Aerosol generating segments and aerosol generating articles including these segments

Abstract

An aerosol-generating segment includes a strip-shaped receptor shell (1) and an aerosol-forming gel (2) contained within the strip-shaped receptor shell. The receptor shell includes a bottom (11), corrugated sidewalls (12), and an opening (13) arranged opposite to the bottom. The aerosol-forming gel is held inside the receptor shell by at least one active locking device (126) along the axial direction of the aerosol-generating segment.

Description

Technical Field

[0001] This disclosure relates to an aerosol generating segment for use in an aerosol generating article. In particular, this disclosure relates to an inductively heated aerosol generating segment that includes an aerosol-forming gel. Background Technology

[0002] Aerosol-generating articles comprising several segments arranged in an end-to-end position are known. One of the segments may be a segment comprising an aerosol-forming matrix and a receptor for heating the aerosol-forming matrix.

[0003] It is desirable to provide an aerosol-generating segment for use in an inductively heated aerosol-generating article, wherein the segment comprises an aerosol-forming matrix in the form of a gel. Summary of the Invention

[0004] According to the present invention, an aerosol-generating segment is provided, comprising a strip-shaped receptor shell and an aerosol-forming gel contained within the strip-shaped receptor shell. The receptor shell includes a bottom, sidewalls, and an opening arranged opposite to the bottom. The aerosol-forming gel is held inside the receptor shell by at least one active locking device along the axial direction of the aerosol-generating segment.

[0005] Aerosol-forming matrices in gel form have the advantage of being able to provide matrices of virtually any shape. However, because the gel itself is airtight, any evaporation of the gel can put pressure on any remaining gel that has not yet evaporated. For example, if a gel rod is heated at one end of a rod, the entire rod may be forced out of its position. However, providing the aerosol-forming matrix in gel form within a shell has several advantages. The gel can, for example, be filled into the shell in liquid form and thus can be in close contact with the shell. Consequently, heat transfer from the shell to the aerosol-forming gel is very direct and optimized. The shell, also made of sensor material, can be directly heated via induction heating in an energy-efficient manner, eliminating the need for additional materials or space for wires or resistance heaters.

[0006] Especially since aerosol-generating articles, including strip-shaped aerosol-generating segments, are typically discarded after use, the shell is generally as open as possible to use as little material as possible. Furthermore, the shell needs to be open to fill the shell or at least to allow the gel to evaporate and exit. An active locking device located in or on the shell, acting axially on the aerosol-forming gel, allows the aerosol-forming gel to be retained within the shell. For example, when the shell is heated at its bottom, the gel evaporates at the bottom end of the shell. The generated vapor then tends to push the remaining unevaporated gel axially out of the shell through an opening in the shell arranged opposite the bottom. The active locking device located in the shell retains this unevaporated gel within the shell.

[0007] The active locking device can be arranged in various positions on or inside the shell, and can also be designed in various shapes to achieve a holding effect along the axial direction of the aerosol generating segment.

[0008] Preferably, at least one of the at least one active locking device is designed as an inwardly pointing seam of the receptor housing. In particular, at least one active locking device may form an inwardly arranged flange of the housing. The seam may be arranged adjacent to an end section of the receptor housing, the end section being arranged opposite to the bottom of the receptor housing.

[0009] Preferably, the active locking device in the form of a seam is formed by an inwardly bent end portion of the sidewall of the receptor shell. From a manufacturing point of view, the inwardly bent end portion of the sidewall is advantageous because it eliminates the need to attach additional seams or flanges to the shell. Furthermore, there is no risk of accidental leakage between the shell and the separately attached seam. Additionally, the shell may be (e.g., formed with) a gel filling and then partially closed by simply bending the end portion of the shell wall inwardly radially.

[0010] Preferably, at least one of the at least one active locking device is designed as a radially inwardly pointing protrusion. The radially inwardly pointing protrusion has a radial extension in the circumferential direction of the sensor housing, said radial extension being larger than the longitudinal extension of the protrusion in the longitudinal direction of the sensor housing. The radially inwardly pointing protrusion preferably forms one or more ribs arranged circumferentially along the inner sidewall of the housing.

[0011] A radially inwardly pointing protrusion may, for example, be formed by a thicker sidewall at the location of the protrusion. A radially inwardly pointing protrusion may, for example, be formed by a partially deformed shell.

[0012] Preferably, the radially inwardly pointing protrusion is a radially inwardly pointing deformation of the sidewall of the receptor shell. The deformation of the sidewall may exist in the shell before it is filled, or it may occur after the shell has been filled, for example, together with the inwardly pointing seam at the open end of the shell.

[0013] The protrusion can be located anywhere along the length of the shell. Preferably, the protrusion is located between half the height of the shell and the opening of the shell. Preferably, the radially inward-pointing protrusion is located in the middle section of the sidewall of the receptor shell.

[0014] The intermediate section may extend substantially between the two extremes of the shell, thus extending between the bottom of the shell and the open end. The intermediate section preferably extends within about 20% to about 95% of the shell's length, more preferably between about 30% and about 90% of the shell's length, for example, between about 40% and about 60% of the shell's length.

[0015] The active locking device preferably includes a plurality of protrusions. These protrusions may be arranged at a distance from each other, for example, along the length of the shell. The protrusions may be arranged, for example, at different circumferential positions. Alternatively or additionally, the protrusions may be arranged opposite each other, for example, at the same longitudinal length position of the shell.

[0016] At least one active locking device may be provided in one, two, three, four, or more sectors of the receptor housing. At least one active locking device may be, for example, a continuous protrusion, such as a continuous rib arranged along the circumference of the receptor housing. At least one active locking device may be, for example, a discontinuous protrusion, such as a discontinuous rib arranged along the circumference of the receptor housing.

[0017] At least one active locking device is preferably located in the circumferential range of at least 5 degrees, 10 degrees, 15 degrees, 20 degrees, 30 degrees, 40 degrees, 45 degrees or at most 20 degrees, 30 degrees, 40 degrees, 45 degrees, 50 degrees, 60 degrees, 70 degrees, 80 degrees, 90 degrees or 180 degrees in each sector.

[0018] Preferably, at least one of the at least active locking devices is arranged along the entire circumference of the receptor housing, particularly along the entire circumference of the sidewall of the receptor housing.

[0019] At least one active locking device may be arranged, for example, sequentially or continuously along the entire length of the shell. For example, at least one active locking device may be formed from a portion of a sidewall or from an entire sidewall that converges radially inward from the bottom of the shell to the opening of the shell. The shell may, for example, be formed as a truncated hollow cone. The shell may, for example, have a folded sidewall structure, wherein some of the folds or corrugations converge radially inward continuously. The converging sidewalls form the active locking device, which is configured to act along the entire length of the shell, serving as a retainer for aerosol gel formation along the longitudinal direction of the shell. Preferably, the corrugations converge radially inward toward the opening of the receptor shell. Preferably, some corrugations, such as one-third, half, or all of the corrugations converge radially inward toward the opening of the receptor shell.

[0020] The aerosol-forming gel can be held in the tube by at least one active locking device, wherein there is a gap in the longitudinal direction of the receptor shell. For example, a gap may exist when the shell is not completely filled with the aerosol-forming gel. The gap then extends between the gel filling level and the active locking device. The filling level may, for example, be at about half or three-quarters of the length of the shell, while the active locking device may, for example, be located at or near the open end of the shell.

[0021] The aerosol-forming gel can be secured in its position within the receptor shell by at least one active locking device. Thus, the aerosol-forming gel can be secured in its position without gaps. For example, the shell can be completely filled with the aerosol-forming gel. Alternatively, the aerosol-forming gel can be secured in its position by an active locking device arranged along the length of the shell. Therefore, the active locking device can be located in the middle section of the shell between the bottom of the shell and the gel filling level. For example, the gel can be filled to approximately three-quarters of the shell's capacity, and the active locking device can be arranged between the bottom of the shell and three-quarters of the shell's capacity, preferably at approximately half the length of the shell.

[0022] The sidewalls of the receptor shell may be made of receptor material. The bottom of the receptor shell may be made of receptor material. Preferably, at least a portion of the bottom of the shell and a portion of the sidewalls are made of receptor material. More preferably, the entire bottom and the entire sidewalls of the shell are made of receptor material.

[0023] The bottom of the receptor housing may be open or closed. For example, the bottom may include one or more openings, for example, for airflow to enter the housing through the bottom opening.

[0024] Preferably, the bottom of the receptor shell is closed.

[0025] The sidewalls of the receptor shell can be flat. Alternatively, the sidewalls of the receptor shell can be corrugated. Preferably, the corrugations are aligned along the longitudinal direction of the receptor shell. The corrugations enlarge the overall surface area of ​​the receptor, thereby increasing the contact surface between the aerosol-forming gel and the receptor material.

[0026] Preferably, the sidewalls of the receptor shell are cylindrical. The cylinder may have a circular or non-circular cross-section.

[0027] The bottom and sidewalls of the receptor shell may comprise the same thickness or the same material. Preferably, the bottom and sidewalls of the receptor shell are made of the same receptor material.

[0028] Preferably, the bottom and sidewalls of the receptor shell are manufactured as a single piece. For example, the bottom and sidewalls are folded from the same sheet of receptor material.

[0029] The bottom can have a circular cross-section, or for example, it can be a polygon.

[0030] The bottom and sidewalls of the receptor shell may include different thicknesses or different materials.

[0031] The receptor shell or a portion thereof may be made of any receptor material suitable for forming a strip-shaped shell containing an aerosol-forming gel, wherein the shell containing the gel is part of or forms an aerosol-generating strip segment. Preferably, the receptor shell comprises or is made of aluminum or stainless steel.

[0032] Preferably, the receptor shell is formed of a receptor material sheet with a thickness between 5 micrometers and 80 micrometers, more preferably between 8 micrometers and 50 micrometers.

[0033] Preferably, the aerosol-forming gel is a gel rod. The gel rod can be formed before being inserted into the shell. The gel rod can be formed in the shell, for example, by filling the shell with a liquid aerosol-forming gel and then allowing the gel to solidify. The gel rod can be inserted into the shell before forming at least one active locking device.

[0034] The filling height of the aerosol-formed gel can be at least 30%, 40%, 50%, 60%, 70%, 80% or at most 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, or 99% of the receptor shell.

[0035] Preferably, the aerosol-forming gel is completely contained within the receptor shell.

[0036] Preferably, the aerosol-forming gel comprises a curable material.

[0037] Preferably, the aerosol-forming gel comprises a thermally reversible material.

[0038] Aerosol-forming gels may include a gelling agent. Preferably, the aerosol-forming gel includes a gelling agent in an amount between 0.5% and 5% by weight, for example, between 0.7% and 2% by weight or between 0.8% and 1% by weight.

[0039] The aerosol-forming segments can be substantially cylindrical in shape. The aerosol-forming segments are generally elongated. The aerosol-forming segments also have a certain length and a circumference that is substantially perpendicular to said length.

[0040] The diameter of the aerosol-generating segment is approximately equal to the diameter of the aerosol-generating article. Preferably, the aerosol-generating segment has a diameter between 5 mm and 10 mm. More preferably, the diameter of the aerosol-generating segment is greater than 5 mm, for example, between 6 mm and 8 mm. The aerosol-generating segment has a certain length, which can be defined as the dimension along the longitudinal axis of the aerosol-generating article. The length of the aerosol-generating segment can be between 5 mm and 20 mm, for example, between 6 mm and 16 mm, or between 7 mm and 12 mm, for example, 7 mm. Preferably, the aerosol-generating segment is substantially cylindrical.

[0041] The present invention also relates to an aerosol generating article, particularly an induction-heatable aerosol generating article, comprising a plurality of segments arranged end-to-end and packaged in packaging material to form a strip. The plurality of segments include aerosol generating strip segments as described in this application.

[0042] Multiple segments may include one or more hollow tubes, spacer elements, airflow guiding elements, cavities, second sensor housing elements, aerosol cooling elements, and filter segments.

[0043] Preferably, the plurality of segments include at least one of a hollow tube, a filter segment, an airflow guiding element, and a cavity.

[0044] The aerosol generating article may include a mouthpiece element. The mouthpiece element may be located at the inlet or downstream end of the aerosol generating article.

[0045] The mouthpiece element may include at least one filter segment. The filter segment may be a cellulose acetate filter segment made of cellulose acetate tow. In one embodiment, the filter segment is 6 mm long, but may have a length between 4 mm and 14 mm.

[0046] The aerosol generating article may include a support element that is located directly downstream of and adjacent to the aerosol generating segment.

[0047] The support element can be formed from any suitable material or combination of materials. For example, the support element can be formed from one or more materials selected from the group consisting of: cellulose acetate, cardboard, crimped paper such as crimped heat-resistant paper or crimped parchment, and polymeric materials such as low-density polyethylene (LDPE). In a preferred embodiment, the support element is formed from cellulose acetate.

[0048] The support element may include a hollow tubular element. In a preferred embodiment, the support element includes a hollow cellulose acetate tube.

[0049] Preferably, the outer diameter of the support element is approximately equal to the outer diameter of the aerosol-generated product.

[0050] The support element may have an outer diameter between 5 mm and 12 mm, for example, between 5 mm and 10 mm or between 6 mm and 8 mm. In a preferred embodiment, the support element has an outer diameter of 7.2 mm plus or minus 10%. The support element may have a length between 5 mm and 15 mm. In a preferred embodiment, the support element has a length of 8 mm. The support element may have a wall thickness between 1.5 mm and 2 mm, preferably between 1.6 mm and 1.8 mm.

[0051] Aerosol-generating articles may include thin support elements. The thin support elements may have an outer diameter between 5 mm and 12 mm, for example, between 5 mm and 10 mm or between 6 mm and 8 mm. In a preferred embodiment, the thin support element has an outer diameter of 7.2 mm plus or minus 10%. The thin support element may have a length between 5 mm and 15 mm. In a preferred embodiment, the thin support element has a length of 8 mm. The thin support element may have a wall thickness between 0.5 mm and 1 mm, preferably between 0.6 mm and 0.9 mm.

[0052] Aerosol generating articles may include aerosol cooling elements. The aerosol cooling elements may be located downstream of the aerosol generating segment; for example, the aerosol cooling elements may be directly downstream of and adjacent to a support element.

[0053] The aerosol cooling element may be located between the support element and the nozzle, which is located at the downstream end of the aerosol-generated article.

[0054] As used herein, the term "aerosol cooling element" describes an element having a large surface area and low suction resistance. In use, an aerosol formed from volatile compounds released from the aerosol forming matrix is ​​drawn through the aerosol cooling element before being delivered to the port of the aerosol generating article. Aerosol cooling elements have low suction resistance compared to filters, such as those formed from fiber bundles, which have high suction resistance. Chambers and cavities within the aerosol generating article, such as expansion chambers and support elements, are also not considered aerosol cooling elements.

[0055] Preferably, the aerosol cooling element has a porosity greater than 50% in the longitudinal direction. Preferably, the airflow path through the aerosol cooling element is relatively unimpeded. The aerosol cooling element can be an aggregated sheet or a rolled and aggregated sheet. The aerosol cooling element may include sheets selected from the group consisting of: polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polylactic acid (PLA), cellulose acetate (CA), and aluminum foil, or any combination thereof.

[0056] In a preferred embodiment, the aerosol cooling element comprises an aggregate sheet of a biodegradable material. For example, an aggregate sheet of non-porous paper or an aggregate sheet of a biodegradable polymeric material, such as polylactic acid or Mater-Bi. Grade (a series of commercially available starch-based copolyesters).

[0057] Preferably, the aerosol cooling element comprises PLA sheet, more preferably a rolled, aggregated sheet of PLA. The aerosol cooling element can be formed from a sheet with a thickness between 10 μm and 250 μm, said thickness being, for example, 50 μm. The aerosol cooling element can be formed from an aggregated sheet with a width between 150 mm and 250 mm. The specific surface area of ​​the aerosol cooling element can be 300 mm per mm of length. 2 With a length of 1000mm per mm 2 Between and at 10 mm per mg weight 2 With 100 mg per 100 mm 2 In some embodiments, the aerosol cooling element may be formed from an aggregated sheet of material having a specific surface area of ​​approximately 35 mm² per mg of weight. 2 The outer diameter of the aerosol cooling element can be between 5mm and 10mm, for example, 7mm.

[0058] In some preferred embodiments, the length of the aerosol cooling element is between 10 mm and 15 mm. Preferably, the length of the aerosol cooling element is between 10 mm and 14 mm, for example, 13 mm.

[0059] In an alternative embodiment, the length of the aerosol cooling element is between 15 mm and 25 mm. Preferably, the length of the aerosol cooling element is between 16 mm and 20 mm, for example, 18 mm.

[0060] Preferably, the aerosol generating strip segment is arranged between the hollow acetic acid tube and the filter segment.

[0061] Aerosol-generating articles can be substantially cylindrical in shape. Aerosol-generating articles can be substantially elongated. Aerosol-generating articles can have a length and a circumference substantially perpendicular to said length.

[0062] The aerosol-generated article may have a total length between 30 mm and 100 mm. In a preferred embodiment, the aerosol-generated article has a total length between 40 mm and 55 mm, for example, 42-52 mm.

[0063] The outer diameter of the aerosol-generated article can be between 5 mm and 12 mm, for example, between 6 mm and 8 mm. In a preferred embodiment, the aerosol-generated article has an outer diameter of 7.2 mm plus or minus 10%.

[0064] This invention also relates to a method for manufacturing aerosol-forming segments. The method includes:

[0065] A strip-shaped receptor shell is provided, including a bottom, sidewalls and an opening opposite the bottom. An aerosol-forming gel is filled into the receptor shell. At least one shape-locking device is provided in the aerosol-forming strip segment to retain the aerosol-forming gel inside the receptor shell.

[0066] At least one shape-locking device may be provided before or after the aerosol-forming gel has been filled into the receptor shell. Preferably, the method includes providing at least one shape-locking device in the aerosol-generating strip segment after the receptor shell has been filled with the aerosol-forming gel.

[0067] As described in the aerosol generation section, the shape-locking device can have different forms and locations. Preferably, the method includes forming at least one shape-locking device by radially inwardly bending at least some portions of the sidewalls of the receptor shell. These portions can be end portions or middle portions of the sidewalls. Thus, the shape-locking device can be arranged at an opening in the shell or at one or more locations along the length of the shell.

[0068] The portion of the sidewall that bends inward is a very simple means of manufacturing an active shape-locking device for maintaining aerosol gel formation in the axial direction within the shell.

[0069] Depending on the filling method and the viscosity of the aerosol-formed gel, active locking formation can be performed either before or after filling the shell.

[0070] Preferably, the aerosol-forming gel is cured after it has been filled into the receptor shell.

[0071] Preferably, the method includes an end portion of the inwardly bent sidewall, thereby defining the size of the opening in the receptor shell. Such active locking devices are particularly advantageous when the locking device directly and partially closes the shell. Such active locking devices are advantageous when they are independent of the filling height of the gel within the shell. Additionally, the size of the active locking device can be varied by changing the length of the inwardly bent end portion.

[0072] The method may include providing corrugations in the sidewalls of the receptor shell. By providing corrugations, the surface of the receptor shell and the contact surface between the receptor and the aerosol-forming gel can be enhanced by having the same circumferential size for both the shell and the aerosol-forming segments.

[0073] Preferably, the corrugations extend from the bottom of the receptor housing to the opening, and thus extend along the entire length of the sidewall of the receptor housing.

[0074] The method may include forming at least one shape-locking device by forming a radially inwardly pointing protrusion in the sidewall of the receptor housing.

[0075] Preferably, the aerosol generating strip segment manufactured according to the method of the present invention is an aerosol generating strip segment according to the present invention and as described herein.

[0076] As used herein, the term "receptor" refers to a material that can convert electromagnetic energy into heat. When located within a fluctuating electromagnetic field, eddy currents are typically induced and hysteresis losses occur within the receptor, causing heating of the receptor. Because the receptor material is in direct physical and thermal contact with the aerosol-forming gel, the aerosol-forming gel is heated by the receptor material.

[0077] The sensor can be formed from any material capable of being inductively heated to a temperature sufficient to generate aerosols from a solid aerosol-forming matrix and an aerosol-forming liquid. Preferred sensors include metals or carbon. Preferred sensors may comprise or be composed of ferromagnetic materials, such as ferromagnetic alloys, ferritic iron, or ferromagnetic steel or stainless steel. Suitable sensors may be aluminum or include aluminum. Preferred sensors may be made of 300 or 400 series stainless steel, such as grade 410, 420, or 430 stainless steel. Different materials will consume different amounts of energy when positioned within an electromagnetic field with similar frequency and field strength. Therefore, parameters of the sensor, such as material type, length, and thickness, can be varied to provide the desired power consumption within a known electromagnetic field.

[0078] The preferred sensor can be heated to temperatures exceeding 250 degrees Celsius.

[0079] "Aerosol-forming gel" is understood herein as a material or mixture of materials that, when heated, can release volatile compounds into an airflow through an article in which a sensor is disposed. The provision of a gel can be advantageous for storage and transport, or during use, as it reduces the risk of leakage from the sensor, aerosol-generating article, or aerosol-generating device.

[0080] Advantageously, the gel is solid at room temperature. In this context, "solid" means that the gel has a stable size and shape and does not flow. In this context, room temperature means 25 degrees Celsius.

[0081] The gel may include an aerosol forming agent. Ideally, the aerosol forming agent is substantially resistant to thermal degradation at the operating temperature of the receptor. Suitable aerosol forming agents are well known in the art and include, but are not limited to: polyols, such as triethylene glycol, 1,3-butanediol, and glycerol; esters of polyols, such as mono, di, or triacetic acid esters of glycerol; and fatty acid esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanoate and dimethyl tetradecanoate. The polyol or mixture thereof may be one or more of triethylene glycol, 1,3-butanediol, and glycerol or polyethylene glycol.

[0082] Advantageously, gels include, for example, thermotropic reversible gels. This means that the gel becomes a fluid when heated to its melting temperature and reverts to a gel at its gelation temperature. The gelation temperature can be at or above room temperature and atmospheric pressure. Atmospheric pressure means 1 atmosphere. The melting temperature can be higher than the gelation temperature. The melting temperature of the gel can be higher than 50 degrees Celsius, or 60 degrees Celsius, or 70 degrees Celsius, and can be higher than 80 degrees Celsius. In this context, melting temperature means the temperature at which the gel ceases to be solid and begins to flow.

[0083] Alternatively, in specific embodiments, the gel is a non-melting gel that does not melt during use of the receptor. In these embodiments, the gel may release the active agent at least partially during use at a temperature at or above the operating temperature of the receptor but below the melting temperature of the gel.

[0084] Preferably, the viscosity of the gel is 50,000 to 10 Pascals per second, more preferably 10,000 to 1,000 Pascals per second, to obtain the desired viscosity.

[0085] In specific embodiments, the gel includes a gelling agent. In specific embodiments, the gel includes agar or agarose or sodium alginate or gellan gum, or mixtures thereof.

[0086] In a specific embodiment, the gel comprises water; for example, the gel is a hydrogel. Alternatively, in a specific embodiment, the gel is non-aqueous.

[0087] Preferably, the gel includes an active agent. In conjunction with specific embodiments, the active agent includes nicotine (e.g., in powder or liquid form) or a tobacco product or another target compound for release, for example, in an aerosol. In a specific embodiment, nicotine is included in a gel having an aerosol-forming agent. It is desirable to lock nicotine into the gel at room temperature to prevent leakage of nicotine from the aerosol-generated article.

[0088] In a specific embodiment, the gel comprises a solid tobacco material that releases flavor compounds when heated. Depending on the specific embodiment, the solid tobacco material is, for example, one or more of the following: powder, granules, pellets, fragments, strips, bands, or sheets, containing one or more of the following: plant materials, such as grass leaves, tobacco leaves, tobacco ribs, reconstituted tobacco, homogenized tobacco, extruded tobacco, and expanded tobacco.

[0089] Examples of gels containing other flavors, such as menthol, exist. Menthol may be added to water or an aerosol forming agent prior to gel formation.

[0090] In embodiments where agar is used as a gelling agent, the gel may comprise between 0.5% and 5% by weight, preferably between 0.8% and 1% by weight, of agar. Preferably, the gel also comprises between 0.1% and 2% by weight of nicotine. Preferably, the gel also comprises between 30% and 90% by weight (or between 70% and 90% by weight) of glycerol. In specific embodiments, the remainder of the gel comprises water and flavoring agents.

[0091] Preferably, the gelling agent is agar, which has the property of melting at temperatures above 85 degrees Celsius and reverting to a gel at around 40 degrees Celsius. This property is suitable for thermal environments. The gel does not melt at 50 degrees Celsius, which is useful, for example, in situations where the system is left in a hot car exposed to sunlight. The phase transition to liquid at around 85 degrees Celsius means that aerosolization can be initiated simply by heating the gel to a relatively low temperature, thus achieving low energy consumption. Using only agarose instead of agar as a component of agar may be beneficial.

[0092] When gellan gum is used as a gelling agent, the gel typically comprises between 0.5% and 5% gellan gum. Preferably, the gel also comprises between 0.1% and 2% nicotine. Preferably, the gel comprises between 30% and 99.4% glycerol. In a specific embodiment, the remainder of the gel comprises water and flavoring agents.

[0093] In one example, the gel comprises 2% by weight nicotine, 70% by weight glycerin, 27% by weight water, and 1% by weight agar.

[0094] In another example, the gel comprises 65% by weight glycerol, 20% by weight water, 14.3% by weight tobacco and 0.7% by weight agar.

[0095] A method for assembling a strip-shaped aerosol generating article including a cup-shaped receptor is also provided. The cup-shaped receptor may be a cup-shaped receptor shell according to the present invention and as described in this application.

[0096] The method includes vertically positioning a hollow tube, providing a cup-shaped receptor in the hollow tube, filling the cup-shaped receptor with an aerosol-forming gel, and inserting an end piece into the hollow tube.

[0097] The hollow tube can be positioned around the sensor, or the cup-shaped sensor can be inserted into the hollow tube. Preferably, the cup-shaped sensor is inserted into the hollow tube.

[0098] Preferably, the method includes inserting a sensor through the top of the hollow tube and positioning the sensor at the bottom of the hollow tube. The cup-shaped sensor may be arranged substantially flush with the bottom of the hollow tube.

[0099] Before positioning the receptor in the hollow tube, the cup-shaped receptor can be filled with an aerosol-formed gel. After positioning the receptor in the hollow tube, the receptor can be filled with a gel. Preferably, the method includes filling the cup-shaped receptor with an aerosol-formed gel after positioning the receptor in the hollow tube.

[0100] The method may include inserting a gel metering device into a hollow tube, metering a desired amount of aerosol-formed gel into the sensor, and withdrawing the gel metering device from the hollow tube. The gel may be in liquid or paste form when filled into the sensor.

[0101] An end piece can be inserted into the hollow tube through its top end and close the hollow tube. The end piece can be arranged flush with the top end of the hollow tube. The end piece can form a recessed end of the hollow tube to form an aerosol generating article with a recessed filter end. The end piece can extend from the hollow tube to form an extended filter portion of the article.

[0102] Preferably, the length of the aerosol-generated article is limited by the length of the hollow tube.

[0103] Preferably, the end piece is a pre-assembled assembly of segments. The end piece may include, for example, one or more filter elements, one or more hollow tubes such as cellulose acetate tubes, or diffuser segments.

[0104] Preferably, the end piece includes at least one of a filter, a hollow tube, and a diffuser element.

[0105] The hollow tube can be a cardboard tube or a plastic tube. Preferably, the hollow tube is a cardboard tube. More preferably, the hollow tube is a spirally wound cardboard tube.

[0106] The hollow tube may have a diameter between 5 mm and 12 mm. Preferably, the diameter of the hollow tube is greater than 5 mm, for example, between 6 mm and 8 mm.

[0107] The hollow tube may have a total length between 30 mm and 100 mm. In a preferred embodiment, the hollow tube has a total length between 40 mm and 55 mm, for example, 42 mm to 52 mm. Preferably, the hollow tube is substantially cylindrical.

[0108] The wall thickness of the hollow tube can be between 0.2 mm and 2 mm, preferably between 0.5 mm and 1.5 mm.

[0109] The method may further include pre-forming a cup-shaped receptor from a receptor sheet. Preferably, the cup-shaped receptor is formed from a disc-shaped receptor sheet. The disc can be cut, for example, from a sheet of aluminum foil or stainless steel foil.

[0110] The cup-shaped receptor may have flat sidewalls. The sidewalls of the cup-shaped receptor may be corrugated. Preferably, the corrugations are aligned along the longitudinal direction of the cup-shaped receptor. When viewed in cross-section along the sidewall, the corrugations may be grooved or have a serrated pattern to form a cupcake-shaped receptor.

[0111] Preferably, when the cup-shaped sensor is inserted and positioned in the hollow tube, the sidewalls of the cup-shaped sensor will apply a retaining force to the hollow tube.

[0112] The sidewalls of the cup-shaped receptor extend radially outward before being pushed radially inward to achieve a generally cylindrical shape, preferably corresponding to the inner diameter of the hollow tube. When the receptor is inserted into the hollow tube, the corrugations allow for a clearly defined folding of the sidewalls. Additionally, the sidewalls can apply a retaining force between the receptor and the hollow tube. This retaining force supports the positioning of the cup-shaped receptor within the hollow tube and prevents displacement of the cup-shaped receptor within the hollow tube after it has been positioned.

[0113] To generate a holding force, the diameter of the cup-shaped receptor is larger than the inner diameter of the hollow tube before positioning the receptor within the hollow tube. Preferably, the diameter of the cup-shaped receptor is at least 10% larger than the inner diameter of the hollow tube. More preferably, the diameter of the cup-shaped receptor is at least 1 mm larger than the inner diameter of the hollow tube. During positioning of the cup-shaped receptor, the sidewalls are compressed radially inward.

[0114] The cup-shaped receptor may have a large diameter over its entire length. Alternatively, it may have a large diameter over a portion of its length. Preferably, the cup-shaped receptor has a large diameter in its opening portion.

[0115] Preferably, the sidewalls of the cup-shaped receptor have a certain degree of elasticity and flexibility. This elasticity and flexibility allow for radial inward pressing of the receptor sidewalls without damaging or destroying the receptor material. The elasticity and flexibility also allow the sidewalls to be pushed radially outward, and generate a retaining force when positioned within a hollow tube.

[0116] A cup-shaped receptor may include an opening having a diameter equal to or greater than that of the bottom of the cup-shaped receptor. The cup-shaped receptor may have an opening whose diameter is smaller than that of the bottom. The cup-shaped receptor may include, for example, an active locking device disposed at the opening portion of the cup-shaped receptor. For example, the cup-shaped receptor may include an inwardly pointing edge disposed around the opening of the cup-shaped receptor.

[0117] The manufacture of a heat-sensitive receptor shell, which has inwardly pointing edges to hold the aerosol-forming gel inside the shell, can be achieved, for example, by embossing or folding. However, the small size of the receptor shell and its use in disposable aerosol-generating articles present significant challenges in the manufacture of such shells. Therefore, it is desirable to make the manufacturing process of such shells inexpensive, use very little material, and allow for large-scale production.

[0118] This invention provides a method for forming a strip-shaped receptor shell with a curved top edge. The method can be particularly used to form strip-shaped receptor shells filled with an aerosol-forming gel to form aerosol-generated strip segments according to the invention and as described herein.

[0119] The method includes loading a forming tool with a sensor sheet disk, such as an aluminum disk, deep-drawing the disk to form a semi-finished shell, widening the sidewalls of the semi-finished shell, and bending the edges inward at the opening of the shell. This forms a strip-shaped sensor shell, which can be removed and further processed, such as being filled with aerosol to form a gel and subsequently introduced into an aerosol-generated article.

[0120] Preferably, the deep drawing of the sensor sheet disc is performed by inserting a plunger into the mold. Thus, the disc is deeply drawn within the mold.

[0121] Preferably, the widening of the sidewall of the semi-finished shell is performed by rotating the plunger along the side of the mold, thereby pressing the sidewall of the semi-finished shell against the wall of the mold.

[0122] Edge formation can be largely achieved by pressing the shell from below against the upper forming tool to radially inward the uppermost portion of the shell's sidewall.

[0123] The invention is defined in the claims. However, a non-exhaustive list of non-limiting embodiments is provided below. Any one or more features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0124] Example Ex1: An aerosol generating segment includes a strip-shaped receptor shell and an aerosol forming gel contained in the strip-shaped receptor shell, wherein the receptor shell includes a bottom, sidewalls and an opening arranged opposite to the bottom, and wherein the aerosol forming gel is held inside the receptor shell by at least one active locking device along the axial direction of the aerosol generating segment.

[0125] Example Ex2: The aerosol generating segment according to Example Ex1, wherein at least one of the at least one active locking device is designed as an inwardly pointing seam of the sensor shell, in particular as an inwardly arranged flange.

[0126] Example Ex3: An aerosol-generated strip segment according to Example Ex2, wherein the seam is arranged adjacent to the end section of the receptor shell, and the end section is arranged opposite to the bottom of the receptor shell.

[0127] Example Ex4: An aerosol-generated strip segment according to any one of Examples Ex2 to Ex3, wherein the seam is formed by the inwardly curved end portion of the sidewall of the receptor shell.

[0128] Example Ex5: An aerosol generating segment according to any of the preceding examples, wherein at least one of the at least one active locking device is designed as a radially inwardly pointing protrusion.

[0129] Example Ex6: An aerosol generating segment according to Example Ex5, wherein the radially inwardly pointing protrusion has a radial extension in the circumferential direction of the receptor shell, the radial extension being greater than the longitudinal extension of the protrusion in the longitudinal direction of the receptor shell.

[0130] Example Ex7: A segment generated by aerosol according to Example Ex5 or Ex6, wherein the radially inwardly pointing protrusion is a radially inwardly pointing deformation of the sidewall of the receptor shell.

[0131] Example Ex8: An aerosol-generated strip segment according to any one of Examples Ex5 to Ex7, wherein the radially inwardly pointing protrusion is arranged in the middle section of the sidewall of the receptor shell.

[0132] Example Ex9: An aerosol generating segment according to any of the preceding examples, wherein the at least one active locking device is disposed in one, two, three, four or more sectors of the receptor housing, preferably disposed in a circumferential range of at least 5 degrees, 10 degrees, 15 degrees, 20 degrees, 30 degrees, 40 degrees, 45 degrees or at most 20 degrees, 30 degrees, 40 degrees, 45 degrees, 50 degrees, 60 degrees, 70 degrees, 80 degrees, 90 degrees or 180 degrees in each sector.

[0133] Example Ex10: An aerosol generating segment according to any of the preceding examples, wherein the aerosol forming gel is held in the cylinder by the at least one active locking device, wherein there is a gap in the longitudinal direction of the receptor shell.

[0134] Example Ex11: An aerosol-generating segment according to any one of Examples Ex1 to Ex9, wherein the aerosol-forming gel is fixed in its position in the receptor shell by at least one active locking device.

[0135] Example Ex12: An aerosol generating segment according to any of the preceding examples, wherein at least one of the at least one active locking device is arranged along the entire circumference of the receptor housing, particularly along the entire circumference of the sidewall of the receptor housing.

[0136] Example Ex13: An aerosol-generated strip segment according to any of the preceding examples, wherein at least a portion of the sidewall of the receptor shell is made of receptor material.

[0137] Example Ex14: An aerosol-generated strip segment according to any of the preceding examples, wherein at least a portion of the bottom of the receptor shell is made of receptor material.

[0138] Example Ex15: An aerosol-generated strip segment according to any of the preceding examples, wherein the bottom of the receptor shell is closed.

[0139] Example Ex16: Aerosol generating segments according to any of the preceding examples, wherein the sidewalls of the receptor shell are flat.

[0140] Example Ex17: an aerosol-generating segment according to any of the preceding examples, wherein the sidewall of the receptor shell is corrugated.

[0141] Example Ex18: A strip segment is generated from an aerosol according to Example Ex17, wherein the corrugations are aligned along the longitudinal direction of the receptor shell.

[0142] Example Ex19: An aerosol-generated segment according to any of the preceding examples, wherein the sidewalls of the receptor shell have a cylindrical shape.

[0143] Example Ex20: An aerosol-generating segment according to any of the preceding examples, wherein the bottom and sidewalls of the receptor shell comprise the same thickness or the same material, or wherein the bottom and sidewalls of the receptor shell comprise the same thickness and the same material.

[0144] Example Ex21: An aerosol-generated strip segment according to any of the preceding examples, wherein the bottom of the receptor shell and the sidewall of the receptor shell are manufactured as a single piece.

[0145] Example Ex22: An aerosol-generated strip segment according to any of the preceding examples, wherein the bottom and sidewalls of the receptor shell comprise different thicknesses or different materials, or wherein the bottom and sidewalls of the receptor shell comprise different thicknesses and different materials.

[0146] Example Ex23: an aerosol-generating segment according to any of the preceding examples, wherein the receptor shell comprises or is made of aluminum or stainless steel.

[0147] Example Ex24: An aerosol generating segment according to any of the preceding examples, wherein the receptor shell is formed of a sheet of receptor material having a thickness between 5 micrometers and 80 micrometers, preferably between 8 micrometers and 50 micrometers.

[0148] Example Ex25: An aerosol-generating segment according to any of the preceding examples, wherein the aerosol-forming gel is a gel rod.

[0149] Example Ex26: An aerosol-generating segment according to any of the preceding examples, wherein the filling height of the aerosol-forming gel is at least 30%, 40%, 50%, 60%, 70%, 80% or at most 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95%, 96%, 97%, 98%, or 99% of the receptor shell.

[0150] Example Ex27: An aerosol-generating segment according to any of the preceding examples, wherein the aerosol-forming gel is completely contained within the receptor shell.

[0151] Example Ex28: An aerosol-forming segment according to any of the preceding examples, wherein the aerosol-forming gel comprises a curable material.

[0152] Example Ex29: Aerosol-forming segments according to Example Ex28, wherein the aerosol-forming gel comprises a thermally reversible material.

[0153] Example Ex30: An aerosol-forming segment according to any of the preceding examples, wherein the aerosol-forming gel comprises a gelling agent in an amount between 0.5% by weight and 5% by weight.

[0154] Example Ex31: An aerosol-generating article comprising a plurality of segments arranged in an end-to-end position and packaged in packaging material to form a strip, said plurality of segments including aerosol-generating strip segments according to any of the preceding examples.

[0155] Example Ex32: An aerosol-generating article according to Example Ex31, wherein the plurality of segments further includes at least one of a hollow tube, a filter segment, an airflow guiding element, and a cavity.

[0156] Example Ex33: An aerosol generating article according to any one of Examples Ex31 to Ex32, wherein the aerosol generating strip segment is arranged between the hollow acetic acid tube and the filter segment.

[0157] Example Ex34: A method for manufacturing aerosol-forming segments, comprising:

[0158] A strip-shaped receptor shell is provided, including a bottom, sidewalls, and an opening opposite the bottom;

[0159] The aerosol was formed into a gel and filled into the receptor shell;

[0160] At least one shape-locking device is provided in the aerosol-generating segment to retain the aerosol-forming gel inside the receptor shell.

[0161] Example Ex35: According to the method of Example Ex34, wherein after the receptor shell is filled with the aerosol-forming gel, the at least one shape-locking device is provided in the aerosol-generating strip segment.

[0162] Example Ex36: At least one shape locking device is formed by radially inwardly bending at least some portions of the sidewall of the sensor housing according to the method of any one of Examples Ex34 or Ex35.

[0163] Example Ex37: According to the method of Example Ex36, the end portion of the sidewall is bent inward, thereby defining the size of the opening of the receptor shell.

[0164] Example Ex38: Corrugations are provided in the sidewall of the receptor housing according to any one of Examples Ex34 to Ex37.

[0165] Example Ex39: According to the method of Example Ex38, the ripples extend from the bottom of the receptor shell to the opening.

[0166] Example Ex40: At least one shape locking device is formed by forming a radially inwardly pointing protrusion in the sidewall of the sensor housing according to any one of Examples Ex34 to Ex39.

[0167] Example Ex41: The method of any one of Examples Ex34 to Ex40, wherein the aerosol forming gel is cured after the aerosol forming gel is filled into the receptor shell.

[0168] Example Ex42: The method according to any one of Examples Ex34 or Ex41, wherein the aerosol generating segment is an aerosol generating segment according to any one of Examples Ex1 to Ex33. Attached Figure Description

[0169] Several examples will now be described further with reference to the accompanying drawings, in which:

[0170] Figure 1 The cup-shaped receptor shell is shown;

[0171] Figure 2 A cup-shaped receptor shell with corrugated sidewalls is shown;

[0172] Figure 3The manufacturing sequence using a cupcake-shaped preformed shell is shown;

[0173] Figures 4 to 6 A schematic diagram shows a longitudinal cross-section through the receptor shell;

[0174] Figure 7 An embodiment of an aerosol-generating article comprising aerosol-generating segments is shown;

[0175] Figure 8 Another embodiment of an aerosol-generating article including aerosol-generating segments is shown;

[0176] Figure 9 Another embodiment of an aerosol-generating article including aerosol-generating segments is shown;

[0177] Figure 10 Another embodiment of an aerosol-generating article including aerosol-generating segments is shown;

[0178] Figures 11 to 16 The manufacturing process of an aerosol-generated article including a cup-shaped receptor is shown;

[0179] Figure 17 and 18 An embodiment of a folded receptor shell with a polygonal bottom is shown;

[0180] Figure 19 and 20 Another embodiment of a folded receptor shell with a polygonal bottom is shown, having an inwardly folded bottom ( Figure 19 ) and outward fold bottom ( Figure 20 );

[0181] Figure 21 The bottom, side, and top views of the aluminum shell with inwardly curved edges are shown.

[0182] Figure 22 A portion of the setup for manufacturing an aerosol-generated article is shown; and

[0183] Figures 23 to 25 The process of forming a cup-shaped aluminum shell is shown. Detailed Implementation

[0184] exist Figure 1 and 2 The image shows an embodiment of a sensor housing that does not yet have an active locking device.

[0185] exist Figure 1The image shows a side perspective view of a cup-shaped shell 1. The shell has a bottom 11 and sidewalls 12 extending from the bottom 11. The shell 1 has an opening 13 arranged opposite to the bottom 11. The shell has the form of an open cylinder with a circular cross-section that is substantially constant along the entire length of the shell. The shell 1 is partially or preferably entirely made of a sensory material such as stainless steel. The shell 1 is partially or completely filled with an aerosol-forming gel (not shown).

[0186] An exemplary eddy current flow induced in the sensor housing 1 by the sensor, particularly the induction coil arranged around the housing, is indicated by an arrow.

[0187] exist Figure 2 The image shows a side perspective view of a cup-shaped shell 1 with corrugated sidewalls 12. Corrugations 120 extend from the bottom 11 to the opposite ends of the shell 1. The corrugations 120 are shown more continuously from the bottom 11 toward the opposite open ends. Exemplary eddy current flows induced in the sensor shell 1 by sensors, particularly induction coils arranged around the shell, are indicated by arrows.

[0188] Active locking device Figure 1 and 2 Not shown in the image.

[0189] like Figure 1 and 2 Exemplary data for the shell shown are: 12 mg to 75 mg of receptor material; 160 mg of aerosol-forming gel; and an expected temperature for the aerosol-forming gel: approximately 190°C to approximately 200°C. An aerosol-generating segment with the aforementioned parameters can achieve a vaporization experience lasting approximately 360 seconds.

[0190] exist Figure 3 In, it is shown as follows Figure 2 An example of the step-by-step manufacturing process of the shell is shown. (As shown) Figure 3 As shown in the left figure, the receptor sheet can be pre-formed into a cupcake shape. The radially outward-pointing sidewalls 12 of the cupcake-shaped shell are pressed radially inward until the shell 1 has substantially the same diameter over its entire length.

[0191] Active locking devices for retaining the gel within the shell may subsequently be provided in the shell 1, for example, in one of a further manufacturing step. Preferably, one or more active locking devices are provided in the shell in a further manufacturing step.

[0192] exist Figures 4 to 6 An example of an active locking device is shown in the image. Figure 4In this structure, the end of the sidewall 12 of the receptor shell 1, opposite the bottom 11 of the shell, points inward. Preferably, this is achieved by radially inwardly bending the end portion 125 of the sidewall 12 of the shell. The end portion 125 then forms an edge to reduce the opening 13 of the shell. Since the diameter of the gel rod is larger than the diameter of the opening 13, the aerosol forming gel 2 rod inside the shell 1 cannot fall out or be pushed out of the opening 13 of the shell 1. The inwardly bent end portion 125 of the sidewall 12 forms an active locking element for the gel 2 and has a retaining effect on the gel in the axial direction 4 of the shell 1. Figure 4 In the middle, the receptor shell 1 is completely filled with aerosol to form a gel.

[0193] exist Figure 5 In the shell, the shell includes a radially inwardly pointing protrusion 126 adjacent to the inwardly curved end portion 125 of the sidewall 12. The protrusion 126 is formed by deformation of the sidewall 12. The protrusion 126 is arranged in the intermediate section 128 of the shell 1, accounting for approximately 40% to 60% of the length or height of the shell. Figure 5 In this configuration, the protrusion 126 is located at approximately 40% of the length of the shell 1. Preferably, the protrusion 126 forms a rib, which extends partially or completely around the circumference of the shell. Figure 5 In the sensor housing 1, approximately half is filled with aerosol-forming gel up to approximately half the height of housing 1. The protrusion 126 forms an active locking element for the gel 2 without any gaps. Due to the distance between the filling height of the aerosol-forming gel and the inwardly curved end portion 125, the inwardly curved end portion 125 forms an active locking element even with gaps.

[0194] exist Figure 6 In this design, the active locking device is formed in the sensor housing 1 by radially inwardly pointing protrusions 126 arranged at different length positions of the housing 1. Measured from the bottom 11 of the housing 1, the first protrusion 126 is located at approximately 20% of the length of the housing 1, while the second protrusion 126 is located at approximately 80% of the length of the housing 1. The protrusions 126 are formed by deformation of the sidewall 12 and form ribs that extend partially or completely around the circumference of the housing 1. Figure 6 The opening 13 of the shell 1 shown has the same diameter as the bottom 11 of the shell 1.

[0195] exist Figures 4 to 6 In the illustrated example, the protrusions 126 are arranged opposite to each other in the shell 1. However, the protrusions may also be arranged, for example, in a staggered manner along the height of the shell 1. Several protrusions (e.g., 3 to 10 protrusions) may be arranged in the shell 1. The protrusions and additional active locking devices together hold the gel 2 in the shell 1 in the axial direction.

[0196] Figure 7An aerosol forming article 5 comprising an aerosol generating strip element 10 according to the present invention is schematically shown. The aerosol generating strip element 10 is a strip element having corrugated sidewalls 12. Figure 7 An active locking device is not shown.

[0197] The aerosol forming article 5 is strip-shaped and comprises six segments arranged end-to-end. The aerosol forming article 5 has an orifice including a filter segment 40 at its nearest or most downstream end. An aerosol cooling segment 30 is arranged adjacent to and upstream of the filter segment 40. A cavity 20 is arranged between the aerosol cooling element 30 and the aerosol forming strip segment 10. Two hollow acetic acid tube segments (HATs) 50, 51 are arranged at the distal end of the aerosol forming article 5. The hollow acetic acid tube 51 arranged at the distal end of the article 5 is a thin hollow acetic acid tube 51, and its wall thickness is less than that of the hollow acetic acid tubes 50 arranged adjacent to the aerosol forming strip segment 10. The hollow acetic acid tube 50 has a wall thickness of approximately 2 mm. The thin hollow acetic acid tube 51 has a wall thickness of approximately 0.8 mm.

[0198] Multiple segments are packaged in packaging material 55, such as paper or plastic packaging material. Individual segments may be packaged individually before assembly and packaged with packaging material 55 to form a strip-shaped aerosol-generated article 5.

[0199] The packaging material 55 includes a row of perforations 555 for airflow to pass through and enter the packaging material 55. The perforations are arranged at the upstream end of the aerosol generating segment 10. The airflow entering the packaging material 55 is outside the sensor housing and along its direction proximal to the end of the article 5. The airflow obtains evaporated material from the heated aerosol forming gel and forms an aerosol in the cavity 20, which is cooled in the aerosol cooling element 30 and filtered in the filter element 40.

[0200] Figure 7 Exemplary values ​​for the lengths of individual segments of the article are: Length of thin HAT segment 51: 6 mm, Length of HAT 50: 5 mm, Length of aerosol generating strip segment 10: 15 mm, Length of cavity 20: 8 mm, Length of aerosol cooling element 30: 7 mm, Length of mouthpiece filter element 40: 4 mm. Total length of article 5: 45 mm.

[0201] exist Figure 8 An embodiment of an aerosol-generating article 5 is schematically illustrated. The article comprises multiple segments packaged in packaging material 55. An aerosol-generating segment 10 is arranged between the farthest front segment 60 and the airflow guiding element 70.

[0202] The aerosol generating segment 10 includes a cup-shaped receptor shell 1. The cup-shaped receptor shell 1 has a constant circular cross-section and includes an inwardly pointing flange 127 to reduce the size of the opening 13 of the shell 1. The shell 1 is made of, for example, aluminum or stainless steel, such as Sxx or S4xx, like SS430.

[0203] Aerosol-formed gel 2 is arranged on the inner side and outer side of shell 1. Figure 8 In the illustrated embodiment, the aerosol generating segment 10 is a gel rod including a receptor shell, the gel rod defining the size of the aerosol generating segment 10.

[0204] The front segment 60 includes ferrite beads 61. The ferrite beads 61 may be, for example, ferrite K1, and may have a size of about 2.4 mm and a weight between 10 mg and 20 mg.

[0205] Ferrite beads 61 are arranged near the proximal end of the front segment 60. Thus, the ferrite beads 61 are positioned near the aerosol-generating segment 10 and close to the bottom 11 of the shell 1 within the aerosol-generating segment 10. Consequently, heating of the shell 1 can be enhanced in the bottom region of the shell 1 opposite the opening 13 of the shell.

[0206] The airflow guiding element 70 includes a truncated hollow cone 71. The truncated end of the hollow cone 71 is oriented opposite to the aerosol generating segment 10. The evaporated gel enters the cone through the truncated end and expands within the cone 71 to distribute across the entire cross-section of the article.

[0207] The packaging material 55, which packages the article 5 and holds the individual segments in place, includes perforations 555 at length positions of the article corresponding to the distal region of the airflow guiding element 70. Air can enter the article 5 through the perforations 555 and then into the airflow guiding element 70. Since the conical inlet is located upstream of the perforations 555 in the article 5, the air is initially guided in an upstream direction. The air acquires the evaporated gel and passes through the cone in a downward direction. The aerosol, including the airflow 333, is then guided further downstream to the opening end (not shown) of the article 5.

[0208] In some embodiments, the thickness of the receptor material of the shell is 8.5 micrometers. In another embodiment, the thickness of the receptor material of the shell is 12 micrometers.

[0209] Shell 1 may, for example, have a weight of about 38 mg when empty and about 225 mg when filled with 187 mg of gel.

[0210] exist Figure 9In this embodiment, the aerosol generating article 5 comprises five segments. An aerosol generating strip segment 10 is sandwiched between two hollow strip segments 50, such as two hollow acetic acid tubes. One hollow tube is located at the farthest end of article 5. Adjacent to the more downstream acetic acid tube 50 are the aerosol cooling element 80 and the filter segment 40 at the closest end of article 5.

[0211] The two hollow tubes 50 can have the same construction. Figure 9 In this configuration, the hollow tube located at the furthest end of the workpiece is shorter than the hollow tube located further upstream, for example, by 2-5 mm. For instance, the shorter hollow tube 50 may have a length of 4 mm. The longer hollow tube 50 may have a length of 8 mm. The hollow tube has a wall thickness of approximately 2 mm.

[0212] Figure 10 The article 5 shown includes five segments: a front bar 90, followed by an aerosol generating strip segment 10, followed by a hollow tube segment 50 and a thin hollow tube segment 51, followed by a filter segment 40 arranged at the nearest end of the article 5.

[0213] The product has a diameter of 7.23 mm (57) and a total length of 45 mm (58). The total length 58 is composed of the lengths of individual segments: filter segment 40: 12 mm, each hollow tube: 8 mm, aerosol generating strip segment 10: 12 mm, and front bar 90: 5 mm.

[0214] The perforations 555 in the packaging material 55 are arranged at a distance 59 of 18 mm from the nearest end of the article 5. The perforations 555 and the airflow entering the article through the perforations 555 just upstream of the filter element 40 can cause turbulence in the thin hollow tube 51. This can improve the filtration effect of the aerosol-containing airflow in the filter element 40.

[0215] exist Figures 11 to 16 The manufacturing process of aerosol-generated article 5 is illustrated in a simplified manner. Figure 11 In this process, a disc 101 of receptor material has been cut from a receptor sheet, such as aluminum foil or stainless steel foil. Figure 12 As shown, the disc 101 forms (preferably folded) a cup-shaped receptor 1. The bottom 11 of the receptor is circular and flat, and the sidewalls 12 of the cup-shaped receptor 1 are corrugated. The corrugations are arranged along the length of the cup-shaped receptor 1.

[0216] like Figure 13As can be seen, the cup-shaped receptor 1 is positioned within the hollow tube 52, such as a spirally wound cardboard tube. The hollow tube 52 is positioned vertically. The cup-shaped receptor is inserted into the hollow tube 52 first through its bottom 11 at the top 520. The cup-shaped receptor 1 is guided through the hollow tube 52 and positioned at the bottom 521 of the hollow tube. The bottom 11 of the receptor 1 may be flush with the bottom 521 of the hollow tube 52.

[0217] The cup-shaped form of the receptor 1 simplifies the insertion of the cup-shaped receptor because the bottom 11 preferably has a smaller diameter than the diameter of the sidewall 12 at the opening of the cup-shaped receptor.

[0218] Preferably, the cup-shaped sensor 1 is slightly clamped in the hollow tube 52 by the spring force of the sidewall 12.

[0219] exist Figure 14 In this device, the metering tip 201 of the metering device 200 is inserted through the top end 520 into the hollow tube 52 to meter a predetermined amount of aerosol-formed gel 2 into the cup-shaped receptor 1. The gel 2 (e.g., containing nicotine) can be supplied in liquid or paste form and can subsequently dry and harden within the cup-shaped receptor. The liquid or paste-like gel 2 flows into the corrugations of the sidewall 11, providing close contact between the gel and the receptor material.

[0220] In such Figure 15 and 16 In the final step shown, end piece 44 is also inserted into hollow tube 52 via tip 520. End piece 44 typically includes one or more filter segments. Preferably, end piece 44 is a pre-assembled segment composition arranged in an end-to-end position. End piece 44 may include segments that influence aerosol formation or have a filtration effect. For example, end piece 44 may include a filter, diffuser, aerosol cooling element, or aerosol guiding element.

[0221] The end piece 44 is positioned at the top end 520 of the hollow tube 52. The end piece 44 can be arranged flush with the top end of the hollow tube 52, or it can be arranged slightly recessed to form the aerosol generating product 5.

[0222] Figures 12 to 16 The cup-shaped receptor 1 shown may also be provided with an active locking device to hold the aerosol-forming gel in the cup-shaped receptor 1 in the axial direction.

[0223] Figure 17 and Figure 18An enlarged example of an embodiment of a folded cup-shaped receptor shell 1 having a flat bottom 11 in the form of a polygon is shown. The sidewalls 12 are corrugated in such a way that some folds 121 of the sidewalls 12 extend from the circumference of the bottom 11 of the cup-shaped receptor 1 to the center of the opposite end of the cup-shaped receptor, thus closing the opening 13 of the cup-shaped receptor to a greater or lesser degree depending on the degree of folding of the sidewalls 12. Some other folds 120 of the sidewalls 12 extend substantially straight from the circumference of the bottom 11 of the cup-shaped receptor 1 to the opposite end of the cup-shaped receptor, thus defining the outer diameter of the cup-shaped receptor 1. Depending on the degree of folding of the cup-shaped receptor, the folds 120 of the sidewalls 12 point to a greater or lesser degree radially outward relative to the bottom 11.

[0224] The continuously converging folds 121 form an active locking device relative to the opening of the cup-shaped receptor 1, which has a retaining effect on the gel in the receptor acting in the axial direction of the cup-shaped receptor.

[0225] When cup receptors are used as Figure 16 In the article shown, the sidewall 12 of the cup-shaped receptor 1 is also configured to have a radial holding force on the cup-shaped receptor itself.

[0226] Figure 19 and Figure 20 This is another example of a folded cup-shaped receptor 1 with a polygonal bottom 11. Figure 19 In the middle, the bottom 11 is folded and corrugated. The bottom 11 points inward to reduce the volume of the cup-shaped receptor and concentrate the receptor material in a smaller area. Figure 20 In the middle, the bottom 11 is folded and corrugated, and points outward to increase the volume of the cup-shaped receptor 1.

[0227] The fold of side wall 12 can be pressed with Figure 17 and 18 Folding in a similar manner as described in the example. The cup-shaped receptor 1 can be used as a cup-shaped receptor shell having an active locking device and a cup-shaped receptor, which has a retaining force on the shell itself to ensure insertion and arrangement in a manner similar to... Figure 16 The aerosol formed in the article is fixed in its position.

[0228] Figure 21A bottom view, a side view, and a top view of the aluminum shell 1 are shown. The aluminum shell has a circular diameter, a small bottom 11, sidewalls 12 with a diameter larger than that of the bottom 11, and an inwardly curved edge 125 on the opposite opening 13 side of the shell. The size of the opening 13 of the shell 1 is defined by the degree of inward curvature of the edge 125. The edge 125 has the function of retaining the gel in the longitudinal axial direction within the shell 1. The edge 125 also forms a surface for sealing a closing seal to the shell 1. The shell can be filled with aerosol-formed gel and sealed, such that the aerosol-generating segments thus formed can be stored for later incorporation into an induction-heatable aerosol-generating article 5.

[0229] Shell 1 is formed by deep drawing an aluminum disc, widening the sidewalls 12 of the shell, and bending the edges 125. The thickness of the aluminum used for the shell can be, for example, 10 micrometers, or 30 micrometers for embossed aluminum. Other materials suitable for induction heating, deep drawing, and bending can be used to form the shell.

[0230] exist Figure 22 The diagram illustrates three sequentially arranged stations 6, 7, and 8 in the aerosol-generated article manufacturing process. At the first station 6 (forming unit), a cup-shaped shell is formed. At the second station (insertion unit), the cup-shaped shell is inserted into a coated cardboard tube, as shown above. Figure 13 As described above. In the third station 8 (filling unit), an aerosol-formed gel is filled into the receptor shell using a metering delivery device 200. For example, as referenced... Figure 15 and 16 The semi-finished products thus manufactured can be further processed.

[0231] exist Figure 23 The image shows the first step of shell forming in forming unit 6. Cavity 661 in the lower part of the forming tool forms a mold.

[0232] The lower part of the forming tool includes a vertically movable lower forming tool 66, the function of which will be described in more detail below. The top surface of the lower forming tool 66 forms the bottom of the mold.

[0233] A sheet blank, such as an aluminum disc, is loaded into the forming unit 6 above cavity 661.

[0234] The plunger 65 is lowered, and at the same time the plunger head 650 is inserted into the cavity 661 from above. The plunger head 650 presses the aluminum disc into the cavity 661.

[0235] The diameter of plunger 65 is smaller than the diameter of cavity 661.

[0236] To widen the sidewalls of the semi-finished shell 111, the plunger head 650 moves along the sidewalls of the mold. Figure 24 and Figure 25The diagram shows the movement of the plunger 65 and the position of the plunger head 650 during the extension of the sidewall of the housing.

[0237] Figure 24 The movement path of the plunger head 650 in the cavity 661, which widens the sidewall of the semi-finished shell 111, is shown. The plunger 650 moves from the center of the cavity 661 to one side of the cavity. It then rotates along the side of the mold defining the cavity. The plunger 65 simultaneously circulates and rotates within the cavity 661. The position of the plunger 65 on one side of the cavity is... Figure 25 As shown in the diagram, the rotation of plunger 65 is indicated by arrow 665.

[0238] To form the edge and bend the upper portion of the sidewall of the semi-finished shell 111, the plunger 65 and the lower forming tool 66 are arranged as follows: Figure 26 The direction of arrow 667 shown is raised.

[0239] The transfer plate 68, which is part of the upper forming tool, includes a mold surface 680 with an inwardly pointing edge mold 681.

[0240] When the lower forming tool 66 and the plunger 65 are raised, the semi-finished shell 111 is guided through the cavity 661, while the plunger head 650 is kept at the center of the semi-finished shell 111. When the semi-finished shell 111 is pressed against the edge mold 681 of the transfer plate 68, the edge 125 of the shell 1 is formed.

[0241] The vacuum applied to the shell ensures that the shell is properly positioned during transfer.

[0242] In such Figure 27 In another step shown, as indicated by arrows 667 and 668, the upper forming tool is further raised and the lower forming tool 66 is lowered to release the finished shell 1.

[0243] The shell 1 is removed from the forming tool 6 via the transfer plate 68.

[0244] Then, the transfer plate 68 can transfer the cup-shaped shell 1 to the next station 7 for insertion into the cardboard tube.

[0245] For the purposes of this specification and the appended claims, unless otherwise indicated, all figures expressing quantities, quantities, percentages, etc., shall be understood to be modified by the term "about" in all cases. Furthermore, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically listed herein. Thus, in this document, the number A is understood to be A ± 2% of A. Within this document, the number A may be considered as a value included within the general standard error of the measurement of the characteristic modified by the number A. In some cases as used in the appended claims, the number A may deviate from the percentages listed above, provided that the amount of deviation from A does not significantly affect the fundamental and novel features of the claimed invention. Furthermore, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically listed herein.

Claims

1. Aerosol-generating rod segment comprising a rod-shaped susceptor shell and an aerosol-forming gel contained in the rod-shaped susceptor shell, wherein the susceptor shell comprises a bottom, a sidewall and an opening arranged opposite the bottom, and wherein the aerosol-forming gel is held inside the susceptor shell along an axial direction of the aerosol-generating rod segment by at least one active locking means, wherein the sidewall of the susceptor shell is corrugated, and wherein at least one of the at least one active locking means is designed as an inwardly directed seam of the susceptor shell, the seam being arranged adjacent to an end section of the susceptor shell, the end section being arranged opposite the bottom of the susceptor shell, and wherein the seam is formed by an inwardly bent end portion of the sidewall of the susceptor shell.

2. Aerosol-generating rod segment according to claim 1, wherein the inwardly directed seam of the susceptor shell is an inwardly arranged flange.

3. Aerosol-generating rod segment according to claim 1, wherein at least one of the at least one active locking means is designed as a radially inwardly directed protrusion.

4. Aerosol-generating rod segment according to claim 3, wherein the radially inwardly directed protrusion is a radially inwardly directed deformation of the sidewall of the susceptor shell.

5. Aerosol-generating rod segment according to claim 1, wherein the aerosol-forming gel is held in the susceptor shell by the at least one active locking means with a gap in a longitudinal direction of the susceptor shell.

6. Aerosol-generating rod segment according to claim 1, wherein at least one of the at least one active locking means is arranged along an entire circumference of the susceptor shell.

7. Aerosol-generating rod segment according to claim 1, wherein at least a portion of the sidewall of the susceptor shell is made of susceptor material.

8. Aerosol-generating rod segment according to claim 1, wherein corrugations of the corrugated sidewall of the susceptor shell converge radially inwardly, forming the at least one active locking means.

9. Aerosol-generating rod segment according to claim 1, wherein corrugations of the corrugated sidewall of the susceptor shell are aligned along a longitudinal direction of the susceptor shell.

10. Aerosol-generating rod segment according to claim 1, wherein at least one of the at least one active locking means is arranged along an entire circumference of the sidewall of the susceptor shell.

11. Aerosol-generating rod segment according to any one of the preceding claims 1-10, wherein the bottom of the susceptor shell and the sidewall of the susceptor shell are manufactured as a single piece.

12. Aerosol-generating article comprising a plurality of segments arranged in an end-to-end position and wrapped in a wrapping material to form a rod, the plurality of segments comprising an aerosol-generating rod segment according to any one of the preceding claims 1-11.

13. Aerosol-generating article according to claim 12, wherein the plurality of segments further comprises at least one of a hollow tube, a filter segment, an airflow directing element and a cavity. ​ ​ 14. An aerosol-generating article according to claim 12 or 13, wherein the aerosol- generating rod segment is arranged between a hollow acetate tube and a filter segment.

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