Aerosol generating article and method for manufacturing aerosol generating article

Abstract

To provide an aerosol generating article capable of optimizing aerosol features generated while the article is used.SOLUTION: An aerosol generating article includes an aerosol generating material part 10 placed in a shell 14 and induction heatable susceptors 12, 20. The aerosol generating material part includes at least 10 aerosol generating bands 18 virtually directed in a first direction. The induction heatable susceptors are placed between aerosol generating bands and include slender parts virtually directed in the first direction.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates generally to aerosol product articles, and more particularly to aerosol product articles for use in an aerosol generating device that heats the aerosol product article to generate an aerosol for a user to inhale. Embodiments of the present disclosure also relate to methods of making the aerosol product article. [Background technology]

[0002] In recent years, devices that heat, rather than burn, aerosol-generating materials to produce aerosols for inhalation have become popular with consumers.

[0003] Such devices can provide heat to the aerosol-generating material using one of several different techniques. One such technique is to provide an aerosol-generating device that uses an induction heating system, into which a user can removably insert an aerosol-producing article containing the aerosol-generating material. In such devices, an induction coil is provided in the device and an inductively heatable susceptor is provided in the aerosol-producing article. When a user activates the device, electrical energy is provided to the induction coil, which in turn generates an alternating electromagnetic field. The susceptor couples with this electromagnetic field and generates heat. This heat is transferred to the aerosol-generating material, for example, by conduction, and as the aerosol-generating material heats, an aerosol is generated.

[0004] The characteristics of the aerosol generated by an aerosol generating device depend on several factors, including the structure of the aerosol product article used with the aerosol generating device. Therefore, it is desirable to provide an aerosol product article that allows for optimization of the characteristics of the aerosol generated during use of the article. It is also generally desirable to provide an aerosol product article that can be easily and consistently mass-produced. Summary of the Invention [Means for solving the problem]

[0005] According to a first aspect of the present disclosure, A shell and an aerosol-generating material portion and an inductively heatable susceptor disposed within a shell, the aerosol-generating material section includes at least ten aerosol-generating zones oriented substantially in a first direction; An inductively heatable susceptor is disposed between the aerosol-generation zones and an aerosol production article is provided including an elongated portion oriented substantially in a first direction.

[0006] The aerosol production article is for use in an aerosol generating device to heat, rather than burn, an aerosol-generating zone within the aerosol-generating material section to volatilize at least one component of the aerosol-generating zone, thereby producing a heated vapor that cools and condenses to form an aerosol for inhalation by a user of the aerosol generating device.

[0007] 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, the terms "aerosol" and "vapor" are used interchangeably herein, particularly with respect to the form of inhalable medium produced for inhalation by a user. Note that we obtain

[0008] Aerosol-producing articles according to the present disclosure can be efficiently manufactured and relatively easily mass-produced by placing the aerosol-generation zone and inductively heatable susceptor within a shell. The shell substantially comprises a material that allows electromagnetic fields to pass through it and does not act as an electromagnetic shield. The shell can comprise, for example, a paper wrapper, or alternatively, a tube or cup comprising paper or a plastic material, e.g., a heat-resistant plastic material such as polyetheretherketone (PEEK).

[0009] Uniform airflow through the aerosol-producing article is achieved by the airflow paths provided by the gaps between the aerosol-producing zones.

[0010] The aerosol product may include at least 20 of the aerosol-generation zones, optionally at least 40 of the aerosol-generation zones, optionally at least 50 of the aerosol-generation zones, or optionally at least 60 of the aerosol-generation zones. The aerosol product may include up to 100 of the aerosol-generation zones, optionally up to 150 of the aerosol-generation zones, or optionally up to 200 of the aerosol-generation zones. A larger number of aerosol-generation zones tends to result in more gaps between the aerosol-generation zones, which may advantageously result in more uniform airflow through the aerosol product. However, an excessive number of aerosol-generation zones is undesirable, since it is typically necessary to decrease the width of the aerosol-generation zones as the number of zones increases to ensure that the aerosol product has appropriate dimensions. If the width of the aerosol-generation zones is too small, the strength of the zones may be reduced, which may result in difficulty in mass production of the aerosol product.

[0011] The inductively heatable susceptor may be strip-shaped and oriented substantially in a first direction. Use of a strip-shaped inductively heatable susceptor may maximize heat transfer from the susceptor to the aerosol-generation zone. Additionally, oriented strip-shaped susceptors may facilitate production of aerosol product articles.

[0012] The inductively heatable susceptor may alternatively be U-shaped, I-shaped or pin-shaped, or may be cylindrical, for example having a circular, rectangular or square cross section.

[0013] The aerosol-generating material portion may be rod-shaped, the shell may comprise a substantially cylindrical packaging material, and the rod-shaped aerosol-generating material portion and the inductively heatable susceptor may be enclosed by the substantially cylindrical packaging material. The aerosol product article is easy to manufacture due to its shape. The shape may also facilitate storage / packaging of multiple aerosol product articles, handling of the article by a user, and insertion of the article into a cavity of an aerosol-generating device.

[0014] One or both ends of each of the inductively heatable susceptor, the rod-shaped aerosol-generating material portion, and the tubular wrapper may be aligned substantially longitudinally, which facilitates manufacturing of the aerosol product article and optimizes airflow through the aerosol product article by allowing air to enter only at the edge of the bundle of aerosol-generating bands and exit only at the opposite edge of the bundle.

[0015] In one embodiment, the aerosol-generation zone, the strip-shaped inductively heatable susceptor, and the shell may be substantially the same length. For example, the aerosol-generation zone, the strip-shaped inductively heatable susceptor, and the tubular wrapping material may be substantially the same length. Such a configuration may be used in conjunction with a shell or ensures that there is a uniform distribution of the aerosol-generating zones in the longitudinal direction within the tubular packing, thereby ensuring uniform airflow through the aerosol product and uniform heating (as the density of the zones is uniform in the first direction). Furthermore, this configuration prevents the aerosol-generating zones from falling out of the tubular packing.

[0016] In another embodiment, at least some of the aerosol-generation zones have a length less than the length of the shell. For example, at least some of the aerosol-generation zones have a length less than the length of the tubular packaging material. Such a configuration can facilitate the manufacture of the aerosol product. Furthermore, the edges of the aerosol-generation zones are exposed to the airflow within the shell so that aerosols can be generated more efficiently.

[0017] The aerosol production article may include at least two strip-shaped inductively heatable susceptors. The use of multiple strip-shaped susceptors results in more uniform and efficient heating of the aerosol-generation zone because the strip-shaped susceptors are at different locations within the shell.

[0018] The main surfaces of the at least two strip-shaped susceptors may be oriented substantially in a second direction that may be substantially perpendicular to the first direction, which may allow the strip-shaped susceptors to be more effectively coupled to and heated by an electromagnetic field generated by an induction coil of the aerosol generating device.

[0019] At least one of the aerosol-generation zones may be disposed between at least two strip susceptors, which do not contact each other and are therefore more efficiently heated.

[0020] The at least two strip susceptors may be surrounded by an aerosol-generation zone, such a configuration providing optimal heating and therefore optimal aerosol generation, since all of the heat generated in the strip susceptors is transferred to the aerosol-generation zone.

[0021] The aerosol-generation zone may be free of folds, particularly in the first direction, which allows for a maximum and uniform density of the aerosol-generation zone within the shell and ensures a uniform airflow.

[0022] The band-shaped inductively heatable susceptor may be free of folds, particularly in the first direction, which results in uniform heating of the aerosol-generation band due to uniform band resistance, thereby avoiding heat concentrations (or hot spots) that may occur in the presence of folds.

[0023] The aerosol product article may be substantially cylindrical and may include a formation for facilitating circumferential positioning of the aerosol product article in the aerosol generation device. The formation may include, for example, a protrusion or a recess, such as a groove, on the outer surface of the aerosol product article. The formation advantageously facilitates positioning of the aerosol product article in the aerosol generation device in an orientation that optimally positions the inductively heatable susceptor relative to the electromagnetic field generated by the induction coil of the aerosol generation device.

[0024] The aerosol product may include a filter comprising, for example, cellulose acetate fibers.

[0025] The aerosol production article may include a vapor cooling region that may advantageously allow heated vapor generated by heating the aerosol-generation zone to be cooled and condensed, e.g., through a filter, to form an aerosol having suitable properties for inhalation by a user. The vapor cooling region may include a hollow chamber that is configured to absorb heat from the heated vapor, causing it to cool and condense. The heat absorbing material may comprise a metal, for example aluminium.

[0026] The aerosol product may have a diameter of 4.0 mm to 10.0 mm, or may be 5.0 mm to 9.0 mm, or in some cases 6.0 mm to 7.5 mm.

[0027] The aerosol-generation zone may have a width of from 0.2 mm to 10.0 mm. The width may be from 0.2 mm to 7.0 mm, optionally from 0.2 mm to 5.0 mm, optionally from 0.2 mm to 3.0 mm, or optionally from 0.2 mm to 2.0 mm.

[0028] The aerosol-generation zone may have a thickness of 0.05 mm to 0.7 mm. The thickness may be 0.05 mm to 0.5 mm, or in some cases 0.05 mm to 0.3 mm.

[0029] The aerosol-generation zone may have a tensile strength of 200 to 900 N / m. The tensile strength may be 300 to 800 N / m, or in some cases 400 to 700 N / m. This helps to ensure that the aerosol-generation zone does not break during the manufacture of the aerosol product.

[0030] The aerosol-generation zone may comprise a plant-derived material, in particular tobacco. The aerosol-generation zone may comprise, for example, reconstituted tobacco, which includes tobacco and any one or more of cellulose fiber, tobacco stem fiber, and an inorganic filler such as CaCO. The aerosol-generation zone may comprise an extruded zone, which may comprise, for example, an extruded aerosol-generating material, such as tobacco or reconstituted tobacco.

[0031] The aerosol-generating zone may include an aerosol-forming agent. Examples of aerosol-forming agents include polyhydric alcohols, such as glycerin or propylene glycol, and mixtures thereof. Typically, the aerosol-generating zone may contain an aerosol-forming agent content of about 5% to about 50% on a dry weight basis. In some embodiments, the aerosol-generating zone may contain an aerosol-forming agent content of about 10% to about 20% on a dry weight basis, and in some cases about 15% on a dry weight basis.

[0032] Inductively heatable susceptors may include, but are not limited to, one or more of aluminum, iron, nickel, stainless steel, and alloys thereof, such as nickel-chromium or nickel-copper. Application of an electromagnetic field in the vicinity of the susceptor may cause the susceptor to generate heat due to eddy currents and magnetic hysteresis losses resulting in electromagnetic-to-thermal energy conversion.

[0033] The induction coil of the aerosol generating device may comprise Litz wire or Litz cable, although it should be understood that other materials may be used. The induction coil may be substantially helical in shape, for example extending around a cavity in which the aerosol product article is placed.

[0034] The circular cross section of the spiral induction coil makes it easier to insert the aerosol product into the aerosol generation device, for example into a cavity in which the aerosol product is received during use, and can ensure uniform heating of the aerosol generation zone.

[0035] The induction coil may be configured, in use, to operate with a varying electromagnetic field having a magnetic flux density of between about 20 mT and about 2.0 T at its highest density point.

[0036] The aerosol generating device may include a power source and circuitry that may be configured to operate at a high frequency, between about 80 kHz and 500 kHz, and optionally between about 150 kHz and 500 kHz. The power supply and circuitry may be configured to operate at frequencies between 250 kHz and possibly around 200 kHz. Depending on the type of inductively heatable susceptor used, the power supply and circuitry may be configured to operate at higher frequencies, for example in the MHz range.

[0037] According to a second aspect of the present disclosure, there is provided a method for continuously producing an aerosol product as defined above, comprising the steps of: (i) providing at least 10 aerosol-generating zones to a packaging station; (ii) providing an inductively heatable susceptor to a packaging station; (iii) packaging the aerosol-generation zone and the inductively heatable susceptor to form a continuous rod; A method is provided, comprising:

[0038] The methods according to the present disclosure facilitate the manufacture of aerosol products, and in particular allow for the relatively easy mass production of aerosol products.

[0039] The method is: (iv) cutting the continuous rod to form a plurality of individual aerosol product pieces; It may further include:

[0040] Step (ii) may comprise positioning an inductively heatable susceptor between the aerosol-generation zones. Positioning the inductively heatable susceptor between the aerosol-generation zones ensures that effective heating of the aerosol-generation zones is achieved.

[0041] Step (i) may include cutting the aerosol-generating sheet to form the aerosol-generating zone immediately prior to or during placement of the end of the aerosol-generating zone within the substantially tubular wrapper formed in step (iii). Manufacture of the aerosol product article is simplified by working with an aerosol-generating sheet rather than multiple aerosol-generating zones up until the point at which the aerosol-generating zone is placed within the substantially tubular wrapper.

[0042] Step (ii) may include, for example, holding the inductively heatable susceptor while placing an end of the inductively heatable susceptor within the substantially cylindrical envelope formed in step (iii) to orient a major surface of the susceptor. In this configuration, the orientation of the inductively heatable susceptor may be ensured. In the case of multiple susceptor strips, for example, the major surfaces of the susceptors may be ensured to be oriented in the same direction, thereby providing an aerosol product with optimal heating and airflow characteristics.

[0043] Step (ii) may include feeding at least two strip-shaped susceptors to a packaging station.

[0044] In one embodiment, each of the at least two susceptor strips may be fed by a different feed unit, allowing the susceptor strips to be precisely positioned within the aerosol product.

[0045] In another embodiment, each of the at least two susceptor strips may be fed by a common feed unit, thereby simplifying the feeding of the susceptor strips to the packaging station.

[0046] The method may further comprise detecting the position of the inductively heatable susceptor within the cross-sectional frame of the continuous rod after step (iii). The detecting step may be performed using a camera.

[0047] The method may further include stopping production to obtain a desired position of the inductively heatable susceptor within the cross-sectional frame of the continuous rod and / or adjusting one or more susceptor feed units based on the detected position. The position of the inductively heatable susceptor within the cross-sectional frame of the continuous rod may be adjusted and optimized, for example, by repositioning one or more susceptor feed units. [Brief explanation of the drawings]

[0048] [Figure 1] 1a-1b are schematic cross-sectional side and end views, respectively, of a first example of an aerosol product article. [Figure 2] 2a-2b are schematic cross-sectional side and end views, respectively, of a second example of an aerosol product. [Figure 3] 3a-3b are schematic cross-sectional side and end views, respectively, of a third example of an aerosol product. [Figure 4] 4a-4b are schematic cross-sectional side and end views, respectively, of a fourth example of an aerosol product article. [Figure 5a] FIG. 10 is a schematic cross-sectional end view of a fifth example of an aerosol production article. [Figure 5b] FIG. 5b is a cross-sectional view taken along line AA in FIG. 5a. [Figure 6a] FIG. 10 is a schematic cross-sectional end view of a sixth example of an aerosol production article. [Figure 6b] FIG. 6b is a cross-sectional view taken along line AA in FIG. 6a. [Figure 7a] FIG. 10 is a schematic cross-sectional end view of a seventh example of an aerosol production article. [Figure 7b] FIG. 7b is a cross-sectional view taken along line AA in FIG. 7a. [Figure 8-1]8a-8c are schematic diagrams of an apparatus and method for producing the first example aerosol product shown in FIGS. 1a and 1b, with FIG. 8a being a top view and FIG. 8b being a side view. [Figure 8-2] 8a-8c are schematic diagrams of an apparatus and method for producing the first example aerosol product shown in FIGS. 1a and 1b, with FIG. 8a being a top view and FIG. 8b being a side view. [Figure 9-1] 9a-9c are schematic diagrams of an apparatus and method for producing an eighth example aerosol product, with FIG. 9a being a top view and FIG. 9b being a side view. [Figure 9-2] 9a-9c are schematic diagrams of an apparatus and method for producing an eighth example aerosol product, with FIG. 9a being a top view and FIG. 9b being a side view. DETAILED DESCRIPTION OF THE INVENTION

[0049] Embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0050] 1a and 1b, there is shown a first example of an aerosol product article 1 for use in an aerosol generating device that includes an induction coil and operates on the principle of induction heating. Such devices are known in the art and will not be described in further detail herein. The aerosol product 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.

[0051] The aerosol product article 1 includes an aerosol-generating material portion 10 having a first end 10a and a second end 10b, and an inductively heatable susceptor 12 disposed within and enclosed by a shell 14. The shell 14 comprises a substantially electrically non-conductive and non-magnetically permeable material. In the illustrated example, the shell 14 comprises a tubular paper wrapper 16.

[0052] The aerosol-generating material section 10 is a first section formed by the longitudinal direction of the aerosol-generating material section 1. 1a and 1b, the aerosol-production article 1 is substantially rod-shaped, including at least ten aerosol-generation zones 18 oriented substantially in the direction of the aerosol-production article 1. A plurality of gaps (not visible in FIGS. 1a and 1b) are typically present between the aerosol-generation zones 18, which provide airflow paths through the aerosol-production article 1. The aerosol-generation zones 18 are free of longitudinal folds, ensuring that the airflow paths are uninterrupted and that uniform airflow through the article 1 is achieved.

[0053] The inductively heatable susceptor 12, like the aerosol-generation zone 18, includes a plurality of strip-shaped susceptors 20 oriented substantially in a first direction defined by the longitudinal direction of the aerosol-product article 1. The strip-shaped susceptors 20 are free of longitudinal folds to prevent hot spots in the aerosol-generating material section 10. As is apparent from FIG. 1b, four strip-shaped susceptors 20 are disposed within the shell 14. In practice, any suitable number of strip-shaped susceptors 20 may be disposed within the shell 14, depending on the heating requirements. Each of the strip-shaped susceptors 20 is advantageously surrounded by the aerosol-generation zone 18, thereby ensuring that heat transfer to the aerosol-generation zone 18 is maximized and further ensuring that the strip-shaped susceptors 20 do not contact one another.

[0054] In the illustrated first example of the aerosol product 1, the tubular packaging material 16, the aerosol-generation band 18, and the band-shaped susceptor 20 are all substantially the same length and their respective ends are aligned longitudinally so that they are at the same height.

[0055] The aerosol product 1 includes a vapor cooling region 22 in the form of a hollow chamber 24 located downstream of the aerosol-generating material section 10. The aerosol product 1 also includes a filter 26, e.g., comprising cellulose acetate fibers, located downstream of the vapor cooling region 22 through which a user can inhale the aerosol or vapor generated during use of the article 1 in an aerosol-generating device. As best seen in Figure 1a, the downstream end of the tubular wrapper 16, the vapor cooling region 22, and the filter 26 are wrapped in a wrapper 28 in the form of a sheet of material, e.g., tipping paper, to assemble the tubular wrapper 16 and the filter 26 and maintain their relative positions.

[0056] The aerosol-generation zone 18 typically comprises a plant-derived material such as tobacco. The aerosol-generation zone 18 advantageously comprises reconstituted tobacco, which includes tobacco and any one or more of cellulose fiber, tobacco stem fiber, and an inorganic filler such as CaCO.

[0057] The aerosol-generation zone 18 includes an aerosol-forming agent, such as glycerin or propylene glycol. Typically, the aerosol-generation zone 18 includes an aerosol-forming agent content of about 5% to about 50% on a dry weight basis. Upon heating, the aerosol-generation zone 18 releases volatile compounds, optionally including flavor compounds such as nicotine or tobacco flavorings.

[0058] During use of the article 1 in an aerosol-generating device, application of a time-varying electromagnetic field near the strip susceptor 20 generates heat in the strip susceptor 20 due to eddy currents and magnetic hysteresis losses. This heat is transferred from the strip susceptor 20 to the aerosol-generation zone 18, heating rather than burning the aerosol-generation zone 18 and releasing one or more volatile compounds, thereby generating vapor. When a user inhales through the filter 26, the heated vapor is drawn downstream through the article 1 from the first end 10 a of the aerosol-generating material portion 10 toward the filter 26. As the heated vapor flows through the vapor cooling region 22 toward the filter 26, it cools and condenses to form an aerosol with suitable properties for inhalation by a user through the filter 26.

[0059] To ensure that the aerosol-producing article 1 is optimally positioned in the cavity or heating compartment of the aerosol-generating device relative to the induction coil, the article 1 is positioned as shown in FIG. As can be best seen in Fig. 1, the strip-shaped susceptor 20 includes protrusions 30 on its outer surface which, during use, can be positioned in correspondingly shaped recesses formed in the housing of the aerosol generating device to ensure optimal coupling of the strip-shaped susceptor 20 with the electromagnetic field generated by the induction coil.

[0060] Referring now to Figures 2a and 2b, there is shown a second example of an aerosol product 2 similar to the aerosol product 1 shown in Figures 1a and 1b, with corresponding elements designated using the same reference numbers.

[0061] The aerosol-producing article 2 corresponds in all respects to the aerosol-producing article 1 shown in Figures 1a and 1b, except that the inductively heatable susceptor 12 is substantially I-shaped or pin-shaped and includes a single elongated portion 32 located in the center of the aerosol-generating material section 10 to ensure uniform heating of the aerosol-generation zone 20.

[0062] In the illustrated example, the I-shaped inductively heatable susceptor 12 extends only partially through the aerosol-generating material section 10, from the first end 10a to a midpoint between the first end 10a and the second end 10b. However, one skilled in the art will appreciate that the inductively heatable susceptor 12 can be the same length as the aerosol-generation zone 18 and extend completely through the aerosol-generating material section 10, from the first end 10a to the second end 10b.

[0063] Referring now to Figures 3a and 3b, there is shown a third example of an aerosol product 3 similar to the aerosol product 1 shown in Figures 1a and 1b, with corresponding elements designated using the same reference numbers.

[0064] 1a and 1b in all respects except that the inductively heatable susceptor 12 is cylindrical. The aerosol-generation zone 18 of the aerosol-generating material section 10 is positioned both inside and outside the cylindrical inductively heatable susceptor 12 to maximize heat transfer to the aerosol-generation zone 18, thereby maximizing the amount of aerosol generated and maximizing energy efficiency.

[0065] In a preferred embodiment, the cylindrical inductively heatable susceptor 12 and the cylindrical wrapper 16 are concentric, thereby ensuring uniform heating of the aerosol-generation zone 18 .

[0066] In the illustrated example, the cylindrical inductively heatable susceptor 12 extends only partially through the aerosol-generating material section 10, from the first end 10a to a midpoint between the first end 10a and the second end 10b. However, one skilled in the art will appreciate that the cylindrical inductively heatable susceptor 12 can be the same length as the aerosol-generation zone 18 and extend completely through the aerosol-generating material section 10, from the first end 10a to the second end 10b.

[0067] Referring now to Figures 4a and 4b, a fourth example of an aerosol product 4 is shown which is similar to the aerosol product 1 shown in Figures 1a and 1b, and corresponding elements are designated using the same reference numbers.

[0068] 1a and 1b, except that the inductively heatable susceptor 12 is substantially U-shaped and includes two elongated portions 12a, 12b extending partially through the aerosol-generating material section 10 from a first end 10a to a midpoint between the first end 10a and the second end 10b, and a connecting portion 12c disposed at the first end 10a connecting the two elongated portions 12a, 12b. In the illustrated example, the upstream end of the U-shaped inductively heatable susceptor 12, defined by the connecting portion 12c, is embedded in the aerosol-generation zone 18 at the first end 10a of the aerosol-generating material section 10. 1, whereby the inductively heatable susceptor 12 is completely surrounded by the aerosol-generation zone 18 .

[0069] Again, those skilled in the art will appreciate that the elongated portions 12 a, 12 b of the U-shaped inductively heatable susceptor 12 can be the same length as the aerosol-generation zone 18 and can extend completely through the aerosol-generating material section 10 from the first end 10 a to the second end 10 b.

[0070] Referring now to Figures 5a and 5b, a fifth example of an aerosol product 5 is shown which is similar to the aerosol product 1 shown in Figures 1a and 1b, and corresponding elements are designated using the same reference numbers.

[0071] The aerosol-producing article 5 includes a shell 14 in the form of a tube 34 having a rectangular cross section and comprising a heat-resistant plastic material such as polyetheretherketone (PEEK). The plastic tube 34 is open at both ends and encloses a plurality of aerosol-generation zones 18 and strip-shaped susceptors 20 oriented along the length of the article 5.

[0072] Referring now to Figures 6a and 6b, a sixth example of an aerosol product 6 is shown which is similar to the aerosol product 5 shown in Figures 5a and 5b, and corresponding elements are designated using the same reference numbers.

[0073] The aerosol-producing article 6 includes a shell 14 in the form of a cup 36 having a rectangular cross section and comprising a plastic material. The plastic cup 36 encloses a plurality of aerosol-generating zones 18 and strip-shaped susceptors 20 oriented along the length of the article 6.

[0074] The plastic cup 36 has a closed end 38 and includes a plurality of openings 40 at the closed end 38 that allow air to flow into the aerosol-generating material portion 10. The openings 40 are typically evenly distributed to ensure uniform airflow through the aerosol-generating material portion 10 during use of the aerosol product article 6 in an aerosol-generating device.

[0075] Referring now to Figures 7a and 7b, there is shown a seventh example of an aerosol product product 7 similar to the aerosol product product 5 shown in Figures 5a and 5b, with corresponding elements designated using the same reference numbers.

[0076] The aerosol-production article 7 includes a shell 14 in the form of a tube 42 having a rectangular cross-section and comprising a plastic material or paper. The tube 42 is open at both ends and encloses a plurality of aerosol-generation zones 18 oriented in the longitudinal direction of the article 7. In this example, the inductively heatable susceptor 12 is cylindrical and has a rectangular cross-sectional shape corresponding to the cross-sectional shape of the tube 42. It will thus be understood that a major surface of the susceptor 12 is oriented in a second direction substantially perpendicular to the longitudinal direction of the article 7 (i.e., the first direction) along which the aerosol-generation zones 18 are oriented, thereby ensuring optimal coupling with the electromagnetic field generated by the induction coil of the aerosol-generating device.

[0077] Apparatus 50, 80 and methods suitable for producing aerosol products according to the present disclosure, such as the aerosol product 1 described above with reference to Figures 1a and 1b, will now be described.

[0078] Referring to Figures 8a-8c, there is shown a schematic diagram of an apparatus 50 and method for producing the first example of the aerosol product article 1 described above with reference to Figures 1a and 1b.

[0079] The apparatus 50 includes a supply reel (not shown) carrying an aerosol-generating sheet 52 in continuous sheet form. The apparatus includes a wrapping station 62 and a cutting station 64. The wrapping station 62 and the cutting station 64 are connected to a susceptor feed unit 54a, 54b, a susceptor feed unit in the form of susceptor feed rollers 56, 58, and a feed roller 60 for supplying a sheet of wrapper paper 70. The apparatus further includes a wrapping station 62 and a cutting station 64.

[0080] During operation, the aerosol-generating sheet 52 is continuously fed from a supply reel to the cutting rollers 54a, 54b. The cutting rollers 54a, 54b include cutting formations that cooperate to cut the aerosol-generating sheet 52 into a plurality of continuous aerosol-generating strips 18, which are then fed to the packaging station 62. Simultaneously, the susceptor feed rollers 56, 58 continuously feed first and second continuous strips 66, 68 of inductively heatable susceptors 12 to the packaging station 62 from a supply reel (not shown).

[0081] A continuous sheet 70 of wrapper paper is fed from a supply reel (not shown) by feed rollers 60 to wrapping station 62. As sheet 70 of wrapper paper is transported and guided through wrapping station 62, sheet 70 is wrapped around continuous aerosol-generation zone 18 and first and second continuous zones 66, 68 of inductively heatable susceptor 12, thereby forming a continuous rod 72.

[0082] The continuous rod 72 is then transferred to the cutting station 64 where it is cut to length at appropriate locations to form a plurality of aerosol product articles 1. The continuous aerosol-generation zone 18, the first and second continuous zones 66, 68 of inductively heatable susceptor 12, and the continuous tubular wrapping material 16 are all cut to the same length at the cutting station 64 to form individual aerosol product articles 1. It should be understood that this type of process is suitable for mass production of aerosol product articles 1.

[0083] The apparatus 50 further includes a camera 74 that detects the position of the susceptor strip 20 within the cross-sectional frame of the continuous rod 72 that is to be cut to form the aerosol product article 1. If the position of the susceptor strip 20 detected by the camera 74 is not optimal, the positions of the susceptor feed rollers 56, 58 may be adjusted, for example manually or automatically, based on the detected positions to ensure that the susceptor strip 20 is optimally positioned. The apparatus 50 may stop producing the aerosol product article 1 while the susceptor feed rollers 56, 58 are repositioned, or alternatively, the apparatus 50 may continue to produce the aerosol product article 1 while the susceptor feed rollers 56, 58 are repositioned.

[0084] In a variation of the apparatus 50 and method, the susceptor feed rollers 56, 58 may continuously feed individual pre-cut strips of susceptor 20 to the packaging station 62 rather than continuous strips 66, 68 of inductively heatable susceptor 12 as described above. In this case, the susceptor feed rollers 56, 58 are adapted to hold one end of each strip of susceptor 20 while the opposite end is appropriately positioned at the packaging station 62.

[0085] 9a-9c, there is shown an example apparatus 80 and method for producing the eighth example aerosol product article 8 shown in Figure 9c. Certain elements of the apparatus 80 and method are similar to the apparatus 50 and method described above with reference to Figures 8a-8c and are therefore designated using the same reference numerals.

[0086] Apparatus 80 includes feed rollers 60, 86 that feed a continuous sheet of wrapper paper 70 from a supply reel (not shown) to packaging station 62. Apparatus 80 further includes a hopper 82 that contains a supply of aerosol-generation zones 18, optionally of varying lengths. During operation, the aerosol-generation zones 18 stored in hopper 82 are randomly positioned on top of the continuous sheet of wrapper paper 70 as it is transported by feed rollers 60, 86 to packaging station 62. In this configuration, the aerosol-generation zones 18 are positioned in a random fashion as shown schematically in Figures 9a-9c. It should be understood that the plates may overlap in the longitudinal direction.

[0087] A susceptor feed unit in the form of susceptor feed rollers 84 continuously feeds first and second continuous bands 66, 68 of inductively heatable susceptors 12 to packaging station 62 from supply reels (not shown).

[0088] As the sheet 70 of wrapper paper is transported and guided through the wrapping station 62, the sheet 70 is wrapped around the aerosol-generation zone 18 and the first and second continuous zones 66, 68 of the inductively heatable susceptor 12, thereby forming a continuous rod 72.

[0089] The continuous rod 72 is then transported to the cutting station 64 where it is cut to length at appropriate locations to form a plurality of aerosol product articles 8. Several of the aerosol-generation bands 18 may be cut at the cutting station 64 depending on their location within the continuous rod 72, while the first and second continuous bands 66, 68 of inductively heatable susceptor 12 and the continuous tubular wrapping material 16 are cut to identical lengths at the cutting station 64 to form individual aerosol product articles 8. It should again be understood that this type of process is suitable for mass production of aerosol product articles 8.

[0090] In a variation of the apparatus 80 and method, the susceptor feed rollers 84 may continuously feed individual pre-cut strip susceptors 20 to the packaging station 62 rather than the continuous strips 66, 68 of inductively heatable susceptors 12 as described above. In this case, the susceptor feed rollers 84 are adapted to hold one end of each strip susceptor 20 while the opposite end is appropriately positioned at the packaging station 62.

[0091] In a further variation of the apparatus 80 and method, the apparatus 80 may include an additional hopper (not shown) positioned downstream of the hopper 82 and containing a supply of susceptor strips 20. The additional hopper may be adapted to place susceptor strips 20 on top of the sheet of wrapper 70, and more particularly on top of the aerosol-generation strip 18 deposited from the hopper onto the sheet of wrapper 70. It should be understood that in this case, susceptor feed rollers 84 are not required.

[0092] 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.

[0093] 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.

[0094] 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 shell (14); an aerosol-producing article comprising an aerosol-generating material portion (10) and an inductively heatable susceptor (12, 20) disposed within the shell (14), the aerosol-generating material section (10) includes at least ten aerosol-generating zones (18) oriented substantially in a first direction; the inductively heatable susceptor (12, 20) is disposed between the aerosol-generation zones (18) and includes an elongated portion oriented substantially in the first direction; Aerosol products.

2. 2. The aerosol product article of claim 1, wherein the inductively heatable susceptor (12, 20) is strip-shaped and oriented substantially in the first direction.

3. 3. The aerosol product article of claim 1, wherein the aerosol-generating material portion (10) is rod-shaped, the shell (14) includes a substantially cylindrical wrapping material (16), and the rod-shaped aerosol-generating material portion (10) and the inductively heatable susceptor (12, 20) are enclosed by the substantially cylindrical wrapping material (16).

4. 4. The aerosol product of claim 3, wherein one or both ends of the inductively heatable susceptor (12, 20), the rod-shaped aerosol-generating material portion (10), and the cylindrical wrapping material (16) are aligned substantially longitudinally.

5. 5. An aerosol production article according to claim 3 or 4, wherein the aerosol-generation zone (18), the strip-shaped inductively heatable susceptor (12, 20), and the tubular wrapper (16) are of substantially the same length.

6. 5. An aerosol-producing article according to claim 3 or 4, wherein at least some of the aerosol-generating zones (18) have a length that is less than the length of the tubular wrapper (16).

7. An aerosol product article according to any one of claims 1 to 6, wherein the aerosol product article comprises at least two strip-shaped inductively heatable susceptors (12, 20).

8. 8. The aerosol product article of claim 7, wherein a major surface of each of the at least two strip-shaped susceptors (12, 20) is oriented substantially in a second direction substantially perpendicular to the first direction.

9. 9. An aerosol production article according to claim 7 or 8, wherein at least one of said aerosol-generation zones (18) is arranged between said at least two strip-shaped susceptors (12, 20).

10. An aerosol production article according to any one of claims 7 to 9, wherein said at least two strip-shaped susceptors (12, 20) are surrounded by said aerosol-generation zone (18).

11. An aerosol production article according to any one of claims 1 to 10, wherein the aerosol-generation zone (18) is free of folds.

12. 12. The aerosol product article according to any one of claims 1 to 11, wherein the aerosol product article is substantially cylindrical and includes a formation (30) for facilitating circumferential positioning of the aerosol product article in an aerosol generation device.

13. A method for continuously producing an aerosol product according to any one of claims 1 to 12, comprising the steps of: (i) providing at least 10 aerosol-generation zones (18) to a packaging station (62); (ii) feeding an inductively heatable susceptor (12, 20) to said packaging station (62); (iii) packaging the aerosol-generation zone (18) and the inductively heatable susceptor (12, 20) to form a continuous rod (72); A method comprising:

14. 14. The method of claim 13, wherein step (ii) comprises positioning the inductively heatable susceptor (12, 20) between the aerosol-generation zones (18).

15. 15. The method of claim 13 or 14, wherein step (i) comprises cutting the aerosol-generating sheet (52) to form the aerosol-generating zone (18) immediately before or while placing the end of the aerosol-generating zone (18) within the substantially tubular wrapping material (16) formed in step (iii).

16. 16. The method of any one of claims 13 to 15, wherein step (ii) comprises holding the inductively heatable susceptor (12, 20) while placing an end of the inductively heatable susceptor (12, 20) within the substantially tubular wrapper (16) formed in step (iii).

17. Step (ii) comprises supplying at least two strip-shaped susceptors (12, 20) to said packaging station (62); (a) each of the at least two strip-shaped susceptors (12, 20) is fed by a different feed unit (56, 58); or (b) each of the at least two strip-shaped susceptors (12, 20) is fed by a common feed unit (84); The method according to any one of claims 13 to 16.

18. The method of any one of claims 13 to 17, further comprising, after step (iii), detecting the position of the inductively heatable susceptor (12, 20) within the cross-sectional frame of the continuous rod (72).

19. 20. The method of claim 18, further comprising stopping production and / or adjusting one or more susceptor feed units (56, 58, 84) based on the detected position to obtain a desired position of the inductively heatable susceptor (12, 20) within the cross-sectional frame of the continuous rod (72).

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