Fabrication of aerosol-generating rods using curved tapered contact surfaces

Abstract

A method is provided for producing an aerosol-generating rod (3). A web material (19) is conveyed over a contact surface (39) of a contact body (27) such that the web material (19) contacts the contact surface (39). The contact surface (39) is curved about an axial direction (33) and tapers along the axial direction (33). A continuous portion of the contact surface (39) spans an angle of at least 90 degrees about the axial direction (33). An additive is discharged from at least one additive discharge port (43) disposed in the contact surface (39). The web material (19) is conveyed through a converging device (5) provided downstream of the contact body (27), and the web material (19) is formed into a rod (3) within the converging device (5).

Description

[Technical field]

[0001] The present disclosure relates to the manufacture of aerosol-generating rods using web materials. [Background technology]

[0002] It is known from practice to mold a web material in a molding device to obtain a rod for use in the manufacture of an aerosol-generating article. A susceptor may be incorporated into the rod in order to make it possible to generate heat by subjecting it to an alternating magnetic field, which heats the rod from the inside and causes the release of an aerosol from the rod. Summary of the Invention

[0003] According to a first aspect of the invention, there is provided a method of making an aerosol-generating rod. A web material is conveyed over a contact surface of a contact body such that the web material contacts the contact surface. The contact surface is curved in an axial direction. The contact surface is tapered along the axial direction. A continuous portion of the contact surface subtends an angle of at least 90 degrees about the axial direction. An additive is discharged from at least one additive outlet disposed in the contact surface. The web material is conveyed through a converging device. The converging device is provided downstream of the contact body. The web material is formed into a rod within the converging device.

[0004] The web material contacts the contact surface having the at least one additive outlet so that the additive can be discharged proximate to the web material. The distance between the at least one additive outlet and the web material being conveyed over the contact surface can be, for example, less than 5 millimeters, or less than 3 millimeters, or less than 2 millimeters, or less than 1 millimeter, or less than 0.5 millimeters.

[0005] The contact surface may be at least partially covered with an additive. The additive at least partially covering the contact surface may be additive dispensed through the at least one dispense port. Contact between the web material and the contact surface may improve distribution of the additive on the web material.

[0006] At least a portion of the additive may be applied directly to the web material from the at least one additive outlet. For example, at least a portion of the additive may be sprayed directly onto the web material from the at least one additive outlet. The at least one additive outlet may comprise a nozzle that sprays the additive onto the web material.

[0007] At least a portion of the additive dispensed from the at least one additive outlet can be indirectly applied to the web material via the contact surface, and at least a portion of the additive can be dispensed from the at least one additive outlet onto the contact surface and from the contact surface to the web material.

[0008] The web material may be conveyed over the contact surface along an axial direction. The web material may be conveyed over the contact surface towards a converging device.

[0009] Upon contact with the contact surface, the web material may be deformed. Upon contact with the contact surface, at least a portion of the web material may be deformed to conform to the shape of the contact surface. Because the contact surface is curved about an axial direction, the web material may be deformed to curve about an axial direction when conveyed over the contact surface. Because the contact surface is tapered along the axial direction, the web material may be deformed to tapered along the axial direction when conveyed over the contact surface.

[0010] As the web material is conveyed over the contact surface, the lateral sides of the web material may be deformed relative to a central portion of the web material as the web material conforms to the shape of the contact surface. The lateral sides of the web material may be deformed toward each other. The deformation of the web material due to contact with the contact surface may reduce a dimension of the web material in a lateral direction perpendicular to the axial direction.

[0011] Contact with the contact surface may preform the web material, facilitating shaping the web material into a rod within the converging device. Contact with the contact surface may deform the web material to facilitate entry of the web material into the converging device. Contact with the contact surface may cause the shape of the web material to become more compact.

[0012] The continuous portion of the contact surface may span an angle of at least 90 degrees about the axial direction such that the web material contacts the contact surface over an angle of at least 90 degrees about the axial direction. The continuous portion of the contact surface may span an angle of at least 90 degrees or more about the axial direction. The continuous portion of the contact surface may span an angle of at least 100 degrees, or at least 120 degrees, or at least 140 degrees, or at least 160 degrees, or at least 180 degrees, or at least 200 degrees, or at least 220 degrees, or at least 240 degrees, or at least 260 degrees, or at least 280 degrees, or at least 300 degrees, or at least 320 degrees, or at least 340 degrees about the axial direction. The continuous portion of the contact surface may span an angle of at least 360 degrees about the axial direction.

[0013] At least the entire continuous portion of the contact surface may be curved about the axial direction.At least the entire continuous portion of the contact surface may be continuously curved about the axial direction.At least the entire continuous portion of the contact surface may have a constant curvature about the axial direction.

[0014] At least a continuous portion of the contact surface may be tapered along the axial direction. At least a continuous portion of the contact surface may have a constant slope along the axial direction.

[0015] The converging device may include side walls defining a forming space. The web material may be conveyed through the forming space of the converging device. The web material may be formed into a rod by engagement with the side walls of the converging device. The converging device may be funnel-shaped. An open cross-section of the converging device may decrease along the path of the web material.

[0016] The web material may be conveyed over the contact surface such that only one side of the web material contacts the contact surface. The additive may be applied to only one side of the web material. The one side of the web material may be an upper side of the web material or an underside of the web material. The one side of the web material may be a side of the web material that faces away from a side wall of the converging device as the web material enters the converging device. By applying the additive to only one side of the web material, migration of the additive from the web material to equipment that contacts the other side of the web material may be reduced or prevented. For example, contamination of the side wall of the converging device with the additive may be reduced or prevented if the additive is applied only to the side of the web material that faces away from the side wall of the converging device as it is conveyed through the converging device.

[0017] The contact body may have a conical shape. The web material may be preformed into a conical shape by contact with the contact body to facilitate forming the web material into a rod.

[0018] The extension length of the contact surface along the axial direction may be at least 1 centimeter, or at least 2 centimeters, or at least 3 centimeters, or at least 4 centimeters, or at least 5 centimeters. The extension length of the contact surface along the axial direction may be less than 15 centimeters, or less than 12 centimeters, or less than 10 centimeters, or less than 8 centimeters, or less than 6 centimeters, or less than 5 centimeters. The extension length of the contact surface along the axial direction may be between 1 centimeter and 10 centimeters, or between 2 centimeters and 6 centimeters, or between 3 centimeters and 5 centimeters.

[0019] The at least one additive orifice may comprise a plurality of additive orifices, for example at least two additive orifices, or at least four additive orifices, or at least six additive orifices, or at least ten additive orifices.

[0020] The additive may be delivered through a plurality of additive outlets, which may be located at different angular positions around the axial direction.

[0021] The method may further include conveying the susceptor through a focusing device. Within the focusing device, the web material may be formed into a rod around the susceptor. The rod may incorporate the susceptor. The rod may incorporate the susceptor in its center. The susceptor may include or be formed from a metallic material. The susceptor may be configured to be heated by exposure to electromagnetic radiation, in particular alternating electromagnetic radiation. Heating the susceptor may allow the rod to be heated from within the rod. When the rod is heated, the rod may emit an aerosol for consumption by a user. The susceptor may be a strand of material. The strand of material may have, for example, a circular cross section, or a rectangular cross section, or a triangular cross section, or an elliptical cross section.

[0022] The web material is deformed by contact with the contact surface such that the web material at least partially curves around the susceptor as it enters the focusing device. The web material may be preformed by contact with the contact surface to reduce a risk of damage to the web material as it contacts the susceptor. The web material may be preformed by contact with the contact surface to facilitate folding of the web material around the susceptor.

[0023] The method may further include conveying the susceptor through the contact body. The susceptor may be conveyed through the contact body along an axial direction. Conveying the susceptor through the contact body may promote curvature of the web material around the susceptor.

[0024] The susceptor may be conveyed through a susceptor guide. The susceptor guide may extend axially beyond the contact body. The susceptor guide may pass through the contact body. The susceptor guide may comprise a sleeve that surrounds the susceptor. The susceptor guide may be provided upstream of the focusing device.

[0025] The susceptor guide may include a susceptor outlet opening. The susceptor may exit the susceptor guide from the susceptor outlet opening. The susceptor outlet opening may be provided upstream of the focusing device. The susceptor outlet opening may be provided downstream of the contact body. The distance between the contact body and the susceptor outlet opening may be at least 1 centimeter, or at least 2 centimeters, or at least 3 centimeters, or at least 4 centimeters, or at least 5 centimeters, or at least 6 centimeters, or at least 7 centimeters, or at least 10 centimeters. The distance between the contact body and the susceptor opening may be less than 30 centimeters, or less than 20 centimeters, or less than 15 centimeters, or less than 10 centimeters, or less than 5 centimeters.

[0026] The web material may be transported over an additional contact surface. The web material may contact an additional contact surface. The web material may be deformed by contact with the additional contact surface.

[0027] The additive may be discharged from the at least one additional additive outlet. The at least one additional additive outlet may be provided in the additional contact surface. The additive discharged from the at least one additional additive outlet may be the same type of additive as the additive discharged from the at least one additive outlet. The additive discharged from the at least one additional additive outlet may be a different type of additive than the additive discharged from the at least one additive outlet.

[0028] An additional contact surface may be provided upstream of the contact surface.An additional contact surface may be provided downstream of the contact surface.

[0029] The additional contact surface may be curved about the axial direction. The additional contact surface may be free of curvature along the axial direction. The additional contact surface may be parallel to the axial direction.

[0030] The additional contact surface may be defined by an additional contact body, which may be, for example, a cylinder or an ellipsoid.

[0031] The contact body with the contact surface and the additional contact body with the additional contact surface may be part of an additive dispensing assembly. The susceptor guide may be part of an additive dispensing assembly. The contact body may be disassembled from the additional contact body. The susceptor guide may be disassembled from the contact body. The susceptor guide may be disassembled from the additional contact body. The contact body, the additional contact body, and the susceptor guide may be disassembled into separate parts. Disassembling the parts may facilitate cleaning of the parts. Disassembling the parts may facilitate replacing one or more of the parts while maintaining the remaining parts.

[0032] The method may include crimping the web material. Crimping the web material may facilitate deformation of the web material. Crimping the web material may include forming ridges and grooves in the web material. The ridges and grooves may run in a direction parallel to the conveying direction of the web material. The crimping may be performed in a crimping device. The crimping device may be upstream of the contact surface. The crimping device may be downstream of the contact surface.

[0033] According to a second aspect of the invention, there is provided an apparatus for manufacturing an aerosol-generating rod. The apparatus comprises an additive application assembly, a conveyor system, and a converging device. The additive application assembly comprises a contact body defining a contact surface. At least one additional additive outlet may be provided at the contact surface. The conveyor system is configured for the web material to be conveyed over the contact surface such that the web material contacts the contact surface. The converging device is provided downstream of the additive application assembly. The additive application assembly comprises a susceptor guide configured to guide a susceptor. The susceptor extends beyond the contact body towards the converging device. The conveyor system is configured to convey the web material through the converging device and form the web material into a rod within the converging device around the susceptor.

[0034] The susceptor guide can extend beyond the contact body toward the focusing device so that the susceptor guide guides the susceptor between the contact body and the focusing device. The susceptor guide can prevent the web material from contacting the susceptor immediately after the additive is applied to the web material from the at least one additive outlet. The susceptor guide can prevent an excessive amount of additive from adhering to the susceptor.

[0035] The contact surface may be curved about the axial direction.

[0036] The at least one additive outlet may include a plurality of additive outlets disposed at different angular positions about the axial direction.

[0037] The contact surface may be tapered along the axial direction.

[0038] The continuous portion of the contact surface may subtend an angle of at least 90 degrees about the axial direction.

[0039] The conveyor system may be configured such that the web material is transported over the contact surface such that only one side of the web material contacts the contact surface.

[0040] The contact body may have a conical shape.

[0041] The susceptor guide may include a sleeve through which the susceptor is conveyed. The sleeve may extend along the axial direction. The sleeve may protrude from a downstream side of the contact body.

[0042] The conveyor system may be configured to transport the susceptor. The conveyor system may be configured to transport the susceptor through a susceptor guide. The conveyor system may be configured to transport the susceptor through a focusing device. The conveyor system may be configured to transport the susceptor through an opening in the contact body. The conveyor system may be configured to transport the susceptor through the contact body.

[0043] The susceptor guide may extend at least partially through the contact body. The susceptor guide may extend completely through the contact body.

[0044] The susceptor guide may include a susceptor outlet opening. The susceptor outlet opening may be provided upstream of the focusing device. The susceptor outlet opening may be provided downstream of the contact body. The susceptor outlet opening may be provided between the contact body and the focusing device. The susceptor outlet opening may be axially oriented. The susceptor outlet opening may be defined by a downstream end of the susceptor guide.

[0045] The contact body and the susceptor guide may be assembled, in particular detachably assembled.

[0046] The additive application assembly may include an additional contact body. The additional contact body may include an additional contact surface. The conveyor system may be configured to transport the web material over the additional contact surface. The conveyor system may be configured to transport the web material in contact with the additional contact surface.

[0047] At least one additional additive outlet may be provided in the additional contact surface.

[0048] An additional contact surface may be provided downstream of the contact surface.

[0049] The additional contact may be a cylindrical contact.

[0050] The contact body and the additional contact body may be removably combined.

[0051] The additional contact body and the susceptor guide may be detachably combined.

[0052] The apparatus may further comprise a crimping device configured to crimp the web material. The crimping device may be provided upstream of the additive application assembly. The crimping device may be provided downstream of the additive application assembly.

[0053] The apparatus may further comprise an additive reservoir. The at least one additive outlet may be connected to the additive reservoir. The at least one additive outlet may be configured to dispense an additive from the additive reservoir.

[0054] The at least one additional additive outlet may be connected to the additive reservoir or the additional additive reservoir. The at least one additional additive outlet may be configured to deliver an additive from the additive reservoir or the additional additive reservoir.

[0055] According to a third aspect of the invention, there is provided the use of a contact surface having at least one additive outlet provided thereon in a process for producing an aerosol-generating rod to apply an additive onto a web material and pre-shape the web material before it enters a focusing device where it is formed into a rod. The contact surface is curved in an axial direction. The contact surface is tapered along the axial direction. A continuous portion of the contact surface subtends an angle of at least 90 degrees about the axial direction.

[0056] According to a fourth aspect of the present invention, there is provided an apparatus for manufacturing an aerosol-generating rod. The apparatus comprises a contact body and a conveyor system. The contact body defines a contact surface. At least one additional additive outlet may be provided in the contact surface. The conveyor system is configured such that a web material is conveyed over the contact surface along an axial direction such that the web material contacts the contact surface. The extension dimension of the contact surface along the axial direction is less than 10 millimeters.

[0057] The narrow configuration of the contact surface, in which the extension dimension of the contact surface along the axial direction is less than 10 millimeters, can reduce contamination of the contact body with additive discharged from the at least one additive discharge port. Further, the narrow contact surface can reduce friction between the web material and the contact surface.

[0058] The extension dimension of the contact surface along the axial direction may be between 1 mm and 10 mm, or between 2 mm and 8 mm, or between 2 mm and 6 mm, or between 3 mm and 4 mm.

[0059] The extension dimension of the contact surface in a lateral direction perpendicular to the axial direction may be, for example, 30 mm to 200 mm, or 50 mm to 180 mm, or 70 mm to 160 mm.

[0060] The contact surface may be flat. The contact surface may be free of curvature in a lateral direction perpendicular to the axial direction. The contact surface may be a horizontal contact surface.

[0061] The opening direction of the at least one additive outlet port may be perpendicular to the axial direction.

[0062] The at least one additive outlet may comprise a plurality of additive outlets. The plurality of additive outlets may be disposed at different positions along a lateral direction perpendicular to the axial direction. The additive outlets may be disposed in a line. The line may extend perpendicular to the axial direction. The additive outlets may be equally spaced apart.

[0063] The apparatus may further include a converging device. The converging device may be provided downstream of the contact body. The conveyor system may be configured to transport the web material through the converging device and form the web material into a rod within the converging device.

[0064] The conveyor system can be configured to transport the susceptor through a focusing device, where the web material can be formed into a rod around the susceptor.

[0065] The apparatus may further include an adjustment assembly. The adjustment assembly may be configured to adjust at least one of a position and an orientation of the contact body. By adjusting at least one of a position and an orientation of the contact body, contact between the web material and the contact surface may be optimized. The contact body may be repositioned using the adjustment assembly to optimize contact pressure between the web material and the contact surface. The contact body may be repositioned with the adjustment assembly to optimize at least one of a position and an orientation of the contact body relative to a path along which the web material is transported.

[0066] The adjustment assembly may be configured to translate the contact body. The adjustment assembly may be configured to rotate the contact body. The adjustment assembly may be configured to translate the contact body and may be configured to rotate the contact body.

[0067] The additive supply path may be provided within the contact body. At least one additive outlet may be connected to the additive supply path. Each additive outlet may be connected to the additive supply path. The at least one additive outlet may be connected to the supply path by at least one branch path branching off from the additive supply path.

[0068] The additive delivery path can be a hollow portion of the contact body. The additive delivery path can be configured to guide the additive. The additive delivery path can be configured to at least partially guide the additive to the at least one additive outlet.

[0069] The additive supply path may extend laterally within the contact body. The lateral direction may be perpendicular to the axial direction. The lateral direction may be parallel to the contact surface.

[0070] The additive delivery pathway may extend laterally within the contact body across at least 30 percent, or at least 40 percent, or at least 50 percent, or at least 60 percent, or at least 70 percent, or at least 80 percent of the extended dimension of the contact body.

[0071] The additive delivery path may terminate in a cleaning opening in the outer surface of the contact body. The cleaning opening may be oriented laterally. The cleaning opening may be configured to allow a brush or the like to be inserted therein.

[0072] The additive delivery path may extend linearly within the contact body. The additive delivery path may extend linearly laterally within the contact body. The linear extension of the additive delivery path may facilitate cleaning of the additive delivery path, such as by inserting a brush into the cleaning opening.

[0073] The additive supply path may be connected to an additive supply port provided on the outer surface of the contact body. The additive supply port may be configured to connect to an external additive supply line. The external additive supply line may be connected to an additive tank.

[0074] The diameter of the additive supply channel can be, for example, 3 millimeters to 20 millimeters, or 3 millimeters to 10 millimeters, or 5 millimeters to 8 millimeters.

[0075] The additive feed path may have a circular cross-section. The additive feed path may have a rectangular cross-section. The additive feed path may have an elliptical cross-section. The additive feed path may have a triangular cross-section. The additive feed path may have a polygonal cross-section.

[0076] The contact piece may include an inclined surface adjacent to the contact surface along the axial direction, the inclined surface being inclined at an angle of 10 degrees to 80 degrees with respect to the contact surface about a horizontal axis perpendicular to the axial direction.

[0077] According to a fifth aspect of the present invention, there is provided a method of manufacturing an aerosol-generating rod. A web material is conveyed along an axial direction on a flat contact surface. The flat contact surface defines a contact body. The web material is in contact with the contact surface. An additive is discharged onto the web material from at least one additive outlet provided on the contact surface. The web material is conveyed over an inclined surface of the contact body. The inclined surface is adjacent to the contact surface along the axial direction. The inclined surface is inclined at 10 degrees to 80 degrees relative to the contact surface about a horizontal axis perpendicular to the axial direction.

[0078] The inclined surface may be inclined at 10 degrees to 60 degrees, or 10 degrees to 50 degrees, or 20 degrees to 40 degrees, or 25 degrees to 35 degrees, or about 30 degrees about the horizontal axis relative to the contact surface.

[0079] The transverse axis may be parallel to the contact surface. The transverse axis may extend along the interface between the contact surface and the inclined surface. The transverse axis may define the interface between the contact surface and the inclined surface.

[0080] The angled surface may be angled relative to the contact surface in a direction away from the web material.

[0081] The contact surface may face upwards, and the inclined surface may be inclined downwards along the axial direction.

[0082] The inclined surface may be a flat surface.

[0083] The beveled surface may extend axially beyond the contact surface by at least 3 millimeters, or at least 5 millimeters, or at least 6 millimeters, or at least 7 millimeters, or at least 8 millimeters. The beveled surface may extend axially beyond the contact surface by less than 50 millimeters, or less than 30 millimeters, or less than 25 millimeters, or less than 20 millimeters, or less than 10 millimeters, or less than 8 millimeters.

[0084] The web material may be conveyed over the inclined surface without contacting the inclined surface. The lack of contact between the web material and the inclined surface may reduce contamination of the contact body with additives downstream of the contact surface.

[0085] Since the inclination of the inclined surface relative to the contact surface is less than 90 degrees, the contact body can extend further along the axial direction than the contact surface, which can facilitate the design of the contact body, especially with regard to providing one or more additive supply lines within the contact body.

[0086] The extension dimension of the contact surface along the axial direction may be less than 10 millimeters.

[0087] The opening direction of the at least one additive outlet port may be perpendicular to the axial direction.

[0088] The web material may be conveyed through a focusing device provided downstream of the contact body to form the web material into a rod.

[0089] In any one of the described embodiments, the contact surface may be located less than 1 meter, or less than 60 centimeters, or less than 40 centimeters from the converging device. The contact surface may be located at least 5 centimeters, or between 5 centimeters and 20 centimeters from the converging device. By providing the contact surface in such close proximity to the converging device, the time that the additive is on the web material before the web material is formed into a rod may be reduced. This may help reduce the amount of additive lost from the web material during transport of the web material.

[0090] In any one of the described embodiments, the additive may include an aerosol generating agent, such as, for example, one or more of glycerin, glycerol, propylene glycol. The additive may include one or more flavorings, such as menthol, spearmint, peppermint, eucalyptus, vanilla, cocoa, chocolate, coffee, tea, spices (such as cinnamon, clove, ginger, etc.), fruit flavors, and combinations thereof. The additive may include nicotine.

[0091] The additive may be delivered, for example, as a liquid or as a gel.

[0092] Preferably, the additive comprises menthol. The additive may comprise at least 40 weight percent, or at least 50 weight percent, or at least 70 weight percent, or at least 80 weight percent, or at least 90 weight percent, or at least 95 weight percent menthol. The additive may be pure menthol. Menthol may act as an aerosol generating agent upon heating of the rod. Menthol has strong physical adhesion and can be applied to the web material in a reproducible manner.

[0093] In any one of the described embodiments, the web material may be a cast of a slurry containing herbaceous material, or a cast of a paste containing herbaceous material. The web material may be a cast leaf material, particularly a tobacco cast leaf material. The slurry or paste may include one or more types of herbaceous material. Casting the herbaceous material as a web allows the herbaceous material to be continuously fed into the production process.

[0094] The web material may comprise chopped or crushed herbaceous material. The chopped or crushed herbaceous material may comprise particulate herbaceous material having a particle size of, for example, 40 micrometers to 500 micrometers.

[0095] The herbaceous material may include homogenized plant material.

[0096] The herbaceous material may, for example, comprise tobacco material, or clove material, or a mixture of clove material and tobacco material. The tobacco material, or clove material, or a mixture of clove material and tobacco material may, but need not, comprise 100 percent of the herbaceous material. The herbaceous material may comprise no tobacco particles and 100 percent clove particles based on the dry weight of the herbaceous material. The herbaceous material may comprise 10 percent to 60 percent clove particles and 40 percent to 90 percent tobacco particles, more preferably 30 percent to 40 percent clove particles and 70 percent to 60 percent tobacco particles, based on the dry weight of the herbaceous material. For example, the web material may comprise a combined content of 40 percent to 90 percent tobacco particles and 10 percent to 60 percent clove particles, based on the dry weight of the web material.

[0097] The web material may include, for example, one or more of eugenol, eugenol acetate, and β-caryophyllene. In particular, the web material may include, on a dry weight basis, at least 125 micrograms of eugenol per gram of web material, on a dry weight basis, at least 125 micrograms of eugenol acetate per gram of web material, on a dry weight basis, and at least 1 microgram of β-caryophyllene per gram of web material, on a dry weight basis.

[0098] The web material may include at least one of cellulose fibers and glycerin. The cellulose fibers may strengthen the web material and increase its resistance to breaking or tearing. The glycerin may facilitate the generation of aerosols upon heating of the web material.

[0099] The web material may have a thickness of less than 1 millimeter, or less than 0.5 millimeters, or less than 0.2 millimeters, or less than 0.1 millimeters, or less than 0.05 millimeters. The web material may have a thickness of at least 0.001 millimeters, or at least 0.01 millimeters, or at least 0.1 millimeters. A web material with a relatively thin thickness may be easier to form into a rod shape. A web material with a relatively thick thickness may be less likely to tear or be damaged when dispensing additives onto the web material.

[0100] An apparatus for producing an aerosol-generating rod according to the second aspect may be adapted for use in a method for producing an aerosol-generating rod according to the first aspect, or in a use according to the third aspect. The method for producing an aerosol-generating rod according to the first aspect, or the use according to the third aspect, may comprise using an apparatus for producing an aerosol-generating rod according to the second aspect.

[0101] An apparatus for manufacturing an aerosol-generating rod according to the fourth aspect may be adapted for use in a method for manufacturing an aerosol-generating rod according to the fifth aspect. The method for manufacturing an aerosol-generating rod according to the fifth aspect may comprise using an apparatus for manufacturing an aerosol-generating rod according to the fourth aspect. [Brief description of the drawings]

[0102] [Figure 1] FIG. 1 shows a schematic side view of an apparatus for producing an aerosol-generating rod according to one embodiment using a contact body having a curved contact surface. [Diagram 2] FIG. 2 shows a schematic perspective view of an additive application assembly according to one embodiment using a contact body having a curved contact surface. [Diagram 3] FIG. 3 illustrates a cross-sectional view of an additive application assembly according to one embodiment using a contact body having a curved contact surface. [Figure 4]FIG. 4 shows a schematic diagram of an apparatus for producing an aerosol-generating rod according to one embodiment using a contact body having a flat contact surface. [Diagram 5] FIG. 5 shows a perspective view from above of a contact according to an embodiment having a flat contact surface. [Figure 6] FIG. 6 shows a bottom perspective view of a contact body according to an embodiment having a flat contact surface. [Figure 7] FIG. 7 shows an embodiment of a contact body having a flat contact surface in a cross section perpendicular to the axial direction. [Figure 8] FIG. 8 illustrates a side view of a contact according to one embodiment having a flat contact surface, viewed along a lateral direction. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0103] The present invention is defined in the claims. However, below is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of the other examples, embodiments, or aspects described herein.

[0104] Example 1: 1. A method for manufacturing an aerosol-generating rod, comprising the steps of: conveying the web material over a contact surface of a contact body such that the web material contacts the contact surface, the contact surface being curved about an axial direction and tapered along the axial direction, with a continuous portion of the contact surface subtending an angle of at least 90 degrees about the axial direction; Discharging an additive from at least one additive discharge port provided on the contact surface; conveying the web material through a converging device provided downstream of the contact body, wherein the web material is formed into a rod within the converging device.

[0105] Example 2: 2. The method of claim 1, wherein as the web material is conveyed over the contact surface, the lateral sides of the web material are deformed relative to a central portion of the web material as the web material conforms to the shape of the contact surface.

[0106] Example 3: 3. The method of claim 1 or 2, wherein the web material is conveyed over the contact surface such that only one side of the web material is in contact with the contact surface.

[0107] Example 4: The method according to any one of the preceding claims, wherein the contact body has a conical shape.

[0108] Example 5: The method according to any one of the first to fourth embodiments, wherein the additive is discharged from a plurality of additive discharge ports provided at different angular positions around the axial direction.

[0109] Example 6: The method of any one of the preceding claims, further comprising conveying the susceptor through a focusing device, wherein the web material is formed into a rod within the focusing device around the susceptor.

[0110] Example 7: The method of example 6, further comprising conveying the susceptor through the contact body.

[0111] Example 8: 8. The method of claim 6 or 7, wherein the susceptor is conveyed through a susceptor guide, the susceptor guide extending axially beyond the contact body.

[0112] Example 9: 9. The method of claim 8, wherein the susceptor exits the susceptor guide through a susceptor outlet opening, the susceptor outlet opening being at least one of: one provided upstream of the focusing device; and one provided downstream of the contact body.

[0113] Example 10: The method of any one of claims 1-9, further comprising conveying the web material over an additional contact surface.

[0114] Example 11: 11. The method of embodiment 10, further comprising dispensing the additive from at least one additional additive outlet in the additional contact surface.

[0115] Example 12: 12. The method of example 10 or 11, wherein an additional contact surface is provided downstream of the contact surface.

[0116] Example 13: The method according to any one of embodiments 10 to 12, wherein the additional contact surface is defined by an additional contact body, which may be a cylinder.

[0117] Example 14: The method of example 13, further comprising dissociating the contact body from the additional contact body.

[0118] Example 15: The method of any one of Examples 1-14, further comprising crimping the web material.

[0119] Example 16: 1. An apparatus for manufacturing an aerosol-generating rod, comprising: an additive application assembly comprising a contact body defining a contact surface, the contact surface having at least one additive outlet; a conveyor system configured to transport the web material over the contact surface such that the web material contacts the contact surface; a focusing device provided downstream of the additive application assembly; the additive application assembly includes a susceptor guide configured to guide the susceptor; a susceptor guide extending beyond the contact body toward the focusing device; The apparatus, wherein the conveyor system is configured to transport the web material through the focusing device and form the web material into a rod around a susceptor within the focusing device.

[0120] Example 17: 17. The device of example 16, wherein the contact surface is curved about the axial direction.

[0121] Example 18: 20. The apparatus of claim 17, wherein the at least one additive outlet comprises a plurality of additive outlets disposed at different angular positions about an axial direction.

[0122] Example 19: 19. The device of example 17 or 18, wherein the contact surface is tapered about the axial direction.

[0123] Example 20: 20. The device of any one of Examples 17-19, wherein the continuous portion of the contact surface subtends an angle of at least 90 degrees about the axial direction.

[0124] Example 21: 21. The apparatus of any one of Examples 16-20, wherein the conveyor system is configured to transport the web material over the contact surface such that only one side of the web material contacts the contact surface.

[0125] Example 22: The device according to any one of Examples 16 to 21, wherein the contact body has a conical shape.

[0126] Example 23: 23. The apparatus of any one of embodiments 16-22, wherein the susceptor guide at least partially penetrates the contact body.

[0127] Example 24: The method of any one of Examples 16 to 23, wherein the susceptor guide includes a susceptor outlet opening, the susceptor outlet opening being at least one of: provided upstream of the focusing device; and provided downstream of the contact body.

[0128] Example 25: The apparatus of any one of Examples 16-24, wherein the additive application assembly comprises an additional contact body, the additional contact body comprises an additional contact surface, and the conveyor system is configured to transport the web material over the additional contact surface.

[0129] Example 26: 26. The device of example embodiment 25, wherein the at least one additional additive outlet is disposed on the additional contact surface.

[0130] Example 27: 27. The apparatus of example 25 or 26, wherein an additional contact surface is provided downstream of the contact surface.

[0131] Example 28: 28. The apparatus of any one of Examples 25 to 27, wherein the additional contact is a cylindrical contact.

[0132] Example 29: The device according to any one of Examples 25 to 28, wherein the contact body and the additional contact body are detachably combined.

[0133] Example 30: 30. The apparatus of any one of Examples 16-29, further comprising a crimping device configured to crimp the web material.

[0134] Example 31: The apparatus of example 31, wherein a crimping device is provided upstream of the additive application device.

[0135] Example 32: 1. Use of a contact surface having at least one additive outlet provided for applying an additive onto a web material and preforming the web material before it enters a focusing device where it is formed into a rod in the manufacture of an aerosol-generating rod, wherein the contact surface is curved about an axial direction and tapered about the axial direction, and a continuous portion of the contact surface spans at least 90 degrees about the axial direction.

[0136] Example 33: 1. An apparatus for manufacturing an aerosol-generating rod, comprising: a contact body defining a contact surface, the contact body having at least one additive outlet disposed in the contact surface; a conveyor system configured to transport the web material axially over the contact surface such that the web material contacts the contact surface; An apparatus in which the extension dimension of the contact surface along an axial direction is less than 10 millimeters.

[0137] Example 34: 34. The device according to embodiment 33, wherein the contact surface has no curvature in a transverse direction perpendicular to the axial direction, in particular the contact surface is flat.

[0138] Example 35: The device of embodiment 33 or 34, wherein the opening direction of at least one additive outlet is perpendicular to the axial direction.

[0139] Example 36: The apparatus of any one of Examples 33 to 35, further comprising a converging device provided downstream of the contact body, the conveyor system configured to transport the web material through the converging device and form the web material into a rod within the converging device.

[0140] Example 37: An apparatus described in any one of Examples 33 to 36, further comprising an adjustment assembly configured to adjust at least one of a position and orientation of the contact body.

[0141] Example 38: The apparatus according to any one of Examples 33 to 37, wherein an additive supply path is provided within the contact body, and at least one additive outlet is connected to the additive supply path.

[0142] Example 39: The apparatus of example 38, wherein the additive supply path extends laterally within the contact body perpendicular to the axial direction.

[0143] Example 40: 40. The apparatus of claim 38 or 39, wherein the additive delivery path terminates in a cleaning opening disposed in the outer surface of the contact body.

[0144] Example 41: The apparatus according to any one of Examples 38 to 40, wherein the additive supply path extends linearly within the contact body.

[0145] Example 42: The device of any one of Examples 33 to 41, wherein the contact body includes an inclined surface adjacent to the contact surface along the axial direction, the inclined surface being inclined at 10 degrees to 80 degrees relative to the contact surface about a horizontal axis perpendicular to the axial direction.

[0146] Example 43: 1. A method for manufacturing an aerosol-generating rod, comprising the steps of: conveying a web material along an axial direction over a flat contact surface defined by a contact body, the web material being in contact with the contact surface; dispensing an additive onto the web material from at least one additive outlet disposed on the contact surface; and conveying a web material over an inclined surface of a contact body, the inclined surface being adjacent to the contact surface along an axial direction, the inclined surface being inclined at an angle between 10 degrees and 80 degrees relative to the contact surface about a transverse axis perpendicular to the axial direction.

[0147] Example 44: 44. The method of claim 43, wherein the extension dimension of the contact surface along the axial direction is less than 10 millimeters.

[0148] Example 45: 45. The method of claim 43 or 44, wherein the opening direction of at least one additive outlet is perpendicular to the axial direction.

[0149] Example 46: 46. ​​The method of any one of claims 43-45, further comprising conveying the web material through a converging device provided downstream of the contact body to form the web material into a rod.

[0150] The embodiments will now be further described with reference to the figures.

[0151] 1 shows a schematic side view of an apparatus 1 for producing an aerosol-generating rod 3. The apparatus 1 comprises a funnel-shaped converging apparatus 5. The converging apparatus 5 includes a sidewall 7 that defines a forming space. The converging apparatus 5 extends from an entrance opening 9 of the converging apparatus 5 to an exit opening 11 of the converging apparatus 5.

[0152] The apparatus 1 comprises a conveyor system 13 comprising a web conveyor 15 and a susceptor 17. The conveyor system 15 is configured to transport a web material 19 through the converging device 5. The susceptor conveyor is configured to transport a susceptor 21 through the converging device 5. The web material 19 and the susceptor 21 are transported through the converging device 5 from an entrance opening 9 of the converging device 5 to an exit opening 11 of the converging device 5. Within the forming space of the converging device 5, the web material 19 is compressed into a rod shape around the susceptor 21. The rod 3, with the web material 19 circumferentially surrounding the susceptor 21, leaves the forming space at the exit opening 11.

[0153] Upstream of the converging device 5, the web material 19 and susceptor 21 pass through an additive application assembly 23. Figure 2 shows a schematic perspective view of the additive application assembly 23 according to one embodiment. Figure 3 shows the additive application assembly 23 in cross-section. The additive application assembly 23 shown in Figures 2 and 3 may be used in the apparatus 1 shown in Figure 1.

[0154] The additive application assembly 23 comprises a body 25, a contact body 27, an additional contact body 29, and a susceptor guide 31. The susceptor guide 31 passes through the body 25, the contact body 27, and the additional contact body 29 along an axial direction 33. The susceptor guide 31 is a sleeve-like element through which the susceptor 21 is conveyed along the axial direction 33. The susceptor 21 enters the susceptor guide 31 through a susceptor inlet opening 35 of the susceptor guide 31 and exits the susceptor guide 31 through a susceptor outlet opening 37 of the susceptor guide 31. The susceptor outlet opening 37 is provided downstream of the body 25, the contact body 27, and the additional contact body 29.

[0155] The contact body 27 includes a contact surface 39. The additional contact body 29 includes an additional contact surface 41. The web material 19 is transported over the contact surface 39 and the additional contact surface 41 essentially along the axial direction 33. The web material 19 contacts the contact surface 39 and the additional contact surface 41.

[0156] Additive outlet 43 is provided in contact surface 39. Additional additive outlet 45 is provided in additional contact surface 41. Additive is discharged from additive outlet 43 and additional additive outlet 45. The additive is discharged onto web material 19 while web material 19 is transported over contact surface 39 and additional contact surface 41.

[0157] The contact body 27 has a conical shape. The contact surface 39 is formed by the outer surface of the contact body 27. The contact surface 39 is curved about the axial direction 33 and is tapered along the axial direction 33.

[0158] The additional contact body 29 has a cylindrical shape. The additional contact surface 41 is formed by an outer surface of the contact body 29. The additional contact surface 41 is curved around the axial direction 33.

[0159] As it is conveyed over the contact surface 39 and the additional contact surface 41, the web material 19 is deformed by contact with the contact surface 39 and the additional contact surface 41. This causes the lateral sides of the web material 19 to deform downwardly relative to a central portion of the web material 19, such that the web material 19 is at least partially curved around the susceptor 21. Thus, the web material 19 is pre-formed before entering the converging device 5.

[0160] The body 25 includes an additive supply inlet 47. An external additive source may be connected to the additive supply inlet 47 to provide additive for delivery from the additive outlet 43 and the additional additive outlet 45. In particular, the additive supply inlet 47 may be connected to an additive tank. A pump may be provided to generate pressure for delivering the additive from the additive outlet 43 and the additional additive outlet 45.

[0161] The main body 25, the contact body 27, the additional contact body 29, and the susceptor guide 31 can be disassembled for cleaning. For example, a threaded connection can be used to connect the main body 25, the contact body 27, the additional contact body 29, and the susceptor guide 31 to each other in a reversible manner.

[0162] FIG. 4 shows another embodiment of the device 1 for the manufacture of aerosol-generating rods 3. The converging device 5 and the transport system 13 can be the same as in the embodiment of FIG. 1. In the embodiment of FIG. 4, the susceptor 21 is transported by a susceptor conveyor 17 without a susceptor guide. However, a susceptor guide can also be provided in the embodiment of FIG. 4. The embodiment of FIG. 4 has an additive application assembly 51 that differs from the additive application assembly 23 of the embodiment of FIGS. 1-3. The additive application assembly 51 is provided upstream of the converging device 5 in the path of the web material 19. The additive application assembly 51 comprises a contact body 53. The contact body 53 comprises a contact surface 55. The web material 19 is transported over the contact surface 55 along an axial direction 57. The web material 19 comes into contact with the contact surface 55.

[0163] 5 shows a perspective view of the contact body 53 from above. The contact surface 55 is flat. The contact surface 55 is parallel to an axial direction 57. The contact surface 55 extends in the axial direction 57 and in a lateral direction 59 perpendicular to the axial direction 57.

[0164] Additive outlets 61 are provided in the contact surface 55. The additive is discharged from the additive outlets 55 onto the web material 19. The extension dimension 63 of the contact surface 55 along the axial direction 57 is less than 10 millimeters, for example between 3 and 5 millimeters.

[0165] The contact body 53 includes an inclined surface 65 adjacent the contact surface 55 along the axial direction 57. The boundary between the contact surface 55 and the inclined surface 65 is defined by a transverse axis 67. The inclined surface 65 is a flat surface that is inclined from the web material 19 at 10 degrees to 80 degrees about the transverse axis 67. In the illustrated embodiment, the inclined surface 65 is inclined at approximately 30 degrees about the transverse axis 67 relative to the contact surface 55. The inclination of the inclined surface 65 may prevent or reduce contact between the web material 19 and the inclined surface 65, thereby reducing undesirable contamination of the contact body 53 with additives.

[0166] 6 shows a bottom perspective view of the contact body 53. The contact body 53 includes an additive supply port 69 disposed on the underside of the contact body 53 opposite the contact surface 55. A cleaning opening 71 is disposed on a lateral surface of the contact body 53.

[0167] 7 is a cross-sectional view through the contact body 53, the cross-section being perpendicular to the axial direction 57. The additive supply path 73 extends within the contact body 53 along the lateral direction 59. The additive supply path 73 has a connection with the additive supply port 69, which can supply additive to the additive supply path 73. The additive supply path 73 is connected to the additive outlet 61, which supplies additive to the additive outlet 61. In the illustrated embodiment, the additive outlet 61 branches directly from the additive supply path 73. Alternatively, a branch path can be provided to connect the additive supply path 73 with the additive outlet 61.

[0168] The additive supply passage 73 terminates in the cleaning opening 71. The additive supply passage 73 extends linearly along the lateral direction 59 within the contact body 53. A cleaning device such as a brush can enter the additive supply passage 73 through the cleaning opening 71 to clean the inside of the contact body 51. In use, the cleaning opening 71 can be closed with a stopper.

[0169] FIG. 8 shows a cross-section through contact body 53, the cross-section being perpendicular to lateral direction 59.

[0170] 4, the additive valve 75 is connected to the additive supply port 69. The additive valve 75 is connected to a pump that supplies the additive from the additive tank.

[0171] As also shown in FIG. 4 , the apparatus 1 includes an adjustment unit 77 for adjusting the position and orientation of the contact body 53 relative to the transport path of the web material 19. The adjustment unit 77 includes a clamp 79 to which the contact body 53 is attached. The clamp 79 is rotatably mounted on a pole 81. The pole 81 is attached to a slider 83 via a lever 85. The lever 85 can be rotated relative to the slider 83. The slider 83 is slidably mounted on a guide rail 85. The position and orientation of the contact body 53 relative to the path of the web material 19 can be adjusted by any one or more of the rotation of the clamp 79 relative to the pole 81, the rotation of the lever 85 relative to the slider 83, and the sliding movement of the slider 83 along the guide rail 85.

[0172] For purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like are understood to be modified in all instances by the term "about." Also, all ranges include the maximum and minimum points disclosed, and include any intermediate ranges thereof, which may or may not be specifically recited herein. Thus, in this context, the number A is understood as A±10 percent. Within this context, the number A may be considered to include a numerical value that is within the general standard error for the measurement of the property that the number A modifies. The number A may deviate by the percentages recited above, in some instances used in the appended claims, provided that the amount by which A deviates does not materially affect the basic and novel properties of the claimed invention. Also, all ranges include the maximum and minimum points disclosed, and include any intermediate ranges thereof, which may or may not be specifically recited herein.

Claims

1. 1. A method for manufacturing an aerosol-generating rod, comprising the steps of: conveying the web material over a contact surface of a contact body such that the web material contacts the contact surface, the contact surface being curved about an axial direction and tapered along the axial direction, a continuous portion of the contact surface subtending an angle of at least 90 degrees about the axial direction; Discharging an additive from at least one additive discharge port provided on the contact surface; conveying the web material through a converging device provided downstream of the contact body, the web material being formed into a rod within the converging device.

2. The method of claim 1 , wherein as the web material is conveyed over the contact surface, lateral sides of the web material are deformed relative to a central portion of the web material as the web material conforms to the shape of the contact surface.

3. The method of claim 1 or 2, wherein the web material is conveyed over the contact surface such that only one side of the web material is in contact with the contact surface.

4. The method according to any one of claims 1 to 3, wherein the contact body has a conical shape.

5. The method according to any one of claims 1 to 4, wherein the additive is discharged from a plurality of additive discharge ports provided at different angular positions around the axial center.

6. The method of any one of claims 1 to 5, further comprising conveying a susceptor through the contact body.

7. The method of claim 6 , wherein the susceptor is conveyed through a susceptor guide, the susceptor guide extending axially beyond the contact body.

8. 1. An apparatus for manufacturing an aerosol-generating rod, comprising: an additive application assembly comprising a contact body defining a contact surface, the contact surface having at least one additive outlet; a conveyor system configured to transport a web material over the contact surface such that the web material contacts the contact surface; a focusing device provided downstream of the additive application assembly; the additive application assembly comprising a susceptor guide configured to guide a susceptor; the susceptor guide extends beyond the contact body toward the focusing device; The apparatus, wherein the conveyor system is configured to transport the web material through the converging device and form the web material within the converging device into the rod around the susceptor.

9. The apparatus of claim 8 , wherein the contact surface is curved about an axial direction.

10. 10. The apparatus of claim 9, wherein the at least one additive outlet comprises a plurality of additive outlets disposed at different angular positions about an axial direction.

11. 11. Apparatus according to claim 9 or 10, wherein the contact surface is tapered about the axial direction.

12. An apparatus according to any one of claims 9 to 11, wherein a continuous portion of the contact surface subtends an angle of at least 90 degrees about an axial direction.

13. The apparatus of any one of claims 8 to 12, wherein the susceptor guide at least partially passes through the contact body.

14. 14. The apparatus of claim 8, wherein the susceptor guide includes a susceptor outlet opening, the susceptor outlet opening being at least one of: provided upstream of the focusing device; and provided downstream of the contact body.

15. 1. A method for using a contact surface having at least one additive outlet adapted to apply an additive onto a web material and pre-shape the web material before it enters a focusing device where it is shaped into the rod in the manufacture of an aerosol-generating rod, wherein the contact surface is curved about an axial direction and tapered about the axial direction, and a continuous portion of the contact surface spans at least 90 degrees about the axial direction.

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