Aerosol-generating products

Abstract

An aerosol-generating article (1) comprises: a plurality of elongated first strips (15) containing aerosol-generating material; a plurality of elongated second strips (13) containing inductively heatable susceptor material; and at least one elongated carrier strip (17), each of the plurality of elongated second strips (13) being attached to the at least one elongated carrier strip. The at least one elongated carrier strip (17) is folded along one or more fold lines (7) to form two or more elongated carrier regions (17a, 17b, 17c), and one or more of the plurality of elongated second strips (13) are attached to each elongated carrier region (17a, 17b, 17c). The elongated first strips (15), the elongated second strips (13) and the at least one elongated carrier strip (17) are arranged to form a rod-shaped aerosol-generating article (1).

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. The present disclosure is particularly applicable to aerosol-generating articles for use with portable (handheld) aerosol-generating devices. 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 the user.

[0003] A commonly used device for risk reduction or risk modification 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 produces 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 variety of different methods to provide heat to the aerosol-generating substrate. One such method is to provide an aerosol-generating device that employs an induction heating system. In such a device, an induction coil is provided within the device, and an inductively heatable susceptor is provided to heat the aerosol-generating substrate. When a 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. When the aerosol-generating substrate is heated, an aerosol is generated.

[0005] The properties of the aerosol generated by an aerosol-generating device depend on many factors, including the construction of the aerosol-generating article used with the aerosol-generating device. It is therefore desirable to provide an aerosol-generating article that optimizes the properties of the aerosol generated during use of the article. It is also generally desirable to provide an aerosol-generating article that can be easily and consistently produced in large quantities. Summary of the Invention

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

[0007] a plurality of elongated first strips containing aerosol-generating material;

[0008] a plurality of second elongated strips comprising an inductively heatable susceptor material; and

[0009] at least one elongated carrier strip, each of the plurality of elongated second strips being attached to the at least one elongated carrier strip;

[0010] in:

[0011] The at least one elongated carrier strip is folded along one or more fold lines to form two or more elongated carrier regions, and one or more of the plurality of elongated second strips is attached to each elongated carrier region, and

[0012] The elongate first strips, the elongate second strips and the at least one elongate carrier strip are arranged to form a rod-shaped aerosol-generating article.

[0013] The aerosol-generating article is used with an aerosol-generating device for heating an aerosol-generating material rather than burning the aerosol-generating material to volatilize at least one component of the aerosol-generating material 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.

[0014] In a general sense, a vapor is a substance that is in the gaseous phase at a temperature below its critical temperature, meaning that it 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, particularly with respect to the form of the inhalable medium produced for inhalation by the user.

[0015] Incorporating an elongated first strip (aerosol generating strip) and a plurality of elongated second strips (receptor strips) into an aerosol generating article provides for efficient heat transfer from the elongated second strip to the elongated first strip during use of the aerosol generating article in an aerosol generating device. By providing an elongated carrier strip having one or more carrier regions to which the elongated second strip is attached, positioning of the elongated second strip relative to the elongated first strip is facilitated, and this further ensures uniform and efficient heat transfer from the elongated second strip to the elongated first strip. Effective and uniform heating of the elongated first strip is thereby achieved, thereby achieving reliable vapor generation. Aerosol generating articles according to the present disclosure can also be efficiently manufactured and relatively easily mass-produced.

[0016] The one or more fold lines may extend generally in the longitudinal direction of the aerosol-generating article. Consequently, the elongated second strips correspondingly extend in the longitudinal direction of the aerosol-generating article. This may facilitate uniform heating of the elongated first strips, which may also extend generally in the longitudinal direction. It may also facilitate manufacturing of the aerosol-generating article.

[0017] One or more of the elongated second strips may be adhered to each elongated carrier region. This provides a secure connection between each elongated second strip and the corresponding elongated carrier region. This may be particularly advantageous during manufacture of the aerosol-generating article (e.g., during folding of the elongated carrier strip along one or more fold lines) and may ensure that the elongated second strips do not become detached from the corresponding elongated carrier region during folding of the elongated carrier strip.

[0018] The at least one elongated carrier strip may be a Z-shaped carrier strip. The Z-shaped carrier strip may define three elongated carrier regions. This shape may facilitate heat transfer from the plurality of elongated second strips to the plurality of elongated first strips, thereby ensuring that the plurality of elongated first strips are heated uniformly and avoiding hot and cold spots in the aerosol-generating article.

[0019] The width of each of the plurality of elongated first strips may be smaller than the width of each of the plurality of elongated second strips. This may facilitate vapor generation by allowing a large number of elongated first strips to be provided in the aerosol-generating article. It may also facilitate the manufacture of the aerosol-generating article.

[0020] Each of the plurality of elongated second strips may have a width that is less than the width of the corresponding elongated carrier region to which the elongated second strip is attached. This may help ensure that the elongated second strips are not folded or otherwise deformed during folding of the elongated carrier strip along one or more fold lines.

[0021] In some embodiments, the at least one elongated carrier strip may define at least a first region and a second region within a cross-section of the aerosol-generating article. Both the first region and the second region may include a plurality of elongated first strips. This may facilitate vapor generation by allowing a plurality of elongated first strips to be provided in the first region and the second region.

[0022] Each of the plurality of elongated first strips may have a distal end, and each of the plurality of elongated second strips may have a distal end. The distal end of the elongated first strip may form the distal end of the aerosol generating article. The distal end of the elongated second strip may be positioned inwardly from the distal end of the elongated first strip. For example, the length of each of the elongated second strips may be less than the length of each of the elongated first strips. With this arrangement, the distal end of the elongated second strip (receptor strip) is not visible at the distal end of the aerosol generating article, and this may improve the user's acceptance of the aerosol generating article. In addition, since the elongated second strip (receptor strip) is completely embedded in the elongated first strip (aerosol generating strip), this may allow aerosol or vapor to be generated more efficiently because the elongated second strip is completely surrounded by the elongated first strip, and therefore heat transfer from the elongated second strip to the elongated first strip is maximized.

[0023] The at least one elongate carrier strip may have a length equal to the length of each of the elongate first strips.This may facilitate manufacture of the aerosol-generating article.

[0024] The at least one elongated carrier strip may contain an aerosol-generating material. This may facilitate the manufacture of the aerosol-generating article and may also allow for the generation of a maximum amount of vapor during use of the aerosol-generating article due to both the plurality of elongated first strips and the at least one elongated carrier strip being heated by heat transferred from the elongated second strip.

[0025] The elongate first strip may have a plurality of different orientations within the cross-section of the rod-shaped aerosol-generating article. This may help ensure uniform heat transfer from the elongate second strip to the elongate first strip and thereby allow the maximum amount of vapour to be generated during use of the aerosol-generating article.

[0026] Each of the plurality of elongated second strips may have a thickness between 1.0 μm and 500 μm, possibly between 10 μm and 100 μm. Each of the plurality of elongated second strips may have a thickness of 50 μm. Elongated second strips (susceptor strips) having these thickness dimensions may be particularly suitable for inductive heating during use of an aerosol-generating article and may also facilitate the manufacture of aerosol-generating articles.

[0027] Each of the plurality of elongate first strips may have a length of between 5.0 mm and 50 mm, possibly between 10 mm and 30 mm. Each of the plurality of elongate first strips may have a length of 20 mm.

[0028] Each of the plurality of elongated first strips may have a thickness of between 50 μm and 500 μm, possibly between 150 μm and 300 μm. Each of the plurality of elongated first strips may have a thickness of 220 μm.

[0029] Each of the plurality of elongated first strips may have a width of between approximately 0.1 mm and 5.0 mm, and possibly between 0.5 mm and 2.0 mm. Each of the plurality of elongated first strips may have a width of 1.0 mm. These width dimensions ensure that the aerosol-generating article contains an optimal number of elongated first strips to allow uniform airflow through the aerosol-generating article and to produce an acceptable amount of vapor or aerosol. If the width of the elongated first strips is too low, the strength of the strips may be reduced, and mass production of the aerosol-generating article may become difficult.

[0030] The inductively heatable susceptor material may comprise a metal. The metal is typically selected from the group consisting of stainless steel and carbon steel. However, the inductively heatable susceptor material may comprise any suitable material, including 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). By applying an electromagnetic field in the vicinity of the aerosol-generating article during use in an aerosol-generating device, the elongated second strip (the susceptor strip) may generate heat due to eddy currents and hysteresis losses, thereby causing conversion of electromagnetic energy into thermal energy.

[0031] The aerosol-generating material can be any type of solid or semi-solid material. Example types of aerosol-generating solids include powders, particles, pellets, fragments, threads, granules, gels, strips, loose leaves, chopped leaves, chopped fillers, porous materials, foams, or sheets. The aerosol-generating material can include plant-derived materials, and in particular can include tobacco materials. It can advantageously include reconstituted tobacco, for example, comprising tobacco and any one or more of cellulose fibers, tobacco stem fibers, and inorganic fillers such as CaCO3.

[0032] Thus, an aerosol-generating device with which an aerosol-generating article is intended for use may be referred to as a "heated tobacco device," a "heat-but-do-not-burn tobacco device," a "device for vaporizing a tobacco product," or the like, and it is to be construed 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 aerosol-generating article may be confined by 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 having a tubular region with an aerosol generating matrix 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 comprising cellulose acetate fiber. The filter segment can constitute a mouthpiece filter and can be coaxially aligned with the aerosol generating matrix consisting of a plurality of elongated first 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 act as a vapor cooling area. The vapor cooling area can advantageously allow the heated vapor generated by heating the aerosol generating strip (elongated first strip, preferably, the at least one elongated carrier strip) to cool and condense to form an aerosol with suitable properties for the user to inhale, for example, through the filter segment.

[0035] The aerosol-generating material may include an aerosol-forming agent. Examples of aerosol-forming agents include polyols and mixtures thereof, such as glycerol or propylene glycol. Typically, the aerosol-generating material may include an aerosol-forming agent content of between about 5% and about 50% (on a dry weight basis). In some embodiments, the aerosol-generating material may include an aerosol-forming agent content of between about 10% and about 20% (on a dry weight basis), and may be about 15% (on a dry weight basis).

[0036] When heated, the aerosol-generating material can 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 It is along Figure 1a An enlarged diagrammatic cross-sectional view of line AA in FIG.

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

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

[0041] Figure 3 is a plan view of a section of a continuous web of susceptor material showing adhesive 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 and a susceptor strip from a continuous web of susceptor material and applying the susceptor strip to a surface of a continuous web of an aerosol-generating substrate;

[0043] Figure 5 It is a diagrammatic stereogram of the receptor cutting unit;

[0044] Figure 6 yes Figure 2a A diagrammatic illustration of a strip cutting unit of an apparatus;

[0045] Figure 7a It is used for manufacturing Figure 1a and Figure 1b a diagrammatic illustration of a second embodiment of an apparatus and method of an aerosol-generating article as set forth in;

[0046] Figure 7b The aerosol generating substrate and the sensor strip move through the aerosol generating substrate and the sensor strip in the direction indicated by the arrow. Figure 7a A plan view of the equipment shown in the figure;

[0047] Figure 8 yes Figure 7a a functional illustration of a portion of an apparatus and method schematically illustrating forming a susceptor patch and a susceptor strip from a continuous web of susceptor material and applying the susceptor strip to a surface of a continuous strip of aerosol-generating substrate; and

[0048] Figure 9 yes Figure 7a Diagrammatic representation of the strip cutting unit of the device. DETAILED DESCRIPTION

[0049] Embodiments of the present disclosure will now be described, by way of example only, and with reference to the accompanying drawings.

[0050] Reference Figure 1a and Figure 1b , shows an example of an aerosol-generating article 1 for use with an aerosol-generating device that includes 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, has a distal end 11a and a proximal end (or mouth end) 11b, and is generally cylindrical. The circular cross-section facilitates gripping of the article 1 by the user and facilitates insertion of the article 1 into the cavity or heating compartment of the aerosol-generating device.

[0051] 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 within 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.

[0052] The aerosol-generating article 1 may have a total length, measured between the distal end 11a and the proximal end (mouth end) 11b, of between 30 mm and 100 mm, possibly between 50 mm and 70 mm. The aerosol-generating article 1 may have a total length of approximately 55 mm. The aerosol-generating substrate 10 may have a total length, measured between the first end 10a and the second end 10b, of between 5.0 mm and 50 mm, possibly between 10 mm and 30 mm. The aerosol-generating substrate 10 may have a total length of approximately 20 mm. The aerosol-generating article 1 may have a diameter of between 5.0 mm and 10 mm, possibly between 6.0 mm and 8.0 mm. The aerosol-generating article 1 may have a diameter of approximately 7.0 mm.

[0053] 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 form 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 uncreased in the longitudinal direction to ensure that the airflow path is uninterrupted and that uniform airflow through the article 1 can be achieved.

[0054] The inductively heatable susceptor 12 comprises a plurality of elongated second strips 13 comprising an inductively heatable susceptor material. The plurality of elongated second strips 13 constitute a susceptor strip 18 and are also generally oriented in the longitudinal direction of the aerosol-generating article 1. The elongated second strips 13 are uncreased in the longitudinal direction to prevent the generation of hot spots in the aerosol-generating substrate 10. Figure 1b It can be clearly seen in FIG. 1 that the width of each of the elongated first strips 15 is smaller than the width of each of the elongated second strips 13 .

[0055] The aerosol-generating article 1 includes an elongated carrier strip 17 oriented generally in the longitudinal direction of the aerosol-generating article 1. The elongated carrier strip 17 has a plurality of fold lines 7 extending generally in the longitudinal direction of the aerosol-generating article 1, and the elongated carrier strip 17 is folded along the fold lines 7 to define elongated carrier regions 17a, 17b, 17c. In the illustrated example, the elongated carrier strip 17 is configured as a generally Z-shaped carrier strip 17 having two fold lines 7 and defining three separate elongated carrier regions 17a, 17b, 17c. However, it should be understood that other configurations of the elongated carrier strip 17 are within the scope of the present disclosure, so long as the elongated carrier strip 17 has at least two elongated carrier regions 17a, 17b. For example, the elongated carrier strip 17 having two elongated carrier regions 17a, 17b can be configured as a V-shaped carrier strip 17 or an L-shaped carrier strip 17.

[0056] The elongate carrier strip 17 contains aerosol-generating material and therefore also constitutes the aerosol-generating strip 16. The elongate carrier strip 17 has the same length as the elongate first strip 15, and therefore the aerosol-generating strips 16 within the aerosol-generating article 1 all have the same length.

[0057] The elongated second strip 13 is adhered to the elongated carrier strip 17. More specifically, and as Figure 1b As can be clearly seen in the figure, one elongated second strip 13 is adhered to each elongated carrier area 17a, 17b, 17c. In the example shown, the width of each of the plurality of elongated second strips 13 is less than the width of the corresponding elongated carrier area 17a, 17b, 17c to which the elongated second strip 13 is attached.

[0058] 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 such 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 strip 13 and the elongated carrier strip 17 are positioned approximately centrally within the cross-section of the aerosol-generating substrate 10, and hence the aerosol-generating article 1. Such an arrangement may, for example, help ensure uniform heat transfer from the elongated second strip 13 to the elongated first strip 15.

[0059] As in Figure 1bAs best seen in FIG, the centrally positioned elongate carrier strip 17 and the elongate second strips 13 adhered to the elongate carrier regions 17a, 17b, 17c can be considered to define at least a first region 5 and a second region 6 within a cross-section of the aerosol-generating substrate 10, and hence within a cross-section of the aerosol-generating article 1. Both the first region 5 and the second region 6 comprise a plurality of elongate first strips 15.

[0060] As in Figure 1a As best seen in FIG, each of the plurality of elongated first strips 15 has a distal end 15a, and each of the plurality of elongated second strips 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 positioned inwardly from the distal ends 15a of the elongated first strips 15. Thus, the distal ends 13a of the elongated second strips 13 (i.e., the susceptors 12) are not visible at the distal end 11a of the aerosol-generating article 1.

[0061] The aerosol-generating article 1 comprises a mouthpiece segment 20 positioned downstream of the aerosol-generating substrate 10. The aerosol-generating substrate 10 and mouthpiece segment 20 are arranged in coaxial alignment within the wrapper 14 to hold the components in place to form the rod-shaped aerosol-generating article 1.

[0062] 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 section 22, a central hole section 23, and a filter section 24. The cooling section 22 includes a hollow paper tube 22a having a thickness greater than that of the paper wrapper 14. The central hole section 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 section 24 typically includes cellulose acetate fibers and acts as a mouthpiece filter. As 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 as it passes through the cooling section 22 and the central hole section 23 to form an aerosol having suitable properties for the user to inhale through the filter section 24.

[0063] The elongated first strip 15 and the elongated carrier strip 17 typically comprise plant-derived material, 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.

[0064] 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). Upon heating, the elongated first strip 15 and the elongated carrier strip 17 release volatile compounds that may include nicotine or flavoring compounds such as tobacco flavoring.

[0065] 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, heating the elongated first strip 15 and the elongated carrier strip 17 without burning them, thereby releasing one or more volatile compounds and thereby generating 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, as the heated vapor flows through the cooling segment 22 and the central aperture segment 23 toward the filter segment 24, the heated vapor cools and condenses to form an aerosol having suitable properties for inhalation by the user through the filter segment 24.

[0066] 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, 230 and method for producing an aerosol-generating article 1).

[0067] Manufacture of an aerosol-generating article: Example 1

[0068] refer to Figure 2a , shows the reference for making the above 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 susceptor strip 18 are Figure 2b A plan view of the device 30 as it moves in the direction of the middle arrow.

[0069] The apparatus 30 includes a substrate supply reel 32 (e.g., a first drum) carrying a continuous web 34 of aerosol-generating substrate 10 having a generally flat surface and a centerline 118, and a first feed roller 36 that controls the feeding of the continuous web 34 of 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.

[0070] The apparatus 30 includes a susceptor supply reel 38 (eg, a second spool) 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 ; a first susceptor cutting unit 48 ; and a second susceptor cutting unit 49 .

[0071] The apparatus 30 further includes an optional heater 50 , a strip cutting unit 52 , feed rollers 54 , a strip folding unit 55 , a rod forming unit 56 , and a rod cutting unit 58 .

[0072] Receptor strip preparation

[0073] In operation, a continuous web 34 of aerosol-generating substrate 10 is continuously supplied from a substrate supply reel 32. Simultaneously, a continuous web 40 of susceptor material is continuously supplied from a 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 across 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 FIG. 1 ). Figure 3 and Figure 4 ), wherein adhesive-free areas 62 are formed between adjacent adhesive areas 60 along the direction of travel of the continuous web 40 of susceptor material.

[0074] The continuous web 40 of susceptor material is supplied from the adhesive applicator unit 46 to a first susceptor cutting unit 48 which continuously cuts the continuous web 40 of susceptor material to form a plurality of susceptor patches 28 (see Figure 4 ). The width of the continuous web 40 of susceptor material, and therefore the susceptor patch 28, is significantly less than the width of the continuous web 34 of the aerosol-generating substrate 10. For example, the continuous web 34 of the aerosol-generating substrate 10 may have a width of approximately 140 mm, while the continuous web 40 of susceptor material, and therefore the susceptor patch 28, may have a width of between approximately 0.1 mm and 5 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 of between approximately 5 mm and 50 mm, and may have a thickness of between approximately 1 μm and 500 μm.

[0075] In order to minimize contamination of the first susceptor cutting unit 48 by the adhesive 47 applied to the continuous web 40 of susceptor material by the adhesive applicator unit 46, the first susceptor cutting unit 48 is located in the adhesive-free areas 62 (i.e., at locations between the adhesive areas 60 on the surface of the continuous web 40 of susceptor material (see Figure 4 )) cutting the continuous web of susceptor material 40. This can be achieved by synchronizing the operation of the first susceptor cutting unit 48 with the movement of the continuous web of susceptor material 40.

[0076] Reference Figure 5 , the first susceptor cutting unit 48 includes a rotary cutting unit 64 that includes 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 suction applied through suction ports 67. The cutting roller 68 includes a plurality of circumferentially spaced cutting elements 72, e.g., 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, the cutting elements 72 cooperate with (eg, extend into) the circumferentially spaced recesses 70. This results in continuous shear cutting of the continuous web 40 of susceptor material to form the plurality of susceptor patches 28.

[0077] The second susceptor cutting unit 49 is positioned downstream of the first susceptor cutting unit 48 and cuts each susceptor patch 28 into a plurality of susceptor strips 18, three susceptor strips 18 in the illustrated embodiment, as shown. Figure 2b As will be apparent from the following description, each sensor strip 18 corresponds to the sensor strips 18 shown above. Figure 1a and Figure 1b The elongate second strip 13 (ie the elongate susceptor 12 ) in the finished aerosol-generating article 1 is depicted.

[0078] Sensor strip application

[0079] The susceptor strips 18 provided by the second susceptor cutting unit 49 may be applied to the surface of the continuous web 34 of the aerosol-generating substrate 10 such that there is a constant and predetermined spacing 74 between the edges of each set of continuous susceptor strips 18 in the longitudinal direction (i.e. the direction of travel) of the continuous web 34, e.g. Figure 2b and Figure 4 , and with small lateral spacing between the susceptor strips 18 in the cross-machine (width) direction of the continuous web 34, as shown in FIG. Figure 2b. The constant and predetermined spacing 74 between the edges of the susceptor strips 18 may be between 1.0 mm and 20 mm. The constant and predetermined spacing 74 may be approximately 5.0 mm. In order to create the constant and predetermined spacing 74 between the edges of adjacent susceptor strips 18 formed by cutting the continuous susceptor patch 28, the first susceptor cutting unit 48 permits relative movement between the continuous web 40 of susceptor material and the support roller 66 for a predetermined period of time immediately after the continuous web 40 of susceptor material conveyed by the support roller 66 has been cut by the cutting roller 68 to form the susceptor patch 28. This relative movement allows the continuous web 40 of susceptor material to remain stationary or travel at a reduced speed for a short period of time after the susceptor patch 28 has been cut from the continuous web 40 of susceptor material. Relative movement between the continuous web of susceptor material 40 and the support roller 66 can be achieved, for example, by reducing the suction force applied by the support roller 66 to the continuous web of susceptor material 40 while maintaining sufficient suction force between the already cut susceptor patches 28 and the support roller 66 to ensure that there is no relative movement between the susceptor patches 28 and the support roller 66. In this way, the susceptor patches 28 that have been cut from the continuous web of susceptor material 40 by the first susceptor cutting unit 48 are conveyed for a short period of time at a faster speed than the continuous web of susceptor material 40 from which they were cut, thereby producing a desired constant and predetermined spacing 74 between the edges of adjacent susceptor patches 28 and, consequently, a desired constant and predetermined spacing between the susceptor strips 18 formed by the second susceptor cutting unit 49 by cutting the spaced-apart susceptor patches 28 supplied by the first susceptor cutting unit 48.

[0080] The susceptor strip 18 to which the adhesive 47 is applied is continuously adhered to the flat surface of the continuous web 34 of aerosol-generating substrate 10 generally along the centerline 118. Exposed side regions 90 of the continuous web 34 of aerosol-generating substrate are thereby formed on both sides of the susceptor strip 18 (see Figure 2b ), because, as described above, the continuous web 34 of aerosol-generating substrate 10 is significantly wider than the susceptor patches 28, and therefore wider than each set of adhered susceptor strips 18. Adjacent sets of susceptor strips 18 are also spaced in the direction of travel of the continuous web 34 of aerosol-generating substrate 10 by a constant and predetermined spacing 74 between the edges of the susceptor strips 28, which is created when the susceptor patches 28 are formed in the first susceptor cutting unit 48.

[0081] To ensure adequate adhesion between the susceptor strips 18 and the generally flat surface of the continuous web 34 of aerosol-generating substrate 10, the susceptor strips 18 may be provided by a cam roller 76 (at Figure 2aThe cam roller 76 (diagrammatically shown in FIG) presses the susceptor strips 18 onto a generally flat surface. The rotation of the cam roller 76 is synchronized with the movement of the continuous web 34 of the aerosol-generating substrate 10 so that the pressing force is applied to the continuous susceptor strips 18 rather than to the spacing areas between the continuous susceptor strips 18.

[0082] Depending on the nature of the adhesive 47 applied to the continuous web 40 of susceptor material (and therefore to the susceptor strips 18) by the adhesive applicator unit 46, the continuous web 34 of aerosol-generating substrate 10 and the susceptor strips 18 adhered to its surface may be heated by an optional heater 50. This may help to cure or solidify the adhesive 47, thereby ensuring a good bond between the susceptor strips 18 and the flat surface of the continuous web 34 of aerosol-generating substrate 10. The heating temperature must be carefully selected based on the properties 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 at the same time avoiding or at least minimizing the release of volatile components from the aerosol-generating substrate 10.

[0083] Strip cutting

[0084] The continuous web 34 of aerosol-generating substrate 10, to whose flat surface a group of longitudinally spaced susceptor strips 18 are adhered, is fed to a strip cutting unit 52. The strip cutting unit 52 cuts only the exposed side regions 90 of the continuous web 34 of aerosol-generating substrate 10 without cutting the susceptor strips 18 to form a plurality of continuous aerosol-generating strips 16 alongside the susceptor strips 18. In an embodiment, the strip cutting unit 52 cuts the exposed side regions 90 of the continuous web 34 of aerosol-generating substrate 10 to form aerosol-generating strips 16 having a strip width of approximately 1 mm.

[0085] 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 exposed side region 90 of the continuous web 34 of the aerosol-generating substrate 10 in the direction of travel of the continuous web 34 so as to form the continuous aerosol-generating strip 16 and in particular to form the continuous aerosol-generating strip 16. Figure 1a and Figure 1b The first long strip 15 is shown.

[0086] In order to provide for cutting only the exposed side region 90 of the continuous web 34 of the aerosol-generating substrate 10 to form the elongated first strip 15, a non-cutting region 92 is defined between the first cutting drum 80 and the second cutting drum 82, which accommodates the susceptor strip 18 (i.e., the elongated second strip 13) and the portion of the continuous web 34 of the aerosol-generating substrate 10 to which the susceptor strip 18 is adhered. In the illustrated embodiment, the first cutting drum 80 is formed without the first cutting formation 84 in the non-cutting region 92. Similarly, the second cutting drum 82 is also formed without the second cutting formation 86 in the non-cutting region 92. In addition, the first cutting drum 80 includes a circumferentially extending recess 94 in its surface in the non-cutting region 92, so that at least a portion of the susceptor strip 18 can be accommodated in the circumferentially extending recess 94 during cutting of the exposed side region 90 of the continuous web 34 of the aerosol-generating substrate 10. It will therefore be appreciated that when the exposed side regions 90 of the continuous web 34 of the aerosol-generating substrate 10 are cut to form the elongate first strips 15 by means of cooperation between the respective first and second cutting formations 84, 86 on the first and second cutting drums 80, 82, the central portion of the continuous web 34 of the aerosol-generating substrate 10 which is contained in the non-cut region 92 and which has not been cut into strips constitutes the portion referred to above. Figure 1b An elongated carrier strip 17 is depicted.

[0087] Strip folding and rod formation

[0088] The elongated first strip 15 (i.e., aerosol-generating strip 16), the elongated carrier strip 17, and the attached elongated second strip 13 (i.e., susceptor strip 18), formed by cutting the exposed side regions 90 of the continuous web 34 of the aerosol-generating substrate 10, are conveyed to the strip folding unit 55, which folds the elongated carrier strip 17 along the folding line 7 to form the aforementioned Z-shaped carrier strip 17 having the elongated carrier regions 17a, 17b, 17c, to which the elongated second strip 13 is attached. Thereafter, the elongated first strip 15 and the Z-shaped carrier strip 17 to which the elongated second strip 13 is attached are conveyed to the rod forming unit 56, where they are formed into a continuous rod 88.

[0089] 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 located 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 elongated first strip 15, the Z-shaped carrier strip 17, and the adhered elongated second strip 13 so that the continuous rod 88 is constrained by the wrap 14.

[0090] Rod cutting

[0091] 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 5.0 mm and 50 mm, possibly between 10 mm and 30 mm. The aerosol-generating articles 1 formed by the rod cutting unit 58 may have a length of 20 mm. It will be appreciated that this length corresponds to the length of the aerosol-generating articles 1 described above with reference to FIG. Figure 1a and Figure 1b The length of the aerosol-generating substrate 10 described above is preferably repeated by the rod cutting unit 58 at approximately the midpoint between the ends of the longitudinally spaced elongated second strips 13 (i.e., susceptor strips 18). In this way, the elongated second strips 13 are not cut by the rod cutting unit 58, thereby reducing wear on the cutting element. In addition, because the elongated second strips 13 are shorter than the aerosol-generating strips 16, the ends of the elongated second strips 13 (i.e., susceptor strips 18) 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.

[0092] Final assembly

[0093] 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 mouthpiece segment 20 described above) and to 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 apparatus 30, or may be a separate, stand-alone unit forming part of the final assembly line.

[0094] Manufacture of an aerosol-generating article: Example 2

[0095] Reference Figure 7a , shows the reference for making the above Figure 1a and Figure 1b A diagrammatic illustration of a second embodiment of an apparatus 230 and method of an aerosol-generating article 1 is described. Figure 7b The aerosol generating substrate 10 and the susceptor strip 18 are Figure 7b A plan view of the apparatus 230 as it moves in the direction of the arrow. The apparatus 230 and the method are similar to those described above with reference to FIG. Figure 6 The apparatus 30 and method are described herein and corresponding components will be identified using the same reference numerals.

[0096] The apparatus 230 includes a substrate supply reel 32 (e.g., a first spool) carrying a continuous web 34 of aerosol-generating substrate 10 having a generally flat surface, and a first feed roller 36 for controlling the feeding of the continuous web 34 of aerosol-generating substrate 10. The apparatus 230 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.

[0097] The apparatus 230 further comprises a rotary cutter unit 290, e.g. comprising a circular cutting knife, which cuts the continuous web 34 of aerosol-generating substrate 10 along one edge 19 to separate a continuous strip 218 of aerosol-generating substrate 10 from the continuous web 34. As discussed below, the continuous strip 218 of aerosol-generating substrate 10 is subsequently folded along the fold line 7 to form the continuous strip 218 of aerosol-generating substrate 10 as described above with reference to FIG. Figure 1a and Figure 1b The elongated carrier strip 17 is formed in the finished aerosol-generating article 1 depicted. The continuous strip 218 of 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., Figure 7a ) is conveyed away from the continuous web 34 of the aerosol-generating substrate 10 so that the continuous strip 218 and the continuous web 34 can be processed separately by the apparatus 230.

[0098] The apparatus 230 further includes a susceptor supply reel 38 (e.g., 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; a first susceptor cutting unit 48; and a second susceptor cutting unit 49.

[0099] The apparatus 230 further includes an optional heater 50 , a feed roller 51 , a strip folding unit 55 , a strip cutting unit 52 , a feed roller 54 , a rod forming unit 56 , and a rod cutting unit 58 .

[0100] Receptor strip preparation

[0101] In operation, a continuous web 34 of aerosol generating substrate 10 is continuously supplied from a substrate supply reel 32, and a continuous strip 218 of aerosol generating substrate 10 is separated from the edge 19 of the continuous web 34 by a rotating cutter unit 290 and conveyed away from the continuous web 34 by conveyor rollers 92, 94, as described above. Simultaneously, a continuous web 40 of susceptor material is continuously supplied from a 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 across 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 8 ), wherein adhesive-free areas 62 are formed between adjacent adhesive areas 60 along the direction of travel of the continuous web 40 of susceptor material.

[0102] The continuous web 40 of susceptor material is supplied from the adhesive applicator unit 46 to a first susceptor cutting unit 48 which continuously cuts the continuous web 40 of susceptor material to form a plurality of susceptor patches 28 (see Figure 8 ). The construction and operation of the first susceptor cutting unit 48 are combined with the above Figure 5 Same as described.

[0103] The second susceptor cutting unit 49 is positioned downstream of the first susceptor cutting unit 48 and cuts each susceptor patch 28 into a plurality of susceptor strips 18, three susceptor strips 18 in the illustrated embodiment, as shown. Figure 7b As will be apparent from the following description, each sensor strip 18 corresponds to the sensor strips 18 shown above. Figure 1a and Figure 1b The elongate second strip 13 (ie the elongate susceptor 12 ) in the finished aerosol-generating article 1 is depicted.

[0104] 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 218 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 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 between about 1 μm and 500 μm.

[0105] In order to minimize contamination of the first susceptor cutting unit 48 by the adhesive 47 applied to the continuous web 40 of susceptor material by the adhesive applicator unit 46, the first susceptor cutting unit 48 is located in the adhesive-free areas 62 (i.e., between the adhesive areas 60 on the surface of the continuous web 40 of susceptor material (see Figure 8 )) cutting the continuous web of susceptor material 40. This can be achieved by synchronizing the operation of the first susceptor cutting unit 48 with the movement of the continuous web of susceptor material 40.

[0106] Sensor strip application

[0107] The susceptor strips 18 provided by the second susceptor cutting unit 49 may be applied to the flat surface of the continuous strip 218 of the aerosol-generating substrate 10 such that there is a constant and predetermined spacing 74 between the edges of each group of continuous susceptor strips 18 in the longitudinal direction (i.e. the direction of travel) of the continuous strip 218, e.g. Figure 7b and Figure 8 and with small lateral spacing between the susceptor strips 18 in the transverse (width) direction of the continuous strip 218, as shown in FIG. Figure 7b . The constant and predetermined spacing 74 between the edges of the susceptor strips 18 may be, for example, between 1.0 mm and 20 mm. The constant and predetermined spacing 74 may be approximately 5.0 mm. The constant and predetermined spacing 74 is achieved in the same manner as described above in connection with the apparatus 30 and corresponding method.

[0108] The susceptor strips 18 to which the adhesive 47 is applied are continuously adhered to the flat surface of the continuous strip 218 of the aerosol-generating substrate 10 approximately along the center of the continuous strip 218. Adjacent groups of susceptor strips 18 are spaced apart in the direction of travel of the continuous strip 218 of the aerosol-generating substrate 10 by a constant and predetermined spacing 74 between the edges of the susceptor patch 28, which is created when the susceptor patch 28 is formed in the first susceptor cutting unit 48.

[0109] To ensure adequate adhesion between the susceptor strip 18 and the generally flat surface of the continuous strip 218 of the aerosol-generating substrate 10, the cam roller 76 (at Figure 7a The cam roller 76 (diagrammatically shown in FIG) presses the susceptor strip 18 onto a generally flat surface. The rotation of the cam roller 76 is synchronized with the movement of the continuous strip 218 of the aerosol-generating substrate 10 so that the pressing force is applied to the continuous susceptor strips 18 rather than to the spacing areas between the continuous susceptor strips 18.

[0110] Depending on the nature of the adhesive 47 applied to the continuous web of susceptor material 40 (and therefore to the susceptor strips 18) by the adhesive applicator unit 46, the continuous strip 218 of aerosol-generating substrate 10 and the susceptor strips 18 adhered to its surface may be heated by an optional heater 50. As described above, this may help to cure or solidify the adhesive 47, thereby ensuring a good bond between the susceptor strips 18 and the flat surface of the continuous strip 218 of aerosol-generating substrate 10.

[0111] Strip cutting

[0112] After the continuous strip 218 of aerosol-generating substrate 10 has been separated from the edge 19 of the continuous web 34 of aerosol-generating substrate 10 by the rotary cutter unit 290, the remaining web 34 of aerosol-generating substrate 10 is fed to the strip cutting unit 52 (at Figure 9 The strip cutting unit 52 cuts the continuous web 34 of aerosol-generating substrate 10 across its entire width to form a plurality of continuous aerosol-generating strips 16 corresponding to the strips described above with reference to FIG. Figure 1a and Figure 1b The elongate first strip 15 in the 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 aerosol-generating strips 16 having a strip width of approximately 1 mm.

[0113] like Figure 7a and Figure 9 As shown in FIG, the strip cutting unit 52 is a rotary cutting 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 thereof so as to form a plurality of aerosol-generating strips 16 and, in particular, to form the plurality of aerosol-generating strips 16. Figure 1a and Figure 1b The first long strip 15 is shown.

[0114] Strip folding and rod formation

[0115] The elongate first strips (ie the aerosol-generating strips 16 ) formed by cutting the continuous web 34 of aerosol-generating substrate 10 are conveyed to the rod-forming unit 56 where they are formed into continuous rods 88 .

[0116] The continuous strip 218 of aerosol-generating substrate 10 (i.e., elongated carrier strip 17) with attached susceptor strip 18 (i.e., elongated second strip 13) is conveyed by feed roller 51 to strip folding unit 55, which folds elongated carrier strip 17 along fold line 7 to form the aforementioned Z-shaped carrier strip 17 having elongated carrier regions 17a, 17b, 17c, to which elongated second strip 13 (i.e., susceptor strip 18) is attached. Thereafter, the Z-shaped carrier strip 17 with attached elongated second strip 13 is conveyed to rod forming unit 56 and combined with elongated first strip 15 (i.e., aerosol-generating strip 16) to form a continuous rod 88.

[0117] 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 located 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 elongated first strip 15, the Z-shaped carrier strip 17, and the adhered elongated second strip 13 so that the continuous rod 88 is constrained by the wrap 14.

[0118] Rod cutting

[0119] 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 5.0 mm and 50 mm, possibly between 10 mm and 30 mm. The aerosol-generating articles 1 formed by the rod cutting unit 58 may have a length of 20 mm. It will be appreciated that this length corresponds to the length of the aerosol-generating articles 1 described above with reference to FIG. Figure 1a and Figure 1b The length of the aerosol-generating substrate 10 described above is preferably repeated by the rod cutting unit 58 at approximately the midpoint between the edges of the longitudinally spaced elongated second strips 13 (i.e., the susceptor strips 18). In this way, the elongated second strips 13 are not cut by the rod cutting unit 58, thereby reducing wear on the cutting element. In addition, because the elongated second strips 13 are shorter than the aerosol-generating strips 16, the ends of the elongated second strips 13 (i.e., the susceptor strips 18) 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.

[0120] Final assembly

[0121] 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 mouthpiece segment 20 described above) 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 apparatus 230, or may be a separate, stand-alone unit forming part of a final assembly line.

[0122] Although exemplary embodiments have been described in the preceding paragraphs, it should be understood 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.

[0123] This disclosure encompasses any combination of the above-described features in all possible variations unless otherwise indicated herein or clearly contradicted by context.

[0124] 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. An aerosol-generating article (1), comprising: a plurality of first elongated strips (15) containing aerosol generating material; a plurality of second elongated strips (13) comprising an inductively heatable susceptor material; as well as at least one elongated carrier strip (17) to which each of the plurality of elongated second strips (13) is attached; in: The at least one elongated carrier strip (17) is folded along one or more fold lines (7) to form two or more elongated carrier regions (17a, 17b, 17c), and one or more of the plurality of elongated second strips (13) is attached to each elongated carrier region (17a, 17b, 17c), and The elongate first strips (15), the elongate second strips (13) and the at least one elongate carrier strip (17) are arranged to form a rod-shaped aerosol-generating article (1).

2. The aerosol-generating article according to claim 1, wherein One or more of these elongate second strips (13) are adhered to each elongate carrier region (17a, 17b, 17c).

3. The aerosol-generating article according to claim 1 or claim 2, wherein: The at least one elongated carrier strip (17) is a Z-shaped carrier strip.

4. The aerosol-generating article according to claim 1 or claim 2, wherein: The width of each of the plurality of elongated first strips (15) is smaller than the width of each of the plurality of elongated second strips (13).

5. The aerosol-generating article according to claim 1 or claim 2, wherein: Each of the plurality of elongated first strips (15) and the plurality of elongated second strips (13) has a distal end (15a, 13a), the distal ends (15a) of the elongated first strips (15) forming the distal end (11a) of the aerosol generating article (1), and the distal ends (13a) of the elongated second strips (13) are positioned inwardly from the distal ends (15a) of the elongated first strips (15) so that the distal ends (13a) of the elongated second strips (13) are not visible at the distal end (11a) of the aerosol generating article (1).

6. An aerosol-generating article according to claim 1 or claim 2, wherein: The length of each of these elongated second strips (13) is less than the length of each of these elongated first strips (15).

7. An aerosol-generating article according to claim 1 or claim 2, wherein: The length of the at least one elongated carrier strip (17) is equal to the length of each of the elongated first strips (15).

8. The aerosol-generating article according to claim 1 or claim 2, wherein: The at least one elongated carrier strip (17) contains an aerosol generating material.

9. An aerosol-generating article according to claim 1 or claim 2, further comprising: A filter segment (24) at the proximal end of the aerosol-generating article (1) and at least one tubular segment upstream of the filter segment (24).

10. An aerosol-generating article according to claim 1 or claim 2, wherein The elongated first strips (15) have a plurality of different orientations within the cross-section of the rod-shaped aerosol-generating article (1).

11. An aerosol-generating article according to claim 1 or claim 2, wherein Each of the plurality of elongated second strips (13) has a thickness between 1 µm and 500 µm.

12. The aerosol-generating article according to claim 11, wherein Each of the plurality of elongated second strips (13) has a thickness between 10 μm and 100 μm.

13. An aerosol-generating article according to claim 1 or claim 2, wherein Each of the plurality of elongated first strips (15) has a length between 10 mm and 30 mm.

14. An aerosol-generating article according to claim 13, wherein each of the plurality of elongate first strips (15) has a length of 20 mm.

15. An aerosol-generating article according to claim 1 or claim 2, wherein Each of the plurality of elongated first strips (15) has a thickness between 150 μm and 300 μm.

16. An aerosol-generating article according to claim 15, wherein each of the plurality of elongated first strips (15) has a thickness of 220 μm.

17. An aerosol-generating article according to claim 1 or claim 2, wherein: The aerosol generating material comprises tobacco material.

18. An aerosol-generating article according to claim 1 or claim 2, wherein The inductively heatable susceptor material comprises metal.

19. An aerosol-generating article according to claim 18, wherein The metal is selected from the group consisting of stainless steel and carbon steel.

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