Susceptor and method for its manufacture

Abstract

To provide a method for manufacturing a susceptor for an inductively heatable aerosol-generating article.SOLUTION: A method includes the steps of providing a band of a susceptor material and providing a compression stage including oppositely disposed compression elements, and in a first portion of the compression stage, the compression elements are arranged to define a progressively narrowing compression gap, and in a second portion of the compression stage, the compression elements are arranged to define a constant compression gap therebetween, the oppositely disposed compression elements are configured to have matching surface structures. The band of the susceptor material is guided through the narrowing compression gap of the compression stage such that the matching surface structures of the compression elements deep draw the band of susceptor material. The present invention also relates to a susceptor element having successively disposed plain and extended portions, and a method of manufacturing the same.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a susceptor and a method for manufacturing a susceptor for use in an inductively heatable aerosol-generating article. [Background technology]

[0002] Aerosol-generating articles including at least one aerosol-forming substrate capable of forming an inhalable aerosol upon heating are generally known. To heat the substrate, the article may be received in an aerosol-generating device including an electric heater. The heater may be an induction heater including an induction source. The induction source is configured to generate an alternating electromagnetic field that inductively heats the susceptor by at least one of eddy currents and hysteresis losses, depending on the electrical and magnetic properties of the susceptor. The susceptor may be an integral part of the article and disposed in thermal proximity or direct physical contact with the substrate to be heated. During operation of the device, volatile compounds are released from the heated aerosol-forming substrate in the article and flow into the airflow drawn through the article during a user's puff. As the released compounds cool, they condense to form an aerosol.

[0003] The susceptor may include or consist of a metal sheet. While such sheet susceptors are easy to manufacture and can provide a wide thermal radiation area due to their two-dimensional nature, the total mass of such susceptors can often still be disproportionate to the radiation surface, resulting in an inefficient use of resources.

[0004] Reducing the mass of a susceptor, and in particular reducing the thickness of the sheet material used to manufacture the susceptor, places high demands on the manufacturing processes involved.

[0005] It would therefore be desirable to have a method for manufacturing susceptors for inductively heatable aerosol-generating articles that allows for high reliability and repeatability even for very thin susceptor materials.

[0006] In particular, it would be desirable to have a method for manufacturing a corrugated susceptor for an inductively heatable aerosol-generating article in which the susceptor is manufactured from very thin susceptor material.

[0007] Additionally, it would be desirable to have a method for manufacturing a susceptor in which a sensory medium is deposited on the susceptor during the molding process.

[0008] Additionally, it would be desirable to have a method for manufacturing a susceptor that provides increased flexibility with respect to the heating profile of the resulting susceptor.

[0009] Additionally, it would be desirable to have a method that allows for the sensory medium to be deposited in predetermined areas of a susceptor element. Summary of the Invention

[0010] The present invention relates to a method for manufacturing a susceptor for an inductively heatable aerosol-generating article, the method comprising the steps of providing a band of susceptor material and providing a compression stage including opposing compression elements, the compression stage having a first portion and a second portion, the compression elements being arranged to define a progressively narrowing compression gap in a process direction and a constant compression gap therebetween in the process direction, the opposing compression elements being configured with matching surface structures, and guiding the band of susceptor material through the narrowing compression gap of the compression stage such that the matching surface structures of the compression elements deep draw the band of susceptor material.

[0011] The matching surface structures of the oppositely disposed compression elements may be configured such that the band of susceptor material is provided with at least one recess on at least one side. The surfaces of the compression elements may include, for example, protruding structures that cooperate with corresponding recessed structures on each oppositely disposed compression element. As the band of susceptor material is guided through the compression elements of the oppositely disposed compression stages, the surface structures deep-draw the band of susceptor material, changing the surface of the susceptor material accordingly.

[0012] Due to the compression gap gradually narrowing in the processing direction, the susceptor material is gradually formed into its final shape. This reduces the risk of material damage during the deep drawing process. In this way, even very thin bands of susceptor material can be processed in the compression stage.

[0013] Advantageously, the first portion of the compression stage, i.e., the portion forming the compression gap that narrows gradually in the processing direction, is located at the upstream end of the compression stage. The second portion of the compression stage is advantageously disposed downstream of the first portion of the compression stage. In this manner, the band of susceptor material is first guided through the first portion of the compression stage, where it is provided with a depression formed in the desired shape.

[0014] In the second part of the subsequent compression stage, the final shape of the susceptor material is established, for which purpose the compression elements of the second part of the compression stage form a constant compression gap in the processing direction and apply a constant pressure to the susceptor material.

[0015] The compression elements may each be configured as a belt guided over a plurality of guide rollers. The belts may be arranged oppositely to define a compression gap through which the band of susceptor material is guided. In a first portion of the compression stage, the guide rollers are further arranged such that the belt defines a progressively narrowing compression gap in the process direction. In a second portion of the compression stage, the guide rollers are arranged such that the belt defines a constant compression gap in the process direction.

[0016] Each belt may be guided over a plurality of guide rollers, at least one of which may be configured as a drive roller, the drive roller being a guide roller connected to a drive motor, the drive roller being used to actuate the corresponding belt.

[0017] The belt may be a toothed belt having a plurality of teeth extending from the surface of the belt. The teeth may be regularly arranged at a constant pitch. The toothed belt may be arranged so that teeth from one belt interpenetrate between two adjacent teeth arranged on the opposite belt. Using two identical belts provides the advantage that only one belt design is used, thus reducing the number of different parts of the device. Additionally, the risk of using the wrong belt is avoided.

[0018] The belts may also be provided with alternating mating female and male teeth. The female teeth are formed with recesses large enough to receive the male teeth therein. The male and female teeth may be arranged in alternating fashion on each belt. In this configuration, both surfaces of the band of susceptor material are provided with alternating protrusions and recesses.

[0019] Alternatively, male teeth may be disposed exclusively on one belt and female teeth on the other belt, in which case only one surface of the band of susceptor material is provided with protrusions and the other surface is provided with only indentations.

[0020] A belt having matching female and male teeth can be advantageous in that it provides a well-defined compression gap through which the band of susceptor material is guided, thus providing increased control of the resulting recesses and protrusions provided to the band of susceptor material.

[0021] The teeth of the belt may have a wide variety of shapes so that various surface patterns can be generated on the surface of the band of susceptor material. The teeth may extend across the entire width of the belt. The teeth may extend across only a portion of the width of the belt. Continuously arranged teeth may be offset from one another. The teeth may be configured to form transverse waves relative to the direction of movement of the band of susceptor material. The teeth may be arranged to form longitudinal or transverse depressions relative to the longitudinal direction of the band of susceptor material and may be distributed according to any desired pattern. The belt may also be provided with rows of parallel teeth. The configuration of the belt teeth determines the resulting shape of the surface of the band of susceptor material. When the depressions in the belt are subsequently filled with a sensory medium, the evaporation characteristics of the sensory medium can be controlled, or at least influenced, by the surface design of the susceptor material.

[0022] The toothed belt can also be used as a timing belt during the deep drawing process of the band of susceptor material. Thus, the belt can not only help to provide a strong draw on the band of susceptor material, but also help synchronize the movement of the belts. Because the surface structures of the belts engage with each other during compression, these surface structures also prevent slippage or any other undesirable relative movement between the belts.

[0023] To assist in the deep drawing process, heating units may be used to heat the band of susceptor material prior to or during the re-forming process in the compression stage.

[0024] The compression elements may be configured as thread-shaped elements. A compression stage may include one or more pairs of consecutively arranged thread-shaped elements. In a first portion of the compression stage, the thread-shaped elements may be configured and arranged such that threads provided on the outer periphery of the thread-shaped elements form a compression gap that gradually narrows in the process direction. In a second portion of the compression stage, the thread-shaped elements may be configured and arranged such that the thread-shaped elements form a constant compression gap in the process direction.

[0025] As the band of susceptor material is guided through the compression gap formed by the oppositely disposed screw-shaped elements, the band of susceptor material is drawn and progressively retracted into the desired corrugated shape. Therefore, the compression stage does not require additional drive means for the band of susceptor material. In addition, the compression stage has a fairly simple structure because it consists essentially of only screw-shaped elements.

[0026] The thread-shaped elements are essentially cylindrical elements, and the outer peripheries of the oppositely disposed thread-shaped elements are provided with corresponding threads having corresponding thread pitches, and the rotation axes of the thread-shaped elements may be oriented essentially parallel to the processing direction of the band of susceptor material.

[0027] To form a gap that narrows gradually in the process direction, the thread-form elements may be arranged with their longitudinal axes slightly inclined toward each other, such that the threads provided on the outer periphery of the thread-form elements form a compression gap that narrows gradually in the process direction. Such an embodiment may be advantageous, since the thread-form elements used have the same and regular cylindrical shape.

[0028] The thread-shaped elements may also be configured with a gradually increasing diameter. In such an embodiment, the thread-shaped elements may be arranged so that their longitudinal axes are oriented parallel to one another. In this configuration, the threads provided on the outer periphery of the thread-shaped elements also form a compression gap that gradually narrows in the processing direction. The parallel arrangement of the longitudinal axes of the thread-shaped elements may provide advantages from a structural standpoint. This may be particularly true when multiple pairs of consecutively arranged thread-shaped compression elements are used. It may be advantageous if all of the compression elements have a common rotation axis.

[0029] In the first part of the compression stage, where the thread-shaped elements form a compression gap that narrows progressively in the process direction, the initially flat band of susceptor material is progressively drawn into a corrugated shape. Again, due to the compression gap narrowing progressively in the process direction, the forming process is slow and smooth so that the risk of material fracture is reduced.

[0030] In the second part of the compression stage, the screw-shaped elements form a compression gap with a constant size in the processing direction, which also serves to maintain the band of susceptor material in the correct final corrugated or wave-like shape.

[0031] A compression stage including a thread-shaped compression element may further include one or more guide elements. The guide element may be a thread-shaped guide element. The thread-shaped guide element may be disposed above or below the pair of thread-shaped compression elements. The thread-shaped guide element may be disposed in engagement with the pair of thread-shaped compression elements. The guide element may have a thread pitch corresponding to the thread pitch of the compression elements. In this manner, the guide element may be rotatably engaged with the compression elements. The guide element and the compression elements may share the same drive element and may be disposed to transversely define a compression gap therebetween.

[0032] The guide elements assist in guiding the band of susceptor material. The guide elements may prevent the band of susceptor material from shifting out of the compression gap due to rotation of the compression elements. It is therefore particularly advantageous if the guide elements are constructed and arranged to confine the compression gap in a transverse direction. Advantageously, two guide elements are provided for each pair of thread-shaped compression elements.

[0033] The compression stage may include a third portion in which the compression elements are arranged to define a gap that progressively expands in the process direction. The compression elements used in the third portion of the compression stage may be generally formed similarly to the compression elements in the first and second portions of the compression stage.

[0034] Thus, if the compression elements of the first part of the compression stage are provided in the form of opposed belts guided over guide rollers, the compression elements of the third stage may likewise be belts guided over guide rollers, in which the guide rollers are arranged to define a gap through which the belts progressively expand in the process direction.

[0035] If the compression elements of the first portion of the compression stage are provided in the form of opposing thread-shaped compression elements, the compression elements of the third stage may likewise be provided in the form of thread-shaped compression elements, In the third portion of the compression stage, the thread-shaped compression elements are arranged such that they define a gap that gradually expands in the processing direction.

[0036] For the formation of a progressively widening gap in the process direction, the same considerations apply as described above for the configuration of the thread-shaped elements used in the first portion of the compression stage, which define a progressively narrowing compression gap in the process direction. Thus, the thread-shaped elements may also be configured to have a progressively decreasing diameter, or the thread-shaped elements may be arranged so that their longitudinal axes are slightly inclined from one another.

[0037] By providing a compression stage having a third compression stage configured such that the compression elements define a gap that gradually expands in the process direction, the compression elements slowly disengage from engagement with the newly formed band of susceptor material. This gradual withdrawal of the compression elements reduces the risk of potential damage to the formed band of susceptor material.

[0038] A third portion of the compression stage defining a gap that gradually widens in the process direction is advantageously located at the downstream end of the compression stage.

[0039] The method may further include a sensory medium injecting step, wherein a sensory medium may be injected into the band of susceptor material. The sensory medium may be injected into the depressions in the band of susceptor material.

[0040] The sensory medium may be injected into the band of susceptor material by a separate injection device.

[0041] The injector may also be included in the compression stage. Advantageously, the injector is included in the third part of the compression stage.

[0042] In embodiments in which the compression elements are provided in the form of opposed toothed belts guided over guide rollers, one or more of the teeth or protruding structures of the belt may be provided with a central hollow channel extending through the entirety of the belt and the protruding tooth elements.

[0043] One or both of the toothed belts may be guided along the pressurized sensory media reservoir. The sensory media reservoir may have an opening facing the rear side of the toothed belt. The rear side of the toothed belt may generally cover the opening of the pressurized sensory media reservoir to prevent the pressurized sensory media from flowing out of the sensory media reservoir. The toothed belt may be guided along the sensory media reservoir such that the central hollow channel of the tooth is in fluid communication with the opening of the pressurized sensory media reservoir.

[0044] When the central hollow channel is in fluid communication with the opening of the pressurized sensate reservoir, a quantity of sensate flows through the central hollow channel and is delivered from the tips of the teeth to the depressions in the band of susceptor material.

[0045] The amount of sensate delivered with each injection step can be adjusted as needed, for example, by changing the pressure in the pressurized sensate reservoir, by changing the speed of the belt, or by changing the size of the tooth channel.

[0046] The injection device may be fixed relative to the compression stage. The injection device may be provided in a third portion of the compression stage. In the third portion of the compression stage, the teeth of the belt are progressively withdrawn from the corrugations provided in the band of susceptor material. The progressive withdrawal of the teeth allows space for the sensory medium to be inserted into the recesses in the band of susceptor material, making the third portion of the compression stage optimally suited for injecting the sensory medium.

[0047] Pressurization of the sensory media reservoir may be achieved by any suitable means, such as a piston or pump, which may be a peristaltic pump or another type of pump useful in working with sensory media.

[0048] If the compression elements in the first portion of the compression stage are provided in the form of opposed thread-shaped compression elements, injection of the sensate medium may be achieved through one or more hollow radial channels opening in thread ridges provided on the outer periphery of one or both of the thread-shaped compression elements, and the one or more hollow radially disposed channels may be connected to a fixed pressurized sensate medium reservoir.

[0049] In particular, when two or more radial channels are provided, each thread-shaped compression element may be provided with a central axial channel that acts as a manifold for the multiple radial channels. The central axial channel may be configured to connect to a sensory media reservoir. The central axial channel may be configured to connect to the sensory media reservoir via a tube or any other conduit.

[0050] Also in this embodiment, radial channels are advantageously provided in the thread-shaped compression elements in the third portion of the compression stage. As previously mentioned, in the third portion of the compression stage, the ridges of the thread-shaped compression elements are progressively withdrawn from the corrugations provided in the band of susceptor material. This leaves sufficient space in the corrugations of the band of susceptor material for the sensory medium, and is therefore an ideally suited point for injecting the sensory medium.

[0051] The amount of sensory medium injected can be determined by the pressure of the sensory medium in the sensory medium reservoir, by the diameter of the axial hollow channel, and by the size and number of hollow radially arranged channels in the screw-shaped compression element.

[0052] The present invention also relates to a method for manufacturing a susceptor for an inductively heatable aerosol-generating article, comprising the steps of providing a band of susceptor material and providing a cutting stage including a periodically corrugated blade, wherein the periodically corrugated blade is used to cut and expand at least a portion of the band of susceptor material such that the band of susceptor material is provided with continuous regions of plain susceptor material and expanded susceptor material.

[0053] A periodic corrugated blade is configured to have a cutting blade with a periodic profile of the corrugation. The exact shape of the corrugation profile can be tailored to the desired characteristics of the expanded portion formed from the cut portion. However, the corrugations should be formed so that the band of susceptor material is not completely severed across the entire width of the band of susceptor material. Instead, the band of susceptor material is only provided with partial cut lines between which unsevered bridges of susceptor material remain.

[0054] The profile of the waveform may have a triangular or other polygonal shape, or may have a rounded shape, such as a sinusoidal shape.

[0055] As described above, the blade having a wave-shaped configuration is configured to partially cut the band of susceptor material along its width. At the same time, the blade is also provided with a shaped portion that stamps the cut portion into the wave-shaped configuration according to the cutting blade design. Thus, the cut portion of the initially flat band of susceptor material is cut and simultaneously expanded into the wave-shaped configuration.

[0056] The cutting and expanding process is preferably a stepwise process, meaning that the band of susceptor material is advanced a predetermined amount between each cutting and expanding step. Additionally, the periodically corrugated blades may be transversely offset between successive cutting and expanding steps.

[0057] During the cutting and expanding process, an initially flat band of susceptor material is incrementally fed into the cutting stage and the cutting blade is reciprocated perpendicular to the feed direction, thus providing alternating offset cuts in the initially flat band that are used to form corresponding expanded portions.

[0058] In this way, a complete band of susceptor material can be transformed into a band of expanded susceptor material, and it is also possible to create a band having continuous portions of expanded and plain susceptor material.

[0059] The expansion process causes the cut portions of the band of susceptor material to expand in the direction of the cut, which extends essentially perpendicular to the flat, uncut portion of the band, thus providing the resulting band with a stepped profile along its length.

[0060] After cutting and expanding, the processed band may be flattened to prepare the susceptor material for further processing. To this end, the band of susceptor material may be flattened by folding or stamping. In this way, a flat band of susceptor material having successively arranged plain and expanded regions may be obtained.

[0061] A band of susceptor material with continuously arranged plain and extended portions offers new possibilities for induction heating processes. The plain portion provides a larger surface and volume for eddy currents than the extended portion. Therefore, more heat is generated in the plain portion of the band of susceptor material region than in the extended region. This can be used to design the heating profile of the susceptor element. It can also be used to determine where to place the sensory medium relative to the susceptor element.

[0062] The method may further include providing a sensory medium to the band of susceptor material. The step of providing a sensory medium to the band of susceptor material may occur simultaneously with the cutting and expanding steps. The step of providing a sensory medium to the band of susceptor material may be performed during the cutting and expanding steps such that the sensory medium is provided to the expanded region.

[0063] For this purpose, a sensory medium reservoir may be provided in the cutting stage. The sensory medium reservoir may have a discharge opening adjacent to the region where the expansion step is performed. The discharge sensory medium reservoir may have a discharge opening positioned so that the band of susceptor material expanded by the cutting blade moves across the discharge opening. The sensory medium reservoir is configured so that the sensory medium is discharged during expansion of the susceptor material. In this way, the sensory medium can be directly taken up by the expanded portion during its production. In particular, the sensory medium may be supplied to the expanded region at the punctured or open portion of the susceptor so that the addition of the sensory medium does not result in a change in thickness.

[0064] The sensory media reservoir may contain a pressurized medium and may have a controllable valve that can be released to release the sensory media. The sensory media reservoir may also include a controllable piston that can change the volume of the sensory media reservoir and force the sensory media out of the release opening.

[0065] Both the valve and the piston may be synchronized with the movement of the cutting blade so that the medium is released during the expansion process. The expanded portion is well suited for providing a sensory medium because, due to the open structure of the expanded portion, the vaporized sensory medium can be easily entrained by the airflow passing through the susceptor material.

[0066] As used herein, the term "expanded susceptor material" refers to a type of susceptor material in which multiple areas of weakness, particularly multiple perforations, are created and then stretched to form a regular pattern of openings resulting from stretching the multiple areas of weakness, particularly from the multiple perforations. The susceptor material may be expanded by puncturing.

[0067] The use of susceptors comprising expanded susceptor material offers several advantages over other types of sheet-like susceptors.

[0068] First, due to certain manufacturing processes, the mass per unit area of ​​the expanded susceptor material is reduced compared to susceptor materials without such openings. At the same time, the surface of the expanded susceptor material is still large enough to provide a wide range of thermal radiation. As a result, the proportionality between the total mass and the thermal radiation surface of a susceptor including the expanded susceptor material is improved compared to a susceptor including a susceptor material without openings. Advantageously, this helps to save resources for the manufacture of the article. Furthermore, the reduced mass per unit area can also be beneficial in terms of reducing the total mass of the article.

[0069] Secondly, compared to susceptor materials that include openings created by material removal, for example by punching, the production of expanded susceptor materials that include openings created as described above, i.e., in particular by weakening, such as by perforating and stretching the susceptor material, advantageously does not involve waste material, and for this reason, the susceptor of the article according to the invention advantageously allows for savings in material and production costs and therefore for saving resources.

[0070] Third, the openings in the susceptor of the article of the present invention are permeable, enhancing the airflow drawn through the article compared to articles including non-permeable susceptors. Furthermore, the openings in the susceptor facilitate the release of material emitted from the heated aerosol-forming substrate and its entry into the airflow. Advantageously, both aspects facilitate aerosol formation.

[0071] Fourth, susceptors comprising expanded susceptor material are stronger than equivalent weight welded or woven susceptor meshes because the susceptor material, although weakened, particularly perforated and stretched, remains in one piece and therefore maintains its strength. At the same time, expanded susceptor material is more flexible and less rigid than susceptor material without apertures. Advantageously, this facilitates material feeding during the manufacture of aerosol-generating articles.

[0072] Fifth, the openings of the expanded susceptor material can be filled with the aerosol-forming substrate during the manufacture of the article. Advantageously, this can support the fixation of the susceptor within the aerosol-forming substrate. As a result, the positional accuracy and stability of the susceptor within the aerosol-forming substrate are significantly improved, while the overall thickness is not affected. Since the sensory material does not protrude from the susceptor, it is easier to handle.

[0073] The method may further include forming the flattened band of susceptor material into a corrugated band of susceptor material, as described above. The band of susceptor material is preferably formed with periodically alternating plain and extended portions. More preferably, the periodicity of these portions corresponds to the periodicity of the corrugations provided on the band of susceptor material. By matching the two periodicities to each other, a corrugated band of susceptor material is obtained in which the extended and plain portions are always provided in the same positions.

[0074] The plain portions may be formed into depressions, also referred to herein as valleys, and the extended portions may be formed into protrusions, also referred to herein as peaks, of the resulting corrugated band of susceptor material. Alternatively, the plain portions may be formed into peaks and the extended portions may be formed into valleys of the resulting corrugated band of susceptor material.

[0075] The method may further include providing two bands of susceptor material. The method may further include overlapping the two bands of susceptor material such that an extended portion of one band of susceptor material is positioned adjacent to a plain portion of the other band of susceptor material. By overlapping the two bands of susceptor material in this manner, an extended portion of one band of susceptor material is positioned adjacent to a plain portion of the other band of susceptor material. This configuration enhances heat transfer from the plain portion to the extended portion, which in turn enhances the vaporization capability of the susceptor arrangement.

[0076] The present invention also relates to a susceptor for an inductively heatable aerosol-generating article provided as a band of susceptor material including portions of continuously disposed plain susceptor material and expanded susceptor material.

[0077] A band of susceptor material with continuously arranged plain and extended portions offers new possibilities for induction heating processes. The plain portion provides a larger surface and volume for eddy currents than the extended portion. Therefore, more heat is generated in the plain portion of the band of susceptor material region than in the extended region. This can be used to design the heating profile of the susceptor element. It can also be used to determine where to place the sensory medium relative to the susceptor element.

[0078] A portion of the expanded susceptor material may be filled with a sensory medium. The sensory medium may be located within holes, voids, or openings in the expanded region, and the sensory medium may not protrude beyond the thickness of the susceptor. A susceptor having a continuously arranged plain portion and an expanded portion provides good heating and vaporization characteristics. The plain portion is used to generate heat that is easily transferred to the expanded portion by conduction. The expanded portion receives heat from the adjacent plain portion so that the sensory medium provided in the expanded portion can be vaporized. Due to the porous structure of the expanded portion, the vaporized sensory medium may engage with airflow passing through both sides of the susceptor material, enhancing overall aerosolization of the sensory medium.

[0079] A band of flat susceptor material having successively disposed plain and expanded portions may be processed to provide corrugations. A band of flat susceptor material having successively disposed plain and expanded portions may be processed to provide valleys and crests. A band of flat susceptor material having successively disposed plain and expanded portions may be processed to provide valleys and crests such that the plain portions are formed into valleys and the expanded portions are formed into crests of the resulting corrugated band of susceptor material.

[0080] The top of the susceptor material extends into the airflow and is therefore a preferred location for vaporization to occur, so this configuration is particularly advantageous when the sensory medium is provided on an extended portion of the band of susceptor material.

[0081] Alternatively, or additionally, the sensate may also be provided in valleys of the susceptor material formed within portions of the plain susceptor material, and because plain susceptor material generates more heat during induction heating, it may be desirable to provide a particular sensate in the plain portions of these bands of susceptor material.

[0082] As an example, the expanded susceptor can be fabricated from a sheet having a thickness ranging from about 0.03 millimeters to about 1 millimeter, more preferably from about 0.05 millimeters to about 0.5 millimeters, e.g., from about 0.07 millimeters to about 0.2 millimeters. The openings in the expanded region can be generally diamond- or rhombus-shaped, with a first diagonal ranging from 0.5 millimeters to 5 millimeters and a second diagonal ranging from 0.3 to 3 millimeters. The open area can range from 30 percent to 70 percent of the total area. The susceptor material can be in the form of a band. The band preferably has a basic rectangular shape with a width of about 2 millimeters to about 8 millimeters, more preferably from about 3 millimeters to about 5 millimeters, e.g., 4 millimeters.

[0083] The present invention further relates to a susceptor arrangement for an inductively heatable aerosol-generating article, as described herein, comprising two bands of susceptor material overlapping each other such that the extended peak region of one band of susceptor material is positioned adjacent to the plain valley region of the other band of susceptor material.

[0084] This susceptor arrangement offers an additional advantage: in this configuration, the extended portion of one band of susceptor material is always disposed adjacent to the plain portion of the other band of susceptor material, allowing inductive heat generated within the plain portion to be delivered directly to the extended portion of the other band of susceptor material. This configuration allows for more efficient heat transfer because the path for heat conduction between adjacent susceptors is short and the surface area for heat conduction between adjacent susceptors is large.

[0085] Furthermore, the peaks on both sides of the susceptor arrangement are formed from extended portions to ensure optimal vaporization conditions on both sides of the susceptor arrangement. Furthermore, the valleys are formed from plain portions of the susceptor and are located directly adjacent to the peaks of other susceptors. Therefore, heat generated in both valleys can be easily conducted to the adjacent susceptors, enhancing the overall vaporization performance of the susceptor arrangement.

[0086] The susceptor arrangement may be provided with a sinusoidal or triangular waveform. The periodicity of the waveform corresponds to the periodicity of the continuous plain and extended portions. By way of example, the waveform may exhibit a peak-to-peak height, prior to formation, of approximately 5 to 15 times the thickness of the flat band.

[0087] As mentioned above, the top of the susceptor arrangement extends into the airflow generated in the aerosol-generating article, and from this perspective it is advantageous to have the top formed from an extended portion of susceptor material that carries the sensory medium.

[0088] However, in that case, the sensory medium may also be susceptible to being adversely affected by additional manufacturing steps performed during further production of the aerosol-forming article. Therefore, it may be advantageous to form the peaks from unloaded plain material and the valleys from loaded extended material. Additional sensory medium may be loaded into the extended portion to enable a more intense user experience.

[0089] By providing a triangular corrugation, the susceptor may be arranged such that the diffusion direction of the vaporized sensory medium can be oriented, for example, the susceptor may be arranged such that the diffusion direction of the vaporized sensory medium is directed in the direction of airflow through the aerosol-generating article and toward the mouth end of the article.

[0090] The present invention also relates to a method for providing a sensory medium to a band of susceptor material, wherein the band of susceptor material is manufactured as described herein. The band of susceptor material may be a corrugated band of susceptor material or may be a flat band of susceptor material including portions of continuously disposed plain susceptor material and expanded susceptor material.

[0091] The sensory medium may be applied to the band of susceptor material by immersion. To this end, the band of susceptor material may be guided through a tank containing the sensory medium. The band of susceptor material may be completely immersed in the sensory medium so that the entire surface of the band of susceptor material is in contact with the sensory medium.

[0092] A pair of guide rollers may be provided to convey the band of susceptor material through the sensory medium tank, between which the band of susceptor material is clamped and transported through the sensory medium tank. Such a pair of guide rollers may be provided at both ends of the sensory medium tank. In this way, the movement of the band of susceptor material through the sensory medium tank can be well controlled.

[0093] This method may be particularly suitable for depositing a sensory medium onto a band of susceptor material that includes a succession of plain and extended portions. The sensory medium may adhere better to the extended portions than to the plain portions. Thus, this method may be particularly suitable for depositing a sensory medium onto the extended portions of the band of susceptor material.

[0094] The sensory medium may be applied to the band of susceptor material via a coating roller, the surface of which may be provided with the sensory medium, and the sensory medium may be deposited on the band of susceptor material by guiding the band of susceptor material over the coating roller.

[0095] The band of susceptor material may be pressed slightly against the covering roller to maintain sufficient contact between the band of susceptor material and the covering roller. If the band of susceptor material is a corrugated band, the band may be guided through a roller gap formed between the covering roller and the counter roller. The distance of this roller gap may be smaller than the distance between the peaks of the corrugations. In this manner, the counter roller may help press the band of susceptor material against the covering roller. The counter roller not only helps to maintain sufficient contact pressure, but also increases the contact surface between the corrugated band of susceptor material and the covering roller so that the sensory medium is provided over a larger area of ​​the band of susceptor material. This method may be particularly suitable for a corrugated band of susceptor material having a sinusoidal corrugation with high elasticity.

[0096] If the band of susceptor material is a corrugated band, the coating roller contacts only the crests of the band of susceptor material. Thus, the sensory medium is provided only to the crests of the corrugated band. The corrugated band of susceptor material may be formed such that the crests are formed from extended portions of susceptor material. The extended portions may better retain the sensory medium than plain portions, making sensory medium deposition more efficient in this configuration.

[0097] The band of susceptor material may also be pressed against the coating roller by two tension rollers provided downstream and upstream of the coating roller. The tension rollers can be used to change the tension of the band of susceptor material near the coating roller. By changing the tension of the band, the coating efficiency can be adjusted. The use of tension rollers can be particularly useful when the band of susceptor material is a flat band.

[0098] The tension roller can also be used to change the contact arc between the band of susceptor material and the coating roller. In this way, the contact time between the band of susceptor material and the coating roller can be changed. Adjusting the contact arc can be used to increase coating efficiency.

[0099] The coating roller may be in fluid communication with the sensory media reservoir. The coating roller may be positioned above the sensory media reservoir at a distance such that a lower portion of the coating roller is immersed in the sensory media provided in the sensory media reservoir. The sensory media may wet the surface of the coating roller and then be deposited onto the band of susceptor material.

[0100] The covering roller may be in direct fluid communication with the sensory media reservoir. The covering roller may also be in indirect fluid communication with the sensory media reservoir. Indirect fluid contact may be established via an intermediate roller, which is in direct contact with the sensory media and transfers the sensory media to the covering roller. One or more intermediate rollers may be provided between the sensory media reservoir and the covering roller. By using one or more intermediate rollers, the amount of sensory media provided to the band of susceptor material after it has been provided to the covering roller can be more precisely controlled.

[0101] The sensory medium may be provided to the band of susceptor material by guiding the band of susceptor material beneath a sensory medium reservoir, which may have an opening at its bottom that may contact the upper surface of the band of susceptor material.

[0102] The band of susceptor material may be transported on an endless moving belt, and the opening of the sensory media reservoir may be located in direct contact with an upper surface of the band of susceptor material.

[0103] Such a configuration may be advantageous for use with a band of susceptor material that is a flat band including continuously disposed plain and extended portions, such that when the plain portion of the band of susceptor material is directly beneath an opening, the plain portion effectively seals the opening and prevents the sensory medium from flowing into the band of susceptor material.

[0104] When the expanded portion of the band of susceptor material is directly beneath the opening, the sensory medium is delivered onto the open expanded portion to its maximum capacity, thus delivering only a limited amount of sensory medium to the band of susceptor material.

[0105] An injection device using a sensory media reservoir provided above the band of susceptor material can also be used with a corrugated band of susceptor material. The bottom opening of the sensory media reservoir does not necessarily have to be in contact with the band of susceptor material. Nevertheless, the sensory media reservoir can be used to deliver sensory media to concave valley portions of the band of susceptor material that are transported below the sensory media reservoir opening.

[0106] This injection device can be used for deposition of a sensory medium onto a band of corrugated susceptor material, the valleys being formed from plain portions of the susceptor material and, optionally, the peaks being formed from expanded susceptor material.

[0107] Because they are made from plain susceptor material, the valleys can retain a significant amount of sensory medium. Furthermore, the amount of sensory medium delivered to each valley of the corrugated band of susceptor material can remain constant. The same amount of sensory medium may be filled into each valley. If the peaks are formed from expanded susceptor material, these peaks may define a maximum fill level of sensory medium. The peaks may act as spillovers to limit the amount of sensory medium delivered to the valleys. Thus, when the fill level of a valley reaches a portion of the porous expanded material region, an excess amount of sensory medium may spill through the porous expanded material.

[0108] The opening of the sensory medium reservoir may be opened and closed via any suitable means known to those skilled in the art. For example, an opening valve may be provided that can be controlled depending on the periodicity of the band of susceptor material loaded with the sensory medium. In this way, the sensory medium can be delivered precisely when the valley is located below the opening.

[0109] A pump, such as a peristaltic pump, may be provided to regulate the flow of sensory medium or the pressure within the sensory medium reservoir. The pump may be synchronized with a valve. In this way, it may be ensured that a sufficient amount of sensory medium is delivered to each valley of the bands of corrugated susceptor material.

[0110] The sensate may be provided to the band of corrugated susceptor material via an injection device utilizing a solid state sensate. The method may include advancing the solid state sensate toward a puncher, cutting a quantity of the sensate, and delivering the quantity of sensate to valleys in the band of corrugated susceptor material.

[0111] A solid-state sensory medium may be easier to handle than a liquid sensory medium. Delivery of the sensory medium in a solid state allows for a consistent and precise dose of the sensory medium. Thus, using this method, a corrugated band of susceptor material may be produced in which every valley is provided with the same predetermined amount of sensory medium.

[0112] The method may further include temporarily liquefying the quantity of sensory medium delivered to the valleys of the bands of corrugated susceptor material.

[0113] Liquefaction of the quantity of sensate can be facilitated by temporarily heating the sensate after delivering it to the valleys of the bands of corrugated susceptor material. Heating can be performed by any suitable heating device. A suitable heating device is a hot air gun. The hot air delivered from such a hot air gun can be sufficient to reduce the viscosity of the sensate. The heated sensate can then begin to become fluid and adhere to the walls of the valleys of the bands of susceptor material.

[0114] This can be advantageous if, as the sensory medium is heated, only the sensory medium is heated while heating of the susceptor material is largely avoided. In this case, the amount of heat required to liquefy the sensory medium can be minimized, and deformation of the susceptor material due to excessive heat is avoided. Furthermore, the cooling process of the sensory medium is accelerated if the susceptor material is heated as little as possible.

[0115] To further accelerate the cooling process of the sensory medium, the band of susceptor material may be conveyed through a cooling station. Cooling stations suitable for this process are known in the art. By accelerating the cooling process, rapid re-gelling of the sensory medium may be achieved. The band of susceptor material may be processed only after the sensory medium has cooled and sufficiently adhered to the susceptor material. Accelerating the cooling process may therefore reduce the time required for the overall manufacturing process.

[0116] The band of corrugated susceptor material may be conveyed through the injector in stages. Each stage may correspond to a pitch width of the band of corrugated susceptor material. After each stage, the injector is activated. A predetermined amount of sensory medium is cut and delivered to the valleys of the band of corrugated susceptor material.

[0117] The stepwise movement of the band of corrugated susceptor material can be established via any suitable conveyor device. The conveyor device can include a toothed endless belt driven by a stepper motor. The toothed belt can have a periodicity corresponding to the periodicity of the band of corrugated susceptor material. In this manner, each tooth of the toothed belt can engage a valley of the band of corrugated susceptor material. By distributing the traction force over multiple engagement points, stress at each individual engagement point can be reduced, and deformation of the band of corrugated susceptor material can be avoided.

[0118] Advancing the sensory medium toward the cutting device and cutting the predetermined amount of sensory medium may be performed using any suitable process and device known in the art. The advancing mechanism may include a piston or clamp that engages the solid state sensory medium and functions to move the solid state sensory medium.

[0119] A puncher may be used to cut a predetermined amount of sensory media. The puncher may be movable perpendicular to the direction of advancement of the sensory media and may include a cutting blade at its forward end. The puncher may be used to cut a predetermined amount of sensory media and force the cut sensory media into valleys in a band of corrugated susceptor material located below the puncher.

[0120] The method may be used to fill the valleys on only one side of a band of corrugated susceptor material. The method may also be used to fill the valleys on both sides of a band of corrugated susceptor material with a sensate medium. This may be done via a two-step process. In the first step, the sensate medium may be filled into the valleys on a first side of the band of corrugated susceptor material. After the sensate medium has cooled sufficiently so that it adheres sufficiently to the valleys of the band of corrugated susceptor material, the band may be turned and the valleys on a second side of the band of corrugated susceptor material may be filled with the sensate medium.

[0121] The sensate within the valleys can adhere to the walls of the corrugated band so that the sensate stays in place even when turned upside down. If the adhesion of the sensate is too weak, for example, due to the vibrations of the moving corrugated band or due to the thixotropic properties of the sensate, the viscosity or adhesion of the sensate can be increased. This can be done by further cooling the metal band or by changing the composition of the sensate.

[0122] The sensory medium may be provided to the band of corrugated susceptor material via a separate injector utilizing a liquid sensory medium. The liquid sensory medium may be provided to a sensory medium reservoir through which the band of corrugated susceptor material is guided. The sensory medium reservoir may have at least one inlet opening for introducing the unloaded band of corrugated susceptor material into the sensory medium reservoir. The sensory medium reservoir may have at least one outlet opening for allowing the loaded band of corrugated susceptor material to exit the sensory medium reservoir.

[0123] The exit opening may be formed from two lips defining a distance therebetween, the distance between the lips corresponding to the distance between the peaks of the bands of corrugated susceptor material.

[0124] The corrugated band is guided through the interior volume of the sensory mediator reservoir and is guided out of the sensory mediator reservoir through an exit opening.

[0125] The two lips that define the exit opening may be resilient, or pre-biased, or both resilient and pre-biased, so that each of the lips is slightly pressed against the band of corrugated susceptor material.

[0126] As the band of corrugated susceptor material is guided through the interior of the liquid medium reservoir and through the exit opening, a liquid sensory medium is received within each valley of the band of corrugated susceptor material, the sensory medium being configured to have a composition such that the sensory medium received within each valley essentially adheres to the walls of the valley of the corrugated band after the corrugated band leaves the sensory medium reservoir through the exit opening.

[0127] As the lips press against the corrugated band from each side, they effectively close the exit opening to prevent excess sensory medium from exiting the sensory medium reservoir. To obtain a reliable seal, the lips may have a length such that each lip constantly contacts at least two peaks on each side of the corrugated susceptor material band.

[0128] The width of the lip may correspond to the width of the corrugated band. The outlet opening of the sensory media reservoir may be provided with suitable sealing elements on the lateral faces of the corrugated band to seal the outlet opening.

[0129] The lips are preferably made of an elastic material. In this way, height differences between the successive peaks of the wavy bands can be compensated. Alternatively, or additionally, the lips may be pre-biased towards each other via a suitable biasing device. In a simple configuration, such biasing can be obtained by a spring mechanism provided between each lip and the corresponding side of the sensory media reservoir.

[0130] Because the band of corrugated susceptor material may be subjected to varying tension and pressure forces during its movement through the sensory medium reservoir, the peak-to-peak distance of the corrugated band may change during the coating process. These varying tension and pressure forces may be caused by the viscosity of the sensory medium or friction between the surfaces of the two lips and the corrugated band at the outlet opening. By configuring the two lips to be elastic or pre-biasing the lips, the distance between the two lips may be dynamically changed to compensate for any changes in the dimensions of the corrugated band. In this way, a leak-proof outlet opening may be achieved, preventing the unwanted spillage of excess sensory medium.

[0131] The expression "sensory medium" is herein understood to be a material or mixture of materials that, preferably when heated, is capable of releasing volatile compounds into an airflow passing through the article in which the susceptor is disposed.

[0132] The sensory medium may be a gel. Providing a gel may be advantageous for storage and transport or during use, as the risk of leakage from the susceptor, aerosol-generating article, or aerosol-generating device may be reduced.

[0133] Advantageously, the gel is solid at room temperature. "Solid" in this context means that the gel has a stable size and shape and does not flow. Room temperature in this context means 25 degrees Celsius.

[0134] The sensory medium can include an aerosol former. Ideally, the aerosol former is substantially resistant to thermal decomposition at the operating temperatures of the susceptor. 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 polyhydric alcohol or mixture thereof can be one or more of triethylene glycol, 1,3-butanediol, and glycerin or polyethylene glycol.

[0135] Advantageously, the sensory medium gel comprises, for example, a thermoreversible gel. This means that the gel becomes fluid when heated to the melting temperature and becomes a gel again at the gelling temperature. The gelling temperature may be at room temperature and above atmospheric pressure. Atmospheric pressure means a pressure of 1 atmosphere. The melting temperature may be higher than the gelling temperature. The melting temperature of the gel may be above 50°C, 60°C, 70°C, or even above 80°C. The melting temperature in this context means the temperature at which the gel is no longer solid and begins to flow.

[0136] Alternatively, in certain embodiments, the gel is a non-melting gel that does not melt during use of the susceptor. In these embodiments, the gel may at least partially release the active agent at temperatures above the operating temperature of the susceptor during use, but below the melting temperature of the gel.

[0137] The gel preferably has a viscosity of 50,000 to 10 Pascals / second, preferably 10,000 to 1,000 Pascals / second, to provide the desired viscosity.

[0138] The gel may comprise a gelling agent, which may comprise agar or agarose or sodium alginate or gellan gum, or a mixture thereof.

[0139] The gel may comprise water, e.g., the gel is a hydrogel. Alternatively, in certain embodiments, the gel is non-aqueous.

[0140] The gel preferably includes an active agent. The active agent may include nicotine (e.g., in powder or liquid form), or a tobacco product or another target compound, for example, for release in an aerosol. The nicotine may be included in the gel along with an aerosol former. Encapsulating the nicotine within the gel at room temperature is desirable to prevent leakage of the nicotine from the aerosol-generating article.

[0141] The gel may include solid tobacco materials that release flavor compounds when heated, which may be one or more of powders, granules, pellets, pieces, spaghetti, strips, or sheets, including one or more of plant materials such as herb leaves, tobacco leaves, tobacco stem fragments, reconstituted tobacco, homogenized tobacco, extruded tobacco, and expanded tobacco.

[0142] The gel may also contain other flavors, such as menthol, which can be added to either the water or the aerosol former prior to formation of the gel.

[0143] In embodiments in which agar is used as the gelling agent, the gel may contain, for example, 0.5 to 5 weight percent, preferably 0.8 to 1 weight percent, agar. Preferably, the gel further contains 0.1 to 2 weight percent nicotine. Preferably, the gel further contains 30 to 90 weight percent (or 70 to 90 weight percent) glycerin. In certain embodiments, the remainder of the gel comprises water and flavoring agents.

[0144] The gelling agent is preferably agar, which has the property of melting at temperatures above 85°C and returning to a gel at around 40°C. This property makes agar suitable for high-temperature environments. The gel does not melt at 50°C, which is useful, for example, if the system is placed in a hot car in the sun. The phase transition to a liquid at around 85°C means that the gel only needs to be heated to a relatively low temperature to induce aerosolization, allowing for low energy consumption. It may be beneficial to use only agarose, one of the components of agar, instead of agar.

[0145] When gellan gum is used as the gelling agent, the gel typically contains 0.5 to 5 weight percent gellan gum. Preferably, the gel further contains 0.1 to 2 weight percent nicotine. Preferably, the gel contains 30 to 99.4 weight percent glycerin. In certain embodiments, the remainder of the gel contains water and flavoring agents.

[0146] In one embodiment, the gel comprises 2 weight percent nicotine, 70 weight percent glycerol, 27 weight percent water, and 1 weight percent agar.

[0147] In another embodiment, the gel comprises 65 weight percent glycerol, 20 weight percent water, 14.3 weight percent tobacco, and 0.7 weight percent agar.

[0148] In particular, the amount of gel per single article may be set or adjusted in relation to the expected delivery of nicotine and / or the expected total aerosol volume generated and / or the expected duration of the user experience.

[0149] As used herein, the term "susceptor material" refers to a material capable of converting electromagnetic energy into heat. When placed in an alternating electromagnetic field, eddy currents are typically induced within the susceptor, and hysteresis losses may occur, causing the susceptor to heat. Because the susceptor material is placed in thermal contact with the sensory medium, the sensory medium is heated by the susceptor material and releases a fluid from the susceptor material.

[0150] The susceptor material may be formed from any material that can be inductively heated to a temperature sufficient to release material from the sensory medium. Preferred susceptor materials include metal or carbon. Preferred susceptor materials may include or consist of ferrous or ferromagnetic materials (e.g., ferritic iron, ferromagnetic alloys such as ferromagnetic steel, stainless steel, or aluminum). The susceptor material preferably contains more than 5 percent, preferably more than 20 percent, preferably more than 50 percent or 90 percent ferromagnetic or paramagnetic material. Preferred susceptors may be heated to temperatures of about 150 degrees Celsius to about 300 degrees Celsius. Preferably, the susceptor may be heated to temperatures of about 200 degrees Celsius to about 270 degrees Celsius, e.g., 235 degrees Celsius.

[0151] The band of susceptor material is preferably a metallic strip of material.

[0152] The band of susceptor material is preferably a stainless steel band, however, the susceptor material may also include or be made of graphite, molybdenum, silicon carbide, aluminum, niobium, Inconel alloy (austenitic nickel-chromium based superalloy), metallized film, ceramic (e.g., zirconia, etc.), transition metal (e.g., iron, cobalt, nickel, etc.), or semi-metallic components (e.g., boron, carbon, silicon, phosphorus, aluminum, etc.).

[0153] The susceptor material is in the form of a band. The band preferably has a basic rectangular shape with a width of about 2 mm to about 8 mm, more preferably about 3 mm to about 5 mm, e.g., 4 mm, and a thickness of about 0.03 mm to about 1 mm, more preferably about 0.05 mm to about 0.5 mm, e.g., about 0.07 mm to 0.2 mm. The width of the band of susceptor material is smaller than the width or diameter of the plug in which the susceptor material is disposed. [Example]

[0154] Below is provided a non-exhaustive list of non-limiting examples, any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0155] Example A: 1. A method for manufacturing a susceptor for an inductively heatable aerosol-generating article, comprising: providing a band of susceptor material; providing a compression stage including oppositely disposed compression elements, wherein in a first portion of the compression stage the compression elements are arranged to define a progressively narrowing compression gap in a process direction and in a second portion of the compression stage the compression elements are arranged to define a constant compression gap therebetween in the process direction, the oppositely disposed compression elements being configured to have matching surface structures; guiding the band of susceptor material through a constricting compression gap of the compression stage such that the matching surface structure of the compression element deep draws the band of susceptor material. Example B: A method according to embodiment A, wherein the compression element is a belt guided over a plurality of guide rollers, and in a first portion of the compression stage, the guide rollers are arranged to define a compression gap through which the belt progressively narrows in the process direction. Example C: The method according to any one of embodiments A or B, wherein the belts are provided with alternatingly arranged teeth such that a tooth on one belt interpenetrates between two adjacent teeth arranged on the opposing belt. Example D: The method according to any one of Examples A to C, wherein the belts are provided with alternatingly arranged matching protruding and recessed structures, the protruding structures from one belt interpenetrating with the recessed structures of the other belt, thereby deep drawing a band of susceptor material guided between the belts. Example E: The method according to example A, wherein the compression element is a thread-shaped element configured and arranged such that threads provided on the outer periphery of the thread-shaped element form a compression gap that narrows progressively in the processing direction. Example F: A method according to embodiment E, wherein the compression elements are thread-shaped elements arranged with their longitudinal axes inclined towards each other so that threads provided on the outer periphery of the thread-shaped elements form a compression gap that gradually narrows in the processing direction. Example G: A method according to embodiment E, in which the compression elements are thread-shaped elements having a gradually increasing diameter and are arranged with their longitudinal axes parallel to each other so that the threads provided on the outer periphery of the thread-shaped elements form a compression gap that gradually narrows in the processing direction. Example H: The method according to any one of embodiments E-G, wherein the compression stage includes one or two thread-shaped guide elements disposed above or below the narrowing compression gap and engaging with the compression element. Example I: The method according to any one of embodiments A-H, wherein the compression stage further includes a third portion, the compression elements arranged to define a gap that gradually expands in the process direction. Example J: The method according to any one of embodiments AI, wherein the portion of the compression stage forming the progressively narrowing compression gap is located at the upstream end of the compression stage. Example K: The method according to any one of embodiments A-J, wherein the portion of the compression stage forming the progressively expanding gap is located at the downstream end of the compression stage. Example L: The method according to any one of embodiments A-K, wherein the method includes a sensate injection step, in which a sensate is injected into depressions in the band of susceptor material formed during the compression step. Example M: A method according to any one of embodiments A-L, wherein the teeth or protruding structures are provided with a central channel in fluid communication with a sensory medium reservoir, and the sensory medium is provided in a recess in the band of susceptor material in the third portion of the compression stage defining a progressively expanding gap. Example N: A method according to any one of embodiments A to M, wherein the protuberances of the screw-shaped compression element arranged to form a gradually expanding gap are comprised of one or more central channels in fluid communication with a sensory medium reservoir, and the sensory medium is provided in a recess in a band of susceptor material in a third portion of the compression stage defining the gradually expanding gap in the processing direction. Example O: 1. A method for manufacturing a susceptor for an inductively heatable aerosol-generating article, comprising: providing a band of susceptor material; providing a cutting stage in the band of susceptor material including a periodically corrugated blade for cutting and expanding at least a portion of the band of susceptor material such that continuous portions of plain susceptor material and expanded susceptor material are provided. Example P: A method according to embodiment O, wherein the cutting process is a stepwise process in which between each cutting step the band of susceptor material is fed forward a predetermined amount and the periodically corrugated blade reciprocates perpendicular to the feeding direction. Example Q: A method according to any one of embodiments O and P, wherein after the cutting process, the band of susceptor material is flattened by folding or stamping to obtain a flat metal band having plain and expanded portions of continuously arranged susceptor material. Example R: The method according to any one of embodiments OQ, wherein the band of susceptor material is provided with a sensory medium such that the expanded area is simultaneously provided with the sensory medium during the cutting and expanding process. Example S: A method according to any one of embodiments Q-R, wherein the band of flattened susceptor material is provided with corrugations such that the plain portions are formed into valleys and the extended portions are formed into peaks of the resulting corrugated band. Example T: The method according to any one of embodiments O-S, wherein the two bands of susceptor material are overlapped such that the expanded portion of one band of susceptor material is positioned adjacent to the plain portion of the other band of susceptor material. Example U: The method according to any one of embodiments Q-R, wherein the sensory medium is provided to the band of susceptor material after the planarization step. Example V: The method according to any one of embodiments A-U, wherein the sensory medium is provided as a gel in the tank, and the treated susceptor material is guided through the sensory medium tank. Example W: The method according to any one of Examples A-V, wherein the sensory medium is provided as a gel in a tank, and the sensory medium is deposited onto the treated susceptor material via a coating roller, the coating roller being in fluid communication with the sensory medium in the tank. Example X: A method according to any one of embodiments A to W, wherein the sensory medium is provided as a gel in a tank having a dispensing opening on its bottom side, and the treated susceptor material having successively arranged plain and extended areas is guided directly below or adjacent to the opening of the sensory medium tank. Example Y: The method according to any one of embodiments A-X, wherein the sensory media reservoir is pressurized such that sensory media expelled from the sensory media reservoir fills the expanded area. Example Z: The method according to any one of embodiments A-Y, wherein the sensory media reservoir is periodically pressurized such that gel is expelled from the sensory media reservoir and fills the expanded portion only if the expanded portion extends adjacent to the opening of the sensory media reservoir. Example ZA: The method according to any one of embodiments A-Z, wherein the sensory medium is provided to the susceptor material via an injection device, the sensory medium being a gel, and the sensory medium is expelled under pressure from the applicator onto the nearby passing band. Example ZB: The method according to any one of Examples A-ZA, wherein the sensory medium is discharged continuously or periodically. Example ZC: The method according to any one of embodiments A-ZB, wherein the infusion device includes a pump, preferably a peristaltic pump, for delivering the sensory medium. Example ZD: the band of susceptor material is provided as a corrugated band and the sensory medium is provided as a solid state gel strip; The method according to any one of Examples A-ZC, wherein the apparatus comprises an advancement mechanism for the gel strip and an injection device including a puncher for cutting a quantity of gel and delivering this quantity of gel into a valley of the band of corrugated susceptor material. Example ZE: The method according to example ZD, wherein the amount of gel material delivered to the valleys is temporarily liquefied by a hot air gun. Example ZF: A method according to embodiment ZD or ZE, wherein the band of corrugated material is conveyed stepwise through the injection device via a toothed belt driven by a stepper motor. Example ZG: The method according to any one of embodiments A-ZF, wherein the valleys on either side of the band of corrugated material are then filled with a sensory medium. Example ZH: A method according to any one of embodiments A-ZG, wherein the band of susceptor material is provided as a corrugated band, the sensory medium is provided as a liquid gel provided within the tank, the side of the tank includes an opening formed by two pre-biased or resilient lips, and the corrugated band is guided through the interior volume of the tank and exits the tank through the opening formed by the two pre-biased or resilient lips. Example ZI: The method according to embodiment ZH, wherein the length of the lip is such that the lip is always pressed against at least two peaks of the corrugated band. Example ZJ: A susceptor for an inductively heatable aerosol-generating article, the susceptor being provided as a band of susceptor material including regions of continuously disposed plain susceptor material and extended susceptor material. Example ZK: A susceptor according to embodiment ZJ, wherein a sensory medium is provided in the expanded portion of the susceptor material. Example ZL: A susceptor according to any one of embodiments ZJ or ZK, wherein the band of susceptor material is provided with corrugations such that the plain portions are formed into valleys and the extended portions are formed into peaks of the resulting corrugated band. Example ZM: The susceptor according to any one of embodiments ZJ-ZL, wherein a sensory medium is provided in valleys formed in the portion of plain susceptor material. Example ZN: A susceptor arrangement for an inductively heatable aerosol-generating article, the susceptor arrangement including two susceptors according to any one of Examples ZJ to ZM, the two susceptors being stacked such that the extended top portion of one susceptor is positioned adjacent to the plain valley portion of the other susceptor. Example ZO: A susceptor arrangement according to embodiment ZN, in which the susceptor arrangement is provided with a sinusoidal or triangular waveform, the periodicity of the waveform corresponding to the periodicity of the successive plain and extended portions.

[0156] 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]

[0157] [Figure 1] FIG. 1 illustrates a method for forming a corrugated band of susceptor material. [Figure 2]FIG. 2 shows one embodiment of a toothed belt. [Figure 3] FIG. 3 shows bands of susceptor material with various surface patterns. [Figure 4] FIG. 4 shows an embodiment of a toothed belt including an injection device. [Figure 5] FIG. 5 illustrates a method for forming a band of corrugated susceptor material. [Figure 6] FIG. 6 is a cross-sectional view of the device of FIG. [Figure 7] FIG. 7 illustrates a method for forming a corrugated band of susceptor material provided with a sensory medium. [Figure 8] FIG. 8 illustrates a method for cutting and expanding a band of flat susceptor material. [Figure 9] Figure 9 shows the cutting and expanding stage. [Figure 10] FIG. 10 shows a band of flat susceptor material with continuous portions of plain susceptor material and expanded susceptor material. [Figure 11] FIG. 11 illustrates a method of providing a sensory medium to the band of susceptor material of FIG. [Figure 12] FIG. 12 shows a band of corrugated susceptor material and a corresponding susceptor arrangement having continuous sections of plain susceptor material and expanded susceptor material. [Figure 13] FIG. 13 shows an apparatus for providing a sensory medium to the susceptor of FIG. [Figure 14] FIG. 14 shows an apparatus for providing a sensory medium to the susceptor of FIG. [Figure 15] FIG. 15 shows an apparatus for providing a sensory medium to a corrugated susceptor. [Figure 16] FIG. 16 shows an apparatus for providing a sensory medium to the susceptor of FIG. [Figure 17] FIG. 17 shows an apparatus for providing a sensory medium to a corrugated susceptor. [Figure 18] FIG. 18 illustrates a method for forming a susceptor arrangement. [Figure 19]FIG. 19 illustrates a method for injecting a solid state sensory medium into a corrugated susceptor. [Figure 20] FIG. 20 illustrates a method for injecting a liquid sensory medium into a corrugated susceptor. [Figure 21] FIG. 21 is a detailed view of the outlet end of the sensory media reservoir of FIG. DETAILED DESCRIPTION OF THE INVENTION

[0158] 1 shows a first embodiment of an apparatus for carrying out the method of the present invention in which an initially flat band of susceptor material 10 is processed into a corrugated band of susceptor material 11. The flat band of susceptor material 10 is a stainless steel band having a width of about 5 millimeters and a thickness of about 0.05 millimeters.

[0159] A flat band of susceptor material 10 is fed into a processing apparatus 12 having a compression stage 14, which provides a desired corrugation to the band of susceptor material 10. To this end, oppositely disposed compression elements 16 are provided, defining a compression gap 18 therebetween.

[0160] The compression elements are each an endless toothed belt 16 guided along guide rollers 20. One of the guide rollers 20 is configured as a drive roller 22 connected to a drive motor (not shown). The guide rollers 20 and drive rollers 22 are arranged to define three different sections of the compression stage 14.

[0161] In a first portion 24 of the compression stage 14, the guide rollers 20, 22 are arranged so that the compression elements 16 define a compression gap 18'' that gradually narrows in the process direction. In a second portion 26 of the compression stage 14, the guide rollers 20, 22 are arranged so that the compression elements 16 define a constant compression gap 18 therebetween in the process direction. In a third portion 28 of the compression stage 14, the guide rollers 20 are arranged so that the compression elements 16 define an expanding compression gap 18 in the process direction.

[0162] The opposing toothed endless belts 16 are arranged so that the teeth 30 of one endless belt interpenetrate between two adjacent teeth 30 on the opposing belt.

[0163] An initially flat band 10 of susceptor material is guided through the compression stage 14 so that the band 10 is fed into the narrowing gap 18 of a first portion 24 of the compression stage 14 .

[0164] The mating surface structures, which are interpenetrating teeth 30 of the opposing compression elements 16, progressively engage the band of susceptor material 10, progressively deep-drawing the material into the predetermined corrugated shape. In a second portion 26 of the compression stage 14, the compression gap 18 is held constant in the process direction. In this portion of the compression stage 14, the compression elements 16 are used to establish the corrugated shape of the band of susceptor material 10.

[0165] At the downstream end of the compression stage 14, the compression elements 16, particularly the teeth 30 of the endless belt 16, are progressively withdrawn from the corrugated band of susceptor material 11. This progressive withdrawal prevents potential damage to the newly formed band of susceptor material 11.

[0166] 2 shows an alternative arrangement of a toothed belt 16 having matching surface structures. The belt 16 is provided with alternatingly arranged, matching female and male teeth 32 and 34. The male teeth 34 include protrusions 36. The female teeth 32 are formed with recesses 38 large enough to receive the protrusions 36 of the male teeth 34 therein. In use, a band of susceptor material 10 is guided between the toothed belt 16 having the female and male teeth 32 and 34. The matching surface structures of the toothed belt 16 form alternatingly arranged depressions in the band of susceptor material 10. In this manner, the initially flat band of susceptor material 10 is transformed into a corrugated band of susceptor material 11.

[0167] In Figure 3, corrugated bands 11 of susceptor material having various surface patterns are shown schematically. In the left view of Figure 3, corrugated bands 11 of susceptor material are shown having a regular, sinusoidal, or wave-like pattern. However, other patterns are possible, as shown in the two other views of Figure 3. The center view of Figure 3 shows a pattern in which a plurality of longitudinal indentations 40 are provided in the band 11 of susceptor material. In the right view of Figure 3, a plurality of transverse indentations 42 are provided in the band 11 of susceptor material.

[0168] 4 shows an arrangement in which the band 10 of susceptor material is provided with corrugations while simultaneously injecting a sensory medium 44 into each of the newly formed depressions 46. The toothed belt 16 shown in FIG. 4 corresponds to the belt 16 of FIG.

[0169] Each male tooth 34 is provided with a central hollow channel 48 that extends entirely through the belt 16 and male tooth 34. The toothed belt 16 is guided along pressurized sensate media reservoirs 50. Each of the sensate media reservoirs 50 has an opening 52 facing the rear side of the respective toothed belt 16. The belt 16 is guided so that the rear side of each toothed belt 16 generally covers the opening 52 of the respective pressurized sensate media reservoir 50. However, as the male teeth 34 and central hollow channel 48 are guided past the openings 52 of the pressurized sensate media reservoirs 50, sensate media 50 can flow through the central hollow channel 48 and be delivered from the tips of the male teeth 34 into the recesses 46 of the band 11 of corrugated susceptor material.

[0170] The injection process is carried out in the third section 28 of the compression stage 14. In this section, the belt 16 is arranged to form a compression gap 18 that expands in the processing direction, thereby progressively withdrawing the male teeth 34 from the female teeth 32. As the protrusions 36 of the male teeth 34 move out of the recesses 46, the recesses 46 create a space for the injection of the sensory medium 44.

[0171] The sensate 44 is provided in gel form. The amount of sensate gel 44 delivered is adjusted by varying the pressure in the pressurized sensate reservoir 50 and by varying the speed of the belt 16. Pressurization of the sensate reservoir 50 is obtained via a pump (not shown).

[0172] 5 to 7 relate to a further embodiment of the invention in which the method is carried out by using compression elements in the form of thread-shaped elements 56. The thread-shaped elements 56 are essentially cylindrical elements, the outer periphery of which is provided with corresponding threads 58 having a corresponding thread pitch.

[0173] As shown in Figure 5, the thread-shaped elements 56 are arranged such that their longitudinal axes 60 are slightly inclined toward each other with respect to the process direction 62, such that threads 58 provided on the outer periphery of the thread-shaped elements 56 form a compression gap 18 that gradually narrows in the process direction. In Figure 5, only the first portion 24 of the compression stage 14 is shown. In the first portion 24 of the compression stage 14, the initially flat band 10 of susceptor material is progressively drawn into the band 11 having a corrugated shape. This first portion 24 is followed by at least the second portion 26, in which the thread-shaped compression elements 56 are arranged to form a constant compression gap 18 in the process direction.

[0174] In the embodiment of FIG. 6, the band of susceptor material 10 is additionally guided in the compression stage 14 by two guide elements 64. The guide elements 64 are also thread-shaped elements. The thread-shaped guide elements 64 are disposed above and below the pair of thread-shaped compression elements 56. The thread-shaped guide elements 64 also have an external thread having a thread pitch corresponding to the thread pitch of the compression elements 56. In this manner, the guide elements 64 rotatably engage with the compression elements 56. The guide elements 64 and the compression elements 64 transversely define a compression gap 18 through which the band of susceptor material 10 is guided.

[0175] FIG. 7 illustrates a third portion 28 of the compression stage 14, in which the compression elements 16 are provided in the form of opposing thread-shaped elements 56. The thread-shaped elements 56 are arranged such that they define a compression gap 18 that gradually widens in a processing direction 62. The compression elements 56 are configured to deliver a sensory media gel 44 to the band 11 of susceptor material. To this end, the compression elements 56 include hollow radial channels 66 that open at thread ridges provided on one outer periphery of the thread-shaped compression elements 56. The hollow, radially disposed channels 66 extend into a central manifold channel 68, which in turn is connected to a fixed pressurized sensory media reservoir (not shown). In FIG. 7, the central axial channel manifold 68 is configured to receive an adapter 70 configured to connect to a pressurized sensory media reservoir. The adapter 70 includes a longitudinal opening 72 that allows fluid communication with the hollow, radially disposed channels 66. In FIG. 7, only the upper compression element 56 is shown. However, a corresponding sensate injection device is also provided in the lower compression element 56 so that sensate 44 is provided on both sides of the band 11 of corrugated susceptor material.

[0176] 7 shows a cross-sectional view of the compression element 56 including fluid channels 66, 68. In this case, three equidistantly spaced radial channels 66 are provided, one for each turn of the thread. Each of the radial channels 66 extends from a central axial channel 68 to the outer periphery of the thread-shaped compression element 56.

[0177] The amount of sensory medium 44 injected into recess 46 is determined by the pressure in the sensory medium reservoir, by the diameter of axial hollow channel 68, and by the size and number of hollow radially disposed channels 66 in thread-shaped compression element 56. Sensory medium 44 may be injected continuously or intermittently. To this end, a controllable valve (not shown) may be provided that can be opened or closed to control the flow of sensory medium into band 11 of susceptor material.

[0178] 8-11 illustrate a method for manufacturing a susceptor for an inductively heatable aerosol-generating article in which an initially flat band of susceptor material is advanced in stages to a cutting stage 80 that includes a periodically corrugated blade 82. The periodically corrugated blade 82 has a periodic trapezoidal shape and is configured to provide partial cuts in the flat band of susceptor material 10 transverse to its longitudinal axis.

[0179] The corrugated blade 82 is simultaneously provided with a shaping portion 83 that, according to the design of the cutting blade 82, stamps the cut portion into the corrugated shape defined by the corrugated blade 82. Thus, the cut portion of the initially flat band 10 of susceptor material is cut and simultaneously expanded into this corrugated shape.

[0180] The cutting and expanding process is a stepwise process. The movement of the cutting blade 82 is a reciprocating movement, as shown by the series of arrows in Figure 8. In the top view of Figure 8, the band of susceptor material 10 has already advanced into the cutting stage 80 a predetermined distance corresponding to the cutting width of the cutting stage 80. As shown by the arrow, the wavy blade 82 moves to the right to a first cutting position.

[0181] In the second view of FIG. 8 , the cutting blade 82 is in a first position and moves downward, simultaneously cutting and expanding the band of susceptor material 10. The cutting blade 82 then moves upward and to the left by half the pitch of the blade's corrugation to a second cutting position. The band of susceptor material 10 again moves forward one step, and the cutting blade 82 moves downward, making a second cut that is transversely offset from the first cut. Similarly, an expansion is made transversely offset from the first expansion step. In the bottom view of FIG. 8 , the cutting blade 82 is again raised and moved backward to the first cutting position. The cutting process may then be repeated as described above. In this manner, the initially flat band of susceptor material 10 is provided with an expanded portion 86 that extends over at least a portion of the length of the band of susceptor material 10.

[0182] The expansion process expands the cut portions of the band 10 of susceptor material in the cut direction, which extends essentially perpendicular to the plane defined by the flat band 10 of susceptor material. In FIG. 9, the initially flat band 10 of susceptor material is provided with successive portions of plain, or uncut, susceptor material 84 and expanded, or cut, susceptor material 86. The resulting partially expanded band 88 is therefore provided with a stepped profile in its length, as shown in the schematic diagram of FIG.

[0183] After cutting and expanding, the band 88 having the continuous plain and expanded portions 84 and 86 may be flattened to prepare the band 88 of susceptor material for further processing. To this end, the band 88 of susceptor material is flattened by a stamping device (not shown). The resulting flat band 90 of susceptor material having the continuous plain and expanded portions 84 and 86 is shown in FIG. 10. As a result of the expansion process, the expanded portions are provided with through-holes separated by straps or tongues of the sheet. By way of example, the width of the straps or tongues can be set equal to the thickness of the susceptor. The holes or perforations can exhibit a maximum opening dimension greater than or at least equal to the thickness of the susceptor.

[0184] 11, the partially expanded band 88 of susceptor material is further provided with a sensory medium 44. The sensory medium 44 is provided to the band 88 of susceptor material during the cutting and expanding process. To this end, the cutting stage 80 is provided with a sensory medium reservoir 50. The sensory medium reservoir 50 has a discharge opening 52 directly adjacent to the cutting and expanding stage 80. During the cutting and expanding step, the portion 86 of the band of susceptor material that is expanded by the cutting blade 82 moves across the discharge opening 52.

[0185] The sensory medium reservoir 50 is configured to release the sensory medium 44 during expansion of the band of susceptor material 10. To this end, the sensory medium reservoir 50 includes a controllable piston 51 that forces the sensory medium 44 out of a discharge opening 52. The piston 51 is synchronized with the cutting blade 82 so that the sensory medium 44 is released during the downward movement of the cutting blade 82 during the expansion stroke.

[0186] The gaps in the expanded portion 86 of the band of susceptor material are well suited to entrapment of the sensory medium 44. Additionally, the expanded portion 86 is open on either side of the band of susceptor material 88 so that, in use, vaporized sensory medium 44 can be readily entrapped by airflow passing through the susceptor element.

[0187] The flattened band of susceptor material 90 having continuous plain portions 84 and expanded portions 86 may be formed into a corrugated band of susceptor material 11, as described above in conjunction with Figures 1 and 5. As shown in the top diagram of Figure 12, the periodicity of the plain portions 84 and expanded portions 86 may correspond to the periodicity of the corrugations provided in the band of susceptor material 11. In this manner, a corrugated band of susceptor material 11 is obtained, but with corrugations, in other words, continuous valleys and peaks, formed from the plain portions 84 and from the expanded portions 86, whereby the expanded portions 86 are provided with a sensory medium 44.

[0188] As shown in the further view of Figure 12, two bands of susceptor material 90 may be overlapped to form a susceptor arrangement 100. Figure 12 shows three alternative arrangements of how two corrugated bands of susceptor material 90 may be overlapped. The arrows in these figures indicate the primary direction of diffusion of the sensory medium 44 as it vaporizes.

[0189] Two bands of susceptor material 90 may be arranged on opposite sides such that the top of the susceptor arrangement 100 is formed from the expanded portion 86 of the corrugated band of susceptor material 90. In use of such a susceptor arrangement 100 in an aerosol generating device, this arrangement allows vaporized material to easily enter an airflow path directed along the susceptor arrangement 100.

[0190] Alternatively, two corrugated bands of susceptor material 90 may also be arranged on opposite sides such that the peaks of the susceptor arrangement 100 are formed from the plain portions 84 of the corrugated bands of susceptor material 90. The peaks formed from the plain portions 84 may prevent the loaded expanded portions 86 from rubbing against additional material provided in the aerosol generation system near the susceptor arrangement 100.

[0191] In the bottom view of Figure 12, a band 90 of corrugated susceptor material is provided with triangular corrugations. The band 90 of corrugated susceptor material is arranged so that the diffusion direction of the vaporized sensory medium is oriented. In Figure 12, the susceptor is arranged so that the diffusion direction faces to the right. This orientation may correspond to the direction of airflow through the aerosol-generating article during use.

[0192] The sensory medium 44 may also be applied to bands 90, 11 of flat or corrugated susceptor material in a subsequent separate process step.

[0193] 13, the band of susceptor material 90 shown in FIG. 10 is provided with sensory media 44 after the band of susceptor material 90 has been partially expanded and flattened. The band of susceptor material 90 is guided through sensory media reservoir 50, which contains sensory media 44 in gel form. The band of susceptor material 90 is completely immersed in sensory media gel 44.

[0194] A pair of guide rollers 92 are provided upstream and downstream of the sensory media reservoir 50 to convey the band of susceptor material 90 through the sensory media reservoir 52. In this manner, the movement of the band of susceptor material 90 through the sensory media reservoir 50 is well controlled.

[0195] The sensory media gel 44 adheres better to the extended portions 86 of the band of susceptor material 90 than to the plain portions 84. Therefore, this method is particularly suitable for selectively depositing the sensory media 44 on the extended portions 86 of the band of susceptor material 90.

[0196] As shown in FIGS. 14 and 15, the sensory medium may also be applied to the band 90 of susceptor material via a coating roller 110 .

[0197] Figure 14 illustrates schematically a method for applying sensory media 44 to a flat band of susceptor material 90. The band of susceptor material 90 is again constructed as described with respect to Figure 10. The band of susceptor material 90 is guided over a coating roller 110. The coating roller 110 is in communication with a sensory media reservoir 50. By guiding the band of susceptor material 90 over the coating roller 110, sensory media 44 is deposited on the band of susceptor material 90.

[0198] 14, the coating roller 110 is in rolling contact with the intermediate roller 112, which is then dipped into the sensory media reservoir 50 containing the sensory media 44 in gel form. The rotating intermediate roller 112 continuously picks up the gel 44 on its surface and dispenses the gel 44 onto the surface of the coating roller 110. From the coating roller 110, the gel 44 is dispensed onto the band 90 of susceptor material.

[0199] Because the gel 44 adheres well to the expanded portions 86 of the band 90 of susceptor material, these portions primarily pick up the sensory media gel 44. Any gel that does not adhere to the band 90 of susceptor material remains on the coating roller 110 and is reapplied to the band 90 of susceptor material on the next rotation of the coating roller 110.

[0200] The band of susceptor material 90 is pressed slightly against the coating roller 110 so that sufficient contact force is maintained between the band of susceptor material 90 and the coating roller 110. In Figure 14, the band of susceptor material 90 is pressed against the coating roller 110 by two tensioning rollers 114 provided downstream and upstream of the coating roller 110. The tensioning rollers 114 are arranged so that the tension in the band of susceptor material 90 near the coating roller 110 is maintained at a predetermined value. The tensioning rollers 114 are used to adjust the band tension as well as the contact arc between the band of susceptor material 90 and the coating roller 110.

[0201] FIG. 15 shows a similar method that can be used to coat a band 11 of primarily corrugated susceptor material. The corrugated band 11 is guided through a roller gap 117 formed between a coating roller 110 and a counter roller 116. The size of this roller gap 117 is somewhat smaller than the peak-to-peak distance 13 of the corrugations of the band 11 of corrugated susceptor material. In this manner, the counter roller 116 presses the band 11 of susceptor material against the coating roller 110. This maintains sufficient contact pressure while simultaneously increasing the contact surface between the band 11 of corrugated susceptor material and the coating roller 110. In FIG. 15, the band 11 of susceptor material is configured with a wave-like shape. However, a corrugated band 11 having a different wave profile may also be used.

[0202] The coating roller 110 contacts only the crests of the band of susceptor material. Thus, only the crests of the corrugated band are provided with the sensory medium 44. Thus, this method may be particularly suitable for use with a corrugated band of susceptor material that includes a plain portion 84 and an extended portion 86, with the crests formed in the extended portion 86 of the susceptor material, as shown in FIG.

[0203] 16 and 17, sensory media 44 may be provided to a band of susceptor material 11, 90 by guiding the band of susceptor material 11, 90 below a sensory media reservoir 50. The sensory media reservoir has a discharge opening 52 at its bottom.

[0204] In Figure 16, a sensate is provided to a band 90 of flat susceptor material, including continuous portions of plain susceptor material 84 and expanded susceptor material 86, as described in connection with Figure 10. Band 90 is conveyed on an endless moving belt 120 that is guided over guide wheels 122. Discharge opening 52 of sensory media reservoir 50 is located directly above and contacts the upper surface of band 90 of susceptor material.

[0205] When the plain portion 84 of the band 90 of susceptor material is directly underneath the discharge opening 52 , the plain portion 84 effectively seals the discharge opening 52 and prevents the flow of sensory medium 44 into the band 90 of susceptor material.

[0206] When the expanded portions 86 of the band 90 of susceptor material are directly under the discharge openings 92, the sensory medium 44 is delivered onto these expanded portions 86. In this manner, only a limited amount of sensory medium 44 is selectively delivered to the band 90 of susceptor material. The sensory medium 44 is located in the open areas of the expanded portions 86 so that there is no increase in the general thickness after loading with the sensory medium. In this manner, further handling of the material is facilitated.

[0207] In Figure 17, an injection device similar to that in Figure 16 is used to deliver sensory media 44 to a corrugated band of susceptor material 11. In this configuration, the discharge opening 52 at the bottom of sensory media reservoir 50 is not necessarily in contact with band of susceptor material 11.

[0208] This injection device is particularly useful for depositing sensate 44 onto a corrugated band 11 of susceptor material in which valleys 94 are formed from the plain portions 84 of the susceptor material. The valleys 94 can retain a significant amount of sensate 44.

[0209] 17, peaks 96 of bands 11 of susceptor material are formed from expanded portions 86. These peaks 96 act as spillovers to limit the amount of sensory medium 44 delivered to valleys 94. Thus, when the fill level of valleys 94 reaches peaks 96 formed from porous expanded material portions 86, excess amounts of sensory medium 44 will spill through the porous expanded material 86.

[0210] An electronically controlled valve (not shown) is provided at the open opening 52 of the sensory medium reservoir 50 to limit the amount of sensory medium 44 delivered to the corrugated band 11. The valve opening is controlled according to the periodicity of the band 11 of susceptor material into which the sensory medium 44 is loaded. In this way, the sensory medium 44 is delivered precisely when the valleys 94 are located below the discharge opening 52.

[0211] Bands 11 of susceptor material provided with sensory media 44 may be sandwiched together to obtain susceptor arrangement 100. A suitable assembly process for this purpose is shown in FIG.

[0212] In the first step, two identical corrugated bands 11 are prepared, with peaks 96 formed from the expanded portions 86 of the susceptor material and valleys 94 formed from the plain portions 84 of the susceptor material and filled with the sensory medium 44.

[0213] One of the bands 11 is turned upside down and moved half a pitch to one side. The bands 11 are then overlapped such that the expanded portions 86 of one band 11 extend into the valleys 94 of the other band 11. As seen in the bottom view of FIG. 18 , the expanded portions 86 of one band 11 cover the sensate 44 provided in the valleys 94 of the other band 11. At the same time, the porous expanded portions 86 allow the vaporized sensate 44 to pass through. The sensate 44 serves to adhere the two corrugated bands 11 of susceptor material together. Using the process shown in FIG. 18 , a very sturdy susceptor arrangement 100 is obtained.

[0214] Sensate 44 may be provided to the band 11 of corrugated susceptor material via an injection device 130 that utilizes solid-state sensate 44. A corresponding method is shown schematically in FIG. 19. The solid-state sensate 44 advances toward a puncher 132, as indicated by arrow 134. The puncher 132 is a movable element configured to cut a quantity of sensate 44 and deliver this quantity of sensate 44 to the valleys 94 of the band 11 of corrugated susceptor material. The advancement mechanism is not further shown in FIG. 19, but any suitable advancement mechanism known to those skilled in the art may be used.

[0215] The band of corrugated susceptor material 11 is conveyed in stages through the injection apparatus 130. The staged movement of the band of corrugated susceptor material 11 is established via a conveyor apparatus 140 including an endless toothed belt 142 driven by a stepper motor 144. Teeth 146 of the toothed belt 142 are provided with a periodicity corresponding to the periodicity of the band of corrugated susceptor material 11. In this manner, each tooth 146 of the toothed belt 142 engages a valley 94 of the band of corrugated susceptor material 11 as the toothed belt 142 conveys the band of corrugated susceptor material 11.

[0216] Each step of the stepper motor 144 and toothed belt 142 corresponds to a pitch width 148 of the band of corrugated susceptor material 11 such that each of the valleys 94 of the band of corrugated susceptor material 11 is successively positioned under the injection device 130. After each step, the puncher 132 is activated to cut a predetermined amount of sensory media 44 and deliver the predetermined amount to the valleys 94 of the band of corrugated susceptor material 11.

[0217] The method further includes temporarily liquefying the amount of sensate 44 delivered to the valleys 94 of the corrugated band of susceptor material 11. To this end, a hot air gun 136 is provided that is directed against the cut sensate 44 within the valleys 94. The hot air reduces the viscosity of the sensate 44. The heated sensate 44 becomes fluid and adheres to the walls of the valleys 94 of the band of susceptor material 11.

[0218] 20 and 21 relate to a method for providing a liquid sensory medium 44 to a band of corrugated susceptor material 11. The liquid sensory medium 44 is provided in a sensory medium reservoir 50 through which the band of corrugated susceptor material 11 is guided. The sensory medium reservoir 50 has an inlet opening (not shown) for introducing the unloaded band of corrugated susceptor material 11 into the sensory medium reservoir 50. The sensory medium reservoir 50 further has an outlet opening 53 that allows the loaded band of corrugated susceptor material 11 to exit the sensory medium reservoir 50.

[0219] The exit opening 53 is formed from two pre-biased lips 150 which define a distance therebetween that corresponds to the peak-to-peak distance 13 of the bands 11 of corrugated susceptor material.

[0220] The undulating band 11 is guided through the interior volume of the sensory media reservoir 50 and is guided out of the sensory media reservoir 50 through an exit opening 53 .

[0221] The two lips 150 that define the outlet opening 53 are formed from a resilient material and are pre-biased so that each lip 150 is pressed slightly against the band of corrugated susceptor material 11. The pre-bias is obtained by a spring mechanism 152 provided between each lip 150 and a corresponding side surface 154 of the sensory media reservoir 50.

[0222] The resilient material of the lip 150 and the spring mechanism 152 cause the lip 150 to press firmly from each side against the band 11 of corrugated susceptor material. In this way, height differences between the successive peaks of the corrugated band 11 are compensated for.

[0223] As lips 150 press against corrugated band 11 from each side, lips 150 effectively close outlet opening 53 to prevent most of the excess sensory medium 44 from leaking from sensory medium reservoir 50. To obtain a reliable seal, lips 150 are configured to have lengths 156 such that each lip 150 constantly contacts at least two peaks on each side of corrugated susceptor material band 11.

[0224] The lip width 158 corresponds to the width of the corrugated band 11. The outlet opening 53 of the sensory media reservoir 50 is provided with a suitable sealing element (not shown) for sealing the outlet opening 53 to the lateral face of the corrugated band 11.

[0225] As the band of corrugated susceptor material 11 is guided through the interior of the liquid sensate reservoir 50 and through the exit opening 53, the liquid sensate 44 is received within each valley 94 of the band of corrugated susceptor material 11. The sensate 44 is configured to have a composition such that the sensate 44 received within each valley 94 essentially adheres to the walls of the valley 94 of the corrugated band 11 after the corrugated band 11 leaves the sensate reservoir 50 through the exit opening 53.

Claims

1. 1. A method for manufacturing a susceptor for an inductively heatable aerosol-generating article, comprising: providing a band of susceptor material; - providing the band of susceptor material with a cutting stage including a periodically corrugated blade for cutting and expanding at least a portion of the band of susceptor material so as to provide continuous portions of plain susceptor material and expanded susceptor material.

2. 2. The method of claim 1, wherein the cutting process is a stepwise process in which the band of susceptor material is fed forward a predetermined amount between each cutting step and the periodically corrugated blade reciprocates perpendicular to the feed direction.

3. 3. The method of claim 1, wherein a sensory medium is provided to the band of susceptor material during the cutting and expanding process, such that the expanded susceptor material portion is simultaneously provided with the sensory medium.

4. 4. The method of claim 1, wherein two bands of susceptor material are overlapped such that the expanded susceptor material portion of one band of susceptor material is located adjacent to the plain portion of the other band of susceptor material.

5. A susceptor for an inductively heatable aerosol-generating article, the susceptor being provided as a band of susceptor material including portions of continuously arranged plain susceptor material and expanded susceptor material, the expanded susceptor material including a plurality of openings.

6. The susceptor of claim 5 , wherein a sensory medium is provided in the expanded susceptor material portion.

7. A susceptor as claimed in any one of claims 5 and 6, wherein the band of susceptor material is provided with corrugations such that the plain portions are formed into valleys and the expanded susceptor material portions are formed into crests of the resulting corrugated band.

8. A susceptor arrangement for an inductively heatable aerosol-generating article, the susceptor arrangement comprising two susceptors as described in claim 7, the two susceptors being stacked such that the extended top portion of one susceptor is positioned adjacent to the plain valley portion of the other susceptor.

Images