Aerosol products

Abstract

The aerosol product article (1) comprises a plurality of elongated first strips (15) containing an aerosol-generating material, a plurality of elongated second strips (13) containing an inductively heatable susceptor material, and at least one elongated carrier strip (17) to which each of the plurality of elongated second strips (13) is attached. The at least one elongated carrier strip (17) is folded along one or more fold lines (7) to form two or more elongated carrier regions (17a, 17b, 17c), and one or more of the plurality of elongated second strips (13) are attached to each of the elongated carrier regions (17a, 17b, 17c). The first elongated strips (15), the second elongated strips (13), and the at least one elongated carrier strip (17) are configured to form a rod-shaped aerosol product article (1).

Description

[Technical Field]

[0001] The present disclosure relates generally to aerosol product articles, and more particularly to aerosol product articles for use with aerosol generating devices for heating the aerosol product article to generate an aerosol for inhalation by a user. The present disclosure is particularly applicable to aerosol product 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 or warm aerosol-generating materials to generate an aerosol for inhalation by the user.

[0003] Commonly available risk reduction or risk modification devices are substrate-heated aerosol-generating devices or so-called heated non-combustion devices. 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, with or without burning the aerosol-generating substrate, generates a vapor that typically cools and condenses to form an aerosol for inhalation by a 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 within 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 to the aerosol-generating substrate, for example, by conduction, and as the aerosol-generating substrate heats, aerosol is generated.

[0005] The characteristics of the aerosol generated by an aerosol generating device depend on several factors, including the structure of the aerosol product article used with the aerosol generating device. Therefore, it is desirable to provide an aerosol product article that allows for optimization of the characteristics of the aerosol generated during use of the article. It is also generally desirable to provide an aerosol product article that can be easily and consistently mass-produced. Summary of the Invention [Means for solving the problem]

[0006] According to a first aspect of the present disclosure, a plurality of elongated first strips containing an aerosol-generating material; a plurality of elongated second strips comprising an inductively heatable susceptor material; at least one elongated carrier strip having a plurality of elongated second strips each attached thereto; at least one elongated carrier strip folded along one or more fold lines to form two or more elongated carrier regions, one or more of the plurality of elongated second strips attached to each of the elongated carrier regions; The first elongated strip, the second elongated strip, and the at least one elongated carrier strip are configured to form a rod-shaped aerosol product article.

[0007] The aerosol-producing article is for use with an aerosol-generating device that heats an aerosol-generating material without burning the aerosol-generating material to volatilize at least one component of the aerosol-generating material, 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 fine solid particles or liquid droplets suspended in air or another gas. However, it should be noted that the terms "aerosol" and "vapor" may be used interchangeably herein, particularly with respect to the form of inhalable medium produced for inhalation by a user.

[0009] The combination of a first elongated strip (aerosol generation strip) and multiple second elongated strips (susceptor strips) within the aerosol product article provides effective heat transfer from the second elongated strips to the first elongated strip during use of the aerosol product article in an aerosol generation device. Providing one or more carrier regions on the elongated carrier strip to which the second elongated strips are attached facilitates positioning of the second elongated strip relative to the first elongated strip, further ensuring uniform and effective heat transfer from the second elongated strips to the first elongated strip. Effective and uniform heating of the first elongated strips, and therefore reliable vapor generation, is achieved. Aerosol product articles according to the present disclosure are also efficient to manufacture and relatively easy to mass-produce.

[0010] The one or more folds may extend substantially in the longitudinal direction of the aerosol product article. Accordingly, the elongated second strip extends correspondingly in the longitudinal direction of the aerosol product article. This may facilitate uniform heating of the elongated first strip, which may also extend substantially in the longitudinal direction. This may facilitate manufacturing of the aerosol product article.

[0011] One or more of the elongated second strips may be adhered to each elongated carrier region, thus providing a secure connection between each elongated second strip and its corresponding elongated carrier region. This may be particularly advantageous during the manufacture of the aerosol product, for example, while folding the elongated carrier strip along one or more folds, to ensure that the elongated second strip does not become detached from its corresponding elongated carrier region while the elongated carrier strip is being folded.

[0012] At least one elongated carrier strip may be a Z-shaped carrier strip. The Z-shaped carrier strip may define three elongated carrier regions. This shape may facilitate heat transfer from the plurality of elongated second strips to the plurality of elongated first strips, thereby ensuring that the plurality of elongated first strips are heated evenly and hot and cold spots in the aerosol product are avoided.

[0013] Each of the plurality of elongated first strips may have a width that is smaller than the width of each of the plurality of elongated second strips. This can facilitate vapor generation by allowing multiple elongated first strips to be provided in the aerosol product article. Manufacture of the aerosol product article can also be facilitated.

[0014] Each of the plurality of elongated second strips may have a width that is less than the width of the corresponding elongated carrier region to which it is attached, which may help ensure that the elongated second strips do not fold or deform while the elongated carrier strip is being folded along one or more fold lines.

[0015] In some embodiments, at least one elongated carrier strip may define at least a first region and a second region within the cross-section of the aerosol product article. Both the first region and the second region may include a plurality of elongated first strips. This may facilitate vapor generation by allowing multiple elongated first strips to be provided within the first region and the second region.

[0016] Each of the plurality of elongated first strips may have a distal end, and each of the plurality of elongated second strips may have a distal end. The distal ends of the elongated first strips may form the distal end of the aerosol product article. The distal ends of the elongated second strips may be disposed inward from the distal end of the elongated first strip. For example, the length of each of the elongated second strips may be smaller than the length of each of the elongated first strips. In this configuration, the distal ends of the elongated second strips (susceptor strips) are not visible at the distal end of the aerosol product article, which may improve user acceptance of the aerosol product article. Furthermore, because the second elongated strip (susceptor strip) is completely embedded in the first elongated strip (aerosol-generation strip), the second elongated strip is completely surrounded by the first elongated strip, allowing for more efficient generation of aerosol or vapor, thus maximizing heat transfer from the second elongated strip to the first elongated strip.

[0017] The length of the at least one elongate carrier strip may be equal to the length of each of the elongate first strips, which may facilitate manufacturing of the aerosol product.

[0018] The at least one elongated carrier strip may include an aerosol-generating material, which may facilitate manufacturing of the aerosol product article and may enable maximum vapor generation during use of the aerosol product article due to heating of both the plurality of elongated first strips and the at least one elongated carrier strip by heat transfer from the elongated second strip.

[0019] The elongated first strip may have a number of different orientations within the cross-section of the rod-shaped aerosol product article, which may help ensure uniform heat transfer from the elongated second strip to the elongated first strip, and therefore may enable the production of a maximum amount of vapor during use of the aerosol product article.

[0020] Each of the plurality of elongated second strips may have a thickness of 1.0 μm to 500 μm, and in some cases 10 μm to 100 μm. Each of the plurality of elongated second strips may have a thickness of 50 μm. Elongated second strips (susceptor strips) having these thickness dimensions may be particularly suitable for induction heating during use of the aerosol product article, and may also facilitate production of the aerosol product article.

[0021] Each of the plurality of elongated first strips may have a length of 5.0 mm to 50 mm, and in some cases 10 mm to 30 mm. Each of the plurality of elongated first strips may have a length of 20 mm.

[0022] Each of the plurality of elongated first strips may have a thickness of 50 μm to 500 μm, and in some cases 150 μm to 300 μm. Each of the plurality of elongated first strips may have a thickness of 220 μm.

[0023] Each of the plurality of elongated first strips may have a width of 0.1 mm to 5.0 mm, and in some cases 0.5 mm to 2.0 mm. Each of the plurality of elongated first strips may have a width of 1.0 mm. These width dimensions ensure that the aerosol product includes an optimal number of elongated first strips that allow for uniform airflow through the aerosol product and the production of an acceptable amount of vapor or aerosol. If the width of the elongated first strips is too small, the strength of the strips may be reduced, which may result in difficulty in mass-producing the aerosol product.

[0024] The inductively heatable susceptor material may include a metal. Typically, the metal is selected from the group consisting of stainless steel and carbon steel. However, the inductively heatable susceptor material may include any suitable material, including, 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. When an electromagnetic field is applied in the vicinity of the aerosol product article during use in the aerosol generating device, the elongated second strip (susceptor strip) may generate heat due to energy conversion from the electromagnetic field to heat as a result of eddy currents and magnetic hysteresis losses.

[0025] The aerosol-forming material may be any type of solid or semi-solid material. Exemplary types of aerosol-forming solids include powders, granules, pellets, shreds, strands, particles, gels, strips, loose-leaf, cut-leaf, cut-filler, porous materials, foam materials, or sheets. The aerosol-forming material may include plant-derived materials, particularly tobacco materials. The aerosol-forming material may advantageously include reconstituted tobacco, for example, including tobacco and any one or more of cellulose fiber, tobacco stem fiber, and inorganic fillers such as CaCO3.

[0026] Accordingly, an aerosol-generating device intended for use with an aerosol-producing article may be referred to as a "heated tobacco device," "heated-non-combustible tobacco device," "device for vaporizing tobacco products," etc., and the device is to be interpreted as a device suitable for achieving these effects. The features disclosed herein are equally applicable to devices designed to vaporize any aerosol-generating substrate.

[0027] The aerosol product may be surrounded by a paper wrapper.

[0028] The aerosol product article may be substantially stick-shaped and generally resemble a cigarette having a tubular region with aerosol-generating substrates arranged in a suitable configuration. The aerosol product article may include a filter segment, e.g., comprising cellulose acetate fibers, at the proximal end of the aerosol product article. The filter segment may constitute a mouthpiece filter and may be coaxially aligned with the aerosol-generating substrate formed by a plurality of elongated first strips. Some designs may include one or more vapor collection regions, cooling regions, and other structures. For example, the aerosol product 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 strips (the elongated first strip and preferably at least one elongated carrier strip) to cool and condense, forming an aerosol with suitable properties for a user to inhale, for example, through the filter segment.

[0029] The aerosol-forming material may include an aerosol-forming agent. Examples of aerosol-forming agents include polyhydric alcohols, such as glycerin or propylene glycol, and mixtures thereof. Typically, the aerosol-forming material may have an aerosol-forming agent content of about 5% to about 50% by dry weight. In some embodiments, the aerosol-forming material may have an aerosol-forming agent content of about 10% to about 20% by dry weight, and in some cases about 15% by dry weight.

[0030] Upon heating, the aerosol-forming material may release volatile compounds, which may include flavor compounds such as nicotine or tobacco flavorings. [Brief explanation of the drawings]

[0031] [Figure 1a] 1 is a schematic cross-sectional side view of one embodiment of an aerosol product; [Figure 1b] FIG. 1b is an enlarged schematic cross-sectional view taken along line AA in FIG. 1a. [Figure 2a] 1 is a schematic diagram of a first embodiment of an apparatus and method for producing the aerosol product shown in FIGS. 1a and 1b. [Figure 2b] 2b is a plan view of the aerosol-generating substrate and susceptor strip as they move through the apparatus shown in FIG. 2a in the direction indicated by the arrows; FIG. [Figure 3] FIG. 2 is a plan view of a cross section of a continuous web of susceptor material showing adhesive and non-adhesive regions. [Figure 4] 2b illustrates the components of the apparatus and the function of the method of FIG. 2a, schematically showing the formation of susceptor patches and susceptor strips from a continuous web of susceptor material, and the application of the susceptor strips 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. 1B is a schematic diagram of a second embodiment of an apparatus and method for producing the aerosol product shown in FIGS. 1a and 1b. [Figure 7b] 7b is a plan view of the aerosol-generating substrate and susceptor strip as they move through the apparatus shown in FIG. 7a in the direction indicated by the arrows. [Figure 8] 7b illustrates the components of the apparatus and the function of the method of FIG. 7a, which schematically shows the formation of susceptor patches and susceptor strips from a continuous web of susceptor material, and the application of the susceptor strips to the surface of a continuous strip of aerosol-generating substrate. [Figure 9] FIG. 7b is a schematic diagram of a strip cutting unit of the apparatus of FIG. 7a; DETAILED DESCRIPTION OF THE INVENTION

[0032] Embodiments of the present disclosure will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0033] 1a and 1b, an example of an aerosol product article 1 for use with an aerosol generating device is shown, the aerosol product article including an induction heating system to inductively heat the aerosol product article, 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 product 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.

[0034] The aerosol product article 1 comprises 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 material that is substantially electrically non-conductive and non-magnetically permeable. In the illustrated example, the wrapper 14 is a paper wrapper, which may comprise tobacco paper.

[0035] The aerosol product 1 may have an overall length of 30 mm to 100 mm, optionally 50 mm to 70 mm, measured between the distal end 11a and the proximal (mouth) end 11b. The aerosol product 1 may have an overall length of approximately 55 mm. The aerosol-generating substrate 10 may have an overall length of 5.0 mm to 50 mm, optionally 10 mm to 30 mm, measured between the first end 10a and the second end 10b. The aerosol-generating substrate 10 may have an overall length of approximately 20 mm. The aerosol product 1 may have a diameter of 5.0 mm to 10 mm, optionally 6.0 mm to 8.0 mm. The aerosol product 1 may have a diameter of approximately 7.0 mm.

[0036] The aerosol-generating substrate 10 comprises a plurality of elongated first strips 15 containing an 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 product article 1. The elongated first strips 15 are typically free of folds in the longitudinal direction, ensuring that the airflow path is uninterrupted and that uniform airflow through the article 1 can be achieved.

[0037] The inductively heatable susceptor 12 includes a plurality of elongated second strips 13 comprising an 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-producing 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. As can be clearly seen in FIG. 1b, each elongated first strip 15 has a width that is smaller than the width of each elongated second strip 13.

[0038] The aerosol product 1 includes an elongated carrier strip 17 oriented substantially in the longitudinal direction of the aerosol product 1. The elongated carrier strip 17 has a plurality of folds 7 extending substantially in the longitudinal direction of the aerosol product 1, and the elongated carrier strip 17 is folded along the folds 7 to define elongated carrier regions 17a, 17b, and 17c. In the illustrated example, the elongated carrier strip 17 is configured as a substantially Z-shaped carrier strip 17 having two folds 7, defining three separate elongated carrier regions 17a, 17b, and 17c. However, it will be understood that other configurations of the elongated carrier strip 17 are fully within the scope of the present disclosure, provided that the elongated carrier strip 17 has at least two elongated carrier regions 17a, 17b. For example, an elongated carrier strip 17 having two elongated carrier regions 17a, 17b can be configured as a V-shaped carrier strip 17 or an L-shaped carrier strip 17.

[0039] The elongated carrier strip 17 contains the aerosol-generating material and thus constitutes a further aerosol-generating strip 16. The elongated carrier strip 17 has the same length as the elongated first strip 15, and therefore all of the aerosol-generating strips 16 in the aerosol product article 1 have the same length.

[0040] The elongated second strips 13 are adhered to the elongated carrier strips 17. More specifically, as can be clearly seen in Figure lb, one elongated second strip 13 is adhered to each of the elongated carrier regions 17a, 17b, 17c. In the illustrated example, each of the plurality of elongated second strips 13 has a width that is smaller than the width of the corresponding elongated carrier region 17a, 17b, 17c to which the elongated second strip 13 is attached.

[0041] The first elongated strips 15, the second elongated strips 13, and the carrier strips 17 are configured to form a substantially rod-shaped aerosol product article 1, and the first elongated strips 15 can be randomly distributed across the cross-section of the rod-shaped aerosol product article 1 such that they have a plurality of different orientations within the cross-section of the aerosol product article 1. Although not apparent from FIG. 1b, 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 a fewer number of the first elongated strips 15 are shown for illustrative purposes only. The second elongated strips 13 and the carrier strips 17 are generally centrally positioned within the cross-section of the aerosol-generating substrate 10 and, therefore, the aerosol product article 1. Such a configuration can help ensure, for example, that there is uniform heat transfer from the second elongated strips 13 to the first elongated strips 15.

[0042] As best seen in Figure lb, the centrally located elongated carrier strip 17 and the elongated second strips 13 adhered to the elongated carrier regions 17a, 17b, 17c can be considered to define at least a first region 5 and a second region 6 within the cross-section of the aerosol-generating substrate 10 and, therefore, within the cross-section of the aerosol product article 1. Both the first region 5 and the second region 6 include a plurality of elongated first strips 15.

[0043] As best seen in FIG. 1a, each of the plurality of elongated first strips 15 has a distal end 15a, and each of the plurality of elongated second strips 13 has 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 product article 1. 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 susceptor 12) is not visible at the distal end 11a of the aerosol product article 1.

[0044] The aerosol product article 1 comprises a mouthpiece segment 20 disposed downstream of an aerosol-generating substrate 10. The aerosol-generating substrate 10 and the mouthpiece segment 20 are coaxially aligned within a wrapper 14, which holds the components together to form the rod-shaped aerosol product article 1.

[0045] In the illustrated embodiment, the mouthpiece segment 20 comprises the following components, sequentially arranged in a coaxial alignment downstream, i.e., from the distal end 11 a to the proximal (mouth) end 11 b of the aerosol product 1: a cooling segment 22, a central hole segment 23, and a filter segment 24. The cooling segment 22 comprises a hollow paper tube 22 a having a thickness greater than that of the paper wrapper 14. The central hole segment 23 may contain a hardened admixture containing cellulose acetate fibers and a plasticizer and functions to increase the strength of the mouthpiece segment 20. The filter segment 24 typically contains cellulose acetate fibers and functions as a mouthpiece filter. As heated vapor flows from the aerosol-generating substrate 10 toward the proximal (mouth) end 11 b of the aerosol product 1, the vapor cools and condenses as it passes through the cooling segment 22 and the central hole segment 23, forming an aerosol with suitable properties for inhalation by a user through the filter segment 24.

[0046] 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.

[0047] The elongated first strip 15 and the elongated carrier strip 17 typically contain an aerosol-forming agent, such as glycerin or propylene glycol. Typically, the elongated first strip 15 and the elongated carrier strip 17 have an aerosol-forming agent content of about 5% to about 50% on a dry weight basis. When heated, the elongated first strip 15 and the elongated carrier strip 17 release volatile compounds, including, in some cases, nicotine or flavor compounds such as tobacco flavorings.

[0048] During use of the article 1 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, causing them to release one or more volatile compounds and thus generate 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 suitable properties for inhalation by a user through the filter segment 24.

[0049] We will now describe apparatus 30, 230 and methods suitable for producing aerosol products according to the present disclosure, such as the aerosol product 1 described above with reference to Figures 1a and 1b.

[0050] [Production of an aerosol product: embodiment 1] Referring to Figure 2a, there is shown a schematic diagram of an apparatus 30 and method for producing the aerosol product 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 strip 18 as they move through the apparatus 30 in the direction of the arrows in Figure 2b.

[0051] The apparatus 30 comprises a substrate supply reel 32 (e.g., a first bobbin) supporting a continuous web 34 of aerosol-generating substrate 10 having a substantially flat surface relative to a centerline 118, and a first supply roller 36 for controlling the supply 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 have therefore been omitted for simplicity.

[0052] The apparatus 30 includes a susceptor supply reel 38 (e.g., a second bobbin) supporting a continuous web 40 of susceptor material, supply rollers 42, 44 for controlling the supply of the continuous web 40 of susceptor material, an adhesive applicator unit 46, a first susceptor cutting unit 48, and a second susceptor cutting unit 49.

[0053] Apparatus 30 further comprises an optional heater 50 , a strip cutting unit 52 , a feed roller 54 , a strip folding unit 55 , a rod forming unit 56 , and a rod cutting unit 58 .

[0054] [Preparation of susceptor strips] In 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 supply rollers 42, 44 to the adhesive applicator unit 46. The adhesive applicator unit 46 applies an adhesive 47 to the surface of the continuous web of susceptor material 40. In the illustrated example, the adhesive applicator unit 46 applies the adhesive 47 to the surface of the continuous web of susceptor material 40 intermittently across the entire width of the web 40. In this manner, discrete adhesive regions 60 (see FIGS. 3 and 4 ) are formed on the surface of the continuous web of susceptor material 40, and adhesive-free regions 62 are formed between adjacent adhesive regions 60 in the direction of travel of the continuous web of susceptor material 40.

[0055] The continuous web 40 of susceptor material is fed from the adhesive applicator unit 46 to a first susceptor cutting unit 48, which continuously cuts the continuous web 40 to form a plurality of susceptor patches 28 (see FIG. 4). The continuous web 40 of susceptor material, and therefore the susceptor patches 28, have a width 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 therefore 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.

[0056] To minimize contamination of the first susceptor cutting unit 48 with the adhesive 47 applied to the continuous web 40 of susceptor material by the adhesive applicator unit 46, the first susceptor cutting unit 48 cuts the continuous web 40 of susceptor material at adhesive-free regions 62. The adhesive-free regions are located between the adhesive regions 60 on the surface of the continuous web 40 of susceptor material (see FIG. 4). This can be achieved by synchronizing the operation of the first susceptor cutting unit 48 with the movement of the continuous web 40 of susceptor material.

[0057] 5, the first susceptor cutting unit 48 includes a rotary cutting unit 64 comprising 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 about its periphery. The support drum 66 is typically a suction drum, and the continuous web of susceptor material 40 and 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, about its periphery, which cooperate with (e.g., extend into) the circumferentially spaced recesses 70 during synchronous counter-rotation of both the support drum 66 and the cutting drum 68, as indicated by the arrows in FIG. 5. This results in successive shear severing of the continuous web 40 of susceptor material to form a plurality of susceptor patches 28 .

[0058] A second susceptor cutting unit 49 is positioned downstream of the first susceptor cutting unit 48 and cuts each susceptor patch 28 into a plurality of susceptor strips 18, and in the illustrated embodiment, into three susceptor strips 18 as best seen in Figure 2b. As will become apparent from the description below, each susceptor strip 18 corresponds to an elongated second strip 13 (i.e., an elongated susceptor 12) in the finished aerosol product article 1 described above with reference to Figures 1a and 1b.

[0059] [Application of susceptor strips] The susceptor strips 18 provided by the second susceptor cutting unit 49 can be applied to the surface of the continuous web 34 of the aerosol-generating substrate 10 so that there is a constant, predetermined spacing 74 between the edges of each successive set of susceptor strips 18 in the longitudinal (i.e., travelling) direction of the continuous web 34, as shown, for example, in FIGS. 2b and 4, and so that there is a small lateral spacing between the susceptor strips 18 in the transverse (width) direction of the continuous web 34, as shown in FIG. 2b. The constant, predetermined spacing 74 between the edges of the susceptor strips 18 can be between 1.0 mm and 20 mm. The constant, predetermined spacing 74 can be approximately 5.0 mm. To create a consistent, predetermined spacing 74 between the edges of adjacent susceptor strips 18 formed by cutting successive susceptor patches 28, the first susceptor cutting unit 48 allows relative motion between the continuous web of susceptor material 40, supported by the support drum 66, and the support drum 66 for a predetermined period of time immediately after the continuous web of susceptor material 40 is cut by the cutting drum 68 to form the susceptor patches 28. This relative motion allows the continuous web of susceptor material 40 to remain stationary or to travel at a reduced speed for a short period of time after the susceptor patches 28 are cut from the continuous web of susceptor material 40. Relative movement between the continuous web of susceptor material 40 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 of susceptor material 40, while at the same time maintaining sufficient suction force between the already-cut susceptor patch 28 and the support drum 66 to ensure that there is no relative movement between the susceptor patch 28 and the support drum 66.In this manner, the susceptor patches 28 cut from the continuous web 40 of susceptor material by the first susceptor cutting unit 48 are transported at a greater speed and for a shorter period of time than the continuous web 40 of susceptor material from which the susceptor patches 28 were cut, thereby creating a desired, constant, predetermined spacing 74 between the edges of adjacent susceptor patches 28, and therefore between the susceptor strips 18 formed by the second susceptor cutting unit 49, by virtue of cutting the spaced apart susceptor patches 28 supplied by the first susceptor cutting unit 48.

[0060] The susceptor strips 18, with the adhesive 47 applied thereto, are continuously and continuously adhered to the flat surface of the continuous web 34 of aerosol-generating substrate 10 substantially along the centerline 118. This results in exposed side regions 90 of the continuous web 34 of aerosol-generating substrate 10 on both sides of the susceptor strips 18 (see FIG. 2b). This is because, as noted above, the continuous web 34 of aerosol-generating substrate 10 is substantially wider than the susceptor patches 28 and, therefore, each set of adhered susceptor strips 18. Adjacent sets of susceptor strips 18 are also spaced apart in the direction of travel of the continuous web 34 of aerosol-generating substrate 10 by a constant, predetermined distance 74 between the edges of the susceptor strips 28, which is created when the susceptor patches 28 are formed in the first susceptor cutting unit 48.

[0061] To ensure that sufficient adhesion exists between the susceptor strips 18 and the substantially flat surface of the continuous web 34 of aerosol-generating substrate 10, the susceptor strips 18 can be pressed onto the substantially flat surface by a cam roller 76, shown schematically in Figure 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 the pressing force is applied to successive susceptor strips 18, rather than to spaced-apart areas between successive susceptor strips 18.

[0062] Depending on the properties of the adhesive 47 applied by the adhesive applicator unit 46 to the continuous web of susceptor material 40 (and thus to the susceptor strips 18), the continuous web 34 of aerosol-generating substrate 10 and the susceptor strips 18 adhered thereto can be heated by an optional heater 50. This heating can help cure or harden the adhesive 47, thereby ensuring a good bond between the susceptor strips 18 and the flat surface of the continuous web 34 of aerosol-generating substrate 10. The heating temperature must be carefully selected based on the properties of both the aerosol-generating substrate 10 and the adhesive 47 to ensure sufficient heating to cure or harden the adhesive 47 while simultaneously avoiding or at least minimizing the release of volatile components from the aerosol-generating substrate 10.

[0063] Strip Cut The continuous web 34 of aerosol-generating substrate 10, with longitudinally spaced sets of susceptor strips 18 adhered to its planar surface, is fed to a strip cutting unit 52. The strip cutting unit 52 cuts only the exposed side regions 90 of the continuous web 34 of aerosol-generating substrate 10, without cutting the susceptor strips 18, to form a plurality of continuous aerosol-generating strips 16 parallel to the susceptor strips 18. In one embodiment, the strip cutting unit 52 cuts the exposed side regions 90 of the continuous web 34 of aerosol-generating substrate 10 to form aerosol-generating strips 16 having a strip width of approximately 1 mm.

[0064] 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 formation 84, and the second cutting drum 82 includes a circumferentially extending second cutting formation 86. The first and second cutting formations 84, 86 cooperate (e.g., intermesh) to shear-cut exposed side regions 90 of the continuous web 34 of the aerosol-generating substrate 10 in the direction of travel of the continuous web 34 to form continuous aerosol-generating strips 16, specifically the elongated first strips 15 illustrated in FIGS. 1a and 1b.

[0065] To cut only the exposed side regions 90 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 corresponding to the susceptor strips 18 (i.e., the elongated second strips 13) and the portion of the continuous web 34 of aerosol-generating substrate 10 to which the susceptor strips 18 will be adhered. In the illustrated embodiment, the first cutting drum 80 is formed without providing the first cut formations 84 in the non-cutting region 92. Similarly, the second cutting drum 82 is also formed without providing the second cut formations 86 in the non-cutting region 92. Furthermore, the first cutting drum 80 includes a circumferentially extending recess 94 in its surface in the non-cutting region 92, so that at least a portion of the susceptor strip 18 can be accommodated in the circumferentially extending recess 94 during cutting of the exposed side regions 90 of the continuous web 34 of aerosol-generating substrate 10. It will therefore be appreciated that, thanks to cooperation between the first cutting formations 84 and the second cutting formations 86 on the first cutting drum 80 and the second cutting drum 82, respectively, when the exposed side regions 90 of the continuous web 34 of aerosol-generating substrate 10 are cut to form the elongated first strips 15, the central portion of the continuous web 34 of aerosol-generating substrate 10 that is accommodated in the non-cutting region 92 and that has not been cut into strips constitutes the elongated carrier strip 17 described above with reference to FIG. 1b.

[0066] [Strip folding and rod structure] The first elongated strips 15 (i.e., aerosol-generating strips 16), the elongated carrier strips 17, and the adhered second elongated strips 13 (i.e., susceptor strips 18) formed by cutting the exposed side regions 90 of the continuous web 34 of aerosol-generating substrate 10 are conveyed to a strip folding unit 55, which folds the elongated carrier strips 17 along fold lines 7 to form the Z-shaped carrier strip 17 described above, having elongated carrier regions 17a, 17b, and 17c to which the adhered second elongated strips 13 are adhered. The first elongated strips 15 and the Z-shaped carrier strip 17 with the adhered second elongated strips 13 are then conveyed to a rod-forming unit 56, where they are formed into a continuous rod 88.

[0067] If desired, a continuous sheet of wrapper paper (not shown) can be supplied to 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 rod-forming unit 56. As the sheet of wrapper paper is conveyed and directed through rod-forming unit 56 or the separate wrapping unit, the wrapper paper can be wrapped around elongated first strip 15, Z-shaped carrier strip 17, and adhered elongated second strip 13 such that a continuous rod 88 is surrounded by wrapper 14.

[0068] [Rod cutting] The continuous rod 88 (optionally surrounded by a wrapper 14) is then conveyed to the rod cutting unit 58, where it is cut to length at appropriate locations to form a plurality of aerosol product articles 1. The aerosol product articles 1 formed by the rod cutting unit 58 may have a length of 5.0 mm to 50 mm, and in some cases 10 mm to 30 mm. The aerosol product articles 1 formed by the rod cutting unit 58 may have a length of 20 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 at the midpoint between the ends of the longitudinally spaced apart elongated second strips 13 (i.e., susceptor strips 18). In this way, the elongated second strips 13 are not cut by the rod cutting unit 58, thereby reducing wear on the cutting elements. Furthermore, because the second elongated strip 13 is shorter than the aerosol-generation strip 16, the ends of the second elongated strip 13 (i.e., the susceptor strip 18) are not visible at either end of the aerosol product article 1 formed by the rod cutting unit 58. It will be appreciated that this type of method is particularly suitable for mass production of the aerosol product article 1.

[0069] [Final assembly] Further units (not shown) may be located downstream of rod cutting unit 58 and may be configured to provide one or more additional components, such as mouthpiece segments 20 described above, for assembly with the individual aerosol product articles 1 formed by rod cutting unit 56 to form finished aerosol product articles 1, for example of the type shown in FIG. 1 . In this case, a separate wrapping unit may be provided downstream of rod cutting unit 58 so that the assembled components can be wound simultaneously to form the finished aerosol product articles 1. The further units may form part of apparatus 30, or may be separate, stand-alone units that form part of the final assembly line.

[0070] [Production of an aerosol product: embodiment 2] Referring to Figure 7a, there is shown a schematic diagram of a second embodiment of an apparatus 230 and method for producing the aerosol product 1 described above with reference to Figures 1a and 1b. Figure 7b is a plan view of the aerosol-generating substrate 10 and susceptor strip 18 as they move through the apparatus 230 in the direction of the arrows in Figure 7b. The apparatus 230 and method are similar to the apparatus 30 and method described above with reference to Figures 2-6, and corresponding components are designated using the same reference numerals.

[0071] The apparatus 230 comprises a substrate supply reel 32 (e.g., a first bobbin) supporting a continuous web 34 of aerosol-generating substrate 10 having a substantially flat surface, and a first supply roller 36 for controlling the supply 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 have therefore been omitted for simplicity.

[0072] The apparatus 230 further comprises 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. As described below, the continuous strip 218 of aerosol-generating substrates 10 is then folded along fold line 7 to form the elongated carrier strip 17 in the finished aerosol product 1 described above with reference to Figures 1a and 1b. The continuous strip 218 of aerosol-generating substrates 10 has a substantially flat surface and is transported away from the continuous web 34 of aerosol-generating substrates 10 by transport rollers 92, 94, for example, in an upward direction as best seen in Figure 7a, so that the continuous strip 218 and the continuous web 34 can be processed separately by the apparatus 230.

[0073] The apparatus 230 also includes a susceptor supply reel 38 (e.g., a second bobbin) supporting a continuous web 40 of susceptor material, supply rollers 42, 44 for controlling the supply of the continuous web 40 of susceptor material, an adhesive applicator unit 46, a first susceptor cutting unit 48, and a second susceptor cutting unit 49.

[0074] The apparatus 230 further comprises an optional heater 50 , a feed roller 51 , a strip folding unit 55 , a strip cutting unit 52 , a feed roller 54 , a rod forming unit 56 , and a rod cutting unit 58 .

[0075] [Preparation of susceptor strips] In 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 conveyed away from the continuous web 34 by the conveying rollers 92, 94 as described above. Simultaneously, the continuous web 40 of susceptor material is continuously fed from the susceptor supply reel 38 via the supply rollers 42, 44 to the adhesive applicator unit 46. The adhesive applicator unit 46 applies an adhesive 47 to the surface of the continuous web of susceptor material 40. In the illustrated example, the adhesive applicator unit 46 applies the adhesive 47 to the surface of the continuous web of susceptor material 40 intermittently and across the entire width of the web 40. In this manner, separate adhesive regions 60 (see Figures 3 and 8) are formed on the surface of the continuous web 40 of susceptor material, and adhesive-free regions 62 are formed between adjacent adhesive regions 60 in the direction of travel of the continuous web 40 of susceptor material.

[0076] The continuous web 40 of susceptor material is fed from the adhesive applicator unit 46 to a first susceptor cutting unit 48, which continuously cuts the continuous web 40 of susceptor material to form a plurality of susceptor patches 28 (see FIG. 8). The structure and operation of the first susceptor cutting unit 48 is similar to that described above in connection with FIG. 5.

[0077] A second susceptor cutting unit 49 is positioned downstream of the first susceptor cutting unit 48 and cuts each susceptor patch 28 into a plurality of susceptor strips 18, three susceptor strips 18 in the illustrated embodiment as best seen in Figure 7b. As will become apparent from the description below, each susceptor strip 18 corresponds to an elongated second strip 13 (i.e., an elongated susceptor 12) in the finished aerosol product article 1 described above with reference to Figures 1a and 1b.

[0078] The continuous web of susceptor material 40, and therefore the susceptor patches 28, have a width that is smaller 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 advancement of the continuous web of susceptor material 40, and a thickness of about 1 μm to 500 μm.

[0079] To minimize contamination of the first susceptor cutting unit 48 with the adhesive 47 applied to the continuous web 40 of susceptor material by the adhesive applicator unit 46, the first susceptor cutting unit 48 cuts the continuous web 40 of susceptor material at adhesive-free regions 62. The adhesive-free regions are located between the adhesive regions 60 on the surface of the continuous web 40 of susceptor material (see FIG. 8). This can be achieved by synchronizing the operation of the first susceptor cutting unit 48 with the movement of the continuous web 40 of susceptor material.

[0080] [Application of susceptor strips] The susceptor strips 18 provided by the second susceptor cutting unit 49 can be applied to the flat surface of the continuous strip 218 of the aerosol-generating substrate 10 so that there is a constant, predetermined spacing 74 between the edges of each successive set of susceptor strips 18 in the longitudinal (i.e., travelling) direction of the continuous strip 218, as shown in, for example, FIGS. 7b and 8, and so that there is a small lateral spacing between the susceptor strips 18 in the transverse (width) direction of the continuous strip 218, as shown in FIG. 7b. The constant, predetermined spacing 74 between the edges of the susceptor strips 18 may be, for example, 1.0 mm to 20 mm. The constant, predetermined spacing 74 may be approximately 5.0 mm. The constant, predetermined spacing 74 is achieved in a manner similar to that described above in connection with the apparatus 30 and corresponding method.

[0081] The susceptor strips 18, with adhesive 47 applied thereto, are continuously and continuously 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 sets of susceptor strips 18 are spaced apart in the direction of travel of the continuous strip 218 of aerosol-generating substrate 10 by constant, predetermined spacings 74 between the edges of the susceptor patches 28, which are created when the susceptor patches 28 are formed in the first susceptor cutting unit 48.

[0082] To ensure that sufficient adhesion exists between the susceptor strip 18 and the substantially flat surface of the continuous strip 218 of aerosol-generating substrate 10, the susceptor strip 18 can be pressed onto the substantially flat surface by a cam roller 76, shown schematically in Figure 7a. The rotation of the cam roller 76 is synchronized with the movement of the continuous strip 218 of aerosol-generating substrate 10 so that the pressing force is applied to the continuous susceptor strip 18 and not to the spaced apart areas between the successive susceptor strips 18.

[0083] Depending on the properties of the adhesive 47 applied by the adhesive applicator unit 46 to the continuous web of susceptor material 40 (and thus to the susceptor strips 18), the continuous strip 218 of aerosol-generating substrate 10, and the susceptor strips 18 adhered thereto, may be heated by an optional heater 50. As discussed above, this heating may help to cure or harden the adhesive 47, thereby ensuring a good bond between the susceptor strips 18 and the flat surface of the continuous strip 218 of aerosol-generating substrate 10.

[0084] Strip Cut After the continuous strip 218 of aerosol-generating substrate 10 has been 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 seen in Figure 9). 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, which correspond to the elongated first strips 15 in the finished aerosol product 1 described above with reference to Figures 1a and 1b. 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.

[0085] 7a 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 formation 84, and the second cutting drum 82 includes a circumferentially extending second cutting formation 86. The first and second cutting formations 84, 86 cooperate (e.g., intermesh) to shear-cut the continuous web 34 of aerosol-generating substrate 10 in the direction of travel of the continuous web 34 to form a plurality of aerosol-generating strips 16, specifically the elongated first strips 15 illustrated in FIGS. 1a and 1b.

[0086] [Strip folding and rod structure] The elongated first strips (i.e., aerosol-generating strips 16) formed by cutting the continuous web 34 of aerosol-generating substrate 10 are transported to a rod-forming unit 56, where the elongated first strips are formed into a continuous rod 88.

[0087] The continuous strip 218 of aerosol-generating substrate 10 (i.e., the elongated carrier strip 17), together with the attached susceptor strip 18 (i.e., the elongated second strip 13), is conveyed by the feed roller 51 to the strip folding unit 55. The strip folding unit folds the elongated carrier strip 17 along the fold lines 7 to form the Z-shaped carrier strip 17 described above, having elongated carrier regions 17a, 17b, and 17c to which the attached elongated second strip 13 (i.e., the susceptor strip 18) is adhered. The Z-shaped carrier strip 17 with the attached elongated second strip 13 is then conveyed to the rod-forming unit 56, where it is joined with the elongated first strip 15 (i.e., the aerosol-generating strip 16) to form a continuous rod 88.

[0088] If desired, a continuous sheet of wrapper paper (not shown) can be supplied to 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 rod-forming unit 56. As the sheet of wrapper paper is conveyed and directed through rod-forming unit 56 or the separate wrapping unit, the wrapper paper can be wrapped around elongated first strip 15, Z-shaped carrier strip 17, and adhered elongated second strip 13 such that a continuous rod 88 is surrounded by wrapper 14.

[0089] [Rod cutting] The continuous rod 88 (optionally surrounded by a wrapper 14) is then conveyed to the rod cutting unit 58, where it is cut to length at appropriate locations to form a plurality of aerosol product articles 1. The aerosol product articles 1 formed by the rod cutting unit 58 may have a length of 5.0 mm to 50 mm, and in some cases 10 mm to 30 mm. The aerosol product articles 1 formed by the rod cutting unit 58 may have a length of 20 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 at the midpoints between the edges of the longitudinally spaced apart elongated second strips 13 (i.e., susceptor strips 18). In this way, the elongated second strips 13 are not cut by the rod cutting unit 58, thereby reducing wear on the cutting elements. Furthermore, because the second elongated strip 13 is shorter than the aerosol-generation strip 16, the ends of the second elongated strip 13 (i.e., the susceptor strip 18) are not visible at either end of the aerosol product article 1 formed by the rod cutting unit 58. It will be appreciated that this type of method is particularly suitable for mass production of the aerosol product article 1.

[0090] [Final assembly] Further units (not shown) may be located downstream of rod cutting unit 58 and may be configured to provide one or more additional components, such as mouthpiece segments 20 described above, for assembly with the individual aerosol product articles 1 formed by rod cutting unit 56 to form finished aerosol product articles 1, for example of the type shown in FIG. 1 . In this case, a separate wrapping unit may be provided downstream of rod cutting unit 58 so that the assembled components can be wound simultaneously to form the finished aerosol product articles 1. The further units may form part of apparatus 230, or may be separate stand-alone units that form part of the final assembly line.

[0091] 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.

[0092] 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.

[0093] 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 plurality of elongated first strips (15) containing an aerosol-forming material; a plurality of elongated second strips (13) comprising an inductively heatable susceptor material; at least one elongated carrier strip (17) to which each of the plurality of elongated second strips (13) is attached; An aerosol product (1) comprising: said at least one elongated carrier strip (17) being folded along one or more fold lines (7) to form two or more elongated carrier regions (17a, 17b, 17c); one or more of the plurality of elongated second strips (13) are attached to each of the elongated carrier regions (17a, 17b, 17c); The first elongated strip (15), the second elongated strip (13), and the at least one carrier elongated strip (17) are configured to form a rod-shaped aerosol product article (1). Aerosol product (1).

2. one or more of said elongated second strips (13) are adhered to each of said elongated carrier regions (17a, 17b, 17c); 10. The aerosol product of claim 1.

3. the at least one elongated carrier strip (17) is a Z-shaped carrier strip; 3. An aerosol product according to claim 1 or 2.

4. Each of the plurality of elongated first strips (15) has a width smaller than the width of each of the plurality of elongated second strips (13). An aerosol product according to any one of claims 1 to 3.

5. each of the plurality of elongated first strips (15) and the elongated second strips (13) has a distal end (15a, 13a); the distal end (15a) of the elongated first strip (15) forms the distal end (11a) of the aerosol product article (1); the distal end (13a) of the second elongated strip (13) is disposed inward from the distal end (15a) of the first elongated strip (15) so that the distal end (13a) of the second elongated strip (13) is not visible at the distal end (11a) of the aerosol product article (1); An aerosol product according to any one of claims 1 to 4.

6. the length of each of the elongated second strips (13) is smaller than the length of each of the elongated first strips (15); An aerosol product according to any one of claims 1 to 5.

7. the length of said at least one elongated carrier strip (17) is equal to the length of each of said elongated first strips (15); An aerosol product according to any one of claims 1 to 6.

8. the at least one elongated carrier strip (17) containing an aerosol-forming material; An aerosol product according to any one of claims 1 to 7.

9. a filter segment (24) at the proximal end of the aerosol product (1); at least one tubular segment (22, 23) upstream of said filter segment (24); Further comprising: An aerosol product according to any one of claims 1 to 8.

10. the elongated first strip (15) has a plurality of different orientations within the cross section of the rod-shaped aerosol product article (1); An aerosol product according to any one of claims 1 to 9.

11. Each of the plurality of elongated second strips (13) has a thickness of 1 μm to 500 μm, preferably 10 μm to 100 μm; An aerosol product according to any one of claims 1 to 10.

12. each of the plurality of elongated first strips (15) has a length of 10 mm to 30 mm; Preferably, each of said plurality of elongated first strips (15) has a length of 20 mm. An aerosol product according to any one of claims 1 to 11.

13. each of the plurality of elongated first strips (15) has a thickness of 150 μm to 300 μm; Preferably, each of the plurality of elongated first strips (15) has a thickness of 220 μm. An aerosol product according to any one of claims 1 to 12.

14. the aerosol-forming material comprises tobacco material; An aerosol product according to any one of claims 1 to 13.

15. the inductively heatable susceptor material comprises a metal selected from the group consisting of stainless steel and carbon steel; An aerosol product according to any one of claims 1 to 14.

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