Composite aerosol-generating material

Abstract

The present invention provides a composite aerosol-generating material (530) comprising two sheets of carrier material (522A, 522B) with a gel (544) interposed therebetween. A manufacturing method and an apparatus for such manufacturing; a composite aerosol-generating material (530), the composite aerosol-generating material comprising a gel (544) interposed between two sheets of carrier material (522A, 522B). The gel (544) is capable of carrying an aerosol-generating substance, such as nicotine. The invention also provides a method of manufacturing the composite aerosol-generating material and a composite aerosol-generating rod.

Description

[0001] This application is a divisional application of Chinese patent application No. PCT / EP2020 / 075903 (international application), No. 202080061703.9 (Chinese application), filed on September 16, 2020, entitled "Composite Aerosol Generating Material". Technical Field

[0002] This disclosure relates to a composite aerosol generating material, a method for manufacturing such a composite aerosol generating material, and apparatus for such manufacturing. Additionally, this disclosure relates to an aerosol generating rod comprising a composite aerosol generating material, a method for manufacturing such a rod, and apparatus for manufacturing such a rod. The aerosol generating rod can be used in aerosol generating articles. The aerosol generating articles can be used with an aerosol generating apparatus. This disclosure particularly, but not exclusively, relates to the application of a gel in a sandwich configuration between an aerosol generating material or a carrier material. Preferably, the gel comprises an active agent, such as a fragrance, humectant, plasticizer, or nicotine. Preferably, the gel comprises a combination of active agents. Background Technology

[0003] To manufacture an aerosol generating rod, the process typically involves the following steps: A flat sheet of aerosol generating material is unwound from a spool of aerosol generating material. Then, the aerosol generating material is sprayed, usually with a liquid or powdered component (such as glycerin or fragrance). Finally, the aerosol generating material is drawn into a funnel-shaped device that gathers the sheet into a continuous cylindrical rod of the desired diameter. The continuous rod is then wrapped and cut to the desired length before being combined with other rods to form an aerosol generating article.

[0004] However, spraying liquid or powder components onto a sheet can lead to certain drawbacks. For example, during the spraying process, typically only a portion of the material is sprayed and adhered to the aerosol-generating material sheet.

[0005] Therefore, it is desirable to provide an improved application method for fragrances and other components that overcomes these drawbacks. It is also desirable to provide an aerosol-generating material for use in an aerosol-generating rod, and an apparatus and method for manufacturing the aerosol-generating material that will reduce the amount of wasted components, thereby also reducing manufacturing costs and requiring less cleaning, thus saving time. Summary of the Invention

[0006] According to one aspect of the present invention, a method for manufacturing a composite aerosol generating material is provided, the method comprising the following steps:

[0007] -Provide a first continuous carrier material sheet;

[0008] - Dispense the gel onto the surface of the first continuous carrier material sheet;

[0009] A second continuous carrier material sheet is provided, and the second continuous carrier material sheet is positioned onto the gel to form a composite material, wherein the gel is interposed between the first continuous carrier material sheet and the second continuous carrier material sheet; and

[0010] - It also includes the step of distributing a larger amount of gel to the central region near the longitudinal axis of the first continuous carrier material sheet, relative to the amount of gel distributed to the lateral region distal to the longitudinal axis of the first continuous carrier material sheet.

[0011] According to another aspect of the present invention, a composite aerosol generating material is provided, comprising:

[0012] -First carrier material sheet;

[0013] -Second carrier material sheet; and

[0014] - A gel, wherein the gel is disposed between the first carrier material sheet and the second carrier material sheet, and wherein the amount of gel disposed in the central region near the longitudinal axis of the first continuous carrier material sheet is larger than the amount of gel disposed in the lateral region distal to the longitudinal axis of the first continuous carrier material sheet.

[0015] The composite aerosol generating material of the present invention can be used in aerosol generating rods or aerosol generating articles. In some embodiments, the composite aerosol generating material is used in an aerosol generating rod.

[0016] This invention provides a method for manufacturing a composite aerosol generating material for use in an aerosol generating rod, comprising the steps of: providing a first continuous carrier material sheet; dispensing a gel onto the surface of the first continuous carrier material sheet; providing a second continuous carrier material sheet; and positioning the second continuous carrier material sheet onto the gel to form a composite material, wherein the gel is inserted between the first and second continuous carrier material sheets. Accurate positioning of the first and second continuous sheets (of carrier material) enables the consistent manufacture of the composite aerosol generating material.

[0017] Preferably, the method for manufacturing the composite aerosol generating material further includes a curling step. This can be curling a first continuous carrier material sheet, a second continuous carrier material sheet, or both. Curling provides manufacturing convenience by facilitating the aggregation of the sheet in subsequent manufacturing steps because the elasticity of the carrier material sheet is reduced due to the curling operation, and multiple ridges and corrugations are provided on the sheet. The ridges and corrugations are regularly distributed at predefined locations and extend substantially over the entire length of the sheet. Therefore, curling helps to aggregate the sheet in a more defined manner. In addition, compared to an uncurled sheet, curling also makes it possible to pull a larger amount of sheet material through a funnel-shaped device to form an aerosol generating rod. Furthermore, curling helps to form a uniform distribution of flow channels and maintains the flow channels by reducing the elasticity of the aerosol generating material sheet. The curling rate, as well as the size and pattern of the grooves or indentations, can be varied. Therefore, a large number of different aerosol flow conditions can be generated to obtain the desired suction resistance characteristics. Preferably, the curling step is performed before dispensing the gel onto the first continuous carrier material sheet or onto a surface portion of the first continuous carrier material sheet. Pre-dispensing curling makes manufacturing easier than post-dispensing curling. It helps prevent the gel from being extruded during curling, thereby reducing the risk of the gel contacting the manufacturing equipment. Furthermore, pre-dispensing curling advantageously allows for the curling of only one of the first or second carrier material sheets, rather than curling a composite aerosol-generating material comprising at least two carrier material sheets.

[0018] In a specific implementation, the method for manufacturing composite aerosol generating materials further includes the step of providing a first continuous carrier material sheet and a second continuous carrier material sheet from different corresponding carrier material sources. Having first and second continuous carrier material sheets from different carrier material sources or being different carrier materials allows for the use of a large number of different materials and combinations of different carrier materials. Therefore, various composite aerosol generating materials comprising different combinations of carrier materials or aerosol generating materials (or both different carrier materials and aerosol generating materials) deliver a large number of different aerosols.

[0019] In a specific implementation, the method for manufacturing composite aerosol generating materials further includes the step of providing both a first continuous carrier material sheet and a second continuous carrier material sheet from a single carrier material source. This simplifies the manufacturing process by generating the first and second continuous carrier material sheets using only one carrier material source.

[0020] In a specific implementation, the method for manufacturing the composite aerosol generating material further includes the step of folding a continuous sheet of a single carrier material source to form both a first continuous carrier material sheet and a second continuous carrier material sheet, such that the first continuous carrier material sheet and the second continuous carrier material sheet are integrally formed with each other via fold lines. Folding the source carrier material sheet to form the first continuous carrier material sheet and the second continuous carrier material sheet allows for easy manufacturing and efficient use of the material. It also prevents the dispensed gel from being extruded on one side.

[0021] Folding of the source carrier material sheet can be performed by any suitable means known in the art, including the use of a guide. Specific embodiments include using a guide to fold the source carrier material sheet. In specific embodiments, the guide used with the invention can be a roller-type guide, such as a directional roller or positioning roller; or a statically bending surface guide; or any combination of the above guide types. Movement of the source carrier material sheet toward the folding device causes the source carrier material sheet to bend itself until the folding process is complete and one lateral segment of the continuous carrier material sheet is fully folded, thereby contacting the gel already dispensed over the other lateral segment of the source carrier material sheet.

[0022] In a specific implementation, the method for manufacturing the composite aerosol generating material further includes the step of cutting a continuous sheet of a single carrier material source to form both a first continuous carrier material sheet and a second continuous carrier material sheet. Cutting the source carrier material to form the first and second continuous carrier material sheets ensures that the materials used for the first and second continuous carrier material sheets are identical, for example, in terms of composition or thickness. Furthermore, by providing two carrier material sheets from a single source, the material properties of the first and second continuous carrier material sheets will be consistent.

[0023] Typically, the width of the carrier material used for cutting can range from 5 cm to 50 cm, preferably from about 20 cm to 40 cm, and more preferably about 25 cm.

[0024] The cutting of the source carrier material sheet typically uses a cutting device, such as one or more of a cutting blade, knife, or saw, or a clamp-saw type cutting blade or circular cutter, to cleanly cut the source carrier material sheet to form a first continuous carrier material sheet and a second continuous carrier material sheet. The cutting blade typically faces the source carrier material. Typically, but not necessarily, the cutting device will be an in-line system that cuts the source carrier material into two segments along the longitudinal direction of the source carrier material sheet. The cutting device can cut the source carrier material into more than two segments as required. The first and second continuous carrier material sheets are formed separately. In embodiments where the second continuous carrier material sheet is positioned to contact the gel, guiding and transporting devices will be needed to position the second continuous carrier material sheet in the desired location, ideally on the gel already dispensed onto the first continuous carrier material sheet. In this way, the gel is embedded in a sandwich configuration between the two continuous carrier material sheets. Typically, the first continuous carrier material sheet formed by cutting the carrier material continues along the same or similar path and direction as the carrier material being cut. The second continuous carrier material sheet is guided by a guiding device to be positioned in contact with the gel, which has been dispensed onto the first continuous carrier material sheet. Preferably, the carrier material sheet is longitudinally cut in the conveying direction of the sheet before the gel is dispensed onto the first continuous carrier material sheet. Cutting the source carrier material sheet before dispensing the gel reduces the risk of the gel contacting the cutting device, such as a cutting blade. It also reduces the risk of dust from the cutting device contacting the gel or the gel nozzle. Preferably, there is a distance between the cutting stage and the gel dispensing stage to prevent dust generated during the cutting stage from interfering with gel dispensing. If the aerosol generating material is cut into more than two carrier material segments or sheets, each segment or sheet can be used or removed in a similar manner as explained for the first or second continuous carrier material sheet. A cutting device can supply first and second continuous carrier material sheets to multiple devices to produce a composite aerosol generating material. The composite aerosol generating material is then assembled together to produce an aerosol generating rod. The sheet cutting device may have a dust-proof device, such as a vacuum source for collecting dust from the cutting blade. The dustproof device allows for a shorter distance between the cutting blade and the gel application stage, thereby enabling faster production of the composite aerosol generating material and subsequent aerosol generating rod. The order of cutting and dispensing the gel is not essential for implementing this invention, and in principle, depending on the implementation, each stage of cutting and dispensing the gel can occur before, after, or simultaneously with another stage. In some embodiments of the invention, the gel is dispensed using a gel dispensing device comprising at least one nozzle. Using a nozzle facilitates accurate gel dispensing, both in terms of the amount of gel dispensed and the location of the dispensed gel. In some embodiments, in conjunction with other steps, the method of manufacturing the composite aerosol generating material further includes the step of adjusting the gel output via a control system.A control system can help to accurately dispense gel, both the amount and location of the dispensed gel. The gel dispensing device can have several nozzles that produce numerous gel strips on a first continuous carrier material sheet. In some embodiments, not all nozzles dispense gel simultaneously. Alternatively, in some embodiments, all nozzles can dispense gel simultaneously. The control system can also record the gel dispensing, including the amount and location of the dispensed gel, making it possible to calculate and track the total amount of any component in the gel. The gel dispensing device (e.g., a dispenser) can also have a temperature control system to control the temperature of the gel. Ideally, the gel dispensing device includes a heater or a thermal sensor, or both. Preferably, such a system will also include a feedback loop for processing information. The system can make any necessary changes, such as to the required heat or the gel dispensing rate. Generally, increasing the temperature reduces the viscosity of the gel and makes it easier or faster to dispense. Some gels may require temperature to achieve optimal dispensing and storage. Bringing the gel to the desired temperature before it reaches the nozzle can contribute to consistent gel dispensing. The heater can be a resistance heater, although any suitable heater can be used. The dispensing device (e.g., a dispenser) can also include a cooling device, such as a cooler. Once the gel is in the correct position, the cooling device can facilitate its solidification. Therefore, the risk of leakage is reduced. Alternatively or additionally, depending on the type of gel used, the cooling device can help hold the first and second continuous carrier material sheets together. In some embodiments, the cooling device reduces the viscosity of the gel so that it remains in the same position once solidified. In other embodiments, the cooling device accelerates the solidification of the gel. The gel dispensing device may also include one or more of the following: a flow meter, a pump, and an actuating tap, thereby allowing fine-tuning of the dispensed gel flow. This has the advantage of being able to make adjustments to maintain a consistent gel flow. This is important because the gel may change over time during the manufacturing process. Many factors, such as humidity and ambient temperature, as well as different variants of the supplied gel, can cause the gel to change. In a preferred embodiment, each nozzle has a flow meter and an actuating tap, thereby allowing independent adjustment of the gel flow dispensed from the nozzle. In some embodiments, the nozzles for dispensing gel onto the first continuous carrier material sheet dispense the same type of gel onto each carrier material sheet. Alternatively, the nozzles for dispensing gel onto the first continuous carrier material sheet may dispense different types of gel. For example, in some embodiments, when the nozzle dispenses different types of gels, one or more nozzles may dispense a fragrance-containing gel. Alternatively, one or more nozzles may dispense a nicotine-containing gel. Alternatively, one or more nozzles may dispense a glycerin-containing gel. Alternatively, one or more nozzles may dispense a propylene glycol-containing gel. Alternatively, one or more nozzles may dispense any combination of the mentioned gel types.Different nozzles for different types of gels allow for fine-tuning and different adjustments to the gel composition. For example, different end products may require more fragrance, or specific ingredients may be preferred at specific locations on the aerosol-generating material sheet.

[0025] In a preferred embodiment, the gel dispensing device dispenses gel on the same side of the first continuous carrier material sheet. Preferably, this is the top side of the sheet, so that the dispensed gel can easily settle and be fixed on the carrier material sheet due to gravity for transport to subsequent manufacturing steps.

[0026] In some embodiments, the method of manufacturing composite aerosol generating materials further includes the step of: unevenly distributing a gel onto one surface of a first continuous carrier material sheet.

[0027] In some embodiments, the method of manufacturing composite aerosol generating materials further includes the step of distributing a larger amount of gel to the central region near the longitudinal axis of the first continuous carrier material sheet, relative to the amount of gel distributed to the lateral region distal to the longitudinal axis of the first continuous carrier material sheet.

[0028] In some embodiments, the method of manufacturing the composite aerosol generating material further includes the step of allocating at least 10% of the gel mass to a central region proximal to the longitudinal axis of the first continuous carrier material sheet, relative to the mass allocated to a lateral region distal to the longitudinal axis of the first continuous carrier material sheet. Alternatively, the method may include the step of allocating at least 15% of the gel mass to the central region. In other embodiments, the method includes allocating at least 20% of the gel mass to the central region, or at least 25% of the gel mass to the central region.

[0029] Controlling the amount and location of gel on the first or second continuous carrier material sheet, or within the composite aerosol generating material, can reduce the risk of gel leakage from the composite aerosol generating material. Avoiding gel leakage also contributes to the uniform fabrication of the composite aerosol generating material, and thus ensures the consistent performance of the final manufactured product.

[0030] In some embodiments, the method of manufacturing a composite aerosol generating material further includes the step of providing a continuous strip of receptor material. Preferably, the method of manufacturing a composite aerosol generating material includes positioning the continuous strip of receptor material onto a gel. Preferably, the continuous strip of receptor material is positioned onto the gel after the gel has been dispensed onto a first continuous carrier material sheet. In some embodiments, the composite aerosol generating material comprises receptor material. The receptor material can be heated by inductive heating. When the receptor material is located in an electromagnetic field, eddy currents are induced, and hysteresis losses occur in the receptor material, resulting in heating of the receptor material. In embodiments where the receptor material is positioned in thermal contact or close thermal proximity with the aerosol generating material or gel, the aerosol generating material or gel is heated. Heating the aerosol generating material or gel may facilitate the release or generation of aerosols. Preferably, the receptor material is in direct physical contact with the gel. Although in alternative embodiments, the receptor material may be positioned between carrier material sheets without direct physical contact with the gel.

[0031] The receptor can be formed from any material capable of being inductively heated to a temperature sufficient to generate or release an aerosol, such as a gel or aerosol-generating material, or a carrier material or gel carrying an aerosol-generating substrate. In some embodiments, the receptor comprises carbon. Preferred receptors may comprise or be composed of ferromagnetic materials, such as ferromagnetic alloys, ferritic iron, or ferromagnetic steel or stainless steel. Preferred receptor materials comprise metals, such as aluminum. Preferred receptors can be heated to temperatures exceeding 50 degrees Celsius. More preferred receptors can be heated to temperatures between about 40 degrees Celsius and about 500 degrees Celsius, particularly between about 50 degrees Celsius and about 450 degrees Celsius, or preferably between about 100 degrees Celsius and about 400 degrees Celsius. The receptor may also include a non-metallic core and a metallic layer disposed on the non-metallic core, such as metallic traces formed on the surface of a ceramic core.

[0032] The receptor may include an outer protective layer, such as a ceramic or glass protective layer encapsulating the receptor. The receptor may also include a protective coating formed of glass, ceramic, or inert metal, which is formed on the core of the receptor material.

[0033] The sensor can be a multi-material sensor. Specifically, the sensor may include a first sensor material and a second sensor material. The first sensor material is preferably optimized for heat loss and therefore heating efficiency. For example, the first sensor material may be aluminum, or an iron-containing material, such as stainless steel. In contrast, the second sensor material is preferably used as a temperature marker. For this purpose, the second sensor material is selected to have a Curie temperature corresponding to a predefined heating temperature of the sensor assembly. At its Curie temperature, the magnetic properties of the second sensor change from ferromagnetic to paramagnetic, accompanied by a temporary change in its resistance. Therefore, by monitoring the corresponding change in the current absorbed by the sensing source, it is possible to detect when the second sensor material reaches its Curie temperature, and therefore when it reaches the predefined heating temperature. The Curie temperature of the second sensor material is preferably below the ignition point of the aerosol-forming substrate, i.e., preferably below 500 degrees Celsius. Suitable materials for the second sensor material may include nickel and certain nickel alloys. Depending on the nature of the impurities, the Curie temperature of nickel is in the range of about 354 degrees Celsius to 360 degrees Celsius. The Curie temperature within this range is ideal because it is roughly the same temperature at which the receptor should be heated to generate aerosols from the aerosol-forming substrate, but still low enough to avoid localized overheating or combustion of the aerosol-forming substrate.

[0034] If the receptor is in the form of a strip, particularly a blade, plate, sheet, strip, or foil, the receptor preferably has a generally rectangular cross-section. In this case, the width of the receptor is preferably greater than its thickness, for example, twice the thickness. Advantageously, the width of the strip-shaped receptor is preferably between about 2 mm and about 8 mm, more preferably between about 3 mm and about 5 mm, and its thickness is preferably between about 0.03 mm and about 0.15 mm, more preferably between about 0.05 mm and about 0.09 mm.

[0035] In specific embodiments, the method of manufacturing a composite aerosol generating material further includes the steps of repeatedly manufacturing the composite aerosol generating material and layering the composite aerosol generating material in a manner where one layer is on top of another. The composite aerosol generating material can therefore include multiple layers, thereby producing a multilayer composite aerosol generating material. The corresponding component layers of the composite aerosol generating material may be the same or different in their composition or structure. Different composite aerosol generating materials can be used, and in some embodiments, various combinations of different carrier layers are used to constitute the final composite aerosol generating material. This allows for the manufacture of many different composite aerosol generating materials, potentially possessing many different aerosol qualities and characteristics. In specific embodiments, the method of manufacturing a composite aerosol generating material includes the step of layering one composite aerosol generating material onto another composite aerosol generating material. In some embodiments, the method of manufacturing a composite aerosol generating material includes the step of layering one composite aerosol generating material onto another composite aerosol generating material and inserting a receptor material between the two layers of composite aerosol generating material. Composite aerosol generating materials or multilayer composite materials can be aggregated together and preferably wrapped to form composite aerosol generating rods.

[0036] In specific embodiments, the manufacturing apparatus or method further includes a layering system. The layering system enables the composite aerosol generating materials to be layered, preferably one layer on top of another. The description and given embodiments only exemplarily relate to a vertical orientation having tops and bottoms of the composite aerosol generating materials stacked on top of each other, but other embodiments having other orientations of the composite aerosol generating materials adjacent to each other can work and are included within the scope of this disclosure. In a preferred embodiment, the composite aerosol generating materials are stacked such that the top and bottom surfaces of the stacked layers of composite aerosol generating materials are gel-free. In these specific embodiments, the outer surfaces of individual composite aerosol generating materials are preferably gel-free.

[0037] In some embodiments, the receptors are positioned between layers of the composite aerosol generating material. In embodiments where there is no gel between the composite aerosol generating material layers (meaning no gel on the outer surface of the composite aerosol generation) and the receptors are positioned between the outer surfaces of the composite aerosol generating material layers, the receptors may not be adjacent to the gel. However, the receptors can still heat the gel through the composite aerosol generating material layers. Advantageously, having receptors between the outer surfaces of the composite aerosol generating material facilitates fabrication. In alternative embodiments, the gel can be positioned or dispensed onto the outer surface of the composite aerosol generating material layers, and therefore in these embodiments, when the receptors are positioned between the outer surfaces of the composite aerosol generating material, the receptors are adjacent to the gel.

[0038] Other embodiments may have gel between the composite aerosol generating materials, but ideally no gel on the outer surface not adjacent to another composite aerosol generating material. Preferably, the gel is only on the inner surface, and therefore no gel on any outer surface. Advantageously, this avoids gel contamination by reducing the risk of gel contact with the encapsulating material or contact surfaces in machinery, such as guiding devices (e.g., guides) for positioning sheets, and funnel-shaped devices for assembling sheets into a continuous cylindrical rod.

[0039] In specific implementations, the layering system includes at least one lateral movement system. Such a lateral movement system can move one material (e.g., a carrier material sheet or composite aerosol generating material) from one side to above (or below) or parallel to another material (e.g., another carrier material sheet or composite aerosol generating material). The manufacturing process, equipment, or layering system may have multiple lateral movement systems. Typically, the number of lateral movement systems in an equipment, layering system, or manufacturing process is equal to the number of segments minus one. Ideally, each lateral movement system is responsible for a different source segment. For example, if the carrier material is cut into two parts to form a first carrier material sheet and a second continuous carrier material sheet, there is a lateral movement system that moves one sheet, for example, the second continuous carrier material sheet is above (or below) the other sheet. Preferably, the lateral movement system places all materials (e.g., carrier material composite aerosol generating material sheets) in a vertical stack, one above the other. Other orientations are possible in other implementations, as explained.

[0040] In some preferred embodiments, the method of manufacturing the composite aerosol generating material further includes the step of pressing the composite aerosol generating material in a direction perpendicular to the planar surface of the composite aerosol generating material. For example, in a vertical stack of composite aerosol generating materials, pressure from a pressing system is applied along the height of the stack. Different pressures can be applied to the material stack. Depending on the desired effect or the size of the stacked material, the pressing system can have variable pressure application. In a specific embodiment, the manufacturing apparatus or system includes two pressure rollers that act together to apply pressure as the composite aerosol generating material passes through the rollers. In a specific embodiment, the manufacturing apparatus or system includes a single pressure roller. Ideally, the pressure of the pressing system is high enough for the material to adhere to the gel strip, but low enough to avoid structural damage to the sheet. Ideally, the gel strip is not pressed to the point that there is no air path between the continuous carrier material sheet or the composite aerosol generating material layer.

[0041] The present invention also provides a composite aerosol generating material, comprising: a first carrier material sheet; a second carrier material sheet; and a gel, wherein the gel is disposed between the first carrier material sheet and the second carrier material sheet.

[0042] In a preferred embodiment, the composite aerosol generating material further includes a receptor material positioned between the first carrier material sheet and the second carrier material sheet. The receptor material can be heated by induction heating. When the receptor material is in an electromagnetic field, eddy currents are induced, and hysteresis losses occur in the receptor material, thereby causing the receptor material to heat up.

[0043] In the manufacture of composite aerosol generating materials, the first carrier material sheet and the second carrier material sheet are preferably continuous sheets. However, continuous sheets can be cut to specific lengths as needed, and therefore are no longer continuous.

[0044] In a preferred embodiment, the gel comprises one or more of fragrance, surfactant, plasticizer, humectant, nicotine, glycerin, or propylene glycol.

[0045] In a preferred embodiment, the carrier material sheet includes tobacco material.

[0046] The present invention also relates to a composite aerosol generating rod comprising a composite aerosol generating material as described herein or manufactured by the steps described herein.

[0047] An apparatus for manufacturing a composite aerosol generating material for use in an aerosol generating rod, comprising: means for supplying a first continuous carrier material sheet; means for dispensing a gel onto the surface of the first continuous carrier material sheet; and a layering system for supplying and positioning a second continuous carrier material sheet onto the gel to form the composite aerosol generating material.

[0048] An example of a supply device is a supply equipment.

[0049] In a specific implementation, in conjunction with other features, the device also includes a cutting blade located upstream of the layering system to cut the source carrier material sheet along the longitudinal axis of the source carrier material sheet to form a first continuous carrier material sheet and a second continuous carrier material sheet.

[0050] In a specific implementation, in conjunction with other features, the device also includes a folding device (e.g., a folder) adapted to fold at least a portion of the source carrier material sheet along its longitudinal axis to form a first continuous carrier material sheet and a second continuous carrier material sheet.

[0051] In a specific implementation, the device further includes a curling system in conjunction with other features. Preferably, the curling system is located upstream of the gel dispensing and layering system.

[0052] The first continuous carrier material sheet, or the second continuous carrier material sheet, or both the first continuous carrier material sheet and the second continuous carrier material sheet, can be rolled up. In the case that the composite aerosol generating material is multilayered, any combination of rolled and non-rolled carrier material sheets can be used to form the multilayer composite aerosol generating material.

[0053] The present invention also discloses an apparatus further comprising a layering device configured to layer composite materials to form a multilayer composite aerosol generating material. This may involve layering the same composite aerosol generating material on itself, or layering different composite aerosol generating materials in a manner where one layer is on top of another. Embodiments of the layering device are apparatuses for layering.

[0054] In specific embodiments, the apparatus further includes a pressing system, wherein the composite aerosol generating material or multilayer composite aerosol generating material, or both, is pressed by at least one pressure roller. In a preferred embodiment, the apparatus further includes means for aggregating the composite aerosol generating material or multilayer composite aerosol generating material, or both. In a preferred embodiment, the apparatus further includes means for wrapping the composite aerosol generating material or multilayer composite aerosol generating material after aggregation. The wrapping means enables the composite aerosol generating material to be cut into aerosol generating rods. In some embodiments, the apparatus includes a cutting blade to cut the continuous length of the wrapped composite aerosol generating material to a desired length. Therefore, the wrapped composite aerosol generating material can be easily transported during the manufacturing process. The apparatus of the present invention may include any features for manufacturing composite aerosol generating materials, such as gel dispensing devices, nozzles, control devices, guides, rollers, pressing systems, or any combination thereof.

[0055] In a specific embodiment, the carrier material sheet comprises a porous material. In a specific embodiment, the carrier material sheet may be composed of a porous material. Porous materials have the advantage of being able to firmly retain the gel. Advantageously, porous carrier materials can retain the gel more firmly than non-porous carrier materials. The pores of the porous material can absorb the gel, and thus allow the gel to easily remain and quickly adhere to the porous carrier material sheet. The porous material can firmly fix the gel to the surface of the carrier sheet by absorbing it through its pores. Therefore, the porous material can prevent the gel from moving in the vicinity of the porous material. The porous material used in this invention helps to reduce gel leakage from the composite aerosol generating material. Composite aerosol generating materials made of porous materials help to reduce gel leakage, thus reducing contamination of mechanical parts during production, for example, reducing contamination of cutting blades when the continuous length of the wrapped composite aerosol generating material is cut to the desired length.

[0056] Porous materials can be any suitable porous material capable of holding or retaining a gel. Ideally, porous materials allow the gel to move within them. In specific embodiments, porous materials include natural, synthetic, or semi-synthetic materials, or combinations thereof. In specific embodiments, porous materials include sheet materials, foams, or fibers, such as loose fibers; or combinations thereof. In specific embodiments, porous materials include woven, nonwoven, or extruded materials, or combinations thereof. Preferably, porous materials include, for example, cotton, paper, viscose, PLA, or cellulose acetate, or combinations thereof. Preferably, porous materials include sheet materials, such as cotton or cellulose acetate. The advantage of porous materials is that the gel is retained within the porous material, which can facilitate the manufacture, storage, or transport of the gel. It can help maintain the desired shape of the gel, especially during manufacture, transport, or use. The porous materials used in this invention can be curled or shredded. In specific embodiments, porous materials include curled porous materials.

[0057] In some embodiments, the gel is at least partially absorbed into the porous material. In the sandwich arrangement of the present invention, the advantage of using two porous carrier materials compared to using only one porous material is that the two porous materials hold the gel in place, thereby improving or better securing the gel. Therefore, using two porous materials in the sandwich-type arrangement according to the present invention is advantageous for providing improved gel retention. Improved gel retention, due to reduced gel movement and leakage, can improve control over gel dispensing and reduce waste. The gel can be accurately positioned, reducing movement or loss of the gel and additives or materials within it. Therefore, improved control over the amount of gel and additives in the gel can be achieved. Reduced gel leakage also reduces contamination of machinery, thus reducing downtime in production for cleaning or servicing machinery.

[0058] In specific embodiments, the carrier material includes an aerosol-generating material. The carrier material may include, for example, tobacco, tobacco material, powdered tobacco, tobacco stems, nicotine, tobacco leaves or cast tobacco, or any combination of the above aerosol-generating materials. The aerosol-generating material may also be a porous material with the advantage of retaining the gel. In specific embodiments, the carrier material may include an aerosol-generating material, and the gel may further include an aerosol-generating substrate. In alternative embodiments, the gel or carrier material may include an aerosol-generating substrate.

[0059] Depending on the specific implementation, the gel includes a gelling agent. In a specific implementation, the gel contains agar or agarose or sodium alginate or gellan gum, or a mixture thereof.

[0060] In a specific embodiment, the gel comprises water; for example, the gel is a hydrogel. Alternatively, in a specific embodiment, the gel is non-aqueous.

[0061] Preferably, the gel includes a surfactant. In a specific embodiment, the surfactant contains nicotine. In a specific embodiment, the nicotine is contained in a gel having an aerosol-forming agent for desired nicotine delivery. It is desirable to prevent leakage by locking the nicotine in the gel at room temperature.

[0062] In a specific embodiment, the gel comprises a solid tobacco material that releases flavor compounds upon heating. Depending on the specific embodiment, the solid tobacco material is, for example, one or more of the following: powder, granules, pellets, shreds, spaghetti, strips, or flakes, containing one or more of the following: plant materials, such as grass leaves, tobacco leaves, tobacco ribs, reconstituted tobacco, homogenized tobacco, extruded tobacco, and expanded tobacco.

[0063] The gel may include any suitable gelling agent. For example, the gelling agent may include one or more biopolymers, such as two or three biopolymers. Preferably, when the gel includes more than one biopolymer, the biopolymers are present in substantially equal weights. The biopolymer may be formed from polysaccharides. Suitable biopolymers as gelling agents include, for example, gellan gum (natural, low-acyl gellan gum, high-acyl gellan gum, preferably low-acyl gellan gum), xanthan gum, alginate (alginic acid), agar, guar gum, etc. Preferably, the gel contains agar. Preferably, the gel contains only a single gelling agent. Preferably, this single gelling agent is agar or guar gum.

[0064] As used herein, the term "aerosol-generating article" is used to describe articles that can generate or release aerosols.

[0065] As used herein, the term "aerosol generating apparatus" is an apparatus used in conjunction with an aerosol generating article to enable the generation of aerosols, typically generated by the aerosol generating article. An aerosol generating apparatus typically includes a heater.

[0066] As used herein, the term "aerosol-generating material" is used to describe materials that contribute to or are capable of generating aerosols, such as cast tobacco. The term also includes materials that contribute to the release from the aerosol-generating substrate, such as aerosol forming agents.

[0067] As used herein, the term "aerosol-generating substrate" is used to describe a substrate capable of generating aerosols, such as cast tobacco or nicotine.

[0068] As used herein, the term "carrier material" is used to describe materials that facilitate or enable carrying, storing, or supporting elements. In this invention, this includes carrying gels, especially when the gel contains an aerosol-generating substrate. The term "carrier" also includes aerosol-generating materials, tobacco, cotton, or any material capable of carrying aerosol-generating substances, such as gels. For example, an aerosol-generating material may absorb a gel and / or not be destroyed by the gel.

[0069] As used herein, the term "composite aerosol generating material" is used to describe a material comprising two or more elements, wherein at least one element comprises an aerosol generating substrate or an aerosol generating material. A composite aerosol generating material does not need to have two or all of the elements to generate an aerosol.

[0070] As used herein, the term "curled" refers to a material having multiple substantially parallel ridges or corrugations. It also includes the process of manufacturing the curled material. Ridges can be longitudinal, transverse, angular, straight, wavy, continuous, interrupted, or any combination thereof. Longitudinal ridges are preferred because they improve the formation of flow channels that extend beyond the substantially full length of the sheet once it is aggregated. Furthermore, longitudinal ridges formed by curling also help achieve a uniform distribution of flow channels across the cross-section of the formed aerosol generating rod compared to uncurled or otherwise curled sheets, as curling facilitates the formation of airflow channels at predetermined locations and ensures that each airflow channel has a relatively similar cross-sectional size. Therefore, a relatively consistent suction resistance (RTD) can be achieved for the aerosol generating rod.

[0071] For the purposes of this disclosure, as used herein, the terms “diameter” or “width” are the maximum lateral dimensions of the composite aerosol generating material or the first or second continuous carrier material sheet, a portion thereof, the aerosol generating article, or the aerosol generating apparatus. For example, “diameter” is the diameter of an object having a circular cross-section, or the length of the diagonal width of an object having a rectangular cross-section.

[0072] As used herein, the term 'aggregate' is used to describe a sheet that is substantially transverse to the longitudinal axis of the composite aerosol generating material, which is wound, folded, or otherwise compressed or contracted; or a first continuous carrier material sheet or a second continuous carrier material sheet; or a composite aerosol generating material.

[0073] As used herein, the term "gel" is used to describe a solid, gel-like semi-rigid material or mixture of materials having a three-dimensional network capable of holding other materials and releasing materials into an aerosol.

[0074] As used herein, the term "longitudinal" is used to describe the direction between the downstream or proximal end of an aerosol-generating article or aerosol-generating material; or a composite aerosol-generating material; or a carrier material sheet and the opposite upstream or distal end.

[0075] As used herein, the term "external" for a reference carrier material sheet is used to describe a portion of the carrier material sheet that is further toward the longitudinal side of the carrier material sheet than the middle of the cross-sectional portion of the carrier material sheet. Similarly, the terms "internal" or "center" are used to describe a portion of the material (reference carrier material sheet) that is located further toward the center of the cross-sectional portion than the portion closer to the longitudinal side of the carrier material sheet.

[0076] As used herein, the term "plasticizer" is used to describe substances, typically solvents, that are added to produce or promote plasticity or flexibility and reduce brittleness.

[0077] As used herein, the term "rod" is used to describe a component, section, or element used in aerosol-generating articles. A "continuous rod" is the precursor to a rod before it is cut to the desired length.

[0078] As used herein, the term "porous material" is used to describe any material capable of holding, retaining, or supporting a gel. Typically, porous media have pathways within their structure that can be filled to retain or hold a fluid or semi-solid, such as a gel. Preferably, the gel is also (to some extent) capable of passing through or transferring along and through channels within the porous material.

[0079] As used herein, the term "sensor" describes an element comprising a material capable of being induced to heat within an alternating electromagnetic field. This can be a result of at least one of hysteresis loss and eddy currents induced in the sensor, depending on the electrical and magnetic properties of the sensor material. In ferromagnetic or ferrimagnetic sensors, hysteresis loss occurs due to the switching of magnetic domains within the material under the influence of an alternating electromagnetic field. If the sensor is conductive, eddy currents can be induced. In the case of conductive ferromagnetic or conductive ferrimagnetic sensors, heat can be generated due to both eddy currents and hysteresis loss. Therefore, a sensor can comprise at least one of conductive and magnetic materials.

[0080] As used herein, the term “pumping resistance” (RTD) is used to describe the resistance to pumping fluids (e.g., gases) through a material. Pumping resistance is expressed and measured according to ISO 6565:2002, as used herein.

[0081] As used in this article, the term "sheet" or "sheet material" is used to describe a flat, layered element whose width and length are substantially greater than its thickness.

[0082] Any feature or step described herein regarding one embodiment, aspect, or example of a composite aerosol generating material, multilayer composite aerosol generating material, or aerosol generating rod or its manufacture (including equipment) may be equally applied to any other embodiment, aspect, or example of a composite aerosol generating material, multilayer composite aerosol generating material, aerosol generating article or aerosol generating rod, its manufacturing method or manufacturing equipment. Example

[0083] Example 1. A method for manufacturing a composite aerosol generating material for use in an aerosol generating rod, comprising the following steps:

[0084] -Provide a first continuous carrier material sheet;

[0085] - Dispense the gel onto the surface of the first continuous carrier material sheet;

[0086] A second continuous carrier material sheet is provided and positioned onto the gel to form a composite material, wherein the gel is inserted between the first continuous carrier material sheet and the second continuous carrier material sheet.

[0087] Example 2. The method for manufacturing composite aerosol generating materials according to Example 1 further includes the step of: rolling up at least one of the first continuous carrier material sheet and the second continuous carrier material sheet.

[0088] Example 3. A method for manufacturing composite aerosol generating materials according to Example 1 or Example 2, further comprising the step of providing the first continuous carrier material sheet and the second continuous carrier material sheet from different corresponding carrier material sources.

[0089] Example 4. A method for manufacturing composite aerosol generating materials according to Example 1 or Example 2, further comprising the step of: providing both the first continuous carrier material sheet and the second continuous carrier material sheet from a single carrier material source.

[0090] Example 5. The method for manufacturing composite aerosol generating materials according to Example 4 further includes the following steps: folding the continuous sheet of the single carrier material source to form both the first continuous carrier material sheet and the second continuous carrier material sheet, such that the first continuous carrier material sheet and the second continuous carrier material sheet are integrated with each other via fold lines.

[0091] Example 6. The method for manufacturing a composite carrier material according to Example 4 further includes the step of cutting a continuous sheet of the single carrier material source to form both the first continuous carrier material sheet and the second continuous carrier material sheet.

[0092] Example 7. A method for manufacturing a composite aerosol generating material according to any one of Examples 1 to 6, further comprising the step of: distributing a larger amount of gel to the central region near the longitudinal axis of the first continuous carrier material sheet, relative to the amount of gel distributed to the lateral region distal to the longitudinal axis of the first continuous carrier material sheet.

[0093] Example 8. A method for manufacturing a composite aerosol generating material according to any one of Examples 1 to 7, further comprising the steps of: providing a continuous receptor material strip, and positioning the continuous receptor material strip onto the gel after dispensing the gel onto the first continuous carrier material sheet.

[0094] Example 9. A method for manufacturing a composite aerosol generating material according to any one of Examples 1 to 8, further comprising the step of: pressing the composite aerosol generating material in a direction perpendicular to the planar surface of the composite aerosol generating material.

[0095] Example 10. A method for manufacturing a composite aerosol generating material according to any one of Examples 1 to 9, wherein the gel contains fragrance or active agent or plasticizer or humectant or nicotine or glycerin or propylene glycol or any combination thereof.

[0096] Example 11. A method for manufacturing a composite aerosol generating material according to any one of Examples 1 to 10, wherein the composite aerosol generating material includes tobacco material.

[0097] Example 12. A composite aerosol generating material, comprising:

[0098] -First carrier material sheet;

[0099] -Second carrier material sheet; and

[0100] - A gel, wherein the gel is disposed between the first carrier material sheet and the second carrier material sheet.

[0101] Example 13. The composite aerosol generating material according to Example 12 further includes a receptor material positioned between the first carrier material sheet and the second carrier material sheet.

[0102] Example 14. The composite aerosol generating material according to Example 12 or Example 13, wherein the first continuous carrier material sheet, or the second carrier material sheet, or both the first carrier material sheet and the second carrier material sheet comprise an aerosol generating material.

[0103] Example 15. A composite aerosol generating rod, comprising: the composite aerosol generating material according to Examples 12 to 14; or comprising the composite aerosol generating material manufactured according to any one of Examples 1 to 11. Attached Figure Description

[0104] Referring now to the accompanying drawings, which depict one or more aspects described in this disclosure. However, it should be understood that other aspects not depicted in the drawings fall within the scope of this disclosure. Similar designations used in the drawings refer to similar parts, steps, etc. However, it should be understood that the use of designations to refer to a part in a given drawing is not intended to limit a part labeled with the same designation in another drawing. Furthermore, the use of different designations to refer to parts in different drawings is not intended to indicate that parts with different designations cannot be the same as or similar to parts with other designations. The drawings are presented for illustrative purposes and not for limitation. The schematic diagrams presented in the drawings are not necessarily drawn to scale.

[0105] Figure 1 This is a schematic perspective view of a cutting system used to cut source carrier material sheets.

[0106] Figure 2 This is a schematic perspective view of an embodiment of a gel dispensing system having several nozzles for a source carrier material sheet.

[0107] Figure 3 A schematic top view of a layered system for manufacturing aerosol-generating material stacks is shown.

[0108] Figure 4 It shows Figure 3 A schematic side view of the hierarchical system.

[0109] Figure 5 This is a schematic perspective view of a system used to manufacture aerosol generating rods.

[0110] Figure 6 This is a schematic cross-sectional view of the composite aerosol generating material according to the implementation plan.

[0111] Figure 7 This is a schematic cross-sectional view of a composite aerosol generating material according to another embodiment.

[0112] Figure 8 This is a schematic cross-sectional view of a composite aerosol generating material according to other implementation schemes.

[0113] Figure 9 This is a schematic cross-sectional view of a composite aerosol generating material according to other implementation schemes.

[0114] Figure 10 It is a schematic cross-sectional view of the composite aerosol generating material including the sensor material according to the implementation plan.

[0115] Figure 11 This is a schematic cross-sectional view of a composite aerosol generating material including sensor materials according to other implementation schemes.

[0116] Figure 12 This is a schematic diagram of the cross-sectional view of the receptor between two composite aerosol generating materials.

[0117] Figure 13 It is a cross-sectional view of the aerosol generating rod, in which the receptor is positioned between the composite aerosol generating materials before aggregation. Detailed Implementation

[0119] Figure 1 An embodiment of the cutting system 10 is shown. A source carrier material sheet 12 is initially unwound from a winding spool (not shown) and conveyed in a direction generally indicated by an arrow. The source carrier material sheet 12 has a longitudinal axis in the longitudinal direction and has a specific width and thickness. In a specific embodiment, the source carrier material 12 is preferably tobacco cast leaf (TCL), but in other embodiments, the source carrier material 12 includes other materials, such as cotton. The cutting system 10 preferably includes cutting blades 20, which in this embodiment are in the form of inline blades 10. In some embodiments, other cutting blades 20 are used, such as circular blades or rotary blades.

[0120] The inline blade 20 has a longitudinal axis perpendicular to the longitudinal axis of the source carrier material sheet 12, such that the sharp edge of the blade 20 points towards the incoming source carrier material sheet 12. The source carrier material sheet 12 is cut by the blade 20 into two segments 22A, 22B along a cutting line 24. In some embodiments, the source carrier material sheet 12 is cut along its longitudinal axis such that the first segment 22A and the second segment 22B have the same width. In other embodiments, the source carrier material sheet 12 is cut along a cutting line 24 offset from the longitudinal axis such that the first segment 22A has a greater width than the second segment 22B, or the second segment 22B has a greater width than the first segment 22A. In other embodiments, the source carrier material sheet 12 is cut, for example, using more than one cutting blade 20 or using the same cutting blade 20 to cut more than two segments 22A, 22B. The cutting process typically generates dust; therefore, in some embodiments, the cutting system 10 also includes a dustproof device within the cutting system 10. For example, the dustproof device is in the form of an air extraction system (not shown), which allows the generated dust to be at least partially discharged in a controlled manner. By including the dustproof device, a higher proportion of dust is prevented from contacting the gel 144 (see [link to product]). Figure 2 Alternatively, source carrier material 12 may be used, otherwise it will lead to pollution and quality problems. The two sections 22A and 22B form a first continuous carrier material sheet and a second continuous carrier material sheet.

[0121] Figure 2 An embodiment of a gel dispensing system 100 is illustrated. The gel dispensing system 100 includes a gel dispensing station 140 having three gel dispensing nozzles 142. Each nozzle 142 dispenses gel 144 onto a surface portion of a segment 122 of a first continuous carrier material sheet 12. Three gel strips 144 are applied to the segment 122 of the first continuous carrier material sheet. The segment 122 of the first continuous carrier material sheet is conveyed in a direction generally indicated by the arrows in this embodiment. In some embodiments, different numbers of gel dispensing stations 140 or nozzles 142 are used. In such embodiments, different numbers of gel strips 144 are produced. In this embodiment, the gel strips 144 dispensed from the nozzles 142 are preferably parallel to each other, but in other embodiments, the gel strips 144 are not parallel to each other, for example, they are wavy, offset, or annular along the longitudinal direction of the segment 122 of the first continuous carrier material sheet.

[0122] In some embodiments, the amount of gel 144 applied to each strip and each dispensing system is calculated such that, during the layering and pressing processes (both as described herein), the gel 144 does not diffuse beyond the surface of the segment 122 of the first continuous carrier material sheet. This prevents the gel 144 from contacting (and thus contaminating) the inner surface of the funnel-shaped device 490 during the aggregation or pressing or encapsulation processes (not shown) (see [link to relevant documentation]). Figure 5 ).

[0123] In some embodiments, the gel dispensing system 100 includes a temperature control system (not shown) having a heater (not shown) and a thermal sensor (not shown) coupled via a feedback loop. The temperature control system heats the gel 144 and controls its temperature to remain within a target temperature range before reaching the gel dispensing station 140. Optionally, the gel dispensing station 140 further includes, for example, a flow meter, a pump, or an actuating tap (not shown), which allows the flow of each nozzle 142 to be independently adjustable, or alternatively or additionally allows the type of gel 144 to be delivered, for example, through different nozzles 142, for example at different locations on a segment 122 of a first continuous carrier material sheet. This is particularly advantageous because it facilitates the application of different amounts of gel 144 and thus facilitates the production of different composite aerosol generating materials. The amount of gel 144 dispensed can be varied by changing, for example, the flow rate of the nozzle or the length of time it takes for the gel 144 to be dispensed from the nozzle. In some embodiments, the variation in the amount of gel 144 can be changed independently for each nozzle. This also allows for adjustment of the flow of gel 144 from each nozzle 142 based on the position of the nozzle 142. For example, a nozzle 142 located near the longitudinal axis of a segment 122 of the first continuous carrier material sheet is adapted to dispense a larger amount of gel 144 than the amount dispensed by the nozzle 142 near the edge of the segment 122 of the first continuous carrier material sheet, in order to prevent the gel 144 from spreading beyond the surface of the segment 122 of the first continuous carrier material sheet during the pressing process. In different embodiments, the flow rate of the dispensed gel 144, the duration of the dispensed gel 144, or the pattern formed by the dispensed gel 144 is varied. It should be understood that the order of the cutting step (of the source carrier material 12) and the gel application step is unrelated. The cutting step of the source carrier material 12 preferably occurs before the gel dispensing step, but in some embodiments, the cutting step occurs after the gel dispensing step, or simultaneously with the gel application step.

[0124] Figures 3 to 4 Schemes of layered systems 250 and 350 for manufacturing aerosol generating rods are described. Layered systems 250 and 350 place two segments 222A and 222B, a first continuous carrier material sheet 222B, and a second continuous carrier material sheet 222A on top of each other to form a composite aerosol generating material 530 (e.g., ...). Figure 6(To be better illustrated). Each of the first continuous carrier material sheet 222B and the second continuous carrier material sheet 222A has a specific width. Each of the first continuous carrier material sheet 222B and the second continuous carrier material sheet 222A has a specific thickness. The composite aerosol generating material 530 includes the first continuous carrier material sheet 222B and the second continuous carrier material sheet 222A, and a gel 244 inserted between the first continuous carrier material sheet 222B and the second continuous carrier material sheet 222A. The layering systems 250, 350 include a lateral movement system that places the second continuous carrier material sheet 222A on top of the first continuous carrier material sheet 222B. In this embodiment, the second continuous carrier material sheet 222A is on top, and the first continuous carrier material sheet 222B is on the bottom. In other embodiments, the composite aerosol generating material 530 is constructed in other ways, for example, the second continuous carrier material sheet 222A is placed below the first continuous carrier material sheet 222B. The lateral movement system places the first continuous carrier material sheet 222B and the second continuous carrier material sheet 222A in a vertical stack, one on top of the other, such that the second continuous carrier material sheet 222A is exactly above and parallel to the first continuous carrier material sheet 222B. In other embodiments, the second continuous carrier material sheet 222A and the first continuous carrier material sheet 222B are offset from each other. Figures 3 to 4 The layering systems 250 and 350 depicted illustrate a lateral movement system for placing a first continuous carrier material sheet 222B and a second continuous carrier material sheet 222A on top of each other. In other embodiments, the layering systems 250 and 350 include multiple lateral movement systems, enabling the fabrication of stacks of more than two carrier material sheets 222A and 222B. Figures 3 to 4 In the illustrated embodiment, the first continuous carrier material sheet 222B and the second continuous carrier material sheet 222A are unwound from separate bobbins (not shown) onto the lateral movement system of the layering system 250, 350. However, in other embodiments, the single-source carrier material sheet 222 is unwound from the bobbin and then cut into separate segments, the first continuous carrier material sheet 222B and the second continuous carrier material sheet 222A. Rollers 252, 254, 256, and 258 facilitate guiding either the first continuous carrier material sheet or the second continuous carrier material sheet, or both.

[0125] like Figure 4As best viewed, the lateral movement system includes a conveyor roller 352, a directional roller 354, and a pair of positioning rollers 356. A first continuous carrier material sheet 322B is conveyed on the conveyor roller 352. A second continuous carrier material sheet 322A is contacted by the directional roller 354 from the side that has not received the gel 344 to avoid contamination. The directional roller 354 is angled such that the movement of the second continuous carrier material sheet 322A is redirected toward the first continuous carrier material sheet 322B. The angle of the directional roller 354 is chosen to save manufacturing space while not applying excessive strain to the second continuous carrier material sheet 322A, which would otherwise alter the structure of the second continuous carrier material sheet 322A. Both the second continuous carrier material sheet 322A and the first continuous carrier material sheet 322B are then guided through the positioning rollers 356, which are positioned adjacent to the first continuous carrier material sheet 322B. The distance from the surface of the first continuous carrier material sheet 322B to the positioning roller 356 is approximately equal to the thickness of the second continuous carrier material sheet 322A. This arrangement allows the two continuous carrier material sheets 322B, 322A to contact as they pass through the positioning roller 356. The axis of rotation of the positioning roller 356 is perpendicular to the conveying direction of the first aerosol-generating material sheet 322B. Figure 3 As can be seen, this aligns the second continuous carrier material sheet 322A with the first continuous carrier material sheet 322B.

[0126] In some embodiments, the layering system further includes a pressing system with two pressure rollers 358 through which the second continuous carrier material sheet 322A and the first continuous carrier material sheet 322B pass. As the first continuous carrier material sheet 322B and the second continuous carrier material sheet 322A are conveyed through the pressure rollers 358, the pressure applied by the pressure rollers 358 allows the second continuous carrier material sheet 322A, the first continuous carrier material sheet 322B, and the insert gel 344 to adhere together. The pressure is calculated to be high enough to facilitate adhesion of the first continuous carrier material sheet 322B and the second continuous carrier material sheet 322A to the gel 344, but low enough so as not to structurally damage the first continuous carrier material sheet 322B and the second continuous carrier material sheet 322A, and further so as not to compress the gel strip 344 to the point that there is no air path between the first continuous carrier material sheet 322B and the second continuous carrier material sheet 322A. In such cases, the first continuous carrier material sheet 322B and the second continuous carrier material sheet 322A having gel 344 will produce an airtight block through which no aerosol or air flows, which in some cases will affect the suction resistance characteristics. In some embodiments, the positioning roller 356 is in the form of a single positioning roller acting on the surface. In some embodiments, the pressure roller 358 is in the form of a single pressure roller acting on the surface.

[0127] Figure 5An embodiment of a layered system 450 for manufacturing an aerosol generating rod is depicted. A tobacco cast leaf (TCL) sheet 412 (an embodiment where the source carrier material is also an aerosol generating material) is unwound from a bobbin (not shown) and coiled by a pair of coiling rollers 470A, 470B, thereby creating ridges and grooves in the source carrier material sheet 412. The coiled source carrier material sheet 412 is then cut into two segments, thereby forming a first continuous carrier material sheet 422B and a first continuous carrier material sheet 422A by a cutting blade 420. In this embodiment, the cutting blade 420 is an in-line cutting blade, and more specifically a circular blade. It should be contemplated that the coiling step is optional. In some embodiments, the cutting step is replaced by providing the first continuous carrier material sheet 422B and the second continuous carrier material sheet 422A from different bobbins or sources. Providing a cutting step reduces the storage space required for multiple bobbins of the first continuous carrier material sheet 422B and the second continuous carrier material sheet 422A. Gel 444 is applied via a gel dispensing system 440 having three nozzles 442, each nozzle dispensing a strip of gel 444 onto the surface of a first continuous carrier material sheet 422B. A second continuous carrier material sheet 422A is guided toward the gel dispensing surface of the first continuous carrier material sheet 422B via a redirection fork 452 to form a composite aerosol generating material or "layer" having the first continuous carrier material sheet 422B and the second continuous carrier material sheet 422A, wherein gel 444 is disposed between the first continuous carrier material sheet 422B and the second continuous carrier material sheet 422A. Figure 5 The diagram shows a detailed cross-sectional view of the composite aerosol generating material, wherein three gel strips 444 of approximately equal width are disposed between a second continuous carrier material sheet 422A and a first continuous carrier material sheet 422B. The composite aerosol generating material, comprising the first continuous carrier material sheet 422B and the second continuous carrier material sheet 422A having gel 444 at its core, is then guided toward the input end of a funnel 490, where it is compressed into a continuous rod 492 shape at the output end of the funnel 490.

[0128] Figure 6A schematic cross-sectional view of a composite aerosol generating material 530 according to an embodiment is depicted. The composite aerosol generating material 530 includes a first carrier material sheet 522B and a second carrier material sheet 522A. Three gel strips 544 are disposed between the first carrier material sheet 522B and the second carrier material sheet 522A. The central gel strip 544B is located in the central region near the longitudinal axis, and the gel strips 544A and 544C are spaced apart in lateral regions on either side of the central gel strip 544B. In this embodiment, the gel strips 544A, 544B, and 544C have the same width. Therefore, it can be said that the gel strips 544A, 544B, and 544C are uniformly arranged. The gel strips 544A and 544C are preferably positioned inwardly from the outer edges of the first carrier material sheet 522B and the second carrier material sheet 522A to avoid gel application onto machinery, for example, to prevent leakage of the gel 544 from contaminating the funnel (not shown). In other embodiments, the gel strips 544 are unevenly distributed (see...). Figure 7 The use of composite aerosol generating material 530 is as described above. Figure 5 The layering system 450 generates the layered material. In some embodiments, the first continuous carrier material sheet 522B and the second continuous carrier material sheet 522A are provided from the same sheet 512, for example, on a single winding bobbin (not shown), and then cut into two pieces via a cutting system 420 to form the first continuous carrier material sheet 522B and the second continuous carrier material sheet 522A. In other embodiments, the first continuous carrier material sheet 522B and the second continuous carrier material sheet 522A are provided from different sources; for example, the first continuous carrier material sheet 522B is disposed on a first winding bobbin (not shown), and the second continuous carrier material sheet 522A is disposed on a different winding bobbin (not shown).

[0129] Figure 7A schematic cross-sectional view of a composite aerosol generating material 630 according to another embodiment is depicted. The composite aerosol generating material 630 includes a first carrier material sheet 622B, a second carrier material sheet 622A, and a third carrier material sheet 622C. Three gel strips 644 are disposed between the first carrier material sheet 622B and the second carrier material sheet 622A. The central gel strip 644B is located in the central region near the longitudinal axis, and gel strips 644A and 644C are spaced apart in lateral regions on either side of the central gel strip 644B. ​​In this embodiment, three additional gel strips 644 are disposed between the first carrier material sheet 622B and the third carrier material sheet 622C. The gel strip 644B in the central region has a larger width than the gel strips 644A and 644B in the lateral regions. Therefore, it can be said that the gel strips 644A, 644B, and 644C are unevenly distributed. In other embodiments, the distribution of gels 644A, 644B, and 644C between the first carrier material sheet 622B and the second carrier material sheet 622A differs from the distribution between the first carrier material sheet 622B and the third carrier material sheet 622C. In some embodiments, gel 644 is uniformly distributed between the first carrier material sheet 622B and the second carrier material sheet 622A, and gel 644 is non-uniformly distributed between the first carrier material sheet 622B and the third carrier material sheet 622C. The gel strips 644A and 644C are preferably positioned inward from the outer edges of the first carrier material sheet 622B and the second carrier material sheet 622A to avoid contamination of the machinery due to gel application, such as leakage of gel 644 into a funnel (not shown). Specifically, in this embodiment, more gel 644 is distributed in the central region near the longitudinal axis of the second carrier material sheet 622A than in the lateral region distributed distal to the longitudinal axis of the second carrier material sheet 622A. Therefore, the central gel strip 644B has a wider width than gel strips 644A and 644C. This reduces the risk of contamination, such as gel 644 leakage into a funnel (not shown). In a specific embodiment, more than 10% (%) of the gel 644 mass is distributed to the central region relative to the lateral region. In other embodiments, more than 20% (%) of the gel 644 mass is distributed to the central region relative to the lateral region of the aerosol-generating material sheet.

[0130] The use of composite aerosol generating material 630 is as described above. Figure 5The layering system 450 generates the material. In a specific embodiment, preferably, the first carrier material sheet 622B, the second carrier material sheet 622A, and the third carrier material sheet 622C are provided from the same carrier material source, for example, on a single winding bobbin (not shown), and then cut into three segments 622A, 622B, and 622C via the cutting system 420. In a specific embodiment, gel 644 is placed on both sides of the first continuous carrier material sheet 622B, and the second continuous carrier material sheet 622A and the third continuous carrier material sheet 622C are placed on the first carrier material sheet 622B via the layering system 450. In some embodiments, the composite aerosol generating material 630 is constructed by providing the first continuous carrier material sheet 622B and the third continuous carrier material sheet 622C and applying a gel strip 644 to the top of each of the first continuous carrier material sheet 622B and the third continuous carrier material sheet 622C. A first continuous carrier material sheet 622B is placed on a third continuous carrier material sheet 622C, and then a second continuous carrier material sheet 622A is placed on top of the first continuous carrier material sheet 622B. Preferably, the top and bottom surfaces of the composite aerosol generating material 630 do not have gel 644. In some embodiments, two of the three first continuous carrier material sheets 622A, second continuous carrier material sheet 622B, or third continuous carrier material sheet 622C are supplied from the same carrier material source, for example, on a single winding bobbin (not shown), and then cut into two segments via a cutting system 420. In a specific embodiment, each of the first continuous carrier material sheets 622A, second continuous carrier material sheet 622B, and third continuous carrier material sheet 622C is supplied from a different source. That is, sheets 622A, 622B, and 622C are unwound from different corresponding winding bobbins. In an alternative embodiment, manufacturing the composite aerosol generating material involves the steps of repeatedly manufacturing the composite aerosol generating material and layering the composite aerosol generating material in a manner that one layer is placed on top of another. This provides composite aerosol generating materials with additional layers and / or different numbers of layers.

[0131] The composite aerosol generating material 630 is manufactured by an apparatus (not shown) having means for supplying a first continuous carrier material sheet 622A. In one embodiment, the means for supplying the first continuous carrier material sheet 622A is a spool (not shown). The apparatus has nozzles for dispensing gel 644 onto the surface of the first continuous carrier material sheet 622A, and a layering system for supplying and positioning a second continuous carrier material sheet 622B onto the gel 644 to form the composite aerosol generating material 630. In another embodiment, the first continuous carrier material sheet 622A is supplied by a cutting blade. The cutting blade is located upstream of the layering system. The cutting blade cuts the source carrier material sheet along its longitudinal axis to form the first continuous carrier material sheet 622A and the second continuous carrier material sheet 622B. Additionally, in some embodiments, the apparatus further includes a folding device that folds a portion of the source carrier material sheet along its longitudinal axis to form the first continuous carrier material sheet 622A and the second continuous carrier material sheet 622B.

[0132] Figure 8A schematic cross-sectional view of a composite aerosol generating material 730 according to another embodiment is depicted. The composite aerosol generating material 730 includes a first carrier material sheet 722A, a second carrier material sheet 722B, a third carrier material sheet 722C, and a fourth carrier material sheet 722D. Three gel strips 744 are disposed between the first carrier material sheet 722A and the second carrier material sheet 722B. The central gel strip 744B is located in the central region near the longitudinal axis, and the gel strips 744A and 744C are spaced apart in lateral regions on either side of the central gel strip 744B. In this embodiment, no gel is disposed between the second carrier material sheet 722B and the third carrier material sheet 722C. Instead, the other three gel strips 744 are disposed between the third carrier material sheet 722C and the fourth carrier material sheet 722D. The composite aerosol generating material 730 includes two composite aerosol generating materials 722A, 722B and 722C, 722D. The gel strip 744B in the central region has a greater width than the gel strips 744A and 744C in the lateral regions. Therefore, it can be said that the gel strips 744A, 744B, and 744C are unevenly distributed. The gel strips 744A and 744C are preferably positioned inward from the outer edges of the first carrier material sheet 722A, the second carrier material sheet 722B, the third carrier material sheet 722C, and the fourth carrier material sheet 722D to avoid mechanical contamination, such as gel 744 leaking into a funnel (not shown). Specifically, in this embodiment, more gel 744 is distributed in the central region near the longitudinal axis of segment 722 than in the lateral regions distributed distal to the longitudinal axis of segment 722. Therefore, the central gel strip 744B has a greater width than the gel strips 744A and 744C. This reduces the risk of contamination, such as gel 744 leaking into a funnel (not shown).

[0133] The use of composite aerosol generating material 730 is as described above. Figure 5The layering system 450 is generated. In a specific embodiment, preferably, the monolith is provided from a single source, for example, on a single winding bobbin (not shown), and then cut into four segments via a cutting system 420 to form a first continuous carrier material sheet 722A, a second continuous carrier material sheet 722B, a third continuous carrier material sheet 722C, and a fourth continuous carrier material sheet 722D. Preferably, the top and bottom surfaces of the composite aerosol generating material 730 do not have gel 744. In some embodiments, at least two of the first continuous carrier material sheet 722A, the second continuous carrier material sheet 722B, the third continuous carrier material sheet 722C, and the fourth continuous carrier material sheet 722D are provided from the same source carrier material sheet, for example, on a single winding bobbin (not shown), and then cut into two segments via a cutting system 420. In a specific embodiment, each of the first continuous carrier material sheet 722A, the second continuous carrier material sheet 722B, the third continuous carrier material sheet 722C, and the fourth continuous carrier material sheet 722D is provided from a different source. That is, pieces 722A, 722B, 722C, and 722D are unwound from different corresponding winding drums.

[0134] Figure 9 A schematic cross-sectional view of a composite aerosol generating material 830 according to another embodiment is depicted. In this embodiment, gel 844 is deposited on sheet 812 (carrier material), and then sheet 812 is folded back onto itself. As shown, this prevents gel 844 from being extruded from one side. The folding of sheet 830 creates two layers, a first continuous carrier material sheet and a second continuous carrier material sheet, which are operatively connected or integrated with each other. The two layers, the first continuous carrier material sheet and the second continuous carrier material sheet, are connected by fold lines (not shown).

[0135] Figure 10 A schematic cross-sectional view of a composite aerosol generating material 930 according to an embodiment is depicted. The composite aerosol generating material 930 includes a first carrier material sheet 922B and a second carrier material sheet 922A. Two gel strips 944 are disposed between the first carrier material sheet 922B and the second carrier material sheet 922A. A centrally positioned receptor material 900 is located in a central region proximal to the longitudinal axis, and the gel strips 944 are spaced apart in lateral regions on either side of the centrally positioned receptor material 900. In this embodiment, the gel strips 944 have the same width. The gel strips 944 are preferably positioned inwardly from the outer edges of the first carrier material 922B and the second carrier material 922A to prevent gel leakage from the composite aerosol generating material 930. The composite aerosol generating material 930 is used as referenced herein. Figure 5 The layered system 450 and the additional receptor material 900 are inserted into the mechanism to generate this. Figure 10In one embodiment, the first continuous carrier material sheet 922B and the second continuous carrier material sheet 922A are provided, for example, from the same sheet 512 on a single winding bobbin (not shown), and then cut into two pieces to form the first continuous carrier material sheet and the second continuous carrier material sheet. Figure 10 In the fabrication of this embodiment, a receptor material 900 is inserted into the first continuous carrier material sheet 922B before the gel is dispensed onto its surface. The receptor material 900 is shown not in direct contact with the gel strip 944. However, it is shown before the composite aerosol generating material 930 has been pressed. Figure 10 The implementation scheme. Once pressed, the gel strip 944 can diffuse laterally between the first carrier material 922B and the second carrier material 922A to directly contact the receptor material 900.

[0136] Figure 11 A schematic cross-sectional view of a composite aerosol generating material 930 according to another embodiment is depicted. The composite aerosol generating material 930 includes a first carrier material sheet 922B, a second carrier material sheet 922A, and a third carrier material sheet 922C. Two gel strips 944 are disposed between the first carrier material sheet 922B and the second carrier material sheet 922A. A centrally located receptor material 900 is located in the central region proximal to the longitudinal axis of the composite aerosol generating material 930 and between the two gel strips 944. In this embodiment, three additional gel strips 944 are disposed between the first carrier material sheet 922B and the third carrier material sheet 922C. Preferably, when pressed… Figure 11 In the composite aerosol generating material 930 of the embodiment, the receptor material 900 can be in direct contact with the gel 944.

[0137] Figure 12 A schematic side view of a composite aerosol generating material 1030 comprising two layers of composite aerosol generating material is depicted. The first composite aerosol generating material includes two continuous carrier material sheets 1022A and 1022B, with a gel 1044A located between the two continuous carrier material sheets 1022A and 1022B. The second aerosol generating material includes two continuous carrier material sheets 1022C and 1022D, with a gel 1044B located between the two continuous carrier material sheets 1022C and 1022D. A receptor or continuous receptor strip 1000 is positioned between the two layers of composite aerosol generating material. In the embodiment shown, the receptor 1000 is not in direct contact with the gels 1044A and 1044B. In use, heat from the receptor 1000 or the continuous receptor strip 100 can still reach the gel through the carrier materials 1022B and 1022C. In this embodiment, the carrier material is entirely cotton. The gel contains nicotine. The receptor strip is aluminum.

[0138] Figure 13 A cross-sectional view along the longitudinal axis of the aerosol generating rod 1130 is depicted. Figure 12 Similar to the implementation scheme, the receptor band 1100 is not positioned near the gels 1144, 1044A, and 1044B between the continuous carrier materials 1122A and 1122B. Figure 13 In one embodiment, a continuous receptor strip 1100 is positioned precisely between the aggregated composite aerosol generating material and the continuous receptor strip 1100. The aggregated material is then wrapped to generate a continuous aerosol generating rod 1130. Figure 13 In this implementation scheme, the carrier material is flax. The receptor bands are carbon. The gel contains nicotine. The gel also contains glycerin.

[0139] Unless otherwise stated, all scientific and technical terms used in this article have their common meanings in the relevant field. Definitions provided are for ease of understanding of certain terms frequently used herein.

[0140] As used in this specification and the accompanying claims, the singular forms “a,” “an,” and “the” cover embodiments with plural references, unless otherwise expressly provided.

[0141] As used in this specification and the accompanying claims, the term "or" is generally used in the sense of including, alternatively or additionally, unless otherwise expressly provided.

[0142] As used in this text, "having," "containing," "including," etc., are used in their open sense and generally mean "including (but not limited to)." It should be understood that phrases such as "basically composed of," "composed of," etc., fall under the category of "including."

[0143] The terms "preferred" and "ideally" refer to embodiments of the invention that provide certain benefits in certain contexts. However, other embodiments may also be preferred in the same or other contexts. Furthermore, the description of one or more preferred embodiments does not imply that other embodiments are useless, and is not intended to exclude other embodiments from the scope of the disclosure including the claims.

[0144] For the sake of clarity and brevity, any directions or orientations mentioned herein, such as “top,” “bottom,” “left,” “right,” “upper,” “lower,” and other orientations or features, are not intended to limit the actual apparatus or system. The apparatus and system described herein can be used in multiple directions and orientations.

[0145] The embodiments illustrated above are not restrictive. Other embodiments consistent with the above embodiments will be readily apparent to those skilled in the art.

Claims

1. A method for manufacturing composite aerosol generating materials, the method comprising the following steps: Provide a first continuous carrier material sheet; The gel is dispensed onto the surface of the first continuous carrier material sheet as a lateral strip, the lateral strip being located in a lateral region distal to the longitudinal axis of the first continuous carrier material sheet; Provide a continuous strip of receptor material and position the continuous strip of receptor material between the lateral strips of the gel; and A second continuous carrier material sheet is provided and positioned onto the gel to form a composite material, wherein the gel and the continuous receptor material strip are inserted between the first continuous carrier material sheet and the second continuous carrier material sheet.

2. The method for manufacturing composite aerosol generating materials according to claim 1, further comprising the following steps: At least one of the first continuous carrier material sheet and the second continuous carrier material sheet is rolled up.

3. The method for manufacturing composite aerosol generating materials according to claim 1 or claim 2, further comprising the following steps: The first continuous carrier material sheet and the second continuous carrier material sheet are provided from different corresponding carrier material sources.

4. The method for manufacturing composite aerosol generating materials according to claim 1 or claim 2, further comprising the following steps: Both the first continuous carrier material sheet and the second continuous carrier material sheet are provided from a single carrier material source.

5. The method for manufacturing composite aerosol generating materials according to claim 4, further comprising the following step: folding The single carrier material source is used to form a continuous sheet to create both the first continuous carrier material sheet and the second continuous carrier material sheet, such that the first continuous carrier material sheet and the second continuous carrier material sheet are integrated with each other via fold lines.

6. The method for manufacturing composite aerosol generating materials according to claim 4, further comprising the following steps: The single carrier material source is cut into continuous sheets to form both the first continuous carrier material sheet and the second continuous carrier material sheet.

7. The method for manufacturing composite aerosol generating materials according to claim 1 or claim 2, further comprising the following steps: Press the composite aerosol generating material in a direction perpendicular to the plane surface of the composite aerosol generating material.

8. The method of manufacturing a composite aerosol generating material according to claim 1 or claim 2, wherein the gel comprises fragrance or surfactant or plasticizer or humectant or nicotine or glycerin or propylene glycol or any combination thereof.

9. The method for manufacturing a composite aerosol generating material according to claim 1 or claim 2, wherein the composite aerosol generating material includes tobacco material.

10. A composite aerosol generating material, comprising: First carrier material sheet; Second carrier material sheet; and A gel, wherein the gel is disposed between a first carrier material sheet and a second carrier material sheet, and wherein the gel is arranged in a lateral stripe along a lateral region located distal to the longitudinal axis of the continuous first carrier material sheet; and The receptor material is positioned between the first carrier material sheet and the second carrier material sheet and between the lateral strips of the gel.

11. The composite aerosol generating material according to claim 10, wherein the continuous first carrier material sheet, or the second carrier material sheet, or both the first carrier material sheet and the second carrier material sheet comprise an aerosol generating material.

12. A composite aerosol generating rod, comprising: The composite aerosol generating material according to claim 10 or 11.

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