Method for manufacturing an aerosol-generating article

Abstract

A method for continuously manufacturing aerosol-generating articles (1, 2) includes: (i) providing a continuous web (34) or continuous strip (218) of aerosol-generating substrate (10) having a substantially flat surface; (ii) providing a continuous web (40) of susceptor material; (iii) intermittently applying an adhesive (47) to a surface of the continuous web of susceptor material (40) to form adhesive regions (60) on the surface; and (iv) adhering the continuous web of susceptor material (40) to the adhesive regions (60). (v) adhering the susceptor patch (28) to a substantially flat surface of the continuous web (34) or continuous strip (218) of aerosol-generating substrate (10); and (vi) forming the continuous web (34) or continuous strip (218) of aerosol-generating substrate (10) and the at least one susceptor patch (28) adhered thereto into a continuous rod (88).

Description

[Technical Field]

[0001] The present disclosure relates generally to aerosol-generating articles, and more particularly to aerosol-generating articles for use with aerosol-generating devices for heating the aerosol-generating article to generate an aerosol for inhalation by a user. Embodiments of the present disclosure relate, inter alia, to methods for continuously producing aerosol-generating articles. The present disclosure is particularly applicable to the manufacture of aerosol-generating articles for use with portable (handheld) aerosol-generating devices. [Background technology]

[0002] In recent years, the popularity and use of risk-reducing or risk-modifying devices (also known as aerosol-generating or vapor-generating devices) has grown rapidly as an alternative to the use of traditional tobacco products. A variety of devices and systems are available that heat and warm an aerosol-generating substance to generate an aerosol for inhalation by the user.

[0003] A commonly available risk reduction or risk modification device is a substrate-heated aerosol-generating device, or so-called heated non-combustion device. This type of device generates an aerosol or vapor by heating an aerosol-generating substrate, typically to a temperature in the range of 150°C to 300°C. Heating the aerosol-generating substrate to a temperature within this range, without burning or combusting the aerosol-generating substrate, generates a vapor that typically cools and condenses to form an aerosol that is inhaled by the user of the device.

[0004] Currently available aerosol-generating devices can provide heat to the aerosol-generating substrate using one of several different techniques. One such technique is to provide an aerosol-generating device that employs an induction heating system. In such devices, an induction coil is provided in the device, and an inductively heatable susceptor is provided to heat the aerosol-generating substrate. When a user activates the device, electrical energy is supplied to the induction coil, which in turn generates an alternating electromagnetic field. The susceptor couples with this electromagnetic field to generate heat, which is transferred, for example by conduction, to the aerosol-generating substrate, which heats up and generates an aerosol.

[0005] It may be convenient to provide both the aerosol-generating substrate and the inductively heatable susceptor together in the form of an aerosol-generating article that a user can insert into an aerosol-generating device. There is therefore a need to provide a method that facilitates the manufacture of aerosol-generating articles, and in particular, that allows for the easy and consistent mass production of aerosol-generating articles. Summary of the Invention [Means for solving the problem]

[0006] According to a first aspect of the present disclosure, there is provided a method for continuously producing an aerosol-generating article, comprising the steps of: (i) providing a continuous web or continuous strip of an aerosol-generating substrate, the continuous web or continuous strip having a substantially flat surface; (ii) providing a continuous web of susceptor material; (iii) intermittently applying an adhesive to a surface of a continuous web of susceptor material to form adhesive areas on the surface; (iv) continuously cutting the continuous web of susceptor material at locations between the bonded regions to form at least one susceptor patch; (v) adhering at least one susceptor patch to a substantially planar surface of a continuous web or continuous strip of aerosol-generating substrate; (vi) forming a continuous web or continuous strip of aerosol-generating substrate and susceptor patches adhered to its surface into a continuous rod; A method is provided which includes:

[0007] The aerosol-generating article produced by this method is for use with an aerosol-generating device to heat the aerosol-generating substrate without burning the aerosol-generating substrate to volatilize at least one component of the aerosol-generating substrate, thereby generating a heated vapor that cools and condenses to form an aerosol for inhalation by a user of the aerosol-generating device. The aerosol-generating device is a handheld, portable device.

[0008] Generally speaking, a vapor is a substance that is in the gas phase below its critical temperature, meaning that the vapor can be condensed into a liquid by increasing the pressure without decreasing the temperature. An aerosol, on the other hand, is a suspension of fine solid particles or liquid droplets in air or another gas. However, it should be noted that, as used herein, the terms "aerosol" and "vapor" may be used interchangeably, particularly with respect to the form of inhalable medium that is generated for inhalation by a user.

[0009] The methods according to the present disclosure facilitate the manufacture of aerosol-generating articles, and in particular allow for consistent and relatively easy mass production of aerosol-generating articles. By cutting the continuous web of susceptor material at locations between the bonded regions, contamination of equipment components (e.g., cutting units) used to perform one or more of the steps of the manufacturing method can be avoided or at least minimized.

[0010] Steps (i) and (ii) can be performed sequentially in any order or can be performed simultaneously.

[0011] Step (iv) may include successively cutting the continuous web of susceptor material at locations between the bonded regions to form a plurality of susceptor patches, thereby facilitating mass production of the aerosol-generating article.

[0012] Step (iii) can include intermittently applying adhesive to a surface of the continuous web of susceptor material across substantially the entire width of the web of susceptor material, such that a good bond between the susceptor patch and the continuous web or strip of aerosol-generating substrate is achieved across the entire width of the susceptor patch.

[0013] This method may include heating the adhesive after step (v) and before step (vi) to cure or solidify the adhesive. This can help strengthen the bond between the susceptor patch and the continuous web or strip of aerosol-generating substrate. However, a trade-off is necessary because excessive heating may initiate the release of one or more volatile components from the aerosol-generating substrate. The goal is to ensure that the volatile components are released only during heating of the aerosol-generating article produced by this method in the aerosol-generating device. On the other hand, insufficient heating may result in the adhesive not curing or solidifying. Therefore, the heating temperature must be carefully selected based on the properties of both the aerosol-generating substrate and the adhesive.

[0014] Step (v) may include pressing at least one susceptor patch against a substantially flat surface of the continuous web or strip of aerosol-generating substrate. The pressing step may be performed using a cam roller. Pressing the susceptor patch against the surface of the continuous web or strip of aerosol-generating substrate may enhance bonding between the susceptor patch and the continuous web or strip of aerosol-generating substrate.

[0015] The at least one susceptor patch can have a length of 5 mm to 50 mm, preferably 10 mm to 30 mm. In one embodiment, the at least one susceptor patch can have a width of 0.1 mm to 5 mm, preferably 0.5 mm to 2 mm. In another embodiment, the at least one susceptor patch can have a width of 0.1 mm to 7 mm, preferably 1 mm to 5 mm. The at least one susceptor patch can have a thickness of 1 μm to 500 μm, in some cases 10 μm to 100 μm, preferably 50 μm. Susceptor patches having these dimensions are particularly suitable for the manufacture of aerosol-generating articles.

[0016] The substantially planar surface of the continuous web or strip of aerosol-generating substrate provided in step (i) may include a centerline. Step (v) may include adhering at least one susceptor patch to the substantially planar surface substantially along the centerline. Accurate and consistent placement of the susceptor patch along the centerline ensures that aerosol-generating articles produced by methods according to the present disclosure have consistent and reproducible properties.

[0017] Step (v) may include adhering a plurality of susceptor patches to a substantially flat surface of a continuous web or strip of aerosol-generating substrate, with a predetermined, regular spacing between each successive susceptor patch. The predetermined, regular "spacing" between each successive susceptor patch is the shortest distance between successive (i.e., adjacent) susceptor patches, i.e., the distance or gap between the edges of successive (i.e., adjacent) susceptor patches. Step (vi) may include forming the continuous web or strip of aerosol-generating substrate and the susceptor patches into a continuous rod, thereby facilitating mass production of aerosol-generating articles. The use of a cam roller to press the susceptor patches against the substantially flat surface of the continuous web or strip of aerosol-generating substrate may be particularly advantageous in this embodiment because it allows for a pressing force to be easily applied at spaced locations along the continuous web or strip of aerosol-generating substrate corresponding to the locations of the applied susceptor patches.

[0018] The method may further comprise (vii) cutting the continuous rod to form a plurality of individual aerosol-generating articles. Each of the individual aerosol-generating articles may comprise at least one susceptor patch. Thus, step (vii) may comprise cutting the continuous rod to form a plurality of individual aerosol-generating articles, each comprising at least one susceptor patch. This facilitates continuous mass production of aerosol-generating articles.

[0019] Step (vii) may include cutting the continuous rod at locations between adjacent susceptor patches. Cutting the continuous rod in this manner ensures that the individual aerosol-generating articles formed by cutting the continuous rod each include a susceptor patch, and therefore the aerosol-generating articles are consistent and reproducible. Also, because the susceptor patches are not cut during step (vii), wear (e.g., on the cutting unit) during the cutting step is minimized.

[0020] Step (vii) may include cutting the continuous rod substantially midway between adjacent susceptor patches. In this manner, the susceptor patches are spaced inward from both ends of the resulting aerosol-generating article and are not visible from either end of the aerosol-generating article. This may improve user acceptance of aerosol-generating articles produced by the methods of the present disclosure. Furthermore, the susceptor is fully embedded in the aerosol-generating substrate of the resulting aerosol-generating article, which may allow for more efficient aerosol or vapor generation because the entire susceptor is surrounded by the aerosol-generating substrate, thereby maximizing heat transfer from the susceptor to the aerosol-generating substrate.

[0021] The at least one susceptor patch may comprise an inductively heatable susceptor material such as, but not limited to, one or more of aluminum, iron, nickel, stainless steel, carbon steel, and alloys thereof, such as nickel-chromium or nickel-copper. During use of the aerosol-generating article in the aerosol-generating device, upon application of an electromagnetic field in its vicinity, the susceptor material may generate heat due to eddy currents and magnetic hysteresis losses, resulting in energy conversion from the electromagnetic field to heat.

[0022] The aerosol-generating substrate can be any type of solid or semi-solid material. Exemplary types of aerosol-generating solids include powders, granules, pellets, shreds, strands, particles, gels, strips, loose-leaf, cut-leaf, cut-filler, porous materials, foam materials, or sheets. The aerosol-generating substrate can include plant-derived materials, particularly tobacco. It can include, for example, reconstituted tobacco containing tobacco and one or more of cellulose fiber, tobacco stem fiber, and inorganic fillers such as CaCO3.

[0023] Thus, the aerosol-generating devices with which the aerosol-generating articles are intended to be used may be referred to as "heated tobacco devices," "heated-non-combustible tobacco devices," "devices for vaporizing tobacco products," etc., and are to be interpreted as devices suitable for achieving these effects. The features disclosed herein are equally applicable to devices designed to vaporize any aerosol-generating substrate.

[0024] The continuous rod may be surrounded by a paper wrapper, and thus the method may further comprise encasing the continuous rod in a paper wrapper.

[0025] The aerosol-generating article may be substantially stick-shaped and generally resemble a cigarette with a tubular region having an aerosol-generating substrate arranged in a suitable configuration. The aerosol-generating article may include a filter segment, e.g., comprising cellulose acetate fibers, at the proximal end of the aerosol-generating article. The filter segment may constitute a mouthpiece filter and, for example, may be coaxially aligned with the aerosol-generating substrate, which may be comprised of multiple aerosol-generating strips. Some designs may also include one or more vapor collection regions, cooling regions, and other structures. For example, the aerosol-generating article may include at least one tubular segment upstream of the filter segment. The tubular segment may function as a vapor cooling region. The vapor cooling region may advantageously allow heated vapor generated by heating the aerosol-generating substrate to cool and condense, for example, through the filter segment, to form an aerosol with suitable properties for inhalation by a user.

[0026] The aerosol-generating substrate may contain an aerosol former. Examples of aerosol formers include polyhydric alcohols such as glycerin or propylene glycol, and mixtures thereof. Typically, the aerosol-generating substrate may contain about 5% to about 50% aerosol former by dry weight. In some embodiments, the aerosol-generating substrate may contain about 10% to about 20% aerosol former by dry weight, and in some cases about 15% aerosol former by dry weight.

[0027] Upon heating, the aerosol-forming substrate may release volatile compounds, which may include flavor compounds such as nicotine or tobacco flavorings. [Brief explanation of the drawings]

[0028] [Figure 1a] 1 is a schematic cross-sectional side view of a first example of an aerosol-generating article. [Figure 1b] FIG. 1b is a schematic cross-sectional view taken along line AA in FIG. 1a. [Figure 2a] 1A and 1B are schematic diagrams of an apparatus and method for manufacturing a first example of an aerosol-generating article shown in FIGS. 1A and 1B. [Figure 2b] 2b is a plan view of the aerosol-generating substrate and susceptor patch as they move through the apparatus shown in FIG. 2a in the direction indicated by the arrows. [Figure 3] FIG. 2 is a plan view of a portion of a continuous web of susceptor material showing bonded and non-bonded areas. [Figure 4] 2b is a functional diagram of a portion of the apparatus and method of FIG. 2a, illustrating generally the formation of susceptor patches from a continuous web of susceptor material and the application of the susceptor patches to the surface of a continuous web of aerosol-generating substrate. [Figure 5] FIG. 2 is a schematic perspective view of a susceptor cutting unit. [Figure 6] FIG. 2b is a schematic diagram of a strip cutting unit of the apparatus of FIG. 2a; [Figure 7a] FIG. 2 is a schematic cross-sectional side view of a second example of an aerosol-generating article. [Figure 7b] FIG. 7b is a schematic cross-sectional view taken along line AA in FIG. 7a. [Figure 8a] 7a and 7b are schematic diagrams of a first embodiment of an apparatus and method for manufacturing the second example aerosol-generating article shown in FIGS. 7a and 7b. [Figure 8b] 8b is a plan view of the aerosol-generating substrate and susceptor patch as they move through the apparatus shown in FIG. 8a in the direction indicated by the arrows. [Figure 9] FIG. 8b is a schematic diagram of a strip cutting unit of the apparatus of FIG. 8a; [Figure 10a] 7a and 7b are schematic diagrams of a second embodiment of an apparatus and method for manufacturing the second example aerosol-generating article shown in FIGS. 7a and 7b. [Figure 10b] 10b is a plan view of the aerosol-generating substrate and susceptor patch as they move through the apparatus shown in FIG. 10a in the direction indicated by the arrows. [Figure 11] 10b is a functional diagram of a portion of the apparatus and method of FIG. 10a, illustrating generally the formation of susceptor patches from a continuous web of susceptor material and the application of the susceptor patches to the surface of a continuous strip of aerosol-generating substrate. [Figure 12] FIG. 10b is a schematic diagram of a strip cutting unit of the apparatus of FIG. 10a; DETAILED DESCRIPTION OF THE INVENTION

[0029] Embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0030] [Aerosol-generating items (Example 1)] 1a and 1b, there is shown a first example of an aerosol-generating article 1 for use with an aerosol-generating device that includes an induction heating system that inductively heats the aerosol-generating article 1, thereby generating an aerosol for inhalation by a user of the device. Such devices are known in the art and will not be described in further detail herein. The aerosol-generating article 1 is elongated and substantially cylindrical, with a distal end 11a and a proximal end (or mouth end) 11b. The circular cross-section facilitates handling of the article 1 by a user and insertion of the article 1 into the cavity or heating compartment of the aerosol-generating device.

[0031] The aerosol-generating article 1 includes an aerosol-generating substrate 10 having a first end 10a and a second end 10b, and an inductively heatable susceptor 12. The aerosol-generating substrate 10 and the inductively heatable susceptor 12 are disposed within and surrounded by a wrapper 14. The wrapper 14 comprises a substantially electrically non-conductive and non-magnetically permeable material. In the illustrated example, the wrapper 14 is a paper wrapper and may include cigarette paper.

[0032] The aerosol-generating article 1 may have an overall length, measured between the distal end 11a and the proximal (mouth) end 11b, of 30 mm to 100 mm, preferably 50 mm to 70 mm, and in some cases about 55 mm. The aerosol-generating substrate 10 may have an overall length, measured between the first end 10a and the second end 10b, of 5 mm to 50 mm, preferably 10 mm to 30 mm, and in some cases about 20 mm. The aerosol-generating article 1 may have a diameter of 5 mm to 10 mm, preferably 6 mm to 8 mm, and in some cases about 7 mm.

[0033] The aerosol-generating substrate 10 includes a plurality of elongated first strips 15 containing aerosol-generating material. The plurality of elongated first strips 15 constitute aerosol-generating strips 16 and are oriented substantially in the longitudinal direction of the aerosol-generating article 1. The elongated first strips 15 are typically free of folds in the longitudinal direction to ensure that the airflow path is uninterrupted and that uniform airflow through the article 1 can be achieved.

[0034] The inductively heatable susceptor 12 includes a plurality of elongated second strips 13 comprising inductively heatable susceptor material. The plurality of elongated second strips 13 form susceptor strips 18 and are oriented substantially in the longitudinal direction of the aerosol-generating article 1. The elongated second strips 13 are free of folds in the longitudinal direction to prevent hot spots in the aerosol-generating substrate 10.

[0035] The aerosol-generating article 1 includes a plurality of elongated third strips 17 (see FIG. 1b) comprising an aerosol-generating material. The elongated third strips 17 also constitute aerosol-generating strips 16 and are oriented substantially in the longitudinal direction of the aerosol-generating article 1. The elongated third strips 17 have the same length as the elongated first strips 15, and therefore all of the aerosol-generating strips 16 in the aerosol-generating article 1 have the same length. The elongated second strips 13 are adhered to the elongated third strips 17, and the elongated second strips 13 and the elongated third strips 17 have the same width. In a preferred embodiment, the elongated first strips 15 also have the same width as the elongated second strips 13 and the elongated third strips 17.

[0036] The first elongated strips 15, the second elongated strips 13, and the third elongated strips 17 are arranged to form a substantially rod-shaped aerosol-generating article 1 and may be randomly distributed throughout the cross-section of the rod-shaped aerosol-generating article 1, such that they have a plurality of different orientations within the cross-section of the aerosol-generating article 1. Although not apparent from FIG. 1b, it will be understood that a sufficient number of first elongated strips 15 are provided to substantially fill the cross-section of the aerosol-generating substrate 10, and that the fewer first elongated strips 15 are shown for illustrative purposes only. It should also be noted that any suitable number of second elongated strips 13 may be arranged within the aerosol-generating substrate 10, depending on the heating requirements. Each second elongated strip 13 is advantageously surrounded by a first elongated strip 15, thereby ensuring that heat transfer to the first elongated strips 15 is maximized and that the possibility of contact between the second elongated strips 13 is minimized.

[0037] As best shown in FIG. 1a, each of the plurality of first elongated strips 15 has a distal end 15a, and each of the plurality of second elongated strips 13 has a distal end 13a. The distal end 15a of the first elongated strip 15 forms the first end 10a of the aerosol-generating substrate 10 and, correspondingly, the distal end 11a of the aerosol-generating article 1. The second elongated strip 13 is shorter than the first elongated strip 15 and the third elongated strip 17. The distal end 13a of the second elongated strip 13 is positioned inward from the distal end 15a of the first elongated strip 15. Thus, the distal end 13a of the second elongated strip 13 is not visible at the distal end 11a of the aerosol-generating article 1.

[0038] The aerosol-generating article 1 includes a mouthpiece segment 20 positioned downstream of the aerosol-generating substrate 10. The aerosol-generating substrate 10 and the mouthpiece segment 20 are positioned in coaxial alignment inside a wrapper 14 to hold the components in place, forming the rod-shaped aerosol-generating article 1.

[0039] In the illustrated embodiment, the mouthpiece segment 20 includes the following components, arranged sequentially and coaxially in a downstream direction, i.e., from the distal end 11a to the proximal (mouth) end 11b of the aerosol-generating article 1: a cooling segment 22, a central hole segment 23, and a filter segment 24. The cooling segment 22 includes a hollow paper tube 22a having a thickness greater than that of the paper wrapper 14. The central hole segment 23 may include a stiffening mixture including cellulose acetate fibers and a plasticizer and functions to increase the strength of the mouthpiece segment 20. The filter segment 24 typically includes cellulose acetate fibers and functions as a mouthpiece filter. As heated vapor flows from the aerosol-generating substrate 10 toward the proximal (mouth) end 11b of the aerosol-generating article 1, the vapor cools and condenses as it passes through the cooling segment 22 and the central hole segment 23, forming an aerosol with properties suitable for inhalation by a user through the filter segment 24.

[0040] The first elongated strip 15 and the third elongated strip 17 typically comprise a plant-derived material such as tobacco. The first elongated strip 15 and the third elongated strip 17 may advantageously comprise reconstituted tobacco, which includes tobacco and any one or more of cellulose fiber, tobacco stem fiber, and an inorganic filler such as CaCO3.

[0041] The first elongated strip 15 and the third elongated strip 17 typically contain an aerosol former such as glycerin or propylene glycol. Typically, the first elongated strip 15 and the third elongated strip 17 contain about 5% to about 50% aerosol former content on a dry weight basis. Upon heating, the first elongated strip 15 and the third elongated strip 17 release volatile compounds, optionally including flavor compounds such as nicotine or tobacco flavorings.

[0042] During use of the article 1 in an aerosol-generating device, when a time-varying electromagnetic field is applied near the second elongated strip 13, heat is generated in the second elongated strip 13 due to eddy currents and magnetic hysteresis losses. The heat is transferred from the second elongated strip 13 to the first elongated strip 15 and the third elongated strip 17, heating the first elongated strip 15 and the third elongated strip 17 without combustion, releasing one or more volatile compounds, thereby generating vapor. When a user inhales through the filter segment 24, the heated vapor is drawn downstream through the article 1 from the first end 10a of the aerosol-generating substrate 10 toward the second end 10b of the aerosol-generating substrate 10 and toward the filter segment 24. As described above, as the heated vapor flows through the cooling segment 22 and the central hole segment 23 toward the filter segment 24, the heated vapor cools and condenses to form an aerosol with properties suitable for inhalation by a user through the filter segment 24.

[0043] [Manufacturing of aerosol-generating articles (Example 1)] Referring to Figure 2a, there is shown a schematic diagram of an apparatus 30 and method for producing the first example of an aerosol-generating article 1 described above with reference to Figures 1a and 1b. Figure 2b is a plan view of the aerosol-generating substrate 10 and susceptor patch 28 as they move through the apparatus 30 in the direction of the arrows in Figure 2b.

[0044] The apparatus 30 includes a substrate supply reel 32 (e.g., a first bobbin) carrying a continuous web 34 of aerosol-generating substrate 10 having a substantially flat surface, and a first feed roller 36 for controlling the feeding of the continuous web 34 of aerosol-generating substrate 10. The apparatus 30 may also include a web tension adjuster and a web edge control system, as will be understood by those skilled in the art, although these additional components are not required in the context of the present disclosure and, therefore, have been omitted for simplicity.

[0045] The apparatus 30 includes a susceptor supply reel 38 (e.g., a second bobbin) carrying a continuous web 40 of susceptor material, feed rollers 42, 44 for controlling the feeding of the continuous web 40 of susceptor material, an adhesive application unit 46, and a susceptor cutting unit 48.

[0046] Apparatus 30 further includes an optional heater 50 , a strip cutting unit 52 , feed rollers 54 , a rod forming unit 56 , and a rod cutting unit 58 .

[0047] [Preparing the susceptor patch] During operation, the continuous web 34 of aerosol-generating substrate 10 is continuously fed from the substrate supply reel 32. Simultaneously, the continuous web 40 of susceptor material is continuously fed from the susceptor supply reel 38 via feed rollers 42, 44 to the adhesive application unit 46. The adhesive application unit 46 applies an adhesive 47 to the surface of the continuous web of susceptor material 40. In the illustrated example, the adhesive application unit 46 applies the adhesive 47 intermittently to the surface of the continuous web of susceptor material 40 across the entire width of the web 40. In this manner, discrete bonded regions 60 (see FIGS. 3 and 4 ) are formed on the surface of the continuous web of susceptor material 40, and non-bonded regions 62 are formed between adjacent bonded regions 60 in the direction of travel of the continuous web of susceptor material 40.

[0048] The continuous web 40 of susceptor material is fed from the adhesive application unit 46 to a susceptor cutting unit 48, which continuously cuts the continuous web 40 to form a plurality of susceptor patches 28. As best shown in FIG. 2b, the continuous web 40 of susceptor material, and thus the susceptor patches 28, have a width that is substantially smaller than the width of the continuous web 34 of aerosol-generating substrate 10. For example, the continuous web 34 of aerosol-generating substrate 10 may have a width of approximately 140 mm, whereas the continuous web 40 of susceptor material, and thus the susceptor patches 28, may have a width of approximately 0.1 mm to 5 mm. In some embodiments, the susceptor patches 28 may have a length of approximately 5 mm to 50 mm in the direction of travel of the continuous web 40 of susceptor material and a thickness of approximately 1 μm to 500 μm.

[0049] To minimize contamination of the susceptor cutting unit 48 with the adhesive 47 applied to the continuous web 40 of susceptor material by the adhesive application unit 46, the susceptor cutting unit 48 cuts the continuous web 40 of susceptor material at the non-bonded regions 62, i.e., at locations between the bonded regions 60 on the surface of the continuous web 40 of susceptor material. This can be achieved by synchronizing the operation of the susceptor cutting unit 48 with the movement of the continuous web 40 of susceptor material.

[0050] 5, the susceptor cutting unit 48 includes a rotary cutting unit 64 that includes a support drum 66 and a cutting drum 68. The support drum 66 supports the continuous web of susceptor material 40 about its periphery and includes a plurality of circumferentially spaced recesses 70 thereabout. The support drum 66 is typically a suction drum, and the continuous web of susceptor material 40 and the susceptor patches 28 are supported about its periphery by suction applied through suction ports 67. The cutting drum 68 includes a plurality of circumferentially spaced cutting elements 72, e.g., protruding cutting blades, thereabout, which cooperate with (e.g., extend into) the circumferentially spaced recesses 70 during synchronous rotation of both the support drum 66 and the cutting drum 68 in opposite directions, as indicated by the arrows in FIG. 5. This results in successive shear cuts of the continuous web of susceptor material 40 to form a plurality of susceptor patches 28.

[0051] [Applying a susceptor patch] The susceptor patches 28 provided by the susceptor cutting unit 48 can be applied to the surface of the continuous web 40 of the aerosol-generating substrate 10 so that there is a fixed, predetermined spacing 74 between the edges of each successive susceptor patch 28, as shown, for example, in FIGS. 2b and 4. The fixed, predetermined spacing 74 can be, for example, 1 mm to 20 mm. To create the fixed, predetermined spacing 74 between the edges of adjacent susceptor patches 28, the susceptor cutting unit 48 permits relative movement between the continuous web 40 of susceptor material and the support drum 66 for a predetermined period of time immediately after the continuous web 40 of susceptor material carried by the support drum 66 is cut by the cutting drum 68 to form the susceptor patches 28. This relative movement allows the continuous web 40 of susceptor material to remain stationary or to move at a reduced speed for a short period of time after the susceptor patches 28 are cut from the continuous web 40 of susceptor material. Relative motion between the continuous web 40 of susceptor material and the support drum 66 can be achieved, for example, by reducing the suction force applied by the support drum 66 to the continuous web 40 of susceptor material, while simultaneously maintaining an appropriate suction force between the already-cut susceptor patches 28 and the support drum 66 to ensure that there is no relative motion between the susceptor patches 28 and the support drum 66. In this manner, the susceptor patches 28 cut from the continuous web 40 of susceptor material by the susceptor cutting unit 48 are conveyed for a short period of time at a faster speed than the continuous web 40 of susceptor material from which they were cut, thereby creating the desired constant, predetermined spacing 74 between the edges of adjacent susceptor patches 28.

[0052] The susceptor patches 28 coated with adhesive 47 are successively adhered to the surface of the continuous web 34 of aerosol-generating substrate 10 substantially along the centerline of the continuous web 34. Adjacent susceptor patches 28 are spaced apart in the direction of movement of the continuous web 34 of aerosol-generating substrate by a constant, predetermined spacing 74 between the edges of the susceptor patches 28, which occurs when the susceptor patches 28 are formed in the susceptor cutting unit 48. To ensure sufficient adhesion between the susceptor patches 28 and the substantially flat surface of the continuous web 34 of aerosol-generating substrate 10, the susceptor patches 28 can be pressed against the substantially flat surface by a cam roller 76, shown schematically in FIG. 2a. The rotation of the cam roller 76 is synchronized with the movement of the continuous web 34 of aerosol-generating substrate 10, so that a pressing force is applied to successive susceptor patches 28 but not to the spaced apart areas between successive susceptor patches 28.

[0053] Depending on the properties of the adhesive 47 applied by the adhesive application unit 46 to the continuous web 40 of susceptor material (and thus to the susceptor patches 28), the continuous web 34 of aerosol-generating substrates 10 and the susceptor patches 28 adhered thereto may be heated by an optional heater 50. This serves to cure or solidify the adhesive 47, thereby ensuring a good bond between each susceptor patch 28 and the surface of the continuous web 34 of aerosol-generating substrates 10. The heating temperature must be carefully selected based on the properties of both the aerosol-generating substrates 10 and the adhesive 47 to ensure that sufficient heating is achieved to cure or solidify the adhesive 47, while avoiding or at least minimizing the release of volatile components from the aerosol-generating substrates 10.

[0054] Strip Cut The continuous web 34 of aerosol-generating substrate 10, having spaced-apart susceptor patches 28 adhered thereto, is fed to a strip cutting unit 52 (best shown in FIG. 6 ), which simultaneously cuts the continuous web 34 of aerosol-generating substrate 10 and the susceptor patches 28 to form a plurality of continuous aerosol-generating strips 16 and a plurality of susceptor strips 18. In one embodiment, the strip cutting unit 52 cuts the continuous web 34 of aerosol-generating substrate 10 and the susceptor patches 28 to form aerosol-generating strips 16 and susceptor strips 18 having strip widths of approximately 1 mm. Thus, it will be appreciated that if the susceptor patches 28 have a width of 5 mm, as described above, cutting each susceptor patch 28 will result in five susceptor strips 18.

[0055] The ends of the susceptor strips 18 formed by cutting the susceptor patches 28 are longitudinally spaced apart by the same predetermined, constant spacing 74 that existed between the edges of adjacent susceptor patches 28. As shown in FIGS. 2a and 6, the strip-cutting unit 52 is a rotary cutter unit 78 and includes first and second cutting drums 80, 82. The first cutting drum 80 includes a circumferentially extending first cutting structure 84, and the second cutting drum 82 includes a circumferentially extending second cutting structure 86. The first and second cutting structures 84, 86 cooperate (e.g., intermesh) to shear-cut the continuous web 34 of aerosol-generating substrate 10 and the susceptor patches 28 in the direction of movement of the continuous web 34 to form a plurality of aerosol-generating strips 16 and a plurality of susceptor strips 18. 2b and 6, the aerosol-generating strips 16 formed by cutting a central region of the continuous web 34 of aerosol-generating substrate 10 having susceptor patches 28 adhered to its surface have susceptor strips 18 (i.e., elongated second strips 13) adhered thereto, and it is the aerosol-generating strips 16 formed by cutting this central region that constitute the elongated third strips 17. On the other hand, the aerosol-generating strips 16 formed by cutting side regions of the continuous web 34 of aerosol-generating substrate 10 do not have susceptor strips 18 adhered thereto on the opposite side from the susceptor patches 28, and it is the aerosol-generating strips 16 formed by cutting these side regions that constitute the elongated first strips 15.

[0056] [Rod formation] The aerosol-generating strip 16 and the susceptor strip 18 are conveyed to the rod-forming unit 56 where they are formed into a continuous rod 88. If desired, a continuous sheet of wrapping paper (not shown) can be supplied to the rod-forming unit 56 from a supply reel (not shown) or can be supplied (again from a supply reel) to a separate wrapping unit which can be located downstream of the rod-forming unit 56. As the sheet of wrapping paper is transported and guided through the rod-forming unit 56 or a separate wrapping unit, it can be wrapped around the aerosol-generating strip 16 and the susceptor strip 18 so that the continuous rod 88 is surrounded by the wrapper 14.

[0057] [Rod cutting] The continuous rod 88 (optionally surrounded by a wrapper 14) is then transported to the rod cutting unit 58, where it is cut to length at appropriate locations to form a plurality of aerosol-generating articles 1. The aerosol-generating articles 1 formed by the rod cutting unit 58 can have a length of 5 mm to 50 mm, preferably 10 mm to 30 mm. It will be understood that this length corresponds to the length of the aerosol-generating substrate 10 described above with reference to FIGS. 1a and 1b. The continuous rod 88 is preferably repeatedly cut by the rod cutting unit 58 substantially midway between the ends of the susceptor strips 18 formed by cutting the continuous susceptor patch 28. In this manner, the susceptor strips 18 are not cut by the rod cutting unit 58, thereby reducing wear on the cutting elements. Furthermore, because the susceptor strips 18 are shorter than the aerosol-generating strips 16, the ends of the susceptor strips 18 are not visible at either end of the aerosol-generating articles 1 formed by the rod cutting unit 58. It will be appreciated that this type of method is particularly suitable for mass production of aerosol-generating articles 1.

[0058] [Final assembly] A further unit (not shown) may be located downstream of the rod cutting unit 58 and may provide one or more additional components, such as the mouthpiece segments 20 described above, and may be configured to assemble these with the individual aerosol-generating articles 1 formed by the rod cutting unit 56 to form finished aerosol-generating articles 1, for example of the type shown in Figure 1. In this case, a separate wrapping unit may be provided downstream of the rod cutting unit 58 to enable the assembled components to be simultaneously wrapped to form the finished aerosol-generating article 1. The further unit may form part of the apparatus 30, or may be a separate, stand-alone unit forming part of the final assembly line.

[0059] [Aerosol-generating items (Example 2)] 7a and 7b, there is shown a second example of an aerosol-generating article 2 for use with an aerosol-generating device that includes an induction heating system for inductively heating the aerosol-generating article, thereby generating an aerosol for inhalation by a user of the device. The aerosol-generating article 2 is similar to the aerosol-generating article 1 described above with reference to Figures 1a and 1b, and corresponding components are identified using the same reference numerals.

[0060] The aerosol-generating article 2 includes an aerosol-generating substrate 10 having a first end 10a and a second end 10b, and an inductively heatable susceptor 12. The aerosol-generating substrate 10 and the inductively heatable susceptor 12 are disposed within and surrounded by a wrapper 14. The wrapper 14 comprises a substantially electrically non-conductive and non-magnetically permeable material. In the illustrated example, the wrapper 14 is a paper wrapper and may include cigarette paper.

[0061] The aerosol-generating article 2 typically has an overall length measured between the distal end 11a and the proximal (mouth) end 11b of 30mm to 100mm, preferably 50mm to 70mm. The aerosol-generating substrate 10 typically has an overall length measured between the first end 10a and the second end 10b of 5mm to 50mm, preferably 10mm to 30mm. The aerosol-generating article 1 typically has a diameter of 5mm to 10mm, preferably 6mm to 8mm.

[0062] The aerosol-generating substrate 10 includes a plurality of elongated first strips 15 containing aerosol-generating material. The plurality of elongated first strips 15 constitute aerosol-generating strips 16 and are oriented substantially in the longitudinal direction of the aerosol-generating article 2. The elongated first strips 15 are typically free of folds in the longitudinal direction to ensure that the airflow path is uninterrupted and that uniform airflow through the article 2 can be achieved.

[0063] The inductively heatable susceptor 12 comprises elongated second strips 13 comprising inductively heatable susceptor material. The elongated second strips 13 can therefore be considered as strip- or blade-shaped elongated susceptors 12, also oriented substantially in the longitudinal direction of the aerosol-generating article 2. As can be clearly seen in Figure 7b, each of the elongated first strips 15 has a width that is smaller than the width of the elongated second strips 13.

[0064] The aerosol-generating article 2 includes at least one elongated carrier strip 17 having first and second major surfaces 17a, 17b. The elongated carrier strip 17 includes an aerosol-generating material and thus also constitutes an aerosol-generating strip 16. The elongated carrier strip 17 is oriented substantially in the longitudinal direction of the aerosol-generating article 2. The elongated carrier strip 17 has the same length as the first elongated strip 15, and therefore all of the aerosol-generating strips 16 in the aerosol-generating article 2 have the same length.

[0065] The elongated second strip 13 is adhered to an elongated carrier strip 17, which, as can be clearly seen in Figure 7b, has a width greater than that of the elongated second strip 13. The elongated second strip 13 has first and second opposing surfaces 13b, 13c. The second surface 13c is adhered to a second major surface 17b of the elongated carrier strip 17 and is entirely covered by the elongated carrier strip 17, more specifically by the second major surface 17b.

[0066] The first elongated strips 15, the second elongated strips 13, and the carrier strips 17 are arranged to form a substantially rod-shaped aerosol-generating article 2, and the first elongated strips 15 can be randomly distributed across the cross-section of the rod-shaped aerosol-generating article 2, resulting in a plurality of different orientations within the cross-section of the aerosol-generating article 2. While not apparent from FIG. 7b, it will be understood that a sufficient number of the first elongated strips 15 are provided to substantially fill the cross-section of the aerosol-generating substrate 10, and that the fewer first elongated strips 15 are shown for illustrative purposes only. The second elongated strips 13 and the carrier strips 17 are approximately centrally positioned within the cross-section of the aerosol-generating substrate 10, and thus the aerosol-generating article 2. Such an arrangement helps ensure uniform heat transfer from the second elongated strips 13 to the first elongated strips 15.

[0067] As best shown in Figure 7b, the centrally located elongated carrier strip 17 and the elongated second strips 13 adhered thereto define first and second regions 5, 6 within the cross-section of the aerosol-generating substrate 10, and hence the aerosol-generating article 2. The first region 5 faces a first major surface 17a of the elongated carrier strip 17, and the second region 6 faces a second major surface 17b of the elongated carrier strip 17. Both the first and second regions 5, 6 comprise a plurality of elongated first strips 15.

[0068] As best shown in Figure 7a, each of the plurality of elongated first strips 15 has a distal end 15a, and the elongated second strips 13 have a distal end 13a. The distal end 15a of the elongated first strips 15 forms the first end 10a of the aerosol-generating substrate 10 and, correspondingly, the distal end 11a of the aerosol-generating article 2. The elongated second strips 13 are shorter than the elongated first strips 15 and the elongated carrier strips 17. The distal end 13a of the elongated second strips 13 is disposed inward from the distal end 15a of the elongated first strips 15. Thus, the distal end 13a of the elongated second strips 13 (i.e., the elongated susceptor 12) is not visible at the distal end 11a of the aerosol-generating article 2.

[0069] The aerosol-generating article 2 includes a mouthpiece segment 20 positioned downstream of the aerosol-generating substrate 10. The aerosol-generating substrate 10 and the mouthpiece segment 20 are positioned in coaxial alignment inside a wrapper 14 to hold the components in place, forming the rod-shaped aerosol-generating article 2. The mouthpiece segment 20 has the same structure and includes the same components as the mouthpiece segment 20 described above in relation to the first example of the aerosol-generating article 1.

[0070] The elongated first strip 15 and the elongated carrier strip 17 typically comprise a plant-derived material such as tobacco. The elongated first strip 15 and the elongated carrier strip 17 may advantageously comprise reconstituted tobacco, which includes tobacco and any one or more of cellulose fiber, tobacco stem fiber, and an inorganic filler such as CaCO3.

[0071] The elongated first strip 15 and the elongated carrier strip 17 typically contain an aerosol former such as glycerin or propylene glycol. Typically, the elongated first strip 15 and the elongated carrier strip 17 contain about 5% to about 50% aerosol former content on a dry weight basis. Upon heating, the elongated first strip 15 and the elongated carrier strip 17 release volatile compounds, optionally including flavor compounds such as nicotine or tobacco flavorings.

[0072] During use of the article 2 in an aerosol-generating device, when a time-varying electromagnetic field is applied near the elongated second strip 13, heat is generated in the elongated second strip 13 due to eddy currents and magnetic hysteresis losses. The heat is transferred from the elongated second strip 13 to the elongated first strip 15 and the elongated carrier strip 17, heating the elongated first strip 15 and the elongated carrier strip 17 without combustion, releasing one or more volatile compounds, thereby generating vapor. When a user inhales through the filter segment 24, the heated vapor is drawn downstream through the article 2 from the first end 10a of the aerosol-generating substrate 10 toward the second end 10b of the aerosol-generating substrate 10 and toward the filter segment 24. As the heated vapor flows through the cooling segment 22 and the central hole segment 23 toward the filter segment 24, the heated vapor cools and condenses to form an aerosol with properties suitable for inhalation by a user through the filter segment 24.

[0073] [Production of an aerosol-generating article (Example 2): Embodiment 1] Referring to Figure 8a, there is shown a schematic diagram of a first embodiment of an apparatus 130 and method for producing the second example aerosol-generating article 2 described above with reference to Figures 7a and 7b. Figure 8b is a plan view of the aerosol-generating substrate 10 and susceptor patch 28 as they move through the apparatus 130 in the direction of the arrows in Figure 8b. The apparatus 130 and method are similar to the apparatus 30 and method described above with reference to Figures 2-6, and corresponding components are identified using the same reference symbols.

[0074] The apparatus 130 includes a substrate supply reel 32 (e.g., a first bobbin) carrying a continuous web 34 of aerosol-generating substrate 10 having a substantially flat surface with a centerline 118, and a first feed roller 36 for controlling the feeding of the continuous web 34 of aerosol-generating substrate 10. The apparatus 130 may also include a web tension adjuster and a web edge control system, as will be understood by those skilled in the art, although these additional components are not required in the context of the present disclosure and therefore have been omitted for simplicity.

[0075] The apparatus 130 includes a susceptor supply reel 38 (e.g., a second bobbin) carrying a continuous web 40 of susceptor material, feed rollers 42, 44 for controlling the feeding of the continuous web 40 of susceptor material, an adhesive application unit 46, and a susceptor cutting unit 48.

[0076] The apparatus 130 further includes an optional heater 50 , a strip cutting unit 52 , feed rollers 54 , a rod forming unit 56 , and a rod cutting unit 58 .

[0077] [Preparing the susceptor patch] In operation, a continuous web 34 of aerosol-generating substrate 10 is continuously fed from substrate supply reel 32. Simultaneously, susceptor patches 28 are prepared in exactly the same manner as described above in connection with apparatus 30 and the corresponding method, and the details will not be repeated. As will become apparent from the following description, each susceptor patch 28 corresponds to an elongated second strip 13 (i.e., an elongated susceptor 12) of the finished aerosol-generating article 2 described above with reference to Figures 7a and 7b.

[0078] [Applying a susceptor patch] The susceptor patches 28 provided by the susceptor cutting unit 48 can be applied to the surface of the continuous web 34 of aerosol-generating substrate 10 so that there is a constant, predetermined spacing 74 between the edges of each successive susceptor patch 28, as shown, for example, in Figures 8b and 4. The constant, predetermined spacing 74, which can be, for example, 1 mm to 20 mm, is achieved in the same manner as described above in connection with the apparatus 30 and corresponding method.

[0079] The susceptor patches 28 coated with adhesive 47 are successively adhered to the flat surface of the continuous web 34 of aerosol-generating substrates 10 substantially along the centerline 118. Exposed side regions 190 of the continuous web 34 of aerosol-generating substrates are thereby formed on both sides of the susceptor patches 28 (see FIG. 8b ) because, as described above, the continuous web 34 of aerosol-generating substrates 10 is substantially wider than the susceptor patches 28. Adjacent susceptor patches 28 are also spaced apart in the direction of travel of the continuous web 34 of aerosol-generating substrates 10 by a constant, predetermined spacing 74 between the edges of the susceptor patches 28, which occurs when the susceptor patches 28 are formed in the susceptor cutting unit 48.

[0080] To ensure sufficient adhesion between the susceptor patches 28 and the substantially flat surface of the continuous web 34 of aerosol-generating substrate 10, the susceptor patches 28 can be pressed against the substantially flat surface by a cam roller 76, shown schematically in FIG. 8 a. The rotation of the cam roller 76 is synchronized with the movement of the continuous web 34 of aerosol-generating substrate 10 so that a pressing force is applied to successive susceptor patches 28 but not to spaced areas between successive susceptor patches 28.

[0081] Depending on the properties of the adhesive 47 applied by the adhesive application unit 46 to the continuous web of susceptor material 40 (and thus to the susceptor patches 28), the continuous web 34 of aerosol-generating substrate 10 and the susceptor patches 28 adhered thereto may be heated by an optional heater 50. As noted above, this serves to cure or solidify the adhesive 47, thereby ensuring a good bond between each susceptor patch 28 and the planar surface of the continuous web 34 of aerosol-generating substrate 10.

[0082] Strip Cut The continuous web 34 of aerosol-generating substrate 10, having spaced-apart susceptor patches 28 adhered to its planar surface, is fed to a strip cutting unit 52 (best shown in FIG. 9 ). The strip cutting unit 52 cuts only the exposed side regions 190 of the continuous web 34 of aerosol-generating substrate 10, without cutting the susceptor patches 28, to form a plurality of continuous aerosol-generating strips 16 along the susceptor patches 28. In one embodiment, the strip cutting unit 52 cuts the exposed side regions 190 of the continuous web 34 of aerosol-generating substrate 10 to form aerosol-generating strips 16 having a strip width of about 1 mm.

[0083] 8a and 9, the strip cutting unit 52 is a rotary cutter unit 78 and includes first and second cutting drums 80, 82. The first cutting drum 80 includes a circumferentially extending first cutting structure 84, and the second cutting drum 82 includes a circumferentially extending second cutting structure 86. The first and second cutting structures 84, 86 cooperate (e.g., intermesh) to shear-sever the exposed side regions 190 of the continuous web 34 of the aerosol-generating substrate 10 in the direction of travel of the continuous web 34 to form a continuous aerosol-generating strip 16, specifically the elongated first strip 15 shown in FIGS.

[0084] To cut only the exposed side regions 190 of the continuous web 34 of aerosol-generating substrate 10 to form the elongated first strips 15, the first and second cutting drums 80, 82 define a non-cutting region 92 therebetween that accommodates the susceptor patches 28 and the portions of the continuous web 34 of aerosol-generating substrate 10 to which the susceptor patches 28 will be adhered. In the illustrated embodiment, the first cutting drum 80 is formed without a first cutting structure 84 in the non-cutting region 92. Similarly, the second cutting drum 82 is formed without a second cutting structure 86 in the non-cutting region 92. Furthermore, because the first cutting drum 80 includes a circumferentially extending recess 94 in the surface of the non-cutting region 92, at least a portion of the susceptor patch 28 can be accommodated in the circumferentially extending recess 94 during cutting of the exposed side regions 190 of the continuous web 34 of aerosol-generating substrate 10. It will therefore be appreciated that when the exposed side regions 190 of the continuous web 34 of aerosol-generating substrates 10 are cut to form elongated first strips 15 by cooperation between the first and second cutting structures 84, 86 on the first and second cutting drums 80, 82, respectively, the central portion of the continuous web 34 of aerosol-generating substrates 10 contained in the non-cutting region 92 and not cut into strips constitutes the elongated carrier strip 17 described above with reference to Figure 7b.

[0085] [Rod formation] The aerosol-generating strips 16 formed by cutting the exposed side regions 190 of the continuous web 34 of aerosol-generating substrate 10, the elongated carrier strips 17, and the adhered susceptor patches 28 are conveyed to the rod-forming unit 56, where they are formed into a rod 88. If desired, a continuous sheet of wrapping paper (not shown) can be supplied to the rod-forming unit 56 from a supply reel (not shown), or can be supplied (again from a supply reel) to a separate wrapping unit that can be located downstream of the rod-forming unit 56. As the sheet of wrapping paper is transported and guided through the rod-forming unit 56 or a separate wrapping unit, it can be wrapped around the aerosol-generating strips 16 and the susceptor patches 28, so that the continuous rod 88 is surrounded by the wrapper 14.

[0086] [Rod cutting] The continuous rod 88 (optionally surrounded by a wrapper 14) is then transported to the rod cutting unit 58, where it is cut to length at appropriate locations to form a plurality of aerosol-generating articles 2. The aerosol-generating articles 2 formed by the rod cutting unit 58 can have a length of 5 mm to 50 mm, preferably 10 mm to 30 mm. It will be understood that this length corresponds to the length of the aerosol-generating substrate 10 described above with reference to FIGS. 7a and 7b. The continuous rod 88 is preferably repeatedly cut by the rod cutting unit 58 substantially midway between the edges of the susceptor patches 28. In this manner, the susceptor patches 28 are not cut by the rod cutting unit 58, thereby reducing wear on the cutting elements. Furthermore, because the susceptor patches 28 are shorter than the aerosol-generating strips 16, the ends of the individual susceptor patches 28 (i.e., the elongated second strips 13) are not visible at either end of the aerosol-generating articles 2 formed by the rod cutting unit 58. It will be appreciated that this type of method is particularly suitable for mass production of aerosol-generating articles 2.

[0087] [Final assembly] Further units (not shown) may be positioned downstream of the rod cutting unit 58 to provide one or more additional components, such as the mouthpiece segments 20 described above, and configured to assemble these with the individual aerosol-generating articles 2 formed by the rod cutting unit 56 to form finished aerosol-generating articles 2, for example of the type shown in Figure 7. In this case, a separate wrapping unit may be provided downstream of the rod cutting unit 58 to simultaneously wrap the assembled components to form the finished aerosol-generating article 2. The further units may form part of the apparatus 130, or may be separate, stand-alone units that form part of the final assembly line.

[0088] [Production of an aerosol-generating article (Example 2): Embodiment 2] Referring to Figure 10a, there is shown a schematic diagram of a second embodiment of an apparatus 230 and method for producing the second example aerosol-generating article 2 described above with reference to Figures 7a and 7b. Figure 10b is a plan view of the aerosol-generating substrate 10 and susceptor patch 28 as they move through the apparatus 230 in the direction of the arrows in Figure 10b. The apparatus 230 and method are similar to the apparatus 30, 130 and methods described above with reference to Figures 2-6 and 8-9, and corresponding components are identified using the same reference symbols.

[0089] The apparatus 230 includes a substrate supply reel 32 (e.g., a first bobbin) carrying a continuous web 34 of aerosol-generating substrate 10 having a substantially flat surface, and a first feed roller 36 for controlling the feeding of the continuous web 34 of aerosol-generating substrate 10. The apparatus 230 may also include a web tension adjuster and a web edge control system, as will be understood by those skilled in the art, although these additional components are not required in the context of the present disclosure and therefore have been omitted for simplicity.

[0090] The apparatus 230 further includes a rotary cutter unit 290, including, for example, a circular cutting knife, which cuts the continuous web 34 of aerosol-generating substrates 10 along one edge 19 to separate the continuous strip 218 of aerosol-generating substrates 10 from the continuous web 34. The continuous strip 218 of aerosol-generating substrates 10 corresponds to the elongated carrier strip 17 of the finished aerosol-generating article 2 described above with reference to Figures 7a and 7b. The continuous strip 218 of aerosol-generating substrates 10 has a substantially flat surface and is transported from the continuous web 34 of aerosol-generating substrates 10 by transport rollers 92, 94, for example, in an upward direction as best shown in Figure 10a, so that the continuous strip 218 and the continuous web 34 can be processed separately by the apparatus 230.

[0091] The apparatus 230 also includes a susceptor supply reel 38 (e.g., a second bobbin) that carries a continuous web 40 of susceptor material, feed rollers 42, 44 for controlling the feeding of the continuous web 40 of susceptor material, an adhesive application unit 46, and a susceptor cutting unit 48.

[0092] The apparatus 230 further includes an optional heater 50 , feed rollers 51 , a strip cutting unit 52 , feed rollers 54 , a rod forming unit 56 , and a rod cutting unit 58 .

[0093] [Preparing the susceptor patch] During operation, the continuous web 34 of aerosol-generating substrate 10 is continuously fed from the substrate supply reel 32, and a continuous strip 218 of aerosol-generating substrate 10 is separated from the edge 19 of the continuous web 34 by the rotary cutter unit 290 and transported away from the continuous web 34 by the transfer rollers 92, 94, as described above. Simultaneously, the continuous web 40 of susceptor material is continuously fed from the susceptor supply reel 38 via feed rollers 42, 44 to the adhesive application unit 46. The adhesive application unit 46 applies an adhesive 47 to the surface of the continuous web of susceptor material 40. In the illustrated example, the adhesive application unit 46 applies the adhesive 47 intermittently to the surface of the continuous web of susceptor material 40 and across the entire width of the web 40. In this manner, discrete bonded areas 60 (see Figures 3 and 11) are formed on the surface of the continuous web of susceptor material 40, and non-bonded areas 62 are formed between adjacent bonded areas 60 in the direction of movement of the continuous web of susceptor material 40.

[0094] The continuous web 40 of susceptor material is fed from the adhesive application unit 46 to a susceptor cutting unit 48, which continuously cuts the continuous web 40 of susceptor material to form a plurality of susceptor patches 28. The structure and operation of the susceptor cutting unit 48 is the same as that described above in connection with Figure 5. As will become apparent from the following description, each susceptor patch 28 corresponds to an elongated second strip 13 (i.e., an elongated susceptor 12) of the finished aerosol-generating article 2 described above with reference to Figures 7a and 7b.

[0095] 10b, the continuous web of susceptor material 40, and therefore the susceptor patches 28, have a width that is less than the width of the continuous strip 218 of aerosol-generating substrate 10. For example, the continuous web of susceptor material 40, and therefore the susceptor patches 28, can have a width of about 0.1 mm to 7 mm. In some embodiments, the susceptor patches 28 can have a length of about 5 mm to 50 mm in the direction of movement of the continuous web of susceptor material 40, and a thickness of about 1 μm to 500 μm.

[0096] To minimize contamination of the susceptor cutting unit 48 with the adhesive 47 applied to the continuous web 40 of susceptor material by the adhesive application unit 46, the susceptor cutting unit 48 cuts the continuous web 40 of susceptor material at the non-bonded regions 62, i.e., at locations between the bonded regions 60 on the surface of the continuous web 40 of susceptor material. This can be achieved by synchronizing the operation of the susceptor cutting unit 48 with the movement of the continuous web 40 of susceptor material.

[0097] [Applying a susceptor patch] The susceptor patches 28 provided by the susceptor cutting unit 48 can be applied to a flat surface of the continuous strip 218 of aerosol-generating substrate 10 so that there is a constant, predetermined spacing 74 between the edges of each successive susceptor patch 28, as shown, for example, in Figures 10b and 11. The constant, predetermined spacing 74, which can be, for example, 1 mm to 20 mm, is achieved in the same manner as described above in connection with the apparatus 30 and corresponding method.

[0098] The susceptor patches 28 coated with adhesive 47 are successively adhered to the flat surface of the continuous strip 218 of aerosol-generating substrate 10 substantially along the center of the continuous strip 218. Adjacent susceptor patches 28 are spaced apart in the direction of movement of the continuous strip 218 of aerosol-generating substrate 10 by a constant, predetermined spacing 74 between the edges of the susceptor patches 28 that occurs when the susceptor patches 28 are formed by the susceptor cutting unit 48.

[0099] To ensure sufficient adhesion between the susceptor patches 28 and the substantially flat surface of the continuous strip 218 of aerosol-generating substrate 10, the susceptor patches 28 can be pressed against the substantially flat surface by a cam roller 76, shown schematically in Figure 10a. The rotation of the cam roller 76 is synchronized with the movement of the continuous strip 218 of aerosol-generating substrate 10 so that a pressing force is applied to successive susceptor patches 28 but not to spaced areas between successive susceptor patches 28.

[0100] Depending on the properties of the adhesive 47 applied by the adhesive application unit 46 to the continuous web 40 of susceptor material (and thus to the susceptor patches 28), the continuous strip 218 of aerosol-generating substrate 10 and the susceptor patches 28 adhered thereto may be heated by an optional heater 50. As noted above, this serves to cure or solidify the adhesive 47, thereby ensuring a good bond between each susceptor patch 28 and the flat surface of the continuous strip 218 of aerosol-generating substrate 10.

[0101] Strip Cut After the continuous strip 218 of aerosol-generating substrate 10 is separated from the edge 19 of the continuous web 34 of aerosol-generating substrate 10 by the rotary cutter unit 290, the remaining web 34 of aerosol-generating substrate 10 is fed to a strip cutting unit 52 (best shown in FIG. 12 ). The strip cutting unit 52 cuts the continuous web 34 of aerosol-generating substrate 10 across its entire width to form a plurality of continuous aerosol-generating strips 16 that correspond to the elongated first strip 15 of the finished aerosol-generating article 2 described above with reference to FIGS. 7 a and 7 b. In one embodiment, the strip cutting unit 52 cuts the continuous web 34 of aerosol-generating substrate 10 to form aerosol-generating strips 16 having a strip width of about 1 mm.

[0102] 10a and 12, the strip cutting unit 52 is a rotary cutter unit 78 and includes first and second cutting drums 80, 82. The first cutting drum 80 includes a circumferentially extending first cutting structure 84, and the second cutting drum 82 includes a circumferentially extending second cutting structure 86. The first and second cutting structures 84, 86 cooperate (e.g., intermesh) to shear-sever the continuous web 34 of aerosol-generating substrate 10 in the direction of movement of the continuous web 34 to form a plurality of aerosol-generating strips 16, specifically the elongated first strips 15 shown in FIGS. 7a and 7b.

[0103] [Rod formation] The aerosol-generating strip 16, formed by cutting the continuous web 34 of aerosol-generating substrate 10, is conveyed to the rod-forming unit 56, where it is formed into a continuous rod 88. The continuous strip 218 of aerosol-generating substrate 10 having the susceptor patches 28 adhered thereto is also conveyed by the feed rollers 51 to the rod-forming unit 56 and combined with the aerosol-generating strip 16 to form the continuous rod 88. If desired, a continuous sheet of wrapping paper (not shown) can be supplied to the rod-forming unit 56 from a supply reel (not shown), or can be supplied (again from a supply reel) to a separate wrapping unit, which can be located downstream of the rod-forming unit 56. As the sheet of wrapping paper is transported and guided through the rod-forming unit 56 or a separate wrapping unit, it can be wrapped around the aerosol-generating strip 16 and the susceptor patches 28, so that the continuous rod 88 is surrounded by the wrapper 14.

[0104] [Rod cutting] The continuous rod 88 (optionally surrounded by a wrapper 14) is then transported to the rod cutting unit 58, where it is cut to length at appropriate locations to form a plurality of aerosol-generating articles 2. The aerosol-generating articles 2 formed by the rod cutting unit 58 can have a length of 5 mm to 50 mm, preferably 10 mm to 30 mm. It will be understood that this length corresponds to the length of the aerosol-generating substrate 10 described above with reference to FIGS. 7a and 7b. The continuous rod 88 is preferably repeatedly cut by the rod cutting unit 58 substantially midway between the edges of the susceptor patches 28. In this manner, the susceptor patches 28 are not cut by the rod cutting unit 58, thereby reducing wear on the cutting elements. Furthermore, because the susceptor patches 28 are shorter than the aerosol-generating strips 16, the ends of the individual susceptor patches 28 (i.e., the elongated second strips 13) are not visible at either end of the aerosol-generating articles 2 formed by the rod cutting unit 58. It will be appreciated that this type of method is particularly suitable for mass production of aerosol-generating articles 2.

[0105] [Final assembly] A further unit (not shown) may be located downstream of the rod cutting unit 58 and may provide one or more additional components, such as the mouthpiece segments 20 described above, and may be configured to assemble these with the individual aerosol-generating articles 2 formed by the rod cutting unit 56 to form finished aerosol-generating articles 2, for example of the type shown in Figure 7. In this case, a separate wrapping unit may be provided downstream of the rod cutting unit 58 so that the assembled components can be wrapped simultaneously to form the finished aerosol-generating article 2. The further unit may form part of the apparatus 230, or may be a separate, stand-alone unit forming part of the final assembly line.

[0106] While exemplary embodiments have been described in the preceding paragraphs, it should be understood that various modifications can be made to these embodiments without departing from the scope of the appended claims. Thus, the breadth and scope of the claims should not be limited to the above-described exemplary embodiments.

[0107] Any combination of the above-described features in all possible variations thereof is encompassed by the present disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.

[0108] Unless the context clearly dictates otherwise, throughout this specification and the claims, the words "comprise," "comprising," and the like are to be construed in an inclusive sense, i.e., "including but not limited to," as opposed to an exclusive or exhaustive sense.

Claims

1. A method for continuously producing aerosol-generating articles (1, 2), comprising the steps of: (i) providing a continuous web (34) or continuous strip (218) of an aerosol-generating substrate (10), said continuous web (34) or said continuous strip (218) having a substantially flat surface; (ii) providing a continuous web of susceptor material (40); (iii) intermittently applying an adhesive (47) to a surface of said continuous web (40) of susceptor material to form adhesive areas (60) on said surface; (iv) continuously cutting said continuous web (40) of susceptor material at locations between said adhesive regions (60) to form at least one susceptor patch (28); (v) adhering the at least one susceptor patch (28) to the substantially planar surface of the continuous web (34) or continuous strip (218) of aerosol-generating substrate (10); (vi) forming the continuous web (34) or continuous strip (218) of aerosol-generating substrate (10) and the susceptor patches (28) adhered to the surface thereof into a continuous rod (88); A method comprising:

2. step (iv) comprising successively cutting said continuous web (40) of susceptor material at locations between said adhesive regions (60) to form a plurality of susceptor patches (28); The method of claim 1.

3. step (iii) comprising intermittently applying the adhesive (47) to the surface of the continuous web (40) of susceptor material across substantially the entire width of the web (40) of susceptor material; The method according to claim 1 or claim 2.

4. After step (v) and before step (vi), heating the adhesive (47) to cure or harden the adhesive (47), 4. The method according to any one of claims 1 to 3.

5. step (v) comprising pressing the at least one susceptor patch (28) against the substantially flat surface of the continuous web (34) or the continuous strip (218); The method according to any one of claims 1 to 4.

6. The pressing step is performed using a cam roller (76). The method of claim 5.

7. the at least one susceptor patch (28) has a length of 5 mm to 50 mm; Preferably, said at least one susceptor patch (28) has a length of between 10 mm and 30 mm. The method according to any one of claims 1 to 6.

8. the substantially flat surface of the continuous web (34) or continuous strip (218) of aerosol-generating substrate (10) provided in step (i) comprises a centerline (118); step (v) comprising adhering said at least one susceptor patch (28) to said substantially flat surface substantially along said centerline (118); The method according to any one of claims 1 to 7.

9. step (v) comprising successively adhering the plurality of susceptor patches (28) to the substantially flat surface of the continuous web (34) or continuous strip (218) of aerosol-generating substrate (10) with a predetermined, regular spacing (74) between each successive susceptor patch (28); step (vi) comprising forming the continuous web (34) or continuous strip (218) of aerosol-generating substrate (10) and the susceptor patch (28) into a continuous rod (88); The method of claim 2.

10. (vii) cutting said continuous rod (88) to form a plurality of individual aerosol-generating articles (1, 2); The method of any one of claims 1 to 9, further comprising:

11. Each individual aerosol-generating article (1, 2) includes at least one susceptor patch (28); The method of claim 10.

12. Step (vii) comprises cutting the continuous rod (88) at locations between adjacent susceptor patches (28); A method according to claim 10 or claim 11 when dependent on claim 9.

13. Step (vii) comprises cutting the continuous rod (88) substantially midway between adjacent susceptor patches (28); The method of claim 12.

Images