Method for making an aerosol-generating article

Abstract

A method for continuously manufacturing an aerosol-generating article (1) comprises: (i) providing a continuous web (34) of an aerosol-generating substrate (10), the continuous web (34) comprising a generally flat surface having a centerline (18); (ii) applying at least one susceptor patch (28) to the generally flat surface substantially along the centerline (18) to leave exposed areas (90) of the continuous web (34) of the aerosol-generating substrate (10) on each side of the at least one susceptor patch (28); (iii) cutting the exposed areas (90) of the continuous web (34) of the aerosol-generating substrate (10) to form a plurality of aerosol-generating strips (15, 16) on each side of the at least one susceptor patch (28); and (iv) forming the plurality of aerosol-generating strips (15, 16) and the at least one susceptor patch (28) into a continuous rod (88).

Description

Technical Field

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

[0002] As an alternative to the use of traditional tobacco products, the popularity and use of reduced-risk or modified-risk devices (also known as aerosol-generating devices or vapor-generating devices) have grown rapidly in recent years. Various devices and systems are available that heat or warm an aerosol-generating substance to produce an aerosol for inhalation by 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] It may be convenient to provide both the aerosol-generating substrate and the inductively heatable susceptor together in the form of an aerosol-generating article that can be inserted into an aerosol-generating device by a user. It would therefore be desirable to provide a method that facilitates the manufacture of aerosol-generating articles and, in particular, enables easy and consistent mass production of aerosol-generating articles. Summary of the Invention

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

[0007] (i) providing a continuous web of an aerosol-generating substrate, the continuous web comprising a substantially planar surface having a centerline;

[0008] (ii) applying at least one susceptor patch to the generally planar surface substantially along the centre line to leave exposed areas of the continuous web of aerosol-generating substrate on each side of the at least one susceptor patch;

[0009] (iii) cutting the exposed areas of the continuous web of aerosol-generating substrate to form a plurality of aerosol-generating strips on each side of the at least one susceptor patch; and

[0010] (iv) forming the plurality of aerosol-generating strips and the at least one susceptor patch 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, an aerosol-generating substrate to volatilize at least one component of the aerosol-generating substrate and thereby generate a heated vapor that cools and condenses to form an aerosol for inhalation by a user of the aerosol-generating device. The aerosol-generating device is a handheld portable device.

[0012] 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.

[0013] The method according to the present disclosure facilitates the manufacture of aerosol-generating articles and, in particular, enables aerosol-generating articles to be produced consistently and relatively easily in large quantities. Since the aerosol-generating strip is formed during step (iii) without cutting the at least one susceptor patch, wear during the cutting step (e.g., on the cutting unit) is minimized. Incorporating the aerosol-generating strip and the susceptor (formed without cutting the susceptor patch into strips) into an aerosol-generating article produced by the method according to the present disclosure provides for efficient heat transfer from the susceptor strip to the aerosol-generating strip during use of the aerosol-generating article in an aerosol-generating device. This, in turn, provides for efficient and uniform heating of the aerosol-generating strip and, therefore, reliable vapor generation.

[0014] Accurate and consistent positioning of the at least one susceptor patch along the centreline of the substantially planar surface of the continuous web of aerosol-generating substrate further helps ensure consistent and repeatable properties of aerosol-generating articles manufactured by methods according to the present disclosure.

[0015] Step (iii) can be performed using a rotary cutter unit. The rotary cutter unit can include a first cutting drum and a second cutting drum. The first cutting drum can have a first cutting formation extending circumferentially. The second cutting drum can have a second cutting formation extending circumferentially. The first cutting formation and the second cutting formation can cooperate to cut exposed areas of the continuous web of aerosol-generating substrate to form the plurality of aerosol-generating strips. The use of a rotary cutter unit allows for easy and rapid production of aerosol-generating articles.

[0016] A non-cutting region is defined between the first cutting drum and the second cutting drum. The non-cutting region can accommodate the at least one susceptor patch and the portion of the aerosol-generating substrate to which the at least one susceptor patch is applied during step (ii). Providing the non-cutting region ensures that the susceptor patch and the lower portion of the aerosol-generating substrate (which serves as the elongated carrier strip for the susceptor patch) are not cut, while ensuring high-speed manufacturing.

[0017] The first cutting drum can be formed to have no first cutting formation in the non-cutting area. For example, the first cutting drum can include a circumferentially extending recess in its surface in the non-cutting area. The second cutting drum can be formed to have no second cutting formation in the non-cutting area. For example, the second cutting drum can include a circumferentially extending recess in its surface in the non-cutting area. In some embodiments, both the first and second cutting drums can be formed to have no first and second cutting formations in the non-cutting area, respectively. In some embodiments, at least a portion of the at least one susceptor patch can be accommodated in the circumferentially extending recess. These arrangements reliably ensure that the susceptor patch and the lower portion of the aerosol generating substrate (i.e., the elongated carrier strip) are not cut during step (iii) and high-speed manufacturing is achieved.

[0018] Each of the plurality of aerosol-generating strips may have a width of between about 0.1 mm and 5.0 mm, possibly between about 0.5 mm and 2.0 mm. Each of the plurality of aerosol-generating strips may have a width of 1.0 mm. These width dimensions ensure that aerosol-generating articles manufactured using the methods according to the present disclosure contain a suitable number of aerosol-generating strips and susceptor 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 aerosol-generating strips is too low, the strength of the strips may be reduced, and thus mass production of aerosol-generating articles may become difficult.

[0019] Step (ii) may comprise adhering the at least one susceptor patch to a substantially flat surface of the continuous web of aerosol-generating substrate using an adhesive. Good bonding between the susceptor patch and the continuous web of aerosol-generating substrate is thereby achieved, thereby ensuring that the susceptor patch does not move relative to the continuous web of aerosol-generating substrate. This, in turn, may help ensure that only exposed areas of the continuous web of aerosol-generating substrate are cut to form the aerosol-generating strip during step (iii).

[0020] Step (ii) may comprise applying a plurality of susceptor patches continuously to a generally flat surface of a continuous web of aerosol-generating substrate, wherein each successive susceptor patch has a predetermined and constant spacing between them. The predetermined and constant 'spacing' between each successive susceptor patch is the shortest distance between successive (i.e., adjacent) susceptor patches, i.e., the distance or gap between the edges of successive (i.e., adjacent) susceptor patches. Step (iii) may comprise cutting the exposed area of ​​the continuous web of aerosol-generating substrate to form a plurality of aerosol-generating strips on each side of the susceptor patches. Step (iv) may comprise forming the plurality of aerosol-generating strips and the susceptor patches into a continuous rod. This facilitates mass production of aerosol-generating articles.

[0021] The at least one susceptor patch may have a length of between 5 mm and 50 mm, preferably between 10 mm and 30 mm. The at least one susceptor patch may have a width of between 0.1 mm and 7 mm, preferably between 1 mm and 5 mm. The at least one susceptor patch may have a thickness of between 1 μm and 500 μm, preferably between 10 μm and 100 μm, possibly about 50 μm. A susceptor patch having these dimensions is particularly suitable for the manufacture of aerosol-generating articles.

[0022] The method may further comprise (v) cutting the continuous rod to form a plurality of individual aerosol-generating articles. Each individual aerosol-generating article may comprise at least one susceptor patch. Thus, step (v) may comprise cutting the continuous rod to form a plurality of individual aerosol-generating articles, each aerosol-generating article comprising at least one susceptor patch. This facilitates continuous and mass production of aerosol-generating articles.

[0023] Step (v) may include cutting the continuous rod at locations between adjacent susceptor patches. Cutting the continuous rod in this manner ensures that each aerosol-generating article formed by cutting the continuous rod includes a susceptor patch, and thus ensures that the aerosol-generating articles are consistent and repeatable. In addition, because the susceptor patches are not cut during step (v), wear during the cutting step (e.g., on the cutting unit) is minimized.

[0024] Step (v) may comprise cutting the continuous rod approximately at the midpoint between adjacent susceptor patches. In this way, the susceptors 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 may improve user acceptance of aerosol-generating articles manufactured by methods according to the present disclosure. Furthermore, the susceptors are fully embedded in the aerosol-generating substrate (i.e., aerosol-generating strip) of the resulting aerosol-generating article, and this may allow for more efficient generation of aerosol or vapor because the entire susceptor is surrounded by the aerosol-generating strip and therefore heat transfer from the susceptor to the aerosol-generating strip is maximized.

[0025] Each susceptor patch may comprise an inductively heatable susceptor material, such as, but not limited to, one or more of aluminum, iron, nickel, stainless steel, carbon steel, and alloys thereof (e.g., nickel-chromium or nickel-copper alloys). Upon application of an electromagnetic field in the vicinity of the aerosol-generating article during use in an aerosol-generating device, the susceptor material may generate heat due to eddy currents and hysteresis losses, thereby causing conversion of electromagnetic energy into thermal energy.

[0026] The aerosol-generating substrate can be any type of solid or semi-solid material. Example types of aerosol-generating solids include powders, microparticles, pellets, fragments, threads, granules, gels, strips, loose leaves, chopped leaves, chopped fillers, porous materials, foams, or sheets. The aerosol-generating substrate can include plant-derived materials, and can particularly include tobacco. 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 CaCO .

[0027] 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.

[0028] The continuous rod may be constrained by a paper wrapper. Thus, the method may further comprise wrapping the continuous rod with a paper wrapper.

[0029] The aerosol-generating article can be formed roughly 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 a suitable manner. The aerosol-generating article can include a filter segment at the proximal end of the aerosol-generating article, for example, the filter segment comprising cellulose acetate fibers. The filter segment can constitute a mouthpiece filter and can be coaxially aligned with an aerosol-generating matrix consisting of a plurality of aerosol-generating strips. In some designs, one or more vapor collection regions, cooling regions 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 region. The vapor cooling region can advantageously allow the heated vapor generated by heating the aerosol-generating strip to cool and condense to form an aerosol having suitable properties for the user, for example, to inhale through the filter segment.

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

[0031] Upon heating, the aerosol-generating substrate (ie, the aerosol-generating rod) can release volatile compounds. The volatile compounds may include nicotine or flavoring compounds such as tobacco flavoring. BRIEF DESCRIPTION OF THE DRAWINGS

[0032] Figure 1a is a diagrammatic cross-sectional side view of an example of an aerosol-generating article;

[0033] Figure 1b It is along Figure 1a An enlarged diagrammatic cross-sectional view of line AA in FIG.

[0034] Figure 2a It is used for manufacturing Figure 1a and Figure 1b A diagrammatic illustration of an apparatus and method for producing an aerosol-generating article as shown;

[0035] Figure 2b The aerosol generating matrix and the sensor patch move through the aerosol generating matrix and the sensor patch in the direction indicated by the arrow. Figure 2a The equipment shown is a plan view;

[0036] Figure 3 is a plan view of a section of a continuous web of susceptor material showing adhesive and non-adhesive areas;

[0037] Figure 4 yes Figure 2a a functional illustration of a portion of an apparatus and method schematically illustrating forming a susceptor patch from a continuous web of susceptor material and applying the susceptor patch to a surface of a continuous web of an aerosol-generating substrate;

[0038] Figure 5 is a diagrammatic stereogram of a susceptor cut unit; and

[0039] Figure 6 is a diagrammatic illustration of a strip cutting unit. DETAILED DESCRIPTION

[0040] Embodiments of the present 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 , 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 and generally cylindrical. The circular cross-section facilitates gripping of the article 1 by the user and insertion of the article 1 into the cavity or heating compartment of the aerosol-generating device.

[0042] 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.

[0043] The aerosol-generating article 1 may have an overall length, measured between the distal end 11a and the proximal end (mouth end) 11b, of between 30 mm and 100 mm, preferably between 50 mm and 70 mm, and may be approximately 55 mm. The aerosol-generating substrate 10 may have an overall length, measured between the first end 10a and the second end 10b, of between 5 mm and 50 mm, preferably between 10 mm and 30 mm, and may be approximately 20 mm. The aerosol-generating article 1 may have a diameter of between 5 mm and 10 mm, preferably between 6 mm and 8 mm, and may be approximately 7 mm.

[0044] 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.

[0045] The inductively heatable susceptor 12 comprises an elongated second strip 13 comprising an inductively heatable susceptor material. Thus, the elongated second strip 13 can be considered as a strip-shaped or blade-shaped elongated susceptor 12 also oriented generally in the longitudinal direction of the aerosol-generating article 1. Figure 1b As can be clearly seen in FIG, the width of each of the elongated first strips 15 is less than the width of the elongated second strips 13.

[0046] The aerosol-generating article 1 comprises at least one elongated carrier strip 17 having a first major surface 17a and a second major surface 17b. The elongated carrier strip 17 contains aerosol-generating material and thus also constitutes the aerosol-generating strip 16. The elongated carrier strip 17 is oriented generally in the longitudinal direction of the aerosol-generating article 1. The elongated carrier strip 17 has the same length as the elongated first strip 15, and thus the aerosol-generating strips 16 within the aerosol-generating article 1 all have the same length.

[0047] The elongated second strip 13 is adhered to the elongated carrier strip 17 and as can be seen in Figure 1b As can be clearly seen in the figure, the width of the elongated carrier strip 17 is greater than the width of the elongated second strip 13. The elongated second strip 13 has a first face 13b and an opposing second face 13c. The second face 13c is adhered to the second major surface 17b of the elongated carrier strip 17 and is entirely covered by the elongated carrier strip 17, and more specifically by the second major surface 17b.

[0048] 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. This arrangement helps ensure uniform heat transfer from the elongated second strip 13 to the elongated first strip 15.

[0049] As in Figure 1bAs best seen in FIG, the centrally positioned elongated carrier strip 17 and the elongated second strips 13 adhered thereto define first regions 5 and second regions 6 within a cross-section of the aerosol-generating substrate 10, and hence within a cross-section of the aerosol-generating article 1. The first regions 5 face the first major surface 17a of the elongated carrier strip 17, and the second regions 6 face the second major surface 17b of the elongated carrier strip 17. Both the first regions 5 and the second regions 6 comprise a plurality of elongated first strips 15.

[0050] As in Figure 1a As best seen in FIG, each of the plurality of elongated first strips 15 has a distal end 15a, and the elongated second strip 13 has a distal end 13a. The distal ends 15a of the elongated first strips 15 form the first end 10a of the aerosol-generating substrate 10 and, accordingly, the distal end 11a of the aerosol-generating article 1. The elongated second strips 13 are shorter than the elongated first strips 15 and the elongated carrier strip 17. The distal ends 13a of the elongated second strips 13 are 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 elongated susceptors 12) are not visible at the distal end 11a of the aerosol-generating article 1.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] Manufacturing of aerosol-generating products

[0057] A method suitable for manufacturing an aerosol-generating article (such as that described above) according to the present disclosure will now be described. Figure 1a and Figure 1b Device 30 and method for producing an aerosol-generating article 1).

[0058] 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 sensor patch 28 are Figure 2b A plan view of the device 30 as it moves in the direction of the arrow.

[0059] 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 18, 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.

[0060] The apparatus 30 includes a susceptor supply reel 38 (eg, a second reel) carrying a continuous web 40 of susceptor material, feed rollers 42 , 44 for controlling the feeding of the continuous web 40 of susceptor material, an adhesive applicator unit 46 , and a susceptor cutting unit 48 .

[0061] The apparatus 30 further includes an optional heater 50 , a strip cutting unit 52 , feed rollers 54 , a rod forming unit 56 , and a rod cutting unit 58 .

[0062] Sensor patch preparation

[0063] 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.

[0064] The continuous web 40 of susceptor material is supplied from the adhesive applicator unit 46 to the susceptor cutting unit 48 which continuously cuts the continuous web 40 of susceptor material to form a plurality of susceptor patches 28. Figure 2b As best seen in FIG, 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 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 approximately 5 mm and 50 mm, and may have a thickness of between approximately 1 μm and 500 μm.

[0065] In order to minimize contamination of the susceptor cutting unit 48 by the adhesive 47 applied to the continuous web of susceptor material 40 by the adhesive applicator unit 46, the susceptor cutting unit 48 cuts the continuous web of susceptor material 40 in the adhesive-free areas 62 (i.e., at locations between the adhesive areas 60 on the surface of the continuous web of susceptor material 40). This can be achieved by synchronizing the operation of the susceptor cutting unit 48 with the movement of the continuous web of susceptor material 40.

[0066] refer to Figure 5 , the 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 the support roller 66 and the cutting roller 68 are rotated along the support roller 66 and the cutting roller 68. Figure 5 During synchronous rotation in opposite directions as indicated by the arrows in FIG. 1 , the cutting elements 72 cooperate with (e.g., extend into) the circumferentially spaced recesses 70. This results in continuous shear cutting of the continuous web 40 of susceptor material to form a plurality of susceptor patches 28. As will be apparent from the following description, each susceptor patch 28 corresponds to the susceptor patch 28 described above with reference to FIG. Figure 1a and Figure 1b The elongate second strip 13 (ie the elongate susceptor 12 ) in the finished aerosol-generating article 1 is depicted.

[0067] Sensor patch application

[0068] The susceptor patches 28 provided by the susceptor cutting unit 48 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 successive susceptor patch 28, e.g. Figure 2b and Figure 4As shown. The constant and predetermined spacing 74 can be, for example, between 1 mm and 20 mm. To create the constant and predetermined spacing 74 between the edges of adjacent susceptor patches 28, the susceptor cutting unit 48 permits relative movement between the continuous web of susceptor material 40 and the support roller 66 for a predetermined period of time immediately after the continuous web of susceptor material 40 carried by the support roller 66 has been cut by the cutting roller 68 to form the susceptor patches 28. This relative movement allows the continuous web of susceptor material 40 to remain stationary or travel at a reduced speed for a short period of time after the susceptor patches 28 have been cut from the continuous web of susceptor material 40. The 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 between the 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 susceptor cutting unit 48 are conveyed for a short period of time at a greater 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.

[0069] The susceptor patch 28, 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 18. Exposed side regions 90 of the continuous web 34 of aerosol-generating substrate are thereby formed on both sides of the susceptor patch 28 (see Figure 2b ), because, as described above, the continuous web 34 of aerosol-generating substrate 10 is significantly wider than the susceptor patches 28. Adjacent susceptor patches 28 are also spaced apart 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 patches 28 that is created when the susceptor patches 28 are formed in the susceptor cutting unit 48.

[0070] To ensure adequate adhesion between the susceptor patch 28 and the generally flat surface of the continuous web 34 of aerosol-generating substrate 10, the susceptor patch 28 may be provided by a cam roller 76 (at Figure 2a The cam roller 76 (diagrammatically shown in FIG) presses the susceptor patch 28 onto a generally flat surface. The rotation of the cam roller 76 is synchronized with the movement of the continuous web 34 of the aerosol-generating substrate 10 so that the pressing force is applied to consecutive susceptor patches 28 rather than to the spacing areas between the consecutive susceptor patches 28.

[0071] Depending on the nature of the adhesive 47 applied to the continuous web 40 of susceptor material (and therefore to the susceptor patches 28) by the adhesive applicator unit 46, the continuous web 34 of aerosol-generating substrate 10 and the susceptor patches 28 adhered to its surface may be heated by an optional heater 50. This may help to cure or solidify the adhesive 47 and thereby ensure a good bond between each susceptor patch 28 and the flat surface of the continuous 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 avoiding, or at least minimizing, the release of volatile components from the aerosol-generating substrate 10.

[0072] Strip cutting

[0073] The continuous web 34 of aerosol-generating substrate 10, to whose flat surface a set of spaced-apart susceptor patches 28 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 patches 28 to form a plurality of continuous aerosol-generating strips 16 alongside the susceptor patches 28. 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.

[0074] 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.

[0075] 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 patch 28 and the portion of the continuous web 34 of the aerosol-generating substrate 10 to which the susceptor patch 28 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 patch 28 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.

[0076] Rod formation

[0077] The aerosol-generating strip 16, the elongated carrier strip 17, and the adhered susceptor patch 28, formed by cutting the exposed side regions 90 of the continuous web 34 of aerosol-generating substrate 10, are conveyed to the 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 to the rod-forming unit 56 from a supply reel (not shown), or can be supplied (also from a supply reel) to a separate wrapping unit that can be positioned downstream of the rod-forming unit 56. As the sheet of wrapping paper is conveyed and guided through the rod-forming unit 56 or the separate wrapping unit, it can be wrapped around the aerosol-generating strip 16 and the susceptor patch 28 so that the continuous rod 88 is constrained by the wrap 14.

[0078] Rod cutting

[0079] The continuous rod 88 (optionally constrained by the wrapper 14) is then conveyed to the rod cutting unit 58 where it is cut into predetermined lengths at appropriate locations to form a plurality of aerosol-generating articles 1. The aerosol-generating articles 1 formed by the rod cutting unit 58 may have a length between 5 mm and 50 mm, preferably between 10 mm and 30 mm. It will be understood that this length corresponds to the length of the aerosol-generating articles 1 described above with reference to FIG. Figure 1a and Figure 1bThe length of the aerosol-generating substrate 10 described above is preferably 100 mm / s. The continuous rod 88 is preferably repeatedly cut by the rod cutting unit 58 approximately at the midpoint between the edges of the susceptor patch 28. In this way, the susceptor patch 28 is not cut by the rod cutting unit 58, thereby reducing wear on the cutting element. In addition, because the susceptor patch 28 is shorter than the aerosol-generating strip 16, the ends of the individual susceptor patches 28 (i.e., the elongated second strip 13) are not visible at either end of the aerosol-generating article 1 formed by the rod cutting unit 58. It will be appreciated that this type of method is particularly suitable for mass production of aerosol-generating articles 1.

[0080] Final assembly

[0081] 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 30, or may be a separate, stand-alone unit forming part of a final assembly line.

[0082] 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.

[0083] This disclosure encompasses any combination of the above-described features in all possible variations unless otherwise indicated herein or clearly contradicted by context.

[0084] Unless the context clearly requires otherwise, throughout the specification and claims, the words "comprising," "including," and the like are to be interpreted in an inclusive rather than an exclusive or exhaustive sense; that is, in the sense of "including but not limited to."

Claims

1. A method for continuously manufacturing an aerosol-generating article (1), the method comprising: (i) providing a continuous web (34) of an aerosol-generating substrate (10), the continuous web (34) comprising a generally flat surface having a centerline (18); (ii) applying at least one susceptor patch (28) to the generally flat surface substantially along the centerline (18) to leave exposed areas (90) of the continuous web (34) of aerosol-generating substrate (10) on each side of the at least one susceptor patch (28); (iii) cutting the exposed areas (90) of the continuous web (34) of the aerosol-generating substrate (10) without cutting the at least one susceptor patch (28) to form a plurality of aerosol-generating strips (15, 16) on each side of the at least one susceptor patch (28); and (iv) forming the plurality of aerosol generating strips (15, 16) and the at least one susceptor patch (28) into a continuous rod (88), wherein each of the plurality of aerosol-generating strips (15, 16) has a width between 0.1 mm and 5.0 mm; or Wherein the at least one sensor patch (28) has a length between 5 mm and 50 mm.

2. The method according to claim 1, wherein Step (iii) is performed using a rotating cutter unit (78).

3. The method according to claim 2, wherein: The rotary cutter unit (78) comprises a first cutting drum (80) having a circumferentially extending first cutting formation (84) and a second cutting drum (82), the first cutting drum having a circumferentially extending second cutting formation (86), and wherein the first and second cutting formations (84, 86) cooperate to cut the exposed area (90) of the continuous web (34) of the aerosol-generating substrate (10) to form the plurality of aerosol-generating strips (15, 16).

4. The method according to claim 3, wherein: The first cutting drum (80) and the second cutting drum (82) define a non-cutting area (92) therebetween to accommodate the at least one susceptor patch (28) and the portion (17) of the aerosol-generating substrate (10) to which the at least one susceptor patch (28) is applied during step (ii).

5. The method according to claim 4, wherein The first cutting drum (80) is formed without the first cutting formations (84) in the non-cutting area (92), or the second cutting drum (82) is formed without the second cutting formations (86) in the non-cutting area (92), or the first and second cutting drums (80, 82) are respectively formed without the first and second cutting formations (84, 86) in the non-cutting area (92).

6. The method according to claim 4 or claim 5, wherein: The first cutting drum (80) includes a circumferentially extending recess (94) in its surface in the non-cutting region (92), and wherein at least a portion of the at least one susceptor patch (28) is received in the circumferentially extending recess (94).

7. The method according to any one of claims 1 to 5, wherein Each of the plurality of aerosol-generating strips (15, 16) has a width between 0.5 mm and 2.0 mm.

8. The method according to claim 7, wherein: Each of the plurality of aerosol-generating strips (15, 16) has a width of 1.0 mm.

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

10. The method according to any one of claims 1 to 5, wherein Step (ii) comprises applying a plurality of susceptor patches (28) successively to the substantially planar surface of the continuous web (34) of the aerosol-generating substrate (10) with a predetermined and constant spacing (74) between each successive susceptor patch (28); Step (iii) comprises cutting the exposed areas (90) of the continuous web (34) of aerosol-generating substrate (10) to form a plurality of aerosol-generating strips (15, 16) on each side of the susceptor patches (28); and Step (iv) comprises forming the plurality of aerosol-generating strips (15, 16) and the receptor patches (28) into a continuous rod (88).

11. The method according to any one of claims 1 to 5, wherein The method further comprises: (v) cutting the continuous rod (88) to form a plurality of individual aerosol-generating articles (1), each aerosol-generating article comprising at least one susceptor patch (28).

12. The method according to any one of claims 1 to 5, wherein The at least one receptor patch (28) has a length between 10 mm and 30 mm.

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