Method for supplying a continuous web of aerosol-forming substrate from a bobbin and aerosol-generating article

Abstract

A method for supplying a continuous web of aerosol-forming substrate (10) from a bobbin (1) comprises providing a bobbin (1) of a continuous web of aerosol-forming substrate (10), and unwinding the continuous web of aerosol-forming substrate (10) from a centre (11) of the bobbin (1). Preferably, rotational movement of the bobbin (1) is prevented during unwinding of the continuous web of aerosol-forming substrate (10).

Description

TECHNICAL FIELD

[0001] The present invention relates to a method for supplying a continuous web of aerosol-forming substrate from a bobbin. The invention further relates to an aerosol-generating article, in particular an aerosol-generating article manufactured using the method. BACKGROUND

[0002] In the manufacture of aerosol-generating products, webs of aerosol-forming substrate, such as tobacco substrate, so-called 'cast leaves', can be used. Cast leaves are manufactured from a tobacco-containing slurry which is spread into a web and dried. The cast leaves thus formed are wound into bobbins for further use, for example for crimping, cutting or collecting and for example into tobacco filter segments. Such tobacco filter segments can in turn be used in consumables for electronic aerosol-generating devices. However, cast leaves tend to be sticky and have a low tensile strength, which complicates handling and can reduce the processing speed of the consumable manufacturing process.

[0003] It is therefore desirable to improve the handling of webs of aerosol-forming substrate, in particular cast leaves. SUMMARY

[0004] According to an aspect of the invention, there is provided a method for supplying a continuous web of aerosol-forming substrate from a bobbin. The method comprises the steps of providing a first bobbin of a continuous web of aerosol-forming substrate and unwinding the continuous web of aerosol-forming substrate from the centre of the first bobbin. Preferably, further steps of the method can comprise preventing rotational movement of the first bobbin during unwinding of the continuous web of aerosol-forming substrate. This can be performed, for example, by keeping the first bobbin stationary while unwinding the continuous substrate from the first bobbin.

[0005] Unwinding the web material from the centre can provide a web having a twisted form. As the continuous web is twisted, crimping or providing an overlying structure to facilitate web shaping or collecting can be omitted. Thus, any mechanical means for crimping or building the continuous web can be omitted, simplifying the equipment build and reducing acquisition and maintenance costs.

[0006] Aerosol-generating articles are manufactured with the twisted web of aerosol-forming substrate, the articles can include porosity due to the twisted nature of the unwound substrate. For example, a rod formed by collecting the unwound substrate can include channels arranged longitudinally along the twisted substrate. This porosity of the aerosol-generating article can be advantageous in terms of aerosol transport through the article. The porosity can also be used to vary the draw resistance in the web of aerosol-forming substrate unwound from the centre of the bobbin or in the aerosol-generating article made from the web.

[0007] With central unwinding, the continuous sheet of aerosol-forming substrate is not pulled parallel from the underlying sheet to the underlying sheet (this corresponds to the direction of rotation of the rotating bobbin). In fact, when unwinding the continuous sheet from the center of the bobbin, the sheet is pulled from the underlying sheet at an angle to said parallel direction (i.e. the direction of the imaginary rotation of the bobbin). Thus, the pulling force is reduced when unwinding from the center compared to the pulling force when pulling the sheet from the outside of the rotating bobbin. This reduced pulling force is particularly advantageous for sticky aerosol-forming substrate, and alternatively or additionally for aerosol-forming substrate with low mechanical properties, such as cast leaves.

[0008] Unwinding the bobbin from its center can also obviate the need to rotate the bobbin. By this, it can not be necessary to rotate or move parts of the apparatus for unwinding the bobbin. In addition, any drive for rotating the bobbin can be omitted. This can further simplify the construction and maintenance of the apparatus. Moreover, the energy consumption and costs of the apparatus can be reduced.

[0009] If the bobbin is not rotated, a larger and heavier bobbin can be used compared to known applications, since the bobbin does not need to be rotated and can even be used if it slightly deformed, e.g. has an oval shape instead of a circular shape.

[0010] With the method according to the application, it is possible to supply the sheet of aerosol-forming substrate from the bobbin faster, thereby increasing the production speed of, e.g., aerosol-generating articles made from or comprising such a sheet of aerosol-forming substrate.

[0011] An "aerosol-forming substrate" is a substrate capable of releasing volatile compounds that can form an aerosol. The volatile compounds can be released by heating or burning the aerosol-forming substrate. As an alternative to heating or burning, in some cases the volatile compounds can be released by a chemical reaction or by a mechanical stimulus such as ultrasound. The aerosol-forming substrate can be a solid. The aerosol-forming substrate can be adsorbed, coated, impregnated or otherwise loaded onto a carrier or support. The aerosol-forming substrate can comprise a botanical material, for example a homogenised botanical material. The botanical material can comprise tobacco, for example a homogenised tobacco material. The aerosol-forming substrate can comprise a tobacco-containing material containing volatile tobacco flavour compounds which are released from the aerosol-forming substrate on heating. The aerosol-forming substrate can alternatively comprise a tobacco-free material. The aerosol-forming substrate can comprise at least one aerosol-former. The aerosol-forming substrate can comprise nicotine and other additives and ingredients, for example flavourants. Preferably, the aerosol-forming substrate is a sheet of tobacco, for example cast leaf tobacco. Cast leaf tobacco is a form of reconstituted tobacco formed from a slurry comprising tobacco particles, fibre particles, aerosol formers, flavourants and a binder. The tobacco particles can be in the form of tobacco dust, the particle size of which is preferably between about 30 microns and 80 microns or 100 microns and 250 microns, depending on the desired sheet thickness and casting gap. The fibre particles can comprise tobacco stem material, stems or other tobacco plant material and other cellulosic fibres, for example wood fibres with a low lignin content. The fibre particles can be selected on a need basis to produce sufficient tensile strength for the cast leaf relative to a low doping rate of, for example, between about 2% and 15%. Alternatively or additionally, fibres such as botanical fibres can be used with the above fibres, or in the alternative, hemp and bamboo.

[0012] Preferably, the sheet of homogenised tobacco material for the aerosol-generating article is formed by a casting process from a slurry comprising particulate tobacco, guar gum, cellulose fibres and glycerol.

[0013] An aerosol former can be added to the slurry forming the cast leaf tobacco. Functionally, the aerosol former should be capable of volatilising within the temperature range in which the cast leaf tobacco is intended to be used in a tobacco product, and facilitate the delivery of nicotine or flavourants or both nicotine and flavourants in an aerosol when the aerosol former is heated above its volatilisation temperature. Preferably, the aerosol former is selected on the basis of its ability to remain chemically stable and to remain substantially stable in the cast leaf tobacco at or around room temperature, but the aerosol former is capable of volatilising at higher temperatures, for example between 40°C and 450°C.

[0014] As used herein, the term aerosol refers to a colloid comprising solid or liquid particles and a gas phase. The aerosol can be a solid aerosol consisting of solid particles and a gas phase or a liquid aerosol consisting of liquid particles and a gas phase. The aerosol can comprise both solid particles and liquid particles in the gas phase. As used herein, both gases and vapours are considered to be gases.

[0015] The aerosol generating substrate can have an aerosol former content of between 5% and 30% by dry weight. In preferred embodiments, the aerosol generating substrate has an aerosol former content of approximately 20% by dry weight.

[0016] Preferably, the aerosol forming substrate comprises an aerosol former.

[0017] As used herein, the term "aerosol former" is used to describe any suitable known compound or mixture of compounds which, in use, facilitates aerosol formation and is substantially resistant to thermal degradation at the operating temperature of the aerosol generating article. Preferably, the aerosol former is polar and is capable of acting as a humectant which is capable of helping to maintain the moisture in the cast leaf tobacco within a desired range. Preferably, the humectant content in the cast leaf tobacco is in the range of between 15% and 35%.

[0018] Suitable aerosol formers are known in the art and include, but are not limited to, polyols, glycol ethers, polyol esters, esters, fatty acids and monohydric alcohols such as methanol and can include one or more of the following compounds: polyols such as propylene glycol; glycerol, erythritol, 1,3-butanediol, tetraethylene glycol, triethylene glycol, triethyl citrate, propylene carbonate, ethyl laurate, triacetin, meso-erythritol, glyceryl diacetate mixture, diethyl suberate, triethyl citrate, benzyl benzoate, benzyl phenyl acetate, ethyl vanillate, glyceryl tributyrate, lauryl acetate, lauric acid, myristic acid and propylene glycol.

[0019] One or more aerosol formers can be combined to take advantage of one or more properties of the combined aerosol formers. For example, triacetin can be combined with glycerol and water to take advantage of the ability of triacetin to transport active components and the humectant properties of glycerol.

[0020] The cast leaf material tends to be sticky and plastically deformable.

[0021] Preferably, the continuous sheet of aerosol forming substrate comprises tobacco material and an aerosol former.

[0022] The thickness of the sheet of aerosol-forming substrate can be between 0.1 mm and 2 mm, preferably between 0.3 mm and 1.5 mm, for example 0.8 mm. Due to manufacturing tolerances, the thickness of the sheet of aerosol-forming substrate can have a deviation of up to about 30%.

[0023] The width of the sheet of aerosol-forming substrate can be selected and adapted according to its application and the manufacturing process of the product comprising one or several sheets of aerosol-forming substrate. Preferably, the more sheets are used for manufacturing the product, the smaller the width of the sheet of aerosol-forming substrate. For example, if only one sheet of aerosol-forming substrate is used, the width of the single sheet can be in the range of 150 mm and 250 mm. It is also possible to manufacture the aerosol-generating article, for example by braiding, using a bobbin of for example two to six, preferably three to four sheets of aerosol-forming substrate, as will be described in more detail below. The width of the sheet of aerosol-forming substrate can then preferably be in the range of 20 mm to 70 mm, more preferably in the range of 25 mm to 45 mm.

[0024] For unwinding the sheet of aerosol-forming substrate, the first bobbin can be arranged in any direction. The first bobbin can for example be arranged such that its axis of rotation is arranged in a horizontal position or in a vertical position or in any position between the horizontal and vertical position. Preferably, the continuous sheet of aerosol-forming substrate is unwound from the first bobbin substantially along its axis of rotation.

[0025] As used herein, by "substantially along the axis of rotation" is meant that the direction of unwinding differs from the direction of the axis of rotation of the bobbin unwinding the continuous sheet by less than about 10 degrees. Preferably, the direction of unwinding and the direction of the axis of rotation of the bobbin correspond to each other.

[0026] Preferably, the axis of rotation of the first bobbin is aligned in a horizontal direction or in a vertical direction. Thereby, the first bobbin is preferably unwound in a horizontal direction or in a vertical direction.

[0027] Arranging and unwinding the bobbins in a horizontal direction can be advantageous in view of the overall horizontal build-up of for example the manufacturing line of the aerosol-generating article. The continuously unwound sheet unwound horizontally can be transported in a horizontal linear direction to for example a rod making machine for forming a rod. Thereby, alignment or deflection elements can be omitted.

[0028] In case of unwinding the spool in a downward vertical direction, gravity can facilitate the unwinding and the transport direction. Unwinding the spool in an upward vertical direction can be facilitated by, for example, an upwardly directed air flow through the center of the vertically arranged spool. If the vertically unwound web is to be further transported or, for example, introduced into a strip manufacturing device in a horizontal position, a deflection element can be provided. The deflection element can deflect the vertically unwound web of aerosol-forming substrate into a horizontal position for further processing of the unwound web.

[0029] The method according to the present application can comprise further steps of providing a second spool of a further continuous material, unwinding the further continuous material from the second spool, and merging the unwound continuous web of aerosol-forming substrate with the unwound further continuous material. Advantageously, the further continuous material is also unwound from the center of the second spool. The second spool can preferably remain fixed or can at least be prevented from rotating while unwinding the further material from the second spool.

[0030] "Merge" as used herein can generally be understood as bringing two or more continuous solids together, wherein continuous solid is used herein to refer to any other continuous material or the continuous web of aerosol-forming substrate. Merging can comprise being brought together adjacently, being intertwined or, for example, being interlaced by braiding. Merging shall also be understood to comprise merging the merged materials, for example merging a strand of material with a strand of continuous solid or another continuous solid.

[0031] Intertwining at least two continuous solids can be performed, for example, by rotating at least two unwound continuous solids around a common rotation axis. For braiding, the supplied unwound continuous solid from the center of the spool does not necessarily need to rotate the spool around its rotation axis. The position of the spool for braiding can be varied depending on the pattern to be braided. The position of the spool can be varied, for example, on a turntable. Such braiding techniques are known from, for example, rope making. However, the techniques can be applied to the present application taking into account the web-like form and the mechanical strength of the continuous solids for merging, in particular, the braiding process.

[0032] "Twist" shall be understood herein as a full rotation of a continuous solid along the longitudinal axis of the continuous solid, in particular the continuous web of aerosol-forming substrate. Twisting is a continuous twisting of the continuous solid in only one rotation direction. Different continuous solids can be twisted in different rotation directions when viewed in the transport direction of the solid. Preferably, twisting comprises at least one full rotation of the continuous solid over a length of 1 meter of the continuous solid.

[0033] The twist can vary depending on the size of the circumference of the centre of the bobbin, so the rotation of the unwound continuous sheet per length varies depending on the size and condition of the bobbin (new bobbin compared to used bobbin). However, the twist differences that can lead to irregularities in the structure and density of the final product made from the twisted sheet can be compensated for by various means. For example, when using several continuous solid sheets, different sizes of bobbins or different conditions of bobbins can be used so that any twist differences can be smoothed along the length of the combined unwound sheets. Another possibility is to slightly rotate the bobbin to compensate for the varying centre circumference of the bobbin. The rotational speed can be varied during the use of the bobbin to preferably keep the twist of the unwound continuous material from the bobbin at a constant level. However, the rotational speed of the bobbin can also be varied during the use of the bobbin to compensate for the varying twist of another bobbin. By this, only one or several bobbins can be provided with a rotation system.

[0034] The other continuous material can be one of a continuous susceptor material, a continuous carrier material or a continuous sheet of aerosol-forming substrate.

[0035] By combining a continuous susceptor material with a continuous sheet of aerosol-forming substrate, an inductively heatable aerosol-forming substrate is formed. Combining the two continuous solids, in particular combining a susceptor material with an aerosol-forming substrate, can provide intimate contact of the two solids. The inductively heatable aerosol-forming substrate formed thereby or the inductively heatable aerosol-generating article containing such an inductively heatable aerosol-forming substrate can have a good heat distribution and a uniform temperature distribution across the cross-section or length of the article.

[0036] Preferably, the other continuous material is a susceptor material, for example a ferromagnetic tape.

[0037] The susceptor material can for example be in the form of a filament, a strip, a sheet or a tape.

[0038] Suitable inductively heatable materials, so-called susceptors, include but are not limited to any material that can be inductively heated to a temperature sufficient to generate an aerosol from an aerosol-forming substrate. Preferred susceptors include metals or carbon. Preferred susceptors can comprise or consist of a ferromagnetic material, for example a ferromagnetic alloy, ferritic iron, or a ferromagnetic steel or stainless steel. Suitable susceptors can be aluminium or comprise aluminium. Preferred susceptors can be heated to a temperature in excess of 250°C.

[0039] The continuous carrier material can be a material that carries an additive, for example a flavourant or an aerosol enhancer. The carrier material can also facilitate the structure or stability of the strand formed by combining a continuous sheet of aerosol-forming substrate with the carrier material and possibly other continuous materials. The carrier material can for example be in the form of a filament, a strip, a sheet or a tape.

[0040] In terms of the composition or porosity of the consolidated strand formed by the two sheets of aerosol-forming substrate or the aerosol-generating article formed with the consolidated strand, other continuous materials in the form of other sheets of aerosol-forming substrate can be advantageous. The two or more aerosol-forming substrates to be consolidated together can be the same or can be different. Due to the twisted form of the unwound substrate, additional porosity can also be introduced to the strand by consolidating two identical (twisted) substrates.

[0041] The consolidation of the two or more continuous solids can be performed, for example, upstream of the rod forming apparatus or any other manufacturing step for forming the aerosol-generating article. The consolidation of the two or more continuous solids can also be performed in the rod forming apparatus. By this, the two or more continuous solids are consolidated by the collecting effect of the appurtenant tongues of this rod forming apparatus.

[0042] As used herein, the terms "upstream" and "downstream" when used to describe the relative position of elements refer to the direction of movement of the continuous sheet of aerosol-forming substrate or other continuous material during the supply and transport process. That is, the continuous solid moves in the downstream direction from the upstream end to the downstream end. Typically, the bobbin is arranged at the upstream end of the supply or handling line.

[0043] To unwind and consolidate the continuous sheet of aerosol-forming substrate and other continuous material, the rotational axes of the first and second bobbins can be aligned on a common axis or can be arranged at an angle.

[0044] If the rotational axis of the first bobbin and the rotational axis of the second bobbin are arranged at an angle, this is preferably done such that the unwound continuous sheet of aerosol-forming substrate and the unwound other continuous material can be consolidated at a consolidation angle of between 5 degrees and 90 degrees. Preferably, the consolidation angle is between 10 degrees and 70 degrees, more preferably between 15 degrees and 45 degrees, for example 30 degrees or 40 degrees.

[0045] The arrangement angle of the rotational axes of the first and second bobbins is preferably the same as the consolidation angle. However, the arrangement angle of the rotational axes of the first and second bobbins can be different from the consolidation angle. This arrangement angle can be, for example, between 0 degrees and 180 degrees. If the arrangement angle is greater than 90 degrees, a deflection means, for example a deflection roller, is preferably provided to deflect either or both of the aerosol-forming substrate or the other material such that the consolidation angle is within the limits indicated above.

[0046] Generally, whenever a value is mentioned throughout this application, this is to be understood such that the value is explicitly disclosed. However, for technical reasons, the value is also to be understood as not necessarily being exactly the specified value. The value can for example include a range of values corresponding to the exact value ± 20 %.

[0047] If the rotational axis of the first spool and the rotational axis of the second spool are aligned on a first common axis, the method can comprise the step of guiding either of the unwound other continuous material or the unwound continuous web of aerosol-forming substrate from the upstream arranged spool through the centre of the downstream arranged spool along the first common axis. Further steps include merging the unwound continuous web of aerosol-forming substrate with the unwound other continuous material, thereby forming a merged strand.

[0048] By guiding the continuous solid unwound from the upstream arranged spool through the centre of the downstream arranged spool, there is no need to re-orient the upstream unwound continuous solid to align the two unwound continuous solids. The merging of the two unwound continuous solids, i.e. the unwound continuous web of aerosol-forming substrate and the unwound other continuous material, can be performed at or immediately next to the centre of the downstream arranged spool. The merged strand thus formed comprises at least two continuous solids unwound from the spools and merged together. The merged strand can comprise several continuous solids merged together, or can comprise two of more than two merged strands as will be described below.

[0049] In case the spools are arranged on a common axis, the unwinding direction and the supply direction preferably correspond to the direction along the common axis.

[0050] Preferably, the continuous web of aerosol-forming substrate or the first spool is arranged downstream of the other continuous material or the second spool, and the other continuous material is guided through the centre of the first spool.

[0051] In some embodiments of the method, the method can comprise the further step of aligning at least one rotational axis of at least one other spool of other continuous material along the first common axis upstream of the first spool and the second spool, guiding the unwound other continuous material from the more upstream arranged spool through the centre of the more downstream arranged spool. Thereby, at least one unwound other continuous material from the at least one more upstream arranged spool is merged with the unwound other continuous material from the more downstream arranged spool and the unwound continuous web of aerosol-forming substrate or the merged strand.

[0052] In case the at least one other spool is arranged on the first common axis, the unwinding and the supply direction preferably correspond to the direction along the first common axis.

[0053] The other continuous material from the at least one other spool is preferably unwound from the centre of the at least one other spool. The at least one other spool preferably remains stationary or is preferably at least prevented from rotating while the other continuous material is unwound from the at least one other spool.

[0054] The at least one other tube can comprise the same or different continuous solid as the first and second tubes. For example, the at least one other tube can comprise a continuous sheet of aerosol-forming substrate or a continuous susceptor material or carrier material.

[0055] Preferably, the most downstream arranged tube is the first tube or a tube comprising a continuous sheet of aerosol-forming substrate. Preferably, the tube with aerosol-forming substrate and the tube comprising a different continuous solid (different from aerosol-forming substrate) are arranged in an alternating fashion.

[0056] The continuous sheets of aerosol-forming substrate on the different tubes can be the same, e.g. in composition and density. Preferably, the continuous sheets of aerosol-forming substrate on the different tubes differ in at least one of composition, porosity or sheet dimensions, e.g. sheet thickness or width.

[0057] The method according to the present application can further comprise the step of providing one or several additional tubes of further continuous material at an angle to the first common axis. The unwound further continuous material from the one or several additional tubes is merged with the merged strand at a merging angle between 5 and 90 degrees.

[0058] If several additional tubes are provided, the rotation axes of the several additional tubes are preferably aligned on a second common axis. If the additional tubes are arranged on a second common axis, preferably the continuous solid from the tube arranged upstream is guided through the centre of the tube arranged downstream.

[0059] If two or more additional tubes are provided at an angle to the first common axis, preferably an additional merged strand is formed with the continuous solid unwound from the two or more additional tubes. The additional merged strand can then be merged with the merged strand, rather than merging the individual unwound continuous solids.

[0060] Preferably, the merging angle is chosen to provide sufficient space for arranging tubes of different sizes next to each other.

[0061] Preferably, the further continuous material from the one or several additional tubes is unwound from the centre of the tube. The one or several additional tubes are preferably held fixed or at least prevented from rotating, while the further continuous material is unwound from the one or several additional tubes.

[0062] The further continuous material on the one or several additional tubes can be the same as the material on the first and second tubes and on the other tubes arranged on the first common axis. Preferably, the further continuous material on the one or several additional tubes is a sheet of aerosol-forming substrate, a susceptor material or a carrier material.

[0063] The method according to the present application can be used for manufacturing aerosol- generating articles, preferably tobacco-containing aerosol-generating articles. One or several unwound continuous solids or one or several consolidated strands can be supplied to, for example, a rod forming apparatus to form, for example, a tobacco-containing rod. Preferably, the method according to the present application is used for manufacturing inductively heatable aerosol-generating articles.

[0064] The specific supply of continuous solids, in particular of several continuous solids, allows for manufacturing different patterned geometrical arrangements in the longitudinal direction as well as in the cross-section of the aerosol-forming article. By this, the structure of the aerosol-forming article can have physical properties not available in prior art articles. For example, several continuous solids can be intertwined or braided, for example, like a rope. Such a structure can have specific physical properties. It can, for example, have a certain elasticity. In addition, susceptor material or flavour or other materials can also be incorporated uniformly in the aerosol-generating article with a repeatable consistent pattern of susceptor material and other materials consolidated with each other.

[0065] According to another aspect of the present application, there is provided an aerosol- generating article for use in an aerosol-generating device, for example, an electronic heating device. The aerosol-generating article comprises a twisted sheet of aerosol-forming substrate. Preferably, the twisted sheet of aerosol-forming substrate is a compressed twisted sheet of aerosol-forming substrate. The sheet of aerosol-forming substrate is twisted along the longitudinal direction of the aerosol-generating article, wherein the twisting is in the same rotational direction along the longitudinal direction of the article. The twisting can be carried out in the aerosol-generating article such that the sheet of aerosol-forming substrate is rotated by at least 5 degrees along the longitudinal direction of the article, preferably by at least 10 degrees over the length of the aerosol-generating article.

[0066] The aerosol-generating article can comprise one or several other materials, preferably one or several twisted other materials. Preferably, the aerosol-generating article comprises one other material, more preferably one twisted other material. Preferably, the one or several other materials is a sheet of continuous material, preferably a twisted sheet, for example, a portion of a tape or a twisted tape. However, the other material can also be a filament, a rod or a needle.

[0067] The aerosol-generating article according to the present application can comprise a portion of a consolidated strand, the consolidated strand comprising a sheet of aerosol-forming substrate and comprising an other twisted material, wherein the consolidated strand can be manufactured using the method according to the present application and as described herein for supplying a continuous sheet of aerosol-forming substrate.

[0068] The aerosol-generating article can further comprise a portion of at least one additional consolidated strand, wherein the at least one additional consolidated strand comprises a twisted sheet of aerosol-forming substrate.

[0069] Preferably, the aerosol-generating article comprises an intertwined or braided structure. The intertwined or braided structure extends along the length of the aerosol-generating article.

[0070] Preferably, the other material is a susceptor material, preferably a susceptor ribbon, thereby forming an aerosol-generating article that can be inductively heated.

[0071] Further aspects and advantages of the aerosol-generating article have been mentioned in relation to the method according to the present application and will not be repeated. In particular, the selection and arrangement of the different continuous solids can be chosen according to the needs of the user or according to the aerosol-generating properties or consumption experience that is desired. BRIEF DESCRIPTION OF DRAWINGS

[0072] The present application is further described with respect to embodiments which are illustrated by means of the following drawings in which:

[0073] Figure 1 showing a spool of a continuous sheet of aerosol-forming substrate being unwound centrally in a horizontal direction;

[0074] Figure 2 showing a spool of a continuous sheet of aerosol-forming substrate being unwound centrally in a vertical direction;

[0075] Figure 3 showing the supply of aerosol-forming substrate and other material at an angle;

[0076] Figure 4 illustrating the manufacture of two merged strands of continuous solids, wherein the two strands are merged together at an angle;

[0077] Figure 5 showing the supply of aerosol-forming substrate and other material along a common axis;

[0078] Figure 6 illustrating the manufacture of a merged strand by supplying three continuous solids along a common axis. DETAILED DESCRIPTION

[0079] In Figure 1 In Fig. 1, a continuous sheet of aerosol-forming substrate 10, such as a continuous sheet of nicotine- or tobacco-containing aerosol-forming substrate, is unwound from the centre 11 of a spool 1. The spool 1 is arranged with its axis of rotation 12 oriented in a horizontal direction. The direction of unwinding 100 of the sheet of aerosol-forming substrate 10 corresponds to the horizontal direction. The unwound sheet of aerosol-forming substrate 10 is transported in a straight line in the horizontal direction to a rod making machine 9. The sheet of aerosol-forming substrate 10 enters an appendage 90 of the rod making machine 9, where it is collected and formed into a rod shape.

[0080] During the unwinding of sheet 10, the bobbin 1 is preferably kept fixed, such that the unwinding sheet has a twisted form, i.e., the sheet rotates about its longitudinal axis or along the unwinding direction. A complete twist then corresponds to a 360-degree rotation of the sheet about its longitudinal axis and to one unwinding of the sheet about the circumference of the center 11 of the bobbin 1.

[0081] Figure 2 Showing with Figure 1 The same arrangement is used, but the tube 1 is arranged such that its axis of rotation 12 is oriented vertically. The sheet of aerosol forming matrix 10 is unwound downwards in the vertical direction 101 and guided into the auxiliary tongue 90 of the strip-making machine 9. Figure 2 In the embodiment shown, gravity facilitates the unwinding. In addition to inserting the sheet of aerosol forming matrix 10 in a straight line into the auxiliary tongue 90, it also supports the alignment of the sheet 10 with the auxiliary tongue 90.

[0082] Figure 3 A method for manufacturing a strip-shaped article comprising a sheet of aerosol forming matrix 10 and other continuous materials is shown. The sheet of aerosol forming matrix 10 and the sheet of other continuous materials 20, such as continuous strip sensor material, are supplied from the centers 11, 21 of two tubes 1, 2.

[0083] Two continuous solids 10 and 20 are transported to an auxiliary tongue 90, where they are joined together. The two continuous solids are supplied to the auxiliary tongue 90 at a joining angle of 68. Figure 3 In the middle, the merging angle 68 is approximately 30 to 45 degrees, depending on the arrangement and size of the cylinders 1 and 2.

[0084] In the unwinding and transporting direction 200, the sheet forming the aerosol matrix 10 is unwound from the center 11 of the bobbin 1. In the unwinding and transporting direction 201, the sheet of other material 20 is unwound from the center 21 of the bobbin 2. The two unwinding directions 200 and 201 cover angles corresponding to the merging angle. Figure 3 In this context, the merging angle 68 corresponds to the arrangement angle of the cylinder 1 of the aerosol forming matrix and the cylinder 1 of other continuous materials. This is because the two continuous solids are unwound in a linear direction parallel to the rotation axes 12 and 22 of the corresponding cylinders 1 and 2.

[0085] The arrangement angle of the tubes 1 and 2 can be less than or greater than the merging angle 68, and can be, for example, in the range of 5 degrees to 160 degrees.

[0086] Figure 5A continuous sheet of aerosol forming matrix 10 and a continuous sheet of other material 20 are shown, supplied along a horizontally arranged common axis 70. A tube 2 of the other material is arranged upstream of the tube 1 of the aerosol forming matrix. The axes of rotation 12 and 22 of the two tubes 1 and 2 are arranged parallel to the common axis 70. A sheet of other material 20, such as a strip sensor material, is unwound from the center of the tube 2. The unwound sheet of other material 20 is guided downstream along the common axis 70 through the center 11 of the tube 1, which is further downstream of the aerosol forming matrix. A sheet of aerosol forming matrix 10 is unwound from the center 11 of the tube 1 and merged with the unwound sheet of other material 20. The sheet of aerosol forming matrix 10 and the sheet of other material 20 form a combined thread 60. The combined thread 60 is then further guided along the common axis 70 into an auxiliary tongue 90 of a strip manufacturing machine 9, in which a strip is formed from the combined thread.

[0087] Figure 6 Show Figure 5 The method involves arranging three tubes 3, 4, and 5 sequentially, preferably at equal intervals along a common axis 71. The unwound solid from the three tubes 3, 4, and 5 forms a wire 61 comprising three continuous solid sheets.

[0088] Compared to Figure 5 In the method shown, other bobbins 5 of the aerosol forming matrix are arranged upstream of bobbins 4 of other continuous materials. The aerosol forming matrix is ​​unwound from bobbins 5 and guided along a common axis 71 through the center 41 of bobbins 4. There, the unwound sheet of the aerosol forming matrix 50 merges with the unwound sheet of the other materials 40. This portion of the thread is further guided downstream through the center 31 of bobbins 3 and merged with the unwound sheet of the aerosol forming matrix 30 unwound from bobbins 3.

[0089] In a series of tubes, tubes of other continuous materials are preferably arranged in an alternating manner with similar or identical materials. Similar or identical materials can be, for example, two identical or different aerosol-forming matrices or two identical or different receptor materials. In a series of tubes, all tubes can comprise completely different solids. For example, a series of three tubes can comprise an aerosol-forming matrix, a receptor material, and a carrier material, such as a flavor carrier material.

[0090] exist Figure 4 In the middle, it is shown that the use is based on Figure 5 and Figure 6 The manufacturing process of two combined wire materials 60, 61 formed by the method shown and described herein.

[0091] exist Figure 4In the example shown in Fig. 1 1, the two consolidated strands 60, 61 are consolidated at a consolidation angle 68, e.g. 30 to 70 degrees, as the two consolidated strands 60, 61 enter the adjunct tongue 90 of the rod making machine 9. Thus, the rod article made in the rod making machine 9 is formed from the two consolidated strands 60, 61 and a total of five continuous solids, e.g. five different continuous solids, at least one of which is a continuous sheet of aerosol-forming substrate. In Figure 4 In the example shown in Fig. 1 1, the first strand 60 preferably comprises a sheet of aerosol-forming substrate 10 and a tape susceptor material 20, while the second strand 61 preferably comprises two sheets of aerosol-forming substrate 30, 50 and a tape susceptor material 40.

[0092] In the example shown in Fig. 1 1, the two consolidated strands 60, 61 are consolidated at a consolidation angle 68, e.g. 30 to 70 degrees, as the two consolidated strands 60, 61 enter the adjunct tongue 90 of the rod making machine 9. Thus, the rod article made in the rod making machine 9 is formed from the two consolidated strands 60, 61 and a total of five continuous solids, e.g. five different continuous solids, at least one of which is a continuous sheet of aerosol-forming substrate. In Figure 4 In the example shown in Fig. 1 1, the two consolidated strands 60, 61 are consolidated at a consolidation angle 68, e.g. 30 to 70 degrees, as the two consolidated strands 60, 61 enter the adjunct tongue 90 of the rod making machine 9. Thus, the rod article made in the rod making machine 9 is formed from the two consolidated strands 60, 61 and a total of five continuous solids, e.g. five different continuous solids, at least one of which is a continuous sheet of aerosol-forming substrate. In

[0093] Preferably, in all the described methods shown in the figures and variants thereof, the continuous solids are unwound from the centre of the bobbins.

[0094] Preferably, in all the described methods shown in the figures and variants thereof, all the bobbins remain stationary while the continuous solids are unwound from the bobbins. In this context, remaining stationary is to be understood in terms of rotation about the rotational axis of the bobbins. However, the bobbins can remain completely stationary, or can for example be moved so as to twist, entangle or weave the unwound continuous solids with each other (while the bobbins preferably do not rotate about their rotational axis).

[0095] Preferably, the continuous solids on different bobbins are different, e.g. in terms of composition, size or shape. In particular, if two or more sheets of aerosol-forming substrate are used to make the consolidated strands or rod articles, preferably the two or more sheets of aerosol-forming substrate are different, e.g. different in terms of composition, size or aerosolisation characteristics.

Claims

1. A method for supplying a continuous web of aerosol-forming substrate from a bobbin, the method comprising: providing a first bobbin of a continuous web of aerosol-forming substrate; and unwinding the continuous web of aerosol-forming substrate from the centre of the first bobbin; providing a second bobbin of a further continuous material, wherein the further continuous material comprises one of a susceptor material or a continuous carrier material; unwinding the further continuous material from the centre of the second bobbin; merging the unwound continuous web of aerosol-forming substrate with the unwound further continuous material, the method further comprising the steps of: aligning the rotational axis of the first bobbin and the rotational axis of the second bobbin along a first common axis; guiding the unwound further continuous material or the unwound continuous web of aerosol-forming substrate from an upstream arranged bobbin through the centre of a downstream arranged bobbin along the first common axis; and merging the unwound continuous web of aerosol-forming substrate with the unwound further continuous material thereby forming a merged strand.

2. The method according to claim 1, further comprising the step of preventing the first bobbin from undergoing rotational motion during unwinding of the continuous web of aerosol-forming substrate.

3. The method according to claim 1 or 2, wherein the continuous web of aerosol-forming substrate comprises a tobacco material and an aerosol-forming agent.

4. The method according to claim 1 or 2, further comprising the step of aligning the rotational axis of the first bobbin in a horizontal or vertical direction and unwinding the first bobbin in a horizontal or vertical direction.

5. The method according to claim 1 or 2, further comprising the steps of: aligning at least one rotational axis of at least one further bobbin of further continuous material upstream of the first bobbin and the second bobbin in such a way that the at least one rotational axis is aligned along a first common axis; guiding the unwound further continuous material from a more upstream arranged bobbin through the centre of a more downstream arranged bobbin; merging at least one unwound further continuous material from at least one more upstream arranged further bobbin with the unwound further continuous material and the unwound continuous web of aerosol-forming substrate from the more downstream arranged bobbin.

6. The method according to claim 1 or 2, further comprising the steps of: providing and arranging one or more additional bobbins of further continuous material in such a way that their rotational axis is at an angle to the first common axis, and merging the unwound further continuous material from the one or more additional bobbins with the merged strand at a merging angle of between 5 degrees and 90 degrees.

Images