Aerosol generating article equipped with a spacer element

Abstract

The present invention relates to an aerosol generating article (10, 40, 50, 70) having a longitudinal passage (18), the aerosol generating article comprising an aerosol generating material segment (26, 52, 72) disposed within the longitudinal passage (18), a heating element (32) located within the aerosol generating material segment, an outer wrapper (34, 54, 74) extending around the longitudinal passage, and two or more spacer elements (36, 42, 44, 46, 58, 60, 62, 64, 78) extending inside the longitudinal passage and at least along the aerosol generating material segment, wherein the spacer elements are not in contact with the heating element (32). The present invention further relates to an apparatus and method for manufacturing an aerosol generating article, and more particularly an aerosol generating material segment of an aerosol generating article.

Description

Technical Field

[0001] The present disclosure relates to an aerosol-generating article for an aerosol-generating device, the aerosol-generating article comprising at least one spacer element. The present disclosure further relates to an apparatus and a method for manufacturing such aerosol-generating articles.

Background Art

[0002] An aerosol-generating article can generate an aerosol from an aerosol-generating substrate. Aerosol-generating articles are known that generate an aerosol from an aerosol-generating substrate without the need for combustion of the aerosol-generating substrate. Such articles are often referred to as "heat-not-burn" aerosol-generating articles because the aerosol-generating substrate is heated to a relatively low temperature to induce aerosol formation, but combustion of the materials contained within the aerosol-generating substrate is prevented. Known aerosol-generating substrates typically cannot be heated to their operating temperature by induction. This means that a separate susceptor is typically required for induction heating.

[0003] When an induction heating susceptor is disposed at the central position of the aerosol-generating substrate, portions of the aerosol-generating substrate that are located far from the susceptor may not reach a temperature high enough to release many volatile compounds. Thus, the peripheral portion of the aerosol-generating substrate may have a limited effect on the volume of the generated aerosol. Therefore, the aerosol-generating article may still contain unused aerosol-generating substrate upon disposal.

[0004] It would be desirable to provide an aerosol-generating article that allows for a reduction in the amount of the aerosol-generating substrate while maintaining a similar user experience. It would be desirable to provide an aerosol-generating article that allows for a reduction in the amount of unused aerosol-generating substrate after use.

Summary of the Invention

[0005] According to a first aspect of the present disclosure, an aerosol generating article having a longitudinal passage is provided. The aerosol generating article comprises an aerosol generating material segment disposed in the longitudinal passage, a heating element located within the aerosol generating material segment, and an outer wrapper extending around the longitudinal passage. Spacer elements extend inside the longitudinal passage and at least along the aerosol generating material segment. The spacer elements are not in contact with the heating element. In particular, the spacer elements are not in surface contact with the heating element. In particular, the aerosol generating article may be provided with two or more spacer elements. The two or more spacer elements may not be in contact with the heating element, and in particular, each of them may not be in contact with the heating element. More specifically, the two or more spacer elements may not have a contact surface with the heating element, and in particular, each of them may not have a contact surface with the heating element. In particular, the spacer elements are disposed at a distance from the heating element. The distance may be at least 0.5 millimeters, in particular at least 1 millimeter, and more specifically at least 1.5 millimeters. In particular, the spacer elements may be spatially separated from the heating element. Aerosol-generating articles can be characterized by the lack of contact between the spacer element and the heating element, particularly by the lack of surface contact between the spacer element and the heating element.

[0006] According to another aspect of the present invention, the spacer element does not have to be in contact with the heating element, but this is not a necessary condition. Therefore, the spacer element may or may not be in contact with the heating element.

[0007] Since a portion of the aerosol-generating substrate can be replaced by a spacer element, a smaller amount of aerosol-generating substrate may be used per aerosol-generating material segment compared to conventional aerosol-generating articles. The spacer element may be made of a less expensive material than the aerosol-generating substrate material.

[0008] The longitudinal passage of the aerosol-generating article may be formed by an outer wrapper. The longitudinal passage may have a cylindrical shape. The longitudinal passage may have a constant cross-section. The longitudinal passage may have a substantially circular cross-section. The aerosol-generating material segment may be rod-shaped, particularly cylindrical with a constant cross-section, and more specifically a substantially circular constant cross-section. The substantially circular cross-section may result from technical tolerances in the method of manufacturing the aerosol-generating article.

[0009] The maximum dimensions of the heating element may extend along the central longitudinal axis of the longitudinal passage. The heating element extends throughout the aerosol-generating material segment from the upstream end to the downstream end. The heating element may have substantially the same length as the aerosol-generating material segment. Multiple heating elements may be distributed along the central longitudinal axis of the longitudinal passage.

[0010] The heating element may be an induction heating element. The heating element may be a susceptor. The susceptor may be a strip susceptor. The susceptor may be a particulate susceptor, or a susceptor filament, or a susceptor mesh, or a susceptor wick, or a susceptor pin, or a susceptor rod, or a susceptor blade, or a susceptor sleeve, or a susceptor cup, or a susceptor coil, or a cylindrical susceptor, or a planar susceptor, or a combination thereof. The thickness of the susceptor may be 30 to 60 micrometers. The length of the susceptor may be 5 to 20 millimeters. The susceptor may be made of a paramagnetic material, a ferromagnetic material, or one of the ferromagnetic materials. The susceptor may contain metal. The susceptor may contain one of the following: aluminum, iron, nickel, copper, bronze, cobalt, ordinary carbon steel, stainless steel, ferritic stainless steel, martensitic stainless steel, or austenitic stainless steel. The susceptor may contain Inconel alloy (austenitic nickel-chromium superalloy). The susceptor may contain transition metals such as Fe, Co, Ni, or metalloid components such as B, C, Si, P, Al. The susceptor may contain mu-metal or permalloy. The susceptor may contain or be made of carbon material. The susceptor may contain or be made of graphite, molybdenum, silicon carbide, niobium, or ceramics such as zirconia. The susceptor may be heated to temperatures above 250°C.

[0011] The aerosol generating material may form an aerosol generating substrate. The aerosol generating material may be a substrate capable of releasing volatile compounds that can form aerosols when heated. The aerosol generating substrate may be configured to generate more than 90%, particularly 100%, of the total volume of aerosols generated by a heated aerosol generating article. The aerosol generating substrate may be formed by a sheet, a crimped sheet, a foil, or a web of the aerosol generating material. The aerosol generating substrate may be a layered substrate.

[0012] The aerosol generating substrate may contain alkaloid compounds. The aerosol generating material may contain nicotine. The aerosol generating substrate may contain plant-derived materials. The aerosol generating substrate may contain tobacco. The aerosol generating material may contain a tobacco blend. The aerosol generating material may contain shredded tobacco material. The aerosol generating substrate may be a homogenized sheet of tobacco. Other plant-derived materials may be part of the aerosol generating substrate, either in place of or in addition to tobacco. The aerosol generating substrate may be a homogenized sheet other than tobacco. The aerosol generating substrate may contain a wetting agent. The aerosol generating substrate may contain aerosol-forming bodies, such as polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin; esters of polyhydric alcohols, such as glycerol mono-, di-, or triacetate; and aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanediate and dimethyl tetradecanediate. The aerosol generating substrate may be a fibrous material. The aerosol generating substrate may be a plastic fibrous material. The aerosol generating substrate may be a biodegradable fibrous material. The aerosol generating substrate may contain cellulose or may be made from cellulose. The aerosol generating substrate may contain cotton or may be made from cotton. The aerosol generating substrate may be a polylactic acid substrate. The aerosol generating substrate may contain acetate.

[0013] The spacer elements may be located within the aerosol-generating material segment. In particular, two or more spacer elements may be located within the aerosol-generating material segment. The spacer elements may be separated from the heating element by the aerosol-generating material. The surface of the heating element does not have to be in direct physical contact with the spacer elements. The heating of the spacer elements due to the heating of the heating element can be reduced to at least less than the heating of the aerosol-generating material.

[0014] The spacer elements may be in surface contact with the outer wrapper. In particular, two or more spacer elements may be in surface contact with the outer wrapper. The spacer elements may be in surface contact only with the aerosol-generating material and the outer wrapper.

[0015] Alternatively, the spacer element may be in surface contact only with the aerosol-generating material.

[0016] The aerosol-generating article may further comprise an inner wrapper that forms a longitudinal passage. The outer wrapper may extend around the inner wrapper. Spacer elements may be disposed between the inner and outer wrappers. In particular, two or more spacer elements may be disposed between the inner and outer wrappers. The spacer elements may be separated from the heating element by at least the inner wrapper. The spacer elements may be in surface contact with the inner and outer wrappers. The outer and inner wrappers may each be made of different materials. Alternatively, the inner and outer wrappers may be made of the same material. The outer and inner wrappers may have different porosities. The inner wrapper may be more porous than the outer wrapper. The outer and inner wrappers may have different thicknesses. The outer wrapper may have a greater thickness than the inner wrapper. The longitudinal passage defined by the outer wrapper may have a substantially circular cross-section. The diameter of the longitudinal passage defined by the outer wrapper may be substantially the same as the diameter of the aerosol-generating article. The longitudinal passage defined by the inner wrapper may have a cross-section that deviates from a circular shape due to the presence of a spacer element positioned between the inner and outer wrappers. The spacer element may be located in a longitudinal groove created by the deformation of the inner wrapper.

[0017] An aerosol-generating article may be provided with two or more spacer elements. In particular, an aerosol-generating article may comprise three distinct spacer elements. Spacer elements, especially two or more spacer elements, may be formed from one or more strings, filaments, threads, fibers, cores, cords, or rods. Spacer elements may be made from aggregates of multiple fibers or aggregates of multiple threads. Multiple fibers or threads may be twisted together or threaded together. Spacer elements may be made from natural fibers, especially hemp, flax, or sisal. Spacer elements may be made from plastic fibers. Spacer elements may be made from foamed material. Spacer elements may contain cellulose or be made from cellulose. In particular, at least one of the two or more spacer elements may contain cellulose or be made from cellulose. Spacer elements may be recycled.

[0018] The spacer elements may contain flavor components. In particular, at least one of two or more spacer elements may contain flavor components. Flavored spacer elements can enhance the user experience. Flavor components may be absorbed into the spacer elements. Flavor components may be adsorbed onto the spacer elements. Adsorbed flavor components may adhere only to the surface of the spacer elements without being absorbed into the spacer elements. Flavor components may include menthol, whether natural or synthetic. Flavor components may also include essential oils. The spacer elements may further contain aerosol-forming materials such as glycerin.

[0019] Alternatively, or additionally, the spacer elements may have a specific color to provide a visual indication of the characteristics of the aerosol-generating segment, such as flavor or nicotine content, during the manufacturing of the aerosol-generating article. In the formed aerosol-generating article, the spacer elements may not be visible during external inspection of the aerosol-generating article.

[0020] The spacer elements may have lower permeability than the aerosol-generating material segments. In particular, two or more spacer elements may each have lower permeability than the aerosol-generating material segments. The permeability of the spacer elements may be at least five times lower than the permeability of the aerosol-generating material segments. The spacer elements may have a lower water content than the aerosol-generating material segments. The spacer elements may further comprise an outer coating. Providing an outer coating layer can advantageously limit the permeation of oxygen or water vapor into the spacer elements, which can help extend the shelf life of the aerosol-generating articles.

[0021] The spacer element can provide a preferred draw resistance RTD value for an aerosol-generating article, including an aerosol-generating segment. Preferred RTD values ​​may range from 20 mm to 70 mm of water column, and particularly from about 35 mm to about 52 mm of water column.

[0022] The spacer elements may extend parallel to the longitudinal axis path. Alternatively, the spacer elements may extend helically around the aerosol-generating material segment. Multiple spacer elements may be twisted or threaded around the inner wrapper of the aerosol-generating segment.

[0023] In a cross-sectional area transverse to the central longitudinal axis of the longitudinal passage, the ratio of spacer elements, particularly spacer elements to aerosol-generating material, may be between 0.25 and 0.45. Specifically, the ratio is the ratio of the cross-sectional area occupied by the spacer elements to the cross-sectional area occupied by the aerosol-generating material. The ratio of the volume of spacer elements to the volume of aerosol-generating material may be between 0.1 and 0.5. This ratio allows for a reduction in the amount of unused aerosol-generating material while maintaining a similar user experience.

[0024] The aerosol generating article may further comprise a mouthpiece disposed at one end of the first longitudinal passage. The aerosol generating article may further comprise a hollow acetate tube, in particular two hollow acetate tubes.

[0025] A second aspect of the present disclosure provides an apparatus for manufacturing an aerosol-generating material segment for an aerosol-generating article. The apparatus comprises a confluence unit having forming chambers that converge axially from a first open end of a forming chamber to a second open end of a forming chamber. The apparatus includes a first conveyor configured to transport aerosol-generating material, particularly formed as a sheet, through the first open end of the forming chamber to confluence the aerosol-generating material with a segment at the second open end of the forming chamber. The apparatus comprises at least a second conveyor configured to transport one or more spacer elements through the first open end of the forming chamber. The confluence unit is configured to confluence one or more spacer elements with the aerosol-generating material segment.

[0026] The first conveyor and the second conveyor may each be equipped with at least one rotating roller, and in particular two rotating rollers.

[0027] The apparatus may further include a susceptor guide for guiding the susceptor band, the susceptor guide extending into the forming chamber from a first open end to a second open end, and the susceptor band being incorporated into a segment of aerosol-generating material at the second open end of the forming chamber.

[0028] The confluence device may include guide elements that help guide the spacer elements toward the forming chamber. The guide elements may include passages. The size of the passages may be adapted to the diameter of the spacer elements. The passages may extend into the interior of the forming chamber. Alternatively, the passages of the guide elements may extend along the outer surface of the confluence device, so that the spacer elements can confluence with the aerosol-generating material and susceptor band at a second open end rather than a first open end.

[0029] The device may further comprise a packaging unit located downstream of the second open end of the forming chamber of the merging device for winding an outer wrapper around the merged segment of the aerosol-generating material and one or more spacer elements.

[0030] The device may further comprise at least one additive supply line that is upstream of the merging device and configured to distribute an additive, particularly a flavor additive, to the spacer elements. The additive supply device may comprise one or more nozzles for spraying the additive onto the spacer elements. The additive supply device may comprise a chamber for restricting the spraying of the additive within the chamber. Alternatively, or in combination, the additive supply device may be provided upstream of the merging device for applying the additive to the aerosol-generating material. The aerosol-generating material and the spacer elements may be supplied with different additives. The aerosol-generating material and the spacer elements may be supplied with the same additive in different amounts.

[0031] According to a third aspect of the present disclosure, a method for manufacturing an aerosol-generating material segment for an aerosol-generating article is provided, the method comprising transporting a spacer element axially through a forming chamber of a merging device, and transporting an aerosol-generating material, particularly in the form of a sheet, axially through the forming chamber of the merging device into a segment incorporating the spacer element.

[0032] The method may further comprise transporting a susceptor band axially through the forming chamber of the merging device and incorporating the susceptor into a segment of the aerosol-generating material within the forming chamber.

[0033] The method may further comprise applying an additive, particularly a flavor additive, onto the spacer element prior to transporting the spacer element axially through the forming chamber of the merging device.

[0034] The method may further include the steps of transporting the wrapper downstream of the confluence device and winding the segments into the wrapper.

[0035] The spacer element may be supplied as a bobbin. Prior to the step of transporting the spacer element, the method may include unwinding the spacer element from the bobbin.

[0036] A fourth aspect of the present disclosure provides a method for manufacturing an aerosol-generating material segment for an aerosol-generating article, the method comprising the steps of forming an aerosol-generating material segment wound around an inner wrapper, providing a spacer element along the inner wrapper, and winding the spacer element and the inner wrapper around an outer wrapper.

[0037] The method may include a further step of incorporating a heat-generating element into the aerosol-generating material segment.

[0038] Each feature described herein in relation to a spacer element may apply to two or more spacer elements, and may apply to each of the two or more spacer elements, or to at least one of the two or more spacer elements. [Brief explanation of the drawing]

[0039] [Figure 1] Figure 1 is a schematic side view of an aerosol generating article according to the first embodiment. [Figure 2] Figure 2 shows a schematic cross-sectional view of the aerosol generating material segment according to the first embodiment. [Figure 3] Figure 3 shows a schematic cross-sectional view of the aerosol generating material segment according to the second embodiment. [Figure 4] Figure 4 shows a schematic cross-sectional view of the aerosol generating material segment according to the third embodiment. [Figure 5] Figure 5 shows a schematic side view of the aerosol generating material segment according to the fourth embodiment. [Figure 6] Figure 6 shows a schematic side view of an apparatus 100 for manufacturing an aerosol generating material segment, particularly an aerosol generating material segment according to the first embodiment. [Modes for carrying out the invention]

[0040] The present invention is defined in the claims. However, a non-exclusive list of non-limiting embodiments is provided below. Any one or more features of each feature in these embodiments may be combined with any one or more features of other embodiments, other forms, or other aspects described herein.

[0041] Example 1: An aerosol generating article having a longitudinal passage, the aerosol generating article comprising: an aerosol generating material segment disposed in the longitudinal passage; a heating element located within the aerosol generating material segment; an outer wrapper extending around the longitudinal passage; and a spacer element extending inside the longitudinal passage and at least along the aerosol generating material segment, wherein the spacer element is not in contact with the heating element.

[0042] Example 2: The aerosol generating article according to Example 1, wherein the longitudinal axial passage is formed by an outer wrapper.

[0043] Example 3: An aerosol generating article according to Example 1 or Example 2, wherein the longitudinal axial passage is formed by an outer wrapper.

[0044] Example 4: An aerosol generating article according to one of Examples 1 to 3, wherein the heating element is an induction heating element.

[0045] Example 5: An aerosol generating article according to one of Examples 1 to 4, wherein the heating element is a susceptor.

[0046] Example 6: The aerosol generating article according to Example 5, wherein the susceptor is a particulate susceptor, or a susceptor filament, or a susceptor mesh, or a susceptor wick, or a susceptor pin, or a susceptor rod, or a susceptor blade, or a susceptor strip, or a susceptor sleeve, or a susceptor cup, or a susceptor coil, or a cylindrical susceptor, or a planar susceptor.

[0047] Example 7: An aerosol generating article according to Example 5 or Example 6, wherein the maximum dimension of the susceptor extends along the central longitudinal axis of the longitudinal passage.

[0048] Example 8: An aerosol generating article according to one of Examples 1 to 7, wherein the aerosol generating material forms an aerosol generating substrate.

[0049] Example 9: An aerosol generating article according to one of Examples 1 to 8, wherein the aerosol generating material includes a tobacco blend.

[0050] Example 10: An aerosol generating article according to one of Examples 1 to 9, wherein the aerosol generating material includes shredded tobacco material.

[0051] Example 11: The aerosol generating article according to claim 8, wherein the aerosol generating substrate is a homogenized sheet of tobacco.

[0052] Example 12: The aerosol generating article according to Example 8, wherein the aerosol generating substrate is a homogenized sheet other than tobacco.

[0053] Example 13: The aerosol generating article according to Example 8, wherein the aerosol generating substrate is a fibrous material, particularly a plastic fibrous material, and more specifically a biodegradable fibrous material.

[0054] Example 14: The aerosol generating article according to Example 8, wherein the aerosol generating substrate contains cellulose or is made of cellulose.

[0055] Example 15: The aerosol generating article according to Example 8, wherein the aerosol generating substrate contains or is made of cotton.

[0056] Example 16: An aerosol generating article according to one of Examples 1 to 15, wherein the spacer element is located within the aerosol generating material segment.

[0057] Example 17: An aerosol-generating article according to one of Examples 1 to 16, wherein the spacer element is in surface contact with the outer wrapper.

[0058] Example 18: An aerosol generating article according to one of Examples 1 to 15, further comprising an inner wrapper that forms a longitudinal passage, an outer wrapper extending around the inner wrapper, and a spacer element disposed between the inner and outer wrappers.

[0059] Example 19: The aerosol-generating article according to Example 18, wherein the spacer element is in surface contact with the inner wrapper and the outer wrapper.

[0060] Example 20: An aerosol generating article according to one of Examples 1 to 19, wherein the aerosol generating article is provided with two or more spacer elements.

[0061] Example 21: The aerosol generating article according to claim 20, wherein the aerosol generating article comprises three separate spacer elements.

[0062] Example 22: An aerosol-generating article according to one of Examples 1 to 21, wherein the spacer element is formed by one or more strings, filaments, threads, fibers, cores, cords, or rods.

[0063] Example 23: The aerosol-generating article according to Example 22, wherein the spacer element is made of an aggregate of multiple fibers or an aggregate of multiple threads.

[0064] Example 24: An aerosol-generating article according to Example 22 or Example 23, wherein the spacer element is made of natural fibers, particularly hemp, flax, or sisal.

[0065] Example 25: The aerosol-generating article according to Example 22 or Example 23, wherein the spacer element is made of plastic fiber.

[0066] Example 26: An aerosol generating article according to one of Examples 1 to 23, wherein the spacer element contains cellulose or is made of cellulose.

[0067] Example 27: An aerosol generating article according to one of Examples 1 to 26, wherein the spacer element contains a flavor component.

[0068] Example 28: The aerosol-generating article according to Example 27, wherein the flavor components are absorbed into the spacer element.

[0069] Example 29: The aerosol generating article according to Example 27, wherein the flavor components are adsorbed onto a spacer element.

[0070] Example 30: An aerosol-generating article according to one of Examples 27 to 29, wherein the flavor component contains either natural or synthetic menthol.

[0071] Example 31: An aerosol generating article according to one of Examples 27 to 30, wherein the flavor component contains an essential oil.

[0072] Example 32: An aerosol generating article according to one of Examples 27 to 31, wherein the spacer element further comprises an aerosol-forming body such as glycerin.

[0073] Example 33: An aerosol-generating article according to one of Examples 1 to 32, wherein the spacer element has lower permeability than the aerosol-generating material segment.

[0074] Example 34: The aerosol-generating article according to Example 33, wherein the permeability of the spacer element is at least 5 times lower than the permeability of the aerosol-generating material segment.

[0075] Example 35: An aerosol-generating article according to one of Examples 1 to 34, wherein the outer wrapper and inner wrapper are made of different materials.

[0076] Example 36: An aerosol-generating article according to one of Examples 1 to 35, wherein the outer wrapper and the inner wrapper have different porosities.

[0077] Example 37: An aerosol-generating article according to one of Examples 1 to 36, wherein the outer wrapper and the inner wrapper have different thicknesses.

[0078] Example 38: An aerosol generating article according to one of Examples 1 to 37, wherein the spacer element extends parallel to the longitudinal axis passage.

[0079] Example 39: An aerosol generating article according to one of Examples 1 to 37, wherein a spacer element extends helically around an aerosol generating material segment.

[0080] Example 40: An aerosol generating article according to one of Examples 1 to 39, wherein the ratio of spacer elements to aerosol generating material in a cross section transverse to the central longitudinal axis of the longitudinal passage is 0.25 to 0.45.

[0081] Example 41: An aerosol generating article according to one of Examples 1 to 40, wherein the ratio of the volume of the spacer element to the volume of the aerosol generating material is between 0.1 and 0.5.

[0082] Example 42: An aerosol generating article according to one of Examples 1 to 41, further comprising a mouthpiece disposed at one end of a first longitudinal passage.

[0083] Example 43: The aerosol generating article according to Example 42, further comprising a hollow acetate tube, in particular two hollow acetate tubes.

[0084] Example 44: Apparatus for manufacturing aerosol-generating material segments for an aerosol-generating article, comprising: a confluence device having forming chambers that converge axially from a first open end of a forming chamber to a second open end of a forming chamber; a first conveyor configured to transport aerosol-generating material, particularly formed as a sheet, through the first open end of the forming chamber to confluence the aerosol-generating material with a segment at the second open end of the forming chamber; and at least a second conveyor configured to transport one or more spacer elements through the first open end of the forming chamber, wherein the confluence device is configured to confluence one or more spacer elements with the aerosol-generating material segment.

[0085] Example 45: The apparatus according to Example 44, further comprising a susceptor guide for guiding a susceptor band, the susceptor guide extending into the forming chamber from a first open end to a second open end, and the susceptor band being incorporated into a segment of aerosol-generating material at the second open end of the forming chamber.

[0086] Example 46: The apparatus according to Example 44 or Example 45, further comprising a packaging unit located downstream of the second open end of the forming chamber of the confluence device for wrapping an outer wrapper around the confluenced segments of aerosol generating material and one or more spacer elements.

[0087] Example 47: A method for manufacturing an aerosol-generating material segment for an aerosol-generating article, comprising the steps of: transporting a spacer element through a forming chamber of a confluence device along the axial direction; and transporting an aerosol-generating material, particularly in the form of a sheet, into a segment incorporating the spacer element by transporting the aerosol-generating material through a forming chamber of a confluence device along the axial direction.

[0088] Example 48: The method according to Example 47, comprising the steps of transporting a susceptor band through a forming chamber of a confluence device along the axial direction, and incorporating the susceptor into a segment of aerosol generating material within the forming chamber.

[0089] Example 49: The method according to Example 47 or Example 48, further comprising the step of applying additives, particularly flavor additives, to the spacer elements before the step of conveying the spacer elements through the forming chamber of the confluence device along the axial direction.

[0090] Example 50: The method according to one of Examples 47 to 49, further comprising the steps of transporting the wrapper downstream of the confluence device and winding the segments into the wrapper.

[0091] Example 51: The method of one of Examples 47 to 50, wherein the method includes unwinding the spacer element from the bobbin before the step of transporting the spacer element.

[0092] Example 52: A method for manufacturing an aerosol-generating material segment for an aerosol-generating article, comprising the steps of: forming an aerosol-generating material segment wound around an inner wrapper; providing a spacer element along the inner wrapper; and winding the spacer element and the inner wrapper into an outer wrapper.

[0093] Example 53: The method according to Example 52, further comprising the step of incorporating a heat-generating element into an aerosol-generating material segment.

[0094] Here, we will further describe the examples with reference to the figures.

[0095] Figure 1 shows a schematic side view of an aerosol generating article 10 according to a first embodiment. The aerosol generating article 10 has a rod shape extending along a central longitudinal axis 12 from the mouth end 14 to the distal end 16, defining a longitudinal passage 18 between the mouth end 14 and the distal end 16. As can be seen from the side view in Figure 1, the aerosol generating article 10 comprises multiple components within the longitudinal passage 18. All components may have the same diameter. Starting from the mouth end 14 and moving toward the distal end 16, the aerosol generating article 10 comprises a mouthpiece 20, a first hollow acetate tube 22, a second hollow acetate tube 24, an aerosol generating material segment 26, and a plug element 28 along the central longitudinal axis 12. In the embodiment of Figure 1, the cross-section of the aerosol generating article 10 along a plane perpendicular to its longitudinal axis 12 is substantially circular.

[0096] The aerosol-generating material segment 26 is disposed within the longitudinal passage 18. The aerosol-generating material segment 26 includes an aerosol-generating substrate 30. The heating element 32 is located within the aerosol-generating substrate 30 of the aerosol-generating material segment 26. The heating element 32 is surrounded by the aerosol-generating material forming the aerosol-generating substrate 30. In the non-limiting embodiment of Figure 1, the heating element 32 is a susceptor 32 having the shape of a strip extending along the entire length of the aerosol-generating material segment 26. In the non-limiting embodiment of Figure 1, the susceptor 32 is centrally located relative to the aerosol-generating material segment 26. The susceptor 32 is in thermal contact with the aerosol-forming substrate 30 so that when the susceptor 32 is induction heated, heat is transferred to the aerosol-generating substrate 30, thereby releasing an aerosol.

[0097] The aerosol-generating article 10 further comprises an outer wrapper 34 extending around a longitudinal passage 18. The longitudinal passage 18 is formed by the outer wrapper 34.

[0098] The aerosol-generating article 10 further comprises a spacer element 36. The spacer element 36 may be made of cellulose. The spacer element 36 extends into the interior of the longitudinal passage 18 along the aerosol-generating material segment 26. The spacer element 36 is separated from the susceptor 32 by the aerosol-generating substrate 30. In the non-limiting embodiment of Figure 1, the spacer element 36 is in surface contact only with the aerosol-generating substrate 30 and the outer wrapper 34. There is no direct surface contact between the spacer element 36 and the susceptor 32.

[0099] This arrangement is also visible in Figure 2, which shows a cross-sectional view of the longitudinal axis passage 18 with respect to the central longitudinal axis 12. Elements with the same reference numbers that have already been described and illustrated in Figure 1 will not be described in detail again, but refer to their descriptions above.

[0100] As can be seen in Figure 2, the spacer element 36 is positioned within the aerosol generating material segment 26 such that the heat generated by the heating of the susceptor 32, schematically represented by arrow 38, primarily heats the aerosol generating substrate 30 that directly surrounds the susceptor 32. The peripheral zone of the aerosol generating material segment 26, i.e., the peripheral zone where the spacer element 36 is located, is not exposed to much of the heat that can be generated by the susceptor 32. Therefore, the spacer element 36 tends to be heated less than the aerosol generating substrate 30 surrounding the susceptor 32.

[0101] In the non-limiting embodiment shown in Figure 2, the spacer element 36 has a substantially elliptical cross-section.

[0102] Figure 3 shows a schematic cross-sectional view of the aerosol-generating material segment of the aerosol-generating article 40 according to the second embodiment. In the second embodiment, the aerosol-generating article 40 differs from the aerosol-generating article 10 in that the aerosol-generating material segment 26 includes three spacer elements 42, 44, and 46 instead of the single spacer element 36 in the first embodiment. Elements with the same reference numbers that have already been described and illustrated in Figures 1 and 2 will not be described in detail again, but refer to their above descriptions.

[0103] The three spacer elements 42, 44, and 46 may be made of cellulose. In the non-limiting embodiment of Figure 3, each of the three spacer elements 42, 44, and 46 has a substantially circular cross-section. In the non-limiting embodiment of Figure 3, the diameter of the cross-section of spacer element 42 is smaller than the diameters of the cross-sections of spacer elements 44 and 46. The diameters of each of the spacer elements 44 and 46 may be substantially the same. In the cross-section of Figure 3, the ratio of spacer elements 42, 44, and 46 to the aerosol generating substrate 30 may be between 0.25 and 0.45. In the non-limiting embodiment of Figure 3, spacer element 42 is in surface contact only with the aerosol generating substrate 30. The two spacer elements 44 and 46 are in surface contact only with the aerosol generating substrate 30 and the outer wrapper 34. None of the spacer elements 42, 44, and 46 are in direct surface contact with the susceptor 32.

[0104] Figure 4 shows a schematic cross-sectional view of the aerosol generating material segment 52 of the aerosol generating article 50 according to the third embodiment.

[0105] As in the first and second embodiments, the aerosol-generating material segment 52 comprises an aerosol-generating substrate 30 and a susceptor 32 located within the aerosol-generating substrate 30. The aerosol-generating material segment 52 of the aerosol-generating article 50 is provided with an outer wrapper 54.

[0106] In the third embodiment, the aerosol generating material segment 52 further comprises an inner wrapper 56. The inner wrapper 56 forms a longitudinal passage for the aerosol generating article 50. The outer wrapper 54 extends around the inner wrapper 56. In the third embodiment, four spacer elements 58, 60, 62, and 64 are disposed between the outer wrapper 54 and the inner wrapper 56. The four spacer elements 58, 60, 62, and 64 are in surface contact only with the outer wrapper 54 and the inner wrapper 56. The four spacer elements 58, 60, 62, and 64 are not in surface contact with the aerosol generating substrate 30 or the susceptor 32.

[0107] The outer wrapper 54 defines a longitudinal passage having a substantially circular cross-section. The inner wrapper 56 defines a longitudinal passage having a non-circular cross-section, in that the inner wrapper 56 is convexly deformed at the positions of the four spacer elements 58, 60, 62, and 64, respectively. The external shape and dimensions of the cross-section of the aerosol-generating material segment 52 of the aerosol-generating article 50 are substantially identical to those of the cross-section of the aerosol-generating material segment 26 according to the first and second embodiments.

[0108] The aerosol generating material segment 52 shown in Figure 4 may be obtained by winding the aerosol generating material 30 and susceptor 32 together inside the inner wrapper 56, providing spacer elements 58, 60, 62, and 64 along the inner wrapper 56, and winding the spacer elements 58, 60, 62, and 64 and the inner wrapper 56 inside the outer wrapper 54.

[0109] In one embodiment, the aerosol-generating material segment 52 shown in Figure 4 may be obtained by spacer elements 58, 60, 62, and 64 having an initial substantially circular cross-section. The spacer elements 58, 60, 62, and 64 may be arranged along an inner wrapper 56. Winding the outer wrapper 54 may have the effect of compressing each of the spacer elements 58, 60, 62, and 64 relative to the inner wrapper 56 and toward the center of the aerosol-generating material segment 52. As a result, the cross-sectional shape of each of the spacer elements 58, 60, 62, and 64 may be altered. In particular, the curvature of the portions of each of the spacer elements 58, 60, 62, and 64 that are in contact with the outer wrapper 54 may be reduced so that the cross-section of the aerosol-generating material segment 52 becomes substantially circular, as shown in Figure 4.

[0110] Figure 5 shows a schematic diagram of the aerosol generating material segment 72 of the aerosol generating article 70 according to the fifth embodiment. As in all the preceding embodiments, the aerosol generating material segment 72 comprises an aerosol generating substrate 30 and a susceptor 32 located within the aerosol generating substrate 30.

[0111] Similar to the fourth embodiment, the aerosol-generating material segment 72 is provided with an outer wrapper 74 and an inner wrapper 76. For clarity, in the schematic diagram of Figure 5, the outer wrapper 74 is only partially wrapped around the inner wrapper 76 and is transparent to allow the spacer element 78 to be visible. The spacer element 78 is positioned between the outer wrapper 74 and the inner wrapper 76. In the fifth embodiment, the spacer element 78 extends helically around the aerosol-generating material segment 72 along its central longitudinal axis 80.

[0112] In alternative embodiments not shown, the spacer element 78 may extend directly helically around the surface of the aerosol-generating substrate 30 without the presence of the inner wrapper 76.

[0113] In all of the embodiments described above, the spacer elements 36, 42, 44, 46, 58, 60, 62, 64, and 78 may be formed from strings, filaments, threads, cores, cords, or rods.

[0114] Figure 6 shows a schematic side view of an apparatus 100 for manufacturing an aerosol-generating article 10 according to a first embodiment. In Figure 6, arrows are used to indicate the movement of components of the apparatus 100. The apparatus 100 includes a confluence device 102 having forming chambers 104 that converge along an axial direction 106 from a first open end 108 of the forming chamber 104 to a second open end 110 of the forming chamber 104. The open end 108 is larger than the second end 110, and as a result, the confluence device 102 has a funnel shape along the axial direction 106. The apparatus 100 includes a first conveyor 112 configured to transport the aerosol-generating material 30, particularly when formed as a sheet, through the first open end 108 of the forming chamber 104. The first conveyor 112 is configured to confluence the aerosol-generating material 30 into a segment 114 at the second open end 110 of the forming chamber 104. The apparatus 100 also includes a band 32 of susceptor material that is conveyed through the forming chamber 104 along the axial direction 106. The band 32 of susceptor material is wound around a bobbin. The apparatus 100 further includes a second conveyor 116 configured to convey spacer elements 36 through a first open end 108 of the forming chamber 104. A confluence device 102 is configured to confluence the spacer elements 36 with the aerosol generating material 30 to form an aerosol generating material segment 114. A cross-section of the aerosol generating material segment 114 can be illustrated by the embodiment in Figure 2.

[0115] The confluence device 102 further comprises a guide element 120 to help guide the spacer element 36 toward the forming chamber 104. The guide element 120 comprises a passage 122. The size of the passage 122 is adapted to the diameter of the spacer element 36. In the embodiment shown in Figure 6, the passage 122 extends into the interior of the forming chamber 104. In alternative embodiments of the device not shown, the passage 122 of the guide element 120 may extend along the outer surface of the confluence device 102, as a result the spacer element 36 confluences with the aerosol generating material 30 and susceptor band 32 at the second open end 110 rather than at the first open end 118.

[0116] Downstream of the second open end 110 of the confluence device 102, the device 100 may further include a packaging unit (not shown in Figure 6) for wrapping an outer wrapper around the confluenced aerosol generating segment 114.

[0117] Downstream of the packaging unit, the apparatus 100 may further include a cutting unit (not shown in Figure 6) for cutting the combined and wound aerosol-generating segments 114 into individual aerosol-generating material segments 26.

[0118] A method for manufacturing an aerosol generating segment 114 includes transporting a spacer element 36 through a forming chamber 104 of a confluence device 102 along an axial direction 106, and confluence the aerosol generating material 30, particularly in the form of a sheet, with the aerosol generating material 30 by transporting the aerosol generating material 30 through the forming chamber 104 of the confluence device 102 along an axial direction 116, thereby confluenced with the segment 114 incorporating the spacer element 36. The method also includes transporting a susceptor band 32 through the forming chamber 104 of the confluence device 102 along an axial direction 116, and incorporating the susceptor 32 into the aerosol generating material segment 30 in the forming chamber 104. A cross-section of the aerosol generating material segment 114 can be illustrated by the embodiment in Figure 2.

[0119] The aerosol-generating material segments shown in Figures 3 and 4 may also be obtained by adding a corresponding number of conveyors 116 configured to transport spacer elements 42, 44, 46, 58, 60, 62, and 64 toward the forming chamber 104 of the confluence device 102.

[0120] For the purposes of this specification and the appended claims, unless otherwise indicated, all numerical values ​​representing quantities, amounts, percentages, etc., should be understood in all instances as being modified by the term “approximately.” Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges within them, which may or may not be specifically listed herein. Thus, in this context, numerical value A is understood as A ± 5% of A. In this context, numerical value A may be considered to include numerical values ​​within the range of general standard errors for the measurement of the characteristic that numerical value A modifies. In some instances used in the appended claims, numerical value A may deviate by the percentages listed above, as long as the amount of deviation from A does not substantially affect the fundamental and novel characteristics of the invention described in the claims. Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges within them, which may or may not be specifically listed herein.

Claims

1. an aerosol generating article having a passage in the longitudinal direction, The aerosol-generating article is an aerosol generating material segment disposed within the aforementioned longitudinal axial passage, A heating element located within the aerosol generating material segment, An outer wrapper extending around the longitudinal passage, The passage in the longitudinal axis direction comprises two or more spacer elements that extend at least along the aerosol generating material segment, An aerosol-generating article in which the spacer element is not in contact with the heat-generating element.

2. The aerosol generating article according to claim 1, wherein the spacer element is located within the aerosol generating material segment.

3. The aerosol generating article according to claim 1 or claim 2, wherein the spacer element is in surface contact with the outer wrapper.

4. The aerosol generating article according to claim 1, further comprising an inner wrapper that forms the longitudinal axial passage, wherein the outer wrapper extends around the inner wrapper, and the spacer element is disposed between the inner wrapper and the outer wrapper.

5. The aerosol generating article according to any one of claims 1 to 4, wherein the spacer element is formed by one or more strings, filaments, threads, fibers, cores, cords, or rods.

6. The aerosol generating article according to any one of claims 1 to 5, wherein at least one of the spacer elements contains cellulose or is made of cellulose.

7. The aerosol generating article according to any one of claims 1 to 6, wherein at least one of the spacer elements contains a flavor component.

8. The aerosol generating article according to any one of claims 1 to 7, wherein each of the spacer elements has lower permeability than the aerosol generating material segment.

9. The aerosol generating article according to any one of claims 1 to 8, wherein the heating element is a susceptor.

10. The aerosol generating article according to any one of claims 1 to 9, wherein in a cross section transverse to the central longitudinal axis of the longitudinal axis passage, the ratio of the spacer element to the aerosol generating material is 0.25 to 0.

45.

11. Apparatus for manufacturing aerosol generating material segments for aerosol generating articles, A confluence device having forming chambers that converge along the axial direction from a first open end of the forming chamber to a second open end of the forming chamber, A first conveyor is configured to transport aerosol generating material, particularly that formed as a sheet, through the first open end of the forming chamber, and to merge the aerosol generating material into a segment at the second open end of the forming chamber. The system comprises at least a second conveyor configured to transport one or more spacer elements through the first open end of the forming chamber, The apparatus is configured such that the confluence device brings the one or more spacer elements together with the aerosol generating material segment.

12. The apparatus according to claim 11, further comprising a packaging unit located downstream of the second open end of the forming chamber of the confluence apparatus for wrapping an outer wrapper around the confluenced segments of the aerosol generating material and the one or more spacer elements.

13. A method for manufacturing an aerosol-generating material segment for an aerosol-generating article, A process of transporting spacer elements through the forming chamber of the confluence device along the axial direction, A method comprising the step of transporting an aerosol generating material, particularly in the form of a sheet, through the forming chamber of the confluence device along the axial direction to confluence it with a segment incorporating a spacer element.

14. A method for manufacturing an aerosol-generating material segment for an aerosol-generating article, A step of forming an aerosol-generating material segment wrapped around an inner wrapper, The process of providing a spacer element along the inner wrapper, A method comprising the step of winding the spacer element and the inner wrapper into the outer wrapper.

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