Method of manufacturing a tubular element for an aerosol-generating article using a multi-layer web material

Abstract

A method of manufacturing a tubular element for an aerosol-generating article, the method comprising: forming an inner tube from a first web material (S1); cutting the inner tube to form a plurality of inner tube segments (S2); feeding the plurality of inner tube segments along a moving delivery path, wherein there is a predefined space between successive inner tube segments (S3); wrapping the plurality of inner tube segments in at least one layer of a second web material to form an outer tube around the inner tube segments (S4); cutting the outer tube in the space between the inner tube segments (S5).

Description

Technical Field

[0001] This disclosure relates to a method for manufacturing a tubular element for an aerosol generating article. This disclosure also relates to an aerosol generating article manufactured using this method. The aerosol generating article includes an aerosol generating matrix for generating, for example, an inhalable aerosol upon heating. Background Technology

[0002] Aerosol-generating articles in which an aerosol-generating matrix, such as a tobacco-containing matrix, is heated rather than burned, are known in the art. Typically, in such heated aerosol-generating articles, aerosols are generated by transferring heat from a heat source to a physically separated aerosol-generating matrix or material, which may be positioned in contact with, within, around, or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the aerosol-generating matrix through heat transfer from the heat source and entrained in the air drawn through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol.

[0003] Many aerosol generating apparatuses for consuming heated aerosol generating articles are known in the art. Such apparatuses include, for example, electrically heated aerosol generating apparatuses, in which aerosols are generated by transferring heat from one or more electrically heated elements of the aerosol generating apparatus to the aerosol generating matrix of the heated aerosol generating article. For example, electrically heated aerosol generating apparatuses have been proposed that include internal resistive heater blades adapted to be inserted into the aerosol generating matrix. Alternatively, inductively heated aerosol generating articles include sensor elements arranged within the aerosol generating matrix, which can be heated by an alternating magnetic field provided by the aerosol generating apparatus.

[0004] Heated aerosol generating articles are typically cigarette-shaped and include multiple elements or rods. For example, such articles typically include: a matrix rod comprising an aerosol generating matrix, a tubular rod downstream of the matrix rod, and a mouthpiece filter section at the mouth end of the article. The tubular rod has an inner cavity or hollow core defining an airflow path. It is known to have two tubular rods: a first tubular rod and a separate second tubular rod, the first tubular rod serving as a spacer between the matrix rod and other components of the aerosol generating article, and the second tubular rod serving as an air cooler to cool air as it passes through the aerosol generating article to facilitate aerosol formation. The second tubular rod is generally adjacent to the first tubular rod.

[0005] Aerosol-generating articles in the form of inhaler articles (e.g., dry powder inhalers) are known in the art. Some dry powder inhalers have a component for storing dry powder, such as a capsule. The capsule can be activated by puncturing a separate puncture element, such as the puncture element of a retainer. Once the capsule is activated, the consumer can inhale through the mouth of the inhaler to generate an airflow through the inhaler. Each airflow from each inhalation can deliver a portion of the dry powder from the capsule into the user's lungs. Such aerosol-generating articles generate aerosols without heating.

[0006] Aerosol-generating articles, such as those for dry powder inhalers, typically include a retainer rod or element having a cavity or hollow core that defines an airflow path and helps retain the capsule or otherwise resist capsule movement, allowing the capsule to be easily punctured. Such a retainer rod is typically formed of two tubular rods: a first tubular rod and a second, separate, smaller tubular rod. The first tubular rod extends across and is secured to the interior of the aerosol-generating article, while the second, smaller tubular rod is secured to the first tubular rod on the capsule-facing side. The smaller diameter of the second tubular rod provides an opening or groove between its outer tubular surface and the inner surface of the aerosol-generating article. This opening or groove collects the dry powder and reduces the likelihood of leakage after the capsule has been punctured (e.g., if the article is tilted).

[0007] Because airflow is confined to its internal cavity, it can be difficult to manufacture and assemble the first and second tubular rods of both heated and unheated aerosol-generating articles (e.g., dry powder inhalers). The ability of the first and second tubular rods to perform their respective functions depends on the accuracy of their positioning and alignment. The quality and consistency of the consumer experience can depend on the internal air path through the aerosol-generating article, and therefore the adjacency and concentricity of the first and second tubular rods are important. Furthermore, the aerosol-generating article may be prone to breakage at the interface between the first and second tubular rods when forces are applied to it (e.g., during insertion into an aerosol-generating device). Summary of the Invention

[0008] A method for manufacturing aerosol-generating articles is desired, which reduces the need for precise positioning and alignment of tubular rods or components. A method for manufacturing aerosol-generating articles is also desired, which produces aerosol-generating articles that are not easily broken at the interface between a first tubular rod and a second tubular rod.

[0009] According to a first embodiment of this disclosure, a method for manufacturing a tubular element for aerosol generation articles is provided. The method may include forming an inner tube from multiple layers of first web material. The method may include cutting the inner tube to form a plurality of inner tube segments. The method may include supplying the plurality of inner tube segments along a moving delivery path. Predefined spaces may exist between consecutive inner tube segments. The method may include wrapping the plurality of inner tube segments in at least one layer of second web material to form an outer tube around the inner tube segments. The method may include cutting the outer tube in the spaces between the inner tube segments.

[0010] According to a first embodiment of this disclosure, a method for manufacturing a tubular element for aerosol generation articles is provided. The method includes: forming an inner tube from multiple layers of first sheet material; cutting the inner tube to form a plurality of inner tube segments; supplying the plurality of inner tube segments along a moving delivery path, wherein a predefined space exists between consecutive inner tube segments; wrapping the plurality of inner tube segments in at least one layer of second sheet material to form an outer tube around the inner tube segments; and cutting the outer tube in the space between the inner tube segments.

[0011] The term "aerosol-generating article" is used herein to refer to an article in which inhalable aerosols are generated from an aerosol-generating matrix and delivered to a consumer. As used herein, the term "aerosol-generating matrix" refers to a matrix from which aerosols may be formed or generated. For example, an aerosol-generating matrix may be able to release volatile compounds to generate aerosols when heated. Alternatively, an aerosol-generating matrix may include particles that can be entrained in an airflow to generate aerosols.

[0012] As used herein, the term "tubular element" refers to a generally hollow, elongated element that defines a lumen or airflow passage along its longitudinal axis. Specifically, the term "tubular" will be used to refer to a tubular element having a substantially cylindrical cross-section and defining at least one airflow conduit that establishes uninterrupted fluid communication between an upstream end and a downstream end of the tubular element. However, it should be understood that alternative geometries (e.g., alternative cross-sectional shapes) of the tubular element may be possible. The tubular element is a separate, discrete component of the aerosol-generating article.

[0013] Advantageously, tubular elements can be formed by wrapping multiple spaced-apart inner tube segments in a web material to form an outer tube around the inner tube segments and cutting the outer tube in the space between the inner tube segments, wherein the inner tube segments and the outer tube are precisely positioned and aligned. Furthermore, more robust tubular elements that are less prone to breakage can be formed.

[0014] Advantageously, by forming a tubular element from an inner tube segment and an outer tube segment, it is possible to use different materials for forming each of the inner and outer tube segments. In particular, different materials can be selected for forming the inner and outer tube segments depending on the specific physical requirements of each of the inner and outer tube segments.

[0015] The tubular element may include a first tubular portion and a second tubular portion. The first and second tubular portions may be integral. As used herein with respect to the first and second tubular portions of the tubular element, the term "integral" is intended to mean that the first and second tubular portions each form part of the tubular element, rather than as separate components. Therefore, the tubular element comprising the first and second tubular portions is a single component of the aerosol-generating article. The first and second tubular portions cannot be separated without the application of a force that would damage or destroy the tubular element.

[0016] Advantageously, a tubular element having a first tubular portion and a second tubular portion with different inner diameters can be formed by wrapping multiple spaced inner tube segments in a web material to form an outer tube around the inner tube segments and cutting the outer tube in the space between the inner tube segments.

[0017] Furthermore, by providing a method for producing a tubular element having an integral first tubular portion and a second tubular portion, the first and second tubular portions advantageously form each part of the tubular element, rather than as separate components. This helps alleviate any difficulties in positioning the first and second tubular portions relative to each other during the assembly of the aerosol-generating article, compared to forming the first and second tubular portions as separate elements. Precise abutment engagement of the first and second tubular portions is not required during the assembly of the aerosol-generating article, as the tubular element with the integral first and second tubular portions is already assembled, automatically achieving this construction advantage. The integral nature of the tubular element also helps ensure axial alignment of the first and second tubular portions. This ensures smooth airflow through the tubular element and contributes to providing a consistent consumer experience.

[0018] In addition, the method of producing a tubular element having an integral first tubular portion and a second tubular portion advantageously helps to strengthen the tubular element and reduce the risk of damage or breakage of the tubular element at the interface between the first tubular portion and the second tubular portion when force is applied to the aerosol generating article (e.g., during the insertion of the aerosol generating article into an aerosol generating apparatus).

[0019] As the inner tube segments are supplied onto the moving delivery path, their longitudinal axes can be substantially aligned with each other. The longitudinal axes of the inner tube segments can also be substantially aligned with the direction of movement of the delivery path. The moving delivery path can be a conveyor, such as a conveyor belt.

[0020] Regarding the characteristic of cutting the outer tube in the space between the inner tube segments, the word "in" in the phrase "in the space" includes cutting the outer tube at the endpoints of the space between the inner tube segments. For example, the outer tube may be cut at the end of the space adjacent to the rear end of an inner tube segment.

[0021] The outer tube can be cut in each space between the inner tube segments.

[0022] In one example, cutting the inner tube may include cutting inner tube segments of twice their length. Each double-length inner tube segment may have twice the length of a first tubular portion of the tubular element. Each space between the inner tube segments may have twice the length of a second tubular portion of the tubular element. In this example, the outer tube may be cut at the midpoint of each space between the inner tube segments. Both the outer and inner tube segments may be cut at the midpoint of each double-length inner tube segment.

[0023] For the purposes of aerosol-generating articles, the term "length" refers to the dimension of a component of the aerosol-generating article in the longitudinal direction of the aerosol-generating article. The longitudinal direction of the aerosol-generating article is the direction corresponding to the main longitudinal axis of the aerosol-generating article, which extends between the upstream and downstream ends of the aerosol-generating article. As used herein, the terms "upstream" and "downstream" describe the relative position of an element or portion of an element of the aerosol-generating article with respect to the direction in which aerosols are transported through the aerosol-generating article during use.

[0024] In another example, cutting the inner tube may include cutting single-length inner tube segments. Each single-length inner tube segment may have the same length as the first tubular portion of the tubular element. Each space between the inner tube segments may have the same length as the second tubular portion of the tubular element. In this example, the outer and inner tube segments may be cut at each end of each space immediately adjacent to the rear end of the inner tube segment.

[0025] The inner tube can be formed from 1 to 20 layers of the first sheet material. The inner tube can also be formed from multiple substantially continuous strips of the first sheet material.

[0026] The inner tube can be formed by helically winding a substantially continuous strip. As used herein, the term "helically winding" or "spiral winding" refers to the process of forming a tube by helically or spirally winding at least one substantially continuous strip of web material around a forming device, such as an elongated cylindrical mandrel. At least one strip of web material is fed to the mandrel such that the direction of entry of at least one strip of web material forms an acute angle with the longitudinal axis of the mandrel.

[0027] Multiple substantially continuous strips can be spirally wound around a cylindrical mandrel in an overlapping manner to form a substantially continuous tube on the mandrel.

[0028] Apart from the innermost substantially continuous strip, the inner surface of each of the plurality of substantially continuous strips may be coated with an adhesive.

[0029] The width of a continuous strip can generally be between 10 mm and 50 mm.

[0030] The thickness of the first sheet material can be between 0.05 mm and 0.1 mm.

[0031] The first sheet material may include one or more of paper, cardboard, cellulose acetate tow, or polylactic acid (PLA).

[0032] Multiple inner tube segments can be wrapped within multiple layers of second sheet material to form an outer tube around the inner tube segments. The outer tube can be formed from 1 to 20 layers of second sheet material.

[0033] The outer tube can be formed by wrapping multiple inner tube segments in parallel with a second web material. As used herein, the term "parallel-wrapped" or "parallel wrapping" refers to the process of forming a tube by wrapping another element (e.g., an inner tube segment) in web material such that opposite edges of the web material are brought together in a parallel manner.

[0034] The thickness of the second sheet material can be between 0.05 mm and 1.1 mm.

[0035] The second sheet material may include one or more of paper, cardboard, cellulose acetate tow, or polylactic acid (PLA).

[0036] In one example, the outer tube may include a first outer tube. The method may further include cutting the first outer tube to form a plurality of first outer tube sub-assemblies. Each first outer tube sub-assembly may include a single-length inner tube segment at each end of the first outer tube assembly. Each first outer tube assembly may include N double-length inner tube segments between the single-length inner tube segments. The method may further include feeding the plurality of first outer tube assemblies onto a moving delivery path. The method may further include wrapping the plurality of first outer tube assemblies in a second layer of second web material to form a second outer tube around the first outer tube assembly. The method may further include cutting the second outer tube and one double-length inner tube segment of each of the N double-length inner tube segments at the midpoint of the double-length inner tube segment to form a plurality of second outer tube assemblies.

[0037] Each second outer tube assembly may include a single-length inner tube segment at each end of the first outer tube assembly. Each second outer tube assembly may include N double-length inner tube segments between the single-length inner tube segments.

[0038] The method may further include cutting a second outer tube assembly at a previously uncut inner tube segment. The second outer tube assembly is located at a second double-length inner tube segment out of N double-length inner tube segments.

[0039] Multiple second outer tube assemblies can be supplied onto the moving delivery path. Multiple second outer tube assemblies can undergo additional wrapping and cutting steps to form additional or subsequent outer tube assemblies.

[0040] Each additional or subsequent outer tube assembly may include a single-length inner tube segment at each end of the first outer tube assembly. Each additional or subsequent outer tube assembly may include N double-length inner tube segments between the single-length inner tube segments.

[0041] The method may also include cutting each additional or subsequent outer tube assembly at a previously uncut inner tube segment.

[0042] Another outer tube assembly can be supplied N-1 more times along the moving delivery path to provide an outer tube with N+1 layers of second sheet material.

[0043] According to a second embodiment of this disclosure, a method for manufacturing a tubular element for aerosol generation articles is provided. The method may include forming an inner tube from multiple layers of first web material. The method may include cutting the inner tube to form a plurality of inner tube segments. The method may include forming an outer tube from multiple layers of third web material. The outer tube may have an inner diameter substantially the same as the outer diameter of the inner tube. The method may include cutting the outer tube to form a plurality of outer tube segments. The outer tube segments may have different lengths than the inner tube segments. The method may include inserting each of the inner tube segments into a corresponding outer tube segment of the outer tube segments. The method may include securing the outer surface of the inner tube segment to the inner surface of the outer tube segment.

[0044] According to a second embodiment of this disclosure, a method for manufacturing a tubular element for aerosol generation articles is provided. The method includes: forming an inner tube from multiple layers of first sheet material; cutting the inner tube to form a plurality of inner tube segments; forming an outer tube from multiple layers of third sheet material, the outer tube having an inner diameter substantially the same as the outer diameter of the inner tube; cutting the outer tube to form a plurality of outer tube segments, the outer tube segments having a different length than the inner tube segments; inserting each of the inner tube segments into a corresponding outer tube segment of the outer tube segments; and fixing the outer surface of the inner tube segment to the inner surface of the outer tube segment.

[0045] When it is mentioned that the inner diameter of the outer tube is substantially the same as the outer diameter of the inner tube, the term "substantially the same" is intended to mean that at least one or both of these diameters include suitable tolerances to allow the inner tube to be inserted into the outer tube without using excessive force, i.e., force that could damage one or the other of the inner tube segment and the outer tube segment.

[0046] Advantageously, tubular elements can be formed by creating inner and outer tube segments of different lengths and inserting the inner tube segment into the outer tube segment, wherein the inner and outer tube segments are accurately positioned and aligned. Furthermore, more robust tubular elements that are less prone to breakage can be formed.

[0047] The tubular element may include a first tubular portion and a second tubular portion. The first tubular portion and the second tubular portion may be integral. This has the same advantages as discussed above with respect to the first exemplary method.

[0048] Furthermore, by forming inner tube segments and outer tube segments of different lengths and inserting the inner tube segments into the outer tube segments, it is advantageous to form tubular elements having a first tubular portion and a second tubular portion with different inner or outer diameters.

[0049] The inner tube can be formed from 1 to 20 layers of the first sheet material. The inner tube can also be formed from multiple substantially continuous strips of the first sheet material.

[0050] Forming the inner tube may include multiple substantially continuous strips of the first sheet material spirally wound around it.

[0051] The thickness of the first sheet material can be between 0.05 mm and 0.1 mm.

[0052] The first sheet material may include one or more of paper, cardboard, cellulose acetate tow, or polylactic acid (PLA).

[0053] The outer tube can be formed from 1 to 20 layers of third sheet material. The outer tube can be formed from multiple substantially continuous strips of third sheet material.

[0054] Forming the outer tube may include multiple substantially continuous strips of a third sheet material spirally wound around it.

[0055] The thickness of the third sheet material can be between 0.05 mm and 0.1 mm.

[0056] The third sheet material may be the same as the first sheet material. The third sheet material may include one or more of paper, cardboard, cellulose acetate tow, or polylactic acid (PLA).

[0057] Multiple substantially continuous strips can be spirally wound around a cylindrical mandrel in an overlapping manner to form a substantially continuous tube on the mandrel.

[0058] Apart from the innermost substantially continuous strip, the inner surface of each of the plurality of substantially continuous strips may be coated with an adhesive.

[0059] The width of a continuous strip can generally be between 10 mm and 50 mm.

[0060] An apparatus including a rotatable roller can be used to insert inner tube segments into outer tube segments. The rotatable roller can rotate about its longitudinal passage. The outer circumferential surface of the roller can be configured to hold multiple inner and outer tube segments. Successive inner and outer tube segments can be arranged circumferentially around the roller. Successive inner and outer tube segments can be arranged parallel to each other. The outer circumferential surface of the roller can be porous. The inner and outer tube segments can be held on the outer circumferential surface of the roller by negative pressure, which acts through the porous outer surface in a direction that counteracts the centrifugal force acting on the inner and outer tube segments. The negative pressure can be provided by air suction. The apparatus may also include a stationary track relative to the rotation of the roller. The stationary track may have a cam surface on the side of the track facing the inner and outer tube segments. The cam surface may be tapered. The cam surface may become wider in the direction of rotation of the roller. The cam surface can be configured to push the inner tube segment into the outer tube segment as the roller rotates.

[0061] Attaching the outer surface of the inner tube segment to the inner surface of the outer tube segment may include gluing or adhering the outer surface of the inner tube segment to the inner surface of the outer tube segment. Adhesive or adhesive may be applied prior to the insertion step. Adhesive or adhesive may be applied to the inner surface of the outer tube segment. Adhesive or adhesive may be applied to the outer surface of the inner tube segment. Adhesive or adhesive may be applied using an adhesive nozzle or roller. Adhesive or adhesive may be applied in a circumferential manner. Adhesive or adhesive may provide an airtight seal between the inner and outer tube segments.

[0062] According to another embodiment of this disclosure, a method for manufacturing an aerosol-generating article is provided. The method may include manufacturing a tubular element according to any of the exemplary methods described above. The method may include providing a matrix element comprising an aerosol-generating matrix.

[0063] According to another embodiment of this disclosure, a method for manufacturing an aerosol-generating article is provided. The method includes: manufacturing a tubular element according to any of the exemplary methods described above, and providing a matrix element comprising an aerosol-generating matrix.

[0064] Tubular elements can be arranged downstream of the matrix elements.

[0065] The method may also include providing an upstream element. The upstream element may be arranged upstream of the matrix element.

[0066] The method may also include providing a mouthpiece element. The mouthpiece element may be disposed downstream of the tubular element.

[0067] The method may also include encapsulating at least a matrix element and a tubular element in a package to form a packaged sub-assembly.

[0068] The method may also include using splicing paper to attach the mouthpiece element to the packaged sub-assembly.

[0069] According to an embodiment of this disclosure, an aerosol generating article is provided. The aerosol generating article may include a matrix element comprising an aerosol generating matrix. The aerosol generating article may include a tubular element. The tubular element may include a first tubular portion. The tubular element may include a second tubular portion. The first tubular portion and the second tubular portion may be integral. The first tubular portion may constitute at least 10% of the length of the tubular element. The second tubular portion may constitute at least 10% of the length of the tubular element.

[0070] In one example, the first tubular portion may have a first inner diameter. The second tubular portion may have a second inner diameter. The first inner diameter may be different from the second inner diameter.

[0071] In another example, the first tubular portion may have a first outer diameter. The second tubular portion may have a second outer diameter. The first outer diameter may be different from the second outer diameter.

[0072] According to an example of this disclosure, an aerosol generating article is provided, comprising: a matrix element including an aerosol generating matrix; and a tubular element including an integral first tubular portion and a second tubular portion. The first tubular portion and the second tubular portion each constitute at least 10% of the length of the tubular element. The first tubular portion has a first inner diameter, and the second tubular portion has a second inner diameter, wherein the first inner diameter is different from the second inner diameter. Alternatively or additionally, the first tubular portion has a first outer diameter, and the second tubular portion has a second outer diameter, wherein the first outer diameter is different from the second outer diameter.

[0073] The first tubular portion and the second tubular portion may each constitute at least 20% of the length of the tubular element, preferably at least 30% of the length of the tubular element, and more preferably at least 40% of the length of the tubular element. In a preferred embodiment, the first tubular portion and the second tubular portion may each constitute about 50% of the length of the tubular element.

[0074] In an exemplary aerosol-generating article, the first tubular portion and the second tubular portion may have different first inner diameters and second inner diameters, respectively. The second tubular portion may be disposed downstream of the first tubular portion.

[0075] The second inner diameter may be larger than the first inner diameter. The second inner diameter may be at least 1 mm larger than the first inner diameter. Optionally, the second inner diameter may be at least 1.2 mm larger than the first inner diameter. Optionally, the second inner diameter may be at least 1.4 mm larger than the first inner diameter. Optionally, the second inner diameter may be at least 1.6 mm larger than the first inner diameter. Optionally, the second inner diameter may be at least 1.8 mm larger than the first inner diameter. Optionally, the second inner diameter may be at least 2.0 mm larger than the first inner diameter.

[0076] The difference between the first inner diameter and the second inner diameter can be between about 0.5 mm and about 3.0 mm, optionally between about 1 mm and about 2.5 mm, and further optionally between about 1.5 mm and about 2.0 mm. In a preferred embodiment, the difference between the first inner diameter and the second inner diameter can be about 1.7 mm.

[0077] The ratio of the second inner diameter to the first inner diameter can be between 1.2 and 2.5, optionally between 1.2 and 2.0, further optionally between 1.3 and 1.7, and even more optionally between 1.4 and 1.6. In one example, the ratio of the second inner diameter to the first inner diameter can be about 1.4. In another example, the ratio of the second inner diameter to the first inner diameter can be between about 2.0 and about 2.5.

[0078] The first tubular portion may include an inner tube segment. The first tubular portion may include a first portion of an outer tube segment. The first portion of the outer tube segment may be arranged around the inner tube segment. The second tubular portion may include a second portion of the outer tube segment. The second portion of the outer tube segment may extend beyond the end of the inner tube segment in the longitudinal direction of the tubular element. The first inner diameter may be the inner diameter of the inner tube segment. The second inner diameter may be the inner diameter of the second portion of the outer tube segment.

[0079] The outer tube segment may overlap with the inner tube segment. The outer tube segment may overlap with at least 50% of the length of the inner tube segment, preferably at least 60% of the length of the inner tube segment, more preferably at least 70% of the length of the inner tube segment, even more preferably at least 80% of the length of the inner tube segment, and even more preferably at least 90% of the length of the inner tube segment. The outer tube segment may overlap with the entire length of the inner tube segment.

[0080] Tubular elements can be hollow. Tubular elements can be hollow along their entire length.

[0081] A first tubular portion of the tubular element may define a first inner cavity of the tubular element, the first inner cavity extending from an upstream end of the first tubular portion to a downstream end of the first tubular portion. A first inner diameter is the inner diameter of the first inner cavity. The first inner cavity may define at least a portion of an airflow path through the tubular element. The first inner cavity may be substantially empty to allow substantially unrestricted airflow along the first inner cavity.

[0082] A second tubular portion of the tubular element may define a second inner cavity of the tubular element, the second inner cavity extending from an upstream end of the second tubular portion to a downstream end of the second tubular portion. The second inner cavity may define at least a portion of an airflow path through the tubular element. The second inner cavity may be substantially empty to allow substantially unrestricted airflow along the second inner cavity.

[0083] The tubular element can be arranged to align with and be downstream of the matrix element. In a preferred embodiment, the tubular element is positioned immediately downstream of the matrix element. The upstream end of the tubular element may be adjacent to the downstream end of the matrix element.

[0084] The tubular element preferably has an outer diameter that is approximately equal to the outer diameter of the matrix element and the outer diameter of the aerosol-generated article.

[0085] The tubular element may have an outer diameter between 5 mm and 12 mm, for example between 5 mm and 10 mm, or between 6 mm and 8 mm. In a preferred embodiment, the tubular element has an outer diameter of 7.1 mm + / - 10%.

[0086] The first tubular portion of the tubular element may have an inner diameter of at least about 2.5 mm, preferably at least about 3.0 mm, and more preferably at least about 3.5 mm. Alternatively or additionally, the first tubular portion of the tubular element may have an inner diameter of less than about 4.0 mm, preferably less than about 3.5 mm or less than about 3.0 mm.

[0087] The inner diameter of the first tubular portion of the tubular element may be between about 2.0 mm and about 4.0 mm, preferably between about 2.5 mm and about 3.5 mm, and more preferably between about 3.0 mm and 3.5 mm. In a preferred embodiment, the first tubular portion of the tubular element may have an inner diameter of about 3.3 mm.

[0088] The peripheral wall of the first tubular portion may have a thickness of at least about 1 mm, preferably at least about 1.5 mm or at least about 2 mm. Alternatively or additionally, the peripheral wall of the first tubular portion may have a thickness of less than about 3 mm, preferably less than about 2.5 mm or less than about 2 mm.

[0089] The peripheral wall of the first tubular portion may have a thickness between about 1 mm and about 3 mm, preferably between about 1.5 mm and about 2.5 mm, and more preferably between about 1.5 mm and 2.0 mm. In a preferred embodiment, the peripheral wall of the first tubular portion may have a thickness of about 1.9 mm.

[0090] The first tubular portion of the tubular element may have a length of at least about 5 mm, preferably at least about 6 mm, and more preferably at least about 7 mm. The first tubular portion of the tubular element may have a length of less than about 15 mm, preferably less than about 12 mm, and more preferably less than about 10 mm.

[0091] The first tubular portion of the tubular element may have a length between about 5 mm and about 15 mm, preferably between about 6 mm and 12 mm, and more preferably between about 7 mm and 10 mm. In a preferred embodiment, the first tubular portion of the tubular element may have a length of about 8 mm or about 9 mm.

[0092] The second tubular portion of the tubular element may have an inner diameter of at least about 4.0 mm, preferably at least about 4.5 mm, and more preferably at least about 5.0 mm. Alternatively or additionally, the second tubular portion of the tubular element may have an inner diameter of less than about 6.0 mm, preferably less than about 5.5 mm or less than about 5.0 mm.

[0093] The second tubular portion of the tubular element may have an inner diameter between about 4.0 mm and about 6.0 mm, preferably between about 4.5 mm and about 6.0 mm, and more preferably between about 4.5 mm and 5.5 mm. In a preferred embodiment, the second tubular portion of the tubular element may have an inner diameter of about 5.0 mm.

[0094] The peripheral wall of the second tubular portion may have a thickness of at least about 0.3 mm, preferably at least about 0.6 mm, and more preferably at least about 0.9 mm. Alternatively or additionally, the peripheral wall of the second tubular portion may have a thickness of less than about 2.5 mm, preferably less than about 2.0 mm, and more preferably less than about 1.5 mm.

[0095] The peripheral wall of the second tubular portion may have a thickness between about 0.3 mm and 2.5 mm, preferably between about 0.6 mm and 2.0 mm, and more preferably between about 0.9 mm and 1.5 mm. In a preferred embodiment, the peripheral wall of the second tubular portion may have a thickness of about 1.05 mm.

[0096] The second tubular portion of the tubular element may have a length of at least about 5 mm, preferably at least about 6 mm, and more preferably at least about 7 mm. The second tubular portion of the tubular element may have a length of less than about 15 mm, preferably less than about 12 mm, and more preferably less than about 10 mm.

[0097] The second tubular portion of the tubular element may have a length between about 5 mm and about 15 mm, preferably between about 6 mm and 12 mm, and more preferably between about 7 mm and 10 mm. In a preferred embodiment, the second tubular portion of the tubular element may have a length of about 8 mm.

[0098] In another exemplary aerosol-generating article, the first tubular portion and the second tubular portion may have different first outer diameters and second outer diameters, respectively.

[0099] The matrix element may include a capsule containing an aerosol-generating matrix. The capsule may be positioned upstream of the tubular element.

[0100] The first outer diameter may be smaller than the second outer diameter. The outer surface of the first tubular portion of the tubular element having the smaller first outer diameter may at least partially define an annular space within the aerosol-generating article. Advantageously, the annular space may define grooves or pores for collecting excess aerosol-generating matrix released from the capsule. The annular space may also collect aerosol-generating matrix released from the capsule as the aerosol-generating article moves through the space between consumer inhalations.

[0101] The first outer diameter may be at least 1 mm smaller than the second outer diameter. Optionally, the first outer diameter may be at least 2 mm smaller than the second outer diameter. More optionally, the first outer diameter may be at least 3 mm smaller than the second outer diameter.

[0102] The difference between the first outer diameter and the second outer diameter can be between about 0.5 mm and about 3.5 mm, optionally between about 1 mm and about 3 mm, and further optionally between about 1.5 mm and about 2.5 mm. In a preferred embodiment, the difference between the first outer diameter and the second outer diameter can be about 2 mm.

[0103] The ratio between the second outer diameter and the first outer diameter can be between 1.2 and 1.8, preferably between 1.3 and 1.6, and more preferably between 1.3 and 1.5. In a preferred embodiment, the ratio between the second outer diameter and the first outer diameter can be about 1.4.

[0104] The first tubular portion may include a first portion of an inner tube segment. The second tubular portion may include a second portion of an inner tube segment. The second tubular portion may include an outer tube segment arranged around the second portion of the inner tube segment. The first outer diameter may be the outer diameter of the first portion of the inner tube segment. The second outer diameter may be the outer diameter of the outer tube segment.

[0105] The outer tube segment may overlap with the inner tube segment. The outer tube segment may overlap with at least 10% of the length of the inner tube segment, preferably at least 20% of the length of the inner tube segment, more preferably at least 30% of the length of the inner tube segment, and even more preferably at least 40% of the length of the inner tube segment. In a preferred embodiment, the outer tube segment may overlap with approximately 50% of the length of the inner tube segment.

[0106] Tubular elements can be hollow. Tubular elements can be hollow along their entire length.

[0107] The tubular element may define an inner cavity extending from an upstream end to a downstream end of the tubular element. The inner cavity may define an airflow path through the tubular element. The inner cavity may be substantially empty to allow substantially unrestricted airflow along it.

[0108] The first tubular portion of the tubular element may have an outer diameter of at least about 4.0 mm, preferably at least about 4.5 mm, and more preferably at least about 5.0 mm. Alternatively or additionally, the first tubular portion of the tubular element may have an outer diameter of less than about 7.0 mm, preferably less than about 6.5 mm or less than about 6.0 mm.

[0109] The first tubular portion of the tubular element may have an outer diameter between about 4.0 mm and about 7.0 mm, preferably between about 4.0 mm and about 6.0 mm, and more preferably between about 4.5 mm and 5.5 mm. In a preferred embodiment, the first tubular portion of the tubular element may have an outer diameter of about 5.0 mm.

[0110] The peripheral wall of the first tubular portion may have a thickness of at least about 0.5 mm, preferably at least about 1.0 mm or at least about 2 mm. Alternatively or additionally, the peripheral wall of the first tubular portion may have a thickness of less than about 3.0 mm, preferably less than about 2.5 mm or less than about 2 mm.

[0111] The peripheral wall of the first tubular portion may have a thickness between about 0.5 mm and 3.0 mm, preferably between about 1.0 mm and 2.5 mm, and more preferably between about 1.0 mm and 2.0 mm. In a preferred embodiment, the peripheral wall of the first tubular portion may have a thickness of about 1.0 mm.

[0112] The first tubular portion of the tubular element may have a length of at least about 3 mm, preferably at least about 4 mm, and more preferably at least about 5 mm. The first tubular portion of the tubular element may have a length of less than about 10 mm, preferably less than about 8 mm, and more preferably less than about 7 mm.

[0113] The first tubular portion of the tubular element may have a length between about 3 mm and about 10 mm, preferably between about 4 mm and 8 mm, and more preferably between about 5 mm and 7 mm. In a preferred embodiment, the first tubular portion of the tubular element may have a length of about 6 mm.

[0114] The second tubular portion of the tubular element may have an outer diameter of at least about 5.0 mm, preferably at least about 6.0 mm, and more preferably at least about 7.0 mm. Alternatively or additionally, the second tubular portion of the tubular element may have an outer diameter of less than about 10.0 mm, preferably less than about 9.0 mm, and more preferably less than about 8.0 mm.

[0115] The second tubular portion of the tubular element may have an outer diameter between about 5.0 mm and about 10.0 mm, preferably between about 6.0 mm and about 9.0 mm, and more preferably between about 6.5 mm and 8.0 mm. In a preferred embodiment, the second tubular portion of the tubular element may have an outer diameter of about 7.0 mm.

[0116] The peripheral wall of the second tubular portion may have a thickness of at least 0.5 mm, preferably at least about 1.0 mm, and more preferably at least about 1.5 mm. Alternatively or additionally, the peripheral wall of the second tubular portion may have a thickness of less than about 3.5 mm, preferably less than about 3.0 mm, and more preferably less than about 2.5 mm.

[0117] The peripheral wall of the second tubular portion may have a thickness between about 0.5 mm and 3.5 mm, preferably between about 1.0 mm and 3.0 mm, and more preferably between about 1.5 mm and 2.5 mm. In a preferred embodiment, the peripheral wall of the second tubular portion may have a thickness of about 2.0 mm.

[0118] The second tubular portion of the tubular element may have a length of at least about 6 mm, preferably at least about 7 mm, and more preferably at least about 8 mm. The second tubular portion of the tubular element may have a length of less than about 12 mm, preferably less than about 11 mm, and more preferably less than about 10 mm.

[0119] The second tubular portion of the tubular element may have a length between about 6 mm and about 12 mm, preferably between about 7 mm and 11 mm, and more preferably between about 8 mm and 10 mm. In a preferred embodiment, the second tubular portion of the tubular element may have a length of about 9 mm.

[0120] The inner diameter of the tubular element can be smaller than the outer diameter of the bladder. Advantageously, this helps prevent the bladder from passing through the tubular element, i.e., through the lumen within the tubular element.

[0121] The inner diameter of the tubular element can be at least 1 mm smaller than the outer diameter of the bladder. Optionally, the inner diameter of the tubular element can be at least 2 mm smaller than the outer diameter of the bladder. More optionally, the inner diameter of the tubular element can be at least 3 mm smaller than the outer diameter of the bladder.

[0122] The inner diameter of the tubular element can be uniform along its entire length. The tubular element may have an inner diameter of less than 4.5 mm, preferably less than 4.0 mm, and more preferably less than 3.5 mm.

[0123] The upstream end of the tubular element can be arranged to engage the outer surface of the sac. The tubular element can act as a retaining rod or element for limiting the downstream movement of the sac. Advantageously, by providing a pressing surface, puncturing the sac to release its contents can be made easier by limiting the movement of the sac.

[0124] The invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0125] Example Ex1: A method for manufacturing a tubular element for aerosol generation articles, the method comprising wrapping an inner tubular segment in at least one layer of web material.

[0126] Example Ex2: According to the method of Example Ex1, the method includes forming an inner tube from multiple layers of first sheet material.

[0127] Example Ex3: According to the method of Example Ex2, the method includes cutting the inner tube to form a plurality of inner tube segments.

[0128] Example Ex4: According to the method of Example Ex3, the method includes supplying the plurality of inner tube segments along a moving delivery path.

[0129] Example Ex5: According to the method of Example Ex4, the method includes providing a predefined space between consecutive inner tube segments.

[0130] Example Ex6: According to the method of Example Ex5, the method includes wrapping the plurality of inner tube segments in at least one layer of second sheet material to form an outer tube around the inner tube segments.

[0131] Example Ex7: According to the method of Example Ex6, the method includes cutting the outer tube in the space between the inner tube segments.

[0132] Example Ex8: According to the method of any of the preceding examples, the tubular element is provided with a first tubular portion and a second tubular portion.

[0133] Example Ex9: According to the method of Example Ex8, cutting the inner tube includes cutting double-length inner tube segments, each double-length inner tube segment having twice the length of the first tubular portion.

[0134] Example Ex10: According to the method of Example Ex8 or Ex9, the space between the inner tube segments is twice the length of the second tubular portion.

[0135] Example Ex11: According to the method of Example Ex9 or Ex10, the outer tube is cut at the midpoint of each space between the inner tube segments.

[0136] Example Ex12: According to the method of Example Ex10 or Ex11, the outer tube and the inner tube segment are cut at the midpoint of each double-length inner tube segment.

[0137] Example Ex13: The method according to any one of Examples Ex2 to Ex12, wherein forming the inner tube comprises a plurality of substantially continuous strips spirally wound around the first web material.

[0138] Example Ex14: According to the method of any one of Examples Ex6 to Ex13, the plurality of inner tube segments are wrapped in a multilayer second sheet material to form an outer tube around the inner tube segments.

[0139] Example Ex15: According to the method of Example Ex14, the plurality of inner tube segments are wrapped in parallel by the second sheet material.

[0140] Example Ex16: The method according to any one of Examples Ex6 to Ex15, wherein the outer tube comprises a first outer tube, and the method further comprises: cutting the first outer tube to form a plurality of first outer tube sub-assemblies, each first outer tube assembly comprising a single-length inner tube segment at each end of the first outer tube assembly, and N double-length inner tube segments between the single-length inner tube segments; supplying the plurality of first outer tube assemblies onto the moving delivery path; wrapping the plurality of first outer tube assemblies in a second layer of second web material to form a second outer tube around the first outer tube assembly; and cutting the second outer tube and one double-length inner tube segment of the N double-length inner tube segments of each first outer tube assembly at the midpoint of the double-length inner tube segment of the N double-length inner tube segments to form a plurality of second outer tube assemblies.

[0141] Example Ex17: According to the method of Example Ex14, a plurality of second outer tube assemblies are supplied to the moving delivery path and undergo additional wrapping and cutting steps to form additional outer tube assemblies, which are supplied to the moving delivery path an additional N-1 times to provide an outer tube having N+1 layers of the second web material.

[0142] Example Ex18: A method of manufacturing a tubular element for aerosol generation articles, the method comprising: forming an inner tubular segment; forming an outer tubular segment; and inserting the inner tubular segment into the outer tubular segment.

[0143] Example Ex19: According to the method of Example Ex18, the method includes forming an inner tube from multiple layers of first web material; cutting the inner tube to form a plurality of inner tube segments; forming an outer tube from multiple layers of third web material, the outer tube having an inner diameter substantially the same as the outer diameter of the inner tube; cutting the outer tube to form a plurality of outer tube segments, the outer tube segments having a different length than the inner tube segments; inserting the inner tube segments into the outer tube segments; and fixing the outer surface of the inner tube segments to the inner surface of the outer tube segments.

[0144] Example Ex20: According to the method of Example Ex19, the formation of the inner tube includes a plurality of substantially continuous strips spirally wound around the first web material.

[0145] Example Ex21: According to the method of Example Ex19 or Ex20, the outer tube is formed by spirally winding a plurality of substantially continuous strips of the third sheet material.

[0146] Example Ex22: According to the method of Example Ex20 or Ex21, the plurality of substantially continuous strips are spirally wound around a cylindrical mandrel in an overlapping manner to form a substantially continuous tube on the mandrel.

[0147] Example Ex23: According to the method of Example Ex21 or Ex22, the inner surface of each of the plurality of substantially continuous strips, except for the innermost substantially continuous strip, is coated with an adhesive.

[0148] Example Ex24: According to the method of either Example Ex21 or Ex23, the width of the substantially continuous strip is between 10 mm and 50 mm.

[0149] Example Ex25: The method according to any one of Examples Ex18 to Ex24, wherein the inner tube or the outer tube comprises 1 to 20 layers of first or third sheet material respectively.

[0150] Example Ex26: The method according to any one of Examples Ex18 to Ex25, wherein the thickness of the first web material or the third web material or both the first web material and the third web material is between 0.05 mm and 0.1 mm.

[0151] Example Ex27: The method of any one of Examples Ex6 to Ex17, wherein the thickness of the second sheet material is between 0.05 mm and 1.1 mm.

[0152] Example Ex28: An aerosol generating article comprising: a matrix element including an aerosol generating matrix; and a tubular element including a first tubular portion and a second tubular portion.

[0153] Example Ex29: An aerosol-generated article according to Example Ex28, wherein the tubular element comprises an integral first tubular portion and a second tubular portion.

[0154] Example Ex30: An aerosol-generated article according to Example Ex28 or Ex29, wherein the first tubular portion and the second tubular portion each constitute at least 10% of the length of the tubular element.

[0155] Example Ex31: An aerosol-generating article according to any one of Examples Ex28 to Ex30, wherein the first tubular portion has a first inner diameter and the second tubular portion has a second inner diameter, the first inner diameter being different from the second inner diameter.

[0156] Example Ex32: An aerosol-generating article according to any one of Examples Ex28 to Ex30, wherein the first tubular portion has a first outer diameter and the second tubular portion has a second outer diameter, the first outer diameter being different from the second outer diameter.

[0157] Example Ex33: An aerosol-generated article according to Example Ex31, wherein the second inner diameter is larger than the first inner diameter.

[0158] Example Ex34: An aerosol-generated article according to Example Ex33, wherein the ratio of the second inner diameter to the first inner diameter is between 1.2 and 1.8.

[0159] Example Ex35: An aerosol-generated article according to Example Ex33 or Ex34, wherein the first tubular portion includes an inner tube segment and a first portion of an outer tube segment arranged around the inner tube segment, the first inner diameter being the inner diameter of the inner tube segment.

[0160] Example Ex36: An aerosol-generating article according to Example Ex35, wherein the second tubular portion includes a second portion of the outer tubular segment extending beyond the end of the inner tubular segment in the longitudinal direction of the tubular element, the second inner diameter being the inner diameter of the second portion of the outer tubular segment.

[0161] Example Ex37: An aerosol-generated article according to Example Ex32, wherein the first tubular portion and the second tubular portion have different first outer diameters and second outer diameters, respectively.

[0162] Example Ex38: An aerosol generating article according to Example Ex37, wherein the matrix element includes a capsule containing an aerosol generating matrix.

[0163] Example Ex39: An aerosol-generated article according to Example Ex37 or Ex38, wherein the first outer diameter is smaller than the second outer diameter.

[0164] Example Ex40: An aerosol-generated article according to any one of Examples Ex37 to Ex39, wherein the ratio of the second outer diameter to the first outer diameter is between 1.2 and 1.8.

[0165] Example Ex41: An aerosol-generated article according to Example Ex39 or Ex40, wherein the first tubular portion includes a first portion of an inner tube segment, and the first outer diameter is the outer diameter of the first portion of the inner tube segment.

[0166] Example Ex42: An aerosol-generated article according to Example Ex41, wherein the second tubular portion comprises a second portion of the inner tube segment and an outer tube segment arranged around the second portion of the inner tube segment, the second outer diameter being the outer diameter of the outer tube segment.

[0167] Example Ex43: An aerosol-generating article according to any one of Examples Ex38 to Ex42, wherein the inner diameter of the tubular element is smaller than the outer diameter of the bladder. Attached Figure Description

[0168] The examples will now be described further with reference to the accompanying drawings, in which:

[0169] Figure 1 This is a schematic longitudinal cross-sectional view of the aerosol-generated product.

[0170] Figure 1A yes Figure 1 A schematic longitudinal cross-sectional view of a tubular element of an aerosol-generating article, which shows the feature in more detail.

[0171] Figure 2 This is a schematic longitudinal cross-sectional view of another aerosol-generated product.

[0172] Figure 2A yes Figure 2 A schematic longitudinal cross-sectional view of a tubular element of an aerosol-generated article, which shows the feature in more detail.

[0173] Figure 3 This is a flowchart of a method for manufacturing tubular components for aerosol generation articles.

[0174] Figure 4 It is a schematic side view of an apparatus for forming a tube from a substantially continuous strip of web material spirally wound around a mandrel.

[0175] Figure 5 It is a schematic side view of an apparatus for forming tubes from multiple substantially continuous strips of web material spirally wound around a mandrel.

[0176] Figure 6 This is a schematic perspective view of another device used to form a tube by spirally winding multiple substantially continuous strips of web material.

[0177] Figure 7 It is a schematic side view of a device used to wrap inner tube segments parallel to each other in web material to form a substantially continuous outer tube and to cut the outer tube to a predetermined size.

[0178] Figure 7A This indicates that when the inner tube segment is supplied to Figure 7A schematic side view of the spaced arrangement between the inner pipe segments in the equipment.

[0179] Figures 8A to 8D They are respectively in Figure 7 A schematic cross-sectional view of the preforming device, gluing device, compression device, and drying device used in the equipment.

[0180] Figure 9 It shows a substantially continuous outer tube comprising inner tube segments, constructed to form individual tubular elements. Figure 7 A schematic side view of the cutting position of the device's cutter.

[0181] Figure 10A This is a schematic diagram of a device used to wrap multiple layers of web material in parallel around an inner tube segment.

[0182] Figure 10B It is by Figure 10A A schematic cross-sectional side view of the outer tube assembly produced by the equipment, showing the location of continuous cuts.

[0183] Figure 10C It is shown that in ten passes Figure 10A The equipment was then by Figure 10A A schematic cross-sectional side view of the outer tube assembly produced by the equipment.

[0184] Figure 10D It is a schematic cross-sectional view of a spirally wound inner tube segment.

[0185] Figure 10E It was through ten times Figure 10A Added after the device Figure 10D A schematic cross-sectional view of the outer pipe section of the inner pipe section.

[0186] Figure 11 This is a flowchart of another method for manufacturing tubular elements for aerosol generation articles.

[0187] Figure 12A and 12B These are schematic longitudinal cross-sectional views of a tubular element, with the inner tube segment inserted into the outer tube segment, in both disassembled and assembled states.

[0188] Figure 12C It shows the application of adhesive to Figure 12A and 12B A rotating nozzle on the inner surface of the outer tube segment of a tubular element.

[0189] Figure 12D The assembly state is shown. Figure 12A and 12B An enlarged view of the tubular element and the adhesive bonding between the inner and outer tubular segments.

[0190] Figure 13 It shows the assembly Figure 12A and 12B Equipment consisting of tubular components.

[0191] Figure 14 It is a schematic longitudinal cross-sectional view of another tubular element into which the inner tube segment is inserted. Detailed Implementation

[0192] refer to Figure 1 The diagram illustrates an aerosol generating article 1 comprising multiple elements assembled in a strip configuration. The aerosol generating article 1 includes a matrix element 2 containing an aerosol generating matrix and a downstream section 4 located downstream of the matrix element 2. Furthermore, the aerosol generating article 1 includes an upstream section 6 located upstream of the matrix element 2. The aerosol generating article 1 extends from an upstream or distal end 8 to a downstream or inlet end 10. The aerosol generating article has an overall length of approximately 45 mm.

[0193] Downstream section 4 includes a tubular element 12 positioned downstream of matrix element 2, the tubular element 12 being longitudinally aligned with matrix element 2. Figure 1 In this example, the upstream end of the tubular element 12 is adjacent to the downstream end of the matrix element 2. The tubular element 12 includes a first tubular portion 14 and a second tubular portion 16, the second tubular portion 16 being downstream of the first tubular portion 14. The first tubular portion 14 and the second tubular portion 16 are integral with the tubular element 12. That is, the first tubular portion 14 and the second tubular portion 16 each form a part of the tubular element 12, rather than being separate components. Therefore, the tubular element 12, including the first tubular portion 14 and the second tubular portion 16, is a single component of the aerosol generating article 1.

[0194] The first tubular portion 14 of the tubular element 12 defines an inner cavity 18 that extends from an upstream end 20 to a downstream end 22 of the first tubular portion 14. The inner cavity 18 is substantially empty, and thus allows for substantially unrestricted airflow along the inner cavity 18. Therefore, the first tubular portion 14 does not substantially contribute to the overall RTD of the aerosol-generating article 1. More specifically, the RTD of the first tubular portion 14 is substantially 0 mmH2O. The first tubular portion 14 of the tubular element 12 is configured to act as a spacer or support element for the aerosol-generating article 1.

[0195] The second tubular portion 16 of the tubular element 12 defines an inner cavity 24 extending from an upstream end 22 to a downstream end 26 of the second tubular portion 16. The inner cavity 24 is substantially empty, and thus allows for substantially unrestricted airflow along it. The second tubular portion does not substantially contribute to the overall RTD of the aerosol-generating article 10. More specifically, the RTD of the second tubular portion 16 is substantially 0 mmH2O. The second tubular portion 16 of the tubular element 12 is configured to act as an aerosol cooling element for the aerosol-generating article 1.

[0196] The aerosol generating article 1 also includes a ventilation zone 28 disposed along the second tubular portion 16 of the tubular element 12. More specifically, the ventilation zone 28 is disposed approximately 2 mm from the upstream end 22 of the second tubular portion 16. The ventilation zone 28 includes a circumferential ring of perforations or vents extending through the wall of the second tubular portion 16. Air can be drawn through the vents and through the second tubular portion 16 to achieve cooling of the aerosol flow generated during heating of the matrix element 2. The ventilation level of the aerosol generating article 1 is approximately 25%.

[0197] exist Figure 1 In this example, downstream section 4 also includes a mouthpiece element 30 located downstream of tubular element 12. More specifically, mouthpiece element 30 is positioned downstream of the second tubular portion 16 of tubular element 12. The upstream end of mouthpiece element 30 is adjacent to the downstream end 26 of the second tubular portion 16 of tubular element 12. Mouthpiece element 30 is provided in the form of a cylindrical rod of low-density cellulose acetate. Mouthpiece element 30 also includes packaging or rod packaging 35 defining an aerosol generating matrix. Mouthpiece element 30 has a length of approximately 12 mm and an outer diameter of approximately 7.1 mm.

[0198] Matrix element 2 comprises an aerosol-generating matrix of one of the types described above. Matrix element 2 is in the form of a strip comprising the aerosol-generating matrix. The aerosol-generating matrix may substantially define the structure and dimensions of strip 2. Strip 2 may also include packaging (not shown) defining the aerosol-generating matrix. Matrix element 2 has an outer diameter of approximately 7.1 mm and a length of approximately 12 mm. However, it should be understood that these dimensions may vary. For example, in another aerosol-generating article, matrix element 2 may have a length of approximately 11 mm.

[0199] The aerosol generating article 1 also includes an elongated receptor element 32 within a matrix element 2. More specifically, the receptor element 32 is arranged substantially longitudinally within the aerosol generating matrix, so as to be generally parallel to the longitudinal direction of the strip-shaped matrix element 2. The receptor element 32 is positioned at a radial center within the matrix element 2 and extends effectively along the longitudinal axis of the matrix element 2. The receptor element 32 extends from the upstream end to the downstream end of the matrix element 2. In practice, the receptor element 32 has substantially the same length as the matrix element 2. Figure 1 In one example, the receptor element 32 is provided in the form of a strip and has a length of about 12 mm, a thickness of about 60 micrometers, and a width of about 4 mm.

[0200] The upstream segment 6 includes an upstream element 34 positioned immediately upstream of the matrix element 2, which is longitudinally aligned with the matrix element 2. Figure 1 In this example, the downstream end of the upstream element 34 is adjacent to the upstream end of the matrix element 2. This advantageously prevents the receptor element 44 from being displaced. Furthermore, this ensures that the consumer will not accidentally come into contact with the heated receptor element 34 after use. The upstream element 34 is provided in the form of a cylindrical cellulose acetate rod defined by a rigid packaging (not shown). The upstream element 34 has a length of approximately 5 mm.

[0201] The aerosol generating article 1 also includes a package 36 defining the upstream element 34, the matrix element 2, and the tubular element 12. The package 36 extends from the upstream or distal end 8 of the aerosol generating article 1 to the downstream end 26 of the second tubular portion 16. Ventilation openings of the ventilation zone 28 extend through the package 36 to communicate with ventilation openings in the tubular element 12. A mouthpiece element 30 is connected to the aerosol generating article 1 via a splice paper 37 defining the mouthpiece element 30 and a portion of the downstream end of the second tubular portion 16 enclosed in the package 36.

[0202] Figure 1A Showing more details Figure 1 The tubular element 12 of the aerosol-generating article 1. A first tubular portion 14 has a length L1 of about 8 mm, and a second tubular portion 16 has a length L2 of about 8 mm. Thus, the first tubular portion 14 and the second tubular portion 16 each constitute about 50% of the total length (L1+L2) of the tubular element 12, which is about 16 mm. However, it should be understood that these lengths and their relative percentages can vary. For example, in another aerosol-generating article, the second tubular portion may have a length of 9 mm.

[0203] The first tubular portion 14 and the second tubular portion 16 have the same outer diameter D of approximately 7.1 mm. extIt is constant over the entire length (L1+L2) of the tubular element 12. The first tubular portion 14 and the second tubular portion 16 have different inner diameters. The first tubular portion 14 has a first inner diameter D1 of approximately 3.3 mm. int Therefore, the thickness of the peripheral wall of the first tubular portion 14 is approximately 1.9 mm. The second tubular portion 16 has a second inner diameter D2 of approximately 5.0 mm. int Therefore, the thickness of the peripheral wall of the second tubular portion 16 is approximately 1.05 mm. The first inner diameter D1 of the first tubular portion 14... int The length L1 of the first tubular portion 14 is uniform, and the second inner diameter D2 of the second tubular portion 16 is uniform. int The second tubular portion 16 is uniform along its length L2. The second inner diameter D2 of the second tubular portion 16 is... int With the first inner diameter D1 of the first tubular portion 14 int The ratio between them is approximately 1.52.

[0204] The tubular element 12 includes an inner tube segment 15 and an outer tube segment 17 surrounding the inner tube segment 15. The inner tube segment 15 has a length L1 equal to the length of the first tubular portion 14. The thickness of the peripheral wall of the inner tube segment 15 is 0.85 mm. The outer tube segment 17 is longer than the inner tube segment 15, such that it extends beyond the length L2 of the second tubular portion at the downstream end 22 of the inner tube segment 15. The outer tube segment 17 extends from the upstream end 20 of the tubular element 12 to the downstream end 26 of the tubular element 12. The thickness of the peripheral wall of the outer tube segment 17 is 1.05 mm. Therefore, the first tubular portion 14 of the tubular element 12 includes the inner tube segment 15 and a first portion of the outer tube segment 17, defined by the length L1, arranged around the inner tube segment 15. The radial thickness of the first tubular portion 14 is equal to the combined thickness of the peripheral walls of the inner tube segment 15 and the outer tube segment 17, which, as discussed above, is 1.9 mm. The second tubular portion 16 includes a second portion of the outer tubular portion 16 extending in the longitudinal direction beyond the downstream end 22 of the inner tubular portion 15. The radial thickness of the second tubular portion 16 is equal to the thickness of the circumferential wall of the outer tubular portion 17. First inner diameter D1 int It is the inner diameter of inner tube segment 15, and the second inner diameter D2 int This is the inner diameter of the second part of the outer tube segment 17. The outer diameter of the inner tube segment 15 and the inner diameter of the outer tube segment 17 (i.e., the second inner diameter D2) are... int They are basically the same.

[0205] Figure 1A The inner tube segment 15 of the tubular element 12 comprises multiple layers of first web material. In particular, the inner tube segment 15 comprises multiple substantially continuous strips of the first web material, which are helically wound using a method further described below. Figure 1AThe outer tube segment 17 of the tubular element 12 includes one or more sheets of a second web material, which are wrapped in parallel around the inner tube segment 15 using the method described further below.

[0206] Figure 2 This is a schematic longitudinal cross-sectional view of another aerosol-generating article 100. The aerosol-generating article 100 is an inhaler article, such as a dry powder inhaler. The aerosol-generating article 100 includes a tubular body 102 having a partially closed distal or upstream end 104 and a partially closed downstream or inlet end 106. An upstream opening 108 is formed in the upstream end 104 of the tubular body 102, and a downstream opening 110 is formed in the inlet end 106 of the tubular body 102. The upstream opening 108 serves as an air inlet, and the downstream opening 110 serves as an air outlet. An airflow path extends between the upstream opening 108 and the downstream opening 110, and through the inner cavity 107 of the tubular body 102. An upstream portion 109 of the inner cavity of the tubular body 102 near the upstream end 104 houses a sac 111 containing nicotine particles.

[0207] The partially closed upstream end 104 of the tubular body 102 prevents the bladder 111 from falling out of the upstream end 104 of the tubular body 102. The diameter of the bladder 111 is larger than the diameter of the upstream opening 108 and therefore cannot pass through the upstream opening 108. A tubular element 112 is disposed downstream of the bladder 111. The tubular element 112 is fixed to the inner surface of the tubular body 102 and acts as a retaining rod to limit the downstream movement of the bladder 111 to retain the bladder 111 in the upstream region of the tubular body 102.

[0208] The tubular element 112 includes a first tubular portion 114 and a second tubular portion 116, the second tubular portion 116 being downstream of the first tubular portion 114. The first tubular portion 114 and the second tubular portion 116 are integral with the tubular element 112. That is, the first tubular portion 114 and the second tubular portion 116 each form a part of the tubular element 112, rather than being separate components. Therefore, the tubular element 112, including the first tubular portion 114 and the second tubular portion 116, is a single component of the aerosol generating article 100.

[0209] The first tubular portion 114 has a first outer diameter smaller than the inner diameter of the tubular body 102. The second tubular portion 116 has a second outer diameter substantially the same as the inner diameter of the tubular body 102. Therefore, the first outer diameter of the first tubular portion 114 differs from the second outer diameter of the second tubular portion 116, specifically, the first outer diameter is smaller than the second outer diameter. The tubular element is fixed to the inner surface of the tubular body 102 in the region of the second tubular portion 116.

[0210] The tubular element 112 defines an inner cavity 118 that extends from the upstream end of the tubular element 112 to its downstream end. The inner cavity 118 is substantially empty, and thus allows for substantially unrestricted airflow along it. The inner diameter of the inner cavity 118 is smaller than the outer diameter of the bladder 111, and thus prevents the bladder from passing through the tubular element 112.

[0211] During use, the consumer uses an external piercing tool 120 (in... Figure 2 (Shown in dashed outline) The sac 111 is punctured via an upstream opening 108. The puncture tool 120 is pushed through the upstream opening 108 and into the sac 111 to create a hole 122 in the sac 111 through which the nicotine particles can exit the sac 111. Significant downstream movement of the sac 111 is restricted by a tubular element 112. The upstream end of the tubular element 112 is in abutment contact with the sac 111 during puncture and holds the sac 111 in place to allow for easier puncture.

[0212] When a consumer inhales or inhales through the mouth end 106 of the aerosol-generating article 100, air is drawn through the upstream opening 108 and through the upstream portion 109 of the inner cavity 107 of the tubular body 102 containing the capsule 111. Nicotine particles exit the capsule and are entrained in the airflow passing through the tubular body 102. The airflow carrying nicotine particles passes through the inner cavity 118 of the tubular element 112 and enters the downstream portion 124 of the inner cavity 107 of the tubular body 102. The inner diameter of the downstream portion 124 of the inner cavity 107 of the tubular body 102 is larger than the inner diameter of the inner cavity 118 of the tubular element 112. As air is transferred from the tubular element 112 to the downstream portion 124 of the inner cavity 107 of the tubular body 102, the expansion of the cross-section of the airflow path causes a vortex effect, which helps to mix the nicotine particles with the airflow before the airflow is inhaled into the consumer's mouth via the downstream opening 110.

[0213] The smaller first outer diameter of the first tubular portion 114 of the tubular element 112 defines an annular space 126 between the outer surface of the first tubular portion 114 and the inner surface of the tubular body 102. The annular space 126 defines grooves or pores for collecting excess nicotine particles released from the capsule 111 when inhaled by a consumer on the aerosol-generating article 100, but not entrained in the airflow. The annular space 126 also collects nicotine particles released from the capsule as the aerosol-generating article 100 moves between consumer inhalations. The annular space 126 created by the tubular element 112 acts as a barrier reducing the likelihood of nicotine particles leaking from the aerosol-generating article 100 between consumer inhalations or between uses of the aerosol-generating article 100.

[0214] Figure 2A Showing more details Figure 2The tubular element 112 of the aerosol-generating article 100. A first tubular portion 114 has a length L1 of about 6 mm, and a second tubular portion 116 has a length L2 of about 9 mm. Thus, the first tubular portion 114 and the second tubular portion 116 each constitute about 50% of the total length (L1+L2) of the tubular element 112. However, it should be understood that these lengths and their relative percentages may vary.

[0215] The first tubular portion 114 and the second tubular portion 116 have the same inner diameter D of approximately 3.0 mm. int It is constant over the entire length (L1+L2) of the tubular element 112. The first tubular portion 114 and the second tubular portion 116 have different outer diameters. The first tubular portion 114 has a first outer diameter D1 of approximately 5.0 mm. ext Therefore, the thickness of the peripheral wall of the first tubular portion 114 is approximately 1.0 mm. The second tubular portion 116 has a second outer diameter D2 of approximately 7.0 mm. ext Therefore, the thickness of the peripheral wall of the second tubular portion 16 is approximately 2.0 mm. The first outer diameter D1 of the first tubular portion 114... ext The length L1 of the first tubular portion 114 is uniform, and the second outer diameter D2 of the second tubular portion 116 is uniform. ext The second tubular portion 116 is uniform along its length L2. The second outer diameter D2 of the second tubular portion 116 is... ext The first outer diameter D1 of the first tubular portion 114 ext The ratio between them is approximately 1.4.

[0216] The tubular element 112 includes an inner tube segment 115 and an outer tube segment 117 surrounding a portion of the inner tube segment 115. The inner tube segment 115 extends from an upstream end 119 of the tubular element 112 to a downstream end 121 of the tubular element 112. The inner tube segment 115 has a length L1 + L2 equal to the combined length of the first tubular portion 114 and the second tubular portion 116. The outer tube segment 117 has a length L2 and is therefore shorter than the inner tube segment 115. The outer tube segment 117 is disposed at the downstream end 121 of the tubular element 112. Thus, the upstream portion of the inner tube segment 115 defining the first tubular portion 114 protrudes from the outer tube segment 117. Therefore, the first tubular portion 114 of the tubular element 112 includes a first portion of the inner tube segment 115 defined by the length L1. The second tubular portion 116 includes a second portion of an inner tube segment defined by a length L2 and an outer tube segment 117 arranged around the second portion of the inner tube segment 115. First outer diameter D1 ext It is the outer diameter of the first part of the inner tube segment 115, and the second outer diameter D2 ext This refers to the outer diameter of the outer tube segment 117. The outer diameter of the inner tube segment 115 (i.e., the first outer diameter D1) extThe inner diameter of the outer tube segment 117 is basically the same.

[0217] Figure 2A The inner tube segment 115 and outer tube segment 117 of the tubular element 112 comprise multiple layers of web material. In particular, the inner tube segment 115 and outer tube segment 117 comprise multiple substantially continuous strips of web material, which are helically wound using a method further described below.

[0218] Figure 3 Tubular elements (e.g.) for manufacturing articles for aerosol generation are shown. Figure 1A A flowchart of a method for forming a tubular element 12. The method includes a first step S1 of forming a substantially continuous inner tube from multiple layers of first web material using a spiral winding process further described below.

[0219] In the second step S2, the method includes cutting the substantially continuous inner tube to form a plurality of inner tube segments. These inner tube segments will extend the entire length of the first tubular portion of the tubular element. Figure 3 In this method, the inner tube segment is cut into double-length inner tube segments, that is, the inner tube segments have twice the length of the first tubular portion. The double-length inner tube segments will then undergo another cutting step to cut them to their final desired size. It should be understood that in other example methods, the inner tube segment may be cut into single-length inner tube segments, that is, the inner tube segments have the same length as the first tubular portion.

[0220] In the third step S3, the method includes supplying multiple inner tube segments along a moving delivery path (e.g., a conveyor belt or other moving device). The inner tube segments are supplied onto the moving delivery path with their longitudinal axes aligned. Predefined spaces are provided between consecutive inner tube segments. Figure 3 In this method, the inner tube segments are double-spaced, meaning the predefined space between the inner tube segments is twice the length of the second tubular portion of the tubular element. It should be understood that in other example methods, the inner tube segments may be single-spaced, meaning the predefined space between the inner tube segments may be equal to the length of the second tubular portion of the tubular element.

[0221] In the fourth step S4, the method includes wrapping a plurality of inner tube segments in at least one layer of second sheet material to form a substantially continuous outer tube around the inner tube segments. The second sheet material is wrapped around the inner tube segments using a parallel wrapping method described further below.

[0222] In step S5, the method includes cutting the outer tube in the space between the inner tube segments. When the method uses double-spaced, double-length inner tube segments, the outer tube is cut at the midpoint of each space between the inner tube segments, and the inner tube segments enclosed by the outer tube are cut at the midpoint of each double-length inner tube segment to form individual tubular elements. When the method uses single-spaced, single-length inner tube segments, the outer tube is cut in the space between the inner tube segments immediately following each inner tube segment to form individual tubular elements.

[0223] Figure 4 A schematic side view of an apparatus 200 is shown for forming a tube 240 from a substantially continuous strip 241 of web material spirally wound around a mandrel 245. Figure 4 Only one strip of the web material is shown to illustrate the basic principle. However, it should be understood that, as discussed below... Figure 5 The principle can be extended to multiple strips of web material to produce thicker tubes. It should also be understood that the web material strips 241 are substantially continuous, i.e., their length is greater than... Figure 4 The one shown is much longer. The web material strip 241 is typically stored on a spool or drum (not shown). The substantially continuous strip 241 of web material is unwound from the spool and guided to the mandrel by one or more alignment and tension rollers (not shown).

[0224] The mandrel is an elongated straight rod or tube with a uniform outer diameter along its entire length, defining the inner diameter of the formed tube 240. A web material strip 241 is supplied to the mandrel 245 at an angle α relative to the longitudinal axis of the mandrel 245. The angle α of the web material strip 241 and the pitch of the formed helix are chosen such that the web material strip 241, once wound, does not overlap itself but follows a helical parallel trajectory, such that the opposite side edges of the web material strip are arranged adjacent to or adjacent to each other once wound. Figure 4 In the image, a side sectional view 246 of the top of the tube 240 is provided above the mandrel 245 to show the side-by-side arrangement of continuous turns of the web material strip 241. The following section discusses... Figure 5 The determination of the entry angle α is described in more detail.

[0225] Figure 5 A schematic side view of an apparatus 300 is shown for forming a tube 340 from a plurality of substantially continuous strips 341a to 341d of web material spirally wound around a mandrel 345. Figure 5 Device 300 is similar to Figure 4 The equipment is 200, but Figure 5 Device 300 is not used as Figure 4The tube 340 is formed not by a single strip of web material, but by multiple substantially continuous strips 341a to 341d of web material. Figure 5 The equipment 300 and associated methods can be used to form inner or outer tubular segments of tubular elements for aerosol-generating articles.

[0226] Each of the multiple strips 341a to 341d of the web material has the same width and is supplied to the mandrel 345 at an angle α relative to the longitudinal axis of the mandrel 345. The angle α of each of the multiple strips 241 of the web material and the pitch of the helix formed by each strip are selected such that each strip 241 of the web material, once wound, does not overlap with itself, but follows a specific path. Figure 4 The spiral trajectory is shown side-by-side. Multiple strips 341a to 341d of web material are supplied to the bottom of the mandrel. Web material strip 341 is at the top and forms the innermost layer of tube 340. Web material strips 341b to 341d are arranged continuously below strip 341a in a partially overlapping manner, forming another partially overlapping layer of tube 340. Figure 5 In the diagram, a side cross-sectional view 346 of the top of the tube 340 is provided above the mandrel 345, and multiple strips 341a to 341d of the web material forming a continuous overlapping layer of the tube 340 are shown. Strip 341a forms the innermost layer, and strip 341d forms the outermost layer. The overlapping strips 341a to 341d of the web material help to reinforce the tube 340, wherein the overlapping portions of the outer strips 341b to 341d reinforce certain points of the tube 340 where the side edges of the strips 341a to 341d are adjacent.

[0227] It should be understood that the strips of the web material 341a to 341d are essentially continuous, that is, their length is greater than that of the web material strips 341a to 341d. Figure 5 The strips shown are much longer. Each of the web material strips 341a to 341d is typically stored on its own spool or drum (not shown). The substantially continuous strips 341a to 341d of web material are unwound from the spool and guided to the mandrel via one or more corresponding alignment and tension rollers (not shown). Although Figure 5 The bends in strips 341b to 341d are shown, but this is purely for illustration purposes. Although Figure 5 Only four strips 341a to 341d of the web material are shown, but it should be understood that any suitable number of strips can be used, and the number of strips determines the specific thickness of the tube 340.

[0228] exist Figure 5In this example, the innermost strip 341a of the web material has no adhesive coating, while the other strips 341b to 341d of the web material have an adhesive coating 347 that substantially covers their entire inner surface. The outer surfaces of strips 341b to 341d are not coated with adhesive. It should be understood that other gluing or bonding arrangements can be used. For example, the surfaces of the web material strips may be partially coated with adhesive. Furthermore, the outer surfaces of the inner strips 341a to 341c may instead be coated with adhesive.

[0229] Fast-acting adhesives, such as ethylene-vinyl acetate (EVA) adhesives, can be used to coat web material strips 341a to 341d. The advantage of fast-acting adhesives is that the strip is fixed into a tubular shape during the spiral winding process. Slower-acting adhesives, such as polyvinyl acetate (PVA), can also be used alone or in combination with EVA. PVA reaches full strength once dry, and therefore a drying station is preferred downstream of the winding process. The adhesive is preferably a liquid adhesive applied via an adhesive roller or through an adhesive nozzle.

[0230] The entry angle α of the web material strips 341a to 341d depends on the strip width and thickness, the mandrel diameter, and the order of a particular strip among the multiple strips 341a to 341d supplied to the mandrel. The angle α used for the strips 341a to 341d should ensure that each strip completes a full turn when wound around the mandrel or around the mandrel and the strip below, and produces a left-right arrangement with itself, i.e., the opposite side edges of each strip of the web material are arranged adjacent to or adjacent to each other once wound, as shown in section 346. In other words, the pitch of the helix of the strip around the mandrel should be equal to the width of the strip.

[0231] The entry angle α of the innermost strip wound on the mandrel can be calculated as follows:

[0232] Equation (1)

[0233] Where the pitch is equal to the width of the strip, D is the inner diameter of the tube, and πD is the inner circumference of the tube, in which case the inner circumference is equal to the outer circumference of the mandrel.

[0234] Therefore, applying Equation 1 to a tube 340 with an inner diameter of 5 mm wound on a mandrel with an outer diameter of 5 mm and to a strip of web material with a width of 10 mm, the innermost strip (i.e., Figure 5 The entry angle α of strip 341a in the middle:

[0235]

[0236] Therefore, angle α equals 32.5 degrees.

[0237] For continuous strips forming a continuous layer in a tube, the winding diameter of the mandrel needs to take into account the already wound underlying layer. For example, if we use standard 80 g / m² uncoated paper with a thickness of approximately 100 micrometers, then for manufacturing the second strip of the second layer (i.e., Figure 5 The circumference of the mandrel with a diameter of 5 mm (strip 341b) will be calculated based on a diameter of 5.1 mm (i.e., the outer diameter of the mandrel plus the thickness of the first layer 341a).

[0238] More generally, the entry angle α of the continuous strip wound on the mandrel can be calculated as follows:

[0239] Equation (2)

[0240] Where W and T are the width and thickness of the web material strip, respectively, D is the inner diameter of the tube or the outer diameter of the mandrel, and N is the order of the web material strips among multiple strips, where N=1 indicates the innermost strip.

[0241] Therefore, applying Equation 2 to a strip of web material with an inner diameter of 5 mm, a width of 10 mm, and a thickness of 100 micrometers, the fourth strip (i.e. Figure 5 The strip 341d in the middle will have an entry angle α equal to the following:

[0242]

[0243] Therefore, the angle α of the fourth band is 31.0 degrees.

[0244] When a tube 340 is formed by winding web material strips 341a to 341d around one end of a mandrel 345, it extends its length and advances toward the other end (not shown) of the mandrel 345, from which the tube is removed. The stable withdrawal speed of the tube 340 is approximately 40 to 60 meters per minute. When using web material strips 341a to 341d with a width of 10 mm, this means that the tube 340 advances approximately 10 mm per turn or revolution on the mandrel 345. Therefore, a suitable rotational speed for the mandrel 340 is between 4000 and 6000 revolutions per minute. The web material strips 341a to 341d advance toward the mandrel with the inner circumference of the tube per turn or revolution. Therefore, for a mandrel with a diameter of 5 mm, the strips 341a to 341d advance toward the mandrel at a speed between 62 and 94 meters per minute.

[0245] The thickness of the tube's peripheral wall depends on the thickness of the web material used and the number of strips in the web material. This is necessary to produce a standard 80 g / m² (gsm) uncoated paper with a thickness of approximately 100 micrometers. Figure 1A The 1.05 mm circumferential wall thickness of the outer tubular segment 17 of the tubular element 12 will require approximately 10 layers or strips of paper. To produce using the same paper... Figure 1A The 0.85 mm circumferential wall thickness of the inner tube segment 15 of the tubular element 12 will require approximately 8 or 9 layers or strips of paper.

[0246] The inventors have discovered that it is possible to produce a 1 mm peripheral wall thickness using a relatively thick web material (i.e., a web material with a thickness of approximately 0.33 mm) with only 3 layers of web material. The inventors have also discovered that it is possible to produce a thicker peripheral wall using 20 or more layers of web material.

[0247] Figure 6 A schematic perspective view of another apparatus 400 for forming a tube by spirally winding multiple substantially continuous strips of web material is shown. Figure 6 Device 400 is similar Figure 5 The apparatus 300 operates in the same manner, but other features used in the winding process are shown. The apparatus 400 includes a mandrel 445 around which multiple substantially continuous strips 448 of web material are wound. A drive unit 447 is disposed at a first end of the mandrel 445, which rotates the mandrel 445 clockwise at a desired rotational speed about its longitudinal axis. As the tube 440 is formed by helically winding the web material strips 448 around the mandrel 445, the tube is also pulled along the mandrel 445 in the direction of arrow A by an elastic band 451, which wraps around the outer surface of the tube 440 in a figure-eight path and is continuously driven by two vertical rollers or rolls 450 on either side of the tube 440.

[0248] The apparatus 400 may also include leveling rollers (not shown) positioned on either side of the mandrel 445 to apply pressure to the layer of tube 440 formed by the web material strip 448 and to level any protruding edges downwards. The tube 400 may also enter a dryer or cooler station (not shown) to dry or cure the adhesive bonding the web material strip 448. Finally, the apparatus 400 includes a cutter (not shown) that cuts the substantially continuous tube 440 exiting the mandrel 445 into tube segments. The cutter may cut the tube 400 into double-length or single-length tube segments as needed.

[0249] Figure 7 A schematic side view of an apparatus 500 is shown for wrapping an inner tube segment 503 parallelly within a web material 531 to form a substantially continuous outer tube 532 and for cutting the outer tube 532 to predetermined dimensions. The inner tube segment 503 has been prepared by a helical winding process (e.g., Figure 6 The device 400) was generated and has now been transferred to Figure 7 500 pieces of equipment are available for further manufacturing.

[0250] exist Figure 7In device 500, the material flow of inner tube segments 503 is supplied onto a moving delivery path in the form of a conveyor 507. The longitudinal axes of the inner tube segments 503 are aligned as they are supplied onto the conveyor 507. The inner tube segments are double-length inner tube segments, wherein each inner tube segment has… Figure 1A The length L1 of the first tubular portion 14 of the tubular element 12 is twice that of the tubular portion 14, i.e., 16 mm. A predefined space 505 exists between the continuous inner tubular segments 503. The predefined space is equal to... Figure 1A The length L2 of the second tubular portion 16 of the tubular element 12 is twice that of the tubular portion 16, i.e., 16 mm. Conveyor 507 conveys spaced-apart inner tube segments 503 to actuator station or device 509, where the inner tube segments 503 are wrapped parallel to each other in a substantially continuous strip 531 of web material unwound from reel or spool 511. The web material strip 531 is supplied to actuator 509 such that its lateral sides are parallel to the longitudinal axis of the inner tube segments 503. The flow of material from the spaced-apart inner tube segments 503 is placed on top of the web material strip 531. In actuator 509, the web material strip 531 is wrapped parallel to the longitudinal axis of the inner tube segments 503 such that the lateral sides of the web material strip 531 are brought closer together, as described below regarding... Figure 8A To describe in more detail.

[0251] Once the inner tube segment 503 has been wrapped parallel to the web material strip 531, the wrapped inner tube segment 503 is conveyed via conveyor 507 to a gluing station or device 513, where glue or adhesive is applied to the lateral side of the web material strip 531, or to one or both main surfaces of the web material strip 531 in areas adjacent to the lateral side of the web material strip 531. (See below for more details.) Figure 8B In more detail, the lateral sides of the web material strip 531 are then glued together in an adjacent or overlapping manner to form a substantially continuous outer tube 532 around the inner tube segment 503.

[0252] The following text is about Figure 8C In more detail, after gluing, the substantially continuous outer tube 532 is conveyed by conveyor 507 to a compression station or device 515, in which the lateral sides of the web material strip 531 are compressed to provide a strong bond between the lateral sides. Then, as described below... Figure 8D Described in more detail, the substantially continuous outer tube 532 is conveyed via conveyor 507 to a drying or cooling station or device 517 to dry or cure the adhesive holding the web material strip together side by side. Finally, the substantially continuous outer tube 532, including inner tube segments 503, is conveyed via conveyor 507 to a cutter 519, which cuts the outer tube 532 and the inner tube segments to form individual tubular elements 512.

[0253] Figure 7A It shows in more detail when the inner tube segment is supplied to Figure 7 A schematic side view of the spaced arrangement between the inner tube segments 503 in the device 500. As discussed above, each inner tube segment 503 has a length of 16 mm 2L1 (i.e., Figure 1A The inner tube segment is twice the length L1 of the first tubular portion 14 of the tubular element 12. Each space 505 between the continuous inner tube segments 503 is 2L2 with a length of 16 mm (i.e., Figure 1A The double space is twice the length L2 of the second tubular portion 16 of the tubular element 12. However, it should be understood that different double lengths or spaces can be used depending on the lengths of the first and second tubular portions of the tubular element. For example, the double space between inner tube segments can be 18 mm.

[0254] Figures 8A to 8D It shows that respectively in Figure 7 A schematic cross-sectional view of the preforming device 509, bonding device 513, compression device 515, and drying device 517 used in the equipment 500. (Reference) Figure 8A The preforming device 509 includes a flexible guide belt 521 that receives the web material strip 531 and the material flow of the inner tube segment 503 on its upper surface. The guide belt 521 extends in a direction parallel to the longitudinal axis of the inner tube segment 503. The preforming device includes a forming element (not shown) having a generally U-shaped or partially circular groove with a radius of curvature that gradually decreases along the length of the forming element. The guide belt 521 passes longitudinally through the groove in the forming element. The gradually decreasing radius of curvature of the groove causes the guide belt 521 and the web material strip 531 received thereon to gradually fold or wrap around the inner tube segment 503, such that the lateral sides 531a and 531b of the web material strip 531 move toward each other.

[0255] refer to Figure 8B The gluing device 513 includes a glue head 523 that applies glue or adhesive to the lateral sides 531a and 531b of the web material strip 531, or to areas on one or both main surfaces of the web material strip 531 adjacent to the lateral sides 531a and 531b of the web material strip 531. The lateral sides 531a and 531b of the web material strip 531 are then glued together in an adjacent or overlapping manner to form a substantially continuous outer tube 532 around the inner tube segment 503.

[0256] refer to Figure 8CThe compression device 515 includes a compressor 525 configured to press the lateral sides 531a and 531b of the web material strip together to provide a strong engagement between the lateral sides 531a and 531b.

[0257] refer to Figure 8D The drying or cooling device 517 includes a dryer for drying or curing the adhesive applied by the gluing device in order to help provide a good bond.

[0258] Figure 9 It is shown that the substantially continuous outer tube 532, including the inner tube segment 503, is Figure 7 A schematic side view of the location where the cutter 519 of the device 500 cuts to form individual tubular elements 512. In the substantially continuous outer tube 532, the inner tube segments 503 are each double-length inner tube segments, each having a length 2L1 of 16 mm. Each space 505 between the continuous inner tube segments 503 is a double space with a length 2L2 of either 16 mm or 18 mm. The substantially continuous outer tube 532 in... Figure 9 The sections at positions 534 and 536, indicated by dashed lines, are cut. At position 534, the substantially continuous outer tube 532 and inner tube segment 503 are cut at the midpoint of each double-length inner tube segment 503. At position 536, the substantially continuous outer tube 532 is cut at the midpoint of each double-length space 505 between the inner tube segments 503. Figure 1A As shown, individual tubular elements 512 are produced by cutting at the midpoint of each double-length inner tube segment 503 and double space 505, each having a first tubular portion 14 with a length L1 of 8 mm and a second tubular portion 16 with a length L2 of 8 mm or 9 mm.

[0259] Figures 10A to 10E An apparatus and method for parallelly wrapping inner tubular segments within a web material are shown, along with the resulting tubular element. When using materials such as those made from... Figure 7 The equipment 500 uses a parallel packaging process to manufacture, for example, Figure 10E When creating the tubular element shown, it is desirable to produce an outer tubular segment with a circumferential wall thickness of approximately 0.5 to 1 mm, ensuring sufficient strength for the second tubular portion of the tubular element. Two options exist for achieving this. The first option involves using a single layer of web material of appropriate thickness. The standard web material used in the parallel wrapping process is 40 gsm paper with a thickness of approximately 55 micrometers. A thicker web material of approximately 1 mm could be used. However, when attempting to use a thicker web material, the gluing process becomes more complex, and the compression stage requires applying high pressure to the tube, which could compromise the ellipticity or roundness of the final tubular element. The second option is to use a parallel wrapping process multiple times, where another layer of web material is added each time a parallel wrapping process is performed, until the desired thickness is achieved.

[0260] Figure 10A A schematic diagram of an apparatus 600 for parallel wrapping of multiple layers of web material around an inner tube segment 603 is shown. Specifically, Figure 10A The apparatus 600 is configured to wrap ten layers of 40 gsm packaging paper in parallel around the inner tube segment 603. This type of paper can have a thickness between 0.032 mm and 0.055 mm. For the purposes of this example, a thickness of 0.05 mm is used. The inner tube segment 603 has been manufactured using the aforementioned spiral winding process and has an inner diameter of 3.3 mm and a circumferential wall thickness of 1.4 mm to provide an outer diameter of 6.1 mm. This inner tube segment 603 in… Figure 10D As shown in the diagram, the desired final outer diameter of the outer tube is 7.1 mm. Therefore, a circumferential wall thickness of 0.5 mm is required. This can be achieved by wrapping ten layers of 40 gsm paper in parallel around the inner tube segment 603.

[0261] Figure 10A The device 600 includes having Figure 7 The parallel wrapping equipment 601 comprises a preforming device 509, a gluing device 513, a compression device 515, and a drying device 517. (Example) Figure 7 As shown, the material flow of spaced-apart inner tube segments 603 is first supplied to a parallel wrapping device 601, and a strip of web material (not shown) is wrapped parallel around the spaced-apart inner tube segments 603 to form a substantially continuous first outer tube 632.

[0262] The device also includes a rotary blade 661 that cuts the first outer tube 632 to form a plurality of first outer tube subassemblies 640. It should be noted that... Figure 10A Only one first outer tube assembly 640 is shown. Figure 10A In this example, each first outer tube assembly 640 includes a single-length inner tube segment 603a at each end of the first outer tube assembly 640, and an intermediate section 642 comprising nine double-length inner tube segments 603b arranged between the single-length inner tube segments 603a at each end of the first outer tube assembly 640. Thus, each first outer tube assembly 640 includes twenty final-length tubular elements. The number of double-length inner tube segments 603b in the intermediate section 642 of the first outer tube assembly 640 is typically represented by N. In this example, N equals nine, and the device is configured to provide N+1 or ten layers of web material.

[0263] like Figure 10AAs indicated by arrow B, each of the plurality of first outer tube assemblies 640 is then fed back into the parallel wrapping device 601 to wrap the plurality of first outer tube assemblies 640 in a second layer of web material (not shown) to form a second outer tube (not shown) around the first outer tube assembly. The second outer tube and one of the nine double-length inner tube segments of each first outer tube assembly are cut at the midpoint of the double-length inner tube segment to form the plurality of second outer tube assemblies (not shown). Each second outer tube assembly has a similar construction to the first outer tube assembly, as they include a single-length inner tube segment at each end of the first outer tube assembly, and nine double-length inner tube segments between the single-length inner tube segments.

[0264] Then, multiple second outer tube assemblies are fed back to the parallel wrapping device 601 and undergo further wrapping and cutting steps to form additional outer tube assemblies. Each time the outer tube assembly passes through the parallel wrapping device 601, an additional layer of web material is added to the outer tube assembly. Thus, by refeeding the outer tube assembly through the parallel wrapping device eight (N-1) times, an outer tube with ten (N+1) layers of web material can be produced. Each time the outer tube assembly passes through the parallel wrapping device 601, the outer diameter of the forming element is adjusted to account for the added additional layer of web material. Each time the outer tube assembly passes through the parallel wrapping device 601 and is cut by the rotary cutter 661, the outer tube assembly is cut at the midpoint of the previously uncut inner tube segment.

[0265] Figure 10B It is by Figure 10A A schematic cross-sectional side view of the outer tube assembly 640 produced by the device, showing the continuous cutting of the outer tube assembly 640 each time it passes through the parallel wrapping device 601 (by... Figure 10B The positions are indicated by the dashed lines in the diagram. A first cut is made at position 634a to form a first outer tube assembly. A second cut is made at position 634b to form a second outer tube assembly. Third and fourth cuts are made at positions 634c and 634d, respectively, to form a third and a fourth outer tube assembly. Further cuts (not shown) are made until all nine double-length inner tube segments 603b have been cut. In this manner, each time an outer tube assembly passes through the parallel wrapping device 601 and is cut, the outer tube assembly is cut at the midpoint of a previously uncut inner tube segment 603b.

[0266] Figure 10C It is shown that in ten passes Figure 10A Equipment 600 after Figure 10AA schematic cross-sectional side view of the outer tubular assembly 640 produced by the device. The peripheral wall thickness T1 of the first tubular portion of each tubular element is now 1.9 mm, i.e., 0.5 mm of thickness has been added to the 1.4 mm thickness of the inner tubular segment by adding 10 layers of 40 gsm paper. The peripheral wall thickness T2 of the second tubular portion of each tubular element is now 0.5 mm and is defined by 10 layers of 40 gsm paper. The outer tubular assembly 640 includes twenty final-length tubular elements 612, each having a length Lp of 16 mm, which include the intermediate portions 642 of the outer tubular assembly 640, each having been... Figure 10A The device 600 cuts nine double-length inner tube segments 603b in half. The outer tube assembly 640 is then cut a final time at cut lines 634 and 635 at each end of each tubular element 612 to produce tubular elements 612 of the final length. These tubular elements 612 are... Figure 10E As shown in the image.

[0267] Figure 11 It is used to manufacture tubular components for aerosol-generating articles (e.g.) Figure 1A tubular element 12 or Figure 2A A flowchart of another method for forming a tubular element 112. The method includes a first step S1 of forming a substantially continuous inner tube from multiple layers of web material using the spiral winding process described above.

[0268] In the second step S2, the method includes cutting the substantially continuous inner tube to form multiple inner tube segments. Figure 1A In the case of the tubular element 12, the inner tube segment 15 will be cut into the length L1 of the first tubular portion 14 of the tubular element 12. Figure 2A In the case of the tubular element 112, the inner tube segment 115 will be cut to the length of the tubular element 112 (L1+L2). It should be understood that the inner tube can be cut to form an inner tube segment of double length, in which case another cutting step will be required to cut the inner tube segment to its desired length.

[0269] In the third step S3, the method includes forming a substantially continuous outer tube from multiple layers of web material using the spiral winding process described above. The web material used to form the outer tube can be the same type of material as the web material used to form the inner tube, or, for example, a different web material can be used if different properties are required for the outer tube. The outer tube has an inner diameter that is substantially the same as the outer diameter of the inner tube.

[0270] In the fourth step S4, the method includes cutting the substantially continuous outer tube to form multiple outer tube segments. Figure 1A In the case of tubular element 12, the outer tube segment 17 will be cut into lengths L1 + L2 of tubular element L12. Figure 2AIn the case of the tubular element 112, the outer tube segment 117 will be cut to the length L2 of the second tubular portion 116 of the tubular element 112. It should be understood that the outer tube can be cut to form an outer tube segment of double length, in which case an additional cutting step will be required to cut the outer tube segment to its desired length.

[0271] In the fifth step S5, the method includes inserting the inner tube segment into a corresponding outer tube segment within the outer tube segment. Although the outer tube segment has an inner diameter substantially the same as the outer diameter of the inner tube segment, sufficient tolerance exists in at least one of the diameters to allow for easy insertion, i.e., inserting the inner tube segment into the outer tube segment does not require excessive force. Preferably, the outer tube segment has an inner diameter slightly larger than the outer diameter of the inner tube segment, or the inner tube segment has an outer diameter slightly smaller than the inner diameter of the outer tube segment. Suitable tolerances are typically between 0.1 mm and 0.3 mm.

[0272] In the sixth step S6, the method includes securing the outer surface of the inner tube segment to the inner surface of its corresponding outer tube segment. This can be accomplished by applying an adhesive to the outer surface of the inner tube segment or the inner surface of the outer tube segment, or both, prior to insertion step S5. Securing the inner and outer tube segments typically involves curing or drying the adhesive to ensure a strong bond between the inner and outer tube segments, and the tubular element having an integral first tubular portion and a second tubular portion.

[0273] Figures 12A to 12D It shows how it can be applied. Figure 11 The method involves steps to manufacture a tubular element 712 having a first tubular portion and a second tubular portion with different inner diameters. The tubular element 712 includes an inner tubular segment 715 and an outer tubular segment 717. The tubular element 712 has... Figure 1A The tubular element 712 has the same shape and size. Specifically, the inner tube segment 715 and outer tube segment 717 of the tubular element 712 have the same dimensions as... Figure 1A The inner tube segment 15 and the outer tube segment 17 of the tubular element 12 are the same, and... Figure 12A As shown above. Furthermore, the arrangement of these components within the tubular element 712 is similar to... Figure 1A The arrangement is the same in the tubular element 12. However, Figure 12A The outer tube segment 717 of the tubular element 712 is used with Figure 1A The outer tube segments of the tubular element 12 are manufactured using different methods. Figure 12A The outer tube segment 717 of the tubular element 712 is made using a spiral winding process, rather than by wrapping one or more layers of web material in parallel around the inner tube segment 715.

[0274] refer to Figure 12AThis shows the tubular element 712 in a disassembled state, i.e., the inner tube segment 715 is separated from the outer tube segment 717. Figure 12A Both the inner tube segment 715 and the outer tube segment 717 in the tubular element have been spiral wound using, for example, a spiral winding process. Figure 5 Or the device shown in Figure 6. The inner tube segment 715 is configured to be inserted into the outer tube segment 717 in the direction of arrow C. The 5 mm outer diameter of the inner tube segment 15 is substantially the same as the 5 mm inner diameter of the outer tube segment 17 to achieve a tight fit. However, as mentioned above regarding Figure 11 As discussed, it should be understood that one or both of these diameters will have sufficient tolerance to allow the inner tube segment 15 to be inserted into the outer tube segment 17 without excessive force. Preferably, the inner tube segment 715 has an outer diameter smaller than the inner diameter of the outer tube segment 717. Any resulting gap (not shown) may be at least partially filled with glue or adhesive to provide fluid buffering during insertion and to provide an airtight connection between the inner tube segment 715 and the outer tube segment 717 after the glue has cured.

[0275] Figure 12B The assembly state is shown. Figure 12A The tubular element 12, wherein the inner tube segment 15 is inserted into the outer tube segment 17. The inner tube segment 715 and the outer tube segment 717 are... Figure 12A The arrangement of these components in the tubular element 712 Figure 1A The arrangement is the same in the tubular element 12.

[0276] Figure 12C A rotating nozzle 772 is shown, which is used for surrounding Figure 12A and 12B A line of glue or adhesive 773 is applied circumferentially to the inner surface of the outer tube segment 717 of the tubular element 712, as shown in a perspective view. The glue line 773 is applied before the inner tube segment 715 is inserted. The glue is EVA glue, but other suitable glues may be used. The glue provides a connection between the inner tube segment 715 and the outer tube segment 717 during and after the insertion of the inner tube segment 715. It should be understood that the glue line 773 may also be applied circumferentially to the outer surface of the inner tube segment 715.

[0277] Figure 12D It is in the assembly state. Figure 12A and 12B A perspective view of a tubular element. Figure 12D There is a [something] on the right side. Figure 12DEnlarged view E shows the interface between the outer surface of the inner tube segment 715 and the outer tube segment 717 within the area enclosed by the circle marked e. Enlarged view E shows the adhesive or glue line 773 between the inner tube segment 715 and the outer tube segment 717. The glue line 773 securely attaches the inner tube segment 715 and the outer tube segment 717 to provide a tubular element 712 having an integral first tubular portion and a second tubular portion. The glue line 773 also facilitates the adjustment of the position of the inner tube segment 715 and the outer tube segment 717 during insertion and creates an airtight barrier to prevent leakage between the inner tube segment 715 and the outer tube segment 717.

[0278] Figure 13 It shows the assembly Figure 12A and 12B An apparatus 800 comprising inner tube segments 715 and outer tube segments 717 of a tubular element 712. The apparatus 800 includes a roller 874 rotatable about its longitudinal axis. The outer peripheral surface 874a of the roller 874 holds a plurality of inner tube segments 715 and outer tube segments 717, wherein consecutive inner tube segments 715 and outer tube segments 717 are arranged circumferentially around the roller and parallel to each other. The longitudinal axis of each outer tube segment 717 is aligned with the longitudinal axis of a corresponding inner tube segment 715. Although... Figure 13 Not shown, but the inner tube segment 715 is arranged on a step extending circumferentially around the drum to align the longitudinal axes of the inner tube segment 715 and the outer tube segment 717. The outer peripheral surface 874a of the drum 874 is porous. The inner tube segment 715 and the outer tube segment 717 are held on the outer peripheral surface 874a of the drum 874 by air suction, which acts through the porous outer surface in the direction that counteracts the centrifugal force acting on the inner tube segment 715 and the outer tube segment 717. However, the inner tube segment 715 and the outer tube segment 717 are still able to slide longitudinally on the outer peripheral surface 874a of the drum 874.

[0279] The device 800 also includes a fixed track 875 that remains stationary relative to the rotation of the roller 874. The fixed track 875 has a cam surface 875a on the side of the track facing the inner tube segment 715 and the outer tube segment 717. The cam surface 875a is tapered and widens in the direction of rotation of the roller 874. When the roller 874 rotates, the end of the inner tube segment 715 facing the fixed track 875 engages the fixed track 875 and is pushed into the outer tube segment 717 by the cam surface 875a as the roller rotates.

[0280] Equipment 800 can be part of a larger overall production line for aerosol-generated articles and can be placed in a spiral winding device (e.g., Figure 5 Between a spiral winding device (or a 6-type spiral winding device) and another device used for assembling aerosol-generated products.

[0281] It should be understood that Figure 11 The steps of this method can also be applied to the manufacture of tubular elements having a first tubular portion and a second tubular portion with different outer diameters. This tubular element 912... Figure 14 As shown in the diagram, the tubular element 912 includes an inner tube segment 915 and an outer tube segment 917. The tubular element 912 has a... Figure 2A The tubular element 712 has the same shape and size. Specifically, the inner tube segment 915 and outer tube segment 917 of the tubular element 712 have the same dimensions as... Figure 2A The inner tube segment 115 and the outer tube segment 117 of the tubular element 112 are the same. Although in Figure 14 The images are shown upside down, but it should be understood that the arrangement of the inner tube segment 915 and the outer tube segment 917 in the tubular element 912 is the same as... Figure 2A These components are the same as those in the tubular element 112. Figure 14 Both the inner tube segment 915 and the outer tube segment 917 in the tubular element 912 have been spiral wound, for example using Figure 5 Or the equipment shown in 6.

[0282] For the purposes of this specification and the appended claims, unless otherwise indicated, all figures representing quantities, quantities, percentages, etc., shall be understood to be modified by the term "about" in all cases. Furthermore, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically listed herein. Thus, in this context, the number A is understood to be 5 percent (5%) of A ± A. In this context, the number A can be considered to include a value within the general standard error for the measurement of the property modified by the number A. In some cases used in the appended claims, the number A may deviate from the percentages listed above, provided that the amount of deviation from A does not materially affect the essential and novel features of the claimed invention. Furthermore, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically listed herein.

Claims

1. A method for manufacturing a tubular element for aerosol generation articles, the method comprising: The inner tube is formed from multiple layers of first-layer material; Cut the inner tube to form multiple inner tube segments; The plurality of inner tube segments are supplied along a moving delivery path, wherein a predefined space exists between consecutive inner tube segments; The plurality of inner tube segments are wrapped in at least one layer of second sheet material to form an outer tube around the inner tube segments; The outer tube is cut in the space between the inner tube segments.

2. The method of claim 1, wherein the tubular element comprises a first tubular portion and a second tubular portion, and wherein cutting the inner tube comprises cutting double-length inner tube segments, each double-length inner tube segment having twice the length of the first tubular portion, and the space between the inner tube segments being twice the length of the second tubular portion.

3. The method of claim 2, wherein the outer tube is cut at the midpoint of each space between the inner tube segments, and wherein the outer tube and the inner tube segments are cut at the midpoint of each double-length inner tube segment.

4. The method according to any one of claims 1 to 3, wherein the plurality of inner tube segments are wrapped in multiple layers of the second sheet material to form an outer tube around the inner tube segments.

5. The method according to any of the preceding claims, wherein the plurality of inner tube segments are wrapped in parallel by the second sheet material.

6. The method according to any one of claims 2 to 5, wherein the outer tube comprises a first outer tube, and the method further comprises: The first outer tube is cut to form a plurality of first outer tube sub-assemblies, each first outer tube assembly including a single-length inner tube segment at each end of the first outer tube assembly, and N double-length inner tube segments between the single-length inner tube segments; The plurality of first outer tube assemblies are supplied to the moving delivery path; Wrap the plurality of first outer tube assemblies within a second layer of the second sheet material to form a second outer tube around the first outer tube assemblies; and Cut the second outer tube and one of the N double-length inner tube segments at the midpoint of one of the N double-length inner tube segments to form a plurality of second outer tube assemblies.

7. The method of claim 6, wherein the plurality of second outer tube assemblies are supplied to the moving delivery path and undergo additional wrapping and cutting steps to form additional outer tube assemblies, the additional outer tube assemblies being supplied to the moving delivery path an additional N-1 times to provide an outer tube having N+1 layers of the second web material.

8. A method for manufacturing a tubular element for aerosol generation articles, the method comprising: The inner tube is formed from multiple layers of first-layer material; Cut the inner tube to form multiple inner tube segments; An outer tube is formed from multiple layers of third-layer material, the outer tube having an inner diameter that is substantially the same as the outer diameter of the inner tube; The outer tube is cut to form multiple outer tube segments, each outer tube segment having a different length than the inner tube segment; Each inner tube segment is inserted into a corresponding outer tube segment of the outer tube segment; The outer surface of the inner tube segment is fixed to the inner surface of the outer tube segment.

9. The method according to any one of the preceding claims, wherein forming the inner tube comprises spirally winding a plurality of substantially continuous strips of the first web material.

10. The method of claim 8 or 9, wherein forming the outer tube comprises a plurality of substantially continuous strips spirally wound around the third sheet material.

11. The method of claim 9 or 10, wherein the plurality of substantially continuous strips are spirally wound in an overlapping manner around a cylindrical mandrel to form a substantially continuous tube on the mandrel.

12. The method of claim 10 or 11, wherein, except for the innermost substantially continuous strip, the inner surface of each of the plurality of substantially continuous strips is coated with an adhesive.

13. The method according to any one of claims 10 to 12, wherein the width of the substantially continuous strip is between 10 mm and 50 mm.

14. The method according to any one of the preceding claims, wherein the inner tube or the outer tube respectively comprises 1 to 20 layers of the first web material or the third web material.

15. The method according to any one of the preceding claims, wherein the thickness of the first web material or the third web material or both the first web material and the third web material is between 0.05 mm and 0.1 mm.

16. The method according to any one of claims 1 to 7, wherein the thickness of the second sheet material is between 0.05 mm and 1.1 mm.

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