comprise one or more strands or strips of aerosol-generating material. The aerosol-generating film may be discontinuous. For example, the aerosol-generating film may comprise one or more discrete portions or regions of aerosol-generating material, such as dots, stripes or lines, which may be supported on a support. In such embodiments, the support may be planar or non-planar. The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-former and one or more other components, such as one or more substances to be delivered, to form a slurry and then heating the slurry to volatilise at least some of the solvent to form the aerosolgenerating film.

The slurry maybe heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt% or 90 wt% of the solvent.

The aerosol-generating material may comprise or be an “amorphous solid”. In some embodiments, the aerosol-generating materiel comprises an aerosol-generating film that is an amorphous solid. The amorphous solid maybe a “monolithic solid”. The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid maybe a dried gel. The amorphous solid maybe a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the amorphous solid may, for example, comprise from about 50wt%, 6owt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or ioowt% of amorphous solid. The amorphous solid may be substantially free from botanical material. The amorphous solid may be substantially tobacco free. The method may comprise handling rods having a susceptor material within the rod. A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material maybe magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor maybe both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms.

The susceptor material within the rods or articles may comprise particulate matter within the rod/article, and may comprise a metal, such as iron or aluminium. The susceptor material may comprise one or more elongate elements located within the rod. The susceptor material may comprise a wire, filament, foil, rod, blade or pin. The susceptor material may be located substantially centrally about the axis of the rod, or maybe off-set from the central axis. The susceptor material maybe distributed throughout the aerosol generating material, and may be evenly distributed or may be distributed with varying density or concentration within the rod. The susceptor material may be more concentrated at an upstream end of the rod and less concentrated at a downstream end of the rod, with respect to the direction of flow of aerosol through the rod during use. Alternatively, the susceptor material maybe less concentrated at an upstream end of the rod and more concentrated at a downstream end of the rod. The susceptor material may change in concentration constantly along the length of the rod between areas of different concentration, or may vary abruptly or unevenly between areas of different concentration within the rod. The susceptor material may extend substantially parallel to the central axis of the rod, or may extend at an angle to the central axis of the rod. The susceptor material may comprise multiple elements within the rod or one single susceptor element.

Rods or articles to be handled by the apparatus and methods of the present invention may, though one or more of the constructions, compositions or materials described above, be heavier and/ or more fragile than other known types of rods of tobacco industry products. Accordingly, it is advantageous to provide a smoother transition of such rods between drums of article manufacturing apparatuses during manufacture, and to reduce impact during transfer between drums, to avoid damage and/or deformation of such rods or articles.

Brief Description of the Drawings

Embodiments of the invention will now be described, by way of example only, with reference to accompanying drawings, in which: Figure 1 is a side view of a portion of a known tobacco industry product manufacturing apparatus; Figure 2 is a perspective view of the portion of apparatus of Figure 1 with a hopper drum removed to illustrate a control flange and drum shaft;

Figure 3 is a side view of a control flange of the apparatus of Figure 1;

Figure 4 is a perspective view of the hopper drum of the apparatus of Figure 1; Figure 5 is a perspective view of a rod guide of the apparatus of Figure 1;

Figure 6 is a perspective view of a grading drum of the apparatus of Figure 1;

Figure 7 is an enlarged schematic side view of a region of the apparatus of Figure 1 showing the interaction between the hopper drum and rod guide, and also illustrating the grading drum; Figure 8 is a perspective view of the apparatus shown in Figure 1 showing the hopper drum, grading drum, and rod guide, with the hopper omitted for clarity;

Figure 9 is a side view of a control flange of a first embodiment of the invention for use in a tobacco industry product manufacturing apparatus of the invention;

Figure 10 is a perspective view of the control flange of Figure 9 in position on a tobacco industry product manufacturing apparatus of the invention, with the hopper drum removed from the drum shaft;

Figure 11 is a close-up view of a discharge region of a hopper drum during use, of a known tobacco industry product manufacturing apparatus;

Figure 12 is a close up view of a discharge region of a hopper drum during use, of a tobacco industry product manufacturing apparatus of the invention comprising the control flange of the first embodiment of the invention of Figure 9;

Figure 13 is a perspective view of a rod guide of a second embodiment of the invention for use in a tobacco industry product manufacturing apparatus of the invention;

Figure 14 is a cross-sectional view of the rod guide of Figure 13 along the line X-X; Figure 15 is a close-up view of a discharge region of a hopper drum during use, of a known tobacco industry product manufacturing apparatus with conventional rod guide; and

Figure 16 is a close-up view of a discharge region of a hopper drum during use, of a tobacco industry product manufacturing apparatus of the invention comprising the rod guide of the second embodiment of the invention of Figures 13 and 14.

Detailed Description

In the figures described herein, like reference numerals are used to illustrate equivalent features, articles or components. Figure 1 shows a schematic side view of a portion of a known tobacco industry product manufacturing apparatus to (“apparatus” hereinafter for brevity). The apparatus to comprises a hopper 11 configured to receive multi-length rods of aerosol-generating material Rm (“rods” hereinafter). That is, the rods Rm are of a length which is a multiple of the rod length which will be present in the final assembled aerosolgenerating consumables (hereinafter “consumables”) produced by the manufacturing apparatus and which are for use in aerosol-generating systems. The rods Rm therefore require cutting and arranging as some of the process steps in the consumable manufacturing process.

In the section of apparatus to shown in Figure 1, the rods Rm are conveyed from the hopper 11 by a hopper drum 12 and are cut into multiple smaller rods Rc by first and second cutting wheels 13, 14 whilst being held on the hopper drum. The cut rods Rc are then transferred to a grading drum 15. The grading drum 15 receives the cut rods Rc from the hopper drum 12 in a staggered manner to enable spacing, shuffling and rearrangement of the cut rods Rc in subsequent manufacturing steps (not shown) into the finished consumables. The rotational direction of the hopper drum 12 and grading drum 15 are shown by respective arrows in Figure 1. The hopper 11 has side walls 16 defining the interior space of the hopper 11, and is open in a transfer region 17 at a bottom area of the hopper 11. The hopper drum 12 is disposed adjacent the hopper 11 and partially within in the transfer region 17 and is configured to receive rods Rm from within the hopper 11 and to convey them away from the hopper 11 for processing into consumables in later processing steps of the apparatus 10.

The hopper drum 12 is shown in more detail in Figure 4 and is a cylindrical component having a central axis A-A and a bore 18 extending axially through the drum 12. The hopper drum 12 is rotatable within the apparatus 10 by being mounted to a rotatable shaft 19 (see Figures 2 and 4) of the apparatus 10 with the rotatable shaft 19 extending through the bore 18. The hopper drum 12 has first and second end faces 20, 21 and a circumferential outer surface 22 extending around the hopper drum 12 between the end faces 20, 21. The outer surface 22 includes a plurality of flutes 23. The flutes 23 are curved depressions or recesses which are configured to receive the rods Rm from the hopper 11 and to retain the rods Rm within the flute 23 as the hopper drum 12 rotates to convey the rods Rm away from the hopper 11 and onwards within the apparatus 10 for processing into consumables. The flutes 23 are elongate and extend in an axial direction of the hopper drum 12. That is, the flutes 23 lie with their elongate length extending in a direction aligned in parallel with the central axis A-A of the hopper drum 12.

A plurality of circumferential grooves 24 are formed in the outer surface 22 of the hopper drum 12. The grooves 24 extend radially inwardly such that they extend into and intersect the flutes 23. A plurality of vacuum ducts 25 (see Figure 7) extend through the body of the hopper drum 12 in a direction parallel to the central axis A-A. The vacuum ducts 25 are arranged circumferentially around the hopper drum 12 and radially inwardly of the flutes 23. Each vacuum duct 25 is open at the first end face 20 of the hopper drum 12 at a respective vacuum port 26. The vacuum ports 26 are therefore disposed in a circular arrangement on the first end face 20 of the hopper drum 12 and at a radial distance rv measured from the central axis A-A of the hopper drum 12/rotatable shaft 19 (see Figure 7). Each flute 23 is provided with a plurality of suction holes 27 which are in fluid communication with an associated respective vacuum duct 25. In an embodiment, each vacuum duct 25 may communicate with the suction holes 27 in two adjacent rows of flutes 23, as shown in Figure 7. In other embodiments, each vacuum duct 25 may communicate with the suction holes 27 in only one row of flutes 23, or more than two rows of flutes 23. Thereby, a vacuum can be applied to suctions holes 27 of one or more flutes 23 by applying a vacuum to the vacuum port 26 of the associated vacuum duct 25.

Figure 3 shows a control flange 30 of the known apparatus 10 shown in Figure 1. The control flange 30 comprises generally circular body having a circular recess 31 formed into a surface 32 of the control flange 30, and a central circular aperture 33. The control flange 30 comprises a top point 30a and a bottom point 30b. When the control flange 30 is installed in the apparatus 10, the top point 30a is uppermost and the bottom point 30b is lowermost. When the apparatus 10 is assembled, the first end face 20 of the hopper drum 12 is received within the circular recess 31 and the rotatable shaft 19 of the apparatus 10 extends through the central circular aperture 33. The control flange 30 includes two arcuate apertures 34 formed through the control flange 30 within the circular recess 31. The arcuate apertures 34 are separated by a bridging portion 41 which is present to provide structural strength to the control flange 30 that may otherwise be compromised by a single long arcuate aperture. However, in other embodiments, one single arcuate aperture, or more than two arcuate apertures may be provided in the control flange 30.

The arcuate apertures 34 extend over only a part of the circumference of the control flange 30, marked by angles V in Figure 3. As mentioned above, the bridging portion 41 may be omitted in some examples, to provide one single arcuate aperture. The arcuate apertures are disposed at a radial distance rv measured from the centre point C of the circular recess 31/circular aperture 33 and, in the assembled apparatus 10, the same radial distance rv from the central axis A-A of the hopper drum 12/rotatable shaft 19. Accordingly, the arcuate apertures 34 may be in fluid communication with one or more vacuum ports 26 depending on the rotational position of the hopper drum 12 relative to the control flange 30. The control flange 30 further comprises a vent cavity 42 arranged in a lower region of the control flange 30. The vent cavity 42 extends over a region of the circumference of the control flange 30, marked by angle NV in Figure 3. The vent cavity 42 also is disposed at a radial distance rv measured from the centre point C of the circular recess 31/circular aperture 32 and, in the assembled apparatus 10, the same radial distance rv from the central axis A-A of the hopper drum 12/rotatable shaft 19. The vent cavity 42 also extends radially outwardly to the edge of the control flange 30 and is open at a radial outer surface 43 of the control flange 30.

The apparatus 10 includes a front guide 28 (and corresponding rear guide at the opposite end of the hopper drum 12 - not referenced in the Figures) which extend around a part of the circumference of the end faces 20, 21 of the hopper drum 12 (as shown in Figure 1). A lower transfer surface 29 is provided beneath the hopper drum 12 over its axial length, and extending around a part of the circumference of the hopper drum 12 in that bottom region of the hopper drum 12. In use, the lower transfer surface 29 assists the transfer of the cut rods Rc from the hopper drum 12 to the grading drum 15, as described in more detail below. Guide members in the form of rod guides 35 are disposed at the bottom region of the hopper drum 12 and comprise elongate arms disposed generally horizontally and extending substantially tangentially relative to the hopper drum 12 (see Figures 1 and 7). A known configuration of rod guide 35 is shown in Figure 5. Each rod guide 35 comprises an elongate arm having a longitudinal axis D-D. In use, the longitudinal axis D-D would lie substantially along the horizontal. The rod guide 35 includes mounting apertures 36 for fixing the rod guide 35 to the apparatus 10 by mounting bolts 37 as shown in Figure 1. The rod guide 35 includes an inclined guide surface 38 at the opposite end of the rod guide 35 to the mounting apertures 36. The rod guides 35 are fixed in the apparatus 10 such that the guide surface 38 locates at least partially within the grooves 24 in the hopper drum 12, and within the flutes 23.

The cutting wheels 13, 14 are mounted adjacent the hopper drum 12 and are staggered in an axial direction of the hopper drum 12 and in a circumferential direction of the hopper drum 12. A perimeter cutting edge 39 of each cutting wheel 13, 14 intersects the outer surface 22 of the hopper drum 12 and extends into a respective cutting groove 40 which is formed circumferentially around the outer surface 22 of the hopper drum 12 and extends through each flute 23. As such, rods Rm which are received in the flutes 23 may be cut into individual smaller cut rods Rc as they pass the cutting wheels 13, 14 as the hopper drum 12 rotates. The grading drum 15 is shown in perspective view in Figure 6 and comprises a cylindrical component having a central axis B-B and a bore 44 extending axially through the drum 15. The grading drum 15 is rotatably mounted beneath the hopper drum 12 as shown in Figure 1. The grading drum 15 has a circumferential outer surface 45 extending around the grading drum. The outer surface 45 includes a plurality of rod seats 46 configured to receive the cut rods Rc from the hopper drum 12/lower transfer surface 29 as the hopper drum 12 rotates, to convey the cut rods Rc away from the hopper drum 12 and onwards within the apparatus 10 for processing into consumables.

The lower transfer surface 29 includes slots 47 through which the rod seats 46 of the grading drum 15 rotate as they pass close to the hopper drum 12 to enable the rod seats 46 to collect the cut rods Rc from the hopper drum 12. The rod seats 46 are circumferentially staggered when viewed in an axial direction of the grading drum 15. This allows the cut rods Rc from one axial row on the hopper drum 12 (i.e. which are axially-aligned in one flute 23 on the hopper drum 12) to be picked up by the grading drum 15 at staggered intervals so they become axially off-set once on the grading drum 15.

Operation of the known apparatus shown in Figure 1 will now be described. The hopper 11 is provided with multiple length rods Rm. The rods Rm are held in the hopper 11 arranged with their axes in parallel and in parallel with the axis A-A of the hopper drum 12. The hopper drum 12 rotates in the direction shown and as a region of the hopper drum 12 passes through the transfer region 17 of the hopper 11, each flute 23 picks up an individual rod Rm and conveys it around and out of the hopper 11. The control flange 30 remains fixed in the apparatus 10 as the hopper drum 12 rotates. A vacuum is applied through the arcuate apertures 34 such that reduced pressure is provided to the vacuum ducts 25 as the respective vacuum ports 26 pass the arcuate apertures 34 and are rendered in fluid communication therewith and thereby subject to the applied vacuum. This in turn creates a suction force through the suction holes 27 in the flutes 23, which are in fluid communication with the vacuum ducts 25. This helps locate and retain the individual rods Rm within a respective flute 23 as the hopper drum 12 rotates through the transfer region 17 of the hopper 11.

It can be seen from the shape and circumferential extent of the arcuate apertures 34 in the control flange 30 shown in Figure 3, that the vacuum is applied to the vent ports 26 and thereby to the suction holes 27 of the flutes 23 over a first range or angle of rotation of the hopper drum 12 relative to the control flange 30, marked V in Figure 3. For the purpose of illustration, this corresponds approximately to the arcuate regions superimposed on the hopper drum 12 in Figure 1 marked V. Over this region of rotation, the rods Rm are held within the flutes 23 by suction. As mentioned above, the arcuate apertures 34 may comprise one single arcuate aperture 34 by omission of a bridging portion 41, or more than two arcuate apertures 34 maybe provided. The vacuum is applied across the circumferential extent of the/all arcuate apertures 34 and is substantially unaffected by the presence of any bridging portion(s) 41. The angle V over which vacuum is applied via the arcuate apertures 34 may therefore be the entire angle V of a single arcuate aperture 34 or the angular extent of all arcuate apertures 34 circumferentially from beginning point to end point, inclusive of any angular range in which a bridging portion 41 may be present.

As the rods Rm pass the cutting wheels 13, 14, the cutting wheels 13, 14 cut the rods Rm into smaller individual cut rods Rc as they are held within the flutes 23. When the vacuum ports 26 reach the vent cavity 42 as the hopper drum 12 rotates, the vacuum ports 26 are rendered in fluid communication with the vent cavity 42. Since the vent cavity 42 is open to atmosphere at the radial outer surface 43 of the control flange 30, the vacuum ports 26 are thereby open to atmosphere when in communication with the vent cavity 42. This removes the suction force through the suction holes 27 in the flutes 23 and allows the cut rods Rc to be released from the flutes 23. The lower transfer surface 29 is disposed in the region of the hopper drum 12 corresponding to the location of the vent cavity 42 in the control flange 30. Accordingly, the cut rods Rc are conveyed around the lower region of the hopper drum 12 over the lower transfer surface 29 until the cut rods Rc are picked up by the grading drum 15 at an upper region thereof. The rod seats 46 of the grading drum 15 pass close to the bottom of the hopper drum 12 though the slots 47 in the lower transfer surface 29.

Thereby, as the cut rods Rc leave the flutes 23 they are picked up by a respective rod seat 46 of the grading drum 15 and conveyed onwards in the rod seat 46 as flute 23 of the hopper drum 12 rotates away from the grading drum 15 and back towards the hopper 11 to collect another multi-length rod Rm.

In ideal operation, the cut rods Rc will consistently, quickly and evenly fall from the respective flute 23 of the hopper drum 12 due to gravity when the suction force is removed from the suction holes 27. However, some rods Rm/Rc of certain compositions of aerosol-generating material being processed by the apparatus 10, may have certain material properties - such as hardness, resilience or elastic/plastic deformability - which can present problems in the cut rods Rc leaving the flutes 23. In some cases, the cut rods may become stuck in the flute, even when the suction force is removed. In particular, rods Rc comprising an aerosol-generating material with a softer material property may tend to deform more easily and become trapped in the flutes 23. Alternatively, or in addition, at elevated rod production speeds, the rods Rc may simply not be able to be released from the flutes 23 quickly enough to transfer from the hopper drum 12 to the grading drum 15 under gravity. This can lead to manufacturing faults, machinery jamming, or at the least, wasted rod material as the rod Rc will be lost from the manufacturing line or actively removed and disposed of.

One known feature intended to avoid such problems of inconsistent or insufficient cut rod Rc extraction from the hopper drum 12 flutes 23, is the provision of a rod guides 35 as described above and illustrated in Figure 5 and, in context in the apparatus 10, in Figures 1 and 7. The rod guides 35 serve to mechanically push the cut rods Rc out of the respective flute 23 and/ or physically guide the rod Rc to pass sufficiently quickly to the grading drum 15. That is, as the hopper drum 12 rotates, the stuck cut rod Rc will abut against the inclined guide surface 38 of the rod guide 35 and as the hopper drum 12 continues to rotate, the cut rod Rc is forced out of the flute 23 and on towards the grading drum 15. Alternatively, even if the rod Rc is not stuck in the flute 23, but the apparatus 10 is running at a sufficiently high speed for the rod Rc to not fall sufficiently quickly from the flute 23 under gravity, the released rod Rc contacts the inclined guide surface 38 and is deflected downwards to aid its movement away from the hopper drum 12 and towards the grading drum 15.

The above-described use of the rod guides 35 is effective at removing cut rods Rc from the flutes 23 and/or aiding rod movement at speed towards the grading drum 15.

However, problems can arise due to the force with which the rods Rc may abut the guide surface 38 of the rod guide 35. Such impact may dent or damage the cut rods Rc, which can cause uneven or damaged consumables being produced. Furthermore, the cut rods Rc may be deflected unevenly from the flutes 23 which may cause them to be inconsistently collected by the grading drum 15.

A control flange 130 of the present invention is shown in Figure 9 and comprises a number of features in common with the control flange 30 shown in Figure 3, wherein like features retain the same reference numerals and a detailed description will not be repeated. The control flange 130 comprises a comprises a generally circular body having circular recess 31 formed in a surface 32, a central circular aperture 33 and two arcuate apertures 34 extending over angles V and separated by a bridging portion 41. The angle V represents a first range or angle of rotation of the hopper drum 12 over which a vacuum or suction is applied to the suction holes 27. The arcuate apertures 34 are disposed at a radial distance rv measured from the centre point C of the circular recess 31/circular aperture 32. The control flange 130 further comprises a vent cavity 42 arranged in a lower region of the control flange 130 and which is also disposed at a radial distance rv measured from the centre point C. The vent cavity 42 extends radially outwardly to the edge of the control flange 130 and is open at a radial outer surface 43 of the control flange 130.

A difference with the control flange 130 of the present invention is that a gas or air manifold 131 is provided (“air manifold” hereinafter). In the exemplary embodiment shown, the air manifold 131 is provided in the vent cavity 42. The air manifold 131 comprises a body having an air inlet 132 and an air outlet 133 which are fluidly communicated by an air channel 134 extending through the body. In the exemplary embodiment shown, the air outlet 133 comprises an arcuate aperture but other shapes of aperture are feasible. The air outlet 133 is disposed at the same radial distance rv from the centre point C as the arcuate apertures 34. The air manifold 131 is disposed such that a surface of the body in which the air outlet 133 is formed is level with the surface of the recess 31 in which the arcuate apertures 34 are formed. Thereby, in an assembled apparatus 10, the first end face 20 of the hopper drum 12 is spaced equally from the surface of the body in which the air outlet 133 is formed and the surface of the recess 31 in which the arcuate apertures 34 are formed, when seen in an axial direction of the hopper drum 12. Such spacing may be between 0.01mm - 2mm for example. Thereby, as the hopper drum 12 rotates, the respective vacuum ports 26 are selectively fluidly communicated with the arcuate apertures 34, the vent cavity 42 and the air outlet 133. The control flange 130 is shown in position on a tobacco industry product manufacturing apparatus 10 of an embodiment of the invention (with the hopper drum removed) in Figure 10. This shows a pressurised air supply line 135 connected to the air inlet 132. Thereby, pressurised air can be supplied to the air outlet 133 from the air inlet 132 via the air channel 134 in the body of the air manifold 131. Although the exemplary embodiments are described and illustrated herein as comprising a supply of pressurised air, it will be appreciated that the invention is not limited to the use of pressurised air and any suitable gas or gas mixture may be used. However, for the purposes of description hereinafter, the invention will be described with reference to air.

Operation of the apparatus 10 shown in Figure 9 will now be described, also with reference to the apparatus 10 of Figure 1 and features therein previously described. Steps of operation previously described will not be repeated in detail. The hopper drum 12 rotates through the transfer region 17 of the hopper 11 and multi-rods Rm are picked up by the flutes 23 and conveyed around and out of the hopper 11. A vacuum is applied through the arcuate apertures 34, vacuum ports 26 and vacuum ducts 25 and so creates a suction force through the suction holes 27 in the flutes 23 to locate and retain the rods Rm within a respective flute 23.

As the rods Rm pass the cutting wheels 13, 14, the cutting wheels 13, 14 cut the rods Rm into smaller individual cut rods Rc as they are held within the flutes 23. When the vacuum ports 26 reach the vent cavity 42 as the hopper drum 12 rotates, the vacuum ports 26 are rendered in fluid communication with the vent cavity 42 and open to atmosphere, so the suction force through the suction holes 27 in the flutes 23 is removed. This can allow the cut rods Rc to be released from the flutes 23 as described previously. However, as also described previously, some rods Rc may remain stuck in the flutes 23 or do not leave the flutes sufficiently quickly under gravity as the hopper drum 12 rotates. A difference in operation over the known apparatus to occurs as the hopper drum 12 continues to rotate such that the vacuum ports 26 come into alignment with, and therefore fluid communication with, the air outlet 133. Since the air outlet 133 is connected to a supply of pressurised air, air pressure is then supplied to the vacuum ports 26 and thereby to the vacuum ducts 25 and the suction holes 27 in the flutes 23. This causes the rods Rc to be urged out of the flutes 23 by force of air pressure. This occurs at the point of rotation of the hopper drum 12 when the flutes 23 are facing the lower transfer surface 29/grading drum 15. For purposes of illustration, this corresponds approximately to the arcuate region superimposed on the hopper drum 12 in Figure 1 marked P, and angle P of the control flange 130 indicated in Figure 9. Angle P represents a second range or angle of rotation of the hopper drum 12. Over this second range of rotation, pressurised air is supplied to the suction holes 27. This results in a consistent ejection of the cut rods Rc from the flutes 23. Angle P may be defined relative to an intended transfer point at which the cut rods Rc are intended to be transferred from the hopper drum 12 to the grading drum 15. Such transfer point may be a point of closest proximity of the hopper drum 12 and grading drum 15. Such transfer point may be a point lying on a straight line or plane extending between the axis A-A of the hopper drum 12 and the axis B-B of the grading drum 15. Such transfer point may lie vertically beneath the axis A-A of the grading drum 12 and/ or vertically above the axis B-B of the grading drum 15. The angle P maybe defined as between 20 - o degrees of rotation of the hopper drum 12 before the transfer point, and between o - 20 degrees of rotation of the hopper drum 12 after the transfer point. That is, the cut rods Rc may experience positive pressure through the suction holes 27 between 20 degrees before transfer point and o degrees, with o degrees being the point of transfer.

The positive pressure may then be removed between o degrees and 20 degrees after transfer point.

The air pressure may be evenly-applied to each rod along its length (as a plurality of suction holes 27 may be provided in each flute). This results in the cut rods Rc being ejected squarely from the flutes 23 and avoids them tilting or one end of a rod Rc moving downwards more than an opposite end during ejection. In other embodiments, or other regions of the flutes 23, the air pressure may be applied through only one suction hole 27 to a respective cut rod Rc. This process helps reduce damage or deformation of the cut rods Rc during the movement from the flute 23 of the hopper drum 12 to the grading drum 15, as can occur in the known apparatus 10 and as described above. This is because physical impact of the cut rods Rc against the guide surface 38 of the rod guides 35 is reduced or avoided. The consistently and evenly- ejected cut rods Rc can then be picked up by the rod seats 46 of the grading drum 15 and conveyed onwards for further processing into consumables as described previously.

The improvement in operation of the apparatus 10 using the control flange 130 of the invention in place of the known control flange 30 described previously is illustrated in Figures 11 and 12. Figure 11 shows a close-up view of a region of a known apparatus 10 during operation, where cut rods Rc are discharged from hopper drum 12. This apparatus 10 uses a known control flange 30 shown in Figure 3 (or the control flange 130 of the invention but without air pressure being applied to the air inlet 132). Figure 12 shows the same region of apparatus 10 during operation as Figure 11, although with the control flange 130 of the invention and air pressure supplied to the air inlet 132. Figure 11 shows the hopper drum 12, the flutes 23, the rod guide 35 and guide surface 38. The cut rods Rc are at the lowermost region of the hopper drum 12 to be transferred to the grading drum 15. The grading drum 15, rod seats 46 and the lower transfer surface 29 are also shown. There is no suction force through the suction holes 27 in the flutes 23 in the region of the hopper drum 12 shown in Figure 11. The cut rod labelled Rc in Figure 11 can be seen to have only slightly left the flute 23 despite having passed the lower transfer surface and there being nothing beneath the cut rod Rc holding it into the flute 23. The cut rod Rc is also spaced apart from the rod seats 46 of the grading drum 15 beneath it and so risks being missed by the passing rod seat 46 intended to collected that cut rod Rc, resulting in a lost rod Rc and a manufacturing fault. The cut rod Rc has also contacted the inclined guide surface 38 of the rod guide

35, shown at point indicated at reference I. This may damage or dent/deform the rod Rc, even if collected by the rod seat 46 of the grading drum 15.

Referring to Figure 12, the difference can be seen with the pressurised air supplied to the air manifold 131, and thereby providing air pressure through the suction holes 27 to aid discharge of the cut rods Rc from the flutes 23. Figure 12 is taken at the same operational position of the apparatus 10 as Figure 11 with regard to the hopper drum 12 and grading drums 15. The difference in effective rod transfer can clearly be seen with the cut rod labelled Rc in Figure 12. Here, the rod Rc has left the flute 23 earlier and more evenly (note there is less tilt on the rod Rc in Figure 12 than the rod Rc deflected by the rod guide in Figure 11). At the same operational position of the apparatus 10, the rod Rc is spaced a distance (marked by arrow G) from the inclined guide surface 38 of the rod guide 35. The cut rod Rc is also noticeably further out of the flute 23, as shown by arrow H in Figure 12. The rod Rc is therefore located to be securely collected by the rod seat 46 of the grading drum 15.

The apparatus 10 using the control flange 130 of the invention therefore provides the advantages of ensuring cut rod Rc transfer consistently and avoiding manufacturing faults, thereby avoiding damaged consumables or material wastage during manufacture, less manufacturing down-time, saving costs and making manufacture more efficient and with increased productivity.

A second aspect of the present invention relates to an improved rod guide 235, shown in Figures 13 and 14. The rod guide 235 of the invention comprises a number of features in common with the rod guide 35 shown in Figure 5, wherein like features retain the same reference numerals and a detailed description will not be repeated. The rod guide 235 comprises an elongate arm having a longitudinal axis D-D which, in use, would lie horizontally, mounting apertures 36 for fixing the rod guide 235 to the apparatus 10 by mounting bolts 37, and an inclined guide surface 38 at the opposite end of the rod guide 235 to the mounting apertures 36. A difference with the rod guide 235 of the invention is that the inclined guide surface 38 includes a plurality of airflow outlets 236. The rod guide 235 includes an airflow inlet 237 which is fluidly connected to the airflow outlets 236 by an airflow passage 238 that extends through the body of the rod guide 235. This can be seen clearly in the cross-sectional view of Figure 14. In operation, a supply of pressurised air is connected to the airflow inlet 237 and so airflow is generated through the airflow passage 238 and out of the airflow outlets 236.

As mentioned previously with reference to the control flange 130, the invention is not limited to the use of pressurised air and any suitable gas or gas mixture may be supplied to the airflow inlet 237. However, for the purposes of description hereinafter, the invention will be described with reference to air.

Operation of the apparatus 10 in use with the rod guide 235 of the invention will now be described. Steps of operation previously described will not be repeated in detail. The hopper drum 12 rotates through the transfer region 17 of the hopper 11 and rod Rm are picked up by the flutes 23 and conveyed around and out of the hopper 11. A vacuum applied through the arcuate apertures 34, vacuum ports 26 and vacuum ducts 25 creates a suction force through the suction holes 27 in the flutes 23 to locate and retain the rods Rm within a respective flute 23.

As the rods Rm pass the cutting wheels 13, 14, the cutting wheels 13, 14 cut the rods Rm into smaller individual cut rods Rc as they are held within the flutes 23.

When the vacuum ports 26 reach the vent cavity 42 as the hopper drum 12 rotates, the vacuum ports 26 are rendered in fluid communication with the vent cavity 42 and open to atmosphere, so the suction force through the suction holes 27 in the flutes 23 removed. This can allows the cut rods Rc to be released from the flutes 23 as described previously. However, as also described previously, some rods Rc may remain stuck in the flutes 23 or do not leave the flutes sufficiently quickly as the hopper drum 12 rotates. A difference in operation over the known apparatus 10 occurs as the hopper drum 12 continues to rotate such that the rods Rc approach the guide surface 38 of the rod guide 235. In the known apparatus, the guide surface 38 physically contacts any stuck or insufficiently released rod Rc to knock them downwards towards the grading drum 15. However, with the rod guide 235 of the invention, the pressurised airflow supplied to the airflow inlet 237 flows through the airflow passage 238 and out of the airflow outlets 236. This creates an air cushion in front of the guide surface 38 and causes the rods Rc to be blown downwards and away from the guide surface 38 before the rods actually come into physical contact with the guide surface 38. In addition, or alternatively, this airflow from the airflow outlets 236 cushions the cut rods Rc as they travel towards the guide surface which may at least reduce the force with which the cut rods Rc contact the guide surface 38, if they contact the guide surface 38 at all. This results in a consistent ejection of the cut rods Rc from the flutes 23. The airflow from the rod guide 235 also causes the cut rods Rc to be directed squarely from the flutes 23 and avoids them tilting or one end of a rod Rc moving downwards more than an opposite end during transfer, which may occur if the rod Rc is physically knocked by the known rod guides 35. This process also helps reduce damage or deformation of the cut rods Rc during the movement from the flute 23 of the hopper drum 12 to the grading drum as physical contact with the rod guide 235 is reduced or avoided. The effectively and evenly-ejected cut rods Rc can then be picked up by the rod seats 46 of the grading drum 15 and conveyed onwards for further processing into consumables as described previously. The improvement in operation of the apparatus to using the rod guide 235 of the invention in place of the known rod guide 35 described previously, is illustrated in Figures 15 and 16. Figure 15 shows a close-up view of a region of an apparatus 10 during operation, where cut rods Rc are discharged from hopper drum 12. This apparatus 10 uses a known rod guide 35 shown in Figure 5 (and also known control flange 30). Figure 16 shows the same region of apparatus 10 during operation as Figure 15, although with the rod guide 235 of the invention and pressurised airflow supplied to the airflow inlet 237.

Figure 15 shows the hopper drum 12, the flutes 23, the rod guide 35 and guide surface 38. The cut rods Rc are at the lowermost region of the hopper drum 12 to be transferred to the grading drum 15. The grading drum 15, rod seats 46 and the lower transfer surface 29 are also shown. There is no suction force through the suction holes 27 in the flutes 23 in the region of the hopper drum 12 shown in Figure 15. The cut rod labelled Rc in Figure 15 can be seen to have struck against the inclined guide surface 38 of the rod guide 35 to aid its deflection downwards towards the grading drum 15. The cut rod Rc has also not entirely left the flute 23 and has not fully contacted the lower transfer surface 29. The cut rod Rc has also been knocked off its parallel orientation from when it was lying in the flute 23 of the hopper drum 12. That is, it has been knocked so that its longitudinal axis is angled with respect to the horizontal. This can be seen by the positions of the cut rod Rc labelled in Figure 15 and the cut rod adjacent it which has already been received in the rod seat 46 and which therefore lies in a horizontal orientation. This is also shown by the non-parallel dot-dash axis lines shown in Figure 15 which run through the cut rod labelled Rc in Figure 15, and through the cut rod Rc adjacent to it. This position of cut rod Rc risks the rod Rc being missed by the passing rod seat 46 intended to collected that cut rod Rc, resulting in a lost rod Rc and a manufacturing fault, and/or may result in damage or dent/deformation of the rod Rc, even if collected by the rod seat 46 of the grading drum 15.

Referring to Figure 16, the difference can be seen with the pressurised airflow supplied to the airflow inlet 237, creating a flow of pressurised air out of the airflow outlets 236. The airflow aids discharge of the cut rods Rc from the flutes 23. Figure 16 is taken at the same operational position of the apparatus 10 as Figure 15 with regard to the hopper drum 12 and grading drums 15. The difference in effective rod transfer can clearly be seen with the cut rod labelled Rc in Figure 16. Here, the rod Rc has further and more evenly left the flute 23 (i.e. there is no axial tilt on the rod Rc in Figure 16). This is also shown by the parallel dot-dash axis lines shown in Figure 16 which run through the cut rod labelled Rc in Figure 16, and through the cut rod adjacent to it. Furthermore, at the same operational position of the apparatus 10, the rod Rc does not contact the rod guide 235, and is spaced a distance (marked by arrows J) from the inclined guide surface 38 of the rod guide 235. That is, the airflow from the airflow outlets 236 has urged the rod Rc evenly from the flute 23 without the rod Rc having to physically contact the guide surface 38 of the rod guide 235. The rod Rc is therefore reliably extracted from the flute 23, with minimal or no impact, dent or damage, and is located to be securely collected by the rod seat 46 of the grading drum 15.

A further advantage provided by the rod guide 235 of the invention relates to the set-up and maintenance of the apparatus 10. In a known apparatus 10, the rod guides 35 must be installed and adjusted to a high degree of accuracy such that rods Rc are discharged from the flutes 23 evenly and level. This is because the impact of the rods Rc on the guide surface 38 can easily knock the rods Rc out of level alignment if the rod guide 38 is not accurately installed in the apparatus 10. For example, the tolerance of the rod guide 35 installation position may be around +/- 0.2mm within the apparatus 10 to achieve acceptable operation.

As described above, using the rod guide 235 of the invention, the air flow from the airflow outlets 236 and resulting air cushion/air flow urging the rods Rc from the flutes 23 helps achieve more even, level and consistent discharge of the rods Rc. This also avoids or reduces the impact of the rods Rc on the guide surface 38. This reduces the degree to which the rods Rc fall or are knocked out of level alignment during discharge from the flutes 23 towards the grading drum 15. Accordingly, the tolerance of installation position of the rod guide 235 in the apparatus can be significantly greater than in the known apparatus 10. For example, a rod guide 235 of the present invention maybe installed in an apparatus 10 with an installation position tolerance of around +/- 1.5mm whilst still achieving acceptable operation. It will be appreciated that this increased tolerance may result in less frequent apparatus maintenance being required to readjust the rod guide position, as well as helping achieve fewer manufacturing faults or lost rods, and less production line down-time. These advantages help towards achieving greater production efficiency and reduced cost of operation. In an embodiment, the airflow outlets 236 are configured to direct the airflow vertically directly downwards, that is, at 90 degrees to the horizontal plane. This substantially corresponds to an angle of 90 degrees from the longitudinal axis D-D of the rod guide 235 since, in use, the rod guide 235 is mounted with its longitudinal axis aligned substantially horizontally, as shown in Figures 1, 7 and 8. This is shown by airflow arrows F in Figure 14. The inclined guide surface 38 is disposed at an angle 0 relative to the horizontal, and to the longitudinal axis D-D of the rod guide 235, as shown in Figures 13 and 14. 0 maybe 30 - 60 degrees, and maybe around 45 degrees. This airflow direction is advantageous for urging the cut rods Rc from the flutes 23 in a direction towards the grading drum 15.

In an embodiment, the or each airflow outlet 236 is configured to direct the airflow F out of the airflow outlet at an angle N measured with respect to the direction normal to the guide surface 38. The angle N is shown in Figure 14. The angle N may vary within the scope of the invention, and may be between 20 - 70 degrees from a direction normal to the guide surface, and wherein the angle may be between 30 - 60 degrees, and may be 40 - 50 degrees, and may be 45 degrees. Again, this airflow direction is advantageous for optimally urging the cut rods Rc from the flutes 23 in a direction towards the grading drum 15.

In an apparatus 10 of the invention, positive air pressure maybe applied through the air outlet 133 of the control flange 130 at different pressures to achieve the abovedescribed advantages. In some embodiments, the applied positive air pressure maybe between 1 - 5 bar, and may be between 1.2 - 4 bar, and may be between 1.3 - 3 bar, and may be between 1.5 - 3 bar, and may be around 2 - 3 and may be 3 bar.

In an apparatus 10 of the invention, pressurised airflow may be applied through the airflow inlet 237, airflow passage 238 and out of the airflow outlet(s) 236 of the rod guide 235 at different pressures to achieve the above-described advantages. In some embodiments, the pressurised airflow may be between 0.5 - 2 bar, and may be between 0.7 - 1.8 bar, and may be between 0.9 - 1.6 bar, and may be between 1 - 1.5 bar.

In providing the control flange 130 of the first embodiment in the apparatus 10 for handling rods of aerosol-generating material, an apparatus 10 is provided which is able to both retain the rods Rm, Rc in the flutes 23 during a first range of rotation V of the hopper drum 12, but also to actively use air (or other gas) pressure to urge the rods Rc out of the flutes 23 over a second range of rotation P of the hopper drum 12. The rods Rc are therefore not just reliant on gravity for their discharge from the flutes 23. This can help overcome problems of rods Rc becoming stuck in the flutes 23, of avoiding deformation or damage by rod impact upon the rod guide 35, and/ or of enabling faster speed of operation of the apparatus 10.

Referring to Figure 9, it can be seen that over a third range of rotation, the vacuum ducts 25 are rendered open to atmosphere such that no vacuum or positive pressure is applied to the suction holes 27 of the respective flute(s) 23. This third range of rotation corresponds to the range of rotation NV over which the vacuum ports 26 are in fluid communication with the vent cavity 42. In the rotational direction of the hopper drum 12, this third range of rotation occurs after the vacuum port 26 is in fluid communication with the arcuate aperture 34 and before coming into fluid communication with the air outlet 133. This is marked NV1 in Figure 9. Also from Figure 9 it can be seen that over a fourth range of rotation, the vacuum ducts 25 are rendered open to atmosphere such that no vacuum or positive pressure is applied to the suction holes 27 of the respective flute(s) 23, which again corresponds to the range of rotation NV over which the vacuum ports 26 are in fluid communication with the vent cavity 42. In the rotational direction of the hopper drum 12, this fourth range of rotation occurs after the vacuum port 26 is in fluid communication with the air outlet 133 and before coming into fluid communication with arcuate aperture 34. This is marked NV2 in Figure 9.

In some embodiments, it may be advantageous for the vacuum ducts 25 to be rendered open to atmosphere between the vacuum being applied and the positive pressure being applied (i.e. over the third range of rotation), and/ or being rendered open to atmosphere between the positive pressure being applied and the vacuum being applied (i.e. over the fourth range of rotation). This may allow the pressure in the vacuum ducts 25 to equalise and provide a smoother pressure change profile within the vacuum ducts, which may result in enhanced control of rod handling.

In some embodiments, there may be smaller third or fourth ranges of rotation. In yet further embodiments, the control flange 130 may be configured such that the vacuum ducts 25 are not rendered open to atmosphere between the vacuum being applied and the positive pressure being applied (i.e. the vacuum ducts 25 are not rendered in fluid communication with the vent cavity 42 over a third range of rotation). Furthermore, the vacuum ducts 25 may not be rendered open to atmosphere between the positive pressure being applied and the vacuum being applied (i.e. the vacuum ducts 25 are not rendered in fluid communication with the vent cavity 42 over a fourth range of rotation). This may allow a quicker pressure change in the vacuum ducts 25, which may assist rod handling at higher machinery speeds.

Although the first aspect of the present invention comprising the control flange 130 is illustrated and described above in the context of a hopper drum 12 handling, conveying and transferring rods Rc to a grading drum 15, it will be appreciated that the invention is not limited to this particular application or apparatus, and is intended within the scope of the invention to be applicable to any drum within an apparatus that is intended to receive, convey and discharge rods within a manufacturing process in a flute 23 or other formation on a drum surface which includes a suction hole to retain rods on the drum over a range of rotation of the drum. Such rods may comprise rods of aerosol-generating material, filter rods, spacer rods or tubes, or any other rod-shaped article or component for assembly into a consumable and which requires handling and conveyance within the apparatus.

In providing the rod guide 235 of the second embodiment in the apparatus 10 for handling rods of aerosol-generating material, an apparatus is provided which is able to actively use air (or other gas) pressure to urge the rods Rc out of the flutes 23 at the desired point of rotation of the hopper drum 12. The rods Rc are therefore not just reliant on physical impact against a guide surface 38 of a rod guide 35, 235 for their discharge from the flutes 23 if required and such impact can be reduced in force or avoided. This may help overcome problems of rods Rc being deformed or damaged by impact upon the rod guide 35, and/or of enabling faster speed of operation of the apparatus 10.

Although the second aspect of the present invention comprising the rod guide 235 is illustrated and described above in the context of a hopper drum 12 handling, conveying and transferring rods Rc to a grading drum 15, it will be appreciated that the invention is not limited to this particular application or apparatus, and is intended within the scope of the invention to be applicable to any drum within an apparatus that is intended to receive, convey and discharge rods within a manufacturing process in a flute 23 or other formation on a drum surface. Such rods may comprise rods of aerosol-generating material, filter rods, spacer rods or tubes, or any other rod-shaped article or component for assembly into a consumable and which requires handling and conveyance within the apparatus.

The apparatus 10 is shown and described above as an apparatus for handling rods of aerosol-generating material from a hopper 11 to a grading drum 15. Such apparatus 10 may comprise part of a larger manufacturing machine which may include further stations for handling, processing, assembling and collating rods into consumables or groups of consumables. Such machine may comprise a single machine and the apparatus 10 may comprise a section of such a machine. Such a machine may comprise a modular machine comprising separate modules assembled and connected together to perform the desired function and manufacturing steps, and the apparatus may comprise a discrete module of such a modular machine, or a portion of such a module of such a modular machine. The apparatus 10 may comprise the hopper, hopper drum 12, and grading drum 15 (and associated components described above). Alternatively, the apparatus 10 may comprise only the hopper drum 12 without also the grading drum

15 or other drums upstream or downstream of the hopper drum 12 in the apparatus. As mentioned above, in such context, the apparatus may comprise a drum other than a hopper drum 12 within the scope of the invention. In the embodiments shown, the flutes 23 are formed integrally with the hopper drum 12 on the outer surface 22 of the drum 12. However, the flutes 23 may be provided as one or more separate components attached to a surface of a drum.

The rod guide 235 may be made or constructed in various ways within the scope of the invention. The rod guide 235 may be made as a single integral component, for example, by moulding or additive layer manufacturing. In alternative embodiments, the rod guide 235 maybe made of two plates joined together. Figures 13 and 14 show how such a rod guide 235 may be formed. Figure 13 shows the rod guide comprising two plates 235a, 235b joined together along a centre line 239. The plates 235a, 235b have respective facing surfaces which are in contact with each other and at which they are joined. The airflow outlets 236 and airflow passage 238 maybe formed into one or both of the plates 235a, 235b, such as into one or both of the facing surfaces of the respective plate(s) 235a, 235b. The plates 235a, 235b maybe secured together in any suitable manner, for example by welding, adhesive bonding, or suitable mechanical fastening such as screws, bolts, etc. The airflow inlet 237 may be integrally formed with one or both of the plates 235a, 235b, or may be a separate component connected to one or both of the plates 235a, 235b by any suitable means, for example by welding, adhesive bonding, or suitable mechanical fastening such as screws, bolts, etc.

The control flange 130 of the invention is illustrated and described above as comprising one air outlet 133 in the manifold 131. However, the invention is not limited to such a configuration and the control flange 130 may comprise two or more air outlets 133. The air outlet 133 is shown as being generally arcuate in shape. This maybe advantageous to follow a rotational path described by the vacuum ports 26 with which the air outlet 133 is intended to communicate. However, the invention is not limited to such a configuration of air outlet 133 and the or each air outlet 133 may be of non-arcuate shape within the scope of the invention. Similarly, the apertures 34 in the control flange 130 for the supply of vacuum to the hopper drum 12 are illustrated and described as being arcuate in shape. Again, this maybe advantageous to follow a rotational path described by the vacuum ports 26 with which the apertures 34 are intended to communicate. However, the invention is not limited to such a configuration of aperture 34 and the or each aperture 34 maybe of non-arcuate shape within the scope of the invention. In some embodiments, the or each aperture 34, and/or the or each air outlet 133 may be substantially circumferentially disposed and may be generally circumferentially disposed about a common centre point of the control flange 130.

The angle P (see Figure 9) over which the air outlet 133 extends, and so the angle of rotation of the hopper drum 12 over which positive air pressure is applied through the suction hole 27, may vary within the scope of the invention, and may be between 1 to 40 degrees, and may be between 5 to 35 degrees, and may be between 10 to 30 degrees, and may be between 15 to 25 degrees.

The control flange 130 is described as comprising a recess 31 formed in the body of the control flange 130. This maybe advantageous to receive a first end face 20 of the hopper drum 12. Such configuration may also reduce loss of vacuum or positive pressure supplied to the vacuum ports 26 during operation. However, the invention is not limited to such a configuration of control flange and in other embodiments of the invention, the control flange 130 may not comprise a recess 31. The hopper drum 12 may be arranged with a first end face 20 flush against or proximate to the surface 32 of the control flange 130 for the vacuum ports 26 to communicate with the aperture(s) 34 and air outlet 133 as the hopper drum 12 rotates. Such spacing may be between 0.01mm - 2mm for example. The exemplary rod guide 235 of the invention is illustrated and described above as comprising three airflow outlets 236. However, the invention is not limited to such a configuration and the rod guide 235 may comprise one or two, or more than three airflow outlets 236. A single airflow outlet may provide a simpler and more cost effective rod guide 235 to manufacture. It maybe advantageous to provide a plurality of airflow outlets 236 in order to generate a more uniform air cushion at the guide surface 38 of the rod guide 235 from the pressurised air being expelled from the airflow outlets 236.

Aspects of the inventions described herein include an apparatus in which positive air pressure is applied through flute suction holes to aid discharge of rods Rc from the flutes 23 of a drum; a control flange configured for use in such an apparatus; an apparatus in which pressurised airflow is provided through a guide member/rod guide to aid discharge of rods Rc from the flutes of a drum; and a guide member/ rod guide configured for use in such an apparatus. It is intended within the scope of the invention that an apparatus may comprise either one of the above-described control flange and rod guide of the inventions separately, or both in combination, to achieve the above-described advantages.

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

Claims

1. An apparatus for handling rods of aerosol-generating material, the apparatus comprising: a rotatable drum having a plurality of elongate flutes provided around an outer surface of the drum and extending in an axial direction of the drum, wherein each flute includes one or more suction holes extending from a surface of a respective flute into communication with an associated vacuum duct within the drum; and a control flange, wherein the drum rotates relative to the control flange in use, and wherein the control flange comprises a first aperture connected to a vacuum source, and a second aperture connected to a source of pressurised gas, wherein as the drum rotates relative to the control flange, the vacuum ducts are in fluid communication with the first aperture over a first range of rotation of the drum to apply a negative pressure to the vacuum ducts, and the vacuum ducts are in fluid communication with the second aperture over a second range of rotation of the drum to apply positive gas pressure to the vacuum ducts.

2. An apparatus according to claim 1, wherein each flute includes a plurality of suction holes.

3. An apparatus according to claim 1 or claim 2, wherein each vacuum duct is open at a first end face of the drum.

4. An apparatus according to any preceding claim, wherein the control flange is disposed adjacent the first end face of the drum.

5. An apparatus according to any preceding claim, wherein the control flange includes a vent cavity which is open to atmosphere, and wherein the vacuum ducts are in fluid communication with the vent cavity over a third range of rotation of the drum which is after being in fluid communication with the first aperture over the first range of rotation of the drum and before being in fluid communication with the second aperture over the second range of rotation of the drum.

6. An apparatus according to claim 5, wherein the vacuum ducts are in fluid communication with the vent cavity over a fourth range of rotation of the drum which is after being in fluid communication with the second aperture over the second range of rotation of the drum before returning to being in fluid communication with the first aperture over the first range of rotation of the drum.

7. An apparatus according to claim 5 or claim 6, wherein the control flange comprises a gas manifold connected to the source of pressurised gas, and wherein the second aperture is formed in the gas manifold.

8. An apparatus according to claim 7, wherein the gas manifold is located within the vent cavity. . An apparatus according to any preceding claim wherein the second range of rotation of the drum extends around a lowermost region of the drum.

10. An apparatus according to any preceding claim wherein the first range of rotation of the drum is greater than the second range of rotation of the drum.

11. An apparatus according to any preceding claim, wherein the second range of rotation is between 1 to 40 degrees, and may be between 5 to 35 degrees, and may be between 10 to 30 degrees, and may be between 15 to 25 degrees.

12. An apparatus according to any preceding claim, wherein the control flange comprises a circular recess and the first end face of the drum is received within the circular recess. 13. An apparatus according to any preceding claim, wherein the second aperture is arcuate.

14. An apparatus according to claim 13 wherein the first aperture is arcuate and wherein the first and second apertures are each disposed circumferentially about a common a centre point.

15. An apparatus according to claim 14 wherein the first and second apertures are disposed at an equal radial distance from the common centre point. 16. An apparatus according to any preceding claim, wherein the rotatable drum comprises a circumferential groove in the outer surface and intersecting the flutes, the apparatus further comprising: a guide member comprising a longitudinal arm having a guide surface at a first end thereof, an airflow outlet located at the guide surface and an airflow passage in fluid communication with the airflow outlet; wherein the airflow passage is connected to a supply of pressurised gas to supply pressurised gas to the airflow outlet; and wherein the guide member is disposed with the guide surface at least partially received within the groove and configured to expel gas from the airflow outlet onto rods carried in the flutes.

17. An apparatus according to claim 16, wherein the guide surface is inclined at an angle relative to a longitudinal axis of the guide member.

18. An apparatus according to claim 17 wherein the angle of the guide surface is between 30 to 60 degrees, and may be around 45 degrees.

19. An apparatus according to any of claims 16 to 18, wherein the airflow outlet is configured to direct airflow out of the airflow outlet at an angle of between 20 - 70 degrees from a direction normal to the guide surface, and wherein the angle may be between 30 - 60 degrees, and may be 40 - 50 degrees, and may be 45 degrees

20. An apparatus according to any of claims 16 to 19, wherein the longitudinal axis of the guide member is substantially horizontal. 21. An apparatus according to any of claims 16 to 20, wherein the airflow outlet is configured to direct airflow vertically downwards out of the airflow outlet.

22. An apparatus according to any of claims 16 to 21, wherein the guide member comprises a plurality of airflow outlets and may comprise three airflow outlets.

23. An apparatus according to any of claims 16 to 22, wherein the guide member comprises two plates secured together at respective facing surfaces, and wherein the airflow passage and airflow outlet(s) are formed into a facing surface of at least one of the plates.

24. An apparatus according to any of claims 16 to 23, wherein the supply of pressurised gas provided to the airflow passage is between 0.5 - 2 bar, and may be between 0.7 - 1.8 bar, and maybe between 0.9 - 1.6 bar, and maybe between 1 - 1.5 bar.

25. An apparatus according to any preceding claim, wherein pressurised gas provided to the second aperture is between 1 - 5 bar, and may be between 1.2 - 4 bar, and may be between 1.3 - 3 bar, and may be between 1.5 - 3 bar, and may be around 2 - 3 bar, and may around 3 bar.

26. A control flange for use with a drum of an apparatus for handling rods of aerosol-generating material, the control flange comprising a plate having: a first aperture extending through the plate and around a first circumferential portion of the plate; a gas manifold comprising a second aperture which extends around a second circumferential portion of the plate.

27. A control flange according to claim 26, further comprising a vent cavity comprising a recessed region formed in the plate.

28. A control flange according to claim 27, further comprising any of the features recited in claims 8 and 13 to 15.

29. A method for handling rods of aerosol-generating material using an apparatus as recited in any of claims 1 to 25, the method comprising: receiving a rod within a flute of the rotatable drum; applying a negative pressure to the one or more suction holes to retain the rod in the flute as the drum rotates relative to the control flange over a first range of rotation; and applying a positive gas pressure to the one or more suction holes to aid discharge of the rod from the flute as the drum rotates relative to the control flange over a second range of rotation.

30. A method according to claim 29, further comprising: rendering the one or more suction holes open to atmosphere over a third range of rotation of the drum which is after the drum has rotated over the first range of rotation and before the drum has rotated over the second range of rotation.

31. A method according to claim 30, further comprising: rendering the one or more suction holes open to atmosphere over a fourth range of rotation of the drum which is after the second range of rotation and before the drum returns to the first range of rotation of the drum.

32. A method according to any of claims 29 to 31, wherein the first range of rotation of the drum is greater than the second range of rotation of the drum.

33. A method according to any of claims 29 to 32, wherein the second range of rotation is between 1 to 40 degrees, and may be between 5 to 35 degrees, and may be between 10 to 30 degrees, and may be between 15 to 25 degrees.

34. A method according to any of claims 29 to 33, wherein the drum comprises a circumferential groove in the outer surface and intersecting the flutes and the apparatus further comprising a guide member comprising an airflow outlet located at a guide surface disposed within the groove, the method further comprising: supplying pressurised gas to the airflow outlet to expel gas from the airflow outlet onto rods carried in the flutes.

35. A method according to claim 34, further comprising expelling the pressurised gas vertically downwards out of the airflow outlet.

36. A method according to claim 34 or claim 35, wherein pressurised gas is provided to the airflow outlet at between 0.5 - 2 bar, and maybe between 0.7 - 1.8 bar, and may be between 0.9 - 1.6 bar, and may be between 1 - 1.5 bar. 37. A method according to any of claims 29 to 36, wherein pressurised gas is provided to the second aperture at between 1 - 5 bar, and maybe between 1.2 - 4 bar, and may be between 1.3 - 3 bar, and may be between 1.5 - 3 bar, and may be between 2 - 3 bar, and may be around 3 bar. 38. A method according to any of claims 29 to 37, wherein the method comprises handling rods of sheet cut aerosol-generating material. 39- A method according to any of claims 29 to 38, wherein the method comprises handling rods having a susceptor material within the rod.