Method for manufacturing an aerosol generating article

Abstract

A method for continuously manufacturing aerosol generating articles (1) includes: (i) providing a continuous web (34) of aerosol generating substrate (10); (ii) applying at least one susceptor patch (28) to a surface of the continuous web (34) of aerosol generating substrate (10); (iii) cutting the continuous web (34) of aerosol generating substrate (10) and the at least one susceptor patch (28) applied to the surface of the continuous web to form a plurality of aerosol generating strips (16) and a plurality of susceptor strips (18); and (iv) forming the plurality of aerosol generating strips (16) and the plurality of susceptor strips (18) into a continuous rod (88).

Description

Technical Field

[0001] This disclosure generally relates to aerosol generating articles, and more specifically 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 this disclosure particularly relate to a method for continuously manufacturing an aerosol generating article. This disclosure is particularly suitable for manufacturing aerosol generating articles for use with portable (handheld) aerosol generating devices. Background Technology

[0002] The popularity and use of devices that reduce or modify the risks of using traditional tobacco products (also known as aerosol generating devices or vapor generating devices) have grown rapidly in recent years. Various devices and systems exist that use heated or warmed aerosol-generating substances to produce aerosols for the user to inhale.

[0003] Commonly used devices that reduce or mitigate risk are aerosol generating devices with a heated substrate, or so-called heated non-burning devices. This type of device generates aerosols or vapors by heating the aerosol generating substrate to a temperature typically in the range of 150°C to 300°C. Heating the aerosol generating substrate to this temperature range without burning or combusting it produces vapors, which are typically cooled and condensed to form an aerosol for the user of the device to inhale.

[0004] Currently available aerosol generating devices can use one of several different methods to provide heat to the aerosol generating matrix. One such method is to provide an aerosol generating device employing an induction heating system. In this device, an induction coil is provided, and a sensor capable of inductively heating is provided to heat the aerosol generating matrix. When the user activates the device, electrical energy is supplied to the induction coil, which in turn generates an alternating electromagnetic field. The sensor couples with the electromagnetic field and generates heat, which is transferred to the aerosol generating matrix, for example, through conduction, and aerosols are generated when the aerosol generating matrix is ​​heated.

[0005] Providing both the aerosol generating matrix and the inductively heated sensor in the form of an aerosol generating article that can be inserted by a user into an aerosol generating device is convenient. Therefore, there is a need for 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 this disclosure, a method for continuously manufacturing aerosol-generating articles is provided, the method comprising:

[0007] (i) Providing a continuous web of aerosol-generating matrix;

[0008] (ii) Applying at least one sensor patch to the surface of a continuous web of the aerosol-generating matrix;

[0009] (iii) Cutting a continuous web of the aerosol generating matrix and applying at least one receptor patch to the surface of the continuous web to form a plurality of aerosol generating strips and a plurality of receptor strips; and

[0010] (iv) Form the plurality of aerosol generating strips and the plurality of receptor strips into a continuous rod.

[0011] The aerosol generating article produced by this method is used with an aerosol generating device that heats, rather than burns, the aerosol generating strip to cause at least one component of the aerosol generating strip to volatilize, thereby generating heated vapor that is cooled and condensed to form an aerosol for inhalation by the user of the aerosol generating device. The aerosol generating device is a handheld portable device.

[0012] In a general sense, vapor is a substance that is in the gaseous phase at temperatures below its critical temperature, meaning that vapor can be condensed into a liquid by increasing its pressure without lowering the temperature. Aerosols, on the other hand, are fine solid particles or droplets suspended 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 the user to inhale.

[0013] The method disclosed herein facilitates the manufacture of aerosol-generating articles, and in particular enables the consistent and relatively easy mass production of these articles. Integrating an aerosol-generating strip and a sensor strip into an aerosol-generating article produced according to the method disclosed provides efficient heat transfer from the sensor strip to the aerosol-generating strip during use in an aerosol-generating apparatus. This, in turn, provides effective and uniform heating of the aerosol-generating strip, and thus, reliable steam generation.

[0014] Step (iii) may include simultaneously cutting a continuous web of aerosol-generating matrix and applying at least one receptor patch to the surface of the continuous web. Providing a single, combined cutting step can facilitate the mass production of aerosol-generating articles.

[0015] Step (iii) can be performed using a rotary cutter unit. The rotary cutter unit may include a first cutting roller and a second cutting roller. The first cutting roller may have a circumferentially extending first cutting forming portion. The second cutting roller may have a circumferentially extending second cutting forming portion. The first forming portion and the second cutting forming portion can cooperate to cut a continuous web of aerosol generating matrix and at least one receptor patch applied to the surface of the continuous web to form the plurality of aerosol generating strips and the plurality of receptor strips. Using a rotary cutter unit allows for easy, continuous, and high-speed manufacturing of aerosol generating articles.

[0016] Each of the plurality of aerosol generating strips and each of the plurality of receptor strips may have a width between approximately 0.1 mm and 5.0 mm, possibly between 0.5 mm and 2.0 mm. Each of the plurality of aerosol generating strips and each of the plurality of receptor strips may have a width of 1.0 mm. These width dimensions ensure that an aerosol generating article manufactured using the method disclosed herein contains an optimal number of aerosol generating strips and receptor strips to allow the gas flow to pass uniformly through the aerosol generating article and to generate an acceptable amount of vapor or aerosol. If the width of these aerosol generating strips and / or receptor strips is too small, the strength of these strips may be reduced, thus making mass production of the aerosol generating article difficult.

[0017] Step (ii) may include using an adhesive to adhere the at least one receptor patch to the surface of a continuous web of the aerosol generating matrix. This achieves a good bond between the receptor patch and the continuous web of the aerosol generating matrix, thereby ensuring that the continuous web of the aerosol generating matrix and the adhered receptor patch can be effectively and reliably cut during step (iii) to form aerosol generating strips and receptor strips.

[0018] This method may include heating the adhesive after step (ii) and before step (iii) to cure or solidify the adhesive. This can help strengthen the bond between the receptor patch and the continuous web of the aerosol-generating matrix. However, a trade-off is necessary because excessive heating may cause one or more volatile components to be released from the aerosol-generating matrix, while the goal is to release these volatile components only during heating of the aerosol-generating article manufactured by this method in the aerosol-generating apparatus. On the other hand, insufficient heating may fail to cure or solidify the adhesive. Therefore, the heating temperature must be carefully selected based on the characteristics of both the aerosol-generating matrix and the adhesive.

[0019] The continuous web of the aerosol-generating matrix provided in step (i) may include a generally flat surface that may have a centerline. Step (ii) may include applying the at least one receptor patch substantially along the centerline to the generally flat surface. Accurate and consistent positioning of the receptor patch along the centerline ensures that aerosol-generating articles manufactured according to the method disclosed herein have consistent and repeatable characteristics.

[0020] Step (ii) may include continuously applying a plurality of receptor patches to the surface of a continuous web of an aerosol generating matrix, wherein each successive receptor patch has a predetermined and constant interval. The predetermined and constant 'interval' between each successive receptor patch is the shortest distance between successive (i.e., adjacent) receptor patches, i.e., the distance or gap between the edges of successive (i.e., adjacent) receptor patches. Step (iii) may include cutting the continuous web of the aerosol generating matrix and the plurality of receptor patches applied to the surface of the continuous web to form a plurality of aerosol generating strips and a plurality of receptor strips. This facilitates the mass production of aerosol generating articles.

[0021] The at least one receptor patch may have a length between 5 mm and 50 mm, preferably between 10 mm and 30 mm. The at least one receptor patch may have a width between 0.1 mm and 5 mm, preferably between 0.5 mm and 2 mm. The at least one receptor patch may have a thickness between 1 μm and 500 μm, preferably between 10 μm and 100 μm, and possibly approximately 50 μm. Receptor patches with these dimensions are particularly suitable for the manufacture of aerosol-generating articles.

[0022] The method may further include (v) cutting the continuous rod to form multiple individual aerosol-generating articles. Each individual aerosol-generating article may include multiple receptor strips formed in step (iii) by cutting a single receptor patch. This facilitates continuous and high-volume production of aerosol-generating articles.

[0023] Step (v) may include cutting the continuous bar at a location between the receptor strips formed in step (iii) by cutting adjacent receptor patches. Cutting the continuous bar in this manner ensures that each aerosol generating article formed by cutting the continuous bar comprises multiple receptor strips formed from individual receptor patches, and thus ensures that the aerosol generating articles are consistent and repeatable. In addition, since the receptor strips are not cut during step (v), wear during the cutting step (e.g., on the cutting unit) is minimized.

[0024] Step (v) may include cutting the continuous bar approximately at the midpoint between the receptor strips formed in step (iii) by cutting adjacent receptor patches. In this manner, the ends of the receptor strips 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 increases user acceptance of the aerosol generating article manufactured according to the method disclosed herein by ensuring that the receptor strips are not visible at the distal end of the aerosol generating article. Furthermore, because the receptor strips are completely embedded in the aerosol generating matrix of the resulting aerosol generating article, this allows for more efficient generation of aerosols or vapors, as the receptor strips are completely surrounded by the aerosol generating strips, and thus heat transfer from the receptor strips to the aerosol generating strips is maximized.

[0025] The at least one receptor patch cut during step (iii) to form the receptor strip may comprise a sensor material capable of inductive heating, such as, but not limited to, one or more of aluminum, iron, nickel, stainless steel, carbon steel, and their alloys (e.g., nickel-chromium or nickel-copper alloys). By applying an electromagnetic field in its vicinity during the use of the aerosol-generating article in the aerosol-generating apparatus, the receptor strip can generate heat due to eddy currents and hysteresis losses, thereby causing a conversion of electromagnetic energy into thermal energy.

[0026] The aerosol generating matrix can be any type of solid or semi-solid material. Examples of solid aerosol generating materials include powders, microparticles, pellets, fragments, threads, granules, gels, strips, loose leaves, chopped leaves, chopped fillers, porous materials, foam materials, or sheets. The aerosol generating matrix can include plant-derived materials, and in particular, tobacco. It can advantageously include reconstituted tobacco, for example, comprising tobacco as well as any one or more of cellulose fibers, tobacco stem fibers, and inorganic fillers such as CaCO3.

[0027] Therefore, aerosol generating devices intended for use with aerosol generating articles can be referred to as “heated tobacco devices,” “heated but not burning tobacco devices,” “devices for vaporizing tobacco products,” etc., which is interpreted as devices suitable for achieving these effects. The features disclosed herein also apply to devices designed to vaporize any aerosol generating matrix.

[0028] The continuous rod can be confined by a paper wrapping. Therefore, the method can further include wrapping the continuous rod with a paper wrapping.

[0029] The aerosol generating article can be generally formed in the shape of a rod and can broadly resemble a cigarette with a tubular region having an aerosol generating matrix arranged in a suitable manner. The aerosol generating article may include a filter section at its proximal end, for example, comprising cellulose acetate fibers. This filter section can constitute a mouthpiece filter. The filter section can be coaxially aligned with the aerosol generating matrix. In some designs, one or more vapor collection areas, cooling areas, and other structures may also be included.

[0030] The aerosol generating matrix 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 matrix may include an aerosol forming agent content of between about 5% and about 50% (based on dry weight). In some embodiments, the aerosol generating matrix may include an aerosol forming agent content of between about 10% and about 20% (based on dry weight), and possibly about 15% (based on dry weight).

[0031] When heated, the aerosol-generating matrix, particularly the aerosol-generating strip, can release volatile compounds. These volatile compounds may include nicotine or flavoring compounds such as tobacco flavorings. Attached Figure Description

[0032] Figure 1a It is a schematic cross-sectional side view of the aerosol-generated product;

[0033] Figure 1b It is along Figure 1a A graphical cross-sectional view of line AA in the diagram;

[0034] Figure 2a It is in accordance with this disclosure for manufacturing Figure 1a and Figure 1b The diagram shows the equipment and methods for generating aerosol products.

[0035] Figure 2b The aerosol generating matrix and receptor patch move in the direction indicated by the arrow. Figure 2a A plan view of the equipment being displayed;

[0036] Figure 3 This is a plan view of a section of a continuous web of sensor material, showing the adhesive and non-adhesive regions;

[0037] Figure 4 yes Figure 2a The device and method are partially illustrated, schematically showing the formation of a receptor patch from a continuous web of receptor material and the application of the receptor patch to the surface of a continuous web of aerosol-generating matrix.

[0038] Figure 5 It is a schematic three-dimensional diagram of the receptor cutting unit; and

[0039] Figure 6 This is a diagram of a cutting unit. Detailed Implementation

[0040] Embodiments of this disclosure will now be described by way of example only and with reference to the accompanying drawings.

[0041] First refer to Figure 1a and Figure 1b This invention illustrates an aerosol generating article 1 for use with an aerosol generating device, which includes an induction heating system to inductively heat the aerosol generating article 1 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 herein. The aerosol generating article 1 is elongated, having a distal end 11a and a proximal end (or mouth end) 11b, and is generally cylindrical. The circular cross-section facilitates the user's grip on the article 1 and facilitates insertion of the article 1 into the cavity or heating chamber of the aerosol generating device.

[0042] The aerosol generating article 1 includes an aerosol generating matrix 10 having a first end 10a and a second end 10b, and a heat-sensitive sensor 12. The aerosol generating matrix 10 and the heat-sensitive sensor 12 are positioned within and enclosed by a package 14. The package 14 comprises a substantially non-conductive and non-magnetic material. In the example shown, the package 14 is a paper package and may include cigarette paper.

[0043] The aerosol generating article 1 may have a total length, measured between the distal end 11a and the proximal end (mouth end) 11b, between 30 mm and 100 mm, preferably between 50 mm and 70 mm, and possibly about 55 mm. The aerosol generating matrix 10 may have a total length, measured between the first end 10a and the second end 10b, between 5 mm and 50 mm, preferably between 10 mm and 30 mm, and possibly 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 possibly about 7 mm.

[0044] The aerosol generating matrix 10 includes a plurality of elongated first strips 15 containing aerosol generating material. The plurality of elongated first strips 15 constitute an aerosol generating strip 16 and are generally oriented in the longitudinal direction of the aerosol generating article 1. The elongated first strips 15 are without creases in the longitudinal direction to ensure that the airflow path is uninterrupted and to ensure that a uniform airflow can be achieved through the article 1.

[0045] The inductively heated sensor 12 includes a plurality of elongated second strips 13 containing inductively heated sensor material. The plurality of elongated second strips 13 constitute sensor strips 18 and are also generally oriented in the longitudinal direction of the aerosol generating article 1. The elongated second strips 13 are without creases in the longitudinal direction to prevent the generation of hot spots in the aerosol generating matrix 10.

[0046] Aerosol generating article 1 includes multiple elongated third articles 17 containing aerosol generating materials (see also...) Figure 1b The elongated third strip 17 also constitutes an aerosol generating strip 16 and is generally oriented in the longitudinal direction of the aerosol generating article 1. The elongated third strip 17 has the same length as the elongated first strip 15, and therefore all the aerosol generating strips 16 within the aerosol generating article 1 have the same length. The elongated second strip 13 is adhered to the elongated third strip 17, and the elongated second strip 13 and the elongated third strip 17 have the same width. In a preferred embodiment, the elongated first strip 15 also has the same width as the elongated second strip 13 and the elongated third strip 17.

[0047] The first elongated strip 15, the second elongated strip 13, and the third elongated strip 17 are arranged to form a generally rod-shaped aerosol generating article 1 and can be randomly distributed across the entire cross-section of the rod-shaped aerosol generating article 1, such that they have multiple different orientations within the cross-section of the aerosol generating article 1. Although from Figure 1b While not explicitly shown, a sufficient number of elongated first strips 15 are provided to substantially fill the cross-section of the aerosol generating matrix 10, and it should be understood that only a smaller number of elongated first strips 15 are shown for illustrative purposes. It should also be noted that any suitable number of elongated second strips 13 can be positioned within the aerosol generating matrix 10, depending on heating requirements. Each of the elongated second strips 13 is advantageously surrounded by an elongated first strip 15, thereby ensuring that heat transfer to the elongated first strip 15 is maximized and the possibility of contact between the elongated second strips 13 is minimized.

[0048] As in Figure 1a As can be best seen, 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 end 15a of the elongated first strip 15 forms the first end 10a of the aerosol generating matrix 10 and the corresponding distal end 11a of the aerosol generating article 1. The elongated second strip 13 is shorter than the elongated first strip 15 and the elongated third strip 17. The distal end 13a of the elongated second strip 13 is positioned inward from the distal end 15a of the elongated first strip 15. Therefore, the distal end 13a of the elongated second strip 13 is not visible at the distal end 11a of the aerosol generating article 1.

[0049] The aerosol generating article 1 includes a nozzle section 20 positioned downstream of the aerosol generating matrix 10. The aerosol generating matrix 10 and the nozzle section 20 are arranged coaxially within a package 14 to hold the components in place to form the rod-shaped aerosol generating article 1.

[0050] In the illustrated embodiment, the mouthpiece section 20 includes the following components arranged coaxially 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 aperture 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 wrapping 14. The central aperture section 23 may include a cured mixture containing cellulose acetate fibers and a plasticizer and is used to increase the strength of the mouthpiece section 20. The filter section 24 typically includes cellulose acetate fibers and acts as a mouthpiece filter. As heated vapor flows from the aerosol generating matrix 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 aperture section 23 to form an aerosol with suitable properties for inhalation by a user through the filter section 24.

[0051] The first and third elongated sections typically include plant-derived materials, such as tobacco. The first and third elongated sections may advantageously include reconstituted tobacco, which comprises tobacco as well as any one or more of cellulose fibers, tobacco stem fibers, and inorganic fillers such as CaCO3.

[0052] Elongated first strip 15 and elongated third strip 17 typically include aerosol forming agents, such as glycerol or propylene glycol. Typically, elongated first strip 15 and elongated third strip 17 contain between approximately 5% and approximately 50% (based on dry weight) of aerosol forming agent. Upon heating, elongated first strip 15 and elongated third strip 17 release volatile compounds that may contain nicotine or flavoring compounds such as tobacco flavorings.

[0053] When a time-varying electromagnetic field is applied near the elongated second strip 13 during use of the article 1 in the aerosol generating apparatus, heat is generated in the elongated second strip 13 due to eddy currents and hysteresis losses. This heat is transferred from the elongated second strip 13 to the elongated first strip 15 and the elongated third strip 17, heating them without burning them, in order to release one or more volatile compounds and thereby generate vapor. When inhaled by a user through the filter section 24, the heated vapor is drawn downstream from the first end 10a of the aerosol generating matrix 10 toward the second end 10b of the aerosol generating matrix 10 and through the article 1 toward the filter section 24. As described above, when the heated vapor flows through the cooling section 22 and the central hole section 23 toward the filter section 24, the heated vapor cools and condenses to form an aerosol with suitable properties for the user to inhale through the filter section 24.

[0054] Manufacturing of aerosol-generating products

[0055] The following will describe, in accordance with this disclosure, the suitability for manufacturing aerosol-generating articles (such as those mentioned above). Figure 1a and Figure 1b Equipment and method for generating aerosol products 1).

[0056] refer to Figure 2a The above reference is shown. Figure 1a and Figure 1b A schematic diagram of the apparatus 30 and method for generating article 1 from aerosols. Figure 2b It is the aerosol generating matrix 10 and the receptor patch 28 along them Figure 2b The plan view when the arrow in the diagram moves through device 30.

[0057] The apparatus 30 includes a matrix supply reel 32 (e.g., a first reel) carrying a continuous web 34 of aerosol generating matrix 10 having a generally flat surface, and a first feed roller 36 controlling the feeding of the continuous web 34 of aerosol generating matrix 10. The apparatus 30 may also include a web tension adjuster and a web edge control system, as will be understood by those skilled in the art, but in the context of this disclosure, these additional components are not necessary and have therefore been omitted for brevity.

[0058] The device 30 includes a sensor supply reel 38 (e.g., a second reel) for carrying a continuous web 40 of sensor material, feed rollers 42, 44 for controlling the feeding of the continuous web 40 of sensor material, an adhesive applicator unit 46, and a sensor cutting unit 48.

[0059] The apparatus 30 further includes an optional heater 50, a strip cutting unit 52, a feed roller 54, a rod forming unit 56, and a rod cutting unit 58.

[0060] Receptor Patch Fabrication

[0061] In operation, a continuous web 34 of aerosol-generating matrix 10 is continuously supplied from matrix supply reel 32. Simultaneously, a continuous web 40 of receptor material is continuously supplied from receptor supply reel 38 via feed rollers 42, 44 to adhesive applicator unit 46. Adhesive applicator unit 46 applies adhesive 47 to the surface of the continuous web 40 of receptor material. In the example shown, adhesive applicator unit 46 applies adhesive 47 intermittently and over the entire width of the web 40 to the surface of the continuous web 40 of receptor material. In this way, discrete adhesive regions 60 are formed on the surface of the continuous web 40 of receptor material (see...). Figure 3 and Figure 4 ), wherein an adhesive-free region 62 is formed between adjacent adhesive regions 60 along the travel direction of the continuous web 40 of the sensor material.

[0062] A continuous web 40 of receptor material is supplied from an adhesive applicator unit 46 to a receptor cutting unit 48, which continuously cuts the continuous web 40 of receptor material to form a plurality of receptor patches 28. (As in...) Figure 2b As best seen, the continuous web 40 of the receptor material and therefore the receptor patch 28 have a width substantially smaller than the width of the continuous web 34 of the aerosol generating matrix 10. For example, the continuous web 34 of the aerosol generating matrix 10 may have a width of approximately 140 mm, while the continuous web 40 of the receptor material and therefore the receptor patch 28 may have a width between approximately 0.1 mm and 5 mm. In some embodiments, the receptor patch 28 may have a length between approximately 5 mm and 50 mm along the direction of travel of the continuous web 40 of the receptor material, and may have a thickness between approximately 1 μm and 500 μm.

[0063] To minimize the contamination of the receptor cutting unit 48 by the adhesive 47 applied to the continuous web 40 of the receptor material by the adhesive applicator unit 46, the receptor cutting unit 48 cuts the continuous web 40 of the receptor material in the adhesive-free region 62 (i.e., the position between the adhesive regions 60 on the surface of the continuous web 40 of the receptor material). This can be achieved by synchronizing the operation of the receptor cutting unit 48 with the movement of the continuous web 40 of the receptor material.

[0064] refer to Figure 5The receptor cutting unit 48 includes a rotary cutting unit 64, which includes a support roller 66 and a cutting roller 68. The support roller 66 supports a continuous web 40 of receptor 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 receptor material and the receptor patch 28 are supported around the periphery of the suction roller by a suction force applied through a suction port 67. The cutting roller 68 includes a plurality of circumferentially spaced cutting elements 72 around its periphery, such as protruding cutting blades, and along the support roller 66 and the cutting roller 68... Figure 5 During synchronous rotation in opposite directions, as indicated by the arrows, the cutting element 72 cooperates with circumferentially spaced recesses 70 (e.g., extending into these recesses). This results in continuous shearing cuts of the continuous web 40 of the receptor material to form a plurality of receptor patches 28.

[0065] Receptor patch application

[0066] The receptor patches 28 provided by the receptor cutting unit 48 can be applied to the surface of the continuous web 34 of the aerosol generating matrix 10, such that there is a constant and predetermined interval 74 between the edges of each successive receptor patch 28, for example, as Figure 2b and Figure 4 As shown. The constant and predetermined interval 74 can be, for example, between 1 mm and 20 mm. In order to create a constant and predetermined interval 74 between the edges of adjacent receptor patches 28, the receptor cutting unit 48 allows relative movement between the continuous web 40 of receptor material and the support roller 66 for a predetermined period of time immediately following the cutting roller 68 cutting the continuous web 40 of receptor material carried by the support roller 66 to form the receptor patch 28. This relative movement allows the continuous web 40 of receptor material to remain stationary or travel at a reduced speed for a short period of time after the receptor patch 28 has been cut from the continuous web 40 of receptor material. The relative movement between the continuous web 40 of receptor material 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 40 of receptor material while maintaining sufficient suction force between the cut receptor patch 28 and the support roller 66 to ensure that there is no relative movement between the receptor patch 28 and the support roller 66. In this way, the sensor patch 28, which has been cut from the continuous web of sensor material 40 by the sensor cutting unit 48, is transported at a greater speed than the continuous web of sensor material 40 from which the sensor patch 28 is cut within a short period of time, thereby creating a desired constant and predetermined interval 74 between the edges of adjacent sensor patches 28.

[0067] Receptor patches 28, to which adhesive 47 is applied, are continuously adhered to the surface of the continuous web 34 of the aerosol generating matrix 10, generally along the centerline of the continuous web 34. Adjacent receptor patches 28 are spaced apart by a constant and predetermined interval 74 between their edges, created during the formation of the receptor patches 28 in the receptor cutting unit 48, along the direction of travel of the continuous web 34 of the aerosol generating matrix. To ensure sufficient adhesion between the receptor patches 28 and the generally flat surface of the continuous web 34 of the aerosol generating matrix 10, a cam roller 76 (in...) can be used... Figure 2a (Illustrated in the middle) The receptor patch 28 is pressed 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 matrix 10, such that the pressing pressure is applied to the continuous receptor patches 28, rather than to the gaps between the continuous receptor patches 28.

[0068] Depending on the properties of the adhesive 47 applied to the continuous web 40 of the receptor material (and thus to the receptor patch 28) by the adhesive applicator unit 46, the continuous web 34 of the aerosol generating matrix 10 and the receptor patch 28 adhered to its surface can be heated by an optional heater 50. This can help cure or solidify the adhesive 47 and thereby ensure good adhesion between each receptor patch 28 and the surface of the continuous web 34 of the aerosol generating matrix 10. The heating temperature must be carefully selected based on the properties of both the aerosol generating matrix 10 and the adhesive 47 to ensure sufficient heating to cure or solidify the adhesive 47 while avoiding or at least minimizing the release of volatile components from the aerosol generating matrix 10.

[0069] Strip cutting

[0070] The continuous web 34 of the aerosol generating matrix 10, on which spaced-apart receptor patches 28 are adhered, is fed to the strip cutting unit 52 (in Figure 6 As best seen in the diagram, the strip cutting unit simultaneously cuts the continuous web 34 of the aerosol generating matrix 10 and the receptor patch 28 to form a plurality of continuous aerosol generating strips 16 and a plurality of receptor strips 18. In an embodiment, the strip cutting unit 52 cuts the continuous web 34 of the aerosol generating matrix 10 and the receptor patch 28 to form aerosol generating strips 16 and receptor strips 18 with strip widths of approximately 1 mm. Therefore, if the receptor patch 28 has a width of 5 mm, as discussed above, it should be understood that five receptor strips 18 are formed by cutting each receptor patch 28.

[0071] The ends of the receptor strips 18 formed by cutting the receptor patches 28 are longitudinally spaced apart by the same predetermined and constant interval 74 existing between the edges of adjacent receptor patches 28. Figure 2a and Figure 6 As shown, the strip cutting unit 52 is a rotary cutter unit 78, and includes a first cutting roller 80 and a second cutting roller 82. The first cutting roller 80 includes a circumferentially extending first cutting forming portion 84, and the second cutting roller 82 includes a circumferentially extending second cutting forming portion 86. The first cutting forming portion 84 and the second cutting forming portion 86 cooperate (e.g., mesh with each other) to shear the continuous web 34 and the receptor patch 28 of the aerosol generating matrix 10 in the traveling direction of the continuous web 34 to form a plurality of aerosol generating strips 16 and a plurality of receptor strips 18. Figure 2b and Figure 6 The lieutenant general understands that the aerosol generating strip 16 formed by cutting the central region of the continuous web 34 of the aerosol generating matrix 10 of the receptor patch 28, which is adhered to the surface of the aerosol generating strip 16, has receptor strips 18 (i.e., elongated second strip 13) adhered to it, and the aerosol generating strip 16 formed by cutting this central region constitutes an elongated third strip 17. On the other hand, the aerosol generating strip 16 formed by cutting the side regions of the continuous web 34 of the aerosol generating matrix 10 on the opposite side of the receptor patch 28 does not have receptor strips 18 adhered to it, and the aerosol generating strip 16 formed by cutting these side regions constitutes an elongated first strip 15.

[0072] Rod Formation

[0073] Aerosol generating strip 16 and receptor strip 18 are conveyed to rod forming unit 56, where they are formed into a continuous rod 88. If desired, a continuous sheet of wrapping paper (not shown) can be supplied from a supply reel (not shown) to rod forming unit 56, or (also from a supply reel) to a separate wrapping unit that can be positioned downstream of rod forming unit 56. As the sheet of wrapping paper is conveyed and guided through rod forming unit 56 or the separate wrapping unit, it can wrap around aerosol generating strip 16 and receptor strip 18, such that the continuous rod 88 is confined by wrapping material 14.

[0074] Rod cutting

[0075] The continuous rod 88 (optionally constrained by the wrapping 14) is then conveyed to the rod cutting unit 58, where the continuous rod is cut at appropriate locations to predetermined lengths 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 reference. Figure 1a and Figure 1bThe length of the described aerosol generating matrix 10. The continuous rod 88 is preferably repeatedly cut by the rod cutting unit 58 approximately at the midpoint between the ends of the receptor strip 18 formed by cutting the continuous receptor patch 28. In this way, the receptor strip 18 is not cut by the rod cutting unit 58, thereby reducing wear on the cutting element. Furthermore, since the receptor strip 18 is shorter than the aerosol generating strip 16, the ends of the receptor strip 18 are not visible at either end of the aerosol generating article 1 formed by the rod cutting unit 58. It should be understood that this type of method is particularly suitable for mass production of the aerosol generating article 1.

[0076] Final assembly

[0077] Additional units (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 aforementioned nozzle segment 20) and assemble these with the respective aerosol-generating articles 1 formed by the rod-cutting unit 56 to form finished aerosol-generating articles 1 of, for example, the type shown in FIG. 1. In this case, a separate wrapping unit may be provided downstream of the rod-cutting unit 58 such that the assembled components can be wrapped simultaneously to form the finished aerosol-generating article 1. The additional units may form part of the device 30 or may be separate, independent units forming part of the final assembly line.

[0078] While exemplary embodiments have been described in the foregoing paragraphs, it should be understood that various modifications may 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.

[0079] Unless otherwise stated herein or the context clearly contradicts it, this disclosure covers any combination of all possible variations of the above features.

[0080] Unless the context clearly requires otherwise, throughout the specification and claims, the words “comprising,” “including,” etc., should be interpreted in a meaning that includes rather than excludes or exhausts; that is, in the meaning of “including but not limited to.”

Claims

1. A method for continuously manufacturing aerosol generating articles (1), the method comprising: (i) providing a continuous web (34) of aerosol generating substrate (10); (ii) applying at least one susceptor patch (28) to a surface of the continuous web (34) of aerosol generating substrate (10), wherein the width of the susceptor patch (28) is less than the width of the continuous web (34); (iii) simultaneously cutting the continuous web (34) of aerosol generating substrate (10) and the at least one susceptor patch (28) applied to the surface of the continuous web in a direction of travel to form a plurality of first aerosol generating strips (16) and a plurality of second aerosol generating strips, wherein the first aerosol generating strips comprise only aerosol generating substrate and the second aerosol generating strips comprise aerosol generating substrate and a susceptor strip (18) applied thereto; and (iv) forming the plurality of first aerosol generating strips (16) and the plurality of second aerosol generating strips into a continuous rod (88); wherein each of the plurality of first aerosol generating strips (16) and each of the plurality of second aerosol generating strips has a width of between 0.1 mm and 5.0 mm, or wherein the at least one susceptor patch (28) has a width of between 5 mm and 50 mm.

2. The method of claim 1, wherein, Step (iii) is performed using a rotary cutter unit (78).

3. The method of claim 2, wherein, The rotary cutter unit (78) comprises a first cutting cylinder (80) having a first cutting formation (84) extending circumferentially and a second cutting cylinder (82) having a second cutting formation (86) extending circumferentially, and wherein the first and second cutting formations (84, 86) cooperate to cut the continuous web (34) of aerosol generating substrate (10) and the at least one susceptor patch (28) applied to the surface of the continuous web to form the plurality of first aerosol generating strips (16) and the plurality of second aerosol generating strips.

4. The method of claim 1, wherein, Each of the plurality of first aerosol generating strips (16) and each of the plurality of second aerosol generating strips has a width of between 0.5 mm and 2.0 mm.

5. The method of claim 1, wherein, Step (ii) comprises adhering the at least one susceptor patch (28) to the surface of the continuous web (34) of aerosol generating substrate (10) using an adhesive (47).

6. The method of claim 5, wherein, The method comprises heating the adhesive (47) to cure or set the adhesive after step (ii) and before step (iii).

7. The method of claim 1, wherein, The continuous web (34) of aerosol generating substrate (10) provided in step (i) comprises a substantially planar surface having a centre line, and step (ii) comprises applying the at least one susceptor patch (28) to the substantially planar surface substantially along the centre line.

8. The method of claim 1, wherein, Step (ii) comprises continuously applying a plurality of susceptor patches (28) to a surface of a continuous web (34) of the aerosol generation substrate (10), wherein there is a predetermined and constant spacing (74) between each successive susceptor patch (28); and Step (iii) comprises cutting the continuous web (34) of the aerosol generation substrate (10) and the plurality of susceptor patches (28) applied to the surface of the continuous web to form a plurality of first aerosol generation strips (16) and a plurality of second aerosol generation strips.

9. The method of claim 1, wherein, The at least one susceptor patch (28) has a length of between 10 mm and 30 mm.

10. The method of claim 1, wherein, The method further comprises: (v) cutting the continuous rod (88) to form a plurality of individual aerosol generation articles (1).

11. The method of claim 4, wherein, Each of the plurality of first aerosol generation strips (16) and each of the plurality of second aerosol generation strips has a width of 1.0 mm.

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