Method for producing susceptor sheet material containing aerosol-forming gel and delivery system - Patents.com

Abstract

A method for manufacturing a susceptor sheet material containing an aerosol-forming gel includes providing a susceptor sheet material having at least one depression on each side of the susceptor sheet material, and applying an aerosol-forming gel to the at least one depression on each side of the susceptor sheet material. Also described is a dispensing device for applying the aerosol-forming gel.

Description

[Technical field]

[0001] The present invention relates to a method for the application of an aerosol-forming gel to a susceptor sheet material and to a dispensing system for the application of an aerosol-forming gel to a susceptor sheet material. [Background technology]

[0002] It is well known to coat susceptor materials with aerosol-forming coatings. This may be done to provide aerosol delivery from a coating that is in direct contact with the heated susceptor. It is also well known to provide susceptor materials of different shapes in the tobacco plug of an inductively heatable aerosol-forming article. This is done, for example, to improve or change the transport of air or aerosol through the tobacco plug.

[0003] It is desirable to provide aerosol generation within an aerosol generating article for use in an electronic aerosol generating device, which allows for high precision in aerosol delivery. Summary of the Invention

[0004] According to the present invention, there is provided a method of manufacturing a susceptor sheet material including an aerosol-forming gel, the method comprising providing a susceptor sheet material having at least one depression and applying an aerosol-forming gel to at least the depression in the susceptor sheet material.

[0005] The method preferably includes providing a susceptor sheet material having at least one depression on each side of the susceptor sheet material, and applying an aerosol-forming gel to the at least one depression on each side of the susceptor sheet material.

[0006] The susceptor sheet material is preferably provided with a plurality of depressions located on one side of the susceptor sheet material.

[0007] The susceptor sheet material is preferably provided with a plurality of depressions located on both sides of the susceptor sheet material.

[0008] Preferably, the aerosol-forming gel is applied to some of the recesses on one side of the susceptor sheet material or to some of the recesses on both sides of the susceptor sheet material, more preferably, the aerosol-forming gel is applied to each recess on one side of the susceptor sheet material or the aerosol-forming gel is applied to each recess on both sides of the susceptor sheet material.

[0009] The method may further include applying different aerosol-forming gels to different recesses of the susceptor sheet material. The different aerosol-forming gels may differ, for example, in at least one of flavor, nicotine content, alkaloid content, type of alkaloid, aerosol-forming agent content, type of aerosol-forming agent, or aerosolization temperature.

[0010] The method preferably includes applying an aerosol-forming gel through a through-hole in at least one moving tooth of a gel administration device.

[0011] The moving teeth of the gel dosing device may be, for example, teeth of a dosing wheel drum, teeth of a dosing roller, or teeth of a dosing belt.

[0012] The method may include applying the aerosol-forming gel through a through hole of at least one moving tooth of a dosing wheel drum having circumferentially arranged teeth. Additionally or alternatively, the method may include applying the aerosol-forming gel through a through hole of at least one moving tooth of a dosing belt and transporting the susceptor sheet material with the dosing belt.

[0013] By provision of a dosing belt, conveying and gel application may be combined in one device.

[0014] The dosing belt preferably comprises a series of teeth substantially corresponding to the morphology of the susceptor sheet material. The teeth (e.g. one tooth, some teeth, or each tooth) comprise a through hole that communicates with the gel reservoir or is adapted to communicate with the gel reservoir. The method preferably includes the step of communicating the teeth of the dosing belt with the reservoir as the teeth pass the reservoir with movement of the dosing belt. Thus, each tooth with a through hole may be in communication with the same reservoir as it passes the reservoir.

[0015] The method preferably includes applying an aerosol-forming gel across the width of the susceptor sheet material through a plurality of through holes disposed across the width of the teeth.

[0016] The method preferably involves continuously applying the aerosol-forming gel along the length of the susceptor sheet material.

[0017] The teeth preferably comprise a plurality of through holes disposed along the width of the teeth. Each through hole substantially terminates at a tip of the tooth. In some embodiments, when the teeth are teeth of a wheel drum or teeth of a conveyor belt, the plurality of through holes are disposed along the width of the drum or belt. This may be preferred because the aerosol-forming gel may be applied to individual depressions disposed across the width of the susceptor sheet material. If a valley extends across the width of the susceptor sheet material, the aerosol-forming gel may also be applied along the width of the valley. In some embodiments, when the teeth are teeth of a dosing roller, the one or more through holes are disposed along the periphery of the teeth. This may be preferred because the aerosol-forming gel may be applied continuously to elongated depressions (e.g. longitudinal grooves, etc.) disposed along the length of the susceptor sheet material. The distribution of the aerosol-forming gel along the width or along the length of the susceptor sheet material may be continuous along the width or along the length. The distribution of the aerosol-forming gel along the width or along the length of the susceptor sheet material may be equal along the width or length with equal amounts of aerosol-forming gel along the width or length.

[0018] The distribution of the aerosol-forming gel along the width or length of the susceptor sheet material may be discontinuous. The distribution of the aerosol-forming gel along the width or length of the susceptor sheet material may not be equal along the width or length. For example, individual droplets of aerosol-forming gel may be disposed across the width of the susceptor sheet or along the length of the susceptor sheet. For example, more aerosol-forming gel may be disposed in the central longitudinal region of the susceptor sheet than in the lateral edge regions of the susceptor sheet. The aerosol-forming gel may form a uniform layer in and along the recesses.

[0019] The number or size of the through-holes in the teeth may be adapted to the properties of the aerosol-forming gel, in particular the viscosity of the aerosol-forming gel.

[0020] The method may include applying the aerosol-forming gel through a through hole of at least one moving tooth of a dosing roller, the moving tooth being arranged parallel to and rotating in the direction of transport of the susceptor sheet material. The moving tooth may be provided with a continuous through hole extending along the entire length of the tooth or along the entire circumference of the dosing roller, respectively, for continuous gel application. In these embodiments, the susceptor sheet material is provided with at least one longitudinally extending depression (e.g. a depression in the form of a groove) arranged along the length of the susceptor material. A susceptor comprising at least one longitudinally arranged depression is simple to manufacture in a continuous forming process. The susceptor material so formed has an inherent stiffness, for example because bending of a susceptor band having a V-shaped or W-shaped cross section requires a greater force than bending of a flat band. For example, any deformation or misalignment of the susceptor in the article is less affected when cutting a continuous article into individual segments. A susceptor with a W-shaped cross section may be provided with different types of aerosol-forming gels on the two sides of the susceptor without the risk of the different types of gels mixing.

[0021] According to the present invention, there is provided a dispensing system for application of an aerosol-forming gel to a susceptor sheet material, the system comprising a susceptor sheet material comprising at least one recess, the system also comprising a gel dispensing device adapted to apply an aerosol-forming gel to the at least one recess of the susceptor sheet material.

[0022] By using a susceptor material with at least one depression, the amount of susceptor material may be increased compared to a flat susceptor material. The amount of susceptor material per length of the article in which the susceptor is disposed may be increased. In particular, the surface area of ​​the susceptor is increased. This is preferred because heat is preferably and mainly generated in the susceptor material by eddy currents. These are mainly skin currents that are generated in the susceptor sheet material when it is inductively heated. With a larger usable surface area per length of susceptor material, more heat can be generated over said length.

[0023] The gel dosing device of the dosing system may comprise at least one tooth substantially corresponding to the shape of the at least one depression in the susceptor sheet material. At least one tooth of the gel dosing device may comprise a through hole in fluid communication with a gel reservoir containing the aerosol-forming gel. In this embodiment, the aerosol-forming gel is delivered from the gel reservoir and through the through hole of the tooth and applied to the susceptor sheet material. The gel is particularly applied into the at least one depression in the susceptor material. The tooth of the dosing device is preferably inserted into the depression of the susceptor material for gel application. When the tooth passes through the depression, a portion of the aerosol-forming gel is deposited in the depression of the susceptor material.

[0024] The through-holes are in fluid communication with the gel reservoir when the aerosol-forming gel is applied to the susceptor. The through-holes do not have to be in fluid communication with the reservoir at all times. The through-holes may be in communication with the reservoir when or shortly before the aerosol-forming gel is applied. A closure may be provided for closing the fluid communication between the through-holes and the gel reservoir.

[0025] The gel dosing device preferably comprises several teeth, at least one of the several teeth comprising a through hole for applying the aerosol-forming gel to the susceptor material. More preferably, the several teeth comprise a through hole for applying the aerosol-forming gel to several cavities in the susceptor material. For example, all teeth of the dosing device may comprise a through hole. Preferably, all teeth comprise a through hole for applying the aerosol-forming gel to at least some cavities in the susceptor material. More preferably, all teeth comprise a through hole for applying the aerosol-forming gel to all cavities in the susceptor material.

[0026] Varying the amount of teeth that are provided with through holes and in communication with a gel reservoir provides the advantage of being able to adjust the amount of aerosol-forming gel that is applied over the length of the susceptor material.

[0027] The through-holes of the gel administration device may communicate with one and the same reservoir. The through-holes of the gel administration device may communicate with different reservoirs. The different reservoirs may comprise the same aerosol-forming gel. The different reservoirs may also comprise different aerosol-forming gels.

[0028] Several dosing devices may be arranged in succession. Each of the several dosing devices is preferably in fluid communication with a gel reservoir containing a different aerosol-forming gel. The susceptor sheet material may then pass through each of the several dosing devices. At each dosing device, one or several or all of the cavities are filled with the aerosol-forming gel. Not only the unfilled cavities but also the already filled cavities are (further) filled when the susceptor passes through the subsequently arranged gel dosing device. Different filling of the cavities may thereby be realised. Alternatively or additionally, multiple filling of the cavities may be realised.

[0029] The aerosol-forming gel(s) may be forced through a pump to the teeth. In some embodiments, the gel reservoir may be pressurized. A combination of pressurized gel and pump may also be implemented to deliver the aerosol-forming gel to the teeth in an administration device.

[0030] The administration system, e.g. the reservoir or administration device, may comprise heating means for heating the aerosol-forming gel. Heating means may for example be provided to liquefy the gel.

[0031] In embodiments in which the susceptor sheet material comprises at least one depression on each side of the susceptor sheet material, the gel dosing device is then adapted to apply the aerosol-forming gel to the at least one depression on each side of the susceptor sheet material.

[0032] The gel dosing device may comprise a dosing wheel drum including circumferentially arranged teeth that substantially correspond to the morphology of the susceptor material (particularly the morphology of the depressions in the susceptor material). In some embodiments, at least one tooth of the dosing wheel drum includes a through hole that is in fluid communication with a gel reservoir that contains the aerosol-forming gel. The circumferentially arranged teeth of the dosing wheel drum are preferably arranged parallel to the axis of rotation of the dosing wheel drum and perpendicular to the conveying direction or length of the susceptor sheet material.

[0033] The gel dosing device preferably comprises a pair of intermeshing dosing wheel drums, both of which are provided with circumferentially arranged teeth, which mesh with each other as the wheel drums rotate. At least one tooth of one of the dosing wheel drums of the pair of dosing wheel drums comprises a through hole which is in fluid communication with a gel reservoir for the aerosol-forming gel. In the pair of intermeshing dosing wheel drums, at least one tooth of both dosing wheel drums of the pair of dosing wheel drums preferably comprises a through hole which is in fluid communication with the gel reservoir. The two wheel drums of the pair of dosing wheel drums may be in fluid communication with the same or different gel reservoirs. With the two wheel drums, the susceptor is guided between the two drums, where the gel is applied to the susceptor.

[0034] The gel dosing device may include a dosing belt for conveying the susceptor sheet material, in which the teeth including the through holes are the teeth of the dosing belt.

[0035] The dosing belt is preferably a toothed conveyor belt, more preferably a closed loop endless belt.

[0036] The gel dosing device may comprise a dosing roller comprising at least one circumferentially disposed tooth that substantially corresponds to the configuration of the at least one longitudinally extending depression in the susceptor material and extends in the direction of rotation of the dosing roller, hi some embodiments, at least one tooth of the dosing roller comprises a through hole in fluid communication with a gel reservoir containing the aerosol-forming gel.

[0037] The gel dosing device preferably comprises a pair of intermeshing dosing rollers. Both dosing rollers are provided with at least one circumferentially arranged tooth, which intermesh with each other as the dosing rollers rotate in the transport direction of the susceptor past the two dosing rollers. At least one tooth of one dosing roller of the pair of dosing rollers is provided with a through hole in fluid communication with a gel reservoir for the aerosol-forming gel. In a pair of intermeshing dosing rollers, at least one tooth of both dosing rollers of the pair of dosing rollers is preferably provided with a through hole in fluid communication with the gel reservoir. The two dosing rollers of the pair of dosing rollers may be in fluid communication with the same or different gel reservoirs. With two dosing rollers, the susceptor is guided between the two rollers, where the gel is applied to the susceptor. In an embodiment with a pair of dosing rollers, preferably one dosing roller is provided with one single tooth with a through hole in communication with a gel reservoir for the aerosol-forming gel, and the other intermeshing dosing roller is provided with two teeth, preferably each tooth with a through hole in communication with a gel reservoir for the aerosol-forming gel. The perforations may be continuous perforations extending along the entire circumference of the dosing roller for continuous gel application.

[0038] Preferably, the tip of the tooth with the through hole and the bottom of the recess in the susceptor sheet material are at least partially spaced apart from each other when the tooth is inserted into the recess for application of the aerosol-forming gel, the distance being preferably selected to leave a space for the aerosol-forming gel to be applied into the recess in the susceptor sheet material.

[0039] This may be achieved, for example, by a tooth with a through hole and with a flat tip. The recess is provided with walls that narrow towards the bottom of the recess. Therefore, when the tooth is fully inserted into the recess in the susceptor material, there is a distance between the bottom of the recess and the flat tip of the tooth. This is advantageous because a gap is formed by this distance.

[0040] Alternatively, or additionally, the teeth may not be inserted, or may not be fully inserted, into the recesses in the susceptor material, such that the distance between the teeth and the susceptor material leaves space for the aerosol-forming gel.

[0041] The aerosol-forming gel is preferably applied only into the depressions of the susceptor material, such that parts of the susceptor sheet material that do not contain depressions, such as the crests of a wave-formed susceptor sheet material, do not have aerosol-forming gel.

[0042] Providing the aerosol-forming gel only in the depressions has the advantage of good localization of the aerosol-forming gel. The depressions provide a boundary for the aerosol-forming gel, not only after application of the aerosol-forming gel, but also after application in the final susceptor sheet material containing the aerosol-forming gel. The gel is prevented from flowing further into other parts of the susceptor material after application of the gel or upon heating. This is an improvement over a flat susceptor sheet. This is also advantageous in view of the amount of aerosol-forming gel heated by the susceptor material, since the size of the contact surface between the susceptor material and the aerosol-forming gel is well defined. Providing the aerosol-forming gel in the depressions of the susceptor material also provides separate aerosol-forming gel portions along and across the susceptor material, which may be heated individually, sequentially, or in groups. This may be used to provide various combinations and variations of aerosol generation.

[0043] The method may also include providing a conduit (e.g., a tube) having at least one gel inlet, guiding a susceptor sheet material inside and along the conduit, and injecting an aerosol-forming gel into the conduit via the at least one gel inlet and into the susceptor sheet material guided inside and along the conduit.

[0044] Accordingly, the gel dosing device may comprise a conduit adapted to guide the susceptor sheet material inside and along the conduit. The conduit comprises at least one gel inlet for injection of the aerosol-forming gel into the conduit and onto the susceptor sheet material guided inside and along the conduit. The at least one gel inlet is preferably arranged to apply the aerosol-forming gel to one side (e.g. the upper or lower side) of the susceptor sheet material.

[0045] The conduit may comprise two or more gel inlets for the injection of the aerosol-forming gel, preferably two gel inlets disposed opposite each other within the conduit, whereby the aerosol-forming gel may be applied to both sides of the susceptor sheet material.

[0046] Two or more gel inlets may also be disposed on the same side of the conduit, whereby the aerosol-forming gels may then be applied to the same side of the susceptor sheet material. Two or more gel inlets may be connected to the same gel reservoir or to different gel reservoirs. The gel inlets on the same side are preferably connected to different reservoirs, preferably containing different aerosol-forming gels. Thereby, sequential injection of different aerosol-forming gels may be realized. The different gels may be applied to the same recess or to different recesses.

[0047] The cross-section of the conduit may substantially correspond to the width and height of the susceptor material. Ideally, the cross-section of the conduit is slightly larger than the width and height of the susceptor material. For example, the cross-section of the conduit is 5 percent to 10 percent larger than the width and height of the susceptor material. The cross-section of the conduit may be, for example, rectangular. The cross-section of the conduit may also have different shapes (for example, oval or square).

[0048] The conduit may, for example, have a shape such that the susceptor material passing through the conduit is provided with the aerosol-forming gel on the entire side of the susceptor material. Preferably, the susceptor material is provided with the aerosol-forming gel on both sides of the susceptor material.

[0049] The cross section of the conduit is preferably reduced when viewed in the direction of transport of the susceptor material through the conduit. The conduit inlet preferably has a cross section larger than the cross section of the susceptor sheet material to simplify the insertion of the susceptor into the conduit. The conduit outlet preferably has a cross section substantially corresponding to the extension of the cross section of the susceptor sheet material. The conduit outlet preferably has a cross section corresponding to the cross section of the sheet material plus 5 percent. Small differences in cross section may avoid or reduce friction. In some embodiments, the cross section of the conduit outlet is slightly larger than the extension of the susceptor sheet material in the height direction. The height direction is the direction of the depression extending from the plane or imaginary plane of the susceptor sheet material. This may allow excess aerosol-forming gel to remain on the susceptor sheet material covering the susceptor sheet material.

[0050] The conduit may include an internal or external drive mechanism that supports passage of the susceptor through the conduit.

[0051] In some embodiments in which the susceptor material passes through a conduit and the passage of the conduit provides the susceptor material with an aerosol-forming gel, not only are depressions in the susceptor material provided with the aerosol-forming gel, but flat portions or, for example, crests of a wave-shaped susceptor are also covered with the aerosol-forming gel.

[0052] A dosing device in the form of a conduit is advantageous in that the entire surface of the susceptor material may be coated with the aerosol-forming gel, and a large amount of the aerosol-forming gel may be provided to the susceptor material. In addition, depending on the physical properties of the aerosol-forming gel applied to the susceptor material, the susceptor material may be embedded within the aerosol-forming gel. The outer shape of the embedded susceptor material may be defined by the shape of the conduit, in particular the inner cross section of the conduit.

[0053] The susceptor sheet material provided with the aerosol-forming gel may be stored, for example coiled on a bobbin. The susceptor sheet material containing the aerosol-forming gel may then be unwound from the bobbin and used in the manufacture of an aerosol-generating article, for example an aerosol-generating rod.

[0054] The susceptor sheet material provided with the aerosol-forming gel may be used directly (particularly in-line) in the manufacture of aerosol-forming articles.

[0055] The gel dosing device may be part of a rod-forming device for forming aerosol-generating rods (e.g., tobacco rods), which are preferably used in the manufacture of inductively heatable aerosol-generating articles for electronic aerosol generating devices, such as hand-held induction heating devices.

[0056] A gel dosing apparatus with a conduit is particularly suitable for the on-line production of a susceptor material that comprises at least one cavity and forms an inductively heatable aerosol-generating rod. The conduit is preferably located within the funnel portion of a rod-forming apparatus for the production of an aerosol-generating article. In such a rod-forming apparatus, an aerosol-generating substrate, such as a tobacco sheet, is assembled into a rod in the funnel portion. Such rod-forming apparatus are well known in the art.

[0057] The dosing device of the present invention may be positioned within or upstream of the funnel section. The susceptor material comprising the aerosol-forming gel from the gel dosing device, in particular from the conduit of the gel dosing device, may be fed directly into the rod-forming device and into the interior of the aerosol-generating substrate or other material used in the rod-forming process. The conduit or the outlet of the conduit serves not only as a guiding means for the susceptor sheet material comprising the aerosol-forming gel, but also as a positioning means. In particular with the conduit, the susceptor material comprising the aerosol-forming gel may be positioned very precisely within the material forming the rod, and therefore within the rod.

[0058] The dosing system may also be combined with a drying device. The drying device preferably removes liquid from the gel and solidifies it on the susceptor. Such a drying device may be an external or internal drying device of the dosing device. An external drying device may be, for example, a fan or a heater provided downstream of the dosing device. An internal drying device may be, for example, a heater in the dosing device, for example integrated in a conduit of the dosing device. The drying device is preferably realized by induction heating of the susceptor sheet material for drying the gel and removing the liquid. Material emissions other than water or liquefied material are preferably prevented or limited to a minimum.

[0059] According to the present invention there is also provided a rod forming apparatus for the manufacture of aerosol generating articles for use in electronic aerosol generating devices, the rod forming apparatus comprising a dosing system according to the present invention and as described herein.

[0060] In the method according to the invention, the susceptor material may be pre-manufactured before the aerosol-forming gel is provided or may be manufactured in-line. For example, the susceptor material comprising at least one depression or a plurality of depressions may be fed, for example, from a bobbin and guided to a dosing system as described herein. Alternatively, the method may include passing the susceptor material (e.g. a flat band or strip of susceptor material, such as a metal band) through a susceptor forming apparatus, whereby a previously flat susceptor sheet material is provided with at least one depression or a plurality of depressions in the forming apparatus.

[0061] Accordingly, the dispensing system may comprise a susceptor forming device adapted to form a susceptor sheet material, the susceptor material being provided with at least one depression by passing the susceptor sheet material through the forming device. The susceptor forming device is arranged upstream of the gel dispensing device. For example, a flat band of susceptor material is fed to the susceptor forming device and formed in the susceptor forming device into a susceptor material with at least one depression. The susceptor sheet material so formed is then further conveyed to the gel dispensing device, where an aerosol-forming gel is applied to the susceptor material.

[0062] The susceptor forming device may comprise or consist of intermeshing rollers, for example in the form of a toothed wheel drum, or a forming roller with at least one circumferentially arranged tooth, the tooth extending in the direction of rotation of the forming roller. The susceptor material being forced between the teeth of the wheel drum or between the teeth of the forming roller is deformed and is provided with depressions in the form of protrusions and depressions or peaks and valleys according to the form of the teeth of the toothed wheel drum or forming roller. The susceptor forming device may also comprise several pairs of intermeshing rollers, for example for subsequent forming of the susceptor material. For example, individual rollers may provide a susceptor sheet material with successive deeper depressions.

[0063] A gel dosing device with intermeshing dosing wheel drums may be combined as a forming and dosing unit, the intermeshing teeth of the gel dosing wheel drums then also serving as forming elements.

[0064] A gel dosing device with intermeshing forming rollers may be combined as a forming and dosing unit. The intermeshing teeth of the gel dosing rollers then also act as forming elements.

[0065] The method may further include passing the susceptor material and the porous sheet material in parallel through a gel dispensing device, where the aerosol-forming gel is applied to the combination of the susceptor sheet material and the porous sheet material.

[0066] The porous sheet material may be, for example, cotton, viscose, or a tow material (eg, cellulose acetate tow).

[0067] The susceptor material and the porous sheet material preferably pass between two gel dosing elements (eg, two gel dosing wheel drums, two gel dosing rollers, or two dosing belts arranged in parallel and facing each other).

[0068] The porous sheet material may serve to secure the aerosol-forming gel to the susceptor material and may serve to secure the position of the aerosol-forming gel along the porous material / susceptor combination, generally due to the porosity of the porous sheet material.

[0069] The porous sheet material may have a wicking effect on the aerosol-forming gel, especially when the gel is applied hot and in more liquid form.

[0070] According to the present invention there is also provided a susceptor sheet material comprising an aerosol-forming gel. The susceptor sheet material comprises a plurality of recesses, at least one of the plurality of recesses in the susceptor material being filled with the aerosol-forming gel. Preferably some or all of the plurality of recesses are filled with the aerosol-forming gel. Preferably the susceptor sheet material comprises a plurality of recesses on both sides of the susceptor sheet material. Preferably at least one recess on both sides of the susceptor sheet material is filled with the aerosol-forming gel.

[0071] In embodiments having a wave-shaped susceptor sheet material, it is preferred that only the troughs of the waves are filled with the aerosol-forming gel. Thereby, only the parts of the walls of the troughs of the susceptor material (parts filled with aerosol-forming gel) contain the aerosol-forming gel. Depending on the filling level of the troughs, the parts of the walls of the troughs that are not in contact with the aerosol-forming gel may be smaller or larger. Therefore, it is preferred that the crests of the waves of the susceptor material, in particular the tips of the crests, are free of aerosol-forming gel. Preferably, all the troughs (most preferably only the troughs) on one or both sides of the susceptor material contain the aerosol-forming gel. Hence, preferably all the peaks on one side, more preferably all the peaks on both sides of the susceptor material are free of aerosol-forming gel.

[0072] In embodiments in which the susceptor sheet material is provided with at least one depression extending along the length of the susceptor sheet material, the aerosol-forming gel is preferably provided continuously and in a constant amount along the length of the at least one depression.

[0073] In embodiments in which the susceptor sheet material is provided with at least one recess extending along the length of the susceptor sheet material on both sides of the susceptor sheet material, different types of aerosol-forming gels are preferably provided on the two sides of the susceptor sheet material. The different types of gels on the two sides of the susceptor may be provided continuously and in constant amounts along the length of the at least one recess on each of the two sides of the susceptor.

[0074] The susceptor sheet material comprising one or more depressions and containing an aerosol-forming gel is preferably manufactured in a dosing device according to the present invention and as described herein.

[0075] The term "susceptor" as used herein refers to a material capable of converting electromagnetic energy into heat. When placed in an alternating electromagnetic field, eddy currents are typically induced and hysteresis losses may occur in the susceptor, causing heating of the susceptor. As the susceptor is placed in thermal contact with the aerosol-forming gel, the aerosol-forming gel is heated by the susceptor and ejects a fluid from the susceptor.

[0076] The susceptor may be formed of any material that can be inductively heated to a temperature sufficient to release material from the aerosol-forming gel. Preferred susceptors include metal or carbon. Preferred susceptors may include or consist of ferrous or ferromagnetic materials (e.g., ferritic iron, ferromagnetic alloys such as ferromagnetic steel, stainless steel, or aluminum). The susceptor preferably includes more than 5 percent, preferably more than 20 percent, preferably more than 50 percent or 90 percent ferromagnetic or paramagnetic materials. Preferred susceptors may be heated to a temperature of about 150 degrees Celsius to about 300 degrees Celsius. The susceptor may preferably be heated to a temperature of about 200 degrees Celsius to about 270 degrees Celsius, for example 235 degrees Celsius.

[0077] The susceptor sheet material is preferably a metallic strip of material.

[0078] The susceptor sheet material is preferably a stainless steel band, however, the susceptor material may also include or be made of graphite, molybdenum, silicon carbide, aluminum, niobium, Inconel alloy (austenitic nickel-chromium based superalloy), metallized films, ceramics (e.g., zirconia, etc.), transition metals (e.g., iron, cobalt, nickel, etc.), or semi-metallic components (e.g., boron, carbon, silicon, phosphorus, aluminum, etc.).

[0079] The susceptor sheet material has the form of a band. The band preferably has a basic rectangular shape with a width of about 2 mm to about 8 mm, more preferably about 3 mm to about 5 mm, for example 4 mm, and a thickness of about 0.03 mm to about 1 mm, more preferably about 0.05 mm to about 0.5 mm, for example about 0.07 mm to 0.2 mm. The width of the susceptor band is smaller than the width or diameter of the plug in which the susceptor is disposed.

[0080] As a general rule, whenever the term "about" is used throughout this specification in connection with a particular value, it is understood that the value following the term "about" does not have to have exactly that particular value due to technical considerations. However, it is understood that the term "about" used in connection with a particular value always includes and also explicitly discloses the particular value following the term "about."

[0081] The term "depression" in combination with the susceptor sheet material as used herein is understood to comprise a non-flat structure including deformations (in the form of indentations and protrusions), peaks and valleys or similar forms, in which the depression forms a protrusion on the opposite side of the susceptor sheet material and the peak forms a valley on the opposite side of the susceptor sheet material. The "depression" may be constrained in the plane of the susceptor sheet material or may be open in the plane of the susceptor sheet material. For example, the depression may be open towards the side edges of the band of susceptor sheet material. A constrained depression preferably has a circular or elliptical shape. An open depression preferably has the form of a groove extending in the susceptor sheet material, preferably in the longitudinal or transverse direction of the susceptor sheet material.

[0082] The depressions preferably form a series of depressions. The series may be a regular series. The series may be an irregular series. The depressions may be arranged in one or several rows along the susceptor sheet material. The depressions in the susceptor sheet material are preferably regularly arranged along the length of the susceptor material. The depressions may have a pointed, rounded or flat shape (V-shaped, U-shaped, trapezoidal).

[0083] The susceptor sheet material may be an elongated susceptor material having a corrugated shape. The susceptor sheet material may be a corrugated band, the corrugations being preferably arranged perpendicular to the longitudinal axis of the band. The susceptor sheet material may be a corrugated band, with one or several corrugations being arranged parallel to the longitudinal axis of the band. The corrugations may have a pointed, rounded or trapezoidal shape. The corrugations may therefore have a triangular shape with pointed tips and valleys. Or the corrugations may have rounded tips and rounded valleys. Or the corrugations may have peaks and valleys with flat tips and flat bottoms.

[0084] The susceptor sheet material preferably has a zigzag or sinusoidal shape along a longitudinal or transverse cross section. When the susceptor sheet material has a wave shape, the distance between adjacent peaks or valleys of the susceptor material is preferably constant. The distance between adjacent peaks and valleys is preferably constant. The peaks and valleys preferably form a continuous periodic function along the length of the wave-form susceptor sheet material. A constant arrangement of peaks and valleys allows the production of a regular continuous susceptor sheet material. This is advantageous in that the final article on which the susceptor sheet material is disposed may have a constant amount and distribution of susceptor material per length of the article, essentially independent of the length of the article. In particular, such a final article may be produced with a constant amount and distribution of aerosol-forming gel per length of the article, essentially independent of the length of the article.

[0085] Preferably, the depth of the depression in the susceptor material is between 0.5 mm and 2.5 mm, more preferably between 1 mm and 2 mm, for example 1.5 mm. The depth of the depression may be kept constant or may vary along the length of the susceptor material. Preferably, the depth of the depression is kept constant along the length of the susceptor material.

[0086] The height between the peaks and valleys of the corrugated susceptor material (from the peak of the wave to the bottom of the valley) is preferably 0.5 mm to 5 mm, preferably 1 mm to 3 mm, for example 2 mm. The height between the peaks and valleys is preferably constant along the length of the susceptor material.

[0087] The width of the susceptor sheet material is preferably greater than the depth of the depressions, and in particular greater than the height between the peaks and valleys of the wave-shaped susceptor sheet material.

[0088] The susceptor sheet material used in the method of the present invention or provided in the dosing system or device is preferably a continuous susceptor sheet material.

[0089] The final length of the susceptor sheet material preferably corresponds to the length of the plug in which it is disposed, in some embodiments, the final length of the susceptor sheet material may be less than the length of the plug in which it is disposed.

[0090] The susceptor sheet material is preferably centrally disposed within a plug, preferably within an aerosol-forming substrate plug (e.g., a tobacco plug), where "centrally" disposed is understood to mean with and disposed along the longitudinal axis of the plug.

[0091] The susceptor sheet material including the aerosol-forming gel may be disposed within a plug that includes or is made of an aerosol-forming substrate. The susceptor sheet material including the aerosol-forming gel may also be disposed within a plug that includes or is made of a non-aerosol-forming substrate.

[0092] In particular, when the susceptor sheet material includes an aerosol-forming gel in an amount that forms sufficient aerosol for a desired application, the plug in which the susceptor sheet material is disposed may be made of a non-aerosol-forming plug material. Such a non-aerosol-forming plug material may be, for example, an aerosol cooling material, a filter material, or an aerosol directing material. For example, such a material may be paper, polylactic acid (PLA), or cellulose acetate tow.

[0093] The susceptor sheet material with the indentations expands the surface area and amount of susceptor material per plug length. Therefore, a larger amount of heat may be brought into the plug compared to a flat rectangular heater blade. In addition, more material may be released at a particular temperature. Or the same amount of material may be released at a lower temperature. The material released from the aerosol-forming gel is preferably added to the material released from the plug. Direct contact between the aerosol-forming gel and the susceptor sheet material may release material at the very beginning of the heating of the susceptor sheet material. As soon as the release of material from the plug of material begins, the heat may be reduced, whereby a uniform and continuous aerosol delivery profile may be achieved throughout the heating of the susceptor sheet material.

[0094] An "aerosol-forming gel" is herein understood to be a material or mixture of materials that has the ability to release a volatile compound into an air stream passing through an article in which the susceptor is disposed, preferably when the gel is heated. The provision of a gel may be advantageous for storage and transportation or during use, since the risk of leakage from the susceptor, aerosol-generating article, or aerosol-generating device may be reduced.

[0095] Advantageously, the gel is solid at room temperature. In this context, "solid" means that the gel has a stable size and shape and does not flow. Room temperature in this context means 25 degrees Celsius.

[0096] The gel may include an aerosol former. Ideally, the aerosol former is substantially resistant to thermal decomposition at the operating temperature of the susceptor. Suitable aerosol formers are well known in the art and include, but are not limited to, polyhydric alcohols (such as triethylene glycol, 1,3-butanediol, glycerin, etc.), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate, etc.), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.). The polyhydric alcohol or mixtures thereof may be one or more of triethylene glycol, 1,3-butanediol, and glycerin or polyethylene glycol.

[0097] Advantageously, the gel comprises, for example, a thermoreversible gel. This means that the gel becomes fluid when heated to the melting temperature and becomes a gel again at the gelling temperature. The gelling temperature may be at room temperature and above atmospheric pressure. Atmospheric pressure means a pressure of 1 atmosphere. The melting temperature may be higher than the gelling temperature. The melting temperature of the gel may be above 50 degrees Celsius or 60 degrees Celsius or 70 degrees Celsius, or even above 80 degrees Celsius. The melting temperature in this context means the temperature at which the gel is no longer solid and starts to flow.

[0098] Alternatively, in certain embodiments, the gel is a non-melting gel that does not melt during use of the susceptor, In these embodiments, the gel may at least partially release the active agent at temperatures equal to or above the operating temperature of the susceptor during use, but below the melting temperature of the gel.

[0099] The gel preferably has a viscosity of 50,000 to 10 Pascals / second, preferably 10,000 to 1,000 Pascals / second, to provide the desired viscosity.

[0100] In combination with certain embodiments, the gel comprises a gelling agent, hi certain embodiments, the gel comprises agar or agarose or sodium alginate or gellan gum, or a mixture thereof.

[0101] In certain embodiments, the gel comprises water, e.g., the gel is a hydrogel. Alternatively, in certain embodiments, the gel is non-aqueous.

[0102] The gel preferably includes an active agent. In combination with certain embodiments, the active agent includes nicotine (e.g., nicotine in powder or liquid form), or a tobacco product or another target compound, for example, for release in an aerosol. In certain embodiments, the nicotine is included in the gel along with an aerosol former. Entrapment of the nicotine in the gel at room temperature is desirable to prevent leakage of the nicotine from the aerosol-generating article.

[0103] In certain embodiments, the gel includes solid tobacco materials that release flavor compounds when heated. Depending on the particular embodiment, the solid tobacco materials are one or more of powders, granules, pellets, pieces, spaghetti, strips, or sheets, including one or more of plant materials such as herb leaves, tobacco leaves, tobacco stem pieces, reconstituted tobacco, homogenized tobacco, extruded tobacco, and expanded tobacco.

[0104] In some embodiments, the gel contains other flavors, such as menthol, which can be added to either the water or the aerosol former prior to formation of the gel.

[0105] In embodiments in which agar is used as the gelling agent, the gel may comprise, for example, 0.5 to 5 weight percent, preferably 0.8 to 1 weight percent, of agar. Preferably, the gel further comprises 0.1 to 2 weight percent nicotine. Preferably, the gel further comprises 30 to 90 weight percent (or 70 to 90 weight percent) glycerin. In certain embodiments, the remainder of the gel comprises water and flavoring agents.

[0106] The gelling agent is preferably agar, which has the property of melting at temperatures above 85 degrees Celsius and returning to a gel at around 40 degrees Celsius. This property makes agar suitable for high temperature environments. The gel does not melt at 50 degrees Celsius, which is useful, for example, if the system is placed in a hot car in the sun. The phase transition to a liquid at around 85 degrees Celsius means that the gel only needs to be heated to a relatively low temperature to induce aerosolization, allowing for low energy consumption. It may be beneficial to use only agarose, one of the components of agar, instead of agar.

[0107] When gellan gum is used as the gelling agent, the gel typically comprises 0.5 to 5 weight percent gellan gum. Preferably, the gel further comprises 0.1 to 2 weight percent nicotine. Preferably, the gel comprises 30 to 99.4 weight percent glycerin. In certain embodiments, the remainder of the gel comprises water and flavorings.

[0108] In one embodiment, the gel comprises 2 percent by weight nicotine, 70 percent by weight glycerol, 27 percent by weight water, and 1 percent by weight agar.

[0109] In another embodiment, the gel comprises 65 percent by weight glycerol, 20 percent by weight water, 14.3 percent by weight tobacco, and 0.7 percent by weight agar.

[0110] The following non-limiting examples are provided in a non-exhaustive list, any one or more features of which may be combined with any one or more features of any other example, embodiment, or aspect described herein.

[0111] Example Ex1: A method for producing a susceptor sheet material comprising an aerosol-forming gel, comprising: providing a susceptor sheet material comprising at least one recess; - applying an aerosol-forming gel to at least said recesses in the susceptor sheet material.

[0112] Example Ex2: providing a susceptor sheet material having at least one recess on each side of the susceptor sheet material; The method of embodiment Ex1, further comprising applying an aerosol-forming gel to the at least one recess on both sides of the susceptor sheet material.

[0113] Example Ex3: The method of any one of the preceding examples, further comprising applying different aerosol-forming gels to different recesses of different susceptor sheet materials, wherein the different aerosol-forming gels differ in at least one of flavor, nicotine, aerosol-forming agent, and aerosolization temperature.

[0114] Example Ex4: A method according to any one of the preceding claims, in which the aerosol-forming gel is applied through a through hole in at least one moving tooth of the gel administration device.

[0115] Example Ex5: A method according to example Ex4, in which the aerosol-forming gel is applied through a through hole in at least one moving tooth of a dosing wheel drum having teeth arranged in a circumferential direction.

[0116] Example Ex6: A method according to example Ex4, in which the aerosol-forming gel is applied through a through hole in at least one moving tooth of the dosing belt, and the dosing belt is used to transport the susceptor sheet material.

[0117] Example Ex7: A method according to any one of the preceding examples, wherein the aerosol-forming gel is applied across the width of the susceptor sheet material through a plurality of through holes disposed across the width of the teeth.

[0118] Example Ex8: The method according to example Ex4, wherein the aerosol-forming gel is applied through a through hole in at least one moving tooth of the dosing roller.

[0119] Example Ex9: The method according to example Ex8, wherein at least one moving tooth of the dosing roller is arranged parallel to the direction of transport of the susceptor sheet material.

[0120] Example Ex10: providing a conduit having at least one gel inlet; Guiding a susceptor sheet material within and along the conduit; The method according to any one of embodiments Ex1 to Ex3, comprising injecting an aerosol-forming gel into the conduit via at least one gel inlet, and injecting into the interior of the conduit and onto a susceptor sheet material guided along the conduit.

[0121] Example Ex11: The method of any one of the preceding embodiments, comprising forming a susceptor sheet material with at least one depression by passing the susceptor sheet material through a susceptor forming apparatus.

[0122] Example Ex12: The method of example Ex11, comprising forming at least one depression in the susceptor sheet material by passing the susceptor sheet material between a pair of intermeshing toothed wheel drums.

[0123] Example Ex13: The method of example Ex11, comprising forming at least one depression in the susceptor sheet material by passing the susceptor sheet material under a forming roller, the forming roller having circumferentially arranged teeth extending in the direction of rotation of the forming roller.

[0124] Example Ex14: The method of any one of the preceding examples, further comprising passing the susceptor sheet material and the porous sheet material in parallel through a gel dosing device, thereby applying an aerosol-forming gel to the combination of the susceptor sheet material and the porous sheet material.

[0125] Example Ex15: A dispensing system for applying an aerosol-forming gel to a susceptor sheet material, comprising: a susceptor sheet material having at least one depression; and a gel dispensing device adapted to apply an aerosol-forming gel to at least one recess in the susceptor sheet material.

[0126] Example Ex16: A dosing system according to example Ex11, wherein the gel dosing device comprises a dosing wheel drum having circumferentially arranged teeth substantially corresponding to the shape of the susceptor sheet material, at least one tooth of the dosing wheel drum having a through hole in fluid communication with the gel reservoir, and the gel dosing device preferably comprises a pair of interlocking dosing wheel drums, wherein at least one tooth of both dosing wheel drums of the pair of dosing wheel drums has a through hole in fluid communication with the gel reservoir.

[0127] Example Ex17: A susceptor sheet material having at least one recess on each side of the susceptor sheet material; A dispensing system according to Ex15, comprising: a gel dispensing device adapted to apply an aerosol-forming gel to at least one recess on each side of the susceptor sheet material.

[0128] Example Ex18: A dosing system as described in example Ex17, wherein the gel dosing device comprises a pair of intermeshing dosing wheel drums having circumferentially arranged teeth substantially corresponding to the shape of the susceptor sheet material, and at least one tooth of both dosing wheel drums of the pair of dosing wheel drums comprises a through hole in fluid communication with the gel reservoir.

[0129] Example Ex19: A dosing system according to example Ex15, wherein the gel dosing device comprises a dosing belt for transporting the susceptor sheet material, and the teeth are teeth of the dosing belt, the dosing belt preferably comprising a series of teeth substantially corresponding to the shape of the susceptor sheet material, and each tooth of the series of teeth comprises a through hole.

[0130] Example Ex20: A gel dosing device comprises a dosing roller having at least one circumferentially arranged tooth, the at least one circumferentially arranged tooth extending in the direction of rotation of the dosing roller; A dosing system as described in embodiment E15, wherein at least one tooth of the dosing roller has a through hole fluidically connected to the gel reservoir, and wherein the gel dosing device preferably comprises a pair of intermeshing dosing rollers, and wherein at least one tooth of both dosing rollers of the pair of dosing rollers has a through hole fluidically connected to the gel reservoir.

[0131] Example Ex21: A dosing system according to any one of examples Ex15 to Ex19, wherein at least one depression is an elongated depression extending perpendicular to the transport direction of the susceptor sheet material.

[0132] Example Ex22: The dosing system according to any one of examples Ex15 to Ex20, wherein at least one depression is an elongated depression extending parallel to the transport direction of the susceptor sheet material.

[0133] Example Ex23: A dosing system as described in example Ex15, wherein the gel dosing device comprises a conduit adapted to guide the susceptor sheet material inside and along the conduit, the conduit comprising at least one gel inlet for injection of the aerosol-forming gel into the conduit and for injection of the aerosol-forming gel into the conduit and into the susceptor sheet material guided inside and along the conduit.

[0134] Example Ex24: An administration system according to example Ex23, wherein the conduit comprises two gel inlets arranged opposite each other in the conduit.

[0135] Example Ex25: A susceptor sheet material comprising an aerosol-forming gel, wherein the susceptor sheet material comprises a plurality of depressions, and at least one depression of the plurality of depressions in the susceptor sheet material is filled with the aerosol-forming gel.

[0136] Example Ex26: The susceptor sheet material according to example Ex25, comprising a plurality of depressions disposed on both sides of the susceptor sheet material, at least one of the plurality of depressions on both sides of the susceptor sheet material being filled with an aerosol-forming gel.

[0137] Example Ex27: The susceptor sheet material according to any one of examples Ex25-Ex26, wherein at least some of the plurality of depressions are elongated depressions extending along the length or width of the susceptor sheet material.

[0138] The invention will now be further described with reference to embodiments, which are illustrated by the following drawings, in which: [Brief description of the drawings]

[0139] [Figure 1] FIG. 1 shows a susceptor band having a triangular wave shape. [Diagram 2] FIG. 2 shows a susceptor band having a sinusoidal shape. [Diagram 3]FIG. 3 shows the susceptor of FIG. 2 with gel in the valleys. [Figure 4] FIG. 4 shows a top or bottom view of a susceptor band having indentations in the form of protrusions and depressions. [Diagram 5] FIG. 5 shows a perspective view of another susceptor band having indentations in the form of protrusions and depressions. [Figure 6] FIG. 6 is a perspective view of the forming apparatus. [Figure 7] FIG. 7 is a schematic diagram of the administration system. [Figure 8] FIG. 8 shows details of the delivery system. [Figure 9] FIG. 9 is a schematic diagram of gel application. [Figure 10] FIG. 10 shows a schematic diagram of an arrangement having a forming device and a dispensing device. [Figure 11] FIG. 11 shows a side cutaway view of the dosing belt. [Figure 12] FIG. 12 is a schematic diagram of a combined forming and dispensing apparatus having a porous sheet material. [Figure 13] FIG. 13 is a schematic diagram of a sequentially arranged forming device and dispensing device with subsequent rod formation. [Figure 14] FIG. 14 shows a forming and subsequent dispensing system integrated into a rod forming apparatus. [Figure 15] FIG. 15 shows a forming apparatus for longitudinally grooved susceptor material. [Figure 16] FIG. 16 is a cross-sectional view of a gel-filled V-shaped susceptor material. [Figure 17] FIG. 17 is a schematic diagram of a forming apparatus for a W-shaped susceptor. [Figure 18] FIG. 18 shows a W-shaped susceptor with both sides of the susceptor filled with gel. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0140] FIG. 1 shows a susceptor sheet material 1 in the form of waves having a zigzag configuration. The peaks 10 and valleys 11 are V-shaped and form regular waves along the length 100 of the susceptor. The valleys 11 form depressions for application of an aerosol-forming gel. The peaks 10 on one side of the susceptor 1 form valleys 11 on the opposite side of the susceptor, and therefore the valleys on the opposite side of the susceptor. The peaks 10 and valleys 11 are disposed perpendicular to the length of the susceptor band 1.

[0141] The height 102 of the susceptor 1 is preferably in the range of 0.5 mm to 5 mm.

[0142] The width 101 of the susceptor 1 is preferably in the range of 2 mm to 8 mm.

[0143] A distance 103 between adjacent peaks 10 or between adjacent valleys 11 is, for example, in the range of 1 mm to 10 mm.

[0144] 2 shows a susceptor sheet material 1 having a sinusoidal configuration. The peaks 10 and valleys 11 have a rounded configuration and are U-shaped. The susceptor forms a regular wave along the length of the susceptor.

[0145] The height, width and distance between the peaks 10 and valleys 11 are preferably within the same ranges as those of the susceptor sheet material 1 shown and described in FIG.

[0146] Figure 3 shows the susceptor 1 of Figure 2 provided with an aerosol-forming gel 2. The gel 2 is disposed in all valleys 11 of the susceptor 1 and across the width of the susceptor 1. The gel 2 is disposed in all valleys 11 on both sides of the susceptor 1. The gel 2 may be the same on both sides of the susceptor 1. The gel 2 may be different on the two sides of the susceptor 1.

[0147] 4 shows one embodiment of a susceptor sheet 1 having two parallel rows of constrained depressions disposed along the length of the susceptor band 1. The depressions may be protrusions 13 and depressions 12 when viewed from a top view of the susceptor. The protrusions 13 and depressions 12 are disposed in an alternating manner along the rows.

[0148] 5, the constrained depressions are also arranged in two parallel rows along the length of the susceptor band 1. However, one row is formed by protrusions 13 and the second row is formed by depressions 12. All or only a portion of the depressions 12 and protrusions 13 may be filled with the aerosol-forming gel.

[0149] Figure 6 shows a forming apparatus comprising two forming rollers 3. The forming rollers 3 are provided with circumferentially disposed teeth 30 which intermesh in a forming section 31 of the former.

[0150] A flat susceptor band 111 is conveyed along a conveying direction 200 and made to pass between two forming rollers 3. The intermeshing teeth 30 form the susceptor band as the band passes between the forming rollers 3. The flat susceptor band 11 is formed into a susceptor band having a wave form 1 according to the form of the teeth of the rollers 3. The form of the teeth 30 as well as the distance of the rollers 3 may define the wave form of the susceptor.

[0151] FIG. 7 shows a gel dosing device 4 comprising a dosing wheel drum 5. The dosing wheel drum 5 comprises teeth 50 arranged in the circumferential direction. One of the teeth comprises three through holes 51 for application of the gel 2. The through hole 51 extends from the tip of the tooth 50 to a centrally arranged shaft 52 (shown in an exploded view). The shaft 52 is provided with a shaft opening 520 in fluid communication with the through hole 51. The shaft 52 is connected to a gel reservoir via a gel line 25. The gel reservoir 20 (e.g. a gel tank) is provided with a pump 21. By means of the pump 21, the gel 2 may be pumped from the gel reservoir 20 through the gel line 25 to the shaft 52 of the dosing wheel drum 5. The gel 2 is then forced out of the teeth of the wheel drum 5 through the shaft opening 520 and the through hole 51.

[0152] The dosing wheel drum 5 may be mounted on and rotate around a shaft 52. Hence, gel may be provided through the through hole 51 and applied to one or several depressions of the susceptor material only when the through hole 51 is disposed simultaneously with the shaft opening 52. The arrangement of the shaft opening 52 with the through hole 51 preferably correlates with the position of the teeth 50 disposed near or within the depressions of the susceptor sheet material.

[0153] Through holes may also be provided in other teeth 50 of the dosing wheel drum 5 .

[0154] Figure 8 shows diagrammatically an individual tooth 50 of a gel dosing device (e.g. a dosing wheel drum as shown in Figure 7). The tooth 50 has a rounded apex 10. Four through holes 51 are disposed equidistantly across the width of the tooth.

[0155] In FIG. 9, the application of gel 2 to two sides of a wave-shaped susceptor sheet material 1 is shown.

[0156] Two teeth 50 of two gel dispensers are shown, one tooth 50 of one dispenser arranged above the susceptor 1 and the other tooth 50 of the second dispenser arranged below the susceptor 1. Each tooth is provided with a through hole 51 that is in fluid communication with a gel reservoir (not shown).

[0157] For gel application, the tips 53 of the teeth 50 are not in contact with the susceptor 1 but are spaced a distance 15 from the bottoms 110 of the valleys 11 of the susceptor 1. The distance 15 leaves space for the gel 2 to be applied to the valleys 11 so that the gel 2 essentially stays within the valleys as applied and is not specifically forced out of the valleys.

[0158] The teeth 50 may be, for example, teeth of a dosing wheel drum 5 as illustrated in FIG. 7, or may be teeth of a dosing belt, as will be explained further below.

[0159] Fig. 10 is a schematic diagram of a combination of a forming device and a subsequent dosing device. The forming device with two toothed forming rollers 3 has already been described in relation to Fig. 6. A flat susceptor band 111 is deformed by the forming device and provided with a corrugated shape. The corrugated susceptor 1 is then guided between two toothed dosing wheel drums 5. The teeth of the dosing wheel drum 5 preferably have the same shape and size as the teeth of the forming rollers 5. At least one tooth of each of the dosing wheel drums 5 is provided with one or several through holes for the application of gel on both sides of the susceptor. The dosing wheel drum 5 including the gel supply may be realized, for example, as shown and described in Fig. 7.

[0160] The forming device and the dosing device can be combined as a forming-dosing device, in which the mating teeth of the dosing wheel drum act as forming-dosing teeth (see also FIG. 11 below).

[0161] In figure 11 a dosing device is shown which comprises a dosing belt 6. The dosing belt 6 may be an endless belt guided around a transport roller 61.

[0162] The dosing belt comprises a continuous series of teeth 60. The distance between the teeth 60 of the dosing belt 6 corresponds to the distance between the wave troughs of the wave-form susceptor 1. The susceptor 1 is thereby transported by the dosing belt 6 while the gel 2 is being dispensed. The teeth 60, preferably all teeth of the dosing belt 6, are provided with through-holes (not shown). The through-holes extend from the tips 62 of the teeth 60 to the gel dispenser 22 arranged below the dosing belt 6. When the dosing belt passes the gel reservoir 22, that tooth of the dosing belt arranged above the gel reservoir 22 is provided with gel. The gel 2 is applied to the lower valleys of the susceptor 1. The teeth 60 of the dosing belt 6 have flat tips 62. A space is formed between the flat tips 62 and the bottom of the valleys of the susceptor 1 for the gel 2.

[0163] Fig. 12 shows a combined forming and dosing apparatus. The combined forming and dosing apparatus comprises two toothed wheel drums 5. Both dosing wheel drums 5 rotate around a center 55 on which gel 2 is provided. The drums further comprise through holes 51 from the center 55 to the tips of the drum teeth 50. In Fig. 12, three through holes 51 of the upper wheel drum are provided with gel 2, and two through holes 51 of the lower wheel drum 5 are provided with gel 2. The teeth 50 provided with gel contact the susceptor 111 to form the susceptor and at the same time provide gel into the formed valleys on both sides of the susceptor 1.

[0164] A flat susceptor band 111 and a porous sheet material 7 (e.g. made of cotton or viscose) are arranged above each other and guided together in a dosing and forming device. The two sheets 111, 7 are made to pass between two dosing wheel drums 5. The susceptor sheet 111 is thereby provided with a wave form according to the intermeshing teeth 50 of the two wheel drums 5. The porous material 7 is arranged parallel to the susceptor 1 and may serve to fix the gel in its position relative to the susceptor 1. The porosity of the porous material may allow at least a part of the gel to pass through the porous material.

[0165] In Fig. 13, a forming device with intermeshing forming rollers 3, for example as described in Fig. 6, is arranged in line with a dosing device 8. The dosing device 8 comprises a conduit in the form of a tube 80 (for example of rectangular or circular cross-sectional shape). A susceptor 1 previously provided with a wave form is guided inside and along the tube 80 in a conveying direction 200 and passes through it. The tube comprises two gel inlets 81. The gel inlets 81 are arranged opposite each other at substantially the same position along the conveying path of the susceptor 1, at the upper and lower sides of the tube 80. An aerosol-forming gel 2 is supplied to the two gel inlets 81 and is applied to the upper side of the susceptor 1 and to the lower side of the susceptor 1 while the latter is moving inside the tube 80.

[0166] The tube 80 is disposed within an inlet section of a funnel portion 95 of the rod-making apparatus 9. The tube 80 extends into a tongue 96 of the funnel portion 95 of the rod-making apparatus 9. As can be seen in more detail in Figure 14, a sensory medium 91 (e.g., tobacco material such as a homogenized tobacco sheet) is guided into the funnel portion 95 and compressed therein. The rod so formed, having a susceptor 1 provided with an aerosol-forming gel 2 in the center of the rod and surrounded by sensory medium 91, is then wrapped with a wrapper 92 (e.g., wrapping paper).

[0167] Since the susceptor 1 is provided with the aerosol-forming gel 2, the sensory medium 91 may include or be replaced by a host medium for hosting the susceptor. The host medium does not have to be or not include an aerosol-forming material used for aerosol formation.

[0168] In Fig. 14, the dosing device also comprises two gel inlets 81. The two gel inlets 81 are arranged below the tube 80 in succession along the tube 80. The first of the two gel inlets 81 may be used for partial filling of valleys in the susceptor. The second gel inlet 81 arranged downstream of the first gel inlet 81 may be used for complete filling of the valleys. Depending on the transport speed of the susceptor 1 through the dosing device and the gel supply, the amount of gel applied to the susceptor may be defined.

[0169] In Fig. 14, two gel inlets 81 are connected to the gel reservoir 20. The gel reservoir may be filled with the same aerosol-forming gel or may comprise separate tank compartments filled with two different gels. The two gel inlets 81 are then preferably connected to separate tank compartments. Thereby, different gels, e.g. having different material compositions, may be applied to the susceptor 1 at the same or different positions along the susceptor 1.

[0170] 15 and 16 show a portion of a forming apparatus for the susceptor material 1. The susceptor material is provided in the form of a flat band 111 from a bobbin 130.

[0171] The band 111 is conveyed along a conveying direction 200 and is adapted to pass under the forming roller 3 and preferably between the forming roller 3 shown in Figure 15 and a lower die 33 shown in Figure 16. The lower die 33 may be a fixed female die or may be part of a separate rotating forming roller.

[0172] The forming roller 3 has the form of a disc and is provided with circumferentially running teeth 30. The disc 3 is arranged parallel to the length of the susceptor 1 and the forming roller 3 rotates against the transport direction 200 of the susceptor material.

[0173] The intermeshing circumferentially running teeth 30 of the forming roller 3 and the V-shaped grooves of the lower die 33 form a susceptor band 111 as the band passes between the forming roller 3 and the lower die 33. A susceptor band is formed having longitudinally running grooves. The susceptor has a cross section in the shape of the letter "v". The grooves form longitudinally running depressions which are filled with an aerosol-forming gel. The gel may be provided continuously or intermittently along the grooves.

[0174] A dosing device for filling the recesses in such a V-shaped susceptor may for example be a dosing roller. The set-up and working principle of a dosing wheel drum is explained in relation to Fig. 7. However, a dosing roller for dosing a quantity of aerosol-forming gel into longitudinally running grooves in a susceptor comprises circumferentially running teeth arranged parallel to the grooves of the susceptor material.

[0175] It will be appreciated that the forming apparatus of FIG. 15 may be combined as a forming and dispensing apparatus.

[0176] FIG. 17 shows a forming apparatus for the production of a susceptor material 1 including a cross section in the shape of the letter "w", shown in more detail in FIG.

[0177] Two forming rollers 3 are provided. One of the rollers 3 has one circumferentially running tooth 30 and the second roller 3 has two circumferentially running teeth 30. The teeth are formed by the circumference of discs arranged parallel to one another along the length of the forming roller 3.

[0178] The intermeshing teeth 30 of the two forming rollers 3 form a susceptor band as the band passes between the forming rollers 3. The flat susceptor band 111 is shaped into a susceptor band having a W-shaped cross section according to the configuration of the teeth 30 of the rollers 3. Two longitudinal grooves are formed on one side of the susceptor 1, representing two depressions, and one longitudinal groove is formed on the opposite side of the susceptor 1, representing one depression.

[0179] In the embodiment of FIG. 18, the cavities on one side of the susceptor 1 are filled with one type of gel 2 and the cavities on the opposite side of the susceptor 1 are filled with a different type of gel 2.

[0180] Also, in embodiments where the recess extends along the length of the susceptor, the groove forms a recess for application of the aerosol-forming gel. The groove on one side of the susceptor 1 forms an apex on the opposite side of the susceptor. The groove and apex are disposed parallel to the length of the susceptor band 1.

[0181] As can be seen from the examples described and shown in this application, susceptor sheet materials with different shapes of depressions can be combined with different dispensing devices. For example, any shape of susceptor sheet material provided with depressions can basically be fed into the conduit of a gel dispensing device for gel application according to Figures 13 and 14.

[0182] Although the dosing wheel drum and dosing belt have been described primarily in combination with susceptor sheet materials having wave-shaped or elongated depressions extending perpendicular to the transport direction of the susceptor sheet material, the dosing wheel drum and dosing belt may also be used to apply gel into longitudinally arranged grooves in the susceptor sheet material. The dosing wheel drum may be provided, for example, as a disk-shaped wheel with circumferentially arranged teeth, where one, some or all of the teeth are intended for applying gel, and the teeth may provide individual dots of gel in the grooves along the length of the susceptor. Alternatively, the dosing wheel drum may be provided with a row of circumferentially arranged teeth to provide gel into a series of parallelly arranged grooves in the susceptor sheet material, or into one groove each of separate susceptor sheet materials arranged parallel to each other.

Claims

1. 1. A method for making a susceptor sheet material containing an aerosol-forming gel, comprising: - providing a susceptor sheet material with at least one recess on each side of said susceptor sheet material; applying an aerosol-forming gel to said at least one recess on both sides of said susceptor sheet material.

2. 10. The method of claim 1, further comprising applying different aerosol-forming gels to different recesses of the susceptor sheet material, the different aerosol-forming gels differing in at least one of flavor, nicotine, aerosol-forming agent, and aerosolization temperature.

3. 3. The method according to any one of claims 1 to 2, wherein the aerosol-forming gel is applied through a through-hole in at least one moving tooth of a gel-administration device.

4. 4. The method of claim 3, wherein the aerosol-forming gel is applied through the through hole in at least one moving tooth of a dosing wheel drum having teeth arranged in a circumferential direction.

5. 4. The method of claim 3, wherein the aerosol-forming gel is applied through the through holes in at least one moving tooth of a dosing belt, and the dosing belt is used to transport the susceptor sheet material.

6. 5. The method of claim 4, wherein the aerosol-forming gel is applied across a width of the susceptor sheet material through a plurality of through holes disposed across a width of the teeth.

7. providing a conduit having at least one gel inlet; directing the susceptor sheet material within and along the conduit; 3. The method of claim 1, comprising injecting an aerosol-forming gel into the conduit through the at least one gel inlet and into the interior of the conduit and onto the susceptor sheet material guided along the conduit.

8. The method of any one of claims 1 to 7, comprising forming the susceptor sheet material to include the at least one depression by passing the susceptor sheet material through a susceptor forming apparatus.

9. 9. The method of any one of claims 1 to 8, further comprising passing the susceptor sheet material and the porous sheet material in parallel through a gel dosing device, thereby applying the aerosol-forming gel to the combination of the susceptor sheet material and the porous sheet material.

10. 1. A dispensing system for applying an aerosol-forming gel to a susceptor sheet material, comprising: a susceptor sheet material having at least one recess on each side of the susceptor sheet material; a gel dispensing device adapted to apply an aerosol-forming gel to the at least one recess on either side of the susceptor sheet material.

11. 11. The dispensing system of claim 10, wherein the gel dosing device comprises a pair of intermeshing dosing wheel drums having circumferentially arranged teeth substantially corresponding to a configuration of the susceptor sheet material, and at least one tooth of both dosing wheel drums of the pair of dosing wheel drums comprises a through hole in fluid communication with a gel reservoir.

12. 12. The dispensing system of claim 11, wherein the gel dispensing device comprises a dispensing belt for transporting the susceptor sheet material, and the teeth with the through holes are teeth of the dispensing belt.

13. 11. The dispensing system of claim 10, wherein the gel dispensing device comprises a conduit adapted to guide the susceptor sheet material inside and along the conduit, the conduit comprising at least one gel inlet for injection of an aerosol-forming gel into the conduit and into the susceptor sheet material guided inside and along the conduit.

14. 14. The delivery system of claim 13, wherein the conduit comprises two gel inlets disposed opposite each other in the conduit.

15. A susceptor sheet material containing an aerosol-forming gel, the susceptor sheet material having a plurality of depressions disposed on both sides of the susceptor sheet material, at least one of the plurality of depressions on both sides of the susceptor sheet material being filled with the aerosol-forming gel.

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