Method for manufacturing aerosol generating articles

Abstract

To provide a method for continuously manufacturing aerosol-generating articles.SOLUTION: A method for continuously manufacturing aerosol-generating articles 1 includes: (i) providing a continuous web 34 of an aerosol-generating substrate 10, the continuous web including a substantially flat surface having a center line 18; (ii) applying at least one susceptor patch 28 to the substantially flat surface substantially along the center line to leave an exposed region 90 of the continuous web of the aerosol-generating substrate on each side of the at least one susceptor patch; (iii) cutting the exposed regions of the continuous web of the aerosol-generating substrate to form a plurality of aerosol-generating strips 15, 16 on each side of the at least one susceptor patch; and (iv) forming the plurality of aerosol-generating strips and the at least one susceptor patch into a continuous rod 88.SELECTED DRAWING: Figure 2b

Description

[Technical Field]

[0001] The present disclosure relates generally to aerosol-generating articles, and more particularly to aerosol-generating articles for use with aerosol-generating devices for heating the aerosol-generating article to generate an aerosol for inhalation by a user. Embodiments of the present disclosure relate, inter alia, to methods for continuously manufacturing aerosol-generating articles. The present disclosure is particularly applicable to the manufacture of aerosol-generating articles for use with portable (handheld) aerosol-generating devices. [Background technology]

[0002] In recent years, the popularity and use of risk-reducing or risk-modifying devices (also known as aerosol-generating or vapor-generating devices) has grown rapidly as an alternative to the use of traditional tobacco products. A variety of devices and systems are available that heat and warm an aerosol-generating substance to generate an aerosol for inhalation by the user.

[0003] Commonly available risk reduction or risk modification devices are substrate-heated aerosol-generating devices, or so-called heated non-combustion devices. This type of device generates an aerosol or vapor by heating an aerosol-generating substrate, typically to a temperature in the range of 150°C to 300°C. Heating the aerosol-generating substrate to a temperature within this range, without burning or combusting the aerosol-generating substrate, generates a vapor that typically cools and condenses to form an aerosol that is inhaled by the user of the device.

[0004] Currently available aerosol-generating devices can provide heat to the aerosol-generating substrate using one of several different techniques. One such technique is to provide an aerosol-generating device that employs an induction heating system. In such devices, an induction coil is provided in the device, and an inductively heatable susceptor is provided to heat the aerosol-generating substrate. When a user activates the device, electrical energy is supplied to the induction coil, which in turn generates an alternating electromagnetic field. The susceptor couples with this electromagnetic field to generate heat, which is transferred, for example by conduction, to the aerosol-generating substrate, which heats up and generates an aerosol.

[0005] It may be convenient to provide both the aerosol-generating substrate and the inductively heatable susceptor together in the form of an aerosol-generating article that a user can insert into an aerosol-generating device. There is therefore a need to provide a method that facilitates the manufacture of aerosol-generating articles, and in particular, that allows for the easy and consistent mass production of aerosol-generating articles. Summary of the Invention [Means for solving the problem]

[0006] According to a first aspect of the present disclosure, there is provided a method for continuously producing an aerosol-generating article, comprising: (i) providing a continuous web of an aerosol-generating substrate, the continuous web comprising a substantially flat surface having a centerline; (ii) applying at least one susceptor patch substantially along a centerline to a substantially planar surface to leave exposed areas of the continuous web of aerosol-generating substrate on either side of the at least one susceptor patch; (iii) cutting the exposed areas of the continuous web of aerosol-generating substrate to form a plurality of aerosol-generating strips on either side of the at least one susceptor patch; (iv) forming a plurality of aerosol-generating strips and at least one susceptor patch into a continuous rod; A method is provided which includes:

[0007] The aerosol-generating article produced by this method is for use with an aerosol-generating device to heat the aerosol-generating substrate without burning the aerosol-generating substrate to volatilize at least one component of the aerosol-generating substrate, thereby generating a heated vapor that cools and condenses to form an aerosol for inhalation by a user of the aerosol-generating device. The aerosol-generating device is a handheld, portable device.

[0008] Generally speaking, a vapor is a substance that is in the gas phase below its critical temperature, meaning that the vapor can be condensed into a liquid by increasing the pressure without decreasing the temperature. An aerosol, on the other hand, is a suspension of fine solid particles or liquid droplets in air or another gas. However, it should be noted that, as used herein, the terms "aerosol" and "vapor" may be used interchangeably, particularly with respect to the form of inhalable medium that is generated for inhalation by a user.

[0009] The method according to the present disclosure facilitates the manufacture of aerosol-generating articles, and in particular allows for consistent and relatively easy mass production of aerosol-generating articles. Because the aerosol-generating strip is formed without cutting at least one susceptor patch in step (iii), wear during the cutting step (e.g., on a cutting unit) is minimized. The combination of the aerosol-generating strip and susceptor (formed without cutting the susceptor patch into strips) in the aerosol-generating article produced by the method according to the present disclosure provides effective heat transfer from the susceptor to the aerosol-generating strip during use of the aerosol-generating article in an aerosol-generating device. This provides effective and uniform heating of the aerosol-generating strip, and therefore reliable steam generation.

[0010] Accurate and consistent positioning of the at least one susceptor patch along the centerline of the substantially planar surface of the continuous web of aerosol-generating substrate further helps ensure that aerosol-generating articles produced by methods according to the present disclosure have consistent and repeatable properties.

[0011] Step (iii) can be carried out using a rotary cutter unit. The rotary cutter unit can include a first cutting drum and a second cutting drum. The first cutting drum can have a first cutting structure extending in a circumferential direction. The second cutting drum can have a second cutting structure extending in a circumferential direction. The first and second cutting structures can cooperate to cut the exposed areas of the continuous web of aerosol-generating substrate to form a plurality of aerosol-generating strips. The use of a rotary cutter unit can facilitate continuous and high-speed production of aerosol-generating articles.

[0012] The first cutting drum and the second cutting drum can define a non-cutting area therebetween. The non-cutting area can accommodate at least one susceptor patch and a portion of the aerosol-generating substrate to which the at least one susceptor patch is applied during step (ii). The provision of the non-cutting area ensures that the susceptor patch and the underlying portion of the aerosol-generating substrate (which serves as an elongated carrier strip for the susceptor patch) are not cut, while also ensuring that high-speed manufacturing is achieved.

[0013] The first cutting drum can be formed without a first cutting structure in the non-cutting region. For example, the first cutting drum can include a circumferentially extending recess in the surface of the non-cutting region. The second cutting drum can be formed without a second cutting structure in the non-cutting region. For example, the second cutting drum can include a circumferentially extending recess in the surface of the non-cutting region. In some embodiments, both the first and second cutting drums may be formed without first and second cutting structures, respectively, in the non-cutting regions. In some embodiments, at least a portion of at least one susceptor patch may be housed in a circumferentially extending recess. These configurations reliably ensure that the susceptor patch and the underlying portion of the aerosol-generating substrate (i.e., the elongated carrier strip) are not cut during step (iii), allowing high-speed manufacturing to be achieved.

[0014] Each of the plurality of aerosol-generating strips may have a width of about 0.1 mm to 5.0 mm, and in some cases about 0.5 mm to 2.0 mm. Each of the plurality of aerosol-generating strips may have a width of 1.0 mm. These width dimensions ensure that aerosol-generating articles manufactured using methods according to the present disclosure include an adequate number of aerosol-generating strips to enable uniform airflow through the aerosol-generating article and the generation of an acceptable amount of vapor or aerosol. If the width of the aerosol-generating strips is too small, the strength of the strips may be reduced, which may result in difficulty in mass-producing the aerosol-generating article.

[0015] Step (ii) may include adhering at least one susceptor patch to a substantially flat surface of the continuous web of aerosol-generating substrate using an adhesive, thereby achieving a good bond between the susceptor patch and the continuous web of aerosol-generating substrate and ensuring that the susceptor patch does not move relative to the continuous web of aerosol-generating substrate. This may help to ensure that only exposed areas of the continuous web of aerosol-generating substrate are cut to form the aerosol-generating strips during step (iii).

[0016] Step (ii) can include sequentially applying a plurality of susceptor patches to a substantially flat surface of the continuous web of aerosol-generating substrate, with a predetermined, regular spacing between each successive susceptor patch. The predetermined, regular "spacing" between each successive susceptor patch is the shortest distance between successive (i.e., adjacent) susceptor patches, i.e., the distance or gap between the edges of successive (i.e., adjacent) susceptor patches. Step (iii) can include cutting the exposed areas of the continuous web of aerosol-generating substrate to form a plurality of aerosol-generating strips on both sides of the susceptor patch. Step (iv) can include forming the plurality of aerosol-generating strips and susceptor patches into a continuous rod, thereby facilitating mass production of aerosol-generating articles.

[0017] The at least one susceptor patch can have a length of 5 mm to 50 mm, preferably 10 mm to 30 mm. The at least one susceptor patch can have a width of 0.1 mm to 7 mm, preferably 1 mm to 5 mm. The at least one susceptor patch can have a thickness of 1 μm to 500 μm, preferably 10 μm to 100 μm, and in some cases 50 μm. Susceptor patches having these dimensions are particularly suitable for the manufacture of aerosol-generating articles.

[0018] The method may further comprise (v) cutting the continuous rod to form a plurality of individual aerosol-generating articles. Each of the individual aerosol-generating articles may comprise at least one susceptor patch. Thus, step (v) may comprise cutting the continuous rod to form a plurality of individual aerosol-generating articles, each comprising at least one susceptor patch. This facilitates continuous mass production of aerosol-generating articles.

[0019] Step (v) may include cutting the continuous rod at locations between adjacent susceptor patches, such that the individual aerosol-generating articles formed by cutting the continuous rod each include a susceptor patch, and thus This ensures that the aerosol-generating article is consistent and reproducible, and because the susceptor patch is not cut during step (v), wear (e.g., on the cutting unit) during the cutting step is minimized.

[0020] Step (v) may include cutting the continuous rod substantially midway between adjacent susceptor patches. In this manner, the susceptors are spaced inward from both ends of the resulting aerosol-generating article and are not visible from either end of the aerosol-generating article. This may improve user acceptance of aerosol-generating articles produced by the methods of the present disclosure. Furthermore, the susceptors are completely embedded in the aerosol-generating substrate (i.e., the aerosol-generating strip) of the resulting aerosol-generating article, which may result in more efficient aerosol or vapor generation because the entire susceptor is surrounded by the aerosol-generating strip, thereby maximizing heat transfer from the susceptor to the aerosol-generating strip.

[0021] Each susceptor patch may comprise an inductively heatable susceptor material such as, but not limited to, one or more of aluminum, iron, nickel, stainless steel, carbon steel, and alloys thereof, such as nickel-chromium or nickel-copper. During use of the aerosol-generating article in the aerosol-generating device, upon application of an electromagnetic field in its vicinity, the susceptor material may generate heat due to eddy currents and magnetic hysteresis losses, resulting in energy conversion from the electromagnetic field to heat.

[0022] The aerosol-generating substrate can be any type of solid or semi-solid material. Exemplary types of aerosol-generating solids include powders, granules, pellets, shreds, strands, particles, gels, strips, loose-leaf, cut-leaf, cut-filler, porous materials, foam materials, or sheets. The aerosol-generating substrate can include plant-derived materials, particularly tobacco. It can include, for example, reconstituted tobacco containing tobacco and one or more of cellulose fiber, tobacco stem fiber, and inorganic fillers such as CaCO3.

[0023] Thus, the aerosol-generating devices with which the aerosol-generating articles are intended to be used may be referred to as "heated tobacco devices," "heated-non-combustible tobacco devices," "devices for vaporizing tobacco products," etc., and are to be interpreted as devices suitable for achieving these effects. The features disclosed herein are equally applicable to devices designed to vaporize any aerosol-generating substrate.

[0024] The continuous rod may be surrounded by a paper wrapper, and thus the method may further comprise encasing the continuous rod in a paper wrapper.

[0025] The aerosol-generating article may be substantially stick-shaped and generally resemble a cigarette with a tubular region having aerosol-generating substrates arranged in a suitable configuration. The aerosol-generating article may include a filter segment, e.g., comprising cellulose acetate fibers, at the proximal end of the aerosol-generating article. The filter segment may constitute a mouthpiece filter and may be coaxially aligned with the aerosol-generating substrates formed by multiple aerosol-generating strips. Some designs may also include one or more vapor collection regions, cooling regions, and other structures. For example, the aerosol-generating article may include at least one tubular segment upstream of the filter segment. The tubular segment may function as a vapor cooling region. The vapor cooling region may advantageously allow heated vapor generated by heating the aerosol-generating strips to cool and condense, for example, through the filter segment, to form an aerosol with suitable properties for inhalation by a user.

[0026] The aerosol-generating substrate may contain an aerosol former. Examples of aerosol formers include polyhydric alcohols such as glycerin or propylene glycol, and mixtures thereof. Typically, the aerosol-generating substrate may contain about 5% to about 50% aerosol former by dry weight. In some embodiments, the aerosol-generating substrate may contain about 10% to about 20% aerosol former by dry weight, and in some cases about 15% aerosol former by dry weight.

[0027] Upon heating, the aerosol-generating substrate (i.e., the aerosol-generating strip) may release volatile compounds, which may include flavor compounds such as nicotine or tobacco flavorings. [Brief explanation of the drawings]

[0028] [Figure 1a] 1 is a schematic cross-sectional side view of an example of an aerosol-generating article. [Figure 1b] FIG. 1b is an enlarged schematic cross-sectional view taken along line AA in FIG. 1a. [Figure 2a] FIG. 1 is a schematic diagram of an apparatus and method for producing the aerosol-generating article shown in FIGS. 1a and 1b. [Figure 2b] 2b is a plan view of the aerosol-generating substrate and susceptor patch as they move through the apparatus shown in FIG. 2a in the direction indicated by the arrows. [Figure 3] FIG. 2 is a plan view of a portion of a continuous web of susceptor material showing bonded and unbonded areas. [Figure 4] 2b is a functional diagram of a portion of the apparatus and method of FIG. 2a, illustrating generally the formation of susceptor patches from a continuous web of susceptor material and the application of the susceptor patches to the surface of a continuous web of aerosol-generating substrate. [Figure 5] FIG. 2 is a schematic perspective view of a susceptor cutting unit. [Figure 6] FIG. 2 is a schematic diagram of a strip cutting unit. DETAILED DESCRIPTION OF THE INVENTION

[0029] Embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0030] 1a and 1b, there is shown an example of an aerosol-generating article for use with an aerosol-generating device that includes an induction heating system for inductively heating the aerosol-generating article, thereby generating an aerosol for inhalation by a user of the device. Such devices are known in the art and will not be described in further detail herein. The aerosol-generating article 1 is elongated and substantially cylindrical. The circular cross-section facilitates handling of the article 1 by a user and insertion of the article 1 into a cavity or heating compartment of the aerosol-generating device.

[0031] The aerosol-generating article 1 includes an aerosol-generating substrate 10 having a first end 10a and a second end 10b, and an inductively heatable susceptor 12. The aerosol-generating substrate 10 and the inductively heatable susceptor 12 are disposed within and surrounded by a wrapper 14. The wrapper 14 comprises a substantially electrically non-conductive and non-magnetically permeable material. In the illustrated example, the wrapper 14 is a paper wrapper and may include cigarette paper.

[0032] The aerosol-generating article 1 may have a total length measured between the distal end 11a and the proximal (mouth) end 11b of 30 mm to 100 mm, preferably 50 mm to 70 mm, and in some cases about 55 mm. The aerosol-generating substrate 10 may have a total length measured between the first end 10a and the second end 10b of 5 mm to 50 mm, preferably 10 mm to 30 mm, and in some cases about 55 mm. In some cases, the diameter of the aerosol-generating article 1 may be about 20 mm. The diameter of the aerosol-generating article 1 may be 5 mm to 10 mm, preferably 6 mm to 8 mm, and in some cases about 7 mm.

[0033] The aerosol-generating substrate 10 includes a plurality of elongated first strips 15 containing aerosol-generating material. The plurality of elongated first strips 15 constitute aerosol-generating strips 16 and are oriented substantially in the longitudinal direction of the aerosol-generating article 1. The elongated first strips 15 are typically free of folds in the longitudinal direction to ensure that the airflow path is uninterrupted and that uniform airflow through the article 1 can be achieved.

[0034] The inductively heatable susceptor 12 comprises elongated second strips 13 comprising inductively heatable susceptor material. The elongated second strips 13 can therefore be considered as strip- or blade-shaped elongated susceptors 12, also oriented substantially in the longitudinal direction of the aerosol-generating article 1. As can be clearly seen in Figure 1b, each of the elongated first strips 15 has a width that is smaller than the width of the elongated second strips 13.

[0035] The aerosol-generating article 1 includes at least one elongated carrier strip 17 having first and second major surfaces 17a, 17b. The elongated carrier strip 17 includes an aerosol-generating material and thus also constitutes an aerosol-generating strip 16. The elongated carrier strip 17 is oriented substantially in the longitudinal direction of the aerosol-generating article 1. The elongated carrier strip 17 has the same length as the first elongated strip 15, and therefore all of the aerosol-generating strips 16 in the aerosol-generating article 1 have the same length.

[0036] The elongated second strip 13 is adhered to an elongated carrier strip 17, which, as can be clearly seen in FIG. 1b, has a width greater than that of the elongated second strip 13. The elongated second strip 13 has first and second opposing surfaces 13b, 13c. The second surface 13c is adhered to a second major surface 17b of the elongated carrier strip 17 and is entirely covered by the elongated carrier strip 17, more specifically by the second major surface 17b.

[0037] The first elongated strips 15, the second elongated strips 13, and the carrier strips 17 are arranged to form a substantially rod-shaped aerosol-generating article 1, and the first elongated strips 15 can be randomly distributed across the cross-section of the rod-shaped aerosol-generating article 1, resulting in a plurality of different orientations within the cross-section of the aerosol-generating article 1. Although not apparent from FIG. 1b, it will be understood that a sufficient number of the first elongated strips 15 are provided to substantially fill the cross-section of the aerosol-generating substrate 10, and that the fewer first elongated strips 15 are shown for illustrative purposes only. The second elongated strips 13 and the carrier strips 17 are approximately centrally positioned within the cross-section of the aerosol-generating substrate 10, and thus the aerosol-generating article 1. Such an arrangement helps ensure uniform heat transfer from the second elongated strips 13 to the first elongated strips 15.

[0038] As best shown in Figure lb, the centrally located elongated carrier strip 17 and the elongated second strips 13 adhered thereto define first and second regions 5, 6 within the cross-section of the aerosol-generating substrate 10, and hence the aerosol-generating article 1. The first region 5 faces a first major surface 17a of the elongated carrier strip 17, and the second region 6 faces a second major surface 17b of the elongated carrier strip 17. Both the first and second regions 5, 6 comprise a plurality of elongated first strips 15.

[0039] As best shown in FIG. 1a, each of the plurality of elongated first strips 15 is The elongated second strip 13 has a distal end 15a, and the elongated second strip 13 has a distal end 13a. The distal end 15a of the elongated first strip 15 forms the first end 10a of the aerosol-generating substrate 10 and, correspondingly, the distal end 11a of the aerosol-generating article 1. The elongated second strip 13 is shorter than the elongated first strip 15 and the elongated carrier strip 17. The distal end 13a of the elongated second strip 13 is disposed inward from the distal end 15a of the elongated first strip 15. Thus, the distal end 13a of the elongated second strip 13 (i.e., the elongated susceptor 12) is not visible at the distal end 11a of the aerosol-generating article 1.

[0040] The aerosol-generating article 1 includes a mouthpiece segment 20 positioned downstream of the aerosol-generating substrate 10. The aerosol-generating substrate 10 and the mouthpiece segment 20 are positioned in coaxial alignment inside a wrapper 14 to hold the components in place, forming the rod-shaped aerosol-generating article 1.

[0041] In the illustrated embodiment, the mouthpiece segment 20 includes the following components, arranged sequentially and coaxially in a downstream direction, i.e., from the distal end 11a to the proximal (mouth) end 11b of the aerosol-generating article 1: a cooling segment 22, a central hole segment 23, and a filter segment 24. The cooling segment 22 includes a hollow paper tube 22a having a thickness greater than that of the paper wrapper 14. The central hole segment 23 may include a stiffening mixture including cellulose acetate fibers and a plasticizer and functions to increase the strength of the mouthpiece segment 20. The filter segment 24 typically includes cellulose acetate fibers and functions as a mouthpiece filter. As heated vapor flows from the aerosol-generating substrate 10 toward the proximal (mouth) end 11b of the aerosol-generating article 1, the vapor cools and condenses as it passes through the cooling segment 22 and the central hole segment 23, forming an aerosol with properties suitable for inhalation by a user through the filter segment 24.

[0042] The elongated first strip 15 and the elongated carrier strip 17 typically comprise a plant-derived material such as tobacco. The elongated first strip 15 and the elongated carrier strip 17 may advantageously comprise reconstituted tobacco, which includes tobacco and any one or more of cellulose fiber, tobacco stem fiber, and an inorganic filler such as CaCO3.

[0043] The elongated first strip 15 and the elongated carrier strip 17 typically contain an aerosol former such as glycerin or propylene glycol. Typically, the elongated first strip 15 and the elongated carrier strip 17 contain about 5% to about 50% aerosol former content on a dry weight basis. Upon heating, the elongated first strip 15 and the elongated carrier strip 17 release volatile compounds, optionally including flavor compounds such as nicotine or tobacco flavorings.

[0044] During use of the article 1 in an aerosol-generating device, when a time-varying electromagnetic field is applied near the elongated second strip 13, heat is generated in the elongated second strip 13 due to eddy currents and magnetic hysteresis losses. The heat is transferred from the elongated second strip 13 to the elongated first strip 15 and the elongated carrier strip 17, heating the elongated first strip 15 and the elongated carrier strip 17 without combustion, releasing one or more volatile compounds, thereby generating vapor. When a user inhales through the filter segment 24, the heated vapor is drawn downstream through the article 1 from the first end 10a of the aerosol-generating substrate 10 toward the second end 10b of the aerosol-generating substrate 10 and toward the filter segment 24. As described above, the heated vapor flows through the cooling segment 22 and the central hole segment 23 toward the filter segment 24. As it flows through the filter segment 24, the heated vapor cools and condenses to form an aerosol with suitable properties for inhalation by a user.

[0045] [Manufacturing of aerosol-generating products] We will now describe an apparatus 30 and method suitable for producing aerosol-generating articles according to the present disclosure, such as the aerosol-generating article 1 described above with reference to Figures 1a and 1b.

[0046] Referring to Figure 2a, there is shown a schematic diagram of an apparatus 30 and method for producing the aerosol-generating article 1 described above with reference to Figures 1a and 1b. Figure 2b is a plan view of the aerosol-generating substrate 10 and susceptor patch 28 as they move through the apparatus 30 in the direction of the arrows in Figure 2b.

[0047] The apparatus 30 includes a substrate supply reel 32 (e.g., a first bobbin) carrying a continuous web 34 of aerosol-generating substrate 10 having a substantially flat surface with a centerline 18, and a first feed roller 36 for controlling the feeding of the continuous web 34 of aerosol-generating substrate 10. The apparatus 30 may also include a web tension adjuster and a web edge control system, as will be understood by those skilled in the art, although these additional components are not required in the context of the present disclosure and, therefore, have been omitted for simplicity.

[0048] The apparatus 30 includes a susceptor supply reel 38 (e.g., a second bobbin) carrying a continuous web 40 of susceptor material, feed rollers 42, 44 for controlling the feeding of the continuous web 40 of susceptor material, an adhesive application unit 46, and a susceptor cutting unit 48.

[0049] Apparatus 30 further includes an optional heater 50 , a strip cutting unit 52 , feed rollers 54 , a rod forming unit 56 , and a rod cutting unit 58 .

[0050] [Preparing the susceptor patch] During operation, the continuous web 34 of aerosol-generating substrate 10 is continuously fed from the substrate supply reel 32. Simultaneously, the continuous web 40 of susceptor material is continuously fed from the susceptor supply reel 38 via feed rollers 42, 44 to the adhesive application unit 46. The adhesive application unit 46 applies an adhesive 47 to the surface of the continuous web of susceptor material 40. In the illustrated example, the adhesive application unit 46 applies the adhesive 47 intermittently to the surface of the continuous web of susceptor material 40 across the entire width of the web 40. In this manner, discrete bonded regions 60 (see FIGS. 3 and 4 ) are formed on the surface of the continuous web of susceptor material 40, and non-bonded regions 62 are formed between adjacent bonded regions 60 in the direction of travel of the continuous web of susceptor material 40.

[0051] The continuous web 40 of susceptor material is fed from the adhesive application unit 46 to a susceptor cutting unit 48, which continuously cuts the continuous web 40 to form a plurality of susceptor patches 28. As best shown in FIG. 2b, the continuous web 40 of susceptor material, and thus the susceptor patches 28, have a width that is substantially smaller than the width of the continuous web 34 of aerosol-generating substrate 10. For example, the continuous web 34 of aerosol-generating substrate 10 may have a width of approximately 140 mm, whereas the continuous web 40 of susceptor material, and thus the susceptor patches 28, may have a width of approximately 0.1 mm to 7 mm. In some embodiments, the susceptor patches 28 may have a length of approximately 5 mm to 50 mm in the direction of travel of the continuous web 40 of susceptor material and a thickness of approximately 1 μm to 500 μm.

[0052] To minimize contamination of the susceptor cutting unit 48 with adhesive 47 applied to the continuous web 40 of susceptor material by the adhesive application unit 46, the susceptor cutting unit 48 cuts the continuous web of susceptor material 40 at the non-bonded areas 62, i.e., at locations between the bonded areas 60 on the surface of the continuous web of susceptor material 40. This can be accomplished by synchronizing the operation of the susceptor cutting unit 48 with the movement of the continuous web of susceptor material 40.

[0053] 5, the susceptor cutting unit 48 includes a rotary cutting unit 64 that includes a support drum 66 and a cutting drum 68. The support drum 66 supports the continuous web of susceptor material 40 about its periphery and includes a plurality of circumferentially spaced recesses 70 thereabout. The support drum 66 is typically a suction drum, and the continuous web of susceptor material 40 and the susceptor patches 28 are supported about its periphery by suction applied through suction ports 67. The cutting drum 68 includes a plurality of circumferentially spaced cutting elements 72, e.g., protruding cutting blades, thereabout, which cooperate with (e.g., extend into) the circumferentially spaced recesses 70 during synchronous rotation of both the support drum 66 and the cutting drum 68 in opposite directions, as indicated by the arrows in FIG. 5. This results in successive shear cuts of the continuous web of susceptor material 40 to form a plurality of susceptor patches 28. As will become apparent from the following description, each susceptor patch 28 corresponds to an elongated second strip 13 (i.e., an elongated susceptor 12) of the completed aerosol-generating article 1 described above with reference to Figures 1a and 1b.

[0054] [Applying a susceptor patch] The susceptor patches 28 provided by the susceptor cutting unit 48 can be applied to the surface of the continuous web 34 of aerosol-generating substrate 10 so that there is a fixed, predetermined spacing 74 between the edges of each successive susceptor patch 28, as shown, for example, in FIGS. 2b and 4. The fixed, predetermined spacing 74 can be, for example, 1 mm to 20 mm. To create the fixed, predetermined spacing 74 between the edges of adjacent susceptor patches 28, the susceptor cutting unit 48 permits relative movement between the continuous web 40 of susceptor material and the support drum 66 for a predetermined period of time immediately after the continuous web 40 of susceptor material carried by the support drum 66 is cut by the cutting drum 68 to form the susceptor patches 28. This relative movement allows the continuous web 40 of susceptor material to remain stationary or to move at a reduced speed for a short period of time after the susceptor patches 28 are cut from the continuous web 40 of susceptor material. Relative motion between the continuous web 40 of susceptor material and the support drum 66 can be achieved, for example, by reducing the suction force applied by the support drum 66 to the continuous web 40 of susceptor material, while simultaneously maintaining an appropriate suction force between the already-cut susceptor patches 28 and the support drum 66 to ensure that there is no relative motion between the susceptor patches 28 and the support drum 66. In this manner, the susceptor patches 28 cut from the continuous web 40 of susceptor material by the susceptor cutting unit 48 are conveyed for a short period of time at a faster speed than the continuous web 40 of susceptor material from which they were cut, thereby creating the desired constant, predetermined spacing 74 between the edges of adjacent susceptor patches 28.

[0055] The susceptor patches 28 coated with adhesive 47 are successively adhered to the flat surface of the continuous web 34 of aerosol-generating substrate 10 substantially along the centerline 18. Exposed side regions 90 of the continuous web 34 of aerosol-generating substrate are thereby formed on either side of the susceptor patches 28 (see FIG. 2b ) because, as noted above, the continuous web 34 of aerosol-generating substrate 10 is substantially wider than the susceptor patches 28. Adjacent susceptor patches 28 are also spaced apart in the direction of travel of the continuous web 34 of aerosol-generating substrate 10 by a constant, predetermined spacing 74 between the edges of the susceptor patches 28, which occurs when the susceptor patches 28 are formed in the susceptor cutting unit 48.

[0056] the susceptor patch 28 and the substantially flat surface of the continuous web 34 of aerosol-generating substrate 10 To ensure sufficient adhesion between the susceptor patches 28, the susceptor patches 28 can be pressed against a substantially flat surface by a cam roller 76, shown schematically in Figure 2a. The rotation of the cam roller 76 is synchronized with the movement of the continuous web 34 of the aerosol-generating substrate 10 so that a pressing force is applied to successive susceptor patches 28 but not to the spaced areas between successive susceptor patches 28.

[0057] Depending on the properties of the adhesive 47 applied by the adhesive application unit 46 to the continuous web 40 of susceptor material (and thus to the susceptor patches 28), the continuous web 34 of aerosol-generating substrates 10 and the susceptor patches 28 adhered thereto may be heated by an optional heater 50. This serves to cure or solidify the adhesive 47, thereby ensuring a good bond between each susceptor patch 28 and the flat surface of the continuous web 34 of aerosol-generating substrates 10. The heating temperature must be carefully selected based on the properties of both the aerosol-generating substrate 10 and the adhesive 47 to ensure that sufficient heating is achieved to cure or solidify the adhesive 47, while avoiding or at least minimizing the release of volatile components from the aerosol-generating substrate 10.

[0058] Strip Cut The continuous web 34 of aerosol-generating substrate 10, having spaced-apart susceptor patches 28 adhered to its planar surface, is fed to a strip cutting unit 52. The strip cutting unit 52 cuts only the exposed side regions 90 of the continuous web 34 of aerosol-generating substrate 10, without cutting the susceptor patches 28, to form a plurality of continuous aerosol-generating strips 16 along the susceptor patches 28. In one embodiment, the strip cutting unit 52 cuts the exposed side regions 90 of the continuous web 34 of aerosol-generating substrate 10 to form aerosol-generating strips 16 having a strip width of about 1 mm.

[0059] 2a and 6, the strip cutting unit 52 is a rotary cutter unit 78 and includes first and second cutting drums 80, 82. The first cutting drum 80 includes a circumferentially extending first cutting structure 84, and the second cutting drum 82 includes a circumferentially extending second cutting structure 86. The first and second cutting structures 84, 86 cooperate (e.g., intermesh) to shear-sever exposed side regions 90 of the continuous web 34 of the aerosol-generating substrate 10 in the direction of travel of the continuous web 34 to form a continuous aerosol-generating strip 16, specifically the elongated first strip 15 shown in FIGS. 1a and 1b.

[0060] To cut only the exposed side regions 90 of the continuous web 34 of aerosol-generating substrate 10 to form the elongated first strips 15, the first and second cutting drums 80, 82 define a non-cutting region 92 therebetween that accommodates the susceptor patch 28 and the portion of the continuous web 34 of aerosol-generating substrate 10 to which the susceptor patch 28 will be adhered. In the illustrated embodiment, the first cutting drum 80 is formed without a first cutting structure 84 in the non-cutting region 92. Similarly, the second cutting drum 82 is formed without a second cutting structure 86 in the non-cutting region 92. Furthermore, the first cutting drum 80 includes a circumferentially extending recess 94 in the surface of the non-cutting region 92, such that at least a portion of the susceptor patch 28 can be accommodated in the circumferentially extending recess 94 during cutting of the exposed side regions 90 of the continuous web 34 of aerosol-generating substrate 10. It will therefore be appreciated that when the exposed side regions 90 of the continuous web 34 of aerosol-generating substrates 10 are cut to form elongated first strips 15 by cooperation between the first and second cutting structures 84, 86 on the first and second cutting drums 80, 82, respectively, the central portion of the continuous web 34 of aerosol-generating substrates 10 contained in the non-cutting region 92 and not cut into strips constitutes the elongated carrier strip 17 described above with reference to Figure 1b.

[0061] [Rod formation] The aerosol-generating strips 16 formed by cutting the exposed side regions 90 of the continuous web 34 of aerosol-generating substrate 10, the elongated carrier strips 17, and the adhered susceptor patches 28 are conveyed to the rod-forming unit 56, where they are formed into a rod 88. If desired, a continuous sheet of wrapping paper (not shown) can be supplied to the rod-forming unit 56 from a supply reel (not shown), or can be supplied (again from a supply reel) to a separate wrapping unit that can be located downstream of the rod-forming unit 56. As the sheet of wrapping paper is transported and guided through the rod-forming unit 56 or a separate wrapping unit, it can be wrapped around the aerosol-generating strips 16 and the susceptor patches 28, so that the continuous rod 88 is surrounded by the wrapper 14.

[0062] [Rod cutting] The continuous rod 88 (optionally surrounded by a wrapper 14) is then transported to the rod cutting unit 58, where it is cut to length at appropriate locations to form a plurality of aerosol-generating articles 1. The aerosol-generating articles 1 formed by the rod cutting unit 58 can have a length of 5 mm to 50 mm, preferably 10 mm to 30 mm. It will be understood that this length corresponds to the length of the aerosol-generating substrate 10 described above with reference to FIGS. 1a and 1b. The continuous rod 88 is preferably repeatedly cut by the rod cutting unit 58 at substantially midpoints between the edges of the susceptor patches 28. In this manner, the susceptor patches 28 are not cut by the rod cutting unit 58, thereby reducing wear on the cutting elements. Furthermore, because the susceptor patches 28 are shorter than the aerosol-generating strips 16, the ends of the individual susceptor patches 28 (i.e., the elongated second strips 13) are not visible at either end of the aerosol-generating articles 1 formed by the rod cutting unit 58. It will be appreciated that this type of method is particularly suitable for mass production of aerosol-generating articles 1.

[0063] [Final assembly] A further unit (not shown) may be located downstream of the rod cutting unit 58 and may provide one or more additional components, such as the mouthpiece segments 20 described above, and may be configured to assemble these with the individual aerosol-generating articles 1 formed by the rod cutting unit 56 to form finished aerosol-generating articles 1, for example of the type shown in Figure 1. In this case, a separate wrapping unit may be provided downstream of the rod cutting unit 58 to enable the assembled components to be simultaneously wrapped to form the finished aerosol-generating article 1. The further unit may form part of the apparatus 30, or may be a separate, stand-alone unit forming part of the final assembly line.

[0064] While exemplary embodiments have been described in the preceding paragraphs, it should be understood that various modifications can be made to these embodiments without departing from the scope of the appended claims. Thus, the breadth and scope of the claims should not be limited to the above-described exemplary embodiments.

[0065] Any combination of the above-described features in all possible variations thereof is encompassed by the present disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.

[0066] Unless the context clearly dictates otherwise, throughout this specification and the claims, the words "comprise," "comprising," and the like are to be construed in an inclusive sense, i.e., "including but not limited to," as opposed to an exclusive or exhaustive sense.

Claims

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

2. Step (iii) is carried out using a rotary cutter unit (78); The method of claim 1.

3. the rotary cutter unit (78) includes a first cutting drum (80) having a circumferentially extending first cutting structure (84) and a second cutting drum (82) having a circumferentially extending second cutting structure (86); the first and second cutting structures (84, 86) cooperate to cut the exposed areas (90) of the continuous web (34) of aerosol-generating substrate (10) to form the plurality of aerosol-generating strips (15, 16); The method of claim 2.

4. the first cutting drum (80) and the second cutting drum (82) define between them a non-cutting area (92) that accommodates the at least one susceptor patch (28) and a portion (17) of the aerosol-generating substrate (10) to which the at least one susceptor patch (28) is applied during step (ii); The method of claim 3.

5. the first cutting drum (80) is formed without the first cutting structure (84) in the non-cutting area (92); or the second cutting drum (82) is formed without the second cutting structure (86) in the non-cutting area (92); or both of the first and second cutting drums (80, 82) are formed without the first and second cutting structures (84, 86), respectively, in the non-cutting region (92). The method of claim 4.

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

7. each of the plurality of aerosol-generating strips (15, 16) has a width of about 0.5 mm to 2.0 mm, preferably 1.0 mm; The method according to any one of claims 1 to 6.

8. step (ii) comprising adhering the at least one susceptor patch (28) to the substantially flat surface of the continuous web (34) of aerosol-generating substrate (10) using an adhesive (47); The method according to any one of claims 1 to 7.

9. step (ii) comprising sequentially applying a plurality of susceptor patches (28) to the substantially flat surface of the continuous web (34) of aerosol-generating substrate (10) with a predetermined, regular spacing (74) between each successive susceptor patch (28); step (iii) comprising cutting the exposed region (90) of the continuous web (34) of aerosol-generating substrate (10) to form a plurality of aerosol-generating strips (15, 16) on either side of the susceptor patch (28); step (iv) comprising forming the plurality of aerosol-generating strips (15, 16) and the susceptor patch (28) into a continuous rod (88); The method according to any one of claims 1 to 8.

10. (v) cutting said continuous rod (88) to form a plurality of individual aerosol-generating articles (1), each comprising at least one susceptor patch (28); The method of any one of claims 1 to 9, further comprising:

11. the at least one susceptor patch (28) has a length of 5 mm to 50 mm; Preferably, said at least one susceptor patch (28) has a length of between 10 mm and 30 mm. The method according to any one of claims 1 to 10.

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