Inductively heated aerosol-forming rods and molding apparatus for use in the manufacture of such rods - Patents.com

Abstract

The present invention relates to an induction-heated aerosol-forming rod for use in an aerosol-generating article. The aerosol-forming rod includes at least one cylindrical core portion including at least one of a first aerosol-forming substrate and a first flavor material. The aerosol-forming rod further includes a first elongated susceptor laterally abutting the cylindrical core portion at a first side along the longitudinal axis of the aerosol-forming rod. The aerosol-forming rod also includes a second elongated susceptor laterally abutting the cylindrical core portion at a second side along the longitudinal axis of the aerosol-forming rod opposite the first side, such that the cylindrical core portion is sandwiched between the first and second elongated susceptors. The aerosol-forming rod further includes a sleeve portion disposed around the core portion, the first susceptor, and the second susceptor, the sleeve portion including at least one of a filler material, a second aerosol-forming substrate, and a second flavor material. The present invention further relates to a molding apparatus for use in manufacturing such an induction heated aerosol-forming rod, the molding apparatus comprising a core-forming device, a sleeve-forming device, a first longitudinal guide and a second longitudinal guide.

Description

[Technical field]

[0001] The present invention relates to an inductively heated aerosol-forming rod comprising one or more aerosol-forming substrates capable of forming an inhalable aerosol when heated. The present invention further relates to a molding apparatus for use in the manufacture of such an inductively heated aerosol-forming rod. [Background technology]

[0002] The generation of inhalable aerosols based on inductive heating of an aerosol-forming substrate is generally known from the prior art. To heat the substrate, the substrate may be arranged in thermal proximity or in direct physical contact with a susceptor that is inductively heated by an alternating electromagnetic field. The electromagnetic field may be provided by an induction source that is part of the aerosol-generating device. Both the susceptor and the aerosol-forming substrate may be assembled into an inductively heated aerosol-forming rod. Among other elements, the rod may be an integral part of a rod-shaped aerosol-forming article that may be received in a cylindrical receiving recess of an aerosol-generating device that comprises an induction source. As part of the induction source, the device may include, for example, a helical induction coil that coaxially surrounds the cylindrical receiving recess so as to provide an alternating electromagnetic field in the recess to heat the susceptor. During operation of the device, volatile compounds are released from the heated aerosol-forming substrate in the article and are entrained in the airflow drawn through the article during a user's puff. As the released compounds cool, they condense to form an aerosol.

[0003] It would be desirable to have an inductively heated aerosol-forming rod for use in aerosol-generating articles that provide a wide variety of different aerosols, that is compatible with existing inductively heated devices that include cylindrical receiving recesses, and that is further desirable to have a molding device for use in the manufacture of such aerosol-forming rods. Summary of the Invention

[0004] According to the present invention, there is provided an inductively heated aerosol-forming rod for use in an aerosol-generating article. The aerosol-forming rod comprises at least one cylindrical core portion comprising at least one of a first aerosol-forming substrate and a first flavouring material. The aerosol-forming rod further comprises a first elongated susceptor laterally abutting the cylindrical core portion at a first side along the longitudinal axis of the aerosol-forming rod. The aerosol-forming rod also comprises a second elongated susceptor laterally abutting the cylindrical core portion at a second side along the longitudinal axis of the aerosol-forming rod opposite the first side, such that the cylindrical core portion is sandwiched between the first elongated susceptor and the second elongated susceptor. Furthermore, the aerosol-forming rod comprises a sleeve portion disposed around the core portion, the first susceptor and the second susceptor, the sleeve portion comprising at least one of a filler material, a second aerosol-forming substrate and a second flavouring material.

[0005] Having at least two different parts in the inductively heated aerosol-forming rod, namely the sleeve part and the core part, advantageously allows to increase the variety of aerosols that can be generated by using the different parts for different purposes. One purpose may be to provide one or more specific sensory stimuli, such as, for example, to provide a specific flavor, to provide a specific tobacco note, to provide nicotine, or to provide stimulation by increasing the visibility of the aerosolization. Such effects may be achieved by appropriate selection of the sensory media of the sleeve part and the core part, for example, by appropriate selection of the first aerosol-forming substrate and the second aerosol-forming substrate. For example, the first sensory media may be homogenized tobacco, such as, for example, tobacco cast leaf, to provide tobacco content, and the second sensory media may be an aerosol-forming liquid that generates a large aerosol volume and additional flavor components. Other specific stimuli may relate, for example, to a specific drawing resistance, or a specific tactile effect, known from conventional tobacco products. Such effects may be achieved, for example, by appropriate selection of the shape of the sleeve part to provide a familiar tactile sensation, and / or by appropriate selection of the filler material to provide a specific drawing resistance.

[0006] The core portion and the sleeve portion are preferably independent objects or entities independent from each other. That is, the core portion and the sleeve portion may be separate from each other. Thus, the core portion may mean the core body and the sleeve portion may mean the sleeve body. The core body and the sleeve body may be independent entities, that is, separate from each other. In particular, the aerosol-generating article may comprise a core body, in particular a core body defining a core portion. Similarly, the aerosol-generating article may comprise a sleeve body, in particular a sleeve body defining a sleeve portion.

[0007] By having at least a first susceptor and a second susceptor, different heating zones can be advantageously provided within the aerosol-forming rod. The first heating zone is provided by that portion of the heating profile of the first susceptor extending along the longitudinal axis of the rod at the outside of the first susceptor opposite the inside of the first susceptor abutting the core portion. Similarly, the second heating zone is provided by that portion of the heating profile of the first susceptor extending along the longitudinal axis of the rod at the outside of the second susceptor opposite the inside of the second susceptor abutting the core portion. The third heating zone is provided along the longitudinal axis of the rod in the region between the first susceptor and the second susceptor, i.e., in the region overlapping with the cylindrical core portion. This third heating zone is substantially the result of the overlap of those portions of the heating profiles of the first susceptor and the second susceptor located between the first susceptor and the second susceptor. Thus, the first and second heating zones can be used to heat the sleeve portion, while the third heating zone can be used to heat the core portion. Due to the overlap of the two heating profiles, the third heating zone can reach a higher temperature than the first and second heating zones. Advantageously, the different heating temperatures can allow the release of volatile compounds from the core portion and the sleeve portion to be specifically adjusted. In particular, the amount of released compounds can be adjusted by selecting a suitable combination of a specific heating temperature and a specific sensory medium with a specific release temperature. Thus, the different heating zones can be beneficially used to design a wide variety of different aerosols by providing different amounts of different aerosols or flavors from different portions of the aerosol-forming rod.

[0008] Furthermore, the inductively heated aerosol generating rod according to the present invention can be used to manufacture rod-shaped aerosol generating articles that are compatible with existing inductively heated aerosol generating devices that have a cylindrical receiving recess, thus allowing the continued use of currently available inductively heated devices, in particular without the need to modify the existing inductively heated devices.

[0009] The first elongated susceptor may laterally abut the cylindrical core portion in a non-bonded manner. Similarly, the second elongated susceptor may laterally abut the cylindrical core portion in a non-bonded manner. As used herein, the term "abutting in a non-bonded manner" refers to an arrangement of the respective susceptor relative to the cylindrical core portion, in which the respective susceptors and the core portion are not fixed and are not permanently attached to each other. In particular, the term "abutting in a non-bonded manner" is understood to be such that the respective susceptor abuts releasably against the core portion and is removable from the core portion in a substantially non-destructive manner. In any case, the term "abutting in a non-bonded manner" excludes configurations in which one of the respective susceptors or the core portion is coated on the respective other. In particular, "abutting in a non-bonded manner" excludes fixed or rigid bonds between the respective susceptors and the core portion, in particular chemical bonds or bonds caused by adhesives that do not belong to either one of the core portion and the respective susceptor. Nevertheless, abutting the respective susceptor to the core portion may involve some non-permanent attractive forces between the core portion and the respective susceptor, such as some non-permanent adhesion between the core portion and the respective susceptor, which may be due to, for example, the adhesive nature of the aerosol-forming substrate. That is, "abutting in a non-bonded manner" may include "abutting in a non-permanently bonded manner." Abutting the respective susceptor laterally to the cylindrical core portion in a non-bonded manner may result from simply placing the respective susceptor with the core portion, in particular by using a molding apparatus according to the present invention and described in detail below.

[0010] The term "aerosol-forming substrate" as used herein means a substrate formed from or including an aerosol-forming material capable of releasing a volatile compound upon heating to generate an aerosol. It is intended that the aerosol-forming substrate is heated, but not combusted, to release the aerosol-forming volatile compound.

[0011] The aerosol-forming substrate may be a solid, a paste-like or a liquid aerosol-forming substrate. In any of these states, the aerosol-forming substrate may contain both solid and liquid components.

[0012] The aerosol-forming substrate may comprise a tobacco-containing material that contains volatile tobacco flavour compounds that are released from the substrate upon heating.

[0013] Alternatively, or additionally, the aerosol-forming substrate may comprise a non-tobacco material.

[0014] In this regard, the aerosol-forming substrate may include one or more of powders, granules, pellets, pieces, spaghetti strands, strips or sheets, and combinations thereof, containing, for example, one or more of herb leaves, tobacco leaves, tobacco stem pieces, reconstituted tobacco, homogenized tobacco, extruded tobacco, and expanded tobacco.

[0015] The aerosol-forming substrate may further comprise at least one aerosol former selected from polyols, glycol ethers, polyol esters, esters, and fatty acids, and may comprise one or more of the following compounds: glycerin, erythritol, 1,3-butylene glycol, tetraethylene glycol, triethylene glycol, triethyl citrate, propylene carbonate, ethyl laurate, triacetin, meso-erythritol, diacetin mixtures, diethyl suberate, triethyl citrate, benzyl benzoate, benzyl phenylacetate, ethyl vanillate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene glycol.

[0016] One or more aerosol formers may be combined to take advantage of one or more properties of the combined aerosol formers, for example, triacetin may be combined with glycerin and water to take advantage of triacetin's ability to carry active ingredients and the humectant properties of glycerin.

[0017] The aerosol former may have certain humectant properties that help maintain a desired level of moisture within the aerosol-forming substrate when the substrate is comprised of a tobacco-based product, particularly a product that includes tobacco particles. In particular, some aerosol formers are hygroscopic materials that function as humectants, i.e., substances that help keep the tobacco substrate, including the humectant, moist.

[0018] In particular, the aerosol-forming substrate may comprise one or more aerosol formers having a weight percentage of the aerosol-forming substrate in the range of 12 weight percent to 20 weight percent, preferably 16 weight percent to 20 weight percent, and most preferably 17 weight percent to 18 weight percent.

[0019] The aerosol-forming substrate may contain other additives and ingredients. Preferably, the aerosol-forming substrate contains nicotine. The aerosol-forming substrate may contain flavourings, in particular additional tobacco or non-tobacco volatile flavour compounds, which are released upon heating of the aerosol-forming substrate. The aerosol-forming substrate may also contain capsules, for example containing additional tobacco or non-tobacco volatile flavour compounds, such capsules may melt during heating of the solid aerosol-forming substrate. The aerosol-forming substrate may also contain a binder material.

[0020] The aerosol-forming substrate is preferably an aerosol-forming tobacco substrate, i.e. a tobacco-containing substrate. The aerosol-forming substrate may contain volatile tobacco flavor compounds that are released from the substrate upon heating. The aerosol-forming substrate may comprise or consist of reconstituted tobacco, such as homogenized tobacco material. The homogenized tobacco material may be formed by agglomerating particulate tobacco. In particular, the aerosol-forming substrate may comprise or consist of cut and blended tobacco leaves. The aerosol-forming substrate may additionally comprise non-tobacco materials, such as homogenized plant-based materials other than tobacco. The reconstituted tobacco is preferably made predominantly from blended tobacco materials, in particular leaf lamina, processed stems and ribs, homogenized plant materials (such as those made into sheet form using a casting process or a papermaking process). The reconstituted tobacco may also comprise other cuts, filler tobaccos, binders, fibers or casings. The reconstituted tobacco comprises at least 25 percent of the plant leaf lamina, more preferably at least 50 percent of the plant leaf lamina, even more preferably at least 75 percent of the plant leaf lamina, and most preferably at least 90 percent of the plant leaf lamina. Preferably, the plant material is one of tobacco, mint, tea, and clove. However, the plant material may be other plant material that has the ability to release a substance upon heating that can then form an aerosol.

[0021] The tobacco plant material preferably includes one or more lamina of bright tobacco, dark tobacco, aromatic tobacco, and filler tobacco. Bright tobacco is a tobacco that generally has large, light-colored leaves. Throughout this specification, the term "bright tobacco" is used for flue-cured tobacco. Examples of bright tobacco include Chinese flue-cured tobacco, Brazilian flue-cured tobacco, American flue-cured tobacco (such as Virginia tobacco), Indian flue-cured tobacco, Tanzanian flue-cured tobacco, or other African flue-cured tobacco. Bright tobacco is characterized by a high sugar-to-nitrogen ratio. From a sensory perspective, bright tobacco is a tobacco type with a spicy and lively sensation after curing. Bright tobacco, as used herein, is tobacco having a reducing sugar content of about 2.5 percent to about 20 percent based on dry weight of the leaf and a total ammonia content of less than about 0.12 percent based on dry weight of the leaf. Reducing sugars include, for example, glucose or fructose. Total ammonia includes, for example, ammonia and ammonia salts. Dark tobacco is tobacco that generally has large, dark leaves. Throughout this specification, the term "dark tobacco" is used for air-cured tobacco. In addition, dark tobacco may be fermented. Tobacco that is primarily used for chewing tobacco, snuff, cigar tobacco, and pipe blends are also included in this category. Typically, these dark tobaccos are air-cured and may be fermented. From a sensory perspective, dark tobacco is a tobacco type with a smoky, dark cigar-type sensation after curing. Dark tobacco is characterized by a low sugar-to-nitrogen ratio. Examples of dark tobacco are Burley Malawi or other African Burley, dark-cured Brazilian Galpao, San-cured or air-cured Indonesian Kasturi. As used herein, dark tobacco is tobacco having a reducing sugar content of less than about 5 percent, based on the dry weight of the leaf, and a total ammonia content of about 0.5 percent or less, based on the dry weight of the leaf.Aromatic tobacco is a tobacco that often has small, light-colored leaves. Throughout this specification, the term "aromatic tobacco" is used in contrast to other tobaccos that have a high aromatic content, such as essential oils. From a sensory perspective, aromatic tobacco is a tobacco type that, after curing, has a spicy and aromatic feel. Examples of aromatic tobacco include Greek Orient, Orient Turkey, semi-orient tobacco but flame-cured, US Burley such as Perique, Rustica, US Burley or Maryland. Filler tobacco is not a specific tobacco type, but includes tobacco types that are used in blends and are primarily used to complement other tobacco types that do not bring a specific characteristic aroma direction to the final product. Examples of filler tobacco are the stems, midribs, or petioles of other tobacco types. A specific example may be the flue-cured stems of the lower part of the flue-cured petioles from Brazil.

[0022] Preferably, the aerosol-forming substrate may comprise a tobacco web, preferably a crimped web. The tobacco web may comprise tobacco material, fiber particles, binder material, and aerosol formers. Preferably, the tobacco web is a cast leaf. A cast leaf is a form of reconstituted tobacco formed from a slurry containing tobacco particles. The cast leaf may further comprise fiber particles or aerosol formers, or both fiber particles and aerosol formers, as well as binders, and, for example, flavors. The tobacco particles may be in the form of tobacco powder having particles of about 10 micrometers to 250 micrometers, preferably particles of about 20 micrometers to 80 micrometers, or particles of about 50 micrometers to 150 micrometers, or particles of about 100 micrometers to 250 micrometers, depending on the desired sheet thickness and the casting gap of the corresponding casting box. The casting gap affects the thickness of the sheet. The fiber particles may comprise tobacco stem material, stems or other tobacco plant material, and other cellulosic fibers, such as plant fibers, preferably wood fibers or flax fibers or hemp fibers. The fiber particles may be selected based on the requirement to provide sufficient tensile strength to the cast leaf for low loadings, e.g., loadings of about 2 percent to 15 percent. Alternatively, fibers such as vegetable fibers may be used in conjunction with or instead of the above-mentioned fiber particles, including hemp and bamboo, or combinations of various fiber types. The aerosol formers included in the slurry forming the cast leaf, or used in other aerosol-forming tobacco substrates, may be selected based on one or more properties. Functionally, the aerosol formers provide a mechanism for volatilizing the aerosol formers and delivering nicotine or flavorings or both in an aerosol state when heated above a particular volatilization temperature of the aerosol formers. Different aerosol formers typically vaporize at different temperatures. The aerosol formers may be any suitable known compound or mixture of compounds that facilitates the formation of a stable aerosol during use.A stable aerosol is substantially resistant to thermal decomposition at the operating temperatures for heating the aerosol-forming substrate. The aerosol former may be selected based on its ability to, for example, remain stable at or near room temperature, but be volatilizable at higher temperatures (e.g., 40 degrees Celsius to 450 degrees Celsius, preferably 40 degrees Celsius to 250 degrees Celsius).

[0023] Crimped tobacco sheets, such as cast leaf, may have a thickness ranging from about 0.02 millimeters to about 0.5 millimeters, preferably from about 0.08 millimeters to about 0.2 millimeters.

[0024] In any configuration, it is preferred that the core portion is always used for aerosol generation. - a porous substrate or foam based on tobacco fibres, said tobacco fibres at least partially forming said first aerosol-forming substrate, - a porous substrate or foam based on vegetable fibres, said vegetable fibres at least partially forming said first aerosol-forming substrate, - a filler comprising tobacco shred material, said shredded tobacco material at least partially forming said first aerosol-forming substrate; - a filler comprising chopped plant material, said chopped plant material at least partially forming said first aerosol-forming substrate; - a liquid-holding material comprising an aerosol-forming liquid, said aerosol-forming liquid at least partially forming said first aerosol-forming substrate; - a liquid retention material comprising at least one flavouring material, said flavouring material at least partially forming said first flavouring material; - cellulose or cellulosic fibres comprising at least one flavouring substance, the flavouring substance at least partially forming a first flavouring material.

[0025] In principle, the sleeve portion may comprise the same material compositions as those described above. - a porous substrate or foam based on tobacco fibres, the tobacco fibres at least partially forming the second aerosol-forming substrate, - a porous substrate or foam based on vegetable fibres, said vegetable fibres at least partially forming said second aerosol-forming substrate, - a filler comprising tobacco shred material, said shredded tobacco material at least partially forming said second aerosol-forming substrate; - a filler comprising chopped plant material, said chopped plant material at least partially forming said second aerosol-forming substrate; - a liquid-holding material comprising an aerosol-forming liquid, said aerosol-forming liquid at least partially forming said second aerosol-forming substrate; - a liquid retention material comprising at least one flavouring substance, said flavouring substance at least partially forming said second flavouring substance; - cellulose or cellulosic fibres, - cellulose or cellulosic fibres comprising flavouring substances, said flavouring substances at least partially forming said second flavouring material, - Acetate tow extended fiber, - vegetable fiber, or - Paper.

[0026] As used herein, the term "liquid-retention material" refers to a high-retention or high-release material (HRM) for storing liquid. The liquid-retention material is configured to essentially retain at least a portion of the liquid, such that this portion is not available for aerosolization before leaving the retention. The use of a liquid-retention material reduces the risk of leakage in the event of failure or cracking of the aerosol-generating article, since the liquid aerosol-forming substrate is safely retained within the retention material. Advantageously, this allows the aerosol-forming rod to be leak-proof.

[0027] As used herein, cut tobacco material may include at least one tobacco lamina, reconstituted tobacco, tobacco rib fragments, or tobacco stem fragments. Similarly, cut plant material may include at least one plant lamina fragments, plant rib fragments, or plant stem fragments.

[0028] By way of example, at least one of the sleeve portion and the core portion may include a porous substrate, such as a porous reconstituted tobacco material. Additionally, the porous substrate may include glycerin, guar, water, tobacco fibers, cellulose fibers, and natural or artificial flavors and nicotine. The porous substrate may be initially provided as a thin sheet material and ultimately formed into the cross-sectional shape of the sleeve portion or the core portion, as described in detail below with respect to the forming apparatus according to the present invention. The sheet material is preferably crimped or folded, or both crimped and folded. The amount and density of the sheet material entering the forming apparatus may be selected to result in a sleeve portion or a core portion having a particular drawing resistance.

[0029] As another example, at least one of the sleeve portion and the core portion may include a porous foam produced from naturally occurring fibers and materials, e.g., fibers and materials of plant or vegetable origin. The foam may include tobacco or tobacco materials, or may be tobacco-free. The porous foam may include nicotine in its original formulation. The porous foam may be impregnated or soaked with an aerosol-forming liquid, among others. The aerosol-forming liquid may include at least one of nicotine and at least one flavoring substance.

[0030] As yet another example, at least one of the sleeve portion and the core portion may include a cast leaf material that is crimped and assembled into the shape of the sleeve portion or core portion, respectively.

[0031] As yet another example, the sleeve portion may comprise a low porosity material comprising at least one of acetate tow expanded fibers, vegetable expanded fibers, and cellulosic fibers. The fibers may be oriented substantially in one direction, in particular in a direction parallel to the longitudinal axis of the aerosol-forming rod. In the aerosol-forming rod, the fibers may be compressed, preferably up to 80%, in particular up to 90%, of their volume before forming the fibers into the aerosol-forming rod. In this low compression configuration, the sleeve portion has low resistance to drawing and is substantially free of filtering capabilities. As a result, the sleeve portion is advantageously used to influence the airflow generated by the negative pressure applied to the aerosol-generating article and from which volatile compounds are released from the core portion. Preferably, in this configuration, the sleeve portion does not comprise an aerosol-forming substrate. In particular, the sleeve portion does not comprise tobacco or tobacco material. Thus, the aerosol formation is concentrated on the aerosol-forming substrate in the core portion. Nevertheless, the sleeve portion may comprise flavoring substances that can be vaporized by the susceptor and mixed into the airflow.

[0032] With regard to enhancing the diversity of the aerosols that can be generated, it is preferred that the second aerosol-forming substrate is different from the first aerosol-forming substrate. The first and second aerosol-forming substrates may differ from each other, for example, in at least one of the following: content, composition, flavor, and texture. For example, the first aerosol-forming substrate may comprise a crimped cast leaf, and the second aerosol-forming substrate may comprise tobacco fibers in the form of a porous substrate or foam.

[0033] Similarly, the second flavorant is preferably different from the first flavorant. The first and second flavorants may differ from each other, for example, in at least one of content, composition, flavor, and texture.

[0034] In general, the cross section of the cylindrical core section, as seen in a plane perpendicular to the longitudinal axis of the aerosol-forming rod, may have any shape. The cylindrical core section preferably has a rectangular or square cross section. These cross-sectional shapes preferably have at least one substantially straight edge. The cylindrical core thus has a flat surface, in particular a flat surface, which can be used as a contact surface against which the susceptor laterally abuts. Advantageously, this enhances the efficiency of heat transfer from the susceptor to the core section. This is especially true when the susceptor includes, as a counter part, a corresponding flat surface that abuts against the flat surface of the core section.

[0035] The cylindrical core portion may also have a star-shaped or elliptical, or oval, or circular, or polygonal, or semi-oval, or semi-elliptical, or semi-circular cross-section. If the cross-section of the core portion includes one or more curved edge portions against which one of the first or second susceptors abuts, each susceptor may also be curved in a direction perpendicular to the longitudinal axis of the aerosol-forming rod corresponding to the curved edge portion of the cross-sectional shape of the core portion to maximize the contact surface between the core portion and each susceptor.

[0036] The cross section of the core portion is preferably substantially constant along the longitudinal axis of the aerosol-forming rod within manufacturing tolerances. However, in some embodiments, it may be desirable to have a discontinuous cylindrical core portion, particularly with a discontinuous susceptor, which, as will be described in more detail below, allows the continuously formed aerosol-forming rod strand to then be cut into individual aerosol-forming rods without the need to cut through a susceptor.

[0037] The cylindrical core portion is preferably strip-shaped. A strip-shaped core portion not only offers the advantage of a flat contact surface of the susceptor as previously described, but may also be advantageous with regard to simple manufacture by a continuous rod-forming process. As used herein, the term "strip-shaped core portion" refers to a cylindrical core portion having a length extension and a width extension, both of which are greater than the thickness extension of the element. The length extension is preferably greater than the width extension. In the case of a strip-shaped core portion, each susceptor preferably abuts against the large side of the core portion. Advantageously, this increases the heating efficiency. The strip-shaped core portion preferably has a rectangular cross section. The strip-shaped core portion may also have a curved rectangular cross section, with the large side of each susceptor being curved.

[0038] The term "susceptor" as used herein refers to an element that includes a material that has the ability to be inductively heated in an alternating electromagnetic field. This can be the result of at least one of hysteresis loss or eddy currents induced in the susceptor, depending on the electrical properties and magnetic properties of the susceptor material. Hysteresis loss occurs in ferromagnetic or ferrimagnetic susceptors due to magnetic domains in the material that are switched under the influence of an alternating electromagnetic field. Eddy currents may be induced if the susceptor is conductive. In the case of a conductive ferromagnetic susceptor or a conductive ferrimagnetic susceptor, heat can be generated due to both eddy currents and hysteresis losses. Thus, a susceptor can include a material that is at least one of conductive and magnetic.

[0039] The first susceptor and the second susceptor may be formed of any material that can be inductively heated to a temperature sufficient to generate an aerosol from the aerosol-forming substrate. A preferred susceptor includes a metal or carbon. A preferred susceptor may include or consist of a ferromagnetic material, such as a ferromagnetic alloy, ferritic iron, or ferromagnetic steel, or stainless steel. Another suitable susceptor may include or consist of aluminum. A preferred susceptor may be heated to a temperature of about 40 degrees Celsius to about 500 degrees Celsius, particularly about 50 degrees Celsius to about 450 degrees Celsius, preferably about 100 degrees Celsius to about 400 degrees Celsius. The susceptor may also include a non-metallic core having a metallic layer disposed thereon (e.g., a metallic track formed on the surface of a ceramic core).

[0040] At least one of the first susceptor and the second susceptor may include a protective outer layer, such as a protective ceramic or glass layer, that encapsulates the respective susceptor. At least one of the first susceptor and the second susceptor may include a protective coating formed of glass, ceramic, or an inert metal formed over a core of susceptor material.

[0041] At least one of the first and second susceptors may be a composite susceptor. In particular, each composite susceptor may comprise a first susceptor material and a second susceptor material. The first susceptor material is preferably optimized with respect to heat loss and therefore heating efficiency. For example, the first susceptor material may be aluminum or a ferrous material such as stainless steel. In contrast, the second susceptor material is preferably used as a temperature marker. For this purpose, the second susceptor material is chosen to have a Curie temperature corresponding to a predetermined heating temperature of the susceptor assembly. At that Curie temperature, the magnetic property of the second susceptor changes from ferromagnetic to paramagnetic, accompanied by a temporary change in its electrical resistance. Therefore, by monitoring the corresponding change in the current absorbed by the induction source, it is possible to detect when the second susceptor material reaches its Curie temperature and therefore the predetermined heating temperature. The second susceptor material preferably has a Curie temperature below the ignition point of the aerosol-forming substrate, i.e., preferably below 500 degrees Celsius. Suitable materials for the second susceptor material may include nickel and certain nickel alloys. Nickel has a Curie temperature in the range of about 354 degrees Celsius to 360 degrees Celsius, depending on the nature of the impurities. This range of Curie temperatures is ideal because it is approximately the same as the temperature to which the respective susceptor must be heated to generate an aerosol from the aerosol-forming substrate, yet is still low enough to avoid localized overheating or combustion of the aerosol-forming substrate.

[0042] At least one of the first susceptor and the second susceptor may be in the form of a pin, rod, filament, or strip. Preferably, the susceptor is a strip or strip-shaped. Susceptor strips or strip-shaped susceptor elements may be advantageous because they may be easily manufactured at low cost.

[0043] At least one of the first susceptor and the second susceptor may be in the form of a pin, rod, filament, or strip. Preferably, at least one of the first susceptor and the second susceptor is a strip or strip-like. Susceptor strips are advantageous because they are easy to manufacture at low cost.

[0044] As used herein, the term "strip-like" refers to an element having a length extension and a width extension, both of which are greater than the thickness extension of the element. The length extension is preferably greater than the width extension. In particular, a susceptor strip may be a susceptor blade, susceptor plate, susceptor sheet, susceptor strip, or susceptor foil.

[0045] At least one of the first susceptor and the second susceptor may have a square or rectangular or semi-oval or semi-elliptical cross section as viewed in a plane perpendicular to the longitudinal axis of the aerosol-forming rod. The cross section of each susceptor preferably has at least one edge portion corresponding to an edge portion of the cross section of the core portion against which the respective susceptor may abut. Thus, a contact surface is achieved between the respective susceptor and the core portion that is large enough for enhanced heat transfer.

[0046] At least one of the first susceptor and the second susceptor may also have a triangular or polygonal or oval or elliptical or circular cross-section.

[0047] When at least one of the first susceptor and the second susceptor has the form of a strip, in particular a blade, plate, sheet, strip or foil, each susceptor preferably has a substantially rectangular cross section. In this case, each susceptor preferably has a width dimension greater than its thickness dimension (e.g. twice its thickness dimension). Advantageously, each strip-like susceptor preferably has a thickness of about 2 mm to about 8 mm, more preferably about 3 mm to about 5 mm, also preferably about 0.03 mm to about 0.15 mm, more preferably about 0.05 mm to about 0.09 mm. The length of the susceptor strip may be, for example, in the range of 8 mm to 16 mm, in particular 10 mm to 14 mm, preferably 12 mm.

[0048] In the case of strip susceptors, each susceptor is preferably arranged such that a large side of the susceptor abuts a large side of the core portion, particularly in the case of strip core portions. Advantageously, this increases the heating efficiency.

[0049] In the case of a semicircular cross-section, the susceptor preferably has a width or radius of about 0.5 millimeters to about 2.5 millimeters.

[0050] At least one of the first susceptor and the second susceptor is preferably dimensionally stable. This means that the respective susceptor remains substantially undeformed during the manufacture of the aerosol-forming rod, or that any deformation of the respective susceptor required to form the aerosol-forming rod remains elastic, such that the respective susceptor returns to its intended shape when the deformation force is removed. To this end, the shape and material of the respective susceptor may be selected to ensure sufficient dimensional stability. Advantageously, this ensures that the original desired cross-sectional profile is maintained throughout the manufacture of the aerosol-forming rod. High dimensional stability reduces variability in product performance. In relation to the forming apparatus according to the present invention and as described in further detail below, this means that the forming apparatus is configured such that the respective susceptor remains substantially undeformed after passing through the forming apparatus. This means that any deformation of the respective susceptor required to form the continuous rod preferably remains elastic, such that the respective susceptor returns to its intended shape when the deformation force is removed.

[0051] At least one of the first susceptor and the second susceptor may have a constant cross-section along the longitudinal axis of the aerosol-forming rod. Alternatively, the cross-section of at least one of the first susceptor and the second susceptor may vary along the longitudinal axis of the aerosol-forming rod. For example, if at least one of the first susceptor and the second susceptor has the form of a strip, at least one of the width and thickness dimensions of the respective susceptor may vary along the longitudinal axis of the aerosol-forming rod.

[0052] The length dimension of at least one of the first and second susceptors preferably corresponds substantially to the length dimension of the aerosol-forming rod measured along the longitudinal axis of the aerosol-forming rod. The length dimension of at least one of the first and second susceptors may, for example, be in the range of 8 mm to 16 mm, in particular 10 mm to 14 mm, preferably 12 mm. Furthermore, the susceptor may have a length dimension equal to the length dimension of at least one of the core and sleeve portions to provide heating along the length extension of the core and sleeve portions, respectively. However, as mentioned above, it may be advantageous to have at least one of the first and second interrupted susceptors, and therefore at least one of the first and second susceptors, in which the length dimension of the respective susceptor is smaller than the length dimension of the aerosol-forming rod.

[0053] At least one of the first susceptor and the second susceptor may include an expanded metal sheet including a plurality of openings through the sheet. As used herein, the term "expanded metal sheet" refers to a type of metal sheet in which a plurality of areas of weakness, particularly a plurality of perforations, are created and then stretched to form a regular pattern of openings resulting from stretching the plurality of areas of weakness, particularly from the perforations.

[0054] The use of a susceptor comprising an expanded metal sheet offers several advantages compared to other types of sheet-like susceptors. Firstly, the proportionality between the total mass and the heat radiating surface of a susceptor comprising an expanded metal sheet is improved compared to a susceptor comprising a metal sheet without openings. Advantageously, this helps to save resources for the manufacture of the article. Furthermore, the reduced mass per unit area can also be beneficial in terms of reducing the total mass of the article. Secondly, the specific manufacturing process of the expanded metal sheet does not involve waste of material. Thirdly, the susceptor of the article according to the invention is permeable due to the openings, enhancing the airflow drawn through the article compared to an article with a non-permeable susceptor. Furthermore, the openings of the susceptor facilitate the release and entrainment in the airflow of material released from the heated aerosol-forming substrate. Advantageously, both aspects facilitate aerosol formation. Fourthly, the openings of the expanded metal sheet can be filled with the aerosol-forming substrate during the manufacture of the rod. Advantageously, this can support the fixation of the susceptor in the aerosol-forming rod. As a result, the positional accuracy and stability of the susceptor within the aerosol-forming rod is significantly improved.

[0055] As used herein, the term "opening" should be understood as an opening extending from one planar side of the expanded sheet material to the opposite planar side thereof through the entire expanded sheet material along its thickness extension. Similarly, the term "perforation" should be understood as a perforation extending from one planar side of the expanded sheet material to the opposite planar side thereof through the entire expanded sheet material along its thickness extension. The term "weakened area" means an area of ​​a metal sheet where the thickness of the material is reduced in a direction perpendicular to the main surface of the metal sheet, i.e., along the thickness extension of the metal. The reduction in the thickness of the material is such that, upon stretching the weakened metal sheet, the weakened area is transformed into an opening through the entire expanded sheet material along its thickness extension. Furthermore, the term "opening" may encompass two types of openings, namely openings with a closed boundary as well as openings with a partially open boundary. An opening with a closed boundary is completely bounded by the material of the metal sheet extended along the periphery of the opening. In contrast, an opening with a partially open boundary is only partially bounded by the material of the metal sheet extended along the periphery of the opening. If present, the one or more openings with partially open boundaries are located at the side edges of the expanded metal sheet, i.e. such openings are open laterally towards the side edges of the expanded metal sheet. If present, the one or more openings with partially open boundaries may result from a weakened area, in particular a perforation generated in the metal sheet that extends beyond the side edges of the metal sheet and is then stretched. Thus, the expanded metal sheet may include one of a plurality of openings with closed boundaries, a plurality of openings with partially open boundaries, or one or more openings with closed boundaries as well as one or more openings with partially open boundaries. The plurality of openings may be arranged in a periodic pattern, in particular a periodic offset pattern. In particular, in an offset arrangement, the plurality of openings may be arranged in a plurality of rows along a first direction, where each row extends in a second direction perpendicular to the first direction and includes one or more openings, and where one or more openings in one row are offset with respect to one or more openings in a respective adjacent row.

[0056] It is preferred that the first and second susceptors and the core portion are strip-like. In particular, the larger side of each strip-like susceptor may abut the larger side of the strip-like core portion. Advantageously, in this configuration, the cross-sectional shape of the core portion largely overlaps with the cross-sectional heating area of ​​each strip-like susceptor, thereby making the heating of the core portion more efficient. Even more preferably, at least one of the width and length dimensions of at least one of the first and second strip-like susceptors is equal to the width or length dimension of the strip-like core portion, respectively. Such an arrangement may also be advantageous for efficient heating of the core portion. At least one of the width and length dimensions of at least one of the first and second strip-like susceptors may be smaller than the width or length dimension of the strip-like core portion, respectively. This may help to save susceptor material. Alternatively, at least one of the width and length dimensions of at least one of the first strip susceptor and the second strip susceptor may be greater than the width or length dimension, respectively, of the strip core portion, which may help to increase the heating rate.

[0057] The core portion may be symmetrically disposed with respect to the longitudinal central axis of the aerosol-forming rod. That is, the longitudinal central axis of the cylindrical core is disposed coaxially with the longitudinal central axis of the aerosol-forming rod. Similarly, the first susceptor and the second susceptor may have the same dimensions and may be symmetrically disposed with respect to the longitudinal central axis of the aerosol-forming rod. Any of these arrangements may be advantageous with respect to a balanced mass distribution of the aerosol-forming rod.

[0058] The sleeve portion preferably surrounds the core portion and the first and second susceptors along the entire circumference of the aerosol-forming rod. Similarly, the sleeve portion is preferably disposed along the entire length dimension of at least one of the core portion, the first and second susceptors, and preferably disposed along the entire length dimensions of the core portion, the first and second susceptors. Thus, the sleeve portion can be uniformly heated by the susceptors.

[0059] In general, the cross section of the sleeve portion as seen in a plane perpendicular to the longitudinal axis of the aerosol-forming rod may have any suitable shape. The sleeve portion preferably has a rectangular, square, elliptical or circular cross section, or a triangular or other polygonal outer cross section. The inner cross section preferably matches the outer cross-sectional profile of the core portion and the assembly of the first susceptor and the second susceptor, both of which abut the core portion.

[0060] The sleeve portion preferably surrounds the first susceptor, the second susceptor and the core portion so as to fill, in particular completely fill, the cylindrical shape of the aerosol-forming rod, and thus the outer cross section of the sleeve portion preferably defines the outer cross-sectional shape of the aerosol-forming rod.

[0061] The aerosol-forming rod preferably has a circular or elliptical or oval cross section. However, the aerosol-forming rod may also have a square or rectangular or triangular or other polygonal cross section. In particular, the outer cross-sectional shape of the sleeve portion may define the outer cross-sectional shape of the aerosol-forming rod.

[0062] According to the present invention there is provided an inductively heated aerosol generating article for use with an inductively heated aerosol generating device, the article comprising an aerosol generating rod according to the present invention and as described herein.

[0063] The term "aerosol-generating article" as used herein refers to an article comprising at least one aerosol-forming substrate for use in an aerosol-generating device. The aerosol-generating article may be intended for single use. The aerosol-generating article may be a tobacco article. In particular, the article may be a rod-shaped article similar to a cigarette.

[0064] In addition to the aerosol-forming rod, the article may further comprise different elements: a support element with a central air passage, an aerosol cooling element, and a filter element. Any one or any combination of these elements may be arranged consecutively in the aerosol-forming rod segment. The aerosol-forming rod is preferably arranged at the distal end of the article. Similarly, the filter element is preferably arranged at the proximal end of the article. Furthermore, these elements may have the same outer cross section as the aerosol-forming rod segment.

[0065] The filter element preferably functions as a mouthpiece or as part of a mouthpiece together with an aerosol cooling element. As used herein, the term "mouthpiece" means a portion of the article through which the aerosol exits the aerosol-generating article. The filter element preferably has an outer diameter approximately equal to the outer diameter of the aerosol-generating article. The filter element may have an outer diameter of 5 millimeters to 10 millimeters, for example 6 millimeters to 8 millimeters. In a preferred embodiment, the filter element has an outer diameter of 7.2 millimeters ±10 percent, preferably ±5 percent. The filter element may have a length of 5 millimeters to 25 millimeters, preferably a length of 10 millimeters to 17 millimeters. In a preferred embodiment, the filter element has a length of 12 millimeters or 14 millimeters. In another preferred embodiment, the filter element has a length of 7 millimeters.

[0066] The support element may be located immediately downstream of the aerosol-forming rod. The support element may abut the aerosol-forming rod. The support element may be formed from any suitable material or combination of materials. For example, the support element may be formed from one or more materials selected from the group consisting of cellulose acetate, cardboard, crimped paper (such as crimped heat-resistant paper or crimped parchment paper), and polymeric materials (such as low-density polyethylene (LDPE)). In a preferred embodiment, the support element is formed from cellulose acetate. The support element may comprise a hollow tubular element. In a preferred embodiment, the support element comprises a hollow cellulose acetate tube.

[0067] The support element preferably has an outer diameter approximately equal to the outer diameter of the aerosol-generating article. The support element may have an outer diameter of 5 millimeters to 12 millimeters, for example 5 millimeters to 10 millimeters, or 6 millimeters to 8 millimeters. In a preferred embodiment, the support element has an outer diameter of 7.2 millimeters ±10 percent, preferably ±5 percent. The support element may have a length of 5 millimeters to 15 millimeters, in particular 6 millimeters to 12 millimeters. In a preferred embodiment, the support element has a length of 8 millimeters. The aerosol-cooling element may be located downstream of the aerosol-forming substrate element, for example immediately downstream of the support element or abutting the support element.

[0068] The aerosol cooling element may be located between the support element and a filter element located at the extreme downstream end of the aerosol-generating article.

[0069] As used herein, the term "aerosol cooling element" is used to describe an element having a large surface area and low draw resistance (e.g., 15 mmWG to 20 mmWG). In use, the aerosol formed by the volatile compounds released from the aerosol-forming rod is drawn through the aerosol cooling element before being conveyed to the mouth end of the aerosol-generating article.

[0070] The aerosol cooling element preferably has a longitudinal porosity of greater than 50 percent. The airflow path through the aerosol cooling element is preferably relatively unrestricted. The aerosol cooling element may be a sheet assembly or a crimped sheet assembly. The aerosol cooling element may comprise a sheet material selected from the group consisting of polyethylene (PE), polypropylene (PP), polyvinyl chloride (PVC), polyethylene terephthalate (PET), polylactic acid (PLA), cellulose acetate (CA), and aluminum foil, or any combination thereof.

[0071] In a preferred embodiment, the aerosol cooling element comprises a biodegradable assembled sheet of material, such as an assembly of sheets of non-porous paper, or a biodegradable polymeric material, such as polylactic acid or Mater-Bi® grades (a commercially available family of starch-based copolyesters).

[0072] The aerosol cooling element preferably comprises an assembly of sheets of PLA, more preferably an assembly of crimped sheets of PLA. The aerosol cooling element may be formed from a sheet having a thickness of 10 micrometers to 250 micrometers, in particular 40 micrometers to 80 micrometers, for example 50 micrometers. The aerosol cooling element may be formed from an assembly of sheets having a width of 150 millimeters to 250 millimeters. The aerosol cooling element may have a specific surface area of ​​300 square millimeters to 1000 square millimeters per millimeter of length and 10 square millimeters to 100 square millimeters per millimeter of weight. In some embodiments, the aerosol cooling element may be formed from an assembly of material sheets having a specific surface area of ​​about 35 square millimeters per millimeter of weight. The aerosol cooling element may have an outer diameter of 5 millimeters to 10 millimeters, for example 7 millimeters.

[0073] In some preferred embodiments, the length of the aerosol cooling element is between 10 millimeters and 15 millimeters. Preferably, the length of the aerosol cooling element is between 10 millimeters and 14 millimeters, for example 13 millimeters. In alternative embodiments, the length of the aerosol cooling element is between 15 millimeters and 25 millimeters. Preferably, the length of the aerosol cooling element is between 16 millimeters and 20 millimeters, for example 18 millimeters.

[0074] The article may further comprise a wrapper surrounding at least a portion of the above-mentioned different elements to hold them together and maintain the desired cross-sectional shape of the article. The wrapper preferably forms at least a portion of the outer surface of the article. For example, the wrapper may be a paper wrapper, in particular a paper wrapper made of cigarette paper. Alternatively, the wrapper may be a foil, for example made of plastic. The wrapper may be fluid-permeable to allow the vaporized aerosol-forming substrate to be released from the article. A fluid-permeable wrapper may also allow air to be drawn into the article through its periphery. Furthermore, the wrapper may comprise at least one volatile substance that is activated upon heating and released from the wrapper. For example, the wrapper may be impregnated with a volatile flavoring substance.

[0075] Inductively heated aerosol generating articles according to the invention preferably have a circular or elliptical or oval cross section, however the articles may also have a square or rectangular or triangular or other polygonal cross section.

[0076] Further features and advantages of the aerosol-generating article according to the invention have been described with respect to the aerosol-forming rod and apply equally.

[0077] The present invention further relates to an aerosol generating system comprising an inductively heated aerosol generating article according to the present invention and as described herein. The system further comprises an inductively heated aerosol generating device for use with the article. The aerosol generating device comprises a receiving cavity for receiving the article at least partially within the receiving cavity. The aerosol generating device further comprises an induction source including at least one induction coil for generating an alternating electromagnetic field, in particular of high frequency, within the receiving cavity so as to inductively heat a susceptor of the article when the article is received within the receiving cavity. The at least one induction coil may be a helical induction coil arranged coaxially around the cylindrical receiving cavity.

[0078] The apparatus may further comprise a power supply and a controller for supplying power and controlling the heating process.As referred to herein, the alternating, particularly high frequency, electromagnetic field may be in the range of 500 kHz to 30 MHz, particularly 5 MHz to 15 MHz, preferably 5 MHz to 10 MHz.

[0079] The aerosol generating device may be, for example, a device as described in WO 2015 / 177256 A1.

[0080] In use, the aerosol-generating article is engaged with an aerosol-generating device such that the susceptor assembly is located within the varying electromagnetic field generated by the inductor.

[0081] Further features and advantages of the aerosol generating system according to the invention have been partially described with respect to the aerosol generating article, and with respect to the receiving cavity, and will not be repeated here.

[0082] According to the present invention there is also provided a molding apparatus for use in the manufacture of the inductively heated aerosol-forming rods according to the present invention and as described herein. The molding apparatus comprises: - a core forming device configured to assemble a core material comprising at least one of a first aerosol-forming substrate and a first flavouring material into a continuous core strand such that, upon passing through the core forming device, the continuous core strand has a cross-sectional shape corresponding to the cross-sectional shape of the cylindrical core portion; - a first longitudinal guide for positioning the first continuous susceptor profile relative to the continuous core strand such that as it passes through the core forming device, the first continuous susceptor profile laterally abuts the continuous core strand on a first side, the first longitudinal guide extending downstream into at least an upstream section of the core forming device; - a second longitudinal guide for positioning the second continuous susceptor profile relative to the continuous core strand such that as it passes through the core forming device, the second continuous susceptor profile laterally abuts the continuous core strand on a second side opposite the first side, the second longitudinal guide extending downstream at least into the upstream section of the core forming device; - a sleeve forming device disposed around at least the downstream section of the core forming device and configured to assemble sleeve material comprising at least one of the filler material, the second aerosol-forming substrate and the second flavor material into a continuous sleeve strand around the continuous core strand, the first continuous susceptor profile and the second continuous susceptor profile, such that the continuous sleeve strand has a cross-sectional shape corresponding to the cross-sectional shape of the sleeve portion as it passes through the sleeve forming device.

[0083] Advantageously, the molding apparatus allows for efficient assembly of the different components of the aerosol-forming rod into the desired shape of the aerosol-forming rod to be manufactured, in particular, the molding apparatus allows for ensuring precise placement of each component in terms of position and shape within their respective tolerances.

[0084] For assembling the core material into a continuous core strand, the core forming device preferably comprises an inner funnel. In this regard, the core forming device may comprise a substantially tubular body. The substantially tubular body may comprise at least one converging section, in particular at least one conical converging section. The at least one converging section is preferably at the upstream end of the core forming device. With respect to the longitudinal central axis of the forming device, the axial length of the at least one converging section may be at least 10 percent, in particular at least 20 percent, preferably at least 30 percent of the axial length of the core forming device. The shape of the inner cross section, in particular the inner cross section of the downstream section of the core forming device, preferably corresponds to the cross-sectional shape of the cylindrical core portion. The assembling is preferably performed transversely to the direction of movement of the core material through the core forming device. Depending on the radial position of the core portion in the aerosol forming rod, the central axis of the inner funnel may be coaxial with the longitudinal central axis of the forming device according to the invention.

[0085] The first and second longitudinal guides advantageously facilitate achieving positions of the first and second susceptor profiles corresponding to their respective predetermined positions on the final aerosol forming rod. Moreover, the first and second longitudinal guides are also preferred in terms of keeping the susceptor profiles dimensionally stable as they pass through the molding device, particularly the core forming device. Even more preferably, the first and second longitudinal guides may be used to initially separate the first and second susceptor profiles from the core material at the upstream end of the core forming device.

[0086] At least the first and second longitudinal guides may comprise guide rails or guide supports with flat guide surfaces for guiding the respective continuous susceptor profiles. This may be particularly advantageous when the respective continuous susceptor profiles are strip-like. Alternatively, at least one of the first and second longitudinal guides may comprise a guide tube. The guide tube preferably has an inner cross-sectional profile that substantially corresponds to the outer cross-sectional profile of the respective susceptor profile. This may be particularly advantageous with regard to the proper guidance of the respective susceptor profile.

[0087] The first and second longitudinal guides are preferably at least partially, preferably completely, realized by a common guide tube extending downstream at least into the upstream section of the core forming device. In this regard, the common guide tube may include a first guide surface and a second guide surface located on either side of the common guide tube on its outer circumferential surface. The first and second guide surfaces are configured to guide the first and second susceptor profiles, respectively, along the length axis at the outer circumferential surface of the common guide tube. In this configuration, the inner space of the common guide tube may be configured to pass and guide the core material therethrough. This setup may be particularly advantageous with regard to a compact design of the molding device. The common guide tube may also serve as part of the core forming device for pre-assembling the core material. The inner cross-sectional shape of the common tube preferably corresponds to the shape of the core part. The first and second guide surfaces on the outer circumferential surface of the common guide tube, respectively, are preferably flat guide surfaces, which may be particularly advantageous when the respective continuous susceptor profiles are strip-like. The outer cross-sectional shape of the common guide tube is preferably rectangular or square.

[0088] According to the invention, the first and second longitudinal guides extend downstream at least into the upstream section of the core forming device. Advantageously, this may allow the first and second susceptor profiles to be further guided in a direction perpendicular to the direction of movement through the molding device by other than the longitudinal guide. As used herein, the term "upstream section of the core forming device" refers to the first stage of the core forming device where the core material is at least partially assembled but has not yet reached its final shape. In particular, when passing through the upstream section of the core forming device, the core material is at least partially assembled in a loose arrangement. "Loose" in this context refers to the core material having a more condensed form that has not yet reached its final assembly at that point. The at least partially assembled core material may be of any shape or form, in particular rod-like, but has a lower density (or a larger diameter) than that of the final rod-like shape after passing completely through the core forming device.

[0089] In particular, at least one of the first and second longitudinal guides and the upstream section of the core forming device may define a respective guide channel or tube through which the susceptor profile may pass. As mentioned above, the guide channel or tube preferably has an inner cross-sectional profile that substantially corresponds to the outer cross-sectional profile of the respective susceptor profile. This may be particularly advantageous with regard to a proper guidance of the respective susceptor profile.

[0090] At least one of the first susceptor profile and the second susceptor profile is preferably not guided at the downstream end of the upstream section of the core forming device or further downstream of the upstream section, and the longitudinal guide can also extend further downstream of the upstream section of the core forming device.

[0091] As a result, at least one of the first and second longitudinal guides may be configured to guide the respective susceptor profile along at least 25 percent, in particular along at least 50 percent, preferably along at least 75 percent, more preferably along at least 90 percent or along 100 percent of the length of the core forming device. To this end, at least one of the first and second longitudinal guides may extend along at least 25 percent, in particular along at least 50 percent, preferably along at least 75 percent, more preferably along at least 90 percent or along 100 percent of the length of the core forming device. The upstream end of at least one of the first and second longitudinal guides is preferably positioned upstream of the upstream end of the core forming device. This ensures that the respective susceptor profile is accurately pre-positioned in its desired final position in the aerosol forming rod before entering the core forming device (i.e. upstream of the core forming device).

[0092] Similarly, the core forming device may extend downstream to at least the upstream section of the sleeve forming device. Advantageously, this ensures proper placement of the core material at a predetermined location in the final aerosol forming rod.

[0093] As used herein, the term "upstream section of the sleeve forming apparatus" refers to a first stage of the sleeve forming apparatus where the sleeve material is at least partially assembled but not yet in its final shape. In particular, as it passes through the upstream section of the sleeve forming apparatus, the sleeve material is at least partially assembled in a loose arrangement. In this context, "loose" refers to the sleeve material having a more compact form at that point that has not yet reached its final assembly. The at least partially assembled sleeve material may be in any form or shape, particularly a rod shape, but has a lower density (or larger diameter) than it will have in its final rod shape after passing completely through the sleeve forming apparatus.

[0094] As described above with respect to the first and second longitudinal guides, the core forming device may extend along at least 25 percent, in particular along at least 50 percent, preferably along at least 75 percent, more preferably along at least 90 percent or along 100 percent of the length of the sleeve forming device. The upstream end of the core forming device may be located at or upstream of the upstream end of the sleeve forming device.

[0095] To adjust the position of at least one of the first and second longitudinal guides relative to the core forming device in at least one direction, the molding device may include a first translation stage. The first translation stage is preferably configured to adjust at least the axial position of at least one of the first and second longitudinal guides relative to the core forming device. As used herein, the term "axial" refers to the direction of movement of the susceptor profile, the core material, and the sleeve material through the molding device, in particular the longitudinal central axis of the molding device. In particular, when at least one of the first and second longitudinal guides is configured to initially separate the respective susceptor profile from the core material at an upstream section of the core forming device, the adjustability of the axial position of the respective longitudinal guide relative to the core forming device makes it possible to adjust the axial position of the respective susceptor profile and the core material together. Additionally or alternatively, the first translation may also be configured to adjust the position of at least one of the first and second longitudinal guides relative to the core forming device in at least one, in particular two, lateral directions perpendicular to the axial direction. The two lateral directions are preferably perpendicular to each other.

[0096] The first translation stage may be configured to simultaneously adjust both the position of the first longitudinal guide and the position of the second longitudinal guide relative to the core forming device. In particular, the position of the first longitudinal guide and the position of the second longitudinal guide may be coupled to each other and thus only adjustable together. Alternatively, the molding device may include two separate first translation stages, one for each of the first longitudinal guide and the second longitudinal guide, to separately adjust their respective orientations relative to the core forming device.

[0097] To adjust the position of the core forming device relative to the sleeve forming device, the molding device may comprise a second translation stage. The second translation stage is preferably configured to adjust the position of the core forming device relative to the sleeve forming device in at least one direction, in particular in at least one lateral direction, preferably in at least two lateral directions. The two lateral directions are preferably perpendicular to each other. As used herein, the term "lateral direction" refers to a direction perpendicular to the direction of movement of the susceptor profile, the core material and the sleeve material through the molding device, in particular a direction perpendicular to the longitudinal central axis of the molding device. Additionally or alternatively, the second translation stage may also be configured to adjust the axial position of the core forming device relative to the sleeve forming device, i.e. in a direction parallel to the direction of movement, in particular the longitudinal central axis of the molding device.

[0098] The first translation stage and the second translation stage may be part of a translation stage system of a molding apparatus.

[0099] To assemble the sleeve material into a continuous sleeve strand around the continuous core strand and the continuous susceptor, the sleeve forming apparatus may include an outer funnel, which may be disposed around at least a downstream section of the core forming apparatus, i.e., a section of the core forming apparatus downstream of the upstream section of the core forming apparatus, as further defined above.

[0100] The molding device may further comprise one or more guide fins disposed on an inner surface of the sleeve forming device, in particular on the inner surface of the outer funnel. Alternatively or additionally, the molding device may comprise one or more guide fins disposed on an outer surface of the core forming device, in particular on the outer surface of the inner funnel. These guide fins are configured to guide the sleeve material towards the downstream end of the sleeve forming device. Advantageously, the guide fins may help to reduce undesired heating of the sleeve forming device and the core forming device during the sleeve forming process, which may be caused by friction between the sleeve material and the inner and outer surfaces of the sleeve forming device, respectively.

[0101] The one or more guide fins are preferably helically twisted relative to the direction of movement of the sleeve material through the forming device. In particular, the one or more guide fins may extend over the entire length dimension of the core forming device or the sleeve forming device, respectively, and preferably extend helically along the entire length dimension. As seen in a cross section perpendicular to the longitudinal axis of the forming device, the one or more guide fins may have a triangular cross section or a semi-oval or semi-elliptical cross section. In the latter two configurations, the semi-long axis of the semi-oval or semi-elliptical cross section is preferably disposed perpendicular to the longitudinal axis of the forming device, and in particular is disposed continuously radially relative to the longitudinal central axis of the mould. The cross section of the one or more guide fins may in particular differ in size. For example, the cross section of the one or more guide fins may decrease along the direction of movement of the sleeve material through the forming device. Similarly, the height of the one or more guide fins, i.e. the extension of the one or more fins in the radial direction relative to the longitudinal central axis of the forming device, may vary, in particular decrease along the direction of movement of the sleeve material through the forming device.

[0102] The one or more guide fins may be substantially interrupted along the length extension, i.e., along the direction of travel of the sleeve material through the forming apparatus.

[0103] In particular, two or more guide fins may be circumferentially arranged on the inner surface of the sleeve forming device, and similarly, two or more guide fins may be circumferentially arranged on the outer surface of the core forming device.

[0104] The one or more guide fins on the inner surface of the sleeve forming device and the one or more guide fins on the outer surface of the core forming device may be arranged at different circumferential positions. In particular, the circumferential positions of the one or more guide fins on the inner surface of the sleeve forming device and the one or more guide fins on the outer surface of the core forming device may be shifted by a certain rotation angle (e.g., by 30 degrees, 60 degrees, 90 degrees, or 120 degrees) relative to the longitudinal central axis of the forming device. In particular, the guide fin on the outer surface of the core forming device may be arranged at a circumferential position, especially centered between the circumferential positions of two adjacent fins on the inner surface of the sleeve forming device.

[0105] Alternatively or additionally to the one or more guide fins, the sleeve forming apparatus may include at least one of one or more cooling ribs on an outer surface of the sleeve forming apparatus and one or more cooling openings in a wall of the sleeve forming apparatus. Advantageously, the one or more cooling ribs or one or more cooling openings may help to reduce undesired heating of the sleeve forming apparatus during the sleeve forming process that may occur due to friction between the sleeve material and the inner surface of the sleeve forming apparatus.

[0106] The forming device may be part of an overall manufacturing device for producing aerosol-forming rods, in particular aerosol-forming rods according to the invention.

[0107] Therefore, the present invention further provides a manufacturing apparatus for producing an aerosol-forming rod, in particular an aerosol-forming rod according to the present invention, which comprises a forming apparatus according to the present invention and as described herein.

[0108] Downstream of the forming device, the manufacturing device may further comprise completing, in particular forming, the continuous first core strand, second core strand, susceptor profile, and continuous sleeve strand entities into a continuous aerosol-forming rod strand. The rod-forming device may comprise a garniture in the form of a continuous conveyor belt. The garniture tape preferably interacts with at least one half funnel to form the final rod shape, preferably providing a wrapper around the continuous core strand, susceptor profile, and continuous sleeve strand entities. The garniture tape is preferably disposed below the central axis of the rod-forming device, and at least one half funnel is preferably located above the central axis and therefore above the garniture tape.

[0109] The garniture tape may support a wrapper. The wrapper may be supplied to the upstream end of the rod forming apparatus by a wrapper supply source. The wrapper supply source may include, for example, a wrapper bobbin. The wrapper is preferably supported on a surface of the garniture tape facing the central axis. Thus, during operation, the wrapper is automatically wound around the continuous sleeve strand. The wrapper supply source may also add adhesive to at least a portion of the wrapper to hold the wrapper around the sleeve portion.

[0110] The rod forming apparatus provides a continuous aerosol forming rod strand at its downstream end, the final rod shape being preferably completely surrounded by a wrapper.

[0111] Downstream of the rod forming device, the manufacturing apparatus may further comprise a cutting device for cutting the continuous aerosol-forming rod strand into individual inductively heated aerosol-forming rods according to the present invention and as described herein.

[0112] The manufacturing apparatus may include a first susceptor source and a second susceptor source configured to respectively supply a first susceptor profile and a second susceptor profile to the inducing apparatus, and the susceptor source may include a first unwinding unit and a second unwinding unit for unwinding the first susceptor profile and the second susceptor profile provided on a bobbin, respectively.

[0113] The manufacturing apparatus may further include a sleeve material supply configured to supply sleeve material to the sleeve forming apparatus. The sleeve material supply may include an unwinding unit for unwinding sleeve material provided on a bobbin.

[0114] The manufacturing apparatus may further comprise a core material supply configured to supply the core material to the core forming apparatus. The core material supply may comprise an unwinding unit for unwinding the core material provided on a bobbin.

[0115] Downstream of at least one of the sleeve material source, the susceptor source, and the core material source, the manufacturing apparatus may further comprise one or more processing units for pre-treating the sleeve material, the first susceptor profile, the second susceptor profile, and the core material, respectively. The one or more processing units may be configured for physical processing of the sleeve material, the first susceptor profile, the second susceptor profile, and the core material, respectively. For example, the processing unit may be configured to crimp the sleeve or core material, in particular the sleeve or core material includes cast leaf material or acetate tow. Alternatively or additionally, the physical processing of the sleeve or core material may include one or more of ionization processing, corona processing, and pre-heating of the sleeve or core material.

[0116] The processing unit for the first susceptor or second susceptor profile, respectively, may be configured to create a plurality of perforations in the respective susceptor profile and stretch the perforated susceptor profile along at least a first direction to create a respective expanded susceptor profile including a plurality of openings resulting from the plurality of perforations.

[0117] The manufacturing apparatus may further comprise a tensioning unit for adjusting the tension of each of the sleeve material and the core material.

[0118] The manufacturing apparatus may further comprise a dispensing unit for adding at least one of a fluid, granules, particles and powder to the sleeve material and the core material, respectively.

[0119] The manufacturing apparatus may further comprise respective buffer units for buffering the sleeve material and the core material, respectively.

[0120] In particular, the manufacturing apparatus may include at least one of a processing unit, a tensioning unit, a dispensing unit, and a buffer for each of the sleeve material and the core material.

[0121] Further features and advantages of the device according to the invention have been explained with reference to the aerosol-forming rod and the aerosol-generating article and apply equally.

[0122] The invention will now be further described, by way of example only, with reference to the accompanying drawings in which: [Brief description of the drawings]

[0123] [Figure 1] FIG. 1 is a schematic diagram of an inductively heated aerosol-generating article comprising an inductively heated aerosol-forming rod according to an exemplary embodiment of the present invention. [Diagram 2] FIG. 2 is a cross-sectional view of the article according to FIG. [Diagram 3] FIG. 3 shows a schematic diagram of the production of an inductively heated aerosol-forming rod according to the present invention. [Figure 4] FIG. 4 is a schematic diagram of a molding apparatus for use in producing an inductively heated aerosol-forming rod according to FIG. [Diagram 5] FIG. 5 shows a detail of an example of the first and second susceptors of the aerosol-forming rod according to FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0124] 1 and 2 show schematic diagrams of an exemplary embodiment of an inductively heated aerosol generating article according to the present invention. The article 1 has a substantially rod-like shape and comprises four elements arranged in coaxial alignment along the longitudinal axis 7 of the article 1: an aerosol-forming rod 10 according to the present invention, a support element 60, an aerosol cooling element 70, and a filter element 80. The aerosol-forming rod 10 is disposed at the distal end 2 of the article 1, while the filter element 80 is disposed at the distal end 3 of the article 1. Optionally, the article 1 may further comprise a distal front element 60 that may be used to cover and protect the distal front end of the aerosol-forming rod 10. Each of the above elements is substantially cylindrical, all of which have substantially the same diameter. Furthermore, the elements are surrounded by an outer wrapper 90 to hold the elements together and maintain the desired circular cross-sectional shape of the rod-like article 1. The wrapper 90 is preferably made of paper.

[0125] The rod-shaped aerosol-generating article 1 may have a length of 30 mm to 110 mm, preferably 40 mm to 60 mm. Similarly, the article 1 may have a diameter of 3 mm to 10 mm, preferably 5.5 mm to 8 mm.

[0126] The support element 60 may comprise a cartoon or cellulosic tube 62 with a central air passage 61 that allows for mixing and homogenization of any aerosol generated within the aerosol-forming rod 10. Alternatively, the support element 60 may be used to keep separate different aerosols generated at different locations within the aerosol-forming rod separate until they reach the aerosol cooling element 70.

[0127] The aerosol cooling element 70 serves primarily to reduce the temperature of the aerosol toward the proximal end 3 of the article 1. The aerosol forming element may include, for example, a biodegradable polymeric material, a low porosity cellulosic material, or combinations thereof and others.

[0128] The filter element 80 may comprise a standard filter material, such as low density acetate tow.

[0129] The filter element 80 alone, or both the aerosol cooling element 70 and the filter element 80 may function as a mouthpiece through which the aerosol exits the aerosol-generating article 1 .

[0130] In the embodiment shown in Figures 1 and 2, the aerosol-forming rod segment 10 has a cylindrical shape with a constant cross-section, e.g., a circular cross-section. As part of the article 1, the aerosol-forming rod 10 may have a length of 5 millimeters to 20 millimeters, preferably 7 millimeters to 13 millimeters. The diameter of the aerosol-forming rod 10 may range from 3 millimeters to 10 millimeters, preferably 5.5 millimeters to 8 millimeters.

[0131] As shown in Figures 1 and 2, the aerosol-forming rod comprises at least four components: a cylindrical core portion 30 including at least one of a first aerosol-forming substrate and a first flavor material; a first elongated susceptor 40 and a second elongated susceptor 50 laterally abutting the cylindrical core portion 30 on either side along the longitudinal axis 7 of the rod 10; and a sleeve portion 20 disposed around the core portion 30, the first susceptor 40 and the second susceptor 50 and including at least one of a filler material, a second aerosol-forming substrate 21 and a second flavor material.

[0132] In this embodiment, the core portion 30 includes a liquid-retaining material 31 impregnated with a liquid (first) flavoring material. The sleeve portion 20 includes a filler including tobacco material, which at least partially forms the second aerosol-forming substrate 21. In addition, the filler may impregnate the liquid aerosol-forming substrate. The susceptor 40 is an elongated strip made of ferromagnetic stainless steel. This material may be advantageous because it provides heat by both eddy currents and hysteresis losses. Optionally, the susceptor 40 may include a nickel coating, which serves primarily as a temperature marker, as further described above. Additionally, the susceptor 40 may include a protective coating to prevent undesired deterioration of the susceptor 40, for example, due to corrosion in a moist environment of the aerosol-forming substrate and flavoring material.

[0133] As further seen in Figures 1 and 2, the first susceptor 40 and the second susceptor 50 according to this embodiment are strip-like, each having a width dimension ranging from 3.5 millimeters to 8 millimeters, preferably from 4 millimeters to 6 millimeters, and a thickness dimension ranging from 0.05 millimeters to 0.4 millimeters, preferably from 0.15 millimeters to 0.35 millimeters. In particular, the susceptors 40, 50 may be made from an expanded metal sheet including a plurality of openings 41, 51 through the sheet. An example of such a susceptor 40, 50 is shown in Figure 5.

[0134] The core portion 30 is also strip-shaped and has a width dimension ranging from 3.5 mm to 8 mm, preferably from 4 mm to 6 mm, and a thickness dimension ranging from 0.5 mm to 7 mm, preferably from 2 mm to 5 mm. As can be further seen in Fig. 1 and Fig. 12, the large side of each susceptor 40, 50 abuts laterally against the large side of the core portion 11. Thus, the first susceptor 40 and the second susceptor 50 are in direct physical contact with the core portion 30. Advantageously, this arrangement allows a very efficient heating of the core portion 30. In particular, the heating profiles of both susceptors 40, 50 are additive, due to the overlap in the common heating zone between the susceptors 40, 50. In the common heating zone, the temperature is higher than in the non-overlapping parts of the heating profiles of the first susceptor 40 and the second susceptor 50, respectively. The respective non-overlapping portions of the heating profiles of the first susceptor 40 and the second susceptor 50 form first and second heating zones, particularly for heating the cut tobacco material (and optionally the liquid aerosol-forming substrate) within the sleeve portion 20. Advantageously, the different heating zones may be beneficially used to design a wide variety of different aerosols by providing different amounts of different aerosols or flavors from different portions 20, 30 of the aerosol-forming rod 10.

[0135] The contact between the core portion 30 and the first susceptor 40 and the second susceptor 50, respectively, is non-bonded, i.e., the susceptors 40, 50 and the core portion 30 are not fixedly attached to one another. Nevertheless, the contact between the core portion 30 and the first susceptor 40 and the second susceptor 50, respectively, may include some non-permanent adhesion, for example, due to the moist or wet nature of the liquid-retaining materials impregnated with the liquid flavoring material.

[0136] The sleeve portion 20 is disposed around the core portion 30, the first susceptor 40 and the second susceptor 50 such that the shredded tobacco material of the sleeve portion 20 completely fills the entire remaining volume of the cylindrical rod 10. In particular, the shredded tobacco material is essentially in physical contact with the strip-like susceptors 40, 50 at the large side of each of the susceptors 40, 50 opposite the large side abutting the core portion 30. Thus, the shredded tobacco material can be heated simultaneously with the flavor material of the core portion 30. Thus, the aerosol-forming rod 10 allows for the simultaneous generation of aerosol and flavor additives. Advantageously, this increases the variety of aerosols that can be generated.

[0137] The inductively heated aerosol-forming rod according to the present invention may be manufactured using a method and manufacturing apparatus 1000 as shown diagrammatically in FIG.

[0138] The manufacturing apparatus 1000 comprises a sleeve material source 200 configured to supply a sleeve material 201 to the sleeve forming device 130 of the molding apparatus 100. The sleeve material source 200 includes an unwinding unit 210 for unwinding the sleeve material 201 provided on a bobbin 211. Downstream of the unwinding unit 210, the manufacturing apparatus 1000 further comprises a buffer 220 for buffering the sleeve material 201, a processing unit 230 for pre-treating the sleeve material 201, a tensioning unit 600 for adjusting the tension of the sleeve material 201, and a dispensing unit 700. In this embodiment, the processing unit 230 may be configured for physical processing of the sleeve material 201, for example, for crimping the sleeve material 201. The crimping of the sleeve material 201 may facilitate the formation of the sleeve portion in the molding apparatus 100. The dispensing unit 700 may be used to apply at least one of a fluid, granules, particles, and powder to the sleeve material, for example, a fluid flavoring material.

[0139] With respect to the core portion of the aerosol-forming rod, the manufacturing apparatus 1000 also includes a core material supply source 300 configured to supply a core material 301 to the core forming device 130 of the molding apparatus 100. The core material supply source 300 includes an unwinding unit 310 for unwinding the core material 301 provided on a bobbin 311.

[0140] Similarly, the manufacturing apparatus 1000 comprises a first susceptor supply source 400 and a second susceptor supply source 500 configured to supply a continuous susceptor profile 401 and a second continuous susceptor profile 501, respectively, to the molding apparatus 100. The susceptor supply source 400 comprises a first unwinding unit 410 for unwinding the first susceptor profile 401 provided on a bobbin 411. Similarly, the second susceptor supply source 500 comprises a second unwinding unit 510 for unwinding the second susceptor profile 501 provided on a bobbin 411. Downstream of the unwinding units 410, 510, the manufacturing apparatus 1000 further comprises a first processing unit 430 and a second processing unit 530 for pre-treating the first susceptor profile 401 and the second susceptor profile 501, respectively. In this embodiment, the first processing unit 430 and the second processing unit 530 are configured to generate a plurality of perforations in the respective susceptor profile 401, 501 and stretch the respective perforated susceptor profile 401, 501 along at least a first direction, here a direction of travel through the manufacturing apparatus 1000, to form an expanded susceptor profile including a plurality of openings 441, 551 resulting from the plurality of perforations. An example of such an expanded susceptor profile 401, 501 is shown in FIG.

[0141] As shown in Figures 1 and 2, in order to obtain the aerosol-forming rod 10, the sleeve material 201, the core material 301, and the first and second susceptor profiles 401 and 501 need to be combined and molded to form a sleeve portion arranged around the core portion, the first susceptor, the second susceptor and the core portion, the first susceptor and the second susceptor. For this purpose, the manufacturing apparatus 1000, as shown in Figure 3, is disposed downstream of the aforementioned units and comprises a molding apparatus 100 into which the sleeve material 201, the core material 301, and the first and second susceptor profiles 401 and 501 are simultaneously fed.

[0142] Fig. 4 shows details of the molding apparatus 100, the lower part of Fig. 4 being a longitudinal section through the apparatus 100, and the upper part of Fig. 4 comprising three transverse sections through the apparatus 100 at three different longitudinal positions as shown in the lower part of Fig. 4. According to the present invention, the molding apparatus 100 comprises a sleeve forming device 120, a core forming device 130 and a common longitudinal guide 140 (all-in-one) realizing a first longitudinal guide and a second longitudinal guide for assembling the first susceptor profile 401 and the second susceptor profile 501, respectively.

[0143] In this embodiment, the core forming apparatus 130 includes an inner funnel 131 configured to assemble the core material 301 into a continuous core strand such that upon passing through the core forming apparatus 301, the continuous core strand has a cross-sectional shape that corresponds to the cross-sectional shape of the cylindrical core portion of the aerosol forming rod that will be produced. The central axis of the inner funnel is coaxial with the central longitudinal axis 107 of the forming apparatus 100, corresponding to the radial position of the core portion within the aerosol forming rod.

[0144] The common longitudinal guide 140 is configured to position the first continuous susceptor profile 401 and the second continuous susceptor profile 501 relative to the continuous core strand so as to laterally abut the continuous core strand in a non-bonded manner upon passing through the inner funnel 131. In this embodiment, the common longitudinal guide 140 includes a guide tube 141 that is coaxially disposed with the longitudinal central axis 107 of the molding apparatus 100 and extends downstream into the upstream section of the core forming apparatus 130. In the upstream section of the core forming apparatus 130, the first core material and the second core material are already preassembled. The upstream section of the core forming apparatus 130 has a length 109 that is about 30 percent of the overall length 108 of the core forming apparatus 130.

[0145] 4, the guide tube 141 has a rectangular cross section, with the upper and lower outer surfaces of the guide tube 141 providing a first guide surface 142 and a second guide surface 144. Together with the side walls, the upper wall and the lower wall of the inner funnel 131, the guide surfaces 142, 144 respectively form guide channels 143, 145 into which the first susceptor profile 401 and the second susceptor profile 501 are respectively introduced and are initially separated from the core material 301 in the upstream section of the core forming apparatus 130.

[0146] In this configuration, the interior space of the common guide tube 141 is configured to pass and guide the core material therethrough. This setup may be particularly advantageous with regard to the compact design of the molding apparatus 100. Thus, the guide tube 141 may also serve as part of the core forming apparatus for pre-assembling the core material.

[0147] At the downstream end of the longitudinal guide 140, the first susceptor profile 401 and the second susceptor profile 501 are released from the guide and the susceptor profiles 401, 501 are allowed to come together with the pre-assembled core material at positions corresponding to their predetermined positions in the final aerosol forming rod.

[0148] To assemble the sleeve material into a continuous first core strand, a continuous sleeve strand around the second core strand, the molding device 100 comprises a sleeve forming device 120. Similar to the core forming device 130, the sleeve forming device 120 also comprises a funnel, which is an outer funnel 121, arranged around at least the downstream section of the core forming device 130. In this embodiment, the outer funnel 121 extends along the entire length of the core forming device 130 so that the inner funnel 131 is fully received within the outer funnel 121. The downstream end of the core forming device 130 opens into the downstream section of the sleeve forming device, where the sleeve material is already preassembled. Thus, at the downstream end of the core forming device 130, a continuous core strand and a susceptor profile laterally abutting the continuous core strand are released into the preassembled sleeve material. This may be advantageous with regard to the positional stability of the core parts and the susceptors in their desired positions in the final aerosol forming rod.

[0149] 4, the molding apparatus 100 further includes two guide fins 180 disposed on an inner surface of the outer funnel 121 of the sleeve forming apparatus 120. These guide fins 180 are configured to guide the sleeve material toward the downstream end of the sleeve forming apparatus 120. Advantageously, the guide fins 180 may help reduce undesired heating of the sleeve forming apparatus and the core forming apparatus during the sleeve forming process that may occur due to friction between different portions of the molding apparatus 100 and the sleeve material.

[0150] To adjust the position of the core portion, the first susceptor and the second susceptor within the aerosol-forming rod, the molding apparatus includes a first translation stage 171 and a second translation stage 172 operably coupled to the common longitudinal guide 140 and the core forming apparatus 130, respectively. In the present invention, the first translation stage 171 is configured to adjust the axial position of the common longitudinal guide 140 relative to the core forming apparatus 130 along the central longitudinal axis 107 of the molding apparatus 100. This allows for adjustment of the axial position of the first susceptor profile 401 and the second susceptor profile 501 together with the pre-assembled core material. The second translation stage 172 is configured to adjust the position of the core forming apparatus 130 relative to the sleeve forming apparatus 120 along three directions: a first direction parallel to the central longitudinal axis 107 of the molding apparatus 100, a second direction perpendicular to the central longitudinal axis 107, and a third direction perpendicular to the second direction and to the central longitudinal axis 107. This allows the position where the continuous core strand and susceptor come together with the pre-assembled sleeve material to be controlled in three dimensions.

[0151] At the downstream end of the sleeve forming apparatus 120, the continuous sleeve strand core strand, the first susceptor profile, the second susceptor profile and the continuous core strand leave the forming apparatus 100. Within the entity, the continuous sleeve strand has a cross-sectional shape corresponding to the cross-sectional shape of the sleeve portion, the continuous core strand has a cross-sectional shape corresponding to the cross-sectional shape of the core portion, and the first susceptor and the second susceptor laterally abut the continuous core strand on either side.

[0152] Referring again to FIG. 3, the manufacturing apparatus 1000 further comprises a rod-forming apparatus 800 downstream of the molding apparatus 100, configured to form the continuous core strand, the first susceptor profile, the second susceptor profile and the continuous sleeve strand into a continuous aerosol-forming rod strand. As not shown in FIG. 3 but described above, the rod-forming apparatus 800 may comprise a garniture tape that interacts with at least one half-funnel to form the final rod shape. The garniture tape may further support a wrapper that is supplied to the upstream end of the rod-forming apparatus 800 by a wrapper source (not shown). During operation, the wrapper is automatically wrapped around the substrate web as it progressively assembles around the sleeve portion such that a continuous aerosol-forming rod strand completely surrounded by the wrapper exits the rod-forming apparatus 800 at its downstream end.

[0153] Downstream of the rod forming device, the manufacturing apparatus 1000 may further comprise a cutting device 900 for cutting the continuous aerosol-forming rod strand into individual inductively heated aerosol-forming rods according to the present invention.

Claims

1. 1. An inductively heated aerosol-forming rod for use in an aerosol-generating article, the aerosol-forming rod comprising: at least one core portion comprising at least one of a first aerosol-forming substrate and a first flavour material; a first elongated susceptor laterally abutting said core portion at a first side along a longitudinal axis of said aerosol-forming rod; a second elongated susceptor laterally abutting the core portion at a second side along the longitudinal axis of the aerosol-forming rod opposite the first side such that the core portion is sandwiched between the first and second elongated susceptors; a sleeve portion disposed around said core portion, said first susceptor and said second susceptor, said sleeve portion comprising at least one of a filler material, a second aerosol-forming substrate and a second flavour material.

2. The core portion is a porous substrate or foam based on tobacco fibres, said tobacco fibres at least partly forming said first aerosol-forming substrate, a porous substrate or foam based on vegetable fibres, said vegetable fibres at least partially forming said first aerosol-forming substrate, a filler comprising tobacco shred material, said shredded tobacco material at least partially forming said first aerosol-forming substrate; a filler comprising chopped plant material, said chopped plant material at least partially forming said first aerosol-forming substrate, a liquid-holding material comprising an aerosol-forming liquid, said aerosol-forming liquid at least partially forming said first aerosol-forming substrate, - a liquid-holding material comprising at least one flavouring substance, said flavouring substance at least partially forming said first flavouring substance; - cellulose or cellulosic fibers comprising a flavoring substance, said flavoring substance at least partially forming said first flavoring material.

3. The sleeve portion is a porous substrate or foam based on tobacco fibres, said tobacco fibres at least partially forming said second aerosol-forming substrate, a porous substrate or foam based on vegetable fibres, said vegetable fibres at least partially forming said second aerosol-forming substrate, a filler comprising tobacco shred material, said shredded tobacco material at least partially forming said second aerosol-forming substrate; a filler comprising chopped plant material, said chopped plant material at least partially forming said second aerosol-forming substrate, a liquid-holding material comprising an aerosol-forming liquid, said aerosol-forming liquid at least partially forming said second aerosol-forming substrate, - a liquid-holding material comprising at least one flavouring substance, said flavouring substance at least partially forming said second flavouring substance, - cellulose or cellulosic fibres, - cellulose or cellulosic fibres comprising flavouring substances, said flavouring substances at least partially forming said second flavouring material, - acetate tow expanded fiber, - vegetable expandable fibres, or The aerosol-forming rod according to claim 1 or 2, comprising at least one of the following:

4. The aerosol-forming rod according to any one of claims 1 to 3, wherein the second aerosol-forming substrate is different from the first aerosol-forming substrate.

5. 5. The aerosol-forming rod according to claim 1, wherein at least one of the first susceptor and the second susceptor comprises an expanded metal sheet including a plurality of openings therethrough.

6. The aerosol-forming rod according to any one of claims 1 to 5, wherein the core portion has a rectangular cross-section, or a square cross-section, or a semi-elliptical cross-section, or a semi-circular cross-section.

7. The aerosol forming rod according to any one of claims 1 to 6, wherein the core portion is disposed symmetrically with respect to a central longitudinal axis of the aerosol forming rod.

8. 8. The aerosol-forming rod according to claim 1, wherein at least one of the first susceptor and the second susceptor is strip-shaped, and a width extension of the strip-shaped first susceptor and the strip-shaped second susceptor, respectively, is constant or varies along a central longitudinal axis of the aerosol-forming rod.

9. An aerosol-generating article comprising an inductively heated aerosol-forming rod according to any one of claims 1 to 8.

10. A molding apparatus for use in the manufacture of an inductively heated aerosol forming rod according to any one of claims 1 to 8, comprising: a core forming device configured to assemble core material comprising at least one of said first aerosol-forming substrate and said first flavour material into a continuous core strand such that, upon passing through said core forming device, said continuous core strand has a cross-sectional shape corresponding to the cross-sectional shape of said core portion; a first longitudinal guide for positioning a first continuous susceptor profile relative to the continuous core strand such that, as it passes through the core forming device, the first continuous susceptor profile laterally abuts the continuous core strand on a first side, the first longitudinal guide extending downstream at least into an upstream section of the core forming device; a second longitudinal guide for positioning a second continuous susceptor profile relative to the continuous core strand such that, as it passes through the core forming device, the second continuous susceptor profile laterally abuts the continuous core strand on a second side opposite the first side, the second longitudinal guide extending downstream at least into an upstream section of the core forming device; - a sleeve forming device arranged around at least a downstream section of the core forming device, the sleeve forming device being configured to assemble sleeve material comprising at least one of the filler material, the second aerosol-forming substrate and the second flavor material into a continuous sleeve strand around the continuous core strand, the first continuous susceptor profile and the second continuous susceptor profile, such that the continuous sleeve strand has a cross-sectional shape corresponding to the cross-sectional shape of the sleeve portion as it passes through the sleeve forming device.

11. The molding apparatus of claim 10 , wherein the sleeve forming device is disposed about at least a downstream section of the core forming device.

12. A moulding apparatus according to any one of claims 10 to 11, wherein the core-forming device comprises an inner funnel and the sleeve-forming device comprises an outer funnel.

13. A molding apparatus according to any one of claims 10 to 12, wherein the first longitudinal guide and the second longitudinal guide are at least partially realised by a common guide tube extending downstream at least into the upstream section of the core forming apparatus.

14. a first translation stage for adjusting the position of at least one of the first longitudinal guide and the second longitudinal guide relative to the core forming device in at least one direction; - a second translation stage for adjusting the position of the core forming device relative to the sleeve forming device in at least one direction.

15. The molding apparatus of any one of claims 10 to 14, further comprising one or more guide fins disposed on at least one of an inner surface of the sleeve forming device and an outer surface of the core forming device.

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