Susceptor and method of manufacturing the same

Abstract

The invention relates to a method for manufacturing a susceptor for an inductively heatable aerosol-generating article, wherein the method comprises the steps of providing a susceptor material web and providing a compression station. The compression station comprises oppositely arranged compression elements, wherein in a first portion of the compression station the compression elements are arranged to define a compression gap that narrows gradually, and wherein in a second portion of the compression station the compression elements are arranged to define a constant compression gap therebetween, and wherein the oppositely arranged compression elements are configured to have matching surface structures. The susceptor material web is guided through the narrowing compression gap of the compression station such that the matching surface structures of the compression elements deep-draw the susceptor material web. The invention further relates to a susceptor element having a generally portion and an extended portion arranged in succession and a method of manufacturing thereof.

Description

Technical Field

[0001] The present invention relates to a sensor and a method for manufacturing the sensor, the sensor being used in an inductively heated aerosol-generating article. Background Technology

[0002] Aerosol generating articles comprising at least one aerosol-forming matrix capable of forming an inhalable aerosol upon heating are well known. For heating the matrix, the article may be received within an aerosol generating apparatus including an electric heater. The heater may be an induction heater including an induction source. Depending on the electrical and magnetic characteristics of the sensor, the induction source is configured to generate an alternating electromagnetic field to inductively heat the sensor through at least one of eddy currents and hysteresis losses. The sensor may be an integral part of the article and arranged to be thermally close to or in direct physical contact with the matrix to be heated. During operation of the apparatus, volatile compounds are released from the heated aerosol-forming matrix within the article and entrained in the airflow inhaled through the article during user inhalation. As the released compounds cool, they condense to form an aerosol.

[0003] Receptors may comprise or be composed of metal sheets. Although such sheet-like receptors are readily fabricated and offer broad thermal emission due to their two-dimensional nature, the total mass of such receptors is often disproportionate to the thermal emission surface area. Consequently, resources are not being used efficiently.

[0004] Reducing the mass of the receptor, especially the thickness of the sheet used to manufacture the receptor, places high demands on the manufacturing process involved. Summary of the Invention

[0005] Therefore, it is desirable to have a method for manufacturing a sensor for inductively heated aerosol-generating articles, which allows for high reliability and reproducibility even for very thin sensor materials.

[0006] In particular, it is desirable to have a method for manufacturing a corrugated sensor for an inductively heated aerosol-generating article, wherein the sensor is made of a very thin sensor material.

[0007] It is also desirable to have a method for manufacturing a sensor, wherein the sensing medium is deposited onto the sensor during the forming process.

[0008] It is also desirable to have a method for manufacturing receptors that provides increased flexibility for the resulting heating distribution of the receptors.

[0009] It is also desirable to have a method that allows the deposition of a sensing medium in a predetermined region of the sensor element.

[0010] This invention relates to a method for manufacturing a sensor for an inductively heated aerosol-generating article, wherein the method includes the steps of providing a sensor material strip and providing a compression stage comprising opposingly arranged compression elements. The compression stage has a first portion and a second portion, wherein in the first portion, the compression elements are arranged to define a gradually narrowing compression gap in a processing direction, and in the second portion, the compression elements are arranged to define a constant compression gap in the processing direction, and wherein the opposingly arranged compression elements are configured to have matching surface structures. The method further includes the step of guiding the sensor material strip through the narrowing compression gap of the compression stage such that the matching surface structures of the compression elements deep-draw the sensor material strip.

[0011] The matching surface structures of the opposing compression elements can be configured such that the receptor material strip has at least one recess on at least one side. For example, the surface of the compression element may include a protruding structure that cooperates with the corresponding recessed structure of the respective opposing compression element. When the receptor material strip is guided through the opposing compression elements on the compression stage, the surface structure deeply penetrates the receptor material strip and modifies the surface of the receptor material accordingly.

[0012] By utilizing a gradually narrowing compression gap in the processing direction, the receptor material is gradually shaped into its final form. This reduces the risk of material damage during deep drawing. In this way, even very thin strips of receptor material can be processed in the compression table.

[0013] Advantageously, the first part of the compression stage (i.e., the part that forms a gradually narrowing compression gap in the processing direction) is located at the upstream end of the compression stage. The second part of the compression stage is advantageously arranged downstream of the first part. In this way, the receptor material strip is first guided through the first part of the compression stage. In this part, the receptor material strip is provided with a recess formed in a desired shape.

[0014] In the subsequent second part of the compression stage, the final shape of the receptor material is confirmed. For this purpose, the compression element of the second part of the compression stage forms a constant compression gap in the processing direction and applies a constant pressure to the receptor material.

[0015] The compression element can be configured as a belt, each of which is guided above a plurality of guide rollers. The belts can be arranged opposite each other such that they form a compression gap through which the receptor material is guided. In a first portion of the compression stage, the guide rollers are further arranged such that the belts define a gradually narrowing compression gap in the processing direction. In a second portion of the compression stage, the guide rollers are arranged such that the belts define a constant compression gap in the processing direction.

[0016] Each belt may be guided over multiple guide rollers. At least one of the guide rollers may be configured as a drive roller. The drive roller is a guide roller connected to a drive motor. The drive roller is used to actuate the corresponding belt.

[0017] The belt can be a toothed belt, having a plurality of teeth extending from the surface of the belt. The teeth can be arranged regularly at a fixed spacing. The toothed belt can be arranged such that teeth from one belt interpenetrate between two adjacent teeth arranged on opposing belts. The advantage of using two identical belts is that only one belt design is used, thus reducing the number of different parts of the device. Additionally, the risk of using an incorrect belt is avoided.

[0018] The belt may also have alternating female and male teeth. The female teeth are formed with recesses large enough to receive the male teeth. The male and female teeth may be arranged alternately on each belt. In this configuration, the two surfaces of the receptor material belt are alternately provided with protrusions and recesses.

[0019] The male tooth can be arranged on only one belt, while the female tooth can be arranged on another belt. In this configuration, only one surface of the receptor material belt has a protrusion, while the other surface has only a recess.

[0020] A belt with matching female and male teeth may be advantageous because the compression gap of the receptor material belt guided by it is clearly defined. In this way, control is gained over the increase in the resulting recesses and protrusions provided to the receptor material belt.

[0021] The teeth of the belt can have a variety of shapes, allowing for the creation of a wide range of surface patterns on the sensor material belt. The teeth can extend across the entire width of the belt. The teeth can extend only a portion of the belt's width. Continuously arranged teeth can be offset from each other. The teeth can be configured to form transverse waves relative to the direction of movement of the sensor material belt. The teeth can be arranged to form longitudinal or transverse recesses relative to the longitudinal direction of the sensor material belt, and can be distributed according to any desired pattern. The belt can also have rows of parallel teeth. The configuration of the belt's teeth determines the resulting shape of the sensor material belt's surface. When the recesses of the belt are subsequently filled with a sensing medium, the evaporation characteristics of the sensing medium can be controlled or at least influenced by the surface design of the sensor material.

[0022] Toothed belts can also be used as timing belts during the deep-drawing process of the sensor material belt. Therefore, the belts contribute to strong tension on the sensor material belt and facilitate synchronized movement. Because the surface structures of the belts engage with each other during compression, these surface structures simultaneously prevent slippage or any other undesirable relative movement between the belts.

[0023] To assist the deep drawing process, heat generation units can be employed. These heat generation units can be used to heat the sensor material strip before or during the re-forming process in the compression table.

[0024] The compression element may be configured as a screw-shaped element. The compression table may include one or more pairs of continuously arranged screw-shaped elements. In a first portion of the compression table, the screw-shaped elements may be configured and arranged such that threads located on the outer circumference of the screw-shaped elements form a gradually narrowing compression gap in the processing direction. In a second portion of the compression table, the screw-shaped elements may be configured and arranged such that the screw-shaped elements form a constant compression gap in the processing direction.

[0025] When the receptor material strip is guided through the compression gap formed by the opposing screw-shaped elements, the strip is both dragged and gradually stretched into the desired corrugated shape. Therefore, no additional drive mechanism for the receptor material strip is required in the compression stage. Furthermore, the compression stage has a fairly simple construction, as it is essentially composed only of screw-shaped elements.

[0026] The screw-shaped element is basically a cylindrical element. The outer circumference of the oppositely arranged screw-shaped elements is provided with corresponding threads having corresponding thread pitches. The axis of rotation of the screw-shaped element can be oriented substantially parallel to the processing direction of the sensor material strip.

[0027] To create a gradually narrowing gap in the processing direction, the screw-shaped elements can be arranged such that their longitudinal axes are slightly inclined toward each other, so that the threads provided on the outer circumference of the screw-shaped elements create a gradually narrowing compression gap in the processing direction. Such embodiments can be advantageous because the screw-shaped elements used therein are identical and have a regular cylindrical shape.

[0028] The screw-shaped element can also be configured with a gradually increasing diameter. In this embodiment, the screw-shaped elements can be arranged such that their longitudinal axes are oriented parallel to each other. In this configuration, the threads located on the outer circumference of the screw-shaped element again form a gradually narrowing compression gap in the processing direction. The parallel configuration of the longitudinal axes of the screw-shaped elements can provide structural advantages. This is particularly true when using multiple consecutively arranged paired screw-shaped compression elements. It can be advantageous if all these compression elements share a common axis of rotation.

[0029] In the first part of the compression stage, specifically in the section where the screw-shaped element forms a gradually narrowing compression gap in the processing direction, the initially flat sensor material strip is gradually stretched into a corrugated shape. Again, due to the gradually narrowing compression gap in the processing direction, the formation process is slow and smooth, reducing the risk of material failure.

[0030] In the second part of the compression stage, a screw-shaped element forms a compression gap of a constant size in the processing direction. This second part again helps to maintain the receptor material strip in the correct final corrugation or wave shape.

[0031] The compression table, including screw-shaped compression elements, may further include one or more guide elements. The guide elements may be screw-shaped guide elements. The screw-shaped guide elements may be arranged above or below a pair of screw-shaped compression elements. The screw-shaped guide elements may be engaged with a pair of screw-shaped compression elements. The thread pitch of the guide elements may correspond to the thread pitch of the compression elements. In this way, the guide elements can be rotatably engaged with the compression elements. The guide elements and compression elements may share the same drive element and may be arranged to laterally define a compression gap between the guide elements and the compression elements.

[0032] The guiding elements help guide the receptor material strip. The guiding elements prevent the receptor material strip from drifting out of the compression gap due to the rotation of the compression element. Therefore, it is particularly advantageous if the guiding elements are constructed and arranged to laterally limit the compression gap. Advantageously, two guiding elements are provided for each pair of screw-type compression elements.

[0033] The compression station may include a third section in which compression elements are arranged to define a gradually expanding gap in the processing direction. The compression elements used in the third section of the compression station may be formed substantially the same as those in the first and second sections of the compression station.

[0034] Therefore, if the compression element in the first part of the compression table is provided in the form of a belt guided above the guide rollers, the compression element in the third table can also be a belt guided above the guide rollers. In the third part of the compression table, the guide rollers are arranged such that the belt defines a gradually widening gap in the processing direction.

[0035] If the compression elements in the first part of the compression station are provided in the form of opposing screw-shaped compression elements, then the compression elements in the third station can also be provided in the form of screw-shaped compression elements. In the third part of the compression station, the screw-shaped compression elements are arranged such that they define a gradually expanding gap in the processing direction.

[0036] To create a gradually widening gap in the processing direction, the same considerations discussed above regarding the construction of the screw-shaped element apply. The screw-shaped element is used in the first part of the compression stage and defines a gradually narrowing compression gap in the processing direction. Therefore, the screw-shaped element can also be configured to have a gradually decreasing diameter, or the screw-shaped elements can be arranged such that their longitudinal axes are slightly inclined away from each other.

[0037] By providing a compression stage with a third compression stage, wherein the compression element is configured to define a gradually expanding gap in the processing direction, the compression element is slowly processed from engagement with the newly formed receptor material strip. With this gradual withdrawal of the compression element, the potential risk of damage to the formed receptor material strip is reduced.

[0038] The third part of the compression stage, which defines a gradually expanding gap in the processing direction, is advantageously located at the downstream end of the compression stage.

[0039] The method may further include a sensing medium injection step, wherein the sensing medium may be injected onto a receptor material strip. The sensing medium may be injected into a recess in the receptor material strip.

[0040] The sensing medium can be injected onto the sensor material strip via a separate injection device.

[0041] The injection device may also be included in the compression stage. Advantageously, the injection device is included in the third part of the compression stage.

[0042] In embodiments where the compression element is provided in the form of a toothed belt guided above a guide roller, one or more of the teeth or protruding structures of the belt may be provided with a central hollow channel that extends completely through the belt and the protruding tooth elements.

[0043] One or two of the toothed belts may be guided along the pressure-sensing medium storage device. The sensing medium storage device may have an opening facing the rear side of the toothed belt. The rear side of the toothed belt may substantially cover the opening of the pressure-sensing medium storage device, thereby preventing the pressure-sensing medium from overflowing from the sensing medium storage device. The toothed belt may be guided along the sensing medium storage device in such a way that the central hollow channel of the teeth is in fluid communication with the opening of the pressure-sensing medium storage device.

[0044] When the central hollow channel is in fluid communication with the opening of the pressurized sensing medium storage device, a certain amount of sensing medium flows through the central hollow channel and is delivered from the tip of the tooth to the recess in the sensor material strip.

[0045] The amount of sensing medium delivered in each injection step can be adjusted as needed. For example, the delivery amount can be adjusted by modifying the pressure in the pressurized sensing medium storage device, by modifying the belt speed, or by modifying the size of the channel in the gear.

[0046] The injection device can be fixed relative to the compression stage. The injection device can be located in the third section of the compression stage. In the third section of the compression stage, the teeth of the belt are gradually withdrawn from the corrugations of the sensor material belt. The third section of the compression stage is optimally suited for injecting the sensing medium because the gradual withdrawal of the teeth provides space for the sensing medium to insert into the recesses of the sensor material belt.

[0047] Pressurization of the sensing medium storage device can be achieved using any suitable means, such as a piston or pump. The pump can be a peristaltic pump or another type of pump that can be used in conjunction with the sensing medium.

[0048] If the compression element in the first part of the compression station is provided in the form of a relative screw-shaped compression element, the injection of the sensing medium can be achieved via one or more hollow radial channels that open at the ridges of threads located on the outer circumference of one or both of the screw-shaped compression elements. One or more hollow, radially arranged channels can be connected to a stationary pressurized sensing medium storage device.

[0049] Specifically, if more than one radial channel is provided, the corresponding screw-shaped compression element may be provided with a central axial channel that acts as a manifold for multiple radial channels. The central axial channel may be configured to connect to the sensing medium storage device. The central axial channel may be configured to connect to the sensing medium storage device via a pipe or any other conduit.

[0050] Also in this embodiment, the radial channel is advantageously located in the screw-shaped compression element of the third section of the compression stage. As described above, in the third section of the compression stage, the ridge of the screw-shaped compression element gradually withdraws from the corrugations of the sensor material strip. This leaves sufficient space for the sensing medium in the corrugations of the sensor material strip, and is therefore an ideal time for the injection of the sensing medium.

[0051] The amount of sensing medium injected can be determined by the pressure of the sensing medium in the sensing medium storage device, the diameter of the axial hollow channel, and the size and number of the hollow radially arranged channels in the screw-shaped compression element.

[0052] The present invention also relates to a method for manufacturing a sensor for an inductively heated aerosol-generating article, wherein the method includes the steps of providing a strip of sensor material and providing a cutting table comprising periodically corrugated blades. Using the periodically corrugated blades, at least a portion of the strip of sensor material is cut and extended such that the strip of sensor material has regions of continuous ordinary and extended sensor material.

[0053] The periodically corrugated blade is constructed to have a cutting blade with a periodically corrugated profile. The exact shape of the corrugated profile is adapted to the desired characteristics of the extended portion formed by the cutting section. However, it is necessary to form corrugations such that the receptor material strip is not completely cut across its entire width. Instead, only partial cutting lines are provided to the receptor material strip, in which uncut bridging portions of the receptor material are preserved.

[0054] The wavy profile can be triangular or other polygonal in shape, or it can be circular, such as a sine wave.

[0055] As described above, the corrugated blade is configured to partially cut the receptor material strip along its width. Simultaneously, the blade also has a forming portion that follows the design of the cutting blade and stamps the cutting portion into a corrugated shape. Therefore, the initially flat receptor material strip is simultaneously cut and expanded into a corrugated shape.

[0056] The cutting and spreading process is preferably a step-by-step process. This means that the receptor material is advanced by a predetermined amount between the individual cutting and spreading steps. Additionally, the periodic corrugated blade can be laterally offset between the successive cutting and spreading steps.

[0057] During the cutting and expansion process, an initially flat strip of receptor material is progressively fed into the cutting table, and the cutting blade reciprocates perpendicular to the feed direction. In this way, the initially flat strip is provided with alternating offset cuts, which are used to form corresponding expansion portions.

[0058] In this way, a complete receptor material strip can be converted into an extended receptor material strip. It is also possible to generate strips with continuous extended and ordinary receptor material portions.

[0059] Through the expansion process, the cut portion of the receptor material strip is extended in the cutting direction, which is substantially perpendicular to the flat, uncut portion of the strip. Therefore, the resulting strip has a stair-step profile along its length.

[0060] After cutting and expansion, the processed strip can be planarized to prepare receptor material for further processing. For this purpose, the receptor material strip can be planarized by folding or stamping. In this way, a flat strip of receptor material with continuously arranged ordinary and extended regions can be obtained.

[0061] The sensor material strip with continuously arranged ordinary and extended sections offers new possibilities for the induction heating process. The ordinary section includes more surface and volume for eddy currents than the extended section. Therefore, more heat is generated in the ordinary section of the sensor material strip compared to the extended region. This can be used to design the heating distribution of the sensor element. It can also be used in decisions regarding the placement of the sensing medium relative to the sensor element.

[0062] The method may further include the step of providing a sensing medium to a strip of receptor material. The step of providing the sensing medium to the strip of receptor material may be performed simultaneously with the cutting and expanding steps. The step of providing the sensing medium to the strip of receptor material may be performed such that the sensing medium is provided to the expanded region during the cutting and expanding steps.

[0063] For this purpose, the cutting table may be provided with a sensing medium storage device. The sensing medium storage device may have a release opening adjacent to the area where the expansion step is performed. The releasing sensing medium storage device may have a release opening positioned such that the strip of sensor material being expanded by the cutting blade moves across the release opening. The sensing medium storage device is configured such that the sensing medium is released during the expansion of the sensor material. In this way, the sensing medium can be directly obtained from the expansion portion during its manufacturing. Specifically, the sensing medium can be fed into the penetration or open portion of the sensor in the expansion region such that the addition of the sensing medium does not cause any thickness change.

[0064] The sensing medium storage device may include a pressurized medium and may have a controllable valve that can be opened to release the sensing medium. The sensing medium storage device may also include a controllable piston that can modify the volume of the sensing medium storage device and can press the sensing medium out of the release opening.

[0065] Both the valve and piston can be synchronized with the movement of the cutting blade, allowing the medium to be released during the expansion step. The expansion section is ideally suited to include a sensing medium because, due to the open structure of the expansion section, the evaporated sensing medium can be easily obtained by the airflow through the sensing material.

[0066] As used herein, the term "extended receptor material" refers to a type of receptor material in which multiple weakened regions, particularly multiple perforations, have been created, and which is subsequently stretched to form a regular pattern of openings originating from the stretching of the multiple weakened regions, particularly from the multiple perforations. The receptor material can be extended through perforation.

[0067] Compared to other types of sheet-like receptors, using receptors that include extended receptor materials offers several advantages.

[0068] First, due to specific manufacturing processes, the mass per unit area of ​​the extended receptor material is reduced compared to receptor materials without this opening. Simultaneously, the surface area of ​​the extended receptor material remains sufficiently large to provide extensive thermal emission. As a result, the ratio between the total mass and thermal emission surface area of ​​the receptor including the extended receptor material is improved compared to receptors including receptor materials without any openings. Advantageously, this helps to save resources used in article manufacturing. Furthermore, the reduction in mass per unit area is also beneficial to the reduction in the total mass of the article.

[0069] Second, compared to receptor materials that include openings created by material removal (e.g., by punching), manufacturing extended receptor materials that include openings created as described above (i.e., by weakening, particularly perforating and stretching, receptor materials) advantageously does not involve material waste. For this same reason, the receptors of the articles according to the invention advantageously allow for savings in materials and production costs, and thus conserve resources.

[0070] Third, due to the opening, the receptors of the article according to the invention are permeable, thereby enhancing the airflow drawn through the article compared to articles comprising impermeable receptors. Furthermore, the openings in the receptors promote the release and entrainment of material volatilized from the heated aerosol-forming matrix into the airflow. Advantageously, both aspects promote aerosol formation.

[0071] Fourth, compared to a welded or woven receptor mesh of the same weight, receptors comprising extended receptor material are more robust because, despite weakening, particularly by perforation and stretching, the receptor material remains intact and thus retains its strength. Simultaneously, extended receptor material is more flexible and less rigid than receptor material without openings. Advantageously, this facilitates material supply during the manufacture of aerosol-generating articles.

[0072] Fifth, the openings in the extended receptor material can be filled with an aerosol-forming matrix during article manufacturing. Advantageously, this supports the fixation of the receptor within the aerosol-forming matrix. Therefore, the positional accuracy and stability of the receptor within the aerosol-forming matrix are significantly improved, while the overall thickness remains unaffected. The receptor material does not protrude from the receptor, facilitating handling.

[0073] The method may further include the step of forming a planarized receptor material strip into a corrugated receptor material strip as described above. Preferably, the receptor material strip is formed with periodically alternating ordinary portions and extended portions. More preferably, the periodicity of these portions corresponds to the periodicity of the corrugations provided to the receptor material strip. A corrugated receptor material strip is obtained by adapting the two periods to each other, wherein the extended portions and ordinary portions are always located in the same position.

[0074] The ordinary portion may be formed as a depression, also referred to herein as a valley, and the extended portion may be formed as a protrusion of the corrugated band of the obtained receptor material, also referred to herein as a peak. Alternatively, the ordinary portion may be formed as a peak, and the extended portion may be formed as a valley of the corrugated band of the obtained receptor material.

[0075] The method may further include the step of providing two receptor material strips. The method may further include the step of stacking the two receptor material strips such that an extended portion of one receptor material strip is positioned adjacent to a common portion of the other receptor material strip. By stacking the two receptor material strips in this manner, the extended portion of one receptor material strip is positioned adjacent to a common portion of the other receptor material strip. This configuration enhances heat transfer from the common portion to the extended portion, which in turn enhances the evaporation capacity of the receptor device.

[0076] The present invention also relates to a sensor for an inductively heated aerosol-generating article, wherein the sensor is provided as a sensor material strip comprising continuously arranged ordinary and extended sensor material portions.

[0077] The sensor material strip with continuously arranged ordinary and extended sections offers new possibilities for the induction heating process. The ordinary section includes more surface and volume for eddy currents than the extended section. Therefore, more heat is generated in the ordinary section of the sensor material strip compared to the extended region. This can be used to design the heating distribution of the sensor element. It can also be used in decisions regarding the placement of the sensing medium relative to the sensor element.

[0078] The extended sensor material portion may be filled with a sensing medium. The sensing medium may be located in pores, voids, or openings within the extended region, and may not protrude from the sensor thickness. A sensor with continuously arranged ordinary and extended portions provides good heatability and simultaneously good evaporation characteristics. The ordinary portion generates heat, which is readily transferred to the extended portion via conduction. The extended portion receives heat from adjacent ordinary portions, allowing the sensing medium supplied to the extended portion to evaporate. Due to the porous structure of the extended portion, the evaporated sensing medium can engage with airflow passing through either side of the sensor material, thereby enhancing the overall aerosolubility of the sensing medium.

[0079] A flat strip of receptor material having continuously arranged ordinary and extended portions can be processed to have corrugations. A flat strip of receptor material having continuously arranged ordinary and extended portions can be processed to have valleys and peaks. A flat strip of receptor material having continuously arranged ordinary and extended portions can be processed to have valleys and peaks, such that the ordinary portions form valleys and the extended portions form peaks of the resulting corrugated strip of receptor material.

[0080] The peaks of the receptor material extend into the airflow and are therefore ideally suited for evaporation. This configuration is particularly advantageous when the extended portion of the receptor material band contains a sensing medium.

[0081] Alternatively or as a supplement, the valleys of the receptor material formed in the ordinary receptor material portion may also be provided with a sensing medium. Since the ordinary receptor material generates more heat when inductively heated, it may be desirable to provide a specific sensing medium at these ordinary portions of the receptor material band.

[0082] As an example, the extended receptor can be made of a sheet with a thickness ranging from about 0.03 mm to about 1 mm, more preferably from about 0.05 mm to about 0.5 mm, for example, from about 0.07 mm to about 0.2 mm. The opening in the extended region can be generally rhomboid or obliquely square in shape, with a first diagonal ranging from 0.5 mm to 5 mm and a second diagonal ranging from 0.3 mm to 3 mm. The opening area can range from 30% to 70% of the total area. The receptor material can be in the form of a strip. Preferably, the strip has a generally rectangular shape and a width preferably between about 2 mm and about 8 mm, more preferably between about 3 mm and about 5 mm, for example, 4 mm.

[0083] The present invention further relates to a sensor device for an inductively heated aerosol-generating article, wherein the sensor device comprises two sensor material bands as described herein. The two sensor material bands are superimposed such that the extended peak region of one sensor material band is positioned adjacent to the common valley region of the other sensor material band.

[0084] Such receptor devices offer additional advantages. Because in this configuration, the extended portion of one receptor material strip is always positioned adjacent to the ordinary portion of another receptor material strip, the induced heat generated in the ordinary portion can be directly delivered to the extended portion of the other receptor material strip. Heat conduction is also more efficient in this configuration due to the shorter heat conduction path and the larger heat conduction surface between adjacent receptors.

[0085] Furthermore, the peaks on either side of the sensor device are formed by extended portions, ensuring optimal evaporation conditions on either side. Additionally, valleys are formed by ordinary portions of the sensor and are positioned directly adjacent to the peaks of another sensor. Therefore, heat generated in any valley can be easily conducted to neighboring sensors, enhancing the overall evaporation performance of the sensor device.

[0086] The receptor device may be provided with sinusoidal or triangular ripples. Advantageously, the periodicity of the ripples corresponds to the periodicity of the continuous ordinary portion and the extended portion. As an example, the ripples may exhibit a peak-to-peak height of approximately 5 to 15 times the thickness of the flat band before formation.

[0087] As mentioned above, the peak of the receptor device extends into the gas flow generated in the aerosol-generating article, making it advantageous from this point of view to form the peak by the extended portion of the receptor material carrying the sensing medium.

[0088] However, in this case, the sensing medium may also be more susceptible to the negative effects of additional manufacturing steps performed during further fabrication of the aerosol-forming article. Therefore, the formation of ordinary material peaks without loading and the formation of valleys from loaded extended material may also be advantageous. To allow for a more immersive user experience, additional sensing medium can be loaded onto the extended portion.

[0089] By providing triangular corrugations, the sensor can be arranged such that the diffusion direction of the evaporating sensing medium can be oriented. For example, the sensor can be arranged such that the diffusion direction of the evaporating sensing medium is guided in the airflow direction through the aerosol-generated article and toward the mouth of the article.

[0090] The present invention also relates to a method for providing a sensing medium to a strip of receptor material, wherein the receptor material strip is manufactured as described herein. The receptor material strip may be a corrugated strip of receptor material or a flat strip of receptor material comprising continuously arranged ordinary and extended receptor material portions.

[0091] The sensing medium can be applied to the receptor material strip by dipping. For this purpose, the receptor material strip can be guided through a tank containing the sensing medium. The receptor material strip can be completely immersed in the sensing medium, such that the entire surface of the receptor material strip is in contact with the sensing medium.

[0092] To convey the sensor material strip through the sensing medium tank, a pair of guide rollers can be provided between which the sensor material strip is clamped and conveyed through the sensing medium tank. The pair of such guide rollers can be located at either end of the sensing medium tank. In this way, the movement of the sensor material strip through the sensing medium tank can be well controlled.

[0093] This method may be particularly suitable for depositing sensing media onto a strip of receptor material comprising a continuous arrangement of a common portion and an extended portion. The sensing media adheres better to the extended portion than to the common portion. Therefore, this method is particularly suitable for depositing sensing media onto the extended portion of a strip of receptor material.

[0094] The sensing medium can be provided to the sensor material strip via a coating roller. The surface of the coating roller may be coated with the sensing medium. By guiding the sensor material strip above the coating roller, the sensing medium can be deposited onto the sensor material strip.

[0095] The sensor material strip can be slightly pressed against the coating roller to maintain sufficient contact between them. If the sensor material strip is corrugated, it can be guided through a gap formed between the coating roller and the opposing roller. This gap can be smaller than the peak-to-peak distance of the corrugations. In this way, the opposing roller helps press the sensor material strip against the coating roller. The opposing roller not only helps maintain sufficient contact pressure but also expands the contact surface between the corrugated sensor material strip and the coating roller, resulting in a larger area of ​​the sensor material strip containing the sensing medium. This method is particularly suitable for corrugated strips of sensor material with highly elastic sinusoidal corrugations.

[0096] If the receptor material strip is corrugated, the coating roller only contacts the peaks of the receptor material strip. Therefore, only the peaks of the corrugated strip have the sensing medium. The corrugated strip of the receptor material can be formed such that the peaks are formed by extended portions of the receptor material. The extended portions can retain the sensing medium better than the ordinary portions, making the deposition of the sensing medium more efficient in this configuration.

[0097] The sensor material strip can also be pressed against the coating roller by two tension rollers located downstream and upstream of the coating roller. The tension rollers can be used to modify the tension of the sensor material strip near the coating roller. By modifying the strip tension, the coating efficiency can be adjusted. The use of tension rollers is particularly useful if the sensor material strip is flat.

[0098] Tension rollers can also be used to modify the contact arc between the sensor material strip and the coating roller. This allows for modification of the contact time between the sensor material strip and the coating roller. Adjustment of the contact arc can improve coating efficiency.

[0099] The coating roller is in fluid communication with the sensing medium storage device. The coating roller can be positioned at a distance above the sensing medium storage device, such that the lower portion of the coating roller is immersed in the sensing medium disposed in the sensing medium storage device. The sensing medium can wet the surface of the coating roller and can subsequently be deposited on the sensor material strip.

[0100] The coating roller can be in direct fluid communication with the sensing medium storage device. The coating roller can also be in indirect fluid communication with the sensing medium storage device. Indirect fluid contact can be established via an intermediate roller that is in direct contact with the sensing medium and transfers the sensing medium to the coating roller. One or more intermediate rollers can be positioned between the sensing medium storage device and the coating roller. By using one or more intermediate rollers, the amount of sensing medium supplied to the coating roller and subsequently to the sensor material strip can be more precisely controlled.

[0101] The sensing medium can be provided to the sensor material strip by guiding the sensor material strip below the sensing medium storage device. The sensing medium storage device may have an opening at its bottom that can contact the upper surface of the sensor material strip.

[0102] The sensor material strip can be conveyed on a circular moving belt. The opening of the sensing medium storage device can be located in direct contact with the upper surface of the sensor material strip.

[0103] This configuration may be advantageous when used with a sensor material strip, which is a flat strip comprising a continuously arranged common section and an extended section. When the common section of the sensor material strip is directly below the opening, the common section effectively seals the opening and prevents the sensing medium from flowing out onto the sensor material strip.

[0104] When the extended portion of the receptor material strip is directly below the opening, the sensing medium is delivered to the extended portion, which then opens to its full capacity. In this way, only a limited amount of sensing medium is delivered to the receptor material strip.

[0105] An injection device using a sensing medium storage device positioned above the sensor material strip can also be used with the corrugated strip of sensor material. The opening at the bottom of the sensing medium storage device may not necessarily contact the sensor material strip. However, the sensing medium storage device can be used to deliver sensing medium to a recessed valley portion of the sensor material strip conveyed below the opening of the sensing medium storage device.

[0106] The injection device can be used to deposit a sensing medium onto a corrugated band of sensor material, wherein valleys are formed by ordinary portions of the sensor material, and wherein, optionally, peaks are formed by extended sensor material.

[0107] Valleys made of ordinary receptor material can retain a large amount of sensing medium. Furthermore, the amount of sensing medium delivered to each valley of the corrugated band of the receptor material can remain constant. The same amount of sensing medium can be filled into each valley. If peaks are formed by expanded receptor material, these peaks can define the maximum filling level of the sensing medium. Peaks can act as overflow sections to limit the amount of sensing medium delivered to the valleys. Therefore, when the filling level in a valley reaches a portion of the porous expanded material region, any excess sensing medium may overflow through the porous expanded material.

[0108] The opening of the sensing medium storage device can be opened and closed by suitable means known to those skilled in the art. For example, an opening valve can be provided, which can be controlled according to the periodicity of the sensor material strip to be loaded with the sensing medium. In this way, the sensing medium can be delivered precisely when the valley is below the opening.

[0109] To regulate the flow of the sensing medium or the pressure within the sensing medium storage device, a pump, such as a peristaltic pump, can be provided. The pump can be synchronized with a valve. In this way, it is ensured that a sufficient amount of sensing medium is delivered to each valley of the corrugated strip of the sensor material.

[0110] The sensing medium can be provided to the corrugated strip of the sensor material via an injection device utilizing a solid sensing medium. The method may include advancing the solid sensing medium toward a punching machine, cutting a quantity of the sensing medium, and delivering that quantity of sensing medium to the valleys of the corrugated strip of the sensor material.

[0111] Solid sensing media are easier to handle than liquid sensing media. Delivering solid sensing media allows for consistent and precise quantification of the sensing medium. Therefore, using this method, corrugated strips of sensor material can be fabricated where all valleys contain the same and predetermined amount of sensing medium.

[0112] The method may further include the step of temporarily liquefying a certain amount of sensing medium delivered to the valleys of the corrugated band of the sensor material.

[0113] A certain amount of the sensing medium can be liquefied by temporarily heating it after delivery to the valleys of the corrugated strip of the receptor material. Heating can be performed by any suitable heating device. A suitable heating device is a hot air gun. The hot air delivered from such a hot air gun is sufficient to reduce the viscosity of the sensing medium. The heated sensing medium can then begin to liquefy and adhere to the walls of the valleys of the receptor material strip.

[0114] When heating the sensing medium, it may be advantageous to heat only the sensing medium and essentially avoid heating the sensor material. In this case, the heat required to liquefy the sensing medium can be minimized, and deformation of the sensor material due to overheating can be avoided. Furthermore, if the sensor material is heated as little as possible, the cooling process of the sensing medium is accelerated.

[0115] To further accelerate the cooling process of the sensing medium, a strip of sensor material can be conveyed through a cooling station. Suitable cooling stations for this process are known in the art. By accelerating the cooling process, rapid re-gelling of the sensing medium can be achieved. The sensor material strip can be processed only after the sensing medium has cooled and fully adhered to the sensor material. Therefore, accelerating the cooling process reduces the time required for the overall manufacturing process.

[0116] The corrugated strip of sensor material can be progressively delivered through the injection device. Each step corresponds to the spacing width of the corrugated strip of sensor material. After each step, the injection device is activated. A predetermined amount of sensing medium is cut and delivered to the valley of the corrugated strip of sensor material.

[0117] The gradual movement of the corrugated belt of the receptor material can be established via any suitable transmitter device. The transmitter device may include a toothed annular belt driven by a stepper motor. The periodicity of the toothed belt corresponds to the periodicity of the corrugated belt of the receptor material. In this way, each tooth of the toothed belt can engage with a valley of the corrugated belt of the receptor material. By distributing the traction force at multiple engagement points, the stress at each individual engagement point can be reduced, and deformation of the corrugated belt of the receptor material can be avoided.

[0118] Suitable processes and apparatus known in the art can be used to advance the sensing medium toward the cutting device and cut a predetermined amount of the sensing medium. The advancing mechanism may include a piston or clamp that engages with and moves the solid sensing medium.

[0119] To cut a predetermined amount of sensing medium, a punching machine can be used. The punching machine can move perpendicular to the direction of advance of the sensing medium and may include a cutting blade at its front end. The punching machine can be used to cut a predetermined amount of sensing medium and push the cut sensing medium into the valley of a corrugated strip of sensor material located below the punching machine.

[0120] This method can only be used to fill the valleys on one side of the corrugated strip of the receptor material. The method can also be used to fill the valleys on either side of the corrugated strip of the receptor material with a sensing medium. This can be performed via a two-step process. In the first step, the valley on the first side of the corrugated strip of the receptor material can be filled with the sensing medium. After the sensing medium has cooled sufficiently to allow it to fully adhere to the valleys of the corrugated strip receptor material, the strip can be turned to fill the valleys on the second side of the corrugated strip of the receptor material with the sensing medium.

[0121] Since the sensing medium on the inner side of the valley may adhere to the wall of the corrugated strip, it should be kept in the proper position even when inverted. If the adhesion of the sensing medium is too weak, for example, due to vibrations from the movement of the corrugated strip or due to the thixotropic properties of the sensing medium, the viscosity or adhesion of the sensing medium can be increased. This can be done by further cooling the metal strip or by changing the composition of the sensing medium.

[0122] The sensing medium can be provided to the corrugated strip of sensor material via another injection device utilizing a liquid sensing medium. The liquid sensing medium can be disposed in a sensing medium storage device, through which the corrugated strip of sensor material is guided. The sensing medium storage device may have at least one inlet opening for introducing the corrugated strip of unloaded sensor material into the sensing medium storage device. The sensing medium storage device may have at least one outlet opening for allowing the corrugated strip of loaded sensor material to exit from the sensing medium storage device.

[0123] The outlet opening can be formed by two lips that define the distance between them. The distance between the lips can correspond to the peak-to-peak distance of the corrugated band of the receptor material.

[0124] The corrugated belt is guided through the internal volume of the sensing medium storage device and exits the sensing medium storage device through the outlet opening.

[0125] The two lips that define the outlet opening can be elastic or pre-biased, or both, such that each lip slightly presses against the corrugated band of the receptor material.

[0126] As the corrugated strip of sensor material is guided through the interior and outlet opening of the liquid medium storage device, the liquid sensing medium is received in each valley of the corrugated strip of sensor material. The sensing medium is configured to have such a composition that, after the corrugated strip has left the sensing medium storage device through the outlet opening, the sensing medium received in each valley substantially adheres to the wall of the valley of the corrugated strip.

[0127] Because the lip edge presses against the corrugated strip from each side, the lip edge effectively closes the outlet opening, preventing excess sensing medium from leaving the sensing medium storage device. For a reliable seal, the lip edge may have a length such that each lip edge contacts at least two peaks on the corresponding side of the corrugated strip of the sensor material at any given time.

[0128] The width of the lip edge can correspond to the width of the corrugated strip. The outlet opening of the sensing medium storage device can be provided with a suitable sealing element to seal the outlet opening on the lateral side of the corrugated strip.

[0129] The lip edges are preferably made of an elastic material. In this way, the height difference between subsequent peaks of the corrugated band can be compensated. Alternatively or additionally, the lip edges can be pre-biased toward each other via a suitable biasing device. In a simple construction, such biasing can be achieved by a spring mechanism between each lip edge and the corresponding side surface of the sensing medium storage device.

[0130] Because the corrugated strip of the sensor material may experience varying tensile and thrust forces during its movement through the sensing medium storage device, the peak-to-peak distance of the corrugated strip may change during the coating process. These varying tensile and thrust forces can be caused by the viscosity of the sensing medium or by friction between the corrugated strip and the surfaces of the two lips at the outlet opening. By constructing the two lips as elastic or by using pre-biased lips, the distance between the two lips can be dynamically varied, compensating for any changes in the size of the corrugated strip. In this way, a seal is achieved at the outlet opening, and undesirable outflow of excess sensing medium is prevented.

[0131] As used herein, “sensing medium” is understood to preferably be a material or mixture of materials capable of releasing volatile compounds into an airflow through which a sensor is disposed when the sensing medium is heated.

[0132] The sensing medium may be a gel. The availability of a gel can be advantageous for storage and transportation, or during use, as it reduces the risk of leakage from the sensor, aerosol-generating article, or aerosol-generating device.

[0133] 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. Room temperature in this context means 25 degrees Celsius.

[0134] The sensing medium may include an aerosol forming agent. Ideally, the aerosol forming agent is substantially resistant to thermal degradation at the sensor's operating temperature. 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.

[0135] Advantageously, the sensing medium is a gel, including, for example, a thermally reversible gel. 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 is no longer solid and begins to flow.

[0136] 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.

[0137] 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.

[0138] The gel may include a gelling agent. The gel may include agar or agarose or sodium alginate or gellan gum, or a mixture thereof.

[0139] The gel may include water; for example, the gel is a hydrogel. Alternatively, in a particular embodiment, the gel is non-aqueous.

[0140] Preferably, the gel includes an active agent. The active agent may include nicotine (e.g., in powder or liquid form) or a tobacco product or another target compound for release, for example, in an aerosol. Nicotine may be contained within the 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.

[0141] Gels may include solid tobacco materials that release flavor compounds when heated. Solid tobacco materials may be 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.

[0142] The gel may include other flavors, such as menthol. Menthol can be added to water or an aerosol forming agent before gel formation.

[0143] 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.

[0144] 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 change 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.

[0145] When gellan gum is used as a gelling agent, the gel typically comprises between 0.5% and 5% gellan gum. Preferably, the gel also contains between 0.1% and 2% nicotine. Preferably, the gel contains between 30% and 99.4% glycerol. In a specific embodiment, the remainder of the gel comprises water and flavoring agents.

[0146] In one example, the gel comprises 2% by weight nicotine, 70% by weight glycerin, 27% by weight water, and 1% by weight agar.

[0147] 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.

[0148] In particular, the amount of gel in each whole article can be set or adjusted relative to the expected delivery of nicotine and / or the total expected aerosol generation and / or the expected duration of the user experience.

[0149] As used herein, the term "sensor material" refers to a material capable of converting electromagnetic energy into heat. When placed in an alternating electromagnetic field, eddy currents are typically induced and hysteresis losses may occur in the sensor, causing heating of the sensor. When the sensor material is positioned in thermal contact with the sensing medium, the sensing medium is heated by the sensor material, releasing fluid from the sensor material.

[0150] The receptor material can be formed of any material that can be inductively heated to a temperature sufficient to release material from the sensing medium. Preferred receptor materials include metals or carbon. Preferred receptor materials may include ferrimagnetic or ferromagnetic materials (e.g., ferritic iron), ferromagnetic alloys (e.g., ferromagnetic steel, stainless steel, or aluminum), or be composed of ferrimagnetic or ferromagnetic materials. Preferably, the receptor material comprises more than 5%, more preferably more than 20%, more preferably more than 50%, or more than 90% ferromagnetic or paramagnetic material. Preferred receptors can be heated to temperatures between about 150 degrees Celsius and about 300 degrees Celsius. Preferably, the receptor can be heated to temperatures between about 200 degrees Celsius and about 270 degrees Celsius, for example, 235 degrees Celsius.

[0151] Preferably, the receptor material strip is a slender metallic material.

[0152] Preferably, the receptor material strip is a stainless steel strip. However, the receptor material may also include or be made of the following: graphite; molybdenum; silicon carbide; aluminum; niobium; Inconelalloy (a superalloy based on austenitic nickel-chromium); metallized film; ceramics such as zirconium oxide; transition metals such as iron, cobalt, and nickel; or metalloid components such as boron, carbon, silicon, phosphorus, and aluminum.

[0153] The receptor material is in the form of a strip. Preferably, the strip has a generally rectangular shape, with a width preferably between about 2 mm and about 8 mm, more preferably between about 3 mm and about 5 mm, for example, 4 mm, and a thickness preferably between about 0.03 mm and about 1 mm, more preferably between about 0.05 mm and about 0.5 mm, for example, between about 0.07 mm and about 0.2 mm. The width of the receptor material strip is smaller than the width or diameter of the rod in which the receptor material is disposed.

[0154] The following is a non-exhaustive list of non-limiting examples. Any one or more features of these examples may be combined with any one or more features of another example, implementation, or aspect described herein.

[0155] Example A: A method for manufacturing a sensor for an inductively heated aerosol-generating article, wherein the method includes the following steps:

[0156] • Provide receptor material strips,

[0157] A compression stage is provided, comprising opposingly arranged compression elements, wherein in a first portion of the compression stage, the compression elements are arranged to define a gradually narrowing compression gap in a processing direction, and wherein in a second portion of the compression stage, the compression elements are arranged to define a constant compression gap in a processing direction, and wherein the opposingly arranged compression elements are configured to have matching surface structures.

[0158] • The sensor material strip is guided through the narrowed compression gap of the compression stage, so that the surface structure of the compression element is matched to the deep-drawn sensor material strip.

[0159] Example B: According to the method of Example A, the compression element is a belt guided above a plurality of guide rollers, wherein in the first part of the compression table, the guide rollers are arranged such that the belt defines a gradually narrowing compression gap in the processing direction.

[0160] Example C: According to the method of any of the preceding examples, the belt is provided with alternately arranged teeth such that the teeth of one belt penetrate each other between two adjacent teeth arranged on opposite belts.

[0161] Example D: According to the method of any of the foregoing examples, the belt has alternating and matching protruding and recessed structures, wherein the protruding structure from one belt penetrates the recessed structure of the other belt to deeply punch a sensor material belt guided between the belts.

[0162] Example E: According to the method of Example A, the compression element is a screw-shaped element, which is constructed and arranged such that the threads provided on the outer circumference of the screw-shaped element form a gradually narrowing compression gap in the processing direction.

[0163] Example F: According to the method of Example E, the compression element is a screw-shaped element, the screw-shaped elements are arranged such that their longitudinal axes are inclined toward each other, such that the threads provided on the outer circumference of the screw-shaped element form a gradually narrowing compression gap in the processing direction.

[0164] Example G: According to the method of Example E, the compression element is a screw-shaped element with a gradually increasing diameter and arranged such that their longitudinal axes are parallel to each other, such that the threads provided on the outer circumference of the screw-shaped element form a gradually narrowing compression gap in the processing direction.

[0165] Example H: According to any one of Examples E to G, the compression stage includes one or two screw-shaped guide elements arranged on top of or below the narrowed compression gap and engaging with the compression element.

[0166] Example I: According to the method of any of the foregoing examples, the compression stage further includes a third portion in which compression elements are arranged to define a gradually expanding gap in the processing direction.

[0167] Example J: According to the method of any of the preceding examples, the portion of the compression stage that forms the gradually narrowing compression gap is located at the upstream end of the compression stage.

[0168] Example K: According to the method of any of the preceding examples, the portion of the compression stage forming the gradually expanding gap is located at the downstream end of the compression stage.

[0169] Example L: The method according to any of the foregoing examples, wherein the method includes a sensing medium injection step, wherein the sensing medium is injected into a recess in the sensor material strip formed during the compression step.

[0170] Example M: ​​According to any of the preceding examples, the tooth or protruding structure is provided with a central channel in fluid communication with the sensing medium storage device, and wherein the sensing medium is provided to the recess of the sensor material strip in a third portion of the compression stage defining the gradually expanding gap.

[0171] Example N: According to any of the preceding examples, the ridge of the screw-shaped compression element arranged to form the gradually expanding gap is configured with one or more central channels in fluid communication with the sensing medium storage device, and wherein the sensing medium is provided in a third portion of the compression stage to a recess of the sensor material strip, the third portion of the compression stage defining a gradually expanding gap in the processing direction.

[0172] Example O: A method for manufacturing a sensor for an inductively heated aerosol-generating article, wherein the method includes the following steps:

[0173] • Provide receptor material strips,

[0174] • A cutting table is provided, the cutting table including periodic corrugated blades for cutting and expanding at least a portion of the receptor material strip, such that the receptor material strip has continuous ordinary and expanded receptor material portions.

[0175] Example P: According to the method of Example O, the cutting process is a step-by-step process, wherein between individual cutting steps, the sensor material is fed forward by a predetermined amount, and the periodic corrugated blade reciprocates perpendicular to the feed direction.

[0176] Example Q: The method according to any one of Examples O and P, wherein after the cutting process, the sensor material strip is flattened by folding or stamping, so as to obtain a flat metal strip having continuously arranged ordinary and extended sensor material portions.

[0177] Example R: The method according to any one of Examples O to Q, wherein during the cutting and expansion process, a sensing medium is provided to the sensor material strip such that the expanded region is simultaneously provided with the sensing medium.

[0178] Example S: According to the method of any one of Examples Q to R, the flattened receptor material strip is corrugated in such a way that the ordinary portion forms a valley and the extended portion forms a peak of the resulting corrugated strip.

[0179] Example T: According to the method of any one of Examples O to S, two receptor material strips are superimposed such that an extended portion of one receptor material strip is positioned adjacent to a normal portion of the other receptor material strip.

[0180] Example U: The method according to any one of Examples Q to R, wherein the sensing medium is provided to the sensor material strip after the flattening step.

[0181] Example V: According to the method of any of the preceding examples, the sensing medium is disposed as a gel in a tank, and the processed sensor material is guided through the sensing medium tank.

[0182] Example W: According to the method of any of the preceding examples, the sensing medium is disposed as a gel in a storage tank, and the sensing medium is deposited onto the processed sensor material via a coating roller, wherein the coating roller is in fluid communication with the sensing medium in the storage tank.

[0183] Example X: According to the method of any of the preceding examples, the sensing medium is disposed as a gel in a tank having a dispensing opening at its bottom side, and the sensor material of the treatment having a continuous arrangement of a general area and an extended area is guided directly below and adjacent to the opening of the sensing medium tank.

[0184] Example Y: According to any of the preceding examples, the sensing medium storage device is pressurized such that sensing medium discharged from the sensing medium storage device fills the extended region.

[0185] Example Z: According to the method of any of the preceding examples, the sensing medium reservoir is periodically pressurized such that the gel is discharged from the sensing medium reservoir only when the extended portion travels to the vicinity of the opening of the sensing medium reservoir to fill the extended portion.

[0186] Example ZA: According to the method of any of the foregoing examples, the sensing medium is provided to the sensor material via an injection device, wherein the sensing medium is a gel, and the sensing medium is ejected under pressure from an applicator to a nearby band.

[0187] Example ZB: The method according to any of the foregoing examples, wherein the sensing medium is ejected continuously or periodically.

[0188] Example ZC: According to any of the preceding examples, the injection device includes a pump for delivering the sensing medium, preferably a peristaltic pump.

[0189] Example ZD: The method according to any of the foregoing examples, wherein the receptor material strip is provided as a corrugated strip, and wherein the sensing medium is provided as a solid gel strip.

[0190] The device includes: an injection device with a propulsion mechanism for the gel strip, and a punching machine for cutting a certain amount of gel and delivering the certain amount of gel to the valley of the corrugated strip of the receptor material.

[0191] Example ZE: According to the method of Example ZD, the amount of gel material delivered to the valley is temporarily liquefied by a hot air gun.

[0192] Example ZF: According to the method of Example ZD or ZE, the corrugated belt material is progressively conveyed through the injection device via a toothed belt driven by a stepper motor.

[0193] Example ZG: According to the method of any of the foregoing examples, the valley on either side of the corrugated strip material is subsequently filled with a sensing medium.

[0194] Example ZH: According to the method of any of the foregoing examples, the sensor material strip is provided as a corrugated strip, and the sensing medium is disposed as a liquid gel in a tank, wherein an opening formed by two pre-biased or elastic lips is provided on one side of the tank, and wherein the corrugated strip is guided through the internal volume of the tank and exits the tank through the opening formed by the two pre-biased or elastic lips.

[0195] Example ZI: According to the method of Example ZH, wherein the length of the lip edge is such that the lip edge presses against at least two peaks of the ripple band at any time.

[0196] Example ZJ: A sensor for an inductively heated aerosol-generating article, wherein the sensor is provided as a sensor material strip comprising continuously arranged ordinary and extended sensor material regions.

[0197] Example ZK: Based on the receptor of example ZJ, the extended receptor material portion is provided with a sensing medium.

[0198] Example ZL: A receptor according to any one of Examples ZJ or ZK, wherein the receptor material strip is corrugated in such a way that the ordinary portion forms a valley and the extended portion forms a peak of the resulting corrugated strip.

[0199] Example ZM: A receptor according to any one of Examples ZJ to ZL, wherein the valley formed in the ordinary receptor material portion has a sensing medium.

[0200] Example ZN: A sensor device for an inductively heated aerosol generating article, wherein the sensor device comprises two sensors according to any one of Examples ZJ to ZM, and wherein the two sensors are superimposed such that the extended peak portion of one sensor is positioned adjacent to the ordinary valley portion of the other sensor.

[0201] Example ZO: A receptor device according to Example ZN, wherein the receptor device has a sinusoidal or triangular ripple, wherein the periodicity of the ripple corresponds to the periodicity of a continuous ordinary portion and an extended portion. Attached Figure Description

[0202] The invention will be further described by way of example only with reference to the accompanying drawings, in which:

[0203] Figure 1 A method for forming corrugated strips of sensor material is shown;

[0204] Figure 2 An embodiment of a toothed belt is shown;

[0205] Figure 3Receptor material strips with various surface patterns are shown;

[0206] Figure 4 An embodiment including a toothed belt with an injection device is shown;

[0207] Figure 5 A method for forming corrugated strips of sensor material is shown;

[0208] Figure 6 yes Figure 5 A cross-sectional view of the device;

[0209] Figure 7 A method for forming a corrugated strip of sensor material with a sensing medium is shown;

[0210] Figure 8 A method for cutting and expanding flat strips of receptor material is shown;

[0211] Figure 9 The cutting and expansion stage is shown;

[0212] Figure 10 A flat band of receptor material with continuous ordinary and extended receptor material portions is shown;

[0213] Figure 11 Showing the direction Figure 10 The method of providing a sensing medium using sensor material strips;

[0214] Figure 12 A corrugated strip of receptor material with continuous ordinary and extended receptor material portions and a corresponding receptor device are shown.

[0215] Figure 13 It shows a method for providing the sensing medium to Figure 10 The sensory apparatus;

[0216] Figure 14 It shows a method for providing the sensing medium to Figure 10 The sensory apparatus;

[0217] Figure 15 An apparatus for providing a sensing medium to a ripple sensor is shown;

[0218] Figure 16 It shows a method for providing the sensing medium to Figure 10 The sensory apparatus;

[0219] Figure 17 An apparatus for providing a sensing medium to a ripple sensor is shown;

[0220] Figure 18 A method for forming a receptor device is shown;

[0221] Figure 19 This illustrates a method for injecting a solid-state sensing medium into a ripple sensor;

[0222] Figure 20 This illustrates a method of injecting a liquid sensing medium into a ripple sensor;

[0223] Figure 21 yes Figure 20 A detailed view of the outlet end of the sensing medium storage device. Detailed Implementation

[0224] exist Figure 1 The image shows a first embodiment of an apparatus for carrying out the method of the present invention, wherein an initially flat strip of receptor material 10 is processed into a corrugated strip of receptor material 11. The flat strip of receptor material 10 is a stainless steel strip having a width of about 5 mm and a thickness of about 0.05 mm.

[0225] A flat strip 10 of receptor material is fed into a processing apparatus 12 having a compression stage 14, in which the receptor material strip 10 is provided with desired corrugations. For this purpose, compression elements 16 are provided arranged opposite each other, defining a compression gap 18 therebetween.

[0226] The compression element is a toothed annular belt 16, each of which is guided above a guide roller 20. One of the guide rollers 20 is configured as a drive roller 22, which is connected to a drive motor (not shown). The guide rollers 20 and the drive roller 22 are arranged to define three different sections of the compression table 14.

[0227] In the first portion 24 of the compression table 14, guide rollers 20 and 22 are arranged such that the compression element 16 defines a gradually narrowing compression gap 18" in the processing direction. In the second portion 26 of the compression table 14, guide rollers 20 and 22 are arranged such that the compression element 16 defines a constant compression gap 18 therebetween in the processing direction. In the third portion 28 of the compression table 14, guide roller 20 is arranged such that the compression element 16 defines an extended compression gap 18 in the processing direction.

[0228] The toothed annular belts 16 arranged opposite to each other are arranged such that the teeth 30 in one annular belt penetrate each other between two adjacent teeth 30 arranged on opposite belts.

[0229] The initially flat sensor material strip 10 is guided through the compression stage 14, thereby feeding the strip 10 into the narrowing gap 18 of the first portion 24 of the compression stage 14.

[0230] The mating surface structure of the interpenetrating teeth 30 of the opposing compression element 16 gradually engages with the receptor material strip 10, and gradually deep-draws the material into a predetermined corrugated shape. In the second part 26 of the compression stage 14, the compression gap 18 remains constant in the processing direction. In this part of the compression stage 14, the compression element 16 is used to confirm the corrugated shape of the receptor material strip 10.

[0231] At the downstream end of the compression stage 14, the teeth 30 of the compression element 16, and in particular the annular belt 16, are gradually withdrawn from the corrugated belt 11 of the sensor material. This gradual withdrawal prevents any potential damage to the newly formed belt 11 of the sensor material.

[0232] exist Figure 2 The diagram depicts an alternative arrangement of toothed belts 16 with matching surface structures. The belt 16 has alternating matching female teeth 32 and male teeth 34. The male teeth 34 include protrusions 36. The female teeth 32 are formed with recesses 38, which are large enough to receive the protrusions 36 of the male teeth 34. In use, a receptor material belt 10 is guided between the toothed belts 16 having female teeth 32 and male teeth 34. The matching surface structures of these toothed belts 16 form alternating recesses in the receptor material belt 10. In this way, the initially flat receptor material belt 10 is transformed into a corrugated belt 11 of receptor material.

[0233] exist Figure 3 The diagram schematically depicts corrugated strips 11 of receptor materials with various surface patterns. Figure 3 The left-hand view shows corrugated strips 11 of the receptor material with regular, sinusoidal, or wavy patterns. However, Figure 3 Other patterns depicted in the other two views are also possible. Figure 3 The intermediate view shows a pattern in which multiple longitudinal recesses 40 are provided to the receptor material strip 11. Figure 3 In the right-side view, multiple lateral recesses 42 are provided to the sensor material strip 11.

[0234] exist Figure 4 The image depicts a configuration in which the sensor material strip 10 is corrugated, and in which the sensing medium 44 is simultaneously injected into each of the newly formed recesses 46. Figure 4 The toothed belt 16 depicted corresponds to Figure 2 Belt 16.

[0235] Each of the male teeth 34 has a central hollow channel 48 that extends completely through the belt 16 and the tooth 34. The toothed belt 16 is guided along the pressure sensing medium storage device 50. Each of the sensing medium storage devices 50 has an opening 52 facing the rear side of the corresponding toothed belt 16. The belt 16 is guided such that the rear side of each of the toothed belts 16 substantially covers the opening 52 of the corresponding pressure sensing medium storage device 50. However, when the male tooth 34 with the central hollow channel 48 is guided through the opening 52 of the pressure sensing medium storage device 50, the sensing medium 50 can flow through the central hollow channel 48 and be delivered from the tip of the male tooth 34 into the recess 46 in the corrugated belt 11 of the sensor material.

[0236] The injection step is performed in the third section 28 of the compression table 14. In this section, the belt 16 is arranged to form an extended compression gap 18 in the processing direction, thereby gradually withdrawing the male tooth 34 from the female tooth 32. As the protrusions 36 of the male tooth 34 move out of the recesses 46, they make room for the injection of the sensing medium 44.

[0237] The sensing medium 44 is provided in gel form. The delivery amount of the sensing medium gel 44 is adjusted by modifying the pressure in the pressurized sensing medium storage device 50 and by modifying the speed of the belt 16. The pressurization of the sensing medium storage device 50 is obtained via a pump (not depicted).

[0238] Figures 5 to 7 In another embodiment of the invention, the method is performed using a compression element in the form of a screw-shaped element 56. The screw-shaped element 56 is essentially a cylindrical element. The outer circumference of the opposing screw-shaped elements 56 is provided with corresponding threads 58 having corresponding thread pitches.

[0239] like Figure 5 As depicted, the screw-shaped elements 56 are arranged such that their longitudinal axes 60 are slightly inclined toward each other, such that the threads 58 provided on the outer circumference of the screw-shaped elements 56 form a compression gap 18 that gradually narrows relative to the processing direction 62 in the processing direction. Figure 5 The image depicts only the first portion 24 of the compression stage 14. In this first portion 24, an initially flat strip of receptor material 10 is gradually stretched into a corrugated strip 11. Following this first portion 24 is at least a second portion 26, in which screw-shaped compression elements 56 are arranged to form a constant compression gap 18 in the processing direction.

[0240] exist Figure 6In this embodiment, the receptor material strip 10 is further guided by two guide elements 64 in the compression stage 14. The guide elements 64 are also screw-shaped elements. The screw-shaped guide elements 64 are arranged above and below a pair of screw-shaped compression elements 56. The screw-shaped guide elements 64 also have external threads, the thread pitch of which corresponds to the thread pitch of the compression elements 56. In this way, the guide elements 64 are rotatably engaged with the compression elements 56. The guide elements 64 and the compression elements 64 laterally define a compression gap 18 through which the receptor material strip 10 is guided.

[0241] Figure 7 A third portion 28 of the compression stage 14 is shown, wherein compression elements 16 are provided in the form of opposing screw-shaped elements 56. The screw-shaped elements 56 are arranged such that they define a compression gap 18 that gradually widens in the processing direction 62. The compression elements 56 are configured to deliver sensing medium gel 44 onto the sensor material strip 11. For this purpose, the compression elements 56 include a hollow radial channel 66 that opens at the ridge of a thread located on the outer circumference of one of the screw-shaped compression elements 56. The hollow, radially arranged channel 66 extends into a central manifold channel 68, which in turn connects to a stationary pressurized sensing medium storage device (not shown). Figure 7 In this configuration, a central axial channel manifold 68 is configured as a receiving adapter 70, which is configured to connect to a pressure-sensing medium storage device. The adapter 70 includes a longitudinal opening 72, which allows fluid communication with a hollow, radially arranged channel 66. Figure 7 In this diagram, only the sensing medium injection device with the upper compression element 56 is depicted. However, the corresponding sensing medium injection device also provides to the lower compression element 56, so that the sensing medium 44 is provided to either side of the corrugated strip 11 of the sensor material.

[0242] exist Figure 7 On the right side, a cross-sectional view of the compression element 56, including fluid channels 66, 68, is depicted. In this case, three equidistant radial channels 66 are provided for each turn of the thread. Each of the radial channels 66 extends from the central axial channel 68 to the outer circumference of the screw-shaped compression element 56.

[0243] The amount of sensing medium 44 injected into the recess 46 is determined by the pressure in the sensing medium storage device, the diameter of the axial hollow channel 68, and the size and number of the hollow radially arranged channels 66 in the screw-shaped compression element 56. The sensing medium 44 can be injected continuously or intermittently. For this purpose, a controllable valve (not shown) that can be opened and closed can be provided to control the flow of the sensing medium onto the sensing material strip 11.

[0244] Figures 8 to 11A method is disclosed for manufacturing a sensor for an inductively heated aerosol-generating article. In this method, an initially flat strip of sensor material is progressively advanced to a cutting table 80 comprising a periodically corrugated blade 82. The periodically corrugated blade 82 has a periodic trapezoidal shape and is configured such that the flat strip 10 of the sensor material has a portion of cut transverse to its longitudinal axis.

[0245] Meanwhile, the corrugated blade 82 also has a forming portion 83, which follows the design of the cutting blade 82 and stamps the cutting portion into a corrugated shape defined by the corrugated blade 82. Therefore, the initially flat sensor material strip 10 is simultaneously cut and expanded into this corrugated shape.

[0246] The cutting and spreading process is a step-by-step process. The movement of the cutting blade 82 is as follows: Figure 8 The series of arrows in the diagram indicate reciprocating movement. Figure 8 In the top view, the sensor material strip 10 has been advanced a predetermined distance into the cutting table 80, the predetermined distance corresponding to the cutting width of the cutting table 80. As indicated by the arrow, the corrugated blade 82 moves to the right into the first cutting position.

[0247] exist Figure 8 In the second view, the cutting blade 82 is in the first position and moves downward to simultaneously cut and extend the receptor material strip 10. Then, the cutting blade 82 moves upward and to the left by half the spacing of the blade corrugations to the second cutting position. The receptor material strip 10 advances again by one step, and the cutting blade 82 moves downward to perform a second cut that laterally deviates from the first cut. Similarly, the extension laterally deviates from the first extension step. Figure 8 In the bottom view, the cutting blade 82 is raised again and moved back to the first cutting position. The cutting process described above can then be performed again. In this way, the initially flat receptor material strip 10 is provided with an extension 86 that extends over at least a portion of the length of the receptor material strip 10.

[0248] Through the expansion process, the cut portion of the receptor material band 10 expands in the cutting direction. The cutting direction extends substantially perpendicular to the plane defined by the flat band 10 of the receptor material. Figure 9 In the initial flat receptor material strip 10, continuous ordinary or uncut receptor material portions 84 and extended or cut receptor material portions 86 are provided. Therefore, the resulting partially extended strip 88, as... Figure 9 The schematic diagram depicts a staircase-shaped outline along the length direction.

[0249] After cutting and extending the strip 88, which has a continuous ordinary portion 84 and an extended portion 86, the strip can be planarized to prepare a receptor material strip 88 for further processing. For this purpose, the receptor material strip 88 is planarized by a stamping device (not shown). Figure 10 The image depicts a flat strip 90 of the resulting receptor material having a continuously arranged ordinary portion 84 and an extended portion 86. Due to the extension process, the extended portion is provided with through holes, which are defined by sheet-like strips or strips. As an example, the width of the strip or strip can be set to be equal to the thickness of the receptor. The holes or perforations can have a maximum opening size greater than or at least equal to the thickness of the receptor.

[0250] like Figure 11 As depicted, a portion of the extended strip of receptor material 88 is further provided with a sensing medium 44. During the cutting and extending process, the sensing medium 44 is provided to the receptor material strip 88. For this purpose, the cutting table 80 is provided with a sensing medium storage device 50. The sensing medium storage device 50 has a release opening 52 directly adjacent to the cutting and extending table 80. During the cutting and extending steps, a portion 86 of the receptor material strip extended by the cutting blade 82 moves across the release opening 52.

[0251] The sensing medium storage device 50 is configured such that the sensing medium 44 is released during the expansion of the sensor material strip 10. For this purpose, the sensing medium storage device 50 includes a controllable piston 51 that presses the sensing medium 44 out of the release opening 52. The piston 51 is synchronized with the cutting blade 82 such that the sensing medium 44 is released during the downward movement of the cutting blade 82 in the expansion step.

[0252] The gaps in the extended portion of the sensor material strip 86 are ideal for acquiring the sensing medium 44. Furthermore, the extended portion 86 is open to either side of the sensor material strip 88, allowing the evaporated sensing medium 44 to be easily acquired by the airflow passing through the sensor element during use.

[0253] As mentioned above Figure 1 and 5 The planarized receptor material strip 90, having a continuous ordinary portion 84 and an extended portion 86, can be formed as a corrugated strip 11 of the receptor material. For example... Figure 12 As depicted in the topmost view, the periodicity of the ordinary portion 84 and the extended portion 86 corresponds to the periodicity of the corrugations provided to the sensor material band 11. In this way, a corrugated band 11 of sensor material is obtained, wherein corrugations (in other words, continuous valleys and peaks) are formed by the ordinary portion 84 and the extended portion 86, whereby the extended portion 86 is provided with the sensing medium 44.

[0254] like Figure 12 As depicted in other views, two receptor material strips 90 can be stacked to form a receptor device 100. Figure 12 Three alternative arrangements of corrugated strips 90 of two sensor materials are shown. The arrows in these views indicate the main diffusion direction of the sensing medium 44 during evaporation.

[0255] The two receptor material strips 90 can be arranged such that on either side, the peak of the receptor device 100 is formed by the extended portion 86 of the corrugated strip 90 of the receptor material. When such a receptor device 100 is used in an aerosol generating apparatus, this arrangement allows the evaporating material to easily enter the airflow path guided along the receptor device 100.

[0256] Alternatively, the two corrugated strips 90 of the receptor material can be arranged such that on either side, the peak of the receptor device 100 is formed by the ordinary portion 84 of the corrugated strip 90 of the receptor material. The peak formed by the ordinary portion 84 can protect the loaded extension portion 86 from friction with additional material of the adjacent receptor device 100 provided in the aerosol generation system.

[0257] exist Figure 12 In the bottommost view, the corrugated strip 90 of the sensor material has triangular corrugations. The corrugated strip 90 of the sensor material is arranged such that the diffusion direction of the evaporating sensing medium is oriented. Figure 12 In this configuration, the receptors are arranged such that the diffusion direction points to the right. This direction corresponds to the airflow direction in which the product is generated via aerosol during use.

[0258] The sensing medium 44 may also be supplied to the flat or corrugated strips 90, 11 of the sensor material in subsequent separate method steps.

[0259] exist Figure 13 In, such as Figure 10 The receptor material strip 90 shown is provided with a sensing medium 44 after the receptor material strip 90 has been partially expanded and planarized. The receptor material strip 90 is guided through a sensing medium storage device 50, which includes the sensing medium 44 in gel form. The receptor material strip 90 is completely immersed in the sensing medium gel 44.

[0260] To allow the sensor material strip 90 to pass through the sensing medium storage device 52, a pair of guide rollers 92 are positioned upstream and downstream of the sensing medium storage device 50. This allows for precise control of the movement of the sensor material strip 90 through the sensing medium storage device 50.

[0261] Compared to the ordinary portion 84 of the receptor material band 90, the sensing medium gel 44 adheres better to the extended portion 86. Therefore, this method is particularly suitable for selectively depositing the sensing medium 44 onto the extended portion 86 of the receptor material band 90.

[0262] like Figure 14 and15 As depicted, the sensing medium can also be provided to the sensor material belt 90 via the coating roller 110.

[0263] Figure 14 A method for providing the sensing medium 44 to a flat strip 90 of the receptor material is schematically illustrated. The receptor material strip 90 is again as described above. Figure 10 The structure is as described above. The sensor material strip 90 is guided above the coating roller 110. The coating roller 110 is in communication with the sensing medium storage device 50. By guiding the sensor material strip 90 above the coating roller 110, the sensing medium 44 is deposited onto the sensor material strip 90.

[0264] exist Figure 14 In this process, the coating roller 110 rolls in contact with the intermediate roller 112, which is then immersed in a sensing medium storage device 50 comprising a sensing medium 44 in gel form. The rotating intermediate roller 112 continuously picks up the gel 44 onto its surface and supplies the gel 44 onto the surface of the coating roller 110. The gel 44 is then supplied from the coating roller 110 to the sensor material belt 90.

[0265] Since gel 44 adheres well to the extended portion 86 of the receptor material strip 90, it is primarily these portions that acquire the sensing medium gel 44. Gel that does not adhere to the receptor material strip 90 remains at the coating roller 110 and is resupplyed to the receptor material strip 90 on the next rotation of the coating roller 110.

[0266] The receptor material strip 90 is slightly pressed against the coating roller 110 to maintain sufficient contact force between the receptor material strip 90 and the coating roller 110. Figure 14 In the process, the sensor material strip 90 is pressed against the coating roller 110 by two tension rollers 114 located downstream and upstream of the coating roller 110. The tension rollers 114 are arranged such that the tension of the sensor material strip 90 near the coating roller 110 is maintained at a predetermined value. The tension rollers 114 are used to adjust the strip tension and the contact arc between the sensor material strip 90 and the coating roller 110.

[0267] Figure 15 A similar method is shown that can be primarily used for coating the corrugated tape 11 of the receptor material. The corrugated tape 11 is guided through a roll gap 117 formed between the coating roller 110 and the opposing roller 116. The size of this roll gap 117 is slightly smaller than the peak-to-peak distance 13 of the corrugations of the receptor material's corrugated tape 11. In this way, the opposing roller 116 presses the receptor material tape 11 against the coating roller 110. This maintains sufficient contact pressure and simultaneously expands the contact surface between the corrugated tape 11 of the receptor material and the coating roller 110. Figure 15In this embodiment, the receptor material strip 11 is constructed to have a wavy shape. However, corrugated strips 11 with different wavy profiles can be used.

[0268] The coating roller 110 only contacts the peaks of the sensor material strip. Therefore, only the peaks of the corrugated strip are provided with the sensing medium 44. Thus, as... Figure 15 As described herein, the method may be particularly suitable for use with a corrugated strip of sensor material comprising a common portion 84 and an extended portion 86, wherein a peak is formed in the extended portion of the sensor material 86.

[0269] like Figure 16 and 17 As depicted, the sensing medium 44 can be provided to the sensor material strips 11, 90 by guiding the sensor material strips 11, 90 below the sensing medium storage device 50. The sensing medium storage device has a release opening 52 at its bottom.

[0270] exist Figure 16 In this context, the sensing medium provides a connection to, for example, the combination of... Figure 10 The device comprises a flat strip 90 of sensor material, consisting of continuous ordinary and extended sensor material portions 84, 86. The strip 90 is conveyed on an annular moving belt 120, which is guided above a guide wheel 122. A release opening 52 of the sensing medium storage device 50 is located directly above and in contact with the upper surface of the sensor material strip 90.

[0271] When the ordinary portion 84 of the sensor material strip 90 is directly below the release opening 52, the ordinary portion 84 effectively seals the release opening 52 and prevents the sensing medium 44 from flowing out onto the sensor material strip 90.

[0272] When the extensions 86 of the receptor material strip 90 are directly below the release opening 92, the sensing medium 44 is delivered onto these extensions 86. In this way, only a limited amount of the sensing medium 44 is selectively delivered to the receptor material strip 90. The sensing medium 44 is located in the opening region of the extensions 86, so that the overall thickness does not increase after the sensing medium is loaded. This facilitates further processing of the material.

[0273] exist Figure 17 In, with Figure 16 A similar injection device is used to deliver the sensing medium 44 to the corrugated strip 11 of the sensor material. In this configuration, the release opening 52 at the bottom of the sensing medium storage device 50 does not necessarily contact the sensor material strip 11.

[0274] This injection device is particularly useful for depositing sensing medium 44 onto the corrugated band 11 of the sensor material, where valleys 94 are formed from ordinary portions of the sensor material 84. Valleys 94 can retain a large amount of sensing medium 44.

[0275] exist Figure 17 In the sensor material band 11, peaks 96 are formed by extension portions 86. These peaks 96 act as overflow portions to limit the amount of sensing medium 44 delivered to the valleys 94. Therefore, when the fill level in the valleys 94 reaches the peaks 96 formed by the porous extension material portions 86, any excess sensing medium 44 overflows through the porous extension material 86.

[0276] To limit the amount of sensing medium 44 delivered to the corrugated belt 11, the release opening 52 of the sensing medium storage device 50 is equipped with an electronically controlled valve (not shown). The opening of the valve is controlled by the periodicity of the sensor material belt 11 to be loaded with sensing medium 44. In this way, the sensing medium 44 is delivered precisely when the valley 94 is located below the release opening 52.

[0277] Through such Figure 17 The method described herein includes a sensor material strip 11 of a sensing medium 44 that can be clamped to obtain a sensor device 100. Figure 18 The appropriate assembly process for this purpose is described in the text.

[0278] In the first step, two identical corrugated bands 11 were prepared, wherein peak 96 was formed by the extended portion of the receptor material 86, and valley 94 was formed by the ordinary portion of the receptor material 84, and filled with the sensing medium 44.

[0279] One of the bands 11 is inverted and shifted to one side by half a spacing. Then, the bands 11 are superimposed on each other, such that the extension 86 of one band 11 extends into the valley 94 of the corresponding other band 11. As... Figure 18 As can be seen in the bottom view, an extension 86 of one band 11 covers the sensing medium 44 provided to the valley 94 of another band 11. Similarly, the porous extension 86 allows the evaporation of the sensing medium 44 to pass through. The sensing medium 44 helps to bond the two corrugated bands 11 of the sensor material together. Figure 18 The process shown yields a very robust sensor device 100.

[0280] The sensing medium 44 can be provided to the corrugated strip 11 of the sensor material via the injection device 130 utilizing the solid sensing medium 44. Figure 19 The corresponding method is schematically depicted. As indicated by arrow 134, the solid sensing medium 44 is advanced toward the punching machine 132. The punching machine 132 is a movable element configured to cut a quantity of the sensing medium 44 and deliver that quantity of sensing medium 44 to the valley 94 of the corrugated strip 11 of the sensor material. The advancement mechanism is... Figure 19 It is not described further, but any suitable propulsion mechanism known to the technician may be used.

[0281] The corrugated strip 11 of receptor material is progressively conveyed through the injection device 130. The progressive movement of the corrugated strip 11 of receptor material is established via a conveyor device 140, which includes a toothed annular belt 142 driven by a stepper motor 144. The teeth 146 of the toothed belt 142 are periodically arranged corresponding to the periodicity of the corrugated strip 11 of receptor material. In this manner, each tooth 146 of the toothed belt 142 engages with a valley 94 of the corrugated strip 11 of receptor material, such that the toothed belt 142 conveys the corrugated strip 11 of receptor material.

[0282] Each step of the stepper motor 144 and the toothed belt 142 corresponds to the spacing width 148 of the corrugated belt 11 of the sensor material, such that each valley 94 of the corrugated belt 11 is continuously positioned below the injection device 130. After each step, the punching machine 132 is activated to cut a predetermined amount of the sensing medium 44 and deliver the predetermined amount to the valley 94 of the corrugated belt 11 of the sensor material.

[0283] The method further includes the step of temporarily liquefying a certain amount of sensing medium 44 delivered to the valleys 94 of the corrugated strip 11 of the sensor material. For this purpose, a hot air gun 136 is provided, which is directed at the cut sensing medium 44 in the valleys 94. The hot air reduces the viscosity of the sensing medium 44. The heated sensing medium 44 becomes fluid and adheres to the walls of the valleys 94 of the sensor material strip 11.

[0284] Figure 20 and 21 A method is disclosed for providing a liquid sensing medium 44 to a corrugated strip 11 of sensor material. The liquid sensing medium 44 is disposed in a sensing medium storage device 50, through which the corrugated strip 11 of sensor material is guided. The sensing medium storage device 50 has an inlet opening (not shown) for introducing the unloaded corrugated strip 11 of sensor material into the sensing medium storage device 50. The sensing medium storage device 50 further has an outlet opening 53 for allowing the loaded corrugated strip 11 of sensor material to exit from the sensing medium storage device 50.

[0285] The outlet opening 53 is formed by two pre-biased lips 150, which define a peak-to-peak distance 13 between them corresponding to the corrugated band 11 of the receptor material.

[0286] The corrugated belt 11 is guided through the internal volume of the sensing medium storage device 50 and exits the sensing medium storage device 50 through the outlet opening 53.

[0287] The two lips 150 defining the outlet opening 53 are formed of an elastic material and are pre-biased such that each lip 150 slightly presses against the corrugated strip 11 of the sensor material. The pre-biasing is achieved by a spring mechanism 152 disposed between each lip 150 and the corresponding side surface 154 of the sensing medium storage device 50.

[0288] Using the elastic material of the lip 150 and the spring mechanism 152, the lip 150 presses tightly against the corrugated band 11 of the receptor material from each side. In this way, the height difference between subsequent peaks of the corrugated band 11 is compensated.

[0289] As the lip 150 presses against the corrugated strip 11 from each side, the lip 150 effectively closes the outlet opening 53, thereby substantially preventing excessive leakage of the sensing medium 44 from the sensing medium storage device 50. To achieve a reliable seal, the lip 150 is configured to have a length 156 such that each lip of the lip 150 contacts at least two peaks on the corresponding side of the corrugated strip 11 of the sensor material at any given time.

[0290] The width 158 of the lip corresponds to the width of the corrugated belt 11. The outlet opening 53 of the sensing medium storage device 50 is provided with a suitable sealing element (not shown) to seal the outlet opening 53 on the lateral side of the corrugated belt 11.

[0291] As the corrugated strip 11 of the sensor material is guided through the interior and outlet opening 53 of the liquid medium reservoir 50, the liquid sensing medium 44 is received in each valley 94 of the corrugated strip 11. The sensing medium 44 is configured to have such a composition that the sensing medium 44 received in each valley 94 substantially adheres to the wall of the valley 94 of the corrugated strip 11 after the corrugated strip 11 has left the sensing medium reservoir 50 through the outlet opening 53.

Claims

1. A method for manufacturing a sensor for an inductively heated aerosol-generating article, wherein the method comprises the following steps: • Provide receptor material strips, A compression stage is provided comprising opposingly arranged compression elements, wherein in a first portion of the compression stage, the compression elements are arranged to define a gradually narrowing compression gap in a processing direction, and wherein in a second portion of the compression stage, the compression elements are arranged to define a constant compression gap therebetween in a processing direction, and wherein the opposingly arranged compression elements are configured to have matching surface structures. • The receptor material strip is guided through the narrowed compression gap of the compression stage, such that the matching surface structure of the compression element deeply punches the receptor material strip.

2. The method of claim 1, wherein the compression element is a belt guided above a plurality of guide rollers, wherein in the first portion of the compression table, the guide rollers are arranged such that the belt defines a gradually narrowing compression gap in the processing direction.

3. The method of claim 2, wherein the belt is provided with alternately arranged teeth such that the teeth of one belt penetrate each other between two adjacent teeth arranged on opposite belts.

4. The method according to claim 1, wherein the compression element is a screw-shaped element, the screw-shaped element being constructed and arranged such that the threads provided on the outer circumference of the screw-shaped element form a gradually narrowing compression gap in the processing direction.

5. The method according to any one of claims 1 to 4, wherein the compression stage further comprises a third portion in which compression elements are arranged to define a gradually expanding gap in the processing direction.

6. The method according to any one of claims 1 to 4, wherein the method includes a sensing medium injection step, wherein the sensing medium is injected into a recess in the sensor material strip formed during the compression step.

7. The method according to any one of claims 1 to 4, wherein the tooth or protruding structure is provided with a central channel in fluid communication with the sensing medium storage device, and wherein the sensing medium is provided in a third portion of the compression stage to a recess of the sensor material strip, the third portion of the compression stage defining a gradually expanding gap in the processing direction.

8. A method for manufacturing a sensor for an inductively heated aerosol-generating article, wherein the method comprises the following steps: • Provide receptor material strips, • A cutting table is provided, the cutting table including periodic corrugated blades for cutting and expanding at least a portion of the receptor material strip, such that the receptor material strip has continuous ordinary and expanded receptor material portions.

9. The method of claim 8, wherein the cutting process is a step-by-step process, wherein between individual cutting steps, the sensor material is fed forward by a predetermined amount, and the periodic corrugated blade reciprocates perpendicular to the feed direction.

10. The method according to any one of claims 8 to 9, wherein during the cutting and expansion process, a sensing medium is provided to the sensor material strip such that the expanded region is simultaneously provided with the sensing medium.

11. The method according to any one of claims 8 to 9, wherein two receptor material strips are superimposed such that an extended portion of one receptor material strip is positioned adjacent to a common portion of the other receptor material strip.

12. A sensor for an inductively heated aerosol-generating article, wherein the sensor is provided as a sensor material strip comprising continuously arranged ordinary and extended sensor material regions, and wherein the extended sensor material includes a plurality of openings.

13. The receptor of claim 12, wherein the portion of the extended receptor material is provided with a sensing medium.

14. The receptor according to any one of claims 12 and 13, wherein the receptor material strip is corrugated in such a way that the ordinary portion forms valleys and the extended portion forms peaks of the resulting corrugated strip.

15. A sensor device for an inductively heated aerosol-generating article, wherein the sensor device comprises two sensors according to any one of claims 12 to 14, and wherein the two sensors are superimposed such that an extended peak portion of one sensor is positioned adjacent to a common valley portion of the other sensor.

Images