Subunit for a smoking article, method and apparatus for manufacturing said subunit

Abstract

Subunit (1) for a smoking article (2), comprising a first portion (4) comprising at least one material (6) with additives and / or flavoring material and a second portion (5) at least partially adjacent to, preferably in contact with, the first portion (4) and comprising an aerosol-forming material (7) at least partially shredded or cut into strips In particular, the material (6) of the first portion (4) comprises at least one weakening pattern.

Description

[0001] “SUBUNIT FOR A SMOKING ARTICUE, METHOD AND APPARATUS FOR MANUFACTURING SAID SUBUNIT”

[0002] Cross-Reference to Related Applications

[0003] This Patent Application claims priority from Italian Patent Application No. 102023000016887 filed on August 7, 2023, the entire disclosure of which is incorporated herein by reference.

[0004] Technical Field

[0005] The present invention relates to a subunit for a smoking article and a relative method and apparatus for manufacturing said subunit.

[0006] In particular, the subunit is obtained using an aerosol-forming material, for example a material based on tobacco (non-limiting list: reconstituted tobacco, pre-treated tobacco, homogenized tobacco) or other vegetable fiber materials (rapeseed, cellulose, hemp).

[0007] The invention can be advantageously, but not exclusively, applied in a subunit for the manufacture of conventional cigarettes with a filter, the end of which opposite the filter can be burnt to produce aerosols, or of new generation cigarettes, such as heat-not-bum cigarettes in which the aerosol-forming material can be heated electrically or with charcoal.

[0008] Background Art

[0009] Subunits for smoking articles comprising, in addition to the aerosol-forming material, also a material with additives, are currently know.

[0010] In known subunits the aerosol-forming material and the material with additives are typically superimposed on one another, both crimped together and subsequently gathered (keeping the web with additive on the outside), so as to produce a continuous strand that is subsequently separated into single subunits. However, these subunits have the drawback that, as the two webs of material are crimped together, they remain integral with each other; therefore, after being gathered a continuous strand comprising a single portion having the two materials blended together is obtained.

[0011] Alternatively, subunits are known in which the aerosol-forming web and the web with additive are superimposed on one another, both cut together and subsequently gathered, so as to produce a continuous strand that is subsequently separated into single subunits.

[0012] Also in this case, as both the materials are superimposed and then cut together, the two materials are mixed together. Therefore, also in this case, after being gathered a continuous strand is obtained, comprising a single portion having the two materials mixed together.

[0013] Moreover, known subunits have the drawback that conventional smoking articles, but also new generation smoking articles, comprising this subunit, are unable to guarantee a constant smoking experience during the whole of the use of the smoking article. In fact, typically, towards the end of the smoking experience, as the components of the materials have evaporation temperatures to generate aerosols of different type, and as the two materials are mixed together, there is no longer a balanced aerosol generation. In other words, the aerosol generated does not comprise the desired aerosol component formed by the aero sol- forming material and the desired additive component released by the web with additive.

[0014] US2022132907 discloses a smoking article provided with a subunit comprising a core portion that is surrounded by a second portion, which is arranged outside the core portion.

[0015] Description of the Invention

[0016] The object of the present invention is to provide a subunit for a smoking article and a relative method and apparatus for manufacturing said subunit, which do not have the drawbacks described above and are, at the same time, simple and inexpensive to manufacture.

[0017] In accordance with the present invention there is provided a subunit for a smoking article, in particular rod-shaped, as claimed in the appended claims.

[0018] Moreover, in accordance with the present invention there is also provided a method for manufacturing the subunit, as claimed in the appended claims.

[0019] Additionally, in accordance with the present invention there is also provided an apparatus for manufacturing the subunit, as claimed in the appended claims.

[0020] The claims describe preferred embodiments of the present invention forming an integral part of the present description.

[0021] Brief Description of the Drawings

[0022] The present invention will now be described with reference to the accompanying drawings, which illustrate some non-limiting exemplary embodiments thereof, wherein:

[0023] - Fig. 1 is a schematic view in longitudinal stub of a subunit produced in accordance with the present invention;

[0024] - Fig. 2 is a schematic view in cross stub of the subunit of Fig. 1;

[0025] - Fig. 3 is a schematic view in longitudinal stub of a possible embodiment of a smoking article comprising the subunit of Fig. 1;

[0026] - Fig. 4 is a schematic view in cross stub of a different embodiment of the subunit of Fig. 1;

[0027] - Fig. 5 is a schematic view in cross stub of a further and different embodiment of the subunit of Fig. 1; and

[0028] - Figs. 6-9 are schematic plan views of possible and different embodiments of an apparatus for manufacturing the subunit of Figs. 1-5.

[0029] Preferred Embodiments of the Invention

[0030] In Figs. 1-5 the number 1 indicates as a whole a subunit for a smoking article 2 (a possible, non-limiting embodiment, of which is schematically illustrated in Fig. 3). In particular, the smoking article 2 is rod- shaped. The subunit 1 has a cylindrical shape and has a longitudinal axis X that is also an axis of symmetry.

[0031] According to a possible (non-limiting) example of embodiment illustrated in Fig. 3, in addition to the subunit 1, the smoking article 2 also comprises at least one further stub 3. In Fig. 3 a single stub 3 has been illustrated. According to embodiments not illustrated, the smoking article 2 comprises more than one stub 3. The stub 3 can for example be a filter segment or a cooling segment or a further segment of aerosol-forming material.

[0032] In accordance with what is illustrated, the subunit 1 comprises a first portion 4 and a second portion 5. The portion 4 comprises (in particular consists of) at least one material 6 with additives or to which additives are addable and / or flavoring material (i.e., provided with an additive comprising a flavor that is released, in use, to flavor the aerosol formed). The material 6 of the portion 4 comprises at least one weakening pattern. Weakening pattern means a weakening made on the material 6 according to a predefined / predetermined pattern, sequence, diagram or design, as will also be better clarified below. The weakening pattern on the material 6 is preferably made to be able to “handle” the material 6 better, i.e., to be able to give it a stable configuration in the final subunit (i.e., to be able to facilitate its arrangement and / or gathering and / or folding during forming of the subunit 1) as will be evident from the description below.

[0033] The second portion 5 is at least partially adjacent to, preferably in contact with, the first portion 4 and comprises (in particular consists of) an aerosol-forming material 7 at least partially shredded (i.e., crumbled or cut into small pieces and also known as “cut rag”) or cut into strips. Preferably, but without limitation, the strips are arranged substantially parallel to one another (in particular, arranged substantially parallel to the longitudinal axis X of the subunit 1).

[0034] In accordance with what is illustrated in Figs. 1-4, the portion 5 at least partially (in particular completely) surrounds the portion 4.

[0035] Advantageously, according to the embodiment illustrated in Figs. 1-4, the first portion 4 is coaxial with respect to the first portion 5.

[0036] In accordance with what is illustrated in Figs. 1-3, the portion 4 is arranged radially more internally with respect to the portion 5. The portion 5 is thus arranged outside the portion 4.

[0037] According to an alternative embodiment, for example illustrated in Fig. 5, the first portion 4 is arranged eccentrically, i.e., decentralized and not coaxial to the axis X, with respect to the first portion 5.

[0038] According to a further alternative embodiment, illustrated in Fig. 4, the portion 4 is arranged peripherally with respect to the portion 5. In this case the portion 4 at least partially (in particular completely) surrounds at least one part of the portion 5. In particular, according to what is illustrated the portion 5 can be embedded inside the portion 4. In other words, in this solution the portion 4 is internally and externally surrounded (with reference to its radial position from the axis X) by the portion 5.

[0039] The arrangement of the portion 4 with respect to the portion 5 can be determined based on the type of smoking article 2 to be obtained by the subunit 1.

[0040] For example, in the case in which the smoking article 2 to be manufactured with the subunit 1 is of the heat-not-bum (hnb) type, the choice of the arrangement of the portion 4 with respect to the portion 5 can be made based on the fact that the article 2 is heated from the inside of the article 2 (for example by a layer of thermally conductive material positioned or positionable inside the article 2) or from the outside of the article 2 (for example by a chamber of a heating device inside which the article 2 is arranged to be consumed).

[0041] The aerosol-forming material 7 is a material suitable to release aerosols to be inhaled or smoked during use by the user. Typically, the aerosol-forming material 7 contains active substances (for example nicotine, cannabidiol, also known as CBD), Delta-9-tetrahydrocannabinol (also known as THC), or a combination thereof.

[0042] The material 7 can be a material based on tobacco or other vegetable fibers, such as rapeseed, hemp, cellulose or a combination of these vegetable fibers.

[0043] The material 6 with additives and / or flavoring material is a material which comprises at least one additive. The material 6 to which additives are addable is a material configured to receive an additive applied thereto. The term “additive” means any of the ingredients typically used in the tobacco industry. Preferably, the additive is selected from: at least one or more aromatic substances (in particular menthol, eugenol, vanillin, limonene, cocoa, licorice, extracts from fruit, spices, herbs and flowers, honey, sugars, tobacco flavorings, or a combination thereof); and / or at least one or more substances which contribute to the generation of aerosols chosen from: a hygroscopic substance, a humectant substance, a moisturizing substance; in particular glycerin, propylene glycol, triacetin, or a combination thereof); and / or at least one or more plasticizing substances, lubricating substances, preservative substances, antiseptic substances, or a combination thereof; and / or at least one or more active substances (in particular, nicotine, cannabidiol (also known as CBD), Delta-9-tetrahydrocannabinol (also known as THC), or a combination thereof); and / or at least one excipient; and / or at least one solvent (in particular water, alcohols, oils, or a combination thereof).

[0044] Advantageously, but without limitation, the at least one additive of the material 6 is in fluid form (in particular, it is a liquid, sol, gel, gas, aerosol, or combination thereof) and / or in solid form (in particular, it is in granules or powders, or a combination thereof). In other words, the additive applied, or to be applied, to the material 6 is a fluid and / or a solid.

[0045] According to a possible (non-limiting) embodiment, the material 6 has a single additive applied thereon. Alternatively, the material 6 has more than one additive applied. In the latter case the additives applied can be different from one another. Additionally, if several additives are present they can have the same consistency (i.e., they can all be in fluid form or in solid form) or they can have a different consistency to one another.

[0046] According to a possible (non-limiting) embodiment, the material 6 can be in the form of a web of material configured to hold and transport the additive. In other words, according to this embodiment, the material 6 is a web of material configured to acquire and transport the additive. In particular, the material 6 is an absorbent material, preferably selected from: paper, cotton, other fibers of vegetable origin.

[0047] According to an alternative (non-limiting) embodiment, the material 6 can be in the form of an element configured to retain a liquid by capillarity. In other words, according to this embodiment, the material 6 is an element configured to trap a liquid by capillarity. According to a possible non-limiting example, the material 6 is a braid or a wick.

[0048] Preferably, the weakening pattern of the material 6 is obtained by mechanical processing.

[0049] Preferably, the weakening pattern of the material 6 is obtained by crimping and / or embossing and / or through or partially through cuts (i.e., slits) and / or creasing and / or rasping and / or scratching and / or removing (i.e., removal of material to obtain through or non-through openings) of material.

[0050] Alternatively, the weakening pattern of the material 6 is obtained by using a laser device, i.e., a device capable of emitting at least a laser beam arranged for producing this weakening pattern (i.e., for producing incisions and / or cuts and / or through openings and / or non-through openings and / or removals of material). The device can comprise one or more laser heads and optionally one or more reflecting surfaces to direct one or more laser beams onto the material 6.

[0051] As stated above, weakening pattern means a weakening made on the material 6 according to a predetermined pattern, sequence, diagram or design, i.e., with reference to the examples above, a sequence and / or combination of lines, through cuts, non-through cuts, through / non-through openings produced on the material 6 according to a predefined arrangement.

[0052] The material 6 is subjected to processing to reduce the mechanical strength of the material 6 such as, for example, through or partially through cuts and / or creasing and / or rasping and / or scratching and / or removal of material. In this way, the propensity of the material 6 to folding is increased, i.e., to facilitate gathering thereof during forming of the continuous strand (in particular of the continuous worm not yet wrapped by a wrapping tape 8, as described below) or arranged with a particular configuration with respect to the portion 5 (i.e., as previously described, outside the portion 5, in such as way as to surround it, or in any case at least partially peripherally to the portion 5).

[0053] Advantageously, the weakening pattern extends “continuously” or “discontinuously” along a longitudinal extension (in particular parallel to the axis X) and / or a transverse extension (in particular transverse, preferably orthogonal, to the axis X) of the material 6. The term “ continuously” means that substantially all the material 6 (along its longitudinal and / or transverse extension) is affected by the weakening pattern. Instead, the term “discontinuously” means that processed areas which are provided with the weakening pattern and intact areas (unprocessed areas) which are free from the weakening pattern are defined in the material 6.

[0054] Advantageously, the subunit 1 comprises a wrapping tape 8 arranged on the portion 5, in such a way as to at least partially (preferably completely) surround it. Typically, the wrapping tape 8 is made of paper.

[0055] According to a possible embodiment, the portion 4 is at least partially in contact with the wrapping tape 8. The portion 4 can be constrained (i.e., connected) to the wrapping tape 8, for example by an adhesive substance.

[0056] Preferably, with reference to the embodiments of Fig. 2 or of Fig. 5, the size ratio between the surfaces, considered in cross stub, between the portion 5 and the portion 4 is greater than 10%, preferably between 10% and 90%, even more preferably between 25% and 85%.

[0057] With specific reference to Fig. 2, in which the portion 4 and the portion 5 have a circular cross stub, the diameter of the portion 5 and of the portion 4 have a proportion (ratio between the two sizes) greater than 20%, preferably between 20% and 90%.

[0058] According to a further aspect of the present invention, there is provided an apparatus 10 for manufacturing a subunit 1, in particular the subunit described above.

[0059] Possible non-limiting embodiments have been schematically illustrated in Figs. 6-9.

[0060] The apparatus 10 comprises two feeding units 11 and 12, a forming unit 13 (also known as forming beam) and singularization unit 14. The feeding unit 11 is configured to provide the at least one material 6 with additives (as illustrated in Fig. 6) or to which additives are addable (as illustrated in Figs. 7-9) which defines the portion 4 of the subunit 1. The feeding unit 12 is configured to provide the aerosol-forming material 7 which defines the portion 5 of the subunit 1. The material 7 fed is at least partially cut into strips or shredded (i.e., crumbled or cut into small pieces also known as “cut rag”). Advantageously, the feeding unit 11 and / or the feeding unit 12 comprises a plurality of unwinding rollers that allow continuous feed of the material 6 or 7 along the apparatus 10 towards the forming unit 13. Preferably, but not necessarily, the materials 6 and 7 are picked up from specific storage devices, such as a reel (for materials substantially in a web) or a collection container (for example for shredded material).

[0061] The forming unit 13 is configured to form a continuous strand comprising the portion 4 and the portion 5. In particular, the forming unit 13 is configured to gather the material 6 and 7 (superimposed).

[0062] The forming unit 13 is arranged downstream of the feeding units 11 and 12 and upstream of the singularization unit 14. The singularization unit 14 is configured to cut (i.e., singularize) the continuous strand into a succession, preferably orderly, of subunits 1 having a predetermined length.

[0063] According to a possible embodiment, the forming unit 13 is configured to at least partially surround the portion 4 with the portion 5, in such a way as to form a continuous strand (in particular a continuous worm that is subsequently wrapped by the wrapping tape 8 so as to form the strand).

[0064] In this regard, the unit 13 can arrange the portion 4 coaxial or misaligned with respect to the portion 5. In the case in which the portion 4 is misaligned, it can be eccentric with respect to the axis X. Moreover, the portion can be at least partially peripheral, i.e., arranged at least partially at a peripheral portion of the portion 5 (as illustrated in Fig. 5).

[0065] Advantageously, the singularization unit 14 comprises a rotating blade or a translating blade or a cutting drum.

[0066] In accordance with what is illustrated in the accompanying figures and as described above, the apparatus 10 is configured to be fed with a material 6 already with additives (as illustrated in Fig. 6) or with a material 6 to which additives are addable (still to be added or with a further additive to be applied, as illustrated in Figs. 7-9). In the latter case, the apparatus 10 comprises at least one application unit 15 configured to apply the additive on the material 6 with additives (to which a further additive is applied) or to which additives are addable. If more than one application unit 15 of the additive is present, each can apply the same additive or each can apply a different additive on the material 6. Advantageously, the at least one application unit 15 is configured for spraying the at least one additive onto the material 6 and / or spreading the at least one additive onto the material 6 and / or atomizing the at least one additive onto the material 6 and / or drizzling the at least one additive onto the material 6 and / or pouring the at least one additive onto the material 6 and / or dropping the at least one additive onto the material 6 and / or spreading the material 6 with the at least one additive and / or immersing the material 6 in the at least one additive.

[0067] Therefore, preferably (but without limitation) the application unit 15 comprises (non-limiting list) a nozzle and / or an application roller and / or a atomizer and / or a spreader.

[0068] Advantageously, but without limitation, the application unit 15 can apply the at least one additive continuously or discontinuously along a longitudinal extension (in particular parallel to a direction DI of feed of the material 6) and / or a transverse extension (in particular transverse, in particular orthogonal, to the direction DI of feed of the material 6). In other words, the term “ continuously” means that the additive is applied on the material 6 without interruptions. Instead, the term “discontinuously” means that the additive is applied on the material 6 intermittently, defining areas provided with the additive and areas without the additive. In the case of “discontinuous” application, it can be carried out in phase with singularization by the singularization unit 14 of the continuous strand. In other words, if the application unit 15 applies the additive discontinuously, it is configured to be activated at least partially simultaneously with the singularization unit 14 di configured to cut the continuous strand.

[0069] According to a possible embodiment, not illustrated, the application unit 15 also comprises a conditioning device, in particular a heating unit, configured to condition, in particular to heat, the at least one additive before being applied on the material 6.

[0070] Advantageously, but without limitation, the apparatus 10 further comprises a preparation unit (not illustrated) configured to prepare the material 6 in such a way as to increase its capacity to hold the at least one additive applied thereon. The preparation unit is arranged upstream of the at least one application unit 15. According to a possible embodiment, the preparation unit is configured to implement the holding capacity through an action (for example electrostatically) or through the application of a substance (for example water, oil, adhesive, polyvinyl alcohol (PVA)) which promotes the hold of the additive on the material 6. According to a possible embodiment, the feeding unit 11 feeds a material 6 to which additives have already been added, onto which a further, and preferably different, additive is applied by the application unit 15.

[0071] According to the above description, the aerosol-forming material 7 fed by the unit 12 is at least partially cut into strips or shredded. The shredded aero sol- forming material 7 is fed to the apparatus 10 already in shredded form (embodiment not illustrated) or is shredded by a shredding unit (not illustrated) of the apparatus 10. Additionally or alternatively, in the case in which the aerosol-forming material 7 fed by the feeding unit 12 is in the form of strips, then it can be fed to the apparatus 10 already cut (embodiment not illustrated) or it can be cut on site by a cutting unit 16 (illustrated schematically in Figs. 6-9). In the latter case, the cutting unit 16 is configured to cut the material 7 into strips parallel to one another and parallel in particular to a direction D2 of feed of the material 7.

[0072] Advantageously, the apparatus 10 comprises a processing unit 17 configured to process the material 6 which is arranged along the feed path of the material 6, downstream of the feeding unit 11. The processing unit 17 comprises at least one device for producing the weakening pattern, for example a device for mechanical processing of the material 6. For example, the device for producing the weakening pattern can be one of the following: a crimping device 17A and / or an embossing device 17B and / or a device 17C for making through or partially through cuts (i.e., slits) and / or creasing and / or rasping and / or scratching and / or removal (i.e., removing to obtain through or non-through openings) of material in the material 6. The device for producing the weakening pattern can be a laser device.

[0073] The at least one device 17A, 17B, 17C is arranged downstream of the feeding unit 11.

[0074] Advantageously, but without limitation, the unit 17 for producing the weakening pattern (i.e., at least one between: the crimping device 17A and / or the embossing device 17B and / or the device 17C for making through or partially through cuts and / or creasing and / or rasping and / or scratching and / or removal of material in the material 6 and / or the laser device) is configured to process the material 6 continuously or discontinuously along the longitudinal extension (in particular parallel to the direction DI of feed of the material 6) and / or the transverse extension (in particular transverse, in particular orthogonal, to the direction DI of feed of the material 6) of the material 6. In other words, as described above, the term “ continuously” means that substantially all the material 6 (along its longitudinal and / or transverse extension) is affected by crimping and / or embossing and / or weakening of material (including weakening produced with the laser device). Instead, the term “discontinuously” means that processed areas which are provided with the weakening pattern and with intact (i.e., unprocessed) areas which are free of the weakening pattern are defined in the material 6. In the case of “discontinuous” production it can be carried out in phase with singularization of the continuous strand by the singularization unit 14. In other words, if the device 17C for making weakenings in the material produces the weakenings discontinuously, the device 17C making the weakenings is configured to be activated at least partially simultaneously with the singularization unit 14 configured to cut the continuous strand.

[0075] Advantageously, in accordance with what is illustrated in the accompanying figures, at least one between: the crimping device 17A and / or the embossing device 17B and / or the device 17C making the weakenings is arranged upstream or downstream of the at least one application unit 15. In other words, if the application unit 15 is single and is configured to apply a single additive on the material 6, the at least one between: the crimping device 17A and / or the embossing device 17B and / or the device 17C for making the weakenings is arranged upstream or downstream of the application unit 15. The same arrangement can be obtained with the use of a laser device (not illustrated) for producing the weakening pattern.

[0076] Alternatively, if more than one application unit 15A and 15B is present, for example as illustrated in Fig. 9, each unit 15A and 15B is configured to apply a respective additive on the same material 6. In this case, as illustrated in Fig. 9, one of these can be arranged upstream of the crimping device 17A and / or of the embossing device 17B and / or of the device 17C for making weakenings, and the other can be arranged downstream of at least one of these. According to an alternative, not illustrated, all the application units 15 are arranged upstream or downstream of the crimping device 17A and / or of the embossing device 17B and / or of the device 17C for making the weakenings. The same arrangement can be obtained with the use of a laser device (not illustrated) for producing the weakening pattern.

[0077] Advantageously, but without limitation, the processing unit 17 performs processing with the devices 17A and / or 17B and / or 17C in their preconfigured and predetermined configuration (for example, in which the center distances of the rollers or the relative distance between two components of the same device are fixed). Alternatively, the devices 17A and / or 17B and / or 17C are adjustable during production (for example in which the center distances of the rollers or the relative distance between two components of the same device are adjustable). This also applies in the case in which a laser device (not illustrated) is used to produce the weakening pattern. In accordance with what is illustrated, a wrapping unit 18 configured to wrap the worm formed by the forming unit 13 with the wrapping tape 8 is arranged downstream of the forming unit 13. In particular, the wrapping unit 18 is configured to receive the wrapping tape 8 from a feeding unit 19 of the tape 8. The feeding unit 19 is arranged upstream of the wrapping unit 18.

[0078] Advantageously, but without limitation, the apparatus 10 comprises a positioning device (not illustrated) configured to provide the material 6 with additives in the material 7. The position of the positioning device is fixed or adjustable (in particular manually or servo-assisted). In particular, the positioning device could be moved during operation of the apparatus 10, for example automatically or in feedback, in order to precisely control the current position of the material 6 with additives (i.e., so that the material 6 is correctly positioned in the predetermined position) in the aerosol-forming material 7.

[0079] Advantageously, the apparatus 10 comprises a sensor configured to detect a radial position (for example measuring the coaxiality or the distance of the outer edge of the strand) of the portion 4 with respect to the portion 5 in the continuous strand and to adjust (regulate) this radial position, in the case in which the value detected differs from (i.e., is not within) a range of reference. In the case in which the sensor detects a deviation from the range of reference, a control system of the apparatus 10 automatically allows the radial position of the material 6 in the aerosol-forming material 7 to be automatically rejected and / or corrected in feedback.

[0080] Advantageously, in addition or alternatively to the sensor described above, the apparatus 10 comprises a sensor configured to detect the amount of the at least one additive applied on the material 6 and / or a flow rate of the at least one additive applied on the material 6 and / or at least one feature, in particular geometric, of the material 6. The sensor that carries out this reading can be a microwave sensor, a capacitive sensor, an optical sensor, a so-called electronic nose (i.e., an electro-chemical sensor capable of detecting specific volatile substances). In particular, as a function of the measurement carried out by the sensor, the control system of the apparatus 10 is configured to adjust in feedback the amount of additive dispensed.

[0081] Advantageously, in addition or alternatively to the sensors described above, the apparatus 10 can have a sensor configured to detect and measure the crimping folds, the presence of and / or embossing pattern, and / or more generally the presence and / or type of weakening produced on the material 6. Advantageously, the apparatus 10 is provided with at least three feet, at least one of which is preferably adjustable in height.

[0082] According to a further aspect of the present invention, there is provided a method for manufacturing the subunit 1, in particular carried out by the apparatus 10 described above.

[0083] The method mainly (but not exclusively) comprises the steps of:

[0084] - providing (in particular by the feeding unit 11) the first portion 4 comprising at least one material 6; wherein the material 6 comprises at least one weakening pattern described above;

[0085] - providing (in particular by the feeding unit 12) the portion 5 comprising an aerosol-forming material 7 at least partially cut into strips or shredded (i.e., crumbled or cut into small pieces and also known as “cut rag”)',

[0086] - forming (in particular by the forming unit 13) a continuous strand comprising at least the first portion 4 and at least the second portion 5; and

[0087] - cutting the continuous strand (in particular, the worm continuously wrapped by the wrapping tape 8) into a succession of subunits 1 of predetermined size (in particular, by the singularization unit 14).

[0088] Advantageously, the step of providing the portion 4 comprises a further step of processing the material 6 to form the weakening pattern. The step of processing the material 6 comprises at least one substep selected from: crimping (by the crimping device 17A) and / or embossing (by the embossing device 17B) and / or making through or partially through cuts and / or creasing and / or rasping and / or scratching and / or removal of material (by the device 17C) in the material 6 and / or weakening by the laser device (not illustrated).

[0089] Advantageously, the step of processing the material 6 is made “continuously” or “discontinuously” along the longitudinal extension (in particular parallel to the direction DI of feed of the material 6) and / or the transverse extension (in particular transverse, preferably orthogonal, to the direction DI of feed of the material 6) of the material 6. The term “continuously” means that substantially all of the material 6 (along its longitudinal or transverse extension) is affected by the weakening pattern. Instead, the term “discontinuously” means that processed areas which are provided with the weakening pattern and intact areas (i.e., not processed) which are free of the weakening pattern are defined in the material 6.

[0090] In particular, if production of the weakening pattern is discontinuous, it can be carried out at least partially simultaneously with the step of cutting the continuous strand.

[0091] Advantageously, the step of providing the portion 4 comprises in addition to the step of processing a further step of applying the at least one additive on the material 6. The material 6 fed in this step can already be provided with the additives and, therefore, in this step a further additive is applied or the material 6 fed could arrive “without additives” and therefore the at least one additive is applied. The application step takes place in particular by spraying the at least one additive onto the material 6 and / or spreading the at least one additive onto the material 6 and / or atomizing the at least one additive onto the material 6 and / or drizzling the at least one additive onto the material 6 and / or pouring the at least one additive onto the material 6 and / or dropping the at least one additive onto the material 6 and / or spreading the material 6 with the at least one additive and / or immersing the material 6 in the at least one additive.

[0092] Preferably, the step of applying the at least one additive to the material 6 provides for: applying a single additive on the material 6; and in which the step of processing the material (in particular, the substep of crimping and / or embossing and / or making through or partially through cuts and / or creasing and / or rasping and / or scratching and / or removal of material and / or weakening by laser beam) takes place upstream or downstream of the step of applying the at least one additive on the material 6; or applying more than one additive; each additive is applied simultaneously or in succession; in the case in which it is applied in succession, the application step is divided into several substeps, in each of the which at least one additive is applied on the material 6 and wherein the step of processing the material (in particular, the substep of crimping and / or embossing and / or making through or partially through cuts and / or creasing and / or rasping and / or scratching and / or removal of material and / or weakening by laser beam) takes place upstream or downstream of the at least one substep of applying the at least one additive on the material 6.

[0093] Advantageously, in addition or alternatively, the application step provides that the at least one additive is applied continuously or discontinuously (i.e., intermittently) along the longitudinal extension and / or the transverse extension of the material 6 defining areas provided with the additive and areas without the additive.

[0094] Preferably, but without limitation, the step of applying the at least one additive on the material 6 comprises a further step of conditioning, in particular heating, the at least one additive upstream of or during the step of applying the at least one additive on the material 6. Advantageously, in addition or alternatively, the step of applying the at least one additive on the material 6 comprises a further step of preparing the material 6 to increase its capacity to hold the at least one additive applied thereon. The step of preparing the material 6 takes place upstream of application of the at least one additive.

[0095] Advantageously, but without limitation, the step of forming the continuous strand comprises a substep of at least partially (preferably completely) surrounding (in particular by the forming unit 13) the portion 4 with a portion 5 to form a continuous strand (in particular, a worm not yet wrapped by the wrapping tape 8).

[0096] Advantageously, but without limitation, the step of forming the continuous strand comprises a substep of arranging the portion 4 coaxial or misaligned with respect to the portion 5.

[0097] Advantageously, but without limitation, the method further comprises a step of detecting by a sensor a radial position (for example, measuring the coaxiality or the distance of the outer edge of the strand) of the portion 4 in the continuous strand and a step of adjusting (regulating) this radial position in the case in which the value detected differs from (i.e., is not comprised in) a range of reference. In the case in which the sensor detects a deviation from the range of reference, the method comprises a further step of discarding and / or correcting in feedback by the control system of the apparatus 10 the radial position of the material 6 in the aerosolforming material 7.

[0098] Advantageously, but without limitation, the method further comprises a step of detecting the amount of the at least one additive applied on the material 6 and / or a step of detecting the flow rate of the at least one additive applied on the material 6 and / or a step of detecting at least one feature, in particular geometric, of the material 6. In particular, as a function of the measurement carried out by the sensor, the control system of the apparatus 10 adjusts in feedback the amount of additive dispensed.

[0099] Advantageously, in addition or alternatively, the method further comprises a step of detecting and measuring the crimping folds and / or a step of detecting the presence of and / or the embossing pattern and / or, more in general, a step of detecting the presence and / or the type of weakening produced on the material 6.

[0100] Preferably, before the singularization step, there is provided a wrapping step (carried out by the wrapping unit 18) in which the worm formed by the forming unit 13 is wrapped with the wrapping tape 8 supplied by the feeding unit 19.

[0101] The embodiments described herein can be combined with one another without departing from the scope of protection of the present invention.

[0102] The subunit 1, its method and the manufacturing apparatus 10 described have many advantages.

[0103] Mainly, by arranging the material 6 inside the aerosol-forming material 7, this facilitates management of the material 6. In fact, typically, due to the additives or to its nature, the material 6 tends to be “sticky”. Therefore, by arranging it in the material 7, the apparatus 10 and the surrounding environment are not contaminated.

[0104] The subunit 1 allows the user to have an improved smoking experience. In fact, the subunit 1 allows an aerosol with a good balance of evaporation of the substances included in the material 6 and in the aero sol- forming material 7 to be developed.

[0105] In fact, the invention allows the additive to be applied with a pattern such as to guarantee the prompt evaporation of each component at the desired instant.

[0106] Moreover, this is further guaranteed by the fact that, as each material is destined uniquely for a specific portion (portion 4 for the material 6 with additives and portion 5 for the aerosolforming material 7), it is possible to optimize heating of the smoking article 2.

[0107] List of Reference Numbers of the Figures

[0108] 1 subunit

[0109] 2 smoking article

[0110] 3 stub

[0111] 4 portion

[0112] 5 portion

[0113] 6 material with additives and / or flavoring material

[0114] 7 aerosol-forming material

[0115] 8 wrapping tape

[0116] 10 manufacturing apparatus

[0117] 11 feeding unit 12 feeding unit

[0118] 13 forming unit

[0119] 14 singularization unit

[0120] 15 application unit 16 cutting unit

[0121] 17 processing unit

[0122] 18 wrapping unit

[0123] 19 feeding unit

[0124] X longitudinal axis DI direction

[0125] D2 direction

Claims

CLAIMS1. A subunit (1) for a smoking article (2) comprising:- a first portion (4) comprising at least one material with additives and / or flavoring material (6); wherein the material (6) of the first portion (4) comprises at least one weakening pattern; and- a second portion (5) at least partially adjacent to, preferably in contact with, the first portion (4) and comprising an aerosol-forming material (7) at least partially shredded or cut into strips.

2. The subunit (1) according to claim 1, wherein the second portion (5) at least partially surrounds the first portion (4).

3. The subunit (1) according to claim 2, wherein the second portion (5) completely surrounds the first portion (4).

4. The subunit (1) according to claim 3, wherein the first portion (4) is coaxial with respect to the second portion (5).

5. The subunit (1) according to claim 1, wherein the first portion (4) is arranged at least partially peripherally with respect to the second portion (5).

6. The subunit (1) according to claim 5, wherein the first portion (4) at least partially surrounds the second portion (5).

7. The subunit (1) according to any one of the preceding claims, wherein the material (6) comprises at least one additive selected from:- at least one or more aromatic substances; in particular menthol, eugenol, vanillin, limonene, cocoa, licorice, extracts from fruit, spices, herbs and flowers, honey, sugars, tobacco flavorings, or a combination thereof; and / or- at least one or more substances which contribute to the generation of aerosols chosen from among: a hygroscopic substance, a humectant substance, a moisturizing substance; in particular glycerin, propylene glycol, triacetin, or a combination thereof; and / or- at least one or more plasticizing substance, lubricating substance, preservative substance, antiseptic substance, or a combination thereof; and / or- at least one or more active substances; in particular, nicotine, cannabidiol, Delta-9- tetrahydrocannabinol, or a combination thereof; and / or- at least one excipient; and / or- at least one solvent; in particular water, alcohols, oils, or a combination thereof.

8. A subunit (1) according to claim 7, wherein the at least one additive of the material (6) is:- in fluid form; in particular, it is a liquid, sol, gel, gas, aerosol, or combination thereof; and / or- in solid form; in particular, it is in granules or powders, or a combination thereof.

9. A subunit (1) according to claim 7 or 8, wherein the material (6) is:- a web configured to hold and transport the additive; in particular an absorbent material, preferably selected from: paper, cotton, other fibers of vegetable origin; or- an element configured to retain a liquid by capillarity; in particular a braid or wick.

10. The subunit (1) according to any one of the preceding claims, wherein the weakening pattern of the material (6) is obtained by crimping and / or embossing and / or through or partially through cuts and / or creasing and / or rasping and / or scratching and / or removing material and / or using at least one laser beam for incisions and / or cuts and / or through openings and / or non- through openings and / or removal of material.

11. The subunit (1) according to claim 10, wherein the weakening pattern extends: continuously along a longitudinal extension and / or a transverse extension of the material (6); or discontinuously along a longitudinal extension and / or a transverse extension of the material (6), so as to define in the material (6) processed areas which are provided with the weakening pattern and intact areas which are free of the weakening pattern.

12. The subunit (1) according to any preceding claim, comprising a wrapping tape (8) disposed on the second portion (5) in such a way as to at least partially surround it.

13. The subunit (1) according to claims 5 and 12, wherein the first portion (4) is at least partially in contact with the wrapping tape (8).

14. A smoking article (2) comprising a subunit (1) according to one of claims 1 to 13.

15. A method for manufacturing a subunit (1) for a smoking article (2), in particular comprising a subunit (1) manufactured according to one of the claims from 1 to 13; the method comprising the steps of:- providing a first portion (4) comprising at least one material with additives or to which additives are addable and / or flavoring material (6) which comprises at least one weakening pattern;- providing a second portion (5) comprising an aerosol-forming material (7) at least partially cut into strips or shredded;- forming a continuous strand comprising at least the first portion (4) and at least the second portion (5); and- cutting the continuous strand into a succession of subunits. (1).

16. The method according to claim 15, wherein the step of providing the first portion (4) comprises the further step of processing the material (6) to form the weakening pattern; the step of processing the material (6) comprises at least one sub-step selected from: crimping and / or embossing and / or through or partially through cuts and / or creasing and / or rasping and / or scratching and / or removal of material and / or use of at least one laser beam for incisions and / or cuts and / or through openings and / or non-through openings and / or removal of material.

17. The method according to claim 16, wherein the step of processing the material (6) is made: continuously along a longitudinal extension and / or a transverse extension of the material (6); or discontinuously along a longitudinal extension and / or a transverse extension of the material (6), so as to define in the material (6) processed areas which are provided with the weakening pattern and intact areas which are free of the weakening pattern.

18. The method according to claim 17, wherein the creation of the weakening pattern is discontinuous and is carried out at least partially simultaneously with the step of cutting the continuous strand.

19. The method according to any claim from 15 to 18, wherein the step of providing the first portion (4) comprises a further step of applying the at least one additive on the material (6); in particular by spraying and / or spreading and / or atomizing and / or drizzling and / or pouring and / or dropping and / or sprinkling and / or immersing the material (6) in at least one additive.

20. The method according to claim 19, wherein the step of applying the at least one additive on the material (6) provides for: applying a single additive on the material (6); and in which the step of processing the materialtakes place upstream or downstream of the step of applying the at least one additive on the material (6); or applying more than one additive; each additive is applied simultaneously or in succession; if it is applied in succession, the application step is divided into several sub-steps, in each of which at least one additive is applied on the material (6) and in which the step of processing the material takes place upstream or downstream of the at least one step of applying the at least one additive on the material (6).

21. The method according to claim 19 or 20, wherein the step of applying the at least one additive on the material (6) provides that the at least one additive is applied continuously, or discontinuously along a longitudinal extension and / or a transversal extension of the material (6) defining additive areas provided with the additive and areas without the additive.

22. An apparatus (10) for manufacturing a subunit (1) for a smoking article (2), in particular comprising a subunit (1) manufactured according to one of claims 1 to 13; the apparatus (10) comprises:- a first feeding unit (11) configured to provide at least one material with additives or to which additives are addable and / or flavoring material (6) comprising at least one weakening pattern and which defines a first portion (4) of the subunit; (1);- a second feed unit (12) configured to provide an aero sol- forming material (7) which defines a second portion (5) of the subunit (1); wherein the aero sol- forming material (7) is at least partially shredded or cut into strips;- a forming unit (13) configured to form a continuous strand comprising the first portion (4) and the second portion (5); and- a singularization unit (14) configured to cut the continuous strand into a succession of subunits (1).

23. The apparatus (10) according to claim 22, comprising a processing unit (17) configured for processing the material (6), arranged downstream of the first feeding unit (11) and comprising at least one device for producing the weakening pattern chosen from among: a crimping device (17A) and / or an embossing device (17B) and / or a device (17C) for making through or partially through cuts and / or creasing and / or rasping and / or scratching and / or removal of material in the material (6) and / or a laser device; wherein the at least one device (17A, 17B, 17C) is arranged downstream of the first feeding unit (11).

24. The apparatus (10) according to claim 23, wherein the processing unit (17) making theweakening pattern is configured to work: continuously along a longitudinal extension and / or a transverse extension of the material (6); or discontinuously along a longitudinal extension and / or a transverse extension of the material (6) so as to define in the material (6) processed areas which are provided with crimping and / or embossing and / or material weakenings and intact areas which are free from crimping and / or embossing and / or material weaknesses.

25. The apparatus (10) according to any claim from 22 to 24, comprising at least one application unit (15) configured to apply the additive on the material (6); in particular the at least one application unit (15) is configured for spraying and / or spreading and / or atomizing and / or drizzling and / or pouring and / or dropping the at least one additive onto the material (6) and / or spreading the material (6) with the at least one additive and / or immersing the material (6) in the at least one additive.

26. The apparatus (10) according to claim 25, wherein the application unit (15) is configured to apply the at least one additive continuously or discontinuously, along a longitudinal extension and / or a transverse extension of the material (6).

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