Method for producing an aerosol-generating article comprising a strip of susceptor material

Abstract

The present invention relates to a method for producing individual aerosol-generating articles each comprising an individual substrate segment, the substrate segment comprising an aerosol-forming substrate (12A) having a susceptor element, the method comprising the following method steps: • A) providing a continuous susceptor material web (16A), • B) partially cutting the continuous susceptor material web at predetermined pre-cut locations to produce a partially cut susceptor material web (16B), • C) using the partially cut susceptor material web to produce the aerosol-generating articles, wherein the pre-cut locations separate individual aerosol-generating articles from each other.

Description

TECHNICAL FIELD

[0001] The present invention relates to a method for producing a plurality of aerosol-generating articles comprising a substrate segment having an aerosol-forming substrate and a susceptor element. The present invention also relates to a system configured for producing a plurality of individual aerosol-generating articles. The present invention also relates to an aerosol-generating article comprising a substrate segment having an aerosol-forming substrate and a susceptor element. BACKGROUND

[0002] Many aerosol-generating articles, in particular heat-not-burn articles, comprise a substrate segment comprising an aerosol-forming substrate and a further susceptor material. The susceptor is capable of heating the aerosol-forming substrate to a temperature below the combustion temperature of the substrate when subjected to an alternating electromagnetic field. During production of the aerosol-generating article, a continuous substrate segment comprising a plurality of individual substrate segments is produced, which also contains a continuous strip of susceptor material integrated within the aerosol-forming substrate. When cutting the continuous substrate segment in order to produce individual substrate segments for the aerosol-generating article, a rotating cutting tool typically impacts the continuous substrate segment with a great momentum. This great momentum is necessary in order to cut through the aerosol-forming substrate and the continuous strip of susceptor material, which is typically a metal or metal alloy, at the same time. However, this can lead to a deformation or dislocation of the strip of susceptor material within the individual aerosol-generating article. In a substrate segment having a length of 12 mm, the impact of the rotating cutting tool can move the strip of susceptor by about 1.8 mm and can cause a deformation of up to 1 mm. These deformations and dislocations can affect the ability of the susceptor material to be heated when subjected to an alternating electromagnetic field. In addition, the susceptor can also contact the wrapper surrounding the substrate segment. This can lead to the susceptor combusting the wrapper during use, which can be undesirable. Furthermore, a dislocated susceptor protruding from an end face of the substrate segment can affect the connection process of a further segment, such as a filter plug segment or a hollow filter plug segment to the substrate segment. Operating the cutting tool with a higher impact can also affect the service life of the cutting tool.

[0003] It is desirable to provide a method for producing a plurality of aerosol-generating articles and a system configured for producing a plurality of individual aerosol-generating articles, which are capable of avoiding or mitigating a deformation or dislocation of the susceptor element. Furthermore, it is desirable to provide a method and a system for producing an aerosol-generating article, which can increase the service life of the cutting tool. SUMMARY

[0004] According to an embodiment of the present application, a method for producing individual aerosol generating articles is provided, each article comprising an individual substrate segment, and the substrate segment comprising an aerosol-forming substrate having a susceptor. The method can comprise a method step A) of providing a continuous susceptor material web. The method can comprise a method step B) of partially cutting the continuous susceptor material web at predetermined pre-cut locations to produce a partially cut susceptor material web. A method step C) can be comprised. This method step C) can comprise using the partially cut susceptor material web to produce the aerosol generating articles, wherein the pre-cut locations separate individual aerosol generating articles from each other.

[0005] According to another embodiment of the present application, a method for producing individual aerosol generating articles is provided. Each aerosol generating article comprises an individual substrate segment, and the substrate segment comprises an aerosol-forming substrate having a susceptor element. The method comprises the following method steps:

[0006] A) providing a continuous susceptor material web,

[0007] B) partially cutting the continuous susceptor material web at predetermined pre-cut locations to produce a partially cut susceptor material web, and

[0008] C) using the partially cut susceptor material web to produce the aerosol generating articles, wherein the pre-cut locations separate individual aerosol generating articles from each other.

[0009] The partially cut susceptor material web can be more easily separated at the pre-cut locations by a cutting tool. This can be due to the partial incision introduced at the pre-cut locations. It can require less cutting tool momentum to completely cut the partially cut susceptor material web at the pre-cut locations. This can reduce the risk of deformation or dislocation of the susceptor material within the substrate segment.

[0010] At least two pre-cut locations can be formed in method step B). The pre-cut locations on the continuous susceptor material web can be arranged in such a way that one individual substrate segment is located between adjacent pre-cut locations. Similarly, one individual susceptor element corresponding to one individual substrate segment can be located between adjacent pre-cut locations.

[0011] This can enable the easy formation of individual substrate segments by cutting adjacent pre-cut locations on the partially cut susceptor material web. In particular, one individual substrate segment can comprise one individual susceptor element. One individual susceptor element can be located between adjacent pre-cut locations.

[0012] A plurality of pre-cut locations can be formed on the continuous susceptor material strip. The plurality of pre-cut locations can allow for the easy formation of a plurality of individual susceptor elements by cutting the susceptor material strip at the plurality of pre-cut locations if an individual susceptor element is located between adjacent pre-cut locations.

[0013] The plurality of pre-cut locations can separate at least 50 individual susceptor elements, preferably between 10 and 50 individual susceptor elements, from each other. Most preferably, the plurality of pre-cut locations separates 10 individual susceptor elements from each other.

[0014] During method step C), in a first embodiment, the aerosol-forming substrate can be positioned around the partially cut susceptor material strip. This can result in a continuous substrate segment comprising the partially cut susceptor material strip. Subsequently, the continuous substrate segment can be cut at the pre-cut locations in order to result in individual aerosol-generating articles.

[0015] The continuous substrate segment comprising the partially cut susceptor material strip can be easier to cut at the pre-cut locations compared to a continuous substrate segment comprising a continuous susceptor material strip without pre-cuts.

[0016] During method step B), a plurality of pre-cuts can be formed. During method step C), the continuous substrate segment can then be cut at all pre-cut locations. This can result in a plurality of individual substrate segments, wherein each individual substrate segment can comprise an individual susceptor element.

[0017] In other cases, during method step C), the continuous substrate segment can be cut at some pre-cut locations. This can provide a plurality of multi-substrate segments. These multi-substrate segments can be further processed in order to result in aerosol-generating articles. A multi-substrate segment can comprise a susceptor material strip which can still comprise pre-cut locations. One multi-substrate segment can contain at least two, more preferably at least 5 or at least 10 individual substrate segments.

[0018] In another embodiment of the method of the present application, during method step C), the partially cut susceptor material strip can be fully cut at the predetermined pre-cut locations. This can result in individual susceptor elements. Subsequently, the aerosol-forming substrate can be positioned around the individual susceptor elements. This can result in a continuous substrate segment comprising the individual susceptor elements. The individual susceptor elements can be spaced apart from each other. The individual susceptor elements can thus not be in contact with each other in the continuous substrate segment.

[0019] During method step C), the individual susceptor elements in the continuous substrate segment can each be spaced apart by a gap. Subsequently, the continuous substrate segment can be cut between the gaps of the individual susceptor strip, thereby resulting in individual substrate segments.

[0020] Such continuous substrate segments with individual susceptor elements can also facilitate the final cutting of the continuous substrate segments. In particular, the cutting tool can only need to cut through the aerosol-forming substrate in the continuous substrate segments between the individual susceptor elements without simultaneously cutting through the susceptor material band. This can facilitate the cutting process and can not require as much force as cutting through the aerosol-forming substrate and the susceptor material band. Thus, this can reduce the risk of deformation and dislocation of the individual susceptor elements within the individual substrate segments. This can also increase the service life of the cutting tool.

[0021] During method step B), the continuous susceptor material band can be partially cut by introducing a cut at the edge of the band. Subsequently, during method step C), the partially cut band can be fully cut in a central portion of the band adjacent to the cut to produce individual susceptor elements.

[0022] This can enable the full cutting of the continuous susceptor material band in order to produce individual susceptor elements. In comparison to a method in which the continuous susceptor material band is fully cut in one step, this method can in particular require less force to be applied by the cutting tool. This method can avoid deformation of the individual susceptor elements. The individual susceptor elements can subsequently be included into a continuous substrate segment comprising the individual susceptor elements.

[0023] The method of the present application can generally provide two different alternative embodiments. A preferred first embodiment can be provided in which a partially cut susceptor material band with pre-cuts is included into the aerosol-forming substrate. This produces a continuous substrate segment comprising the partially cut susceptor material band. Due to the pre-cut locations, this continuous substrate segment can easily be further cut into individual substrate segments.

[0024] Another embodiment of the method of the present application can provide a method in which the partially cut susceptor material band can be fully cut into individual susceptor elements at the pre-cut locations. These individual susceptor elements can subsequently be included into the aerosol-forming substrate. This can produce a continuous substrate segment comprising the individual susceptor elements. This method also enables easy cutting of the continuous substrate segment as the cutting tool can only have to cut the aerosol-forming substrate of the substrate segment located between the individual susceptor elements. This method of the present application can not cut through the susceptor material.

[0025] The individual susceptor elements produced by fully cutting the partially cut susceptor material band can have a susceptor element length which is less than the substrate segment length of the finished individual substrate segments.

[0026] For example, the susceptor element length can be about 5% or about 10% less than the substrate segment length. This can enable positioning of an individual susceptor element within the aerosol-forming substrate of a substrate segment, without any susceptor material being present at the end face of the individual substrate segment. The individual susceptor element can thus be centrally positioned within the aerosol-forming substrate of the substrate segment.

[0027] This can enable the production of substrate segments comprising less susceptor material. This can also result in less waste after consumption of the aerosol-generating article.

[0028] In embodiments of the method of the application, in case the partially cut susceptor material band is fully cut at the pre-cut location to produce individual susceptor elements before the susceptor elements are included into the aerosol-forming substrate, the method can further comprise increasing the gap between adjacent susceptor elements. This can be achieved by transporting the individual susceptor elements on an accelerated band. In particular, the partially cut susceptor material band can be transported on a first band, and the individual susceptor elements can be transported on an accelerated band as a second band. The speed of the second band can be higher than the speed of the first band. The speed of the second band can be between 10% and 30% higher, preferably 20% higher, than the speed of the first band. This can increase the gap between adjacent individual susceptor elements.

[0029] If the gap between adjacent individual susceptor elements is increased, it can be easier to produce individual substrate segments by cutting through the gap between adjacent individual susceptor elements after the adjacent individual susceptor elements have been integrated into a continuous substrate segment. In particular, if the gap is larger, the positioning of the cutting tool for cutting through the gap relative to the continuous substrate segment can not be as critical. In case there is some misalignment between the later full cut for producing individual substrate segments and the final cut of the continuous substrate segment in method step C), the larger gap between adjacent individual susceptor elements within the continuous substrate segment can still enable reliable cutting of the continuous substrate segment through the gap.

[0030] The partial cutting in method step B) can comprise one or more of the following: creating perforations in the continuous susceptor material band, creating a cut at one or both edges of the continuous susceptor material band, or creating a plurality of recesses in the susceptor material band.

[0031] These methods for partially cutting the continuous susceptor material band can be particularly suitable in order to weaken the susceptor material at the pre-cut location. This can further ease the provision of the final cut at the pre-cut location with a reduced force.

[0032] The continuous susceptor material band can comprise a width. The continuous susceptor material band can comprise a central longitudinal axis. The continuous susceptor material band can extend along its central longitudinal axis. The pre-cuts or plurality of pre-cuts can be created in the band between a quarter and a half of the width of the continuous susceptor material band. Preferably, the pre-cuts can be created at opposite edges of the continuous susceptor material band and can extend towards the central longitudinal axis of the band.

[0033] During method step C), the continuous substrate portion can be overwrapped with a wrapping material, preferably with paper.

[0034] Providing a wrapping material around the continuous substrate segment can result in a strip-shaped continuous substrate segment, wherein the wrapping material stabilizes the substrate segment. As already mentioned above, the continuous substrate segment can comprise a continuous partially cut susceptor material band or individual susceptor elements, which can be spaced apart within the continuous substrate segment.

[0035] During method step C), one of the partially cut continuous susceptor material band or the individual susceptor elements can be transported through the funnel-shaped guiding element. The guiding element can be configured for positioning aerosol-forming substrate around one of the partially cut continuous band or the individual susceptor elements.

[0036] The funnel-shaped guiding element can be configured for compressing aerosol-forming substrate around one of the partially cut continuous susceptor material band or the individual susceptor elements. This can result in a continuous substrate segment, which can comprise the partially cut continuous susceptor material band or the individual susceptor elements.

[0037] During one or both of method step B) and method step C), one of the partially cut continuous susceptor material band or the individual susceptor elements can be transported on a transport device. The transport device can comprise a band, preferably a toothed band, more preferably a U-toothed band.

[0038] Such a band, preferably a toothed band, can be particularly well suited for transporting the partially cut continuous susceptor material band or the individual susceptor elements. These special bands can also be particularly well configured for transporting the continuous substrate segment after the susceptor material band or the individual susceptor elements have been included into the aerosol-forming substrate.

[0039] The toothed band can comprise U-shaped grooves, which can extend parallel to the transport direction of the toothed band. These U-shaped grooves can be configured to accommodate the continuous substrate segment, in particular a strip-shaped continuous substrate segment.

[0040] The toothed band can be created from a flexible polymer, such as rubber or other flexible polymers, such as nylon or aramid fibers.

[0041] During method step B), the continuous susceptor material strip can be guided through at least one rotary knife cylinder or a rotary cylinder with a punching tool. This can allow for a partial cutting of the continuous susceptor material strip.

[0042] In particular, at least one of the rotary knife cylinder or the rotary cylinder with a punching tool can be capable of partially cutting the continuous susceptor material strip at a predetermined pre-cut location. This predetermined pre-cut location can be at opposite edges of the strip or at a predetermined position on the strip. For example, the rotary knife cylinder or the rotary cylinder with a punching tool can be located on opposite edges of the strip configured to create a pre-cut in the opposite edges of the susceptor material strip. As already described above, these pre-cuts can cover only a small portion of the width of the susceptor material strip, for example between a quarter and a half of the width. Alternatively, the pre-cuts can extend along a large portion of the width of the susceptor material strip or over the full length of the width of the susceptor material strip. For example, a perforation line can be formed in the continuous susceptor material strip. This can be achieved by using a rotary cylinder with a punching tool.

[0043] During method step C), the individual susceptor elements can remain centrally positioned within the individual matrix segments after cutting.

[0044] In particular, the individual matrix segments can comprise an individual central longitudinal axis. The individual matrix segments can be strip-shaped. Similarly, the continuous matrix segment can comprise a continuous central longitudinal axis. The individual susceptor elements can be positioned within the continuous matrix segment in such a way that the individual susceptor elements are arranged along the continuous central longitudinal axis, preferably wherein the individual susceptor elements can lie in a plane, wherein the continuous central longitudinal axis also extends within this plane.

[0045] Due to the pre-cut location, the individual matrix segments can be created by cutting the continuous matrix segment through the gap between adjacent individual susceptor elements or at the pre-cut completely without applying too much force. Thus, the individual susceptor elements can remain centrally positioned within the individual matrix segments after cutting.

[0046] Thus, the individual susceptor elements within the individual matrix segments can maintain their position after cutting. Thus, the individual susceptor elements can lie in a plane after cutting, wherein the individual central longitudinal axis of the matrix segments can also extend within this plane.

[0047] The individual susceptor elements centrally positioned within the individual matrix segments can be more easily and reliably heated by applying an external alternating electromagnetic field.

[0048] During method step B), the flat areas on the opposite edges of the continuous susceptor material strip can be removed as partial cuts. This can result in a central link portion connecting the different adjacent portions of the partially cut susceptor material strip.

[0049] This can result in a pre-cut in the partially cut susceptor material strip, which can occupy a larger area on the partially cut strip. In case of misalignment between the pre-cut and the final cut, the final cut can still cut through the central link portion. Thus, the pre-cut occupying a larger area on the partially cut strip can allow for a larger allowance of misalignment between the pre-cut and the final cut.

[0050] During method step C), a detection device can be used for detecting one of: the position of the pre-cut on the continuous susceptor material strip or the position of the gap between the plurality of individual susceptor elements. The detection device can be selected from: an x-ray device, an inductive sensor, an infrared camera analyzer, a device for measuring impedance.

[0051] These detection devices can be configured to detect the pre-cut position on the continuous susceptor material strip including into the continuous substrate segment or the gap between the plurality of individual susceptor elements in the continuous substrate segment. Alternatively, it is noted that there can be a detection device. In contrast, the main machine drive of the system for producing the aerosol generating article can allow for synchronization of the pre-cut and the final cut.

[0052] During method step C), the continuous substrate segment can be cut by a rotating blade. This can result in that the cutting is implemented so as to produce any of a plurality of substrate segments, which can comprise, for example, up to 10 individual substrate segments. Alternatively, the rotating blade can cut the continuous substrate segment into individual substrate segments comprising individual susceptor elements.

[0053] The continuous susceptor material strip can have an elongated flat shape. In particular, the continuous susceptor material strip can comprise a continuous strip having opposite edges. The individual susceptor elements cut from the continuous susceptor material strip can also have an elongated flat shape. The individual susceptor elements can have a width and can have a length. The ratio of the length to the width of the individual susceptor elements can be between 1.5 to 4.5, preferably between 1.8 to 3.5, more preferably between 1.9 to 2.5. In one embodiment, the length of the individual susceptor elements can be between 9 mm to 12 mm and the width can be between 3 mm to 6 mm, preferably, the length can be between 10 to 12 mm and the width can be between 4 to 5 mm.

[0054] The length of the substrate segment can be between 10 and 15 mm, preferably 12 mm. If a single substrate segment has a length of 12 mm, then a multi-substrate segment comprising 10 individual substrate segments can thus have a length of 120 mm.

[0055] Generally, the susceptor element comprises or is made of a material that is capable of generating heat when penetrated by an alternating magnetic field. If the susceptor element is conductive, then eddy currents are generally induced by the alternating magnetic field. If the susceptor element is magnetic, then another effect that generally contributes to the heating is commonly referred to as hysteresis loss. Hysteresis loss arises primarily due to the movement of magnetic domain blocks within the material of the susceptor element, as the magnetic orientation of these magnetic domain blocks will align with the alternating magnetic induction field. Another effect that contributes to the hysteresis loss is that magnetic domains will grow or shrink within the material of the susceptor element. Generally, all these changes in the material of the susceptor element that occur on a nanometer scale or below are referred to as “hysteresis loss” as they generate heat in the material of the susceptor element. Thus, if the susceptor is both magnetic and electrically conductive, then both the generation of eddy currents and hysteresis loss will contribute to the heating of the susceptor element. If the material of the susceptor element is magnetic but not conductive, then hysteresis loss will be the only means by which the susceptor element heats up when penetrated by an alternating magnetic field. According to the present invention, the material of the susceptor element can be magnetic and electrically conductive.

[0056] The susceptor material may, for example, comprise a ferromagnetic material. Preferably, the susceptor material can comprise a ferromagnetic alloy. More preferably, the susceptor material can comprise ferritic iron, in particular a ferromagnetic steel or stainless steel.

[0057] The susceptor element comprising the susceptor material can heat an aerosol-forming substrate that surrounds the susceptor element.

[0058] As used herein, the term “aerosol-forming substrate” relates to a substrate that is capable of releasing one or more volatile compounds that can form an aerosol. Such volatile compounds can be released by heating the aerosol-forming substrate. The aerosol-forming substrate can suitably be part of an aerosol-generating article or a smoking article.

[0059] The aerosol-forming substrate can be a solid aerosol-forming substrate. The aerosol-forming substrate can comprise both a solid component and a liquid component. The aerosol-forming substrate can comprise a tobacco-containing material containing volatile tobacco flavour compounds that are released from the substrate upon heating. The aerosol-forming substrate can comprise a non-tobacco material. The aerosol-forming substrate can comprise an aerosol former that facilitates the formation of a dense and stable aerosol. Suitable aerosol formers are well known in the art and include, but are not limited to: polyhydric alcohols such as triethylene glycol, 1,3-butanediol and glycerol; esters of polyhydric alcohols such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or poly-carboxylic acids such as dimethyl dodecanedioate and dimethyl tetradecanedioate. The aerosol former can be a polyhydric alcohol or a mixture thereof, for example triethylene glycol, 1,3-butanediol and glycerol. The aerosol former can be propylene glycol. The aerosol former can comprise both glycerol and propylene glycol.

[0060] In a method step D) following the method step C), one or both of the filter segment and the hollow rod segment can be connected to one of: a separate substrate segment or a multi-substrate segment. This method step D) can result in a final aerosol-generating article. This aerosol-generating article can comprise: a substrate segment comprising an aerosol-forming substrate with a susceptor element; and one or both of a further filter segment and a hollow rod segment.

[0061] Preferably, the filter segment and the hollow rod segment are located downstream of the substrate segment in the aerosol-forming article. If both the filter segment and the hollow rod segment are present, the hollow rod segment can be located between the filter segment and the substrate segment in the aerosol-forming article. Alternatively, the aerosol-forming article can be formed only of the substrate segment.

[0062] The aerosol-forming article can be inserted into a cavity of an aerosol-generating device. Furthermore, the aerosol-generating device can comprise a heating element. The heating element can comprise an induction coil for heating the susceptor material via induction heating.

[0063] If the susceptor element comprised in the substrate segment of the aerosol-forming article is not deformed and centrally located within the aerosol-forming substrate of the substrate segment, induction heating can be more efficient. In particular, the eddy currents induced by the induction coil in the susceptor element also depend on the shape of the susceptor element and its position relative to the heating element of the aerosol-generating device. Thus, producing an aerosol-generating article comprising a susceptor element having a uniform shape and position within the substrate segment can greatly increase the efficiency of induction heating.

[0064] As used herein, the terms "upstream" and "downstream" are used to describe the relative positions of components or parts of components of an aerosol-generating article or aerosol-generating device, with respect to the direction of air flow through the aerosol-generating article or aerosol-generating device during use. Aerosol-generating articles according to the present application comprise a proximal end through which, in use, aerosol exits the device. The proximal end of an aerosol-generating article can also be referred to as the mouth end or downstream end. The mouth end is downstream of the distal end. The mouth end can comprise a mouthpiece. The distal end of an aerosol-generating article can also be referred to as the upstream end. Components or parts of components of an aerosol-generating article can be described as being upstream or downstream of each other based on their relative positions with respect to the air flow path through the aerosol-generating article.

[0065] The present application also provides a method for producing individual aerosol-generating articles each comprising an individual substrate segment comprising an aerosol-forming substrate with a susceptor element, the method comprising the following method steps:

[0066] A) providing a continuous susceptor material web,

[0067] B) partially cutting the continuous susceptor material web at predetermined pre-cut locations to produce a partially cut susceptor material web,

[0068] C) using the partially cut susceptor material web to produce the aerosol-generating articles, wherein the pre-cut locations separate the individual aerosol-generating articles from each other, wherein the partially cut susceptor material web is fully cut at the predetermined pre-cut locations during method step C), thereby producing individual susceptor elements, and wherein the aerosol-forming substrate is positioned around the susceptor web, thereby producing a continuous substrate segment comprising individual partially pre-cut susceptor elements.

[0069] Such a method can provide the advantage that the continuous substrate segment can be easily fully cut at the predetermined pre-cut locations.

[0070] This method can be combined with any of the further method features disclosed herein.

[0071] In one embodiment of this method, during method step C), the individual susceptor elements in the continuous substrate segment can each be spaced apart by a gap, and subsequently the continuous substrate segment can be cut between the gaps of the individual susceptor elements. This can produce individual substrate segments.

[0072] In a further embodiment of this method, during method step B), the flat areas on the opposite edges of the continuous susceptor material web can be removed as partial cuts. This can produce central link portions connecting different portions of the partially cut susceptor material web.

[0073] The present invention also provides a system configured to produce individual aerosol generating articles, each article comprising an individual substrate segment having a susceptor element. The system can comprise a pre-cutting device configured to partially cut a continuous susceptor material web to produce pre-cut locations on the continuous susceptor material web. The pre-cut locations can separate the individual aerosol generating articles from each other. The system can comprise a substrate segment forming device configured to produce the aerosol generating articles. The substrate segment forming device can use the partially cut susceptor material web for producing the aerosol generating articles. The system can also comprise a transport device configured to transport the continuous susceptor material web between the pre-cutting device and the substrate segment forming device.

[0074] According to another embodiment, the present invention provides a system configured to produce individual aerosol generating articles, each article comprising an individual substrate segment having a susceptor element. The system comprises a pre-cutting device configured to partially cut a continuous susceptor material web to produce pre-cut locations on the continuous susceptor material web, wherein the pre-cut locations separate the individual aerosol generating articles from each other. Further, the system comprises a substrate segment forming device configured to produce the aerosol generating articles using the partially cut susceptor material web. The system also comprises a transport device configured to transport the continuous susceptor material web between the pre-cutting device and the substrate segment forming device.

[0075] Such a system is well suited to produce aerosol generating articles comprising susceptor elements having a uniform shape and well-defined position within the substrate segment in order to facilitate inductive heating.

[0076] Further, the pre-cutting device of the system can be configured to produce at least two pre-cuts. In particular, the pre-cutting device can also be configured to arrange the positions of the at least two pre-cuts on the continuous susceptor material web in such a way that one single individual substrate segment is located between adjacent pre-cut locations. The single individual substrate segment can correspond to one single susceptor element located between adjacent pre-cut locations.

[0077] The pre-cutting device can comprise one of the following: a knife, a rotating drum with punching tools or a rotating knife drum. The rotating knife drum can comprise a plurality of knives located on the circumference of the drum. Preferably, the distance between adjacent knives on the knife drum or between adjacent punching tools on the rotating drum is the same as the distance of adjacent pre-cuts on the partially cut susceptor material web. For example, if the distance between two adjacent pre-cuts is 12 mm, the distance can be 12 mm.

[0078] According to a first embodiment of the present application, the substrate segment forming device can be configured for producing a continuous substrate segment comprising a partially cut susceptor material band. The system for producing aerosol generating articles can further comprise a substrate cutting device for cutting the continuous substrate segment at a pre-cut location.

[0079] In this embodiment, the continuous susceptor material band is only partially cut to produce a partially cut susceptor material band. This partially cut susceptor material band can then be included into the continuous substrate segment. Thereafter, the continuous substrate segment can be cut at the pre-cut location of the partially cut susceptor material band for producing individual or more substrate segments.

[0080] This can allow reliably producing individual substrate segments comprising individual susceptor elements with greater reliability.

[0081] The substrate cutting device can comprise a cutting tool for cutting the continuous substrate segment at the pre-cut location. This can enable cutting the aerosol forming substrate at the pre-cut location and additionally also cutting the partially cut continuous susceptor material band at the pre-cut location for producing individual substrate segments.

[0082] The substrate cutting device can be configured to impact the continuous substrate segment with a lower momentum in order to avoid or reduce deformation or dislocation of the susceptor elements of the individual substrate segments.

[0083] The substrate cutting device can comprise a rotating knife. The rotating knife can for example be a stainless steel knife. The rotating knife can be operated at a rotation speed of about 800 rpm at a transport speed of 200 m / min. The rotating knife can cut the continuous substrate segment at an inclination of 45°.

[0084] In an alternative embodiment of the present application, the system for producing individual aerosol generating articles can comprise a susceptor cutting device in addition to the pre-cutting device. The susceptor cutting device can be configured for cutting the partially cut susceptor material band into individual susceptor elements. The substrate segment forming device can then be configured for producing a continuous substrate segment comprising individual susceptor elements.

[0085] In this alternative embodiment of the present application, the partially cut susceptor material band is further cut into individual susceptor elements. Due to the lower impact of the susceptor cutting device, deformation of the individual susceptor elements can be avoided.

[0086] The susceptor cutting device can comprise a rotating knife.

[0087] Further, in this alternative embodiment of the present application, the system can comprise a substrate cutting device which can be configured for cutting through the aerosol-forming substrate between the individual susceptor elements in the continuous substrate section.

[0088] The substrate cutting device can operate with reduced impact as it can only have to cut through the aerosol-forming substrate between adjacent individual susceptor elements included in the continuous substrate section, but not through the susceptor material. The transport device can also be configured for transporting the partially cut susceptor material band from the pre-cutting device to the susceptor cutting device. Further, in the first and second embodiments, the transport device can be configured for transporting the continuous substrate section from the substrate section forming device to the substrate cutting device.

[0089] Further, the system for producing individual aerosol-generating articles can comprise a reel configured for unwinding the continuous susceptor material band. The reel can operate at a speed sufficient to unwind the continuous susceptor material band and to feed it through the transport device.

[0090] The transport device can comprise a band. Preferably, the transport device can comprise a toothed band, more preferably a band with U-shaped teeth.

[0091] The band can operate at a speed sufficient to transport the continuous susceptor material band between the pre-cutting device and the substrate section forming device. The speed can be between 150 m / min and 400 m / min, preferably between 200 m / min and 300 m / min.

[0092] The substrate section forming device can comprise a funnel-shaped guiding element for positioning the aerosol-forming substrate around one of: the partially cut continuous susceptor material band or the plurality of individual susceptor elements.

[0093] The substrate section forming device can compress the aerosol-forming substrate around the partially cut susceptor material band or around the individual susceptor elements for producing the continuous substrate section.

[0094] The system for producing individual aerosol-generating articles can comprise a modified commercially available device. The commercially available device can be modified by comprising the pre-cutting device. In addition, the commercially available device can be modified by comprising the susceptor cutting device. One commercially available device which can be modified according to the present application can be the Hauni KDF manufactured by Hauni Maschinenbau GmbH.

[0095] Further, the present application provides an aerosol-generating article comprising a substrate segment comprising an aerosol-forming substrate and a susceptor element. The susceptor element can comprise a first susceptor end face and a second susceptor end face. At least one of the first susceptor end face and the second susceptor end face can have a tapered shape.

[0096] The first susceptor end face and the second susceptor end face having a tapered shape can be created by a central joining portion between adjacent susceptor elements in a strip of susceptor material cut by a cutting portion. This central joining portion can be formed when flat areas on opposite edges of a continuous strip of susceptor material are removed in order to create a pre-cut using a larger area.

[0097] An aerosol-generating article comprising such a susceptor element can be more easily heated via inductive heating due to the absence of deformation of the susceptor element.

[0098] The susceptor element of the aerosol-generating article can comprise a flat, elongated shape. Such a susceptor element embedded in the aerosol-forming substrate can allow for uniform heating of the aerosol-forming substrate upon inductive heating of the susceptor element.

[0099] One or both of the first susceptor end face and the second susceptor end face can comprise a rounded edge. The rounded edge can be created by removing a larger flat area from opposite edges of a continuous strip of susceptor material when creating a pre-cut.

[0100] The susceptor element can comprise a flat surface. The surface of the susceptor element can not be curved due to the reduced impact on the susceptor cutting device or the substrate cutting device due to the pre-cut.

[0101] The aerosol-generating article can comprise a first article end face and an opposite second article end face. The first susceptor end face and the second susceptor end face can be spaced apart from these first and second article end faces.

[0102] A susceptor comprising such a first susceptor end face and a second susceptor end face can not be deformed. Such a susceptor can not be curved during cutting of a continuous substrate segment. The first susceptor end face and the second susceptor end face can be spaced apart from the respective article end faces as in the continuous substrate segment, the aerosol-forming substrate is located between adjacent individual susceptor elements. Cutting between adjacent individual susceptor elements can create an aerosol-generating article in which the susceptor end faces are then spaced apart from the respective article end faces.

[0103] The susceptor element can be centrally positioned within the substrate segment of the aerosol generating article. The aerosol generating article can comprise a tubular elongated shape. The aerosol generating article can comprise a central longitudinal axis. The susceptor element can be positioned within the substrate segment in such a way that the susceptor element is arranged along a continuous central longitudinal axis, preferably wherein the susceptor element can be located in a plane, wherein the continuous central longitudinal axis also extends within this plane.

[0104] Such centrally positioned susceptor elements can be able to reliably and uniformly heat the surrounding aerosol-forming substrate. In addition, any harm to a user that can be caused by dislocation of the susceptor element can be avoided.

[0105] The aerosol generating article can generate an aerosol by heating the aerosol-forming substrate to a temperature below the combustion temperature by inductive heating. Such aerosol generating articles can also be referred to as "heat-not-burn products".

[0106] The present invention also provides an aerosol generating article produced according to any of the methods described herein.

[0107] A non-exhaustive list of non-limiting examples is provided below. Any one or more features of these examples can be combined with any one or more features of another example, embodiment or aspect described herein.

[0108] Example A: A method for producing individual aerosol generating articles each comprising an individual substrate segment, the substrate segment comprising an aerosol-forming substrate with a susceptor element, the method comprising the following method steps:

[0109] A) providing a continuous susceptor material band,

[0110] B) partially cutting the continuous susceptor material band at predetermined pre-cut locations to produce a partially cut susceptor material band,

[0111] C) using the partially cut susceptor material band to produce the aerosol generating articles, wherein the pre-cut locations separate the individual aerosol generating articles from each other.

[0112] Example B: The method according to example A, wherein at least two pre-cut locations are formed in method step B), and wherein the pre-cut locations on the continuous susceptor material band are arranged in such a way that one individual substrate segment is located between adjacent pre-cut locations.

[0113] Example C: The method according to any of the preceding examples, wherein during method step C) the aerosol-forming substrate is positioned around the partially cut strip of susceptor material, thereby creating a continuous substrate segment comprising a partially cut strip, and wherein subsequently the continuous substrate segment is cut at the pre-cut locations.

[0114] Example D: The method according to the preceding example, wherein during method step B) a plurality of pre-cuts are formed, and

[0115] wherein during method step C) the continuous substrate segment is cut at all pre-cut locations, thereby creating a plurality of individual substrate segments, or wherein during method C) the continuous substrate segment is cut at some pre-cut locations, thereby providing a plurality of multi-substrate segments, preferably wherein one multi-substrate segment comprises at least two, more preferably at least 5 or at least 10 individual substrate segments.

[0116] Example E: The method according to example A or example B, wherein during method step C) the partially cut strip of susceptor material is fully cut at the predetermined pre-cut locations, thereby creating individual susceptor elements, and wherein subsequently the aerosol-forming substrate is positioned around the individual susceptor strip, thereby creating a continuous substrate segment comprising individual susceptor elements.

[0117] Example F: The method according to the preceding example, wherein during method step C) the individual susceptor elements in the continuous substrate segment are each separated by a gap, and wherein subsequently the continuous substrate segment is cut between the gaps of the individual susceptor strip, thereby creating individual substrate segments.

[0118] Example G: The method according to any of the preceding examples E or F, wherein during method step B) the continuous strip of susceptor material is partially cut by creating a cut at an edge of the strip, and wherein during method step C) the partially cut strip is fully cut in a central portion of the strip adjacent to the cut to create the individual susceptor elements.

[0119] Example H: The method according to any of the preceding examples, wherein the partial cutting in method step B) comprises one or more of: creating perforations in the strip, creating a cut at one or both edges of the strip, creating a plurality of recesses in the strip.

[0120] Example I: The method according to any of the preceding examples, wherein during method step C) the continuous substrate segment is overwrapped with a wrapping material, preferably with paper.

[0121] Example J: The method according to any one of the preceding examples, wherein during method step C) the partially cut continuous tape or one of the individual susceptor elements is transported through a funnel-shaped guiding element for positioning the aerosol-forming substrate around the partially cut continuous tape or one of the individual susceptor elements.

[0122] Example K: The method according to any one of the preceding examples, wherein during one or both of method step B) and method step C) the partially cut continuous tape or one of the individual susceptor elements is transported on a belt, preferably a toothed belt, more preferably a U-toothed belt.

[0123] Example L: The method according to any one of the preceding examples, wherein during method step B) the continuous susceptor material tape is guided through at least one rotating knife cylinder or a rotating cylinder with a punching tool for partially cutting the continuous susceptor material tape.

[0124] Example M: The method according to any one of the preceding examples, wherein during method step C) the individual susceptor elements remain centrally positioned within the individual substrate segments after cutting.

[0125] Example N: The method according to any one of the preceding examples, wherein during method step B) flat areas on opposite edges of the continuous susceptor material tape are removed as partial cuts, thereby creating central link portions connecting different portions of the partially cut susceptor material tape.

[0126] Example O: The method according to any one of the preceding examples, wherein during method step C) a detection device is used for detecting one of: the pre-cut locations on the partially cut susceptor material tape or the positions of the gaps between the individual susceptor elements within the continuous substrate segment, preferably wherein the detection device is selected from the group consisting of: an X-ray device, an inductive sensor, an IR camera analyzer, a device for measuring impedance.

[0127] Example P: The method according to any one of the preceding examples, wherein during method step C) the continuous substrate segment is cut by a rotating blade, preferably wherein the rotating blade is controlled by the detection device of example O.

[0128] Example Q: The method according to any one of the preceding examples, wherein the susceptor material comprises a ferromagnetic material, preferably a ferromagnetic alloy, more preferably ferritic iron, ferromagnetic steel or stainless steel.

[0129] Example R: The method according to any one of the preceding examples, wherein in method step D) after method step C), one or both of the filter section and the hollow rod section are connected to one of: a separate matrix section or a multi-matrix section.

[0130] Example S: A system configured to produce individual aerosol-generating articles each comprising a separate matrix section, the matrix section comprising an aerosol-forming substrate with susceptor elements, the system comprising:

[0131] - a pre-cutting device configured to partially cut a continuous susceptor material web to produce pre-cut locations on the continuous susceptor material web, wherein the pre-cut locations separate individual aerosol-generating articles from each other,

[0132] - a matrix section forming device configured to produce aerosol-generating articles using the partially cut susceptor material web, and

[0133] - a transport device configured to transport the continuous susceptor material web between the pre-cutting device and the matrix section forming device.

[0134] Example T: The system according to the preceding example, wherein the pre-cutting device is configured to produce at least two pre-cuts, wherein the pre-cutting device is further configured to position the at least two pre-cuts on the continuous susceptor material web in such a way that one single individual matrix section is located between adjacent pre-cut locations.

[0135] Example U: The system according to any one of the preceding examples S or T, wherein the matrix section forming device is configured to produce a continuous matrix section comprising the partially cut susceptor material web, the device further comprising a matrix cutting device for cutting the continuous matrix section at the pre-cut locations.

[0136] Example V: The system according to the preceding examples S or T, the device further comprising a susceptor cutting device for cutting the partially cut susceptor material web into individual susceptor elements at a plurality of pre-cut locations, further wherein the matrix section forming device is configured to produce a continuous matrix section comprising the individual susceptor elements.

[0137] Example W: The system according to the preceding examples, further comprising a matrix cutting device for cutting the continuous matrix section between the individual susceptor elements.

[0138] Example X: The system of any of the preceding Examples S to W, further comprising a spool configured for unwinding the continuous susceptor material band.

[0139] Example Y: The system of any of the preceding Examples S to X, wherein the transport device comprises a belt, preferably a belt with teeth, more preferably a belt with U-shaped teeth.

[0140] Example Z: The system of any of the preceding Examples S to Y, wherein the matrix segment forming device comprises a funnel-shaped guiding element for positioning the aerosol-forming substrate around one of: a partially cut continuous band or a plurality of individual susceptor elements.

[0141] Example AA: The system of any of the preceding Examples S to Z, wherein the pre-cutting device comprises a knife roller, a knife or a roller with a punching tool for providing partial cuts.

[0142] Example AB: The system of any of the preceding Examples S to AA, wherein one or both of the susceptor cutting device or the matrix cutting device comprises a rotating blade.

[0143] Example AC: An aerosol-generating article comprising:

[0144] - a matrix segment comprising an aerosol-forming substrate and a susceptor element, wherein the susceptor element comprises a first susceptor end face and a second susceptor end face, wherein at least one of the first susceptor end face and the second susceptor end face has a conical shape.

[0145] Example AD: The aerosol-generating article of the preceding Example, wherein one or both of the first susceptor end face and the second susceptor end face comprises a rounded edge.

[0146] Example AE: The aerosol-generating article of the preceding Example AC or AD, wherein the susceptor element comprises a flat surface, preferably wherein the surface is not curved.

[0147] Example AF: The aerosol-generating article of any of the preceding Examples AC to AE, wherein the susceptor element is centrally positioned within the matrix segment.

[0148] Example AG: An aerosol-generating article produced according to the method of any of Examples A to R.

[0149] Features described in relation to one embodiment can equally apply to other embodiments of the application. BRIEF DESCRIPTION OF DRAWINGS

[0150] The application will be further described, by way of example only, with reference to the accompanying drawings in which:

[0151] Figure 1A A cross-sectional view of a substrate segment with deformed susceptor elements is shown;

[0152] Figure 1B A schematic perspective view of a substrate segment comprising susceptor elements is shown;

[0153] Figure 2 A schematic view of a pre-cutting device cutting pre-cuts into a continuous susceptor material strip is depicted;

[0154] Figure 3 A schematic view of a system configured for producing aerosol generating articles with a pre-cutting device according to a first embodiment of the application is shown;

[0155] Figure 4 A schematic view of a system for producing aerosol generating articles with a pre-cutting device and a susceptor cutting device according to a second embodiment of the application is shown;

[0156] Figure 5 A cross-sectional view along a central longitudinal axis of a continuous substrate segment comprising a partially cut continuous susceptor material strip produced according to a first embodiment of the application is shown;

[0157] Figure 6 A cross-sectional view along a central longitudinal axis of a continuous substrate segment comprising individual susceptor elements spaced apart by gaps according to a second embodiment is depicted;

[0158] Figure 7 A schematic view of a transport device comprising a first and a second strip is shown;

[0159] Figure 8A A perspective view of a cylinder with a piercing tool and its counter-cylinder is shown;

[0160] Figure 8B A cross-sectional view of a cylinder with a piercing tool and its respective counter-cylinder is depicted;

[0161] Figure 9A and 9B Different embodiments of pre-cuts in a partially cut continuous susceptor material strip are shown, wherein flat areas on the opposite edges of the continuous susceptor material strip have been removed; and

[0162] Figure 9C A substrate segment with fully cut susceptor elements having tapered end faces is shown. DETAILED DESCRIPTION

[0163] In the following in all figures, identical elements are denoted by the same reference signs.

[0164] Figure 1A A cross-sectional view of a substrate segment 10 is shown, which is manufactured based on a process that does not form pre-cuts in the susceptor element. This process involves the following last step: a rotary knife cuts the continuous substrate segment into individual substrate segments with great momentum in order to cut through the aerosol-forming substrate 12 and the metallic susceptor element 16 at the same time. This great momentum results in a bending of the susceptor element 16 and its simultaneous dislodgement from the center of the substrate segment. Due to the deformation and dislodgement of the susceptor element, the heating of the aerosol-forming substrate by inductive heating can be unsatisfactory. The substrate segment 10 is over-wrapped with a packaging material 14.

[0165] Figure 1B A schematic perspective view of a substrate segment 10 is depicted, in which a susceptor element 16 having an elongated and rectangular shape is centrally located within the substrate segment. The susceptor element 16 is located in a plane within the substrate segment 10 that is also occupied by the central longitudinal axis 24 of the substrate segment. In contrast to the shape and position of the susceptor element shown in Figure 1A Figure 1B The shape and position of the susceptor element 16 in

[0166] Figure 2 A schematic perspective view of a pre-cutting device 21 configured to partially cut a continuous susceptor material strip is depicted. The pre-cutting device 21 comprises a knife cylinder 18 with a knife 18A and a corresponding counter cylinder 20. The continuous susceptor material strip 16A is guided between the knife cylinder 18 and the counter cylinder 20. The knife cylinder 18 produces a pre-cut 22 at one edge of the continuous susceptor material strip 16A, thereby producing a partially cut continuous susceptor material strip 16B. A second pair of knife and counter cylinders can be present on the opposite edge of the continuous susceptor material strip 16A in order to produce a corresponding pre-cut on the opposite edge of the strip (not shown in Figure 2 ). Two adjacent pre-cuts 22 separate one susceptor element from the next, so that the final cut that separates the individual susceptor elements from each other can be made more easily.

[0167] Figure 3 ​A schematic drawing of a system configured for producing individual aerosol generating articles according to a first embodiment of the present application is depicted. This system typically uses a pre-cutting device 21 with a knife drum 18 and a counter drum 20 to produce pre-cuts in a continuous susceptor material web 16A and subsequently positions aerosol-forming substrate 12A around the partially cut susceptor material web 16B. This forms a continuous substrate segment 10A with a partially cut susceptor material web by compressing the aerosol-forming substrate 12A around the partially cut susceptor material web using a substrate segment forming device 24 with funnel-shaped guiding elements. The continuous substrate segment 10A comprises a partially cut susceptor material web with pre-cuts 22. For the sake of clarity, only the susceptor portion of the continuous substrate segment is shown in Figure 3

[0168] Figure 4 A schematic drawing of a system configured for producing individual aerosol generating articles according to a second embodiment of the present application is depicted. In contrast to the first embodiment of the present application shown in Figure 3

[0169] Figure 5 ​​A cross-sectional view of a continuous substrate segment 10A according to a first embodiment of the application is depicted along its central longitudinal axis, the continuous substrate segment comprising a partially cut continuous susceptor material band 16B. Pre-cuts 22 are present in the partially cut continuous susceptor material band 16B, which remove flat areas on the opposite edges of the continuous band. Only central link portions 36 are present between adjacent substrate segments. The partially cut continuous susceptor material band 16B is embedded in the aerosol-forming substrate 12 and surrounded by the wrapper material 14. The central link portions 36 connecting different susceptor elements can be cut along the cut lines 34, thereby resulting in individual substrate segments 10. Cutting along the cut lines 34 will result in individual substrate segments 10, wherein the end faces of the susceptor elements provided therein will have a tapered shape. The arrow 38 indicates the direction of transport of the continuous substrate segment 10A through a system for producing individual aerosol-generating articles.

[0170] Figure 6 A continuous substrate segment 10A comprising individual susceptor elements 16 according to a second embodiment of the application is shown. A substrate cutting device can finally cut the continuous substrate segment 10A along the cut lines 30 within the gaps 16C for producing individual substrate segments 10.

[0171] Figure 7 A schematic view of a transport device comprising a first band 40 and a second band 42 as an acceleration band is depicted. After the final cutting of the partially cut continuous susceptor material band at the pre-cuts, individual susceptor elements 16 are obtained, which are separated by the cut-outs 17 between adjacent susceptor elements. These fully separated susceptor elements 16 are transported on the first band 40 and subsequently picked up by the second band 42. The speed of the second band 42 is higher than the speed of the first band 40 such that gaps 16C between adjacent susceptor elements are created. The susceptor elements 16 spaced apart by the gaps 16C are subsequently included into a continuous substrate segment 10A, as shown in Figure 4 .

[0172] Figure 8A A schematic perspective view of a drum 18 with a punching tool 18B and its corresponding counter drum 20 is shown. The counter drum 20 comprises a complementary structure 18C, which is able to at least partially accommodate the punching tool 18B when the drum 18 and the counter drum 20 are rotating. A continuous susceptor material band can be guided between the drum 18 and the counter drum 20 such that the punching tool 18B can create pre-cuts in the band.

[0173] Figure 8BA schematic cross-sectional view of the cylinder 18 with the punching tool 18B and its counter-cylinder 20 is shown. It can be clearly seen that the complementary structure 18C can at least partially accommodate the punching tool 18B such that pre-cuts can be produced in the susceptor material strip guided between both cylinders 18 and 20.

[0174] Figure 9A and 9B A schematic top view of several portions of a partially cut susceptor material strip 16B is depicted. Different pre-cuts 22 have been introduced at opposite edges of the strip. In Figure 9A a rectangular edge is formed at the pre-cut 22, while in Figure 9B a rounded edge 44 is formed. Figure 9A and Figure 9B Two pre-cuts 22 of the strip 16B produce a central link portion 36 connecting two adjacent susceptor elements.

[0175] Figure 9C A schematic cross-sectional view of a matrix segment 10 is shown, wherein two central link portions flanking a susceptor element 16 have been cut, thereby producing tapered end faces 44A and 44B of the susceptor element.

Claims

1. A method for producing individual aerosol-generating articles each comprising an individual substrate segment, the substrate segment comprising an aerosol-forming substrate with susceptor elements, the method comprising the following method steps: A) providing a continuous susceptor material web, B) partially cutting the continuous susceptor material web at predetermined pre-cut locations to produce a partially cut susceptor material web, C) using the partially cut susceptor material web to produce the aerosol-generating articles, wherein the pre-cut locations separate individual aerosol-generating articles from each other, wherein during method step C) the partially cut susceptor material web is fully cut at the predetermined pre-cut locations, thereby producing individual susceptor elements, and wherein subsequently the aerosol-forming substrate is positioned around the individual susceptor web, thereby producing a continuous substrate segment comprising individual susceptor elements.

2. The method according to claim 1, wherein at least two pre-cut locations are formed in method step B), and wherein the pre-cut locations on the continuous susceptor material web are arranged in such a way that one individual substrate segment is located between adjacent pre-cut locations.

3. The method according to claim 1, wherein during method step C) the individual susceptor elements in the continuous substrate segment are each spaced apart by a gap, and wherein subsequently the continuous substrate segment is cut between the gaps of the individual susceptor web, thereby producing individual substrate segments.

4. The method according to claim 1, wherein the partial cutting in method step B) comprises one or more of the following: producing perforations in the susceptor material web, producing a cut at one or both edges of the susceptor material web, producing a plurality of recesses in the susceptor material web.

5. The method according to claim 1, wherein during method step B) flat areas on opposite edges of the continuous susceptor material web are removed as partial cuts, thereby producing a central link portion connecting different portions of the partially cut susceptor material web.

6. A system configured for producing individual aerosol-generating articles each comprising an individual substrate segment, the substrate segment comprising an aerosol-forming substrate with susceptor elements, the system comprising: - a pre-cutting device configured for partially cutting a continuous susceptor material web to produce pre-cut locations on the continuous susceptor material web, wherein the pre-cut locations separate individual aerosol-generating articles from each other, - a susceptor cutting device for cutting the partially cut susceptor material web into individual susceptor elements at the plurality of pre-cut locations, - a substrate segment forming device configured for producing aerosol-generating articles using the partially cut susceptor material web, wherein the substrate segment forming device is configured for producing a continuous substrate segment comprising the individual susceptor elements, and - a transport device configured for transporting the continuous susceptor material web between the pre-cutting device and the substrate segment forming device.

7. The system according to claim 6, wherein the pre-cutting device is configured to produce at least two pre-cuts, wherein the pre-cutting device is further configured to position the at least two pre-cuts on the continuous susceptor material web in such a way that one single individual substrate segment is located between adjacent pre-cut positions.

8. The system according to claim 7, further comprising a substrate cutting device for cutting the continuous substrate segments between the individual susceptor elements.

9. The system according to claim 6, wherein the transport device comprises a belt.

10. The system according to claim 9, wherein the belt is a toothed belt.

11. The system according to claim 10, wherein the toothed belt is a U-shaped toothed belt.

12. An aerosol-generating article comprising: - a substrate segment comprising an aerosol-forming substrate and a susceptor element, wherein the susceptor element comprises a first susceptor end face and a second susceptor end face, wherein at least one of the first susceptor end face and the second susceptor end face has a conical shape, - wherein the aerosol-generating article comprises a first article end face and an opposite second article end face, and - wherein the first susceptor end face and the second susceptor end face are spaced apart from these first and second article end faces.

13. The aerosol-generating article according to claim 12, wherein one or both of the first susceptor end face and the second susceptor end face comprise a rounded edge.

14. A method for producing individual aerosol-generating articles each comprising an individual substrate segment comprising an aerosol-forming substrate with a susceptor element, the method comprising the following method steps: A) providing a continuous susceptor material web, B) partially cutting the continuous susceptor material web at predetermined pre-cut positions to produce a partially cut susceptor material web, C) using the partially cut susceptor material web to produce the aerosol-generating articles, wherein the pre-cut positions separate individual aerosol-generating articles from each other, wherein during method step C) the partially cut susceptor material web is fully cut at the predetermined pre-cut positions, thereby producing individual susceptor elements, and wherein the aerosol-forming substrate is positioned around the susceptor web, thereby producing a continuous substrate segment comprising individual partially pre-cut susceptor elements.

Images