Method for manufacturing an aerosol-generating article including a band of susceptor material

Abstract

The present invention relates to a method for producing individual aerosol-generating articles, each comprising an individual substrate section, the substrate section comprising an aerosol-forming substrate (12A) having susceptor elements, the method comprising the method steps of: B) providing a continuous band of susceptor material (16A); C) partially cutting the continuous band of susceptor material at predetermined pre-cut locations to produce partially cut bands of susceptor material (16B); and D) producing aerosol-generating articles using the partially cut band of susceptor material, the pre-cut locations separating the individual aerosol-generating articles from one another.

Description

[Technical Field]

[0001] The present invention relates to a method for producing a plurality of aerosol-generating articles comprising a substrate section having an aerosol-forming substrate and a susceptor element.The present invention further relates to a system configured for producing a plurality of individual aerosol-generating articles.The present invention further relates to an aerosol-generating article comprising a substrate section having an aerosol-forming substrate and a susceptor element. [Background technology]

[0002] Many aerosol-generating articles, particularly non-heat-burning articles, include a substrate section containing an aerosol-forming substrate and an additional susceptor material. When subjected to an alternating electromagnetic field, the susceptor can heat the aerosol-forming substrate to a temperature below the substrate's combustion temperature. During the manufacture of aerosol-generating articles, a continuous substrate section is produced that includes multiple individual substrate sections, and also contains a continuous band of susceptor material integrated within the aerosol-forming substrate. When cutting a continuous substrate section to produce individual substrate sections for aerosol-generating articles, a rotary cutting tool often impacts the continuous substrate section with a large momentum. This large momentum is necessary to simultaneously cut the aerosol-forming substrate and the continuous band of susceptor material, which is often a metal or metal alloy. However, this can lead to deformation or displacement of the band of susceptor material within the individual aerosol-generating articles. For a substrate section having a length of 12 mm, the impact of the rotary cutting tool can move the susceptor band by approximately 1.8 mm, sometimes resulting in deformation of up to 1 mm. These deformations and displacements can affect the susceptor material's ability to heat when subjected to an alternating electromagnetic field. Furthermore, the susceptor may also come into contact with the wrapping paper surrounding the substrate section. This can be undesirable, as the susceptor may burn the wrapping paper during use. Displaced susceptors protruding from the end face of the substrate section can further affect the connection process of additional sections, such as filter plugs or hollow filter plugs, to the substrate section. Operating the cutting tool with greater impact can also affect the cutting tool's service life.

[0003] It would be desirable to provide a method for manufacturing a plurality of aerosol-generating articles, and a system configured to manufacture a plurality of individual aerosol-generating articles, that can avoid or reduce deformation or displacement of the susceptor elements.Furthermore, it would be desirable to provide a method and system for manufacturing aerosol-generating articles that can extend the useful life of the cutting tool. Summary of the Invention

[0004] According to one embodiment of the present invention, there is provided a method for producing individual aerosol-generating articles, each article comprising an individual substrate section, and a substrate section comprising an aerosol-forming substrate having a susceptor. The method may include method step A) of providing a continuous band of susceptor material. The method may also include method step B) of partially cutting the continuous band of susceptor material at predetermined pre-cut locations to produce partially-cut bands of susceptor material. Method step C) may also include producing the aerosol-generating articles using the partial bands of susceptor material, the pre-cut locations separating the individual aerosol-generating articles from one another.

[0005] According to another embodiment of the present invention, there is provided a method for manufacturing individual aerosol-generating articles, each of which comprises an individual substrate section, the substrate section comprising an aerosol-forming substrate having a susceptor element. The method comprises: A) providing a continuous band of susceptor material; B) partially cutting the continuous band of susceptor material at predetermined pre-cut locations to produce partially cut bands of susceptor material; C) manufacturing aerosol-generating articles using the partially cut band of susceptor material, where pre-cut locations separate individual aerosol-generating articles from one another.

[0006] The partially cut band of susceptor material may be more easily separated by the cutting tool at the pre-cut location. This may be due to the partial cut introduced at the pre-cut location. Completely cutting the partially cut band of susceptor material at the pre-cut location may require less movement of the cutting tool. This may reduce the risk of deformation or displacement of the susceptor material within the substrate section.

[0007] At least two precut locations may be formed in method step B). The precut locations on the continuous band of susceptor material may be arranged such that one individual substrate section is located between adjacent precut locations. A similar individual susceptor element corresponding to one individual substrate section may be located between adjacent precut locations.

[0008] This may allow for the simple formation of individual substrate sections by cutting adjacent pre-cut locations on the partially cut band of susceptor material. In particular, one individual substrate section may comprise one individual susceptor element. One individual susceptor element may be located between adjacent pre-cut locations.

[0009] Multiple precut locations may be formed on a continuous band of susceptor material, which may allow for easy formation of multiple individual susceptor elements by cutting the band of susceptor material at the multiple precut locations, where one individual susceptor element is located between adjacent precut locations.

[0010] The plurality of pre-cut locations may separate at least 50 individual susceptor elements, preferably 10 to 50 individual susceptor elements, and most preferably, the plurality of pre-cut locations separate 10 individual susceptor elements.

[0011] During method step C), the aerosol-forming substrate may, in the first embodiment, be positioned around the partially cut band of susceptor material, thereby producing a continuous substrate section comprising the partially cut band of susceptor material, which may then be cut at pre-cut locations to produce individual aerosol-generating articles.

[0012] A continuous substrate section including a partially cut band of susceptor material may be easier to cut at the precut locations compared to a continuous substrate section including a continuous band of susceptor material without a precut.

[0013] During method step B), a plurality of precuts may be formed. During method step C), the continuous substrate section may then be cut at all of the precut locations. This may produce a plurality of individual substrate sections, each of which may include an individual susceptor element.

[0014] Alternatively, during method step C), the continuous substrate section may be cut at some of the pre-cut locations to provide a plurality of substrate sections. These plurality of substrate sections may be further processed to produce aerosol-generating articles. Each of the plurality of substrate sections may comprise a band of susceptor material, which may still comprise the pre-cut locations. A plurality of substrate sections may comprise at least two, more preferably at least five, or at least ten individual substrate sections.

[0015] During method step C), in another embodiment of the method of the present invention, the partially cut band of susceptor material may be completely cut at predetermined pre-cut locations, thereby producing individual susceptor elements. Aerosol-forming substrates may then be positioned around the individual susceptor elements, thereby producing a continuous substrate section comprising individual susceptor elements. The individual susceptor elements may be spaced apart from one another. Thus, the individual susceptor elements may not contact one another within the continuous substrate section.

[0016] During method step C), the individual susceptor elements within the continuous substrate section may each be spaced apart by a gap, after which the continuous substrate section may be cut between the gaps of the individual susceptor bands, thereby producing the individual substrate sections.

[0017] Such a continuous substrate section with individual susceptor elements may also facilitate the final cutting of the continuous substrate section. In particular, a cutting tool may only need to cut the aerosol-forming substrate within the continuous substrate section between the individual susceptor elements, without simultaneously cutting the bands of susceptor material. This facilitates the cutting process and may not require as much force as cutting the aerosol-forming substrate and the bands of susceptor material. This may therefore reduce the risk of deformation and displacement of the individual susceptor elements within the individual substrate sections. This may also extend the useful life of the cutting tool.

[0018] During method step B), the continuous band of susceptor material may be partially cut by making incisions at the ends of the band, after which, during method step C), the partially cut band may be completely cut at a central portion of the band adjacent the incision to produce individual susceptor elements.

[0019] This may allow for the continuous band of susceptor material to be completely cut to produce individual susceptor elements. This method may require less force to be applied by the cutting tool, particularly compared to methods in which the continuous band of susceptor material is completely cut in one step. This method may avoid deformation of the individual susceptor elements. The individual susceptor elements may then be assembled into a continuous substrate section comprising the individual susceptor elements.

[0020] The method of the present invention can generally be provided in two different alternative embodiments. A first preferred embodiment may be provided in which a partially cut band of susceptor material having precuts is incorporated into an aerosol-forming substrate, thereby producing a continuous substrate section comprising the partially cut band of susceptor material. This continuous substrate section can be easily further cut into individual substrate sections by the precut locations.

[0021] Another embodiment of the method of the present invention may provide a method in which a partially cut band of susceptor material can be completely cut into individual susceptor elements at pre-cut locations. These individual susceptor elements may then be incorporated into an aerosol-forming substrate. This may result in the production of a continuous substrate section containing individual susceptor elements. This method also allows for the easy cutting of continuous substrate sections, since the cutting tool only needs to cut the aerosol-forming substrate at the substrate sections located between the individual susceptor elements. This method of the present invention does not require cutting the susceptor material.

[0022] Individual susceptor elements produced by completely cutting the partially cut band of susceptor material may have a susceptor element length that is shorter than the substrate section length of the finished individual substrate section.

[0023] For example, the length of the susceptor element may be about 5 percent or about 10 percent less than the length of the substrate section. This may allow the individual susceptor elements to be positioned within the aerosol-forming substrate of the substrate section without susceptor material being present on the end faces of the individual substrate sections. Thus, the individual susceptor elements may be positioned centrally within the aerosol-forming substrate of the substrate section.

[0024] This may allow for the manufacture of substrate sections that incorporate less susceptor material, which may also result in less post-consumer waste of the aerosol-generating article.

[0025] In an embodiment of the method of the present invention, when the partially cut band of susceptor material is completely cut at the pre-cut locations to produce individual susceptor elements prior to assembly of the susceptor elements into the aerosol-forming substrate, the method may further include increasing the gap between adjacent susceptor elements. This may be done by transporting the individual susceptor elements on an acceleration belt. In particular, the partially cut band of susceptor material may be transported on a first belt, and the individual susceptor elements may be transported on the acceleration belt as a second belt. The speed of the second belt may be faster than the speed of the first belt. The speed of the second belt may be 10 to 30 percent, preferably 20 percent, faster than the speed of the first belt. This may increase the gap between adjacent individual susceptor elements.

[0026] If the gap between individual adjacent susceptor elements increases, it may be easier to produce the individual substrate sections by cutting the gaps of the individual adjacent susceptor elements after they have been assembled into a continuous substrate section. In particular, if the gap is large, the positioning of the cutting tool relative to the continuous substrate section to cut through the gap may not be as important. Even if there is some deviation between the later complete cut in method step C) to produce the individual substrate section and the final cut of the larger gap in the continuous substrate section between individual adjacent susceptor elements within the continuous substrate section, it may be possible to reliably cut the continuous substrate section through the gap.

[0027] Partially cutting in method step B) may include one or more of creating perforations in the continuous band of susceptor material, creating incisions in one or both edges of the continuous band of susceptor material, or creating a plurality of recesses in the band of susceptor material.

[0028] These methods for partially cutting a continuous band of susceptor material may be particularly suitable for weakening the susceptor material at the pre-cut locations, which may further reduce the need to provide a final cut with reduced force at the pre-cut locations.

[0029] The continuous band of susceptor material may have a width. The continuous band of susceptor material may have a central longitudinal axis. The continuous band of susceptor material may extend along its central longitudinal axis. The precut or precuts may be fabricated within the band at one-quarter to one-half of the width of the continuous band of susceptor material. Preferably, the precuts may be fabricated at opposing edges of the continuous band of susceptor material and may extend toward the central longitudinal axis of the band.

[0030] During method step C), the continuous substrate portion may be overlapped with a wrapping material, preferably paper.

[0031] Providing wrapping material around the continuous substrate section may produce a rod-like continuous substrate section, with the wrapping material stabilizing the substrate section. As already mentioned above, the continuous substrate section may include either continuous partially cut bands of susceptor material or individual susceptor elements, which may be spaced apart within the continuous substrate section.

[0032] During method step C), the continuous band of partially cut susceptor material or one of the individual susceptor elements may be conveyed through a funnel-shaped guide element, which may be configured to position an aerosol-forming substrate around the continuous band of partially cut susceptor material or one of the individual susceptor elements.

[0033] The funnel-shaped guide element may be configured to compress the aerosol-forming substrate around one of the continuous bands of partially cut susceptor material or individual susceptor elements, which may produce a continuous substrate section that may include either the continuous bands of partially cut susceptor material or individual susceptor elements.

[0034] During one or both of method steps B) and C), the continuous band of partially cut susceptor material or one of the individual susceptor elements may be transported on a transport device, which may comprise a belt, preferably a toothed belt, more preferably a U-shaped toothed belt.

[0035] Such belts, preferably toothed belts, may be particularly well suited for transporting either continuous bands of partially cut susceptor material or individual susceptor elements. These special belts may also be particularly well configured for transporting continuous substrate sections after the bands of susceptor material or individual susceptor elements have been incorporated into the aerosol-forming substrate.

[0036] The toothed belt may include U-shaped grooves that may extend parallel to the conveying direction of the toothed belt. These U-shaped grooves may be configured to accommodate continuous substrate sections, in particular rod-shaped continuous substrate sections.

[0037] The toothed belt may be made from a flexible polymer such as rubber or other flexible polymers such as nylon or aramid fibers.

[0038] During method step B), the continuous band of susceptor material may be guided through at least one rotating knife drum or rotating drum with a punching tool, which may allow partial cutting of the continuous band of susceptor material.

[0039] In particular, at least one of the rotating knife drum or rotating drum with punching tools may be capable of partially cutting the continuous band of susceptor material at predetermined precut locations. The predetermined precut locations may be on opposing edges of the band or may be predetermined locations on the band. For example, the rotating knife drum or rotating drum with punching tools may be located on opposing edges of the band of susceptor material configured to produce precuts on opposing edges of the band of susceptor material. These precuts may cover only a small portion of the width of the band of susceptor material, for example, one-quarter to one-half of the width, as already mentioned above. Alternatively, the precuts may extend along most of the width or over the entire length of the band of susceptor material. For example, perforation lines may be formed in the continuous band of susceptor material. This may be done by employing a rotating drum with punching tools.

[0040] During method step C), the individual susceptor elements may remain centrally positioned within the individual substrate sections after cutting.

[0041] In particular, the individual substrate sections may include individual central longitudinal axes. The individual substrate sections may be rod-shaped. Similarly, the continuous substrate section may include a continuous central longitudinal axis. The individual susceptor elements may be positioned within the continuous substrate section such that the individual susceptor elements are disposed along a continuous central longitudinal axis, and preferably the individual susceptor elements may lie in a plane, with the continuous central longitudinal axis also extending in that plane.

[0042] The pre-cut locations allow individual substrate sections to be produced by cutting the continuous substrate section completely through the gap between adjacent individual susceptor elements or at the pre-cut without applying excessive force, and therefore, the individual susceptor elements may remain centered within the individual substrate section after cutting.

[0043] As a result, the individual susceptor elements within the individual substrate sections may retain their position after cutting, and thus, the individual susceptor elements after cutting may lie in a plane, and the individual central longitudinal axes of the substrate sections may also extend in that plane.

[0044] Individual susceptor elements centrally located within individual substrate sections can be heated more easily and reliably by applying an external alternating electromagnetic field.

[0045] During method step B), flat areas on opposing edges of the continuous band of susceptor material may be removed as partial cuts, thereby creating central link portions connecting different adjacent portions of the partially cut band of susceptor material.

[0046] This may create a precut in the partially cut band of susceptor material, which may occupy a larger area on the partially cut band. If there is misalignment between the precut and the final cut, the final cut may also sever the central link portion. Therefore, creating a precut that occupies a larger area on the partially cut band may allow for greater tolerance for misalignment between the precut and the final cut.

[0047] During method step C), a detection device may be used to detect the position of one or more pre-cut positions on the continuous band of susceptor material or the position of the gap between the individual susceptor elements. The detection device may be selected from the group consisting of an X-ray device, an induction sensor, an infrared camera analyzer, and a device for measuring impedance.

[0048] These detection devices may be configured to detect the pre-cut location either on a continuous band of susceptor material incorporated into a continuous substrate section, or on a gap between multiple individual susceptor elements within a continuous substrate section. Alternatively, a note detection device may be present. Alternatively, the main mechanical drive of the system for manufacturing the aerosol-generating article may enable synchronization of the pre-cut with the final cut.

[0049] During method step C), the continuous substrate section may be cut by a rotating blade. This may allow cutting to produce a plurality of substrate sections, which may comprise, for example, up to 10 individual substrate sections. Alternatively, the rotating blade may cut the continuous substrate section into individual substrate sections comprising individual susceptor elements.

[0050] The continuous band of susceptor material may have an elongated, flat shape. In particular, the continuous band of susceptor material may comprise a continuous band having opposing edges. Individual susceptor elements cut from the continuous band of susceptor material may also have an elongated, flat shape. Individual susceptor elements may have a length. The length to width ratio of an individual susceptor element may be 1.5 to 4.5, preferably 1.8 to 3.5, and more preferably 1.9 to 2.5. In one embodiment, the length of an individual susceptor element may be 9 mm to 12 mm, and the width may be 3 mm to 6 mm, preferably 10 to 12 mm, and the width may be 4 to 5 mm.

[0051] The length of a substrate section may be 10-15 mm, preferably 12 mm, so a plurality of substrate sections comprising 10 individual substrate sections may have a length of 120 mm where one single substrate section has a length of 12 mm.

[0052] Generally, susceptor elements include or are made of a material capable of generating heat when penetrated by an alternating magnetic field. If the susceptor is conductive, eddy currents are typically induced by the alternating magnetic field. If the susceptor is magnetic, another effect that typically contributes to heating is commonly referred to as hysteresis loss. Hysteresis loss is primarily caused by the movement of magnetic domain blocks within the susceptor element material because their magnetic field orientation aligns with the alternating magnetic induction field. Another effect that contributes to hysteresis loss is when magnetic domains expand or contract within the susceptor element material. Generally, all of these changes, which occur at the nanoscale or below within the susceptor element material, are referred to as "hysteresis loss" because they generate heat within the susceptor element material. Thus, if the susceptor is both magnetic and conductive, both hysteresis loss and the generation of eddy currents will contribute to the heating of the susceptor element. If the material of the susceptor element is magnetic but not conductive, hysteresis losses are the only means by which the susceptor element will heat up when penetrated by an alternating magnetic field. According to the present invention, the material of the susceptor element may be both magnetic and conductive.

[0053] The susceptor material may, for example, comprise a ferromagnetic metal, preferably a ferromagnetic metal, more preferably a ferritic iron, especially a ferromagnetic steel, or a stainless steel.

[0054] The susceptor element, which includes the susceptor material, may heat the aerosol-forming substrate surrounding the susceptor element.

[0055] The term "aerosol-forming substrate" as used herein relates to a substrate capable of emitting one or more volatile compounds capable of forming an aerosol. Such volatile compounds may be emitted by heating the aerosol-forming substrate. The aerosol-forming substrate may conveniently be part of an aerosol-generating article or a smoking article.

[0056] The aerosol-forming substrate may be a solid aerosol-forming substrate. The aerosol-forming substrate may contain both solid and liquid components. The aerosol-forming substrate may include a tobacco-containing material containing volatile tobacco flavor compounds that are released from the substrate upon heating. The aerosol-forming substrate may include a non-tobacco material. The aerosol-forming substrate may include an aerosol former that facilitates the formation of a high-density, stable aerosol. Suitable aerosol formers are well known in the art and include, but are not limited to, polyhydric alcohols (e.g., triethylene glycol, 1,3-butanediol, glycerin), esters of polyhydric alcohols (e.g., glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of monocarboxylic, dicarboxylic, or polycarboxylic acids (e.g., dimethyl dodecanedioate, dimethyl tetradecanedioate). The aerosol former may be a polyhydric alcohol or a mixture thereof (e.g., triethylene glycol, 1,3-butanediol, glycerin). The aerosol former may be propylene glycol. The aerosol former may include both glycerin and propylene glycol.

[0057] In method step D), after method step C), one or both of the filter section and the hollow plug section may be connected to an individual substrate section or to one of a plurality of substrate sections. This method step D) may result in a final aerosol-generating article. The aerosol-generating article may comprise an aerosol-forming substrate having a susceptor element and a substrate section further comprising one or both of the filter section and the hollow plug section.

[0058] The filter section and hollow plug section are preferably located downstream of the substrate section within the aerosol-forming article. When both the filter section and hollow plug section are present, the hollow plug section may be located between the filter section and the substrate section within the aerosol-forming article. Alternatively, the aerosol-forming article may be formed from only the substrate section.

[0059] The aerosol-forming article may be inserted into a cavity of an aerosol-generating device. The aerosol-generating device may further include a heating element. The heating element may include an induction coil for heating the susceptor material via induction heating.

[0060] Induction heating can be more efficient when the susceptor elements included in the substrate section of the aerosol-forming article are uniform and centrally located within the aerosol-forming substrate of the substrate section. In particular, the eddy currents induced in the susceptor elements by the induction coil also depend on the shape of the susceptor element and its position relative to the heating element of the aerosol-generating device. Therefore, manufacturing an aerosol-generating article that includes susceptor elements with uniform shape and position within the substrate section can significantly improve the efficiency of induction heating.

[0061] As used herein, the terms "upstream" and "downstream" are used to describe the relative positions of components or portions of components of an aerosol-generating article or an aerosol-generating device with respect to the direction in which air flows along an airflow path through the aerosol-generating article or aerosol-generating device during use. An aerosol-generating article according to the present invention has a proximal end through which aerosol exits the device during use. The proximal end of an aerosol-generating article may also be referred to as the mouth end or downstream end. The mouth end is downstream of the distal end. The mouth end may comprise the mouthpiece. The distal end of an aerosol-generating article may also be referred to as the upstream end. Components or portions of components of an aerosol-generating article may be described as being upstream or downstream of one another based on their relative positions with respect to the airflow path through the aerosol-generating article.

[0062] The present invention also provides a method for manufacturing individual aerosol-generating articles each comprising an individual substrate section, the substrate section comprising an aerosol-forming substrate having a susceptor element, the method comprising: A) providing a continuous band of susceptor material; B) partially cutting the continuous band of susceptor material at predetermined pre-cut locations to produce partially cut bands of susceptor material; C) a method step of manufacturing aerosol-generating articles using a band of partially cut susceptor material, where pre-cut locations separate individual aerosol-generating articles from one another, and during method step C), the partially cut band of susceptor material is completely cut at the predetermined pre-cut locations, thereby producing individual susceptor elements, and an aerosol-forming substrate is positioned around the susceptor band, thereby producing a continuous substrate section comprising individual partially pre-cut susceptor elements.

[0063] Such a method may offer the advantage that continuous substrate sections may be easily cut perfectly at predetermined pre-cut locations.

[0064] This method may be combined with any of the additional method features disclosed herein.

[0065] In one embodiment of this method, during method step C), the individual susceptor elements within the continuous substrate section may each be spaced apart by a gap, and the continuous substrate section may then be cut between the gaps between the individual susceptor elements to produce the individual substrate sections.

[0066] In a further embodiment of this method, during method step B), flat areas on opposing edges of the continuous band of susceptor material may be removed as partial cuts, thereby creating central link portions connecting different portions of the partially cut band of susceptor material.

[0067] The present invention also provides a system configured to produce individual aerosol-generating articles, each article comprising an individual substrate section having a susceptor element. The system may include a pre-cutting device configured to partially cut a continuous band of susceptor material to produce pre-cut locations on the continuous band of susceptor material. The pre-cut locations may separate the individual aerosol-generating articles from one another. The system may include a substrate section-forming device configured to produce the aerosol-generating articles. The substrate section-forming device may employ the partially cut band of susceptor material to produce the aerosol-generating articles. The system may also include a conveying device configured to convey the continuous band of susceptor material between the pre-cutting device and the substrate section-forming device.

[0068] According to another embodiment, the present invention provides a system configured to produce individual aerosol-generating articles, each article comprising an individual substrate section having a susceptor element. The system includes a pre-cutting device configured to partially cut a continuous band of susceptor material to produce pre-cut locations on the continuous band of susceptor material, the pre-cut locations separating the individual aerosol-generating articles from one another. The system further includes a substrate section-forming device configured to produce the aerosol-generating articles using the partially cut band of susceptor material. The system also includes a transport device configured to transport the continuous band of susceptor material between the pre-cutting device and the substrate section-forming device.

[0069] Such a system is well suited for producing aerosol-generating articles that include susceptor elements having uniform shapes and well-defined locations within a substrate section to facilitate inductive heating.

[0070] The precut device of the system may be further configured to produce at least two precuts. In particular, the precut device may be further configured to position the at least two precuts on the continuous band of susceptor material such that one single individual substrate section is located between adjacent precut locations. The single individual substrate section may correspond to one single susceptor element located between adjacent precut locations.

[0071] The pre-cutting device may include one of a rotating drum with knives, punching tools, or a rotating knife drum. The rotating knife drum may include multiple knives positioned around the drum. The pitch between adjacent knives on the knife drum or adjacent punching tools on the rotating drum is preferably the same as the distance between adjacent pre-cuts on the partially cut band of susceptor material. For example, if the distance between two adjacent pre-cuts is 12 mm, the pitch may be 12 mm.

[0072] According to one first embodiment of the present invention, the substrate section forming apparatus may be configured to produce a continuous substrate section comprising a partially cut band of susceptor material. The system for producing aerosol-generating articles may further comprise a substrate cutting apparatus for cutting the continuous substrate section at pre-cut locations.

[0073] In this embodiment, the continuous band of susceptor material is only partially cut to produce partially cut bands of susceptor material. This partially cut band of susceptor material may then be incorporated into continuous substrate sections. The continuous substrate sections may then be cut at the pre-cut locations of the partially cut band of susceptor material to produce individual or larger substrate sections.

[0074] This may allow for more reliable and consistent manufacturing of individual substrate sections, including individual susceptor elements.

[0075] The substrate cutting device may comprise a cutting tool for cutting continuous substrate sections at pre-cut locations, which may enable cutting of the aerosol-forming substrate located at the pre-cut locations, and may additionally cut a continuous band of partially cut susceptor material at the pre-cut locations to produce individual substrate sections.

[0076] The substrate cutting device may be configured to impact successive substrate sections with less momentum to avoid or reduce deformation or displacement of the susceptor elements of the individual substrate sections.

[0077] The substrate cutting device may include a rotary knife. The rotary knife may be, for example, a stainless steel knife. At a conveying speed of 200 m / min, the rotary knife may be operated at a rotational speed of about 800 rpm. The rotary knife may cut the continuous substrate section at a 45° angle.

[0078] In an alternative embodiment of the invention, the system for producing individual aerosol-generating articles separate from the pre-cutting device may also include a susceptor cutting device configured to cut the partially cut band of susceptor material into individual susceptor elements, and a substrate section forming device configured to then produce continuous substrate sections comprising the individual susceptor elements.

[0079] In this alternative embodiment of the present invention, the partially cut band of susceptor material is further cut into individual susceptor elements, and due to the low impact of the susceptor cutting device deformation of the individual susceptor elements can be avoided.

[0080] The susceptor cutting device may include a rotating blade.

[0081] In this alternative embodiment of the present invention, the system may further comprise a substrate cutting device that may be configured to cut the continuous substrate section between the individual susceptor elements.

[0082] The substrate cutting device may operate with reduced impact due to the fact that it only needs to cut the aerosol-forming substrate between adjacent individual susceptor elements incorporated into a continuous substrate section, and does not need to cut the susceptor material. The conveying device may also be configured to transport the partially cut bands of susceptor material from the pre-cutting device to the susceptor cutting device. In both the first and second embodiments, the conveying device may further be configured to transport the continuous substrate section from the substrate section forming device to the substrate cutting device.

[0083] The system for manufacturing individual aerosol-generating articles may further include a bobbin configured to unwind a continuous band of susceptor material. The bobbin may be operated at a speed sufficient to unwind and feed the continuous band of susceptor material through a conveying device.

[0084] The conveying device may comprise a belt, preferably a toothed belt, more preferably a U-shaped toothed belt.

[0085] The belt may be operated at a speed fast enough to transport a continuous band of susceptor material between the pre-cutting device and the substrate section forming device, and the speed may be between 150 m / min and 400 m / min, preferably between 200 m / min and 300 m / min.

[0086] The substrate section forming device may comprise a funnel-shaped guide element for positioning the aerosol-forming substrate around a continuous band of partially cut susceptor material or one of a plurality of individual susceptor elements.

[0087] The substrate section forming device may compress the aerosol-forming substrate around a partially cut band of susceptor material or around individual susceptor elements to produce a continuous substrate section.

[0088] The system for producing individual aerosol-generating articles may comprise a modified commercially available device. The commercially available device may be modified by including a pre-cutting device. Additionally, the commercially available device may be modified by including a susceptor cutting device. One commercially available device that may be modified according to the present invention may be the Hauni KDF, manufactured by Hauni Maschinenbau GmbH.

[0089] The present invention further provides an aerosol-generating article comprising an aerosol-forming substrate and a substrate section including a susceptor element, the susceptor element may include first and second susceptor end faces, at least one of the first and second susceptor end faces may have a tapered shape.

[0090] The first and second susceptor end faces having tapered shapes may be obtained by cutting a central link portion between adjacent susceptor elements within a partially cut band of susceptor material, which may be formed when flat areas on opposing edges of a continuous band of susceptor material are removed to create a precut with a larger area.

[0091] Aerosol-generating articles including such susceptor elements may be easier to heat via induction heating since there is no deformation of the susceptor element.

[0092] The susceptor elements of the aerosol-generating article may have a flat, elongated shape. Such susceptor elements embedded in the aerosol-forming substrate may enable uniform heating of the aerosol-forming substrate upon inductive heating of the susceptor elements.

[0093] One or both of the first and second susceptor end faces may include rounded edges, which may be obtained by removing larger flat areas from opposing edges of a continuous band of susceptor material when manufacturing the precut.

[0094] The susceptor element may include a flat surface, which may be non-curved due to pre-cutting to reduce impact from a substrate cutting device or a susceptor cutting device.

[0095] The aerosol-generating article may have a first article end face and an opposing second article end face, and the first and second susceptor end faces may be spaced apart from the first and second article end faces.

[0096] A susceptor having such first and second susceptor end faces may not be deformed. Such a susceptor may not bend during cutting of the continuous substrate section. The first and second susceptor end faces may be spaced apart from the respective article end faces because the aerosol-forming substrate is located between adjacent individual susceptor elements in the continuous substrate section. By cutting between adjacent individual susceptor elements, an aerosol-generating article can be obtained in which the susceptor end faces are spaced apart from the respective article end faces.

[0097] The susceptor elements may be centrally positioned within the substrate section of the aerosol-generating article. The aerosol-generating article may have a tubular, elongated shape. The aerosol-generating article may have a central longitudinal axis. The susceptor elements may be positioned within the substrate section such that the susceptor elements are arranged along a continuous central longitudinal axis, and preferably the susceptor elements lie in a plane, with the continuous central longitudinal axis also extending within that plane.

[0098] Such a centrally located susceptor element may ensure uniform heating of the surrounding aerosol-forming substrate, and may also avoid hazards to the user that may result from displacement of the susceptor element.

[0099] The aerosol-generating article may generate the aerosol by heating the aerosol-forming substrate to a temperature below combustion temperature via induction heating. Such an aerosol-generating article may be referred to as a "heat-not-burn product."

[0100] The present invention also provides an aerosol-generating article produced by the methods described herein. [Example]

[0101] The following provides a non-exhaustive list of non-limiting examples, any one or more of the features of which may be combined with any one or more features of any other example, embodiment, or aspect described herein.

[0102] Example A: 1. A method for manufacturing individual aerosol-generating articles each comprising an individual substrate section, the substrate section comprising an aerosol-forming substrate having a susceptor element, the method comprising: A) providing a continuous band of susceptor material; B) partially cutting the continuous band of susceptor material at predetermined pre-cut locations to produce partially cut bands of susceptor material; C) manufacturing aerosol-generating articles using partially cut bands of susceptor material, wherein pre-cut locations separate individual aerosol-generating articles from one another. Example B: The method of embodiment A, wherein at least two precut locations are formed in method step B), and the precut locations on the continuous band of susceptor material are set so that one individual substrate section is located between adjacent precut locations. Example C: The method of any of Examples A-B, wherein during method step C), the aerosol-forming substrate is positioned around the partially cut band of susceptor material, thereby producing a continuous substrate section comprising the partially cut band, and the continuous substrate section is then cut at the pre-cut locations. Example D: During method step B), a plurality of precuts are formed, The method of any one of Examples A-C, wherein during method step C), the continuous substrate section is cut at all pre-cut locations, thereby producing a plurality of individual substrate sections, or wherein during method C), the continuous substrate section is cut at some of the pre-cut locations, thereby providing a plurality of the plurality of substrate sections, preferably one of the plurality of substrate sections comprising at least two, more preferably at least five, or at least ten individual substrate sections. Example E: The method according to Example A or Example B, wherein during method step C), the partially cut band of susceptor material is completely cut at predetermined pre-cut locations, thereby producing individual susceptor elements, and thereafter an aerosol-forming substrate is positioned around the individual susceptor band, thereby producing a continuous substrate section comprising individual susceptor elements. Example F: The method of any one of Examples A to E, wherein during method step C), the individual susceptor elements within the continuous substrate section are each spaced apart by a gap, and the continuous substrate section is then cut between the gaps of the individual susceptor bands, thereby producing the individual substrate sections. Example G: A method as described in either Example E or Example F, wherein during method step B), a continuous band of susceptor material is partially cut by creating incisions at the edges of the band, and during method step C), the partially cut band is completely cut in a central portion of the band adjacent the incision to produce individual susceptor elements. Example H: The method of any of Examples A-G, wherein partially cutting in method step B) includes one or more of creating perforations in the band, creating incisions in one or both edges of the band, and creating multiple recesses in the band. Example I: The method of any of embodiments AH, wherein during method step C), the continuous substrate section is overlapped with a wrapping material, preferably paper. Example J: The method of any of embodiments A-I, wherein during method step C), the partially cut continuous band or one of the individual susceptor elements is conveyed through a funnel-shaped guide element to position the aerosol-forming substrate around the partially cut continuous band or one of the individual susceptor elements. Example K: The method of any of embodiments A-J, wherein during one or both of method steps B) and C), the partially cut continuous band or one of the individual susceptor elements is conveyed on a belt, preferably a toothed belt, more preferably a U-shaped toothed belt. Example L: The method of any of embodiments A-K, wherein during method step B), the continuous band of susceptor material is guided through at least one rotating knife drum or rotating drum having a punching tool for partially cutting the continuous band of susceptor material. Example M: The method of any of embodiments A-L, wherein during method step C), the individual susceptor elements remain centered within the individual substrate sections after cutting. Example N: The method of any of embodiments A-M, wherein during method step B), flat areas on opposing edges of the continuous band of susceptor material are removed as partial cuts, thereby creating a central link portion connecting different portions of the partially cut band of susceptor material. Example 0: The method of any of Examples A-N, wherein during method step C), a detection device is employed to detect one of the pre-cut locations on the partially cut band of susceptor material or the location of a gap between a plurality of individual susceptor elements within the continuous substrate section, preferably the detection device is selected from the group consisting of an X-ray device, an induction sensor, an IR camera analyzer, and a device for measuring impedance. Example P: The method of any of embodiments A-O, wherein during method step C), the continuous substrate section is cut by a rotating blade, preferably the rotating blade being controlled by the detection device of embodiment O. Example Q: The method of any of embodiments AP, wherein the susceptor material comprises a ferromagnetic material, preferably a ferromagnetic alloy, more preferably ferritic iron, ferromagnetic steel, or stainless steel. Example R: The method of any of embodiments A-Q, wherein in method step D), after method step C), one or both of the filter section and the hollow plug section are connected to an individual substrate section or one of a plurality of substrate sections. Example S: A system configured to manufacture individual aerosol-generating articles, each comprising an individual substrate section, the substrate section comprising an aerosol-forming substrate having a susceptor element; a pre-cutting device configured to partially cut a continuous band of susceptor material to produce pre-cut locations on the continuous band of susceptor material, the pre-cut locations separating individual aerosol-generating articles from one another; and a substrate section forming apparatus configured to produce aerosol-generating articles using partially cut bands of susceptor material; a conveying device configured to convey the continuous band of susceptor material between the pre-cutting device and the substrate section forming device. Example T: The system of Examples A-S, wherein the precut device is configured to produce at least two precuts, and the precut device is further configured to set the positions of the at least two precuts on the continuous band of susceptor material so that one single individual substrate section is located between adjacent precut positions. Example U: A system described in either Example S or Example T, wherein the substrate section forming apparatus is configured to produce a continuous substrate section including a band of partially cut susceptor material, and the apparatus further includes a substrate cutting apparatus for cutting the continuous substrate section at a pre-cut location. Example V: The system of Example S or Example T, wherein the apparatus further comprises a susceptor cutting device for cutting the partially cut band of susceptor material into individual susceptor elements at multiple pre-cut locations, and the substrate section forming device is configured to produce continuous substrate sections including the individual susceptor elements. Example W: The system of any one of Examples A-V, further comprising a substrate cutting device for cutting continuous substrate sections between individual susceptor elements. Example X: The system of any one of embodiments S through W, further comprising a bobbin configured to unwind a continuous band of susceptor material. Example Y: The system of any one of Examples S-X, wherein the conveying device comprises a belt, preferably a toothed belt, more preferably a U-shaped toothed belt. Example Z: A system described in any of Examples S to Y, wherein the substrate section forming device includes a funnel-shaped guide element for positioning the aerosol-forming substrate around a partially cut continuous band or one of a plurality of individual susceptor elements. Example AA: The system of any of Examples S through Z, wherein the pre-cut device includes a knife drum, knife, or drum having a punching tool for providing the partial cut. Example AB: The system of any one of Examples S through AA, wherein one or both of the susceptor cutting device or the substrate cutting device comprises a rotating blade. Example AC: An aerosol-generating article, comprising: an aerosol-generating article comprising: an aerosol-forming substrate; and a substrate section comprising a susceptor element, the susceptor element having first and second susceptor end faces, at least one of the first and second susceptor end faces having a tapered shape. Example AD: The aerosol-generating article of any one of Examples A-AC, wherein one or both of the first and second susceptor end faces include rounded edges. Example AE: 31. An aerosol-generating article according to claim 29 or 30, wherein the susceptor elements have flat surfaces, preferably without curves. Example AF: The aerosol-generating article of any one of Examples AC through AE, wherein the susceptor element is centrally located within the substrate section. Example AG: An aerosol-generating article produced by the method described in any one of Examples A to R.

[0103] Features described with respect to one embodiment may equally apply to other embodiments of the invention.

[0104] The invention will now be further described, by way of example only, with reference to the accompanying drawings in which: [Brief explanation of the drawings]

[0105] [Figure 1A] FIG. 1A shows a cross-sectional view of a substrate section having a deformed susceptor element. [Figure 1B] FIG. 1B shows a schematic perspective view of a substrate section including a susceptor element. [Figure 2] FIG. 2 shows a schematic diagram of a precutting apparatus for cutting precuts in a continuous band of susceptor material. [Figure 3] FIG. 3 shows a schematic diagram of a system configured to manufacture aerosol-generating articles using a pre-cutting apparatus according to a first embodiment of the present invention. [Figure 4]FIG. 4 is a schematic diagram of a system for manufacturing aerosol-generating articles having a pre-cutting device and a susceptor cutting device in accordance with a second embodiment of the present invention. [Figure 5] FIG. 5 shows a cross-sectional view along the central longitudinal axis of a continuous substrate section comprising a continuous band of partially cut susceptor material produced according to a first embodiment of the present invention. [Figure 6] FIG. 6 shows a cross-sectional view along the central longitudinal axis of a continuous substrate section including individual susceptor elements spaced apart by gaps according to a second embodiment. [Figure 7] FIG. 7 shows a schematic diagram of a conveying device comprising a first belt and a second belt. [Figure 8A] FIG. 8A shows a perspective view of a drum with a punching tool and its counter-drum. [Figure 8B] FIG. 8B shows a cross-sectional view of a drum with punching tools and their respective counter-drums. [Figure 9A] 9A and 9B show different embodiments of precuts within a continuous band of partially cut susceptor material, where flat areas on opposing edges of the continuous band of susceptor material have been removed. [Figure 9B] Same as above. [Figure 9C] FIG. 9C shows a substrate section with a fully cut susceptor element having tapered end faces. DETAILED DESCRIPTION OF THE INVENTION

[0106] In the following, like elements are designated by like reference numerals throughout the figures.

[0107] FIG. 1A shows a cross-sectional view of a substrate section 10 fabricated according to a process without precuts in the susceptor element. This process involves a final step in which a rotary knife cuts the continuous substrate section into individual substrate sections with a large momentum to simultaneously cut through the aerosol-forming substrate 12 and the metallic susceptor element 16. This large momentum causes the susceptor element 16 to bend and simultaneously move away from the center of the substrate section. Due to the deformation and displacement of the susceptor element, induction heating may be insufficient to heat the aerosol-forming substrate. The substrate section 10 is then overwrapped with a wrapping material 14.

[0108] 1B shows a schematic perspective view of substrate section 10 with susceptor element 16 having an elongated rectangular shape centrally located within the substrate section. Susceptor element 16 lies in a plane within substrate section 10 and occupies a central longitudinal axis 24 of the substrate section. The shape and position of susceptor element 16 in FIG. 1B compares favorably with the shape and position of the susceptor element shown in FIG. 1A.

[0109] FIG. 2 shows a schematic perspective view of a pre-cutting apparatus 21 configured to partially cut a continuous band of susceptor material. The pre-cutting apparatus 21 includes a knife drum 18 having knives 18A and a respective counter drum 20. A continuous band of susceptor material 16A is guided between the knife drum 18 and the counter drum 20. The knife drum 18 makes a pre-cut 22 at one end of the continuous band of susceptor material 16A, resulting in a partially cut continuous band of susceptor material 16B. A second pair of knife drums and counter drums may be present on the opposing edge of the continuous band of susceptor material 16A to make corresponding pre-cuts on the opposing edge of the band (not shown in FIG. 2). Two adjacent pre-cuts 22 separate one susceptor element from the next, thereby facilitating the final cut that separates the individual susceptor elements from one another.

[0110] FIG. 3 shows a schematic diagram of a system configured to manufacture individual aerosol-generating articles according to a first embodiment of the present invention. This system generally involves creating precuts in a continuous band of susceptor material 16A, including a precutting device 21 having a knife drum 18 and a counter drum 20, and then positioning an aerosol-forming substrate 12A around the partially cut band of susceptor material 16B. A substrate section forming device 24 having a funnel-shaped guide element compresses the aerosol-forming substrate 12A around the partially cut band of susceptor material to form a continuous substrate section 10A having the partially cut band of susceptor material. The continuous substrate section 10A includes the partially cut band of susceptor material with the precut 22. For clarity, only the susceptor portion of the continuous substrate section is shown in FIG. 3, not the aerosol-forming substrate surrounding the susceptor. A substrate cutting device 30, a rotating knife, cuts the continuous substrate section into individual substrate sections 10 at the precut locations. Optionally, there may be a detection device 26 which, in combination with a computing system 28, may control the substrate cutting device 30 and ensure reliable cutting of the continuous substrate section 10A at the precut 22. Additionally, there is a bobbin 23 from which the continuous band 16A of susceptor material is unwound.

[0111] FIG. 4 shows a schematic cross-sectional view of a system configured to produce individual aerosol-generating articles according to a second embodiment of the present invention. In contrast to the first embodiment of the present invention shown in FIG. 3, an additional susceptor cutting device 32 is present, which cuts the continuous band 16B of partially cut susceptor material into individual susceptor elements 16 before disposing the aerosol-forming substrate 12A around the individual susceptor elements 16. A substrate section forming device 24 then produces continuous substrate sections 10A having individual susceptor elements 16. Adjacent susceptor elements 16 are spaced apart by gaps 16C. A substrate cutting device 30 finally cuts the continuous substrate section 10A into individual substrate sections 10 by cutting the continuous substrate section between the gaps 16C of adjacent susceptor elements.

[0112] FIG. 5 depicts a cross-sectional view of a continuous substrate section 10A along its central longitudinal axis, the continuous substrate section including a continuous band 16B of partially cut susceptor material according to a first embodiment of the present invention. Precuts 22 are present within the continuous band 16B of partially cut susceptor material, which remove flat areas on opposing edges of the continuous band. Only a central link portion 36 exists between adjacent substrate sections. The continuous band 16B of partially cut susceptor material is embedded within an aerosol-forming substrate 12 and surrounded by a packaging material 14. The central link portions 36 connecting different susceptor elements are cut along score lines 34 to produce individual substrate sections 10. Cutting along score lines 34 produces individual substrate sections 10, with the end faces of the susceptor elements disposed therein having tapered shapes. Arrows 38 indicate the direction of transport of the continuous substrate section 10A through a system for producing individual aerosol-generating articles.

[0113] 6 shows a continuous substrate section 10A including individual susceptor elements 16 according to a second embodiment of the present invention. A substrate cutting device can finally cut the continuous substrate section 10A along score lines 30 in gaps 16C to produce individual substrate sections 10.

[0114] 7 shows a schematic diagram of a conveying apparatus including a first belt 40 and a second belt 42 as acceleration belts. After completely cutting the continuous band of partially cut susceptor material with precuts, individual susceptor elements 16 are obtained and separated by cuts 17 between adjacent susceptor elements. These completely separated susceptor elements 16 are conveyed on the first belt 40 and then picked up by the second belt 42. Because the speed of the second belt 42 is faster than the speed of the first belt 40, gaps 16C are created between adjacent susceptor elements. The susceptor elements 16, spaced apart by gaps 16C, are then incorporated into the continuous substrate section 10A as shown in FIG. 4.

[0115] 8A shows a schematic perspective view of a drum 18 having a punching tool 18B and its corresponding counter-drum 20. The counter-drum 20 includes a complementary structure 18C that can at least partially accommodate the punching tool 18B when the drum 18 and counter-drum 20 rotate. A continuous band of susceptor material can be guided between the drum 18 and counter-drum 20 so that the punching tool 18B can produce precuts in the band.

[0116] 8B shows a schematic cross-sectional view of a drum 18B with a punching tool 18B and its counter-drum 20. It can be clearly seen that a complementary structure 18C can at least partially accommodate the punching tool 18B so that precuts can be made in the band of susceptor material guided between both drums 18 and 20.

[0117] 9A and 9B show schematic top views of a part of a band 16B of susceptor material that has been partially cut. Different precuts 22 have been introduced into opposite edges of the band. In FIG. 9A, rectangular edges are formed by the precuts 22, while in FIG. 9B, rounded edges 44 are formed. The precuts 22 in both FIG. 9A and FIG. 9B result in a central link portion 36 that connects two adjacent susceptor elements.

[0118] FIG. 9C shows a schematic cross-sectional view of substrate section 10 in which both central link portions adjacent susceptor element 16 have been severed, resulting in tapered end faces 44A and 44B of the susceptor element.

Claims

1. 1. A method for manufacturing individual aerosol-generating articles each comprising an individual substrate section, the substrate section comprising an aerosol-forming substrate having a susceptor element, the method comprising: A) providing a continuous band of susceptor material; B) partially cutting the continuous band of susceptor material at predetermined pre-cut locations to produce partially cut bands of susceptor material; C) a method step of manufacturing the aerosol-generating articles using the partially cut band of susceptor material, wherein the pre-cut locations separate individual aerosol-generating articles from one another, and during method step C), the partially cut band of susceptor material is completely cut at predetermined pre-cut locations, thereby producing individual susceptor elements, and thereafter the aerosol-forming substrate is positioned around the individual susceptor elements, thereby producing a continuous substrate section comprising individual susceptor elements.

2. 2. The method of claim 1, wherein at least two precut locations are formed in method step B), and the precut locations on the continuous band of susceptor material are set so that one individual substrate section is located between adjacent precut locations.

3. 3. The method according to claim 1, wherein during method step C), the individual susceptor elements within the continuous substrate section are each spaced apart by a gap, and the continuous substrate section is then cut between the gaps of the individual susceptor elements, thereby producing individual substrate sections.

4. 2. The method of claim 1, wherein partially cutting in method step B) comprises one or more of creating perforations in the band, creating incisions in one or both edges of the band, and creating a plurality of recesses in the band.

5. 2. The method of claim 1, wherein during method step B), flat areas on opposing edges of the continuous band of susceptor material are removed as partial cuts, thereby creating central link portions connecting different portions of the partially cut band of susceptor material.

6. 1. A system configured to produce individual aerosol-generating articles, each comprising an individual substrate section, the substrate section comprising an aerosol-forming substrate having a susceptor element; a pre-cutting device configured to partially cut a continuous band of susceptor material to produce pre-cut locations on said continuous band of susceptor material, said pre-cut locations separating individual aerosol-generating articles from one another; and a susceptor cutting device for cutting the partially cut band of susceptor material into individual susceptor elements at the plurality of pre-cut locations; a substrate section forming apparatus configured to produce an aerosol-generating article using the partially cut band of susceptor material, the substrate section forming apparatus configured to produce a continuous substrate section comprising the individual susceptor elements; and a conveying device configured to convey the continuous band of susceptor material between the pre-cutting device and the substrate section forming device.

7. 7. The system of claim 6, wherein the precut device is configured to produce at least two precuts, and the precut device is further configured to position the at least two precuts on the continuous band of susceptor material such that one single individual substrate section is located between adjacent precut locations.

8. The system of claim 7 further comprising a substrate cutting device for cutting the continuous substrate section between the individual susceptor elements.

9. 7. The system of claim 6, wherein the conveying device comprises a belt, preferably a toothed belt, more preferably a U-shaped toothed belt.

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