EP4719727A1

EP4719727A1 - Apparatus for punching a part from a web comprising an array of sub components and locating it on a component

Info

Publication number: EP4719727A1
Application number: EP24732059.1A
Authority: EP
Inventors: Sam WHIFFEN; Josef DRIVER; Nicholas HUNTFORD
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2023-05-31
Filing date: 2024-05-30
Publication date: 2026-04-08
Also published as: GB202308153D0; WO2024246529A1

Abstract

An apparatus for positioning a heater component on a consumable unit for use in an aerosol delivery system is disclosed. The apparatus comprises a machine tray support for locating a machine tray of consumable units. The consumable units are arranged in an array in the machine tray. The apparatus further comprises a platform for holding a support web comprising an array of sub-components in a position above the machine tray support and a punch having an array of protrusions configured to engage the array of sub-components by displacement of the punch toward the machine tray support to separate the sub-components from the support web and locate the sub-components on the consumable units. Each protrusion comprises an opening fluidly connected to a pump. The pump is configured to generate suction at the opening so as to retain a component over the opening following separation of the component from the support web. A method of positioning a sub-component on a consumable unit for use in an aerosol delivery system is also disclosed.

Description

APPARATUS FOR PUNCHING A PART FROM A WEB COMPRISING AN ARRAY OF SUB COMPONENTS AND LOCATING IT ON A COMPONENT

Field

The present invention relates to an apparatus and a method for forming a cut portion of sheet material and locating said cut portion of sheet material in a component for use in a delivery system.

Background

There exists a need to provide an apparatus and a method for the efficient manufacture of components for delivery systems which may involve supplying a continuous sheet material; tensioning a portion of the sheet material; cutting the cut portion of sheet material from the tensioned portion of sheet material, and locating the cut portion of sheet material within the component for use in a delivery system. These, and other manufacturing steps, may need to be carried out on a plurality of components in quick succession.

Summary

According to the present disclosure, there is provided an apparatus for positioning a heater component on a consumable unit for use in an aerosol delivery system, the apparatus comprising: a machine tray support for locating a machine tray of consumable units, the consumable units being arranged in an array in the machine tray; a platform for holding a support web comprising an array of sub-components in a position above the machine tray support; and a punch having an array of protrusions configured to engage the array of sub-components by displacement of the punch toward the machine tray support to separate the sub-components from the support web and locate the sub-components on the consumable units, wherein each protrusion comprises an opening fluidly connected to a pump, the pump being configured to generate suction at the opening so as to retain a component over the opening following separation of the component from the support web.

The apparatus may further comprise an actuator arranged to move the punch toward the machine tray support.

The platform may be slidably mounted relative to the machine tray support between an engaged position and a disengaged position, in which a machine tray is insertable into, or is removable from, the machine tray support. The platform may comprise a support surface having an array of apertures that correspond to the array of protrusions, so that, the protrusions are moveable into the apertures to separate sub-components from a support web held by the support surface by pushing the sub-components through the apertures.

The support surface may comprise an alignment element associated with each aperture. Each alignment element may be configured to engage a corresponding consumable unit or the machine tray to adjust for any misalignment between the consumable unit and a corresponding sub-component of the support web when the platform is in the engaged position.

Each alignment element may comprise a chamfer of a lower edge of each aperture. The platform may be mounted on a pillar for linear movement between the engaged and disengaged positions.

The platform may be supported by four pillars arranged around the machine tray support.

The punch may comprise a compression plate configured to clamp the support web between the support surface of the platform and the compression plate.

The compression plate may depend from a lower surface of the punch via a plurality of springs.

The compression plate may comprise an array of apertures that correspond to the array of protrusions, so that, the protrusions maybe moveable into the apertures to separate sub-components from the support web held between the support surface of the platform and the compression plate.

The machine tray support may comprise one or more rails configured to support opposing sides of the machine tray so that the machine tray can be inserted into the machine tray support by sliding the machine tray along said rails. The machine tray support may include a stop against which the machine tray abuts when inserted into a predetermined position.

The actuator may be configured to move the platform between the engaged and disengaged positions.

The pump may be configured to switch off to release a component retained over the opening of each protrusion when the components reach a predetermined height above the machine tray support

The pump may be configured to generate a flow of air out of the opening to force a component retained over the opening of each protrusion towards the machine tray when the components reach a predetermined height above the machine tray support. Each protrusion may comprise an outer part and inner part. The inner part may be movable relative to the outer part from a first position in which an end of the inner part is substantially flush with an end of the outer part and a second position, in which the inner part extends from the outer part so that the end of the inner part is offset from the end of the outer part.

The suction generated by the pump maybe applied through the inner part.

The outer part may be configured to contact each sub-component of the support web to separate each sub-component from the support web.

The outer part may have an external dimension greater than the inner part.

The apparatus may further comprise a picker configured to retrieve a support web from a stack of support webs and insert the support web into the clamp.

The picker may comprise an arm moveable linearly in two axes.

The apparatus maybe configured to perform a first operation in which the punch engages a first population of the array of sub-components; and a second operation in which the punch engages a second population of the array of sub-components. The picker may be configured to change the position of the support web within the clamp between the first and second operations.

The picker may comprise a suction head configured to releasably attach the support web to the picker.

According to another aspect of the present invention there is provided a method of positioning a sub-component on a consumable unit for use with an inhalation device, the method comprising: locating a machine tray of consumable units a machine tray support, the consumable units being held in an array in the machine tray; clamping a support web comprising an array of sub-components in a position above the machine tray support; and operating a punch having an array of protrusions configured to engage the array of sub-components by displacing of the punch toward the machine tray support to separate the sub-components from the support web and locate the sub- components on the consumable units held in the machine tray, wherein the heights of the protrusions vary to stagger engagement of the protrusions with the subcomponents as the punch moves toward the support web.

Brief Description of the Drawings Embodiments of the invention will be described, by way of example only, with reference to the accompanying drawings, in which:

FIGs. 1A and 1B show an isometric and exploded view respectively of a consumable unit for use in an aerosol delivery system;

FIG. 2 shows an apparatus according to an embodiment of the invention; FIGs. 3A and 3B show a schematic side view of a punch according to an embodiment of the invention;

FIGs. 4A and 4B show a schematic front view of an apparatus according to an embodiment of the invention;

FIG. 5 shows a schematic top view of a picker according to an embodiment of the invention;

FIG. 6 shows a schematic side view of a machine tray according to an embodiment of the invention; and

FIG. 7 shows a diagram of method steps of a method according to an embodiment of the invention.

Detailed Description As used herein, the term “delivery system” is intended to encompass systems that deliver at least one substance to a user, and includes: combustible aerosol provision systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material); non-combustible aerosol provision systems that release compounds from an aerosol-generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials; and aerosol-free delivery systems that deliver the at least one substance to a user orally, nasally, transdermally or in another way without forming an aerosol, including but not limited to, lozenges, gums, patches, articles comprising inhalable powders, and oral products such as oral tobacco which includes snus or moist snuff, wherein the at least one substance may or may not comprise nicotine.

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

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

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

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

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

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

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

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

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

FIGs. 1A and 1B illustrate a component 1 for use in a delivery system (not shown). As shown in FIG. 1A, the component 1 is a mouthpiece assembly that is configured to be attachable to a main body of a delivery system. For example, the delivery system is a non-combustible aerosol provision device, having a main body that typically comprises a battery. As shown in FIG. 1B, the component comprises a mouthpiece 2, a heater 3, a wick 4, a heater support 5 and an end cap 6.

FIG.2 illustrates an apparatus 7 according to an embodiment of the invention for positioning a heater component on a consumable unit for use in an aerosol delivery system. The heater component corresponds to the heater 3 of the mouthpiece assembly 1 shown in FIG. 1B.

The apparatus 7 comprises a machine tray support 8, for locating a machine tray 9 of consumable units 1, and a platform 10 for holding a support web 11 in a position above the machine tray support 8. The support web 11 comprises an array of sub-components 3 (i.e., the heater 3) which will be removed from the support web 11 and placed within the consumable units 1 located on the machine tray 9. The machine tray 9 comprises an array within which the consumable units 1 are arranged.

Additionally, the apparatus 7 comprises a punch 12. As seen in FIGs. 3A and 3B, the punch 12 has an array of protrusions 13 configured to engage the array of subcomponents 3, by displacement of the punch 12 toward the machine tray support 8 to separate the sub-components 3 from the support web 11 and locate the sub-components 3 on the consumable units 1 arranged beneath the punch 12 on the machine tray 9. In some embodiments, apparatus 7 comprises an actuator which is arranged to displace the punch 12 in a downward direction toward the machine tray support 8. Each protrusion 13 comprises an opening 14 fluidly connected to a pump (not shown). The pump is configured to generate suction at the opening 14 so as to retain a component 3 over the opening 14 following separation of the component 3 from the support web 11.

In some embodiments, the heights of the protrusions 13 vary to stagger engagement of the protrusions 13 with the sub-components 3 as the punch 12 moves toward the support web 11. In some embodiments, the pump is configured to switch off when the components reach a predetermined height above the machine tray support. When the pump is switched off, and the suction is no longer generated, the components are released into position within the machine tray. Additionally, the pump maybe also configured to generate a flow of air out of the opening to force a component retained over the opening of each protrusion towards the machine tray when the components reach a predetermined height above the machine tray support. As shown in FIGs. 3A and 3B, in some embodiments, each protrusion 13 comprises an outer part 20 and an inner part 21, the outer part 20 having an external dimension greater than the inner part 21. The inner part 21 is moveable relative to the outer part 20 between a first position and a second position, In the first position (FIG. 3A), an end of the inner part 21 is substantially flush with and end of the outer part 20. In the second position (FIG. 3B), the inner part 21 extends from the outer part 20 so that the end of the inner part 21 is offset from the end of the outer part 20. During operation of the punch 12, the protrusions 13 are configured to contact the sub-components 3 and separate them from the support web 11. In particular, the sub-components 3 are attached to the support web by a plurality of tangs. The movement protrusions 13 breaks the tangs and thus releases the sub-components 3 from the support web 11.

In particular, the outer part 20 of the protrusions 13 is configured to contact each sub- component 3 of the support web 11 to separate each sub-component 3 from the support web 11. In other words, as the punch 12 moves towards the machine tray support 8, the outer part 20 of the protrusions 13 breaks the plurality of tangs securing the subcomponents 3 to the support web 11. The inner part 21 of the protrusions 13 is configured to guide the suction provided by the pump to the sub-components 3 located on the support web 11. In other words, the suction generated by the pump is applied through the inner part 21 of the protrusions 13. The extension of the inner part 21 relative to the outer part 20 provides more accurate placement of the sub-components 3 within consumable units 1 located on the machine tray 9. Additionally, it is to be appreciated that the outer and inner parts of the protrusions are optional, and the suction maybe provided in the same manner through a single-piece protrusion.

Referring back to FIG. 2, the platform 10 is slidably mounted relative to the machine tray support 8 between an engaged position and a disengaged position. In the disengaged position, the platform 10 is spaced from the machine tray support 8 to facilitate the insertion or removal of a machine tray 9 from the machine tray support 8. In the engaged position, the platform 10 contacts the machine tray 9 located in the machine tray support 8. Furthermore, the platform 10 comprises a support surface 16 on which the support web 11 is held in position above the machine tray support 8. The support surface 16 comprises an array of apertures 17 (shown in FIGS. 4A and 4B) which correspond to the array of protrusions 13 of the punch 12. The protrusions 13 are moveable into the apertures 17 to separate the sub-components 3 from the support web 11 held by the clamp 15 by pushing the sub-components 3 through the apertures 17. Additionally, the support surface 16 comprises an alignment element 18 associated with each aperture 17. Each alignment element 18 is configured to engage a corresponding consumable unit 1 or the machine tray 9 to adjust for any misalignment between the consumable unit 1 and a corresponding sub-component 3 of the support web 11 when the platform

10 is in the engaged position. In some embodiments, each alignment element 18 comprises a chamfer of a lower edge of each aperture 17 in the support surface 16 of the clamp 10. As seen in FIG. 4A, the punch 12 further comprises a compression plate 15. The compression plate 15 depends from a lower surface of the punch 12 and is configured to contact the support web 11 held on the support surface 16 of the platform 10 prior to contact from the punch 12. In other words, the compression plate 15 is configured to clamp the support web 11 between the support surface 16 of the platform 10 and the compression plate 15. The compression plate 15 comprises an array of apertures 29 that correspond to the array of protrusions 13. This ensures that the protrusions 13 are moveable into the apertures 29 to separate sub-components 3 from the support web 11 held between the support surface 16 of the platform 10 and the compression plate 15. Additionally, the compression plate 15 depends from the lower surface of the punch 12 via a plurality of springs 30 which prevent the support web 11 from deforming when coming into contact with the punch 12. In other words, as the springs 30 compress, a force is applied to the support web 11 which prevents the support web 11 from deforming when the protrusions 13 impact the tangs that join the sub-components 3 to the support web 11.

The operation of the apparatus 7 will now be described in relation to FIGs. 4A and 4B. Initially, the platform 10 is in the disengaged position and a machine tray 9 is able to be inserted into the machine tray support 8 below the punch 12. In particular, the machine tray support 8 comprises one or more rails 19 (shown in Figure 2) configured to support opposing sides of the machine tray 9 so that it can be inserted into the machine tray support 8 by sliding the machine tray 9 along the rails 19. Additionally, in some embodiments, the machine tray support 8 includes a stop against which the machine tray abuts when inserted into a predetermined position. Once a machine tray 9 is located in the machine tray support 8, the platform 10 moves from the disengaged position to the engaged position where the platform 10 contacts the machine tray 9. In some embodiments, the actuator which moves the punch 12 towards the machine tray support 8 is also configured to move the platform 10 between the engaged and disengaged positions. The platform 10 is mounted on a pillar for linear movement between the engaged and disengaged positions. It is to be appreciated that the platform 10 maybe mounted on any number of pillars. For example, as shown in Figure 2, the platform 10 is mounted on four pillars arranged around the machine tray support 8.

Next, a support web 11 is placed on the support surface 16 of the platform 10 where the support web 11 is held in position above the machine tray 9 located in the machine tray support 8. The actuator is then activated to move the punch 12 toward the machine tray support 8. As the punch 12 moves in a downward direction, the compression plate 15 comes into contact with the support web 11 and clamps the support web 11 between itself and the support surface 16 of the platform 10. The springs 30 compress and the punch 12 continues moving toward the machine tray support 8. Each of the protrusions 13 of the punch 12 contacts a corresponding sub-component 3 on the support web 11 and pushes the sub-components 3 through the corresponding apertures 17 in the support surface 16. As the sub-components 3 are removed from the support web 11, the pump is activated to generate suction through the opening 14 in each protrusion 13 so that the components 3 are retained over the opening 14 following separation from the support web 11. The pump is then turned off so that the sub-components 3 are located within the corresponding consumable units 1 arranged within the machine tray 9. In some embodiments, the pump is further configured to generate a flow of air out of the opening 14 in order to push and thus disengage the components 3 from the protrusions 13. Additionally, as described above, the protrusions 13 of the punch 12 may comprise an outer part 20 and an inner part 21. The outer part 20 is configured to separate the sub-components 3 from the support web 11 and the inner part 21 is configured to provide the suction to each sub-component 3. The inner part 21 is also moveable relative to the outer part 20 such that the components separated from the support web are arranged just above their final position within the consumable units 1. In other words, the combined extension of the punch towards the machine tray support and the extension of the inner part of the protrusions relative to the outer part results in the components being accurately placed within the consumable units. Finally, the punch 12 is returned to the starting position and the platform to is retuned to the disengaged position so that the machine tray 9 can be removed from the machine tray support 8, and so that another machine tray 9 can be loaded into the apparatus 7. In some embodiments, the apparatus 7 further comprises a picker 22 (shown in FIG. 5). The picker 22 is configured to retrieve a support web 11 from a stack 23 of support webs 11 and insert the support web 11 into the clamp 15. The picker comprises an arm 24 that is moveable linearly in two axes A, B, and a suction head 25 configured to releasably attach the support web 11 to the picker 22. During operation of the apparatus 7, once the platform 10 has been moved into the engaged position, the picker 22 is configured to retrieve a support web 11 from the stack 23 and to place the support web 11 on the clamp 15. Once the support web 11 is in position, the punch 12 is actuated to remove the sub-components 3 from the support web 11. The punch 12 then returns to the starting position and the picker 22 is configured to remove the support web 11 from the clamp 15-

In some embodiments, the apparatus 7 is configured to perform a first operation, in which the punch 12 engages a first population of the array of sub-components 3, and a second operation, in which the punch 12 engages a second population of the array of sub-components 3. In other words, the apparatus 7 may be configured to first fill half of the machine tray 9 with sub-components 3, and then perform a second operation to fill the other half of the machine tray 9 with sub-components 3. The picker 22 is configured to change the position of the support web 11 within the clamp 15 between the first and second operations. It is to be appreciated that the apparats 7 may be configured to perform any number of operations. For example, the array of the machine tray 9 may comprise four rows of forty consumable units 1 and the support web 11 may comprise one hundred and sixty sub-components 3. Between each punch operation, the picker 22 is configured to move the support web 11 between four different positions in order to completely fill the consumable units 1 located on the machine tray 9 with sub- components 3. In order to ensure proper alignment, in some embodiments, the support web 11 comprises a plurality of holes (not shown) which are configured to interact with a plurality of locating pins (not shown) on the clamp 15.

As seen in FIG. 6, the machine tray 9 comprises a pair of cam followers 26 that are configured to interact with the rail 19 to retain the machine tray 9 in position and to direct the machine tray 9 along the rail 19. Each of the pair of cam followers 26 comprises a spring 27 that is configured to suspend a component holding plate 28 of the machine tray 9 above the rail 19. The spring 27 of each cam follower 26 is at least partially compressed when the punch 12 is in an end position. This ensures that the machine tray 9 in not damaged when the punch 12 is in the end position.

FIG. 7 shows a diagram illustrating a method, according to an embodiment of the invention, of positioning a sub-component on a consumable unit for use in an aerosol delivery system. The method comprises a first step Si of locating a machine tray of consumable units in a machine tray support. The consumable units are held in an array in the machine tray. The method further comprises a second step S2 of clamping a support web comprising an array of sub-components in a position above the machine tray support. Once the support web is clamped in position, the method comprises a third step S3 of operating a punch having an array of protrusions configured to engage the array of sub-components by displacing the punch toward the machine tray support to separate the sub-components from the support web and locate the sub-components on the consumable units held in the machine tray. The heights of the protrusions vary to stagger engagement of the protrusions with the sub-components as the punch moves toward the support web. 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 positioning a heater component on a consumable unit for use in an aerosol delivery system, the apparatus comprising: a machine tray support for locating a machine tray of consumable units, the consumable units being arranged in an array in the machine tray; a platform for holding a support web comprising an array of sub-components in a position above the machine tray support; and a punch having an array of protrusions configured to engage the array of sub- components by displacement of the punch toward the machine tray support to separate the sub-components from the support web and locate the sub-components on the consumable units, wherein each protrusion comprises an opening fluidly connected to a pump, the pump being configured to generate suction at the opening so as to retain a component over the opening following separation of the component from the support web.

2. An apparatus according to claim 1, further comprising an actuator arranged to move the punch toward the machine tray support. 3. An apparatus according to claims 1 or 2, wherein the platform is slidably mounted relative to the machine tray support between an engaged position and a disengaged position, in which a machine tray is insertable into, or is removable from, the machine tray support. 4. An apparatus according to any of claims 1 to 3, wherein the platform comprises a support surface having an array of apertures that correspond to the array of protrusions, so that, the protrusions are moveable into the apertures to separate subcomponents from a support web held by the support surface by pushing the subcomponents through the apertures.

5. An apparatus according to claim 4, wherein the support surface comprises an alignment element associated with each aperture, each alignment element being configured to engage a corresponding consumable unit or the machine tray to adjust for any misalignment between the consumable unit and a corresponding sub-component of the support web when the platform is in the engaged position.

6. An apparatus according to claim 5, wherein each alignment element comprises a chamfer of a lower edge of each aperture.

7. An apparatus according to any of claims 3 to 6, wherein the platform is mounted on a pillar for linear movement between the engaged and disengaged positions.

8. An apparatus according to any of claims 3 to 7, wherein the platform is supported by four pillars arranged around the machine tray support. . An apparatus according to any of claims 4 to 8, wherein the punch comprises a compression plate configured to clamp the support web between the support surface of the platform and the compression plate. 10. An apparatus according to claim 9, wherein the compression plate depends from a lower surface of the punch via a plurality of springs.

11. An apparatus according to claims 9 or 10, wherein the compression plate comprises an array of apertures that correspond to the array of protrusions, so that, the protrusions are moveable into the apertures to separate sub-components from the support web held between the support surface of the platform and the compression plate.

12. An apparatus according to any preceding claim, wherein the machine tray support comprises one or more rails configured to support opposing sides of the machine tray so that the machine tray can be inserted into the machine tray support by sliding the machine tray along said rails.

13. An apparatus according to any preceding claim, wherein the machine tray support includes a stop against which the machine tray abuts when inserted into a predetermined position.

14. An apparatus according to claim 3, when dependent on claim 2, wherein the actuator is configured to move the platform between the engaged and disengaged positions. 15- An apparatus according to any preceding claim, wherein the pump is configured to switch off to release a component retained over the opening of each protrusion when the components reach a predetermined height above the machine tray support. 16. An apparatus according to any preceding claim, wherein the pump is configured to generate a flow of air out of the opening to force a component retained over the opening of each protrusion towards the machine tray when the components reach a predetermined height above the machine tray support. 17. An apparatus according to any preceding claim, wherein each protrusion comprises an outer part and inner part.

18. An apparatus according to claim 17, wherein the inner part is movable relative to the outer part from a first position in which an end of the inner part is substantially flush with an end of the outer part and a second position, in which the inner part extends from the outer part so that the end of the inner part is offset from the end of the outer part.

19. An apparatus according to claims 17 or 18, wherein the suction generated by the pump is applied through the inner part.

20. An apparatus according to any of claims 17 to 19, wherein the outer part is configured to contact each sub-component of the support web to separate each subcomponent from the support web.

21. An apparatus according to any of claims 17 to 20, wherein the outer part has an external dimension greater than the inner part.

22. An apparatus according to any preceding claim, wherein the apparatus further comprises a picker configured to retrieve a support web from a stack of support webs and insert the support web into the clamp.

23. An apparatus according to claim 22, wherein the picker comprises an arm moveable linearly in two axes.

24. An apparatus according to any preceding claim, wherein the apparatus is configured to perform a first operation in which the punch engages a first population of the array of sub-components; and a second operation in which the punch engages a second population of the array of sub-components.

25. An apparatus according to claim 24, when dependent on claims 15 or 16, wherein the picker is configured to change the position of the support web within the clamp between the first and second operations. 26. An apparatus according to any of claims 22 to 25, wherein the picker comprises a suction head configured to releasably attach the support web to the picker.

27. A method of positioning a sub-component on a consumable unit for use in an aerosol delivery system, the method comprising: locating a machine tray of consumable units in a machine tray support, the consumable units being held in an array in the machine tray; clamping a support web comprising an array of sub-components in a position above the machine tray support; and operating a punch having an array of protrusions configured to engage the array of sub-components by displacing the punch toward the machine tray support to separate the sub-components from the support web and locate the sub-components on the consumable units held in the machine tray, wherein the heights of the protrusions vary to stagger engagement of the protrusions with the sub-components as the punch moves toward the support web.