Consumables for use in non-combustion aerosol delivery devices

Abstract

To provide: a susceptor arrangement for use in a method of manufacturing a consumable for use in a non-combustible aerosol provision device; an assembly for use in a method of manufacturing a consumable; a consumable for use in a non-combustible aerosol provision device; and a non-combustible aerosol provision system.SOLUTION: A susceptor arrangement 1 comprises first and second susceptor portions 2, and a connector 3 joining the first and second susceptor portions to each other, where the first and second susceptor portions are spaced by the connector. A method of manufacturing a consumable for use in a non-combustible aerosol provision device comprises providing the susceptor. The method further comprises: forming an assembly comprising the susceptor arrangement and an aerosol-generating material; and dividing the assembly, where the dividing comprises dividing the connector and the aerosol-generating material. According to the present disclosure, there is also provided a method of manufacturing a consumable for use in a non-combustible aerosol provision device.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a method for manufacturing a consumable for use in a non-combustion aerosol delivery device, a susceptor apparatus used in a method for manufacturing a consumable for use in a non-combustion aerosol delivery device, an assembly used in a method for manufacturing a consumable for use in a non-combustion aerosol delivery device, a consumable for use in a non-combustion aerosol delivery device, and a non-combustion aerosol delivery system. [Background technology]

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco and produce smoke during use. Attempts have been made to create products that release compounds without combustion to replace these items. Examples of such products include so-called "heat-without-combustion" products or tobacco heating devices or products, which release compounds by heating materials without burning them. The materials may be, for example, tobacco or other tobacco products, which may or may not contain nicotine. Summary of the Invention

[0003] In a first aspect of the present disclosure, there is provided a method for manufacturing a consumable for use in a non-combustion aerosol delivery device, the method comprising: providing a susceptor assembly including first and second susceptor portions and a connector joining the first and second susceptor portions to each other, the first and second susceptor portions being spaced apart from each other by the connector; forming an assembly including the susceptor assembly and an aerosol-generating material; and dividing the assembly, which includes dividing the connector and the aerosol-generating material.

[0004] The dividing optionally includes using a cutter to cut the connector.

[0005] The forming optionally includes embedding at least a portion of the susceptor device in an aerosol-generating material.

[0006] Forming optionally includes combining the susceptor device with the aerosol-generating material on a wrapper and wrapping the wrapper around the susceptor device and the aerosol-generating material.

[0007] Optionally, a susceptor device is placed on the wrapper in front of the aerosol-generating material.

[0008] Optionally, an aerosol-generating material is placed on the wrapper prior to the susceptor unit.

[0009] Optionally, the connector includes a weakened region of the susceptor device.

[0010] Optionally, the susceptor is integrally formed with the weakened region.

[0011] Optionally, the connector comprises a support to which the susceptor is secured.

[0012] Optionally, the support comprises a heating material that is heatable by penetration with a fluctuating magnetic field.

[0013] Optionally, the support does not include a heating material that can be heated by penetration with a fluctuating magnetic field.

[0014] Optionally, the substrate comprises one or more of paper, metal foil, alloy foil and aerosol-generating material.

[0015] A second aspect of the present disclosure provides a susceptor apparatus for use in a method for manufacturing a consumable for use in a non-combustion aerosol delivery device, the susceptor apparatus including first and second susceptor portions and a connector joining the first and second susceptor portions to each other, the first and second susceptor portions being spaced apart from each other by the connector.

[0016] Optionally, the connector includes a weakened region of the susceptor device.

[0017] Optionally, the susceptor portion is integrally formed with the weakened region.

[0018] Optionally, the susceptor unit includes at least one additional susceptor section and at least one additional connector, the susceptor unit being configured in a repeating sequence of susceptor section followed by connector followed by susceptor section.

[0019] Optionally, the connector includes a support to which the susceptor portion is secured.

[0020] Optionally, the susceptor unit includes at least one further susceptor part, and the first susceptor part, the second susceptor part and the at least one further susceptor part are fixed to a support.

[0021] Optionally, the susceptor portions are spaced apart from one another on a support, the support including weakened regions between the susceptor portions.

[0022] Optionally, the support comprises a heating material that is heatable by penetration with a fluctuating magnetic field.

[0023] Optionally, the support does not include a heating material that can be heated by penetration with a fluctuating magnetic field.

[0024] Optionally, the substrate comprises one or more of paper, metal foil, alloy foil and aerosol-generating material.

[0025] In some embodiments, the susceptor unit includes a plurality of first susceptor portions and a plurality of second susceptor portions.

[0026] In some embodiments, the plurality of first susceptor portions overlap in the axial direction of the susceptor unit, and / or the plurality of second susceptor portions overlap in the axial direction of the susceptor unit.

[0027] In some embodiments, the plurality of first susceptor portions are parallel to one another, for example, the longitudinal axes of the plurality of first susceptor portions may be parallel.

[0028] In some embodiments, the plurality of second susceptor portions are parallel to one another, for example, the longitudinal axes of the plurality of second susceptor portions may be parallel.

[0029] In some embodiments, the plurality of first susceptor portions extend in the same direction and / or the plurality of second susceptor portions extend in the same direction.

[0030] In some embodiments, each first susceptor portion is aligned with a corresponding second susceptor portion.

[0031] In some embodiments, the longitudinal axis of each first susceptor portion is aligned with the longitudinal axis of the corresponding second susceptor portion in a direction perpendicular to the longitudinal axis.

[0032] In some embodiments, the susceptor unit includes at least 2, 3, 4, 5, 6, 7, 8, 9, or 10 first susceptor portions. In some embodiments, the susceptor unit includes 2, 3, 4, 5, 6, 7, 8, 9, or 10 first susceptor portions.

[0033] In some embodiments, the susceptor unit includes at least 2, 3, 4, 5, 6, 7, 8, 9, or 10 second susceptor portions. In some embodiments, the susceptor unit includes 2, 3, 4, 5, 6, 7, 8, 9, or 10 second susceptor portions.

[0034] In some embodiments, a connector joins each first susceptor portion to each second susceptor portion, and each first susceptor portion is spaced from its respective second susceptor portion by the connector. The connector includes a support, and the support joins each first susceptor portion to its respective second susceptor portion. In some embodiments, the support includes a sheet material.

[0035] In some embodiments, the susceptor device includes a plurality of connectors, each connector joining a first susceptor portion to a respective second susceptor portion, and each first susceptor portion being spaced from its respective second susceptor portion by its respective connector, and in some embodiments, each connector includes a weakened region.

[0036] In some embodiments, dividing the assembly includes dividing each connector and aerosol-generating material.

[0037] In some embodiments, the connectors of the susceptor unit are spaced apart from one another.

[0038] In some embodiments, the first susceptor portions of the assembly are substantially equally spaced apart and / or the second susceptor portions of the assembly are substantially equally spaced apart.

[0039] In a third aspect of the present disclosure, there is provided an assembly for use in a method for manufacturing a consumable for use in a non-combustion based aerosol delivery device, the assembly comprising a susceptor apparatus according to the second aspect of the present disclosure and an aerosol generator in thermal contact with the susceptor apparatus, the assembly being separable by a process comprising separating the connector and the aerosol-generating material.

[0040] Optionally, the assembly includes a wrapper around the susceptor device and the aerosol-generating material.

[0041] In a fourth aspect of the present disclosure, there is provided a consumable for use in a non-combustion based aerosol delivery device, the consumable manufactured according to a method including a method according to the first aspect of the present disclosure.

[0042] In a fifth aspect of the present disclosure, there is provided a consumable for use in a non-combustion based aerosol delivery device, the consumable comprising at least one susceptor portion, a connector portion secured to or integrally formed with the or each susceptor portion, and an aerosol-generating material in thermal contact with the or each susceptor portion, the connector portion extending over at least one end of the aerosol-generating material.

[0043] Optionally, the consumable includes a susceptor device including at least one susceptor portion thereof, and the connector portion includes a weakened region of the susceptor device.

[0044] Optionally, the weakened region is integrally formed with the at least one susceptor portion.

[0045] Optionally, the connector portion includes a support to which the at least one susceptor portion is fixed.

[0046] Optionally, the or each susceptor portion is at least partially embedded in the aerosol-generating material.

[0047] Optionally, the or each susceptor portion is substantially coaxial with a central axis of the consumable.

[0048] Optionally, the support comprises a heating material that is heatable by penetration with a fluctuating magnetic field.

[0049] Optionally, the support does not include a heating material that can be heated by penetration with a fluctuating magnetic field.

[0050] Optionally, the substrate comprises one or more of paper, metal foil, alloy foil and aerosol-generating material.

[0051] Optionally, the or each susceptor portion comprises one or more materials selected from the group consisting of aluminium, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain carbon steel, mild steel, stainless steel, ferritic stainless steel, molybdenum, silicon carbide, copper and bronze.

[0052] Optionally, the or each susceptor portion comprises nickel.

[0053] Optionally, the or each susceptor portion comprises nickel coated steel.

[0054] Optionally, the susceptor device includes perforations.

[0055] Optionally, the susceptor device includes a weakened region.

[0056] Optionally, the susceptor device comprises different first and second materials.

[0057] Optionally, the or each susceptor portion comprises a first region comprising a first material and a second region comprising a second material.

[0058] Optionally, the first and second materials have different electrical and / or magnetic conductivity.

[0059] Optionally, the first material comprises a material that is heatable by the penetration of a fluctuating magnetic field and the second material comprises a material that is not heatable by the penetration of a fluctuating magnetic field or that is not substantially heatable by the penetration of a fluctuating magnetic field.

[0060] Optionally, one of the first and second materials is coated with the other of the first and second materials.

[0061] Optionally, the first material is coated with a second material.

[0062] Optionally, the first and second materials are such that, in use, when a varying magnetic field penetrates the first and second materials, a temperature difference is created between the first and second materials due to the penetration of the varying magnetic field into the first and second materials.

[0063] Optionally, the first and second materials have different thermal masses.

[0064] Optionally, the or each susceptor portion comprises a base portion and an embeddable portion for at least partially embedding in the aerosol-generating material.

[0065] Optionally, the base is substantially flat.

[0066] Optionally, the base is generally circular.

[0067] Optionally, the base comprises a material that is heatable by the penetration of a varying magnetic field.

[0068] The optional embeddable portion comprises a thermally conductive material.

[0069] Optionally, the implantable portion comprises a material that can be heated by the penetration of a varying magnetic field.

[0070] Optionally, the implantable portion comprises a material that is not heatable by the penetration of a fluctuating magnetic field, or that is not substantially heatable by the penetration of a fluctuating magnetic field.

[0071] Optionally, the implantable portion comprises a first and a second material.

[0072] Optionally, the implantable portion comprises one of the first and second materials and the base comprises the other of the first and second materials.

[0073] Optionally the or each susceptor portion comprises hollow or perforated or recessed, mesh or expanded metal.

[0074] Optionally, the or each susceptor portion comprises a pin, mesh or blade.

[0075] Optionally, the or each susceptor portion comprises a plurality of pins, meshes or blades.

[0076] Optionally, the or each susceptor portion includes a plurality of openings or recesses, the openings and / or recesses being filled with an aerosol-generating material.

[0077] Optionally, at least a portion of the or each susceptor portion is annular.

[0078] Optionally, the or each susceptor portion comprises a plurality of annular portions, preferably the annular portions of each susceptor portion are arranged substantially coaxially.

[0079] Optionally, the aerosol-generating material is non-liquid.

[0080] Optionally, the aerosol-generating material comprises tobacco.

[0081] Optionally, the susceptor extends the majority of the length of the consumable, and preferably the susceptor extends substantially the entire length of the consumable.

[0082] The features described above, including those of the susceptor and / or aerosol-generating material, are applicable to any of the disclosed embodiments described herein.

[0083] In a sixth aspect of the present disclosure, there is provided a non-combustion aerosol delivery system comprising a consumable according to the fourth aspect of the present disclosure or the fifth aspect of the present disclosure and a non-combustion aerosol delivery device for causing heating of an aerosol-generating material of the consumable and volatilizing at least one component of the aerosol-generating material, the device comprising a heating region for accommodating the consumable, and a magnetic field generator for generating a fluctuating magnetic field that penetrates a susceptor portion of the consumable when the consumable is in the heating region, causing heating of the aerosol-generating material.

[0084] Optionally, the device is for causing heating of the consumable aerosol-generating material without burning the aerosol-generating material to volatilize at least one component of the aerosol-generating material.

[0085] Optionally, the magnetic field generator comprises at least one coil.

[0086] Optionally, the coil is helical.

[0087] Optionally, the coil is a flat coil and may be a two-dimensional spiral.

[0088] Optionally, the system of the present invention includes a second coil, preferably the second coil is helical.

[0089] Optionally, the magnetic field generator is configured to generate a varying magnetic field for penetrating the base of the susceptor portion when the consumable is at least partially in the heating zone.

[0090] Optionally, the coil is configured to generate a varying magnetic field for penetrating the base of the susceptor portion when the consumable is at least partially in the heating region, and the second coil is configured to generate a varying magnetic field for penetrating the implantable portion of the susceptor portion when the consumable is at least partially in the heating region.

[0091] Optionally, the second coil extends around at least a portion of the circumference of the implantable portion of the susceptor portion.

[0092] Optionally, the susceptor portion and / or the heating material comprises one or more materials selected from the group consisting of an electrically conductive material, a magnetic material, and an electrically conductive magnetic material.

[0093] Optionally, the susceptor portion and / or the heating material comprises a metal or metal alloy.

[0094] Optionally, the susceptor portion and / or heating material comprises one or more materials selected from the group consisting of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain carbon steel, mild steel, stainless steel, ferritic stainless steel, molybdenum, silicon carbide, copper and bronze.

[0095] Optionally, the aerosol-generating material is a non-liquid material.

[0096] Optionally, the aerosol-generating material comprises tobacco.

[0097] Optionally, the aerosol-generating material is a reconstituted aerosolizable material, such as reconstituted tobacco.

[0098] Further features and advantages will become apparent from the following description of preferred embodiments of the invention, given by way of example only, with reference to the accompanying drawings.

[0099] Some embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0100] [Figure 1] 1 is a schematic diagram of a susceptor apparatus according to one embodiment. [Figure 2] 1 is a schematic diagram of a susceptor apparatus according to one embodiment. [Figure 3] 1 is a schematic diagram of a susceptor apparatus according to one embodiment. [Figure 4] 1 is a flowchart of a method according to one embodiment. [Figure 5] 1 is a schematic diagram of an assembly according to one embodiment. [Figure 6] 1 is a schematic diagram of a consumable item according to one embodiment. [Figure 7] 1 is a schematic diagram of a susceptor apparatus according to one embodiment. [Figure 8] 1 is a schematic diagram of an assembly according to one embodiment. [Figure 9] 1 is a schematic diagram of an assembly according to one embodiment. [Figure 10] 1 illustrates a non-combustion based aerosol delivery system according to one embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0101] As used herein, an "aerosol-generating material" is a material that can generate an aerosol when excited, for example, by heating, irradiation, or in some other way. The aerosol-generating material may be in the form of a solid, liquid, or gel, which may or may not contain, for example, an active agent and / or flavoring. In some embodiments, the aerosol-generating material may comprise an "amorphous solid," alternatively referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that retains a fluid, such as a liquid, within its interior. In some embodiments, the aerosol-generating material comprises from about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0102] The aerosol-generating material may include one or more active agents and / or flavorants, one or more aerosol-forming materials, and one or more other functional materials, if desired.

[0103] In some embodiments, the aerosol-generating material may comprise tobacco material, which is any material containing tobacco or a derivative thereof. The tobacco material may include one or more of powdered tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco, and / or tobacco extract. In some embodiments, the aerosol-generating material may comprise a tobacco substitute.

[0104] As used herein, a "consumable" is an item containing or consisting of an aerosol-generating material, some or all of which is intended to be consumed by a user upon use. A consumable may also include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transport component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater, that radiates heat so that the aerosol-generating material generates an aerosol upon use.

[0105] As used herein, a "susceptor" is a material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material such that the penetration of the varying magnetic field results in induction heating of the heating material. The heating material may be an electrically conductive material such that the penetration of the varying magnetic field results in magnetic hysteresis heating of the heating material. The susceptor may be both electrically conductive and magnetic, such that the heating material can be heated by both heating mechanisms.

[0106] When a susceptor is integrated into a consumable, heat is generated within the susceptor itself, rather than by conduction from an external heat source, resulting in a faster temperature rise and more uniform heat distribution within the consumable. This can be achieved, among other things, by the appropriate choice of material and geometry, and the appropriate magnitude and orientation of the varying magnetic field relative to the susceptor. Furthermore, because induction heating and magnetic hysteresis heating do not require a physical connection between the source of the varying magnetic field and the susceptor, material deposits on the susceptor, such as residue or condensation, are not an issue, allowing for greater design freedom and control over the heating regime, as well as lower costs.

[0107] During the manufacture of consumables, such as those for use in non-combustion aerosol delivery devices, an aerosol-generating material, such as tobacco, is placed in contact with paper. The paper is then wrapped around the aerosol-generating material, enclosing it to form a rod. The rod is cut to a desired length, and a filter is then attached (usually at one end of the cut rod) to form the consumable.

[0108] A susceptor may be provided within such a consumable to allow the consumable to be heated in any of the above-described ways. Conventional consumables may not include a susceptor, and therefore, cutting equipment used to cut the rod to a desired length is typically configured to completely cut through the aerosol-generating material (e.g., tobacco) and one or more layers of paper. However, if the susceptor is provided as a continuous, uniform piece (e.g., a long piece of metal with uniform dimensions and material properties) throughout the rod before it is cut to a desired length, this can cause damage to existing cutting equipment used to cut the rod to a desired length online. Furthermore, not only are the equipment unsuitable for cutting susceptors in terms of strength / robustness, but the time required to cut the rod is increased when a continuous susceptor is present, thereby affecting the production rate (and quality) of the consumable that can be produced.

[0109] FIG. 1 shows a schematic diagram of a susceptor apparatus 1 for use in a method for manufacturing a consumable for use in a non-combustion aerosol delivery device according to one embodiment. The susceptor apparatus 1 includes susceptor portions 2 and connectors 3 that join the susceptor portions 2 together. The apparatus thus shows a series of susceptor portions 2 that are physically connected to one another. The physical connection can be direct (e.g., the susceptor portions 2 are integrally formed with the connectors 3) or indirect (e.g., the susceptor portions 2 are not physically connected to one another). The susceptor portions 2 are spaced apart by the connectors 3. The connectors 3 serve several functions, such as maintaining the susceptor portions 2 at a predetermined distance from one another, allowing for easier handling of the susceptor portions 2 as a single item during manufacturing, and maintaining a uniform structure for the susceptor portions 2. For example, the connectors 3 reduce the degree to which the susceptor portions 2 can twist relative to one another so that each is positioned in roughly the same position and orientation during manufacturing of the consumable.

[0110] The term "susceptor portion" herein should be understood to mean the portion of the susceptor assembly that functions primarily or exclusively as a susceptor (or heater) when the consumable containing the susceptor portion is exposed to a varying magnetic field. In some instances, the terms "susceptor" or "individual susceptor" are used instead of susceptor portion to indicate that these are portions of the susceptor device 1 that function primarily as heaters. As discussed below, the connector 3 in some embodiments includes or consists of a material that heats when exposed to a varying magnetic field, although generally the connector's primary function is not to function as a primary heat source in some implementations.

[0111] Two susceptors 2 are shown in Figure 1. However, the susceptor apparatus 1 may be configured with any suitable number of susceptors 2, for example, 2, 3, 4, 5, or 6 susceptors 2. The susceptor apparatus 1 may include an alternating row of susceptors 2 and connectors 3. The susceptor apparatus 1 may be wound on a reel or the like for convenient storage of the susceptor apparatus 1.

[0112] As shown in Figure 1, the susceptor device 1 includes susceptors 2 and weakened regions 4 of the device 1 between the susceptors 2. The connectors 3 include or consist of the weakened regions 4. The weakened regions 4 allow the susceptors 2 to be easily separated from one another when necessary. This reduces the risk of damage to any cutting equipment used to cut the susceptor device 1 during consumable manufacturing, as described below.

[0113] The weakened region 4 may be a relatively weaker region than each of the susceptors 2. For example, the weakened region 4 may be a region of the susceptors 2 that is easier to cut than each of the susceptors 2.

[0114] Generally, the or each weakened region is a region of the susceptor device 1 that has particular characteristics that make it easier to cut the weakened region relative to other regions of the susceptor device (and particularly regions containing the susceptor). In some embodiments, the weakened region 4 is formed by providing perforations in the susceptor device 1. That is, in these embodiments, the amount of material cut in the weakened region is reduced relative to other regions of the susceptor device. Alternatively or additionally, the weakened region 4 may have different geometric characteristics (e.g., width and / or length) than the susceptor 2, as shown, for example, in FIG. 3. That is, in these embodiments, the amount of material cut in the weakened region is reduced relative to other regions of the susceptor device. In other embodiments, the weakened region 4 may alternatively or additionally comprise a different material than the susceptor 2.

[0115] 1, in some embodiments, the susceptor 2 is integrally formed with the weakened region 4. Alternatively, the susceptor 2 and connector 3 may be formed as separate components and then connected together.

[0116] FIG. 2 shows a schematic diagram of a susceptor apparatus 1 according to one embodiment. As shown in FIG. 1, the susceptor apparatus 1 includes an individual susceptor 2 and a connector 3. In the embodiment of FIG. 2, the connector 3 includes a support 5 to which the susceptor 2 is secured. The susceptor 2 may be secured to the support 5 by any suitable means, such as, but not limited to, gluing or welding. The type of securing mechanism may be selected based on the material of the support 5 and the material of the susceptor 2. In some embodiments, the susceptor 2 may be crimped to the support 5 using any suitable method, effectively securing the susceptor 2 to the support 5. In some embodiments, the susceptor 2 may be encapsulated by or embedded within the support 5. For example, the support 5 may include two layers (such as two sheets of paper) that are stuck together to capture the susceptor 2 therebetween. The support 5 helps prevent the susceptor 2 from twisting or warping and keeps the susceptor 2 flat. In some embodiments, the susceptor 2 may not be flat. The support 5 helps to maintain the shape of the susceptor 2.

[0117] In some embodiments, the susceptor device 1 has markings on at least one surface thereof. For example, markings may be provided on at least one surface of the support 5. The markings aid in monitoring the movement of the support 5 and / or the susceptor device 1 during the manufacturing process. For example, the markings may be used to determine how far the support 5 should be positioned on the consumable and / or to adjust the timing of the movement of the support 5. In some embodiments, the support 5 may be provided on or wound around a bobbin.

[0118] In some embodiments, the support 5 comprises a heating material heatable by penetration with a fluctuating magnetic field. Alternatively, the support 5 does not comprise a heating material heatable by penetration with a fluctuating magnetic field. The support 5 may comprise one or more of paper, paper, metal foil, metal alloy foil, and an aerosol-generating material. In the embodiment of FIG. 2, a single support 5 is shown. In other embodiments, more than one support 5 may be utilized. For example, two supports 5 may be secured to opposing sides of the susceptor 2 such that the susceptor 2 is sandwiched between the supports 5.

[0119] The susceptor 2 and / or heating material may comprise one or more materials selected from the group consisting of an electrically conductive material, a magnetic material, and a magnetically conductive material. In some embodiments, the susceptor and / or heating material comprises a metal or metal alloy. In some embodiments, the susceptor and / or heating material comprises one or more materials selected from the group consisting of aluminum, gold, iron, nickel, cobalt, conductive carbon, graphite, steel, plain carbon steel, mild steel, stainless steel, ferritic stainless steel, molybdenum, silicon carbide, copper, and bronze.

[0120] Figure 3 shows a schematic diagram of a susceptor apparatus 1 according to one embodiment. The susceptor apparatus 1 includes a susceptor 2 and a connector 3. The connector 3 includes a support 5. As shown in Figure 3, the support may include a weakened region along line X, which is formed by changing the geometric characteristics of the support 5.

[0121] 4 is a flowchart of a method 10 for manufacturing a consumable for use in a non-combustion-based aerosol delivery device according to one embodiment. The method 10 includes providing 11 a susceptor apparatus 1 including individual susceptors 2 and connectors 3 joining the susceptors 2 to one another. The susceptor sections 2 are spaced apart by the connectors 3. The method 10 also includes forming 12 an assembly including the susceptor apparatus 1 and an aerosol-generating material, and dividing 13 the assembly. Dividing 13 includes dividing the connectors 3 and the aerosol-generating material.

[0122] In some embodiments, dividing 13 includes using a cutter to cut the connector. The cutter may be an online component of the consumable manufacturing system or may be separate from the consumable manufacturing system. The cutter may be the same cutter used to cut the consumable to a desired length.

[0123] In some embodiments, forming 12 includes at least partially burying the susceptor device 1 in the aerosol-generating material. Forming 12 may also include completely burying the susceptor device 1 in the aerosol-generating material.

[0124] In some embodiments, forming 12 includes combining the susceptor device 1 with the aerosol-generating material on a wrapper and wrapping the wrapper around the susceptor device 1 and the aerosol-generating material. The susceptor device 1 may be placed on the wrapper before the aerosol-generating material. Alternatively, the aerosol-generating material may be placed on the wrapper before the susceptor device 1.

[0125] As mentioned above, in some embodiments, the connector 3 comprises a weakened region of the susceptor device 1. The susceptor 2 may be integrally formed with the weakened region.

[0126] In some embodiments, the connector 3 comprises a support to which the susceptor 2 is secured. The support may be made from any of the materials described above for the support.

[0127] FIG. 5 shows a schematic diagram of an assembly 20 for use in a method for manufacturing a consumable product for use in a non-combustion aerosol delivery device, according to one embodiment. The assembly 20 includes a susceptor apparatus 1 and an aerosol-generating material 21 in thermal contact with the susceptor apparatus 1. The susceptor apparatus 1 may be any susceptor apparatus described herein, such as one of the susceptor apparatuses 1 described with reference to FIGS. 1-3. The assembly 20 is separable by a process that includes separating the connector 3 and the aerosol-generating material 21. In one embodiment, the separating process forms individual objects. Each of the individual objects may be a consumable product or may be used in the manufacture of a consumable product. For example, the assembly 20 may be separable along line Y. In some embodiments, the assembly 20 includes a wrapper around the susceptor apparatus 1 and the aerosol-generating material 21.

[0128] FIG. 6 shows a schematic diagram of a consumable 30 for use in a non-combustion-based aerosol delivery device according to one embodiment. The consumable 30 includes at least one individual susceptor 31 and a connector portion 32 secured to or integrally formed with the or each susceptor 31. The consumable includes an aerosol-generating material 33 in thermal contact with the or each susceptor 31. The connector portion 32 extends to at least one end 34 of the aerosol-generating material 33. As shown in FIG. 6, in one embodiment, each connector portion 32 may extend to two opposing ends of the aerosol-generating material 33. In one embodiment, the connector portion 32 is part of a connector as described herein.

[0129] In some embodiments, consumable product 30 is manufactured according to the methods described herein. In particular, consumable product 30 may be manufactured according to the method described with reference to FIG.

[0130] In some embodiments, consumable 30 comprises a susceptor device including at least one susceptor 31 thereof, and connector portion 32 comprises a weakened region of the susceptor device.

[0131] As shown in Figure 6, the weakened region is integrally formed with the at least one susceptor 31. Alternatively, the weakened region may be formed separately from the at least one susceptor 31 and then attached to the at least one susceptor 31 in the form of a support.

[0132] In some embodiments, the connector portion 32 includes a support having at least one susceptor 31 secured thereto. The support may include a heating material heatable by a fluctuating magnetic field. Alternatively, the support may not include a heating material heatable by penetration by a fluctuating magnetic field. In some embodiments, the support includes one or more of paper, metal foil, metal alloy foil, and aerosol-generating material.

[0133] In some embodiments, the or each susceptor 31 is at least partially embedded in the aerosol-generating material 33. For example, the or each susceptor 31 may be embedded such that at least a portion of the susceptor 31 protrudes from the aerosol-generating material 33. Alternatively, the or each susceptor 31 may be fully embedded in the aerosol-generating material 33 such that none of the susceptor 31 protrudes from the aerosol-generating material 33. This helps to avoid user contact with the susceptor 31, which may become hot during use of the consumable 30.

[0134] 6, the or each susceptor 31 is substantially coaxial with the central axis of the consumable 30. Alternatively, the or each susceptor 31 may be positioned in other ways such that the or each susceptor 31 is capable of heating the aerosol-generating material 33 of the consumable 30.

[0135] 7 shows a schematic diagram of a susceptor apparatus 1 according to one embodiment. The susceptor apparatus 1 includes a plurality of first susceptor portions 2A and a plurality of second susceptor portions 2B. The susceptor apparatus 1 further includes a connector 3 that connects the first and second susceptor portions 2A and 2B.

[0136] In some embodiments, the connector 3 includes a support 5, such as a support 5 similar to the support 5 in the embodiment of FIG. 2 or the embodiment of FIG. 3. For example, the support 5 may include a heating material heatable by penetration with a fluctuating magnetic field. Alternatively, the support 5 may not include a heating material heatable by penetration with a fluctuating magnetic field. The support 5 may include one or more of paper, metal foil, metal alloy foil, and aerosol-generating material. In the embodiment of FIG. 7, a single support 5 is shown. In other embodiments, more than one support 5 may be provided; for example, two supports 5 may be secured to opposing surfaces of the first and second susceptors 2 such that the susceptor portions 2A, 2B are sandwiched between the supports 5.

[0137] The plurality of first and second susceptor portions 2A, 2B are fixed to the support 5 using any of the methods described above, for example using an adhesive.

[0138] Each first susceptor part 2A is spaced from a corresponding second susceptor part 2B by a connector 3, which in this example includes a support 5. The assembly including the susceptor device 1 and the aerosol-generating material includes any of the steps of the method of FIG. The assembly is formed and processed according to any of the processes described above. In this example, the assembly is separated by separating the connector 3 and the aerosol-generating material, for example using a cutter.

[0139] The first susceptor portions 2A may be arranged parallel to one another. For example, the longitudinal axes of the first susceptor portions 2A may be parallel to one another. Alternatively, the second susceptor portions 2B may be arranged parallel to one another. For example, the longitudinal axes of the second susceptor portions 2B may be parallel to one another.

[0140] 7, each first susceptor portion 2A is aligned with a corresponding second susceptor portion 2B. The longitudinal axis of each first susceptor portion 2A is aligned with the longitudinal axis of the corresponding second susceptor portion 2B in a direction perpendicular to the longitudinal axis. However, it should be appreciated that in other embodiments, the first and second susceptor portions 2A, 2B may be misaligned or may be offset, for example, in a direction perpendicular to the center or longitudinal axis of each susceptor portion 2A, 2B.

[0141] 8, the susceptor apparatus 1 includes three first susceptor portions 2A and three second susceptor portions 2B. However, it should be appreciated that in other embodiments, a different number of first and / or second susceptor portions 2A, 2B may be provided, for example, 2, 3, 4, 5, 6, 7, 8, 9, or 10 first and / or second susceptor portions 2A, 2B. The susceptor apparatus 1 may include the same number of first and second susceptor portions 2A, 2B or different numbers of first and second susceptor portions 2A, 2B.

[0142] In some embodiments, the first and second susceptor portions 2A, 2B have the same shape. In other embodiments, the first susceptor portion 2A has a different shape than the second susceptor portion 2B.

[0143] 8 shows a schematic cross-section of an assembly 50 for use in a method for manufacturing a consumable for use in a non-combustion-based aerosol delivery device according to one embodiment. The assembly 50 includes a susceptor apparatus 1 according to the embodiment of FIG. 7 and an aerosol-generating material 51 in thermal contact with the susceptor apparatus 1. As with the previous embodiment, the assembly 50 can be separated by a process that includes separating the connector 3 and the aerosol-generating material 51. For example, the assembly 50 can be separated along the support 5 between the first and second susceptor portions 2A and 2B such that a portion of the support 5 and the first susceptor portion 2A can be removed from another portion of the support 5 and the second susceptor portion 2B.

[0144] In one embodiment, the dividing step forms individual objects. For example, in some embodiments, a first object is formed that includes a portion of the aerosol-generating material 51, a portion of the support 5, and a first susceptor portion 2A. A second object is formed that includes another portion of the aerosol-generating material 51, another portion of the support 5, and a second susceptor portion 2B. Each of the individual objects may be a consumable product or may be used in the manufacture of a consumable product. For example, the assembly 50 may be divisible such that the susceptor device 1 is divided along line X shown in FIG. 7. In some embodiments, the assembly 50 includes a wrapper wrapped around the susceptor device 1 and the aerosol-generating material 51.

[0145] In some embodiments, the or each connector 3 of the susceptor unit 1 includes a weakened area that facilitates splitting the susceptor unit 1, as described above.

[0146] Providing multiple susceptor portions helps to heat the aerosol-generating material more uniformly, and in some embodiments, the susceptor portions of the consumable are substantially equally spaced about the consumable to facilitate uniform heating of the aerosol-generating material.

[0147] In some embodiments, the consumable (not shown) includes a plurality of individual susceptor portions and a connector portion affixed to or integrally formed with each susceptor portion. In some embodiments, the connector portions may be affixed to or integrally formed with all of the susceptor portions, for example, all of the susceptor portions may be affixed to a single support 5 or may be sandwiched between a set of supports 5. In other embodiments, the consumable includes a plurality of connector portions, each of which is connected to a corresponding first and second susceptor portion.

[0148] The consumable includes an aerosol-generating material in thermal contact with each susceptor portion. The or each connector portion may extend to at least one end of the aerosol-generating material, or may extend to two opposite ends of the aerosol-generating material. In one embodiment, the or each connector portion is part of a connector as described herein.

[0149] In FIG. 8, a plurality of first susceptor portions 2A are aligned in a direction perpendicular to the central axis of the assembly 50, and a plurality of second susceptor portions (not shown in FIG. 8) are aligned in a direction perpendicular to the central axis of the assembly 50. However, it should be recognized that other relative positions of the susceptor portions 2A, 2B are possible. For example, FIG. 9 is a cross-sectional view of another embodiment in which a first susceptor portion 2A is disposed about and spaced apart from the central axis of the assembly 50. Similarly, a second susceptor portion (not shown in FIG. 9) is disposed about and spaced apart from the central axis of the assembly 50. Such a configuration of susceptor portions helps to uniformly heat the aerosol-generating material. Optionally, each susceptor portion 2A, 2B may be curved so that it extends partially around the central axis of the assembly 50. However, in other embodiments, one, more than one, or each susceptor portion may be substantially flat.

[0150] It should be appreciated that a susceptor apparatus 1 including a plurality of first susceptor portions 2A and a plurality of second susceptor portions 2B may include any of the features of the susceptor apparatus described herein (including any of the embodiments of FIGS. 1-6), but may also include features adapted to include a plurality of first susceptor portions and a plurality of second susceptor portions. For example, in a modification of the embodiment of FIG. 1, a susceptor apparatus is provided that includes a plurality of first susceptor portions 2A, a plurality of second susceptor portions 2B, and a plurality of connectors 3, each of which is configured as described with reference to FIG. 1. Each first susceptor portion 2A is connected to a corresponding second susceptor portion 2B by a corresponding connector 3. The first susceptor portion 2A, the second susceptor portion 2B, and the connectors 3 together form a susceptor apparatus. The connectors 3 are spaced apart from one another. The susceptor device and aerosol-generating material are then formed into an assembly, and the assembly is separated by separating the connector and aerosol-generating material.

[0151] In other embodiments, the first susceptor parts 2A and the second susceptor parts 2B are connected to a common connector 3, for example, fixed to a common support 5 (e.g., in a variation of the embodiment of FIG. 2 or FIG. 3). The susceptor parts 2A, 2B being connected to the same connector 3 allows for accurate relative positioning of the susceptor parts 2A, 2B during the remaining processing steps.

[0152] 8 and 9, the support 5 is not shown, but it should be appreciated that the first and second susceptor portions 2A, 2B are fixedly held in place by the support 5 within the assembly 50. In other embodiments, the support 5 is omitted.

[0153] FIG. 10 shows a schematic diagram of a non-combustion aerosol delivery system 40 according to one embodiment. The non-combustion aerosol delivery system 40 includes a consumable 30. The consumable 30 may be any consumable 30 described herein, such as the consumable described with reference to FIG. 6 or various variations of the consumables described herein. The system also includes a non-combustion aerosol delivery device 42 for causing heating of the aerosol-generating material of the consumable 30 and volatilizing at least one component of the aerosol-generating material. The device 42 includes a heating region 43 that houses the consumable 30 and a magnetic field generator 44 that generates a varying magnetic field that penetrates a susceptor of the consumable 30 when the consumable 30 is in the heating region 43, thereby causing heating of the aerosol-generating material.

[0154] In some embodiments, device 42 is adapted to cause heating of the consumable aerosol-generating material without burning the aerosol-generating material, thereby volatilizing at least one component of the aerosol-generating material.

[0155] In some embodiments, the aerosol-generating material is a non-liquid material. In some embodiments, the aerosol-generating material comprises tobacco. In some embodiments, the aerosol-generating material is a reconstituted aerosolizable material, such as reconstituted tobacco.

[0156] The above-described embodiments should be understood as illustrative examples of the present invention. Further embodiments of the present invention are contemplated. It should be understood that any feature described with respect to any one embodiment may be used alone or in combination with other features described, and may be used in combination with one or more features of any of the other embodiments or in any combination with any of the other embodiments. Furthermore, equivalents and modifications not described above may also be employed without departing from the scope of the present invention, as defined in the appended claims.

Claims

1. 1. A method for manufacturing a consumable for use in a non-combustion based aerosol delivery device, comprising: providing a susceptor apparatus including a plurality of first susceptor portions extending in the same direction to define a first longitudinal axis and a plurality of second susceptor portions extending in the same direction to define a second longitudinal axis spaced from the first longitudinal axis, and at least one connector joining the first and second susceptor portions to one another, the first and second susceptor portions being spaced apart from one another by the at least one connector; forming an assembly including a susceptor device and an aerosol-generating material; and dividing the assembly including dividing the connector and the aerosol-generating material.

2. 10. The method of claim 1, wherein dividing includes using a cutter to sever the connector.

3. 3. The method of claim 1, wherein forming comprises embedding at least a portion of the susceptor device in an aerosol-generating material.

4. To form, combining a susceptor device with an aerosol-generating material on a wrapper; 4. The method of claim 1, further comprising wrapping a wrapper around the susceptor device and the aerosol-generating material.

5. 5. The method of claim 4, wherein the susceptor device is positioned on the wrapper before the aerosol-generating material.

6. 5. The method of claim 4, wherein the aerosol-generating material is placed on the wrapper prior to the susceptor device.

7. 7. The method of claim 1, wherein a connector joins each first susceptor portion to each second susceptor portion, and each first susceptor portion is spaced apart from its respective second susceptor portion by the connector.

8. 8. The method of claim 1, wherein the susceptor device includes a plurality of connectors, each connector joining a first susceptor portion to a respective second susceptor portion, and each first susceptor portion being spaced apart from its respective second susceptor portion by its respective connector.

9. 9. The method of claim 8, wherein dividing the assembly includes dividing each connector and aerosol-generating material.

10. 10. The method of claim 1, wherein the first susceptor portions of the assembly are spaced substantially equally apart from one another and / or the second susceptor portions of the assembly are spaced substantially equally apart from one another.

11. A susceptor apparatus for use in a method for manufacturing a consumable for use in a non-combustion aerosol delivery device, comprising: a plurality of first susceptor portions extending in the same direction to define a first longitudinal axis; a plurality of second susceptor portions extending in the same direction to define a second longitudinal axis spaced from the first longitudinal axis; and at least one connector joining the first and second susceptor portions to each other, wherein the first and second susceptor portions are spaced apart from each other by the at least one connector.

12. The susceptor device of claim 11, wherein the connector comprises a weakened region of the susceptor device.

13. 13. The susceptor device of claim 12, wherein the susceptor portion is integrally formed with the weakened region.

14. The susceptor device of claim 13, wherein the susceptor device includes at least one separate susceptor portion and at least one separate connector, and the susceptor device is configured in a repeating sequence of a susceptor portion followed by a connector followed by a susceptor portion.

15. 12. The susceptor device according to claim 11, wherein the connector includes a support to which the susceptor portion is fixed.

16. 16. The susceptor device of claim 15, wherein the susceptor device includes at least one other susceptor portion, and the first susceptor portion, the second susceptor portion, and the at least one other susceptor portion are fixed to a support.

17. 17. The susceptor device of claim 15 or 16, wherein the susceptor sections are spaced apart from one another on a support, the support including weakened areas between the susceptor sections.

18. 18. The susceptor device according to claim 15, wherein the support includes a heating material that can be heated by the penetration of a fluctuating magnetic field.

19. 18. The susceptor device according to claim 15, wherein the support does not include a heating material that can be heated by the penetration of a fluctuating magnetic field.

20. 20. The susceptor device of claim 15, wherein the support comprises one or more of paper, metal foil, alloy foil, and aerosol-generating material.

21. 21. The susceptor device of claim 11, wherein a connector joins each first susceptor portion to each second susceptor portion, and each first susceptor portion is spaced apart from its respective second susceptor portion by the connector.

22. 22. A susceptor device according to any one of claims 11 to 21, characterized in that the susceptor device includes a plurality of connectors, each connector joining a first susceptor portion to a respective second susceptor portion, and each first susceptor portion being spaced apart from its respective second susceptor portion by its respective connector.

23. A susceptor device as described in any one of claims 11 to 22, characterized in that the multiple first susceptor portions are spaced substantially equally apart from each other, and / or the multiple second susceptor portions are spaced substantially equally apart from each other.

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