Method for making an aerosol-generating article

Abstract

A method for continuously manufacturing an aerosol-generating article (1) comprises: (i) providing a continuous web (34) of an aerosol-generating substrate (10); (ii) separating a continuous strip (18) of the aerosol-generating substrate (10) from the continuous web (34) of the aerosol-generating substrate (10) provided in step (i), the continuous strip (18) having a substantially flat surface; (iii) applying at least one sensor patch (28) to the aerosol-generating substrate (10) obtained in step (ii); (iv) cutting the continuous web (34) of the aerosol generating substrate (10) to form a plurality of aerosol generating strips (15, 16); and (v) combining the at least one receptor patch (28) and the continuous strip (18) of the aerosol generating substrate (10) obtained in step (iii) with the plurality of aerosol generating strips (15, 16) obtained in step (iv) to form a continuous rod (88).

Description

Technical Field

[0001] The present disclosure relates generally to aerosol-generating articles, and more particularly to an aerosol-generating article for use with an aerosol-generating device that heats the aerosol-generating article to generate an aerosol for inhalation by a user. Embodiments of the present disclosure relate in particular to a method for continuously manufacturing an aerosol-generating article. The present disclosure is particularly suitable for manufacturing an aerosol-generating article for use with a portable (handheld) aerosol-generating device. Background Art

[0002] As an alternative to the use of traditional tobacco products, the popularity and use of reduced-risk or modified-risk devices (also known as aerosol-generating devices or vapor-generating devices) have grown rapidly in recent years. Various devices and systems are available that heat or warm an aerosol-generating substance to produce an aerosol for inhalation by a user.

[0003] A commonly used risk-reduced or risk-modified device is a heated substrate aerosol-generating device or a so-called heat-not-burn device. This type of device generates an aerosol or vapor by heating an aerosol-generating substrate to a temperature typically in the range of 150° C. to 300° C. Heating the aerosol-generating substrate to a temperature within this range without burning or combusting the aerosol-generating substrate generates a vapor that typically cools and condenses to form an aerosol that is inhaled by the user of the device.

[0004] Currently available aerosol generating devices can use one of a number of different methods to provide heat to the aerosol generating substrate. One such method is to provide an aerosol generating device that uses an induction heating system. In such a device, an induction coil is provided in the device, and an inductively heatable susceptor is provided to heat the aerosol generating substrate. When the user activates the device, electrical energy is supplied to the induction coil, which in turn generates an alternating electromagnetic field. The susceptor couples with the electromagnetic field and generates heat, which is transferred to the aerosol generating substrate, for example, by conduction, and an aerosol is generated when the aerosol generating substrate is heated.

[0005] It may be convenient to provide both the aerosol-generating substrate and the inductively heatable susceptor together in the form of an aerosol-generating article that can be inserted into an aerosol-generating device by a user. It is therefore desirable to provide a method that facilitates the manufacture of aerosol-generating articles and in particular enables easy and consistent mass production of aerosol-generating articles. Summary of the invention

[0006] According to a first aspect of the present disclosure, there is provided a method for continuously manufacturing an aerosol-generating article, the method comprising:

[0007] (i) providing a continuous web of an aerosol-generating substrate;

[0008] (ii) separating a continuous strip of aerosol-generating substrate from the continuous web of aerosol-generating substrate provided in step (i), the continuous strip having a substantially flat surface;

[0009] (iii) applying at least one susceptor patch to the substantially flat surface of the continuous strip of aerosol-generating substrate obtained in step (ii);

[0010] (iv) cutting the continuous web of aerosol-generating substrate to form a plurality of aerosol-generating strips; and

[0011] (v) combining the continuous strip of the at least one susceptor patch and the aerosol-generating substrate obtained in step (iii) with the plurality of aerosol-generating strips obtained in step (iv) to form a continuous rod.

[0012] The aerosol-generating article produced by the method is used with an aerosol-generating device for heating an aerosol-generating substrate rather than burning the aerosol-generating substrate to volatilize at least one component of the aerosol-generating substrate and thereby generate a heated vapor that cools and condenses to form an aerosol for inhalation by a user of the aerosol-generating device. The aerosol-generating device is a handheld portable device.

[0013] In a general sense, a vapor is a substance that is in the gaseous phase at a temperature below its critical temperature, which means that the vapor can be condensed into a liquid by increasing its pressure without lowering the temperature, while an aerosol is a suspension of fine solid particles or liquid droplets in air or another gas. However, it should be noted that the terms 'aerosol' and 'vapor' are used interchangeably in this specification, especially with respect to the form of the inhalable medium produced for inhalation by the user.

[0014] The method according to the present disclosure facilitates the manufacture of aerosol-generating articles, and in particular enables aerosol-generating articles to be consistently and relatively easily mass-produced. Manufacturing can be simplified by cutting a continuous web of an aerosol-generating substrate to form an aerosol-generating strip during step (iv), and then combining the aerosol-generating strip with the at least one receptor patch during step (v). Combining the aerosol-generating strip and the receptor into an aerosol-generating article produced by the method according to the present disclosure provides efficient heat transfer from the receptor to the aerosol-generating strip during use of the aerosol-generating article in an aerosol-generating device. This in turn provides efficient and uniform heating of the aerosol-generating strip, and therefore, reliable vapor generation.

[0015] Step (ii) may comprise separating the continuous strip of the aerosol-generating substrate from the edge of the continuous web of the aerosol-generating substrate.The remainder of the continuous web of the aerosol-generating substrate may be readily used during subsequent steps of the manufacturing process.

[0016] Step (ii) may comprise cutting the continuous web of the aerosol-generating substrate to separate the continuous strip of the aerosol-generating substrate therefrom. Step (ii) may be performed using a rotary cutter unit. The continuous strip may be easily separated from the continuous web of the aerosol-generating substrate by the cutting operation. The use of a rotary cutter unit may in particular allow for easy implementation of continuous and high-speed manufacturing of aerosol-generating articles.

[0017] Step (iii) may comprise adhering the at least one susceptor patch to a substantially flat surface of the continuous strip of aerosol-generating substrate, thereby achieving good bonding between the susceptor patch and the continuous strip of aerosol-generating substrate, thereby ensuring that the continuous strip of aerosol-generating substrate and the adhered susceptor patch can be effectively and reliably combined with the aerosol-generating strip to form a continuous rod during step (v).

[0018] The substantially flat surface of the continuous strip of aerosol-generating substrate provided in step (ii) may include a centerline, and step (iii) may include applying the at least one susceptor patch to the substantially flat surface substantially along the centerline. Accurate and consistent positioning of the susceptor patch along the centerline of the continuous strip of aerosol-generating substrate may ensure that aerosol-generating articles manufactured by methods according to the present disclosure have consistent and repeatable properties.

[0019] In some embodiments of the method, after step (ii) and before step (iii), the continuous strip of aerosol-generating substrate may be conveyed away from the continuous web of aerosol-generating substrate. Such an arrangement may allow high-speed and automated manufacturing of aerosol-generating articles by allowing steps (iii) and (iv) to be performed at different locations, and then the continuous strip of aerosol-generating substrate obtained in step (iii) to which the susceptor patch is applied is combined with the plurality of aerosol-generating strips obtained in step (iv) to form a continuous rod.

[0020] Step (iii) may comprise applying a plurality of susceptor patches successively to the generally flat surface of the continuous strip of aerosol generating substrate, wherein each successive susceptor patch has a predetermined and constant spacing between them. The predetermined and constant 'spacing' between each successive susceptor patch is the shortest distance between successive (i.e. adjacent) susceptor patches, i.e. the distance or gap between the edges of successive (i.e. adjacent) susceptor patches. Each of the plurality of susceptor patches may have substantially the same size. Aerosol generating articles having consistent and repeatable properties may be mass produced by this method.

[0021] The method may further comprise: before step (iii), providing a continuous web of susceptor material, and continuously cutting the continuous web of susceptor material to form the susceptor patches. Mass production of aerosol-generating articles is thereby easily achieved.

[0022] The step of continuously cutting the continuous web of susceptor material comprises uniformly cutting the continuous web of susceptor material at predetermined and constant intervals. By doing so, the susceptor patches have substantially the same length in the direction of travel of the continuous web of susceptor material. Thus, aerosol-generating articles manufactured by this method have consistent and repeatable properties.

[0023] Step (iv) may be performed using a rotary cutter unit. The rotary cutter unit may include a first cutting drum and a second cutting drum. The first cutting drum may have a first cutting formation extending circumferentially. The second cutting drum may have a second cutting formation extending circumferentially. The first cutting formation and the second cutting formation may cooperate to cut the continuous web of the aerosol-generating substrate to form the plurality of aerosol-generating strips. The use of a rotary cutter unit allows for easy implementation of continuous and high-speed manufacture of aerosol-generating articles.

[0024] Each susceptor patch may have a length of between 5 mm and 50 mm, preferably between 10 mm and 30 mm. Each susceptor patch may have a width of between 0.1 mm and 7 mm, preferably between 1 mm and 5 mm. Each susceptor patch may have a thickness of between 1 μm and 500 μm, preferably between 10 μm and 100 μm, possibly about 50 μm. Resusceptor patches with these dimensions are particularly suitable for the manufacture of aerosol generating articles.

[0025] The predetermined and constant spacing between each consecutive receptor patch may be between 1 mm and 20 mm, preferably between 2 mm and 10 mm.

[0026] Each of the plurality of aerosol generating strips may have a width between about 0.1 mm and 5.0 mm, possibly between about 0.5 mm and 2.0 mm. Each of the plurality of aerosol generating strips may have a width of 1.0 mm. These width dimensions ensure that aerosol generating articles manufactured using the methods according to the present disclosure contain an optimal number of aerosol generating strips to allow airflow to pass evenly through the aerosol generating article and produce an acceptable amount of vapor or aerosol. If the width of the aerosol generating strips is too low, the strength of the strips may be reduced, and mass production of aerosol generating articles may become difficult.

[0027] The method further comprises (vi): cutting the continuous rod to form a plurality of individual aerosol-generating articles, each aerosol-generating article comprising at least one susceptor patch. Continuous and large-scale production of aerosol-generating articles is thereby easily achieved.

[0028] Step (vi) may comprise cutting the continuous rod at locations between adjacent susceptor patches. Cutting the continuous rod in this manner ensures that each aerosol-generating article formed by cutting the continuous rod each comprises a susceptor patch, and therefore ensures that the aerosol-generating articles are consistent and repeatable. In addition, since the susceptor patches are not cut during step (vi), wear during the cutting step (e.g., on the cutting unit) is minimized.

[0029] Step (vi) may include cutting the continuous rod approximately at the midpoint between adjacent susceptor patches. In this way, the susceptor patches are spaced inwardly from both ends of the resulting aerosol-generating article and are not visible at either end of the aerosol-generating article. This can improve user acceptance of aerosol-generating articles manufactured by the methods according to the present disclosure. In addition, the susceptor is completely embedded in the aerosol-generating substrate (i.e., aerosol-generating strip) of the resulting aerosol-generating article, and this can allow for more efficient generation of aerosol or vapor because the entire susceptor is surrounded by the aerosol-generating strip and therefore heat transfer from the susceptor to the aerosol-generating strip is maximized.

[0030] Each susceptor patch may include an inductively heatable susceptor material such as, but not limited to, one or more of aluminum, iron, nickel, stainless steel, carbon steel, and alloys thereof (e.g., nickel-chromium or nickel-copper alloys). By applying an electromagnetic field in the vicinity of the aerosol-generating article during use in an aerosol-generating device, the susceptor material may generate heat due to eddy currents and hysteresis losses, thereby causing conversion of electromagnetic energy into thermal energy.

[0031] Aerosol generation substrate can be any type of solid or semi-solid material. Aerosol generation solid example types include powder, microparticles, pellets, fragments, lines, particles, gels, strips, loose leaves, chopped leaves, chopped fillers, porous materials, foam materials or sheets. Aerosol generation substrate can include plant-derived materials, and can especially include tobacco. It can advantageously include reconstituted tobacco, for example, the reconstituted tobacco includes tobacco and cellulose fibers, tobacco stem fibers and any one or more of inorganic fillers such as CaCO3.

[0032] Thus, an aerosol-generating device with which an aerosol-generating article is intended to be used may be referred to as a "heated tobacco device", "heat-but-not-burn tobacco device", "device for vaporizing tobacco products", etc., and this is interpreted as a device suitable for achieving these effects. The features disclosed herein are equally applicable to devices designed to vaporize any aerosol-generating substrate.

[0033] The continuous rod may be constrained by a paper wrapper. Thus, the method may further comprise wrapping the continuous rod with a paper wrapper.

[0034] The aerosol generating article can be roughly formed in the shape of a stick, and can be broadly similar to a cigarette with a tubular region having an aerosol generating substrate arranged in an appropriate manner. The aerosol generating article can include a filter segment at the proximal end of the aerosol generating article, for example including cellulose acetate fibers. The filter segment can constitute a mouthpiece filter, and can be coaxially aligned with an aerosol generating substrate consisting of a plurality of aerosol generating strips. In some designs, one or more vapor collection areas, cooling areas and other structures can also be included. For example, the aerosol generating article can include at least one tubular segment upstream of the filter segment. The tubular segment can serve as a vapor cooling area. The vapor cooling area can advantageously allow the heated vapor generated by heating the aerosol generating strip to cool and condense to form an aerosol with suitable properties for the user, for example, to inhale through the filter segment.

[0035] The aerosol generating substrate may include an aerosol former. Examples of aerosol formers include polyols and mixtures thereof, such as glycerol or propylene glycol. Typically, the aerosol generating substrate may include an aerosol former content between about 5% and about 50% (based on dry weight). In some embodiments, the aerosol generating substrate may include an aerosol former content between about 10% and about 20% (based on dry weight) and may be about 15% (based on dry weight).

[0036] Upon heating, the aerosol-generating substrate (ie, the aerosol-generating rod) may release volatile compounds. The volatile compounds may include nicotine or flavoring compounds such as tobacco flavoring. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] Figure 1a is a diagrammatic cross-sectional side view of an example of an aerosol-generating article;

[0038] Figure 1b is along Figure 1a An enlarged diagrammatic cross-sectional view of line AA in FIG.

[0039] Figure 2a It is used to manufacture Figure 1a and Figure 1b A diagrammatic illustration of an apparatus and method for producing an aerosol-generating article as shown in FIG.

[0040] Figure 2b The aerosol generating matrix and the sensor patch move through the aerosol generating matrix and the sensor patch in the direction indicated by the arrow. Figure 2a The equipment shown is a plan view;

[0041] Figure 3 is a plan view of a section of a continuous web of susceptor material showing adhesive areas and non-adhesive areas;

[0042] Figure 4 yes Figure 2a a functional illustration of a portion of an apparatus and method schematically illustrating forming a susceptor patch from a continuous web of susceptor material and applying the susceptor patch to a surface of a continuous strip of an aerosol generating substrate;

[0043] Figure 5 is a diagrammatic stereogram of a susceptor cut unit; and

[0044] Figure 6 is a diagrammatic illustration of a strip cutting unit. DETAILED DESCRIPTION

[0045] Embodiments of the present disclosure will now be described, by way of example only, and with reference to the accompanying drawings.

[0046] First refer to Figure 1a and Figure 1b , shows an example of an aerosol-generating article 1 for use with an aerosol-generating device, the aerosol-generating device comprising an induction heating system to inductively heat the aerosol-generating article and thereby generate an aerosol for inhalation by a user of the device. Such devices are known in the art and will not be described in further detail in this specification. The aerosol-generating article 1 is elongated and generally cylindrical. The circular cross-section facilitates gripping of the article 1 by the user and insertion of the article 1 into a cavity or heating compartment of the aerosol-generating device.

[0047] The aerosol-generating article 1 comprises an aerosol-generating substrate 10 having a first end 10a and a second end 10b and an inductively heatable susceptor 12. The aerosol-generating substrate 10 and the inductively heatable susceptor 12 are positioned in and enclosed by a wrapper 14. The wrapper 14 comprises a substantially non-conductive and non-magnetically permeable material. In the illustrated example, the wrapper 14 is a paper wrapper and may comprise cigarette paper.

[0048] The aerosol-generating article 1 may have a total length measured between the distal end 11a and the proximal end (mouth end) 11b, which is between 30 mm and 100 mm, preferably between 50 mm and 70 mm, and may be about 55 mm. The aerosol-generating substrate 10 may have a total length measured between the first end 10a and the second end 10b, which is between 5 mm and 50 mm, preferably between 10 mm and 30 mm, and may be about 20 mm. The aerosol-generating article 1 may have a diameter between 5 mm and 10 mm, preferably between 6 mm and 8 mm, and may be about 7 mm.

[0049] The aerosol-generating substrate 10 comprises a plurality of elongated first strips 15 containing an aerosol-generating material. The plurality of elongated first strips 15 constitute an aerosol-generating strip 16 and are oriented generally in the longitudinal direction of the aerosol-generating article 1. The elongated first strips 15 are crease-free in the longitudinal direction to ensure that the airflow route is not interrupted and that a uniform airflow through the article 1 can be achieved.

[0050] The inductively heatable susceptor 12 comprises an elongated second strip 13 containing an inductively heatable susceptor material. Thus, the elongated second strip 13 can be regarded as a strip-shaped or blade-shaped elongated susceptor 12 that is also oriented generally in the longitudinal direction of the aerosol-generating article 1. Figure 1b It is clearly seen in FIG. 1 that the width of each of the elongated first strips 15 is less than the width of the elongated second strips 13 .

[0051] The aerosol-generating article 1 comprises at least one elongated carrier strip 17 having a first major surface 17a and a second major surface 17b. The elongated carrier strip 17 contains an aerosol-generating material and thus also constitutes an aerosol-generating strip 16. The elongated carrier strip 17 is oriented generally in the longitudinal direction of the aerosol-generating article 1. The elongated carrier strip 17 has the same length as the elongated first strip 15, and thus the aerosol-generating strips 16 within the aerosol-generating article 1 all have the same length.

[0052] The elongated second strip 13 is adhered to the elongated carrier strip 17 and as can be seen in Figure 1bAs can be clearly seen in the figure, the width of the elongated carrier strip 17 is greater than the width of the elongated second strip 13. The elongated second strip 13 has a first face 13b and an opposite second face 13c. The second face 13c is adhered to the second major surface 17b of the elongated carrier strip 17 and is entirely covered by the elongated carrier strip 17 and more specifically by the second major surface 17b.

[0053] The elongated first strip 15, the elongated second strip 13 and the elongated carrier strip 17 are arranged to form a generally rod-shaped aerosol-generating article 1, and the elongated first strip 15 may be randomly distributed across the cross section of the rod-shaped aerosol-generating article 1 so that they have a plurality of different orientations within the cross section of the aerosol-generating article 1. Figure 1b Although not apparent in the figure, a sufficient number of elongated first strips 15 are provided to substantially fill the cross-section of the aerosol-generating substrate 10, and it should be understood that for illustrative purposes, only a smaller number of elongated first strips 15 are shown. The elongated second strips 13 and the elongated carrier strip 17 are positioned approximately in the center of the cross-section of the aerosol-generating substrate 10 and, therefore, the aerosol-generating article 1. Such an arrangement helps to ensure uniform heat transfer from the elongated second strips 13 to the elongated first strips 15.

[0054] As in Figure 1b As best seen in the figure, the centrally positioned elongated carrier strip 17 and the elongated second strips 13 adhered thereto define first regions 5 and second regions 6 within the cross section of the aerosol generating substrate 10 and hence within the cross section of the aerosol generating article 1. The first regions 5 face the first major surface 17a of the elongated carrier strip 17 and the second regions 6 face the second major surface 17b of the elongated carrier strip 17. Both the first regions 5 and the second regions 6 comprise a plurality of elongated first strips 15.

[0055] As in Figure 1a As best seen in the figure, each of the plurality of elongated first strips 15 has a distal end 15a, and the elongated second strip 13 has a distal end 13a. The distal ends 15a of the elongated first strips 15 form the first end 10a of the aerosol-generating substrate 10 and, accordingly, the distal end 11a of the aerosol-generating article 1. The elongated second strips 13 are shorter than the elongated first strips 15 and the elongated carrier strip 17. The distal ends 13a of the elongated second strips 13 are located inwardly from the distal ends 15a of the elongated first strips 15. Therefore, the distal ends 13a of the elongated second strips 13 (i.e., the elongated susceptors 12) are not visible at the distal end 11a of the aerosol-generating article 1.

[0056] The aerosol-generating article 1 comprises a mouthpiece segment 20 positioned downstream of an aerosol-generating substrate 10. The aerosol-generating substrate 10 and the mouthpiece segment 20 are arranged in coaxial alignment within a wrapper 14 to hold the components in place to form a rod-shaped aerosol-generating article 1 .

[0057] In the illustrated embodiment, the mouthpiece segment 20 includes the following components arranged in coaxial alignment in succession in the downstream direction (in other words, from the distal end 11a to the proximal end (mouth end) 11b of the aerosol generating article 1): a cooling segment 22, a central hole segment 23, and a filter segment 24. The cooling segment 22 includes a hollow paper tube 22a having a thickness greater than that of the paper wrapper 14. The central hole segment 23 may include a solidified mixture containing cellulose acetate fibers and a plasticizer, and is used to increase the strength of the mouthpiece segment 20. The filter segment 24 typically includes cellulose acetate fibers and acts as a mouthpiece filter. When the heated vapor flows from the aerosol generating substrate 10 toward the proximal end (mouth end) 11b of the aerosol generating article 1, the vapor cools and condenses when passing through the cooling segment 22 and the central hole segment 23 to form an aerosol having suitable properties for the user to inhale through the filter segment 24.

[0058] The elongated first strip 15 and the elongated carrier strip 17 typically comprise plant-derived materials, such as tobacco. The elongated first strip 15 and the elongated carrier strip 17 may advantageously comprise reconstituted tobacco, which comprises tobacco and any one or more of cellulose fibers, tobacco stem fibers, and inorganic fillers such as CaCO3.

[0059] The elongated first strip 15 and the elongated carrier strip 17 typically include an aerosol former, such as glycerol or propylene glycol. Typically, the elongated first strip 15 and the elongated carrier strip 17 include an aerosol former content of between about 5% and about 50% (on a dry weight basis). When heated, the elongated first strip 15 and the elongated carrier strip 17 release volatile compounds that may include nicotine or flavor compounds such as tobacco flavors.

[0060] When a time-varying electromagnetic field is applied near the elongated second strip 13 during use of the article 1 in an aerosol generating device, heat is generated in the elongated second strip 13 due to eddy currents and hysteresis losses. Heat is transferred from the elongated second strip 13 to the elongated first strip 15 and the elongated carrier strip 17 to heat the elongated first strip 15 and the elongated carrier strip 17 without burning them so as to release one or more volatile compounds and thereby generate vapor. When a user inhales through the filter segment 24, the heated vapor is drawn through the article 1 in a downstream direction from the first end 10a of the aerosol generating substrate 10 toward the second end 10b of the aerosol generating substrate 10 and toward the filter segment 24. As described above, when the heated vapor flows through the cooling segment 22 and the central hole segment 23 toward the filter segment 24, the heated vapor cools and condenses to form an aerosol having suitable properties for the user to inhale through the filter segment 24.

[0061] Manufacture of aerosol-generating articles

[0062] A method suitable for manufacturing an aerosol generating article (such as that described above) according to the present disclosure will now be described. Figure 1a and Figure 1b Device 30 and method for producing an aerosol-generating article 1).

[0063] refer to Figure 2a , shows the above reference for making Figure 1a and Figure 1b Diagrammatic representation of an apparatus 30 and method of describing an aerosol-generating article 1 . Figure 2b The aerosol generating substrate 10 and the sensor patch 28 are Figure 2b A plan view of the device 30 as it moves in the direction of the arrows.

[0064] The apparatus 30 includes a substrate supply reel 32 (e.g., a first reel) carrying a continuous web 34 of an aerosol-generating substrate 10 having a substantially flat surface, and a first feed roller 36 that controls the feeding of the continuous web 34 of the aerosol-generating substrate 10. The apparatus 30 may also include a web tensioning regulator and a web edge control system, as will be understood by one of ordinary skill in the art, but these additional components are not necessary in the context of the present disclosure and have therefore been omitted for the sake of brevity.

[0065] The apparatus 30 further comprises a rotating cutter unit 90, for example comprising a circular cutting knife, which cuts the continuous web 34 of the aerosol-generating substrate 10 along one edge 19 to separate a continuous strip 18 of the aerosol-generating substrate 10 from the continuous web 34. The continuous strip 18 of the aerosol-generating substrate 10 corresponds to the continuous strip 18 of the aerosol-generating substrate 10 described above with reference to Figure 1a and Figure 1b The elongated carrier strip 17 in the finished aerosol-generating article 1 is depicted. The continuous strip 18 of the aerosol-generating substrate 10 has a generally flat surface and is conveyed by conveyor rollers 92, 94, for example, in an upward direction (e.g., in Figure 2a 18 and the continuous web 34 are conveyed away from the aerosol-generating substrate 10 so that the continuous strip 18 and the continuous web 34 can be processed separately by the apparatus 30.

[0066] The apparatus 30 also includes a susceptor supply reel 38 (eg, a second reel) carrying a continuous web 40 of susceptor material, feed rollers 42 , 44 for controlling the feeding of the continuous web 40 of susceptor material, an adhesive applicator unit 46 , and a susceptor cutting unit 48 .

[0067] The apparatus 30 further includes an optional heater 50 , a feed roller 51 , a strip cutting unit 52 , a feed roller 54 , a rod forming unit 56 , and a rod cutting unit 58 .

[0068] Receptor patch preparation

[0069] In operation, a continuous web 34 of an aerosol generating substrate 10 is continuously supplied from a substrate supply reel 32, and a continuous strip 18 of the aerosol generating substrate 10 is separated from an edge 19 of the continuous web 34 by a rotating cutter unit 90 and conveyed away from the continuous web 34 by conveyor rollers 92, 94, as described above. At the same time, a continuous web 40 of susceptor material is continuously supplied from the susceptor supply reel 38 via feed rollers 42, 44 to an adhesive applicator unit 46. The adhesive applicator unit 46 applies an adhesive 47 to the surface of the continuous web 40 of susceptor material. In the example shown, the adhesive applicator unit 46 applies the adhesive 47 to the surface of the continuous web 40 of susceptor material intermittently and over the entire width of the web 40. In this way, discrete adhesive areas 60 are formed on the surface of the continuous web 40 of susceptor material (see Figure 3 and Figure 4 ), wherein adhesive-free areas 62 are formed between adjacent adhesive areas 60 along the travel direction of the continuous web 40 of susceptor material.

[0070] The continuous web 40 of susceptor material is supplied from the adhesive applicator unit 46 to the susceptor cutting unit 48, which continuously cuts the continuous web 40 of susceptor material to form a plurality of susceptor patches 28. Figure 2b As best seen in FIG. 4 , the width of the continuous web 40 of susceptor material, and therefore the susceptor patch 28, is less than the width of the continuous strip 18 of the aerosol-generating substrate 10. For example, the continuous web 40 of susceptor material, and therefore the susceptor patch 28, may have a width of between about 0.1 mm and 7 mm. In some embodiments, the susceptor patch 28 may have a length in the direction of travel of the continuous web 40 of susceptor material, between about 5 mm and 50 mm, and may have a thickness of between about 1 μm and 500 μm.

[0071] In order to minimize soiling of the susceptor cutting unit 48 by the adhesive 47 applied to the continuous web 40 of susceptor material by the adhesive applicator unit 46, the susceptor cutting unit 48 cuts the continuous web 40 of susceptor material in the adhesive-free areas 62, that is, at locations between the adhesive areas 60 on the surface of the continuous web 40 of susceptor material. This can be achieved by synchronizing the operation of the susceptor cutting unit 48 with the movement of the continuous web 40 of susceptor material.

[0072] refer to Figure 5, the susceptor cutting unit 48 includes a rotary cutting unit 64 including a support roller 66 and a cutting roller 68. The support roller 66 supports the continuous web 40 of susceptor material around its periphery and includes a plurality of circumferentially spaced recesses 70 around its periphery. The support roller 66 is typically a suction roller, and the continuous web 40 of susceptor material and the susceptor patch 28 are supported around the periphery of the suction roller by a suction force applied through the suction ports 67. The cutting roller 68 includes a plurality of circumferentially spaced cutting elements 72, such as protruding cutting blades, around its periphery and between the support roller 66 and the cutting roller 68 along the periphery. Figure 5 During synchronous rotation in opposite directions as indicated by the arrows in FIG. 1 , the cutting elements 72 cooperate with (e.g., extend into) the circumferentially spaced recesses 70. This results in continuous shear cutting of the continuous web 40 of susceptor material to form a plurality of susceptor patches 28. As will be apparent from the following description, each susceptor patch 28 corresponds to the above referenced Figure 1a and Figure 1b The elongate second strip 13 (ie the elongate susceptor 12) in the finished aerosol-generating article 1 is depicted.

[0073] Receptor patch application

[0074] The susceptor patches 28 provided by the susceptor cutting unit 48 may be applied to the planar surface of the continuous strip 18 of the aerosol-generating substrate 10 such that there is a constant and predetermined spacing 74 between the edges of each continuous susceptor patch 28, e.g. Figure 2b and Figure 42. The susceptor patch 28 is formed by cutting the susceptor patch 28 with the susceptor cutting unit 48. The susceptor cutting unit 48 is configured to provide a plurality of susceptor patches 28 having a plurality of webs 40, 400 of susceptor material, and a plurality of support rollers 66. The susceptor patch 28 is formed by cutting the susceptor patch 28 with the susceptor cutting unit 48 ... In this way, the susceptor patches 28 that have been cut from the continuous web 40 of susceptor material by the susceptor cutting unit 48 are conveyed for a short period of time at a greater speed than the continuous web 40 of susceptor material from which they were cut, thereby producing a desired constant and predetermined spacing 74 between the edges of adjacent susceptor patches 28.

[0075] The susceptor patch 28 to which the adhesive 47 is applied is continuously adhered to the flat surface of the continuous strip 18 of the aerosol generating substrate 10 approximately along the center of the continuous strip 18. Adjacent susceptor patches 28 are spaced apart in the direction of travel of the continuous strip 18 of the aerosol generating substrate 10 by a constant and predetermined spacing 74 between the edges of the susceptor patches 28 that is created when the susceptor patches 28 are formed in the susceptor cutting unit 48. In order to ensure sufficient adhesion between the susceptor patches 28 and the substantially flat surface of the continuous strip 18 of the aerosol generating substrate 10, a cam roller 76 (at Figure 2a The cam roller 76 (diagrammatically shown in FIG. 1 ) presses the susceptor patch 28 onto a generally flat surface. The rotation of the cam roller 76 is synchronized with the movement of the continuous strip 18 of the aerosol-generating substrate 10 so that the pressing force is applied to the continuous susceptor patches 28 rather than to the spacing areas between the continuous susceptor patches 28.

[0076] Depending on the nature of the adhesive 47 applied to the continuous web 40 of susceptor material (and thus to the susceptor patches 28) by the adhesive applicator unit 46, the continuous strip 18 of aerosol-generating substrate 10 and the susceptor patches 28 adhered to its surface may be heated by an optional heater 50. This may help to cure or solidify the adhesive 47 and thereby ensure a good bond between each susceptor patch 28 and the flat surface of the continuous strip 18 of aerosol-generating substrate 10. The heating temperature must be carefully selected based on the characteristics of both the aerosol-generating substrate 10 and the adhesive 47 to ensure that sufficient heating is achieved to cure or solidify the adhesive 47 while avoiding or at least minimizing the release of volatile components from the aerosol-generating substrate 10.

[0077] Strip cutting

[0078] After the continuous strip 18 of the aerosol generating substrate 10 has been separated from the edge 19 of the continuous web 34 of the aerosol generating substrate 10 by the rotating cutter unit 90, the remaining web 34 of the aerosol generating substrate 10 is fed to the strip cutting unit 52. The strip cutting unit 52 cuts the continuous web 34 of the aerosol generating substrate 10 across its entire width to form a plurality of continuous aerosol generating strips 16 corresponding to the continuous web 34 described above with reference to FIG. Figure 1a and Figure 1b An elongated first strip 15 in a finished aerosol-generating article 1 is depicted. In an embodiment, the strip cutting unit 52 cuts the continuous web 34 of aerosol-generating substrate 10 to form an aerosol-generating strip 16 having a strip width of approximately 1 mm.

[0079] like Figure 2a and Figure 6 As shown, the strip cutting unit 52 is a rotary cutter unit 78 and includes a first cutting drum 80 and a second cutting drum 82. The first cutting drum 80 includes a circumferentially extending first cutting formation 84, and the second cutting drum 82 includes a circumferentially extending second cutting formation 86. The first cutting formation 84 and the second cutting formation 86 cooperate (e.g., intermesh) to shear cut the continuous web 34 of the aerosol-generating substrate 10 in the direction of travel of the continuous web 34 so as to form a plurality of aerosol-generating strips 16 and in particular to form Figure 1a and Figure 1b The first long strip 15 is shown.

[0080] Rod formation

[0081] The aerosol generating strips 16 formed by cutting the continuous web 34 of the aerosol generating substrate 10 are conveyed to the rod forming unit 56, where they are formed into a continuous rod 88. The continuous strip 18 of the aerosol generating substrate 10 with the susceptor patch 28 adhered thereto is also conveyed to the rod forming unit 56 by the feed roller 51 and combined with the aerosol generating strips 16 to form a continuous rod 88. If desired, a continuous sheet of wrapping paper (not shown) can be supplied to the rod forming unit 56 from a supply reel (not shown), or can be supplied (also from a supply reel) to a separate wrapping unit that can be positioned downstream of the rod forming unit 56. As the sheet of wrapping paper is conveyed and guided through the rod forming unit 56 or the separate wrapping unit, it can be wrapped around the aerosol generating strips 16 and the susceptor patch 28 so that the continuous rod 88 is confined by the wrap 14.

[0082] Rod cutting

[0083] The continuous rod 88 (optionally constrained by the wrapper 14) is then conveyed to the rod cutting unit 58, where it is cut into predetermined lengths at appropriate locations to form a plurality of aerosol-generating articles 1. The aerosol-generating articles 1 formed by the rod cutting unit 58 may have a length between 5 mm and 50 mm, preferably between 10 mm and 30 mm. It should be understood that this length corresponds to the above referenced Figure 1a and Figure 1b The length of the aerosol generating substrate 10 described. The continuous rod 88 is preferably repeatedly cut by the rod cutting unit 58 approximately at the midpoint between the edges of the susceptor patch 28. In this way, the susceptor patch 28 is not cut by the rod cutting unit 58, thereby reducing wear on the cutting element. In addition, because the susceptor patch 28 is shorter than the aerosol generating strip 16, the ends of the individual susceptor patches 28 (i.e., the elongated second strip 13) are not visible at either end of the aerosol generating article 1 formed by the rod cutting unit 58. It will be appreciated that this type of method is particularly suitable for mass production of aerosol generating articles 1.

[0084] Final Assembly

[0085] A further unit (not shown) may be arranged downstream of the rod cutting unit 58 and may be configured to provide one or more additional components (such as the above-mentioned mouthpiece segment 20) and assemble these with the individual aerosol-generating articles 1 formed by the rod cutting unit 56 to form a finished aerosol-generating article 1 of the type illustrated in Figure 1, for example. In this case, a separate wrapping unit may be provided downstream of the rod cutting unit 58 so that the assembled components can be wrapped simultaneously to form the finished aerosol-generating article 1. The further unit may form part of the device 30, or may be a separate stand-alone unit forming part of the final assembly line.

[0086] Although exemplary embodiments have been described in the preceding paragraphs, it should be appreciated that various modifications can be made to these embodiments without departing from the scope of the appended claims. Therefore, the breadth and scope of the claims should not be limited to the exemplary embodiments described above.

[0087] Unless otherwise indicated herein or clearly contradicted by context, this disclosure encompasses any combination of the above-described features in all possible variations thereof.

[0088] Unless the context clearly requires otherwise, throughout the specification and claims, the words "comprising," "including," and the like are to be interpreted in an inclusive rather than an exclusive or exhaustive sense; that is, in the sense of "including but not limited to."

Claims

1. A method for continuously manufacturing an aerosol-generating article (1), the method comprising: (i) providing a continuous web (34) of an aerosol-generating substrate (10); (ii) separating a continuous strip (18) of aerosol-generating substrate (10) from the continuous web (34) of aerosol-generating substrate (10) provided in step (i), the continuous strip (18) having a substantially flat surface; (iii) applying at least one susceptor patch (28) to a substantially flat surface of the continuous strip (18) of aerosol-generating substrate (10) obtained in step (ii); (iv) cutting the remaining continuous web (34) of the aerosol-generating substrate (10) after the continuous strip of aerosol-generating substrate has been separated in step (ii) to form a plurality of aerosol-generating strips (15, 16); (v) combining the at least one receptor patch (28) and the continuous strip (18) of aerosol-generating substrate (10) obtained in step (iii) with the plurality of aerosol-generating strips (15, 16) obtained in step (iv) to form a continuous rod (88); and (vi) cutting the continuous rod (88) to form a plurality of individual aerosol-generating articles (1), each aerosol-generating article comprising at least one susceptor patch (28).

2. The method according to claim 1, wherein: Step (ii) comprises separating the continuous strip (18) of the aerosol-generating substrate (10) from an edge (19) of the continuous web (34) of the aerosol-generating substrate (10).

3. The method according to claim 1 or claim 2, wherein: Step (ii) comprises cutting the continuous web (34) of aerosol-generating substrate (10) to separate continuous strips (18) of aerosol-generating substrate (10) therefrom.

4. The method according to claim 1 or claim 2, wherein: Step (ii) is performed using a rotating cutter unit (90).

5. The method according to claim 1 or claim 2, wherein: Step (iii) comprises adhering the at least one receptor patch (28) to the substantially planar surface of the continuous strip (18) of the aerosol-generating substrate (10).

6. The method according to claim 1 or claim 2, wherein: The substantially planar surface of the continuous strip (18) of aerosol-generating substrate (10) provided in step (ii) comprises a centre line, and step (iii) comprises applying the at least one susceptor patch (28) to the substantially planar surface substantially along the centre line.

7. The method according to claim 1 or claim 2, wherein: After step (ii) and before step (iii), the continuous strip (18) of aerosol-generating substrate (10) is conveyed away from the continuous web (34) of aerosol-generating substrate (10).

8. The method according to claim 1 or claim 2, wherein: Step (iii) comprises applying a plurality of susceptor patches (28) successively to the substantially planar surface of the continuous strip (18) of the aerosol-generating substrate (10) with a predetermined and constant spacing (74) between each successive susceptor patch (28).

9. The method according to claim 8, wherein: Each of the plurality of receptor patches (28) has substantially the same size.

10. The method according to claim 1 or claim 2, wherein: The method further comprises, prior to step (iii), providing a continuous web (40) of susceptor material, and continuously cutting the continuous web (40) of susceptor material to form the susceptor patches (28).

11. The method according to claim 10, wherein: The step of continuously cutting the continuous web (40) of susceptor material includes uniformly cutting the continuous web (40) of susceptor material at predetermined and constant intervals so that the susceptor patches (28) have substantially the same length in the direction of travel of the continuous web (40) of susceptor material.

12. The method according to claim 1 or claim 2, wherein: Another rotary cutter unit (78) is used to perform step (iv).

13. The method according to claim 12, wherein: The rotary cutter unit (78) comprises a first cutting drum (80) and a second cutting drum (82), the first cutting drum having a circumferentially extending first cutting formation (84), the second cutting drum having a circumferentially extending second cutting formation (86), and wherein the first and second cutting formations (84, 86) cooperate to cut the continuous web (34) of the aerosol generating substrate (10) to form the plurality of aerosol generating strips (15, 16).

14. The method according to claim 13, wherein: The at least one receptor patch (28) has a length between 5 mm and 50 mm, and each of the plurality of aerosol generating strips (15, 16) has a width between greater than 0.5 mm and 2.0 mm.

15. The method according to claim 14, wherein: The at least one receptor patch (28) has a length between 10 mm and 30 mm, and each of the plurality of aerosol generating strips (15, 16) has a width of 1.0 mm.

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