Apparatus for cutting sheets of aerosol-generating material

Abstract

An apparatus for cutting a sheet of aerosol-generating material is disclosed. The apparatus includes a laser generator configured to cut the sheet of aerosol-generating material with a laser emitted by the laser generator as the sheet of aerosol-generating material is conveyed along a conveying path. An apparatus for manufacturing a sheet of aerosol-generating material is also disclosed, the apparatus including the apparatus for cutting a sheet of aerosol-generating material according to the present invention. Also disclosed is a consumable comprising a sheet of aerosol-generating material formed into a packaged rod and having a distal end for insertion into an aerosol generating device, the aerosol generating device including a heating element contained within the aerosol-generating material at the distal end of the rod. At the distal end of the rod a portion of the sheet of aerosol-generating material is cut into strips extending from said distal end of the packaged rod.

Description

[Technical Field]

[0001] The present disclosure relates to an apparatus for cutting a sheet of aerosol-generating material, an apparatus for manufacturing a sheet of aerosol-generating material, an apparatus and method for manufacturing an aerosol-generating consumable, a sheet of aerosol-generating material wound on a bobbin, a consumable comprising a sheet of aerosol-generating material, and a non-combustion aerosol delivery system comprising a consumable of the present invention and an aerosol-generating device. [Background technology]

[0002] Certain tobacco industry products, when used, generate an aerosol that is inhaled by the consumer. For example, tobacco heating devices heat an aerosol-generating material, such as tobacco, to form an aerosol by heating the aerosol-generating material without burning it. During manufacture, a sheet or web of aerosol-generating material is unwound from a bobbin and fed to a consumable forming unit that gathers the sheet or web into a rod, wraps the rod in a wrapper, and cuts the rod into rod sections that each form an individual consumable. The sheet may be cut into strips or strands before being gathered into a rod. Summary of the Invention

[0003] Some embodiments described herein provide an apparatus for cutting a sheet of aerosol-generating material that includes a laser generator configured such that a laser emitted by the laser generator cuts the sheet of aerosol-generating material as the sheet is transported along a transport path.

[0004] The apparatus of the present invention may include a control unit configured to control the laser generator.

[0005] The control unit may be configured to control the laser generator to cut the sheet of aerosol-generating material into a plurality of continuous, parallel, elongated strips of aerosol-generating material extending in a direction along the transport path.

[0006] The control unit may be configured to control the laser generator to intermittently cut the sheet of aerosol-generating material to form individual cut sections spaced apart from one another in a direction extending along the transport path.

[0007] Each individual cut section may comprise a plurality of parallel elongated strips of aerosol-generating material extending in a direction along the transport path.

[0008] The control unit may be configured to control the laser generator to form registration marks on the sheet of aerosol-generating material.

[0009] The registration mark may be at least one cut or perforation in the sheet spaced from said individual cut sections.

[0010] Each registration mark may be a pattern of cuts, perforations or other indicia formed in the sheet.

[0011] The control unit may be configured to form registration marks between or adjacent to the individual cut sections.

[0012] In some other embodiments described herein, there is provided an apparatus for producing a sheet of aerosol-generating material comprising an apparatus for cutting a sheet of aerosol-generating material according to the present invention.

[0013] The apparatus of the present invention may include a unit for producing a sheet of aerosol-generating material and a winding unit for winding the produced sheet onto a bobbin. The apparatus for cutting the sheet of aerosol-generating material may be configured to cut the sheet using the winding unit before winding it onto the bobbin.

[0014] In some other embodiments described herein, there is provided an apparatus for producing an aerosol-generating consumable from a sheet of aerosol-generating material, the apparatus comprising: a conveyor for conveying a sheet of aerosol-generating material along a conveying path; a laser generator configured to emit a laser to cut the sheet of aerosol-generating material as the sheet is conveyed along the conveying path; and a consumable forming unit for receiving the cut sheet of aerosol-generating material as it is conveyed along the conveying path and forming it into a rod.

[0015] The apparatus of the present invention may include a control unit configured to control the laser generator to cut the sheet into a plurality of parallel elongated strips of aerosol-generating material extending longitudinally along the transport path.

[0016] The apparatus of the present invention may include a control unit configured to control the laser generator to intermittently cut the sheet to form discrete cut sections, each cut section being spaced apart from an adjacent cut section in a direction extending along the transport path.

[0017] Each individual cut section may comprise a plurality of parallel elongated strips of aerosol-generating material extending in a direction along the transport path.

[0018] The control unit may be configured to control the laser generator to form registration marks on the sheet.

[0019] The apparatus of the present invention may include a scanner configured to read the registration mark and send a signal to the control unit indicative of the presence of the registration mark.

[0020] The control unit may be configured to control the consumable forming unit in dependence on said signal.

[0021] The consumable forming unit may include a garniture for wrapping the rod-shaped sheet in a wrapper to form a packaged rod, and a cutter for cutting the packaged rod into individual rod sections.

[0022] The control unit may be configured to control the cutter to cut the wrapped rod into individual rod sections in dependence on said signal indicating the presence of the registration mark.

[0023] The control unit may be configured to control the cutter in dependence on said signal such that individual cut sections extend from respective ends of said individual rod sections.

[0024] The apparatus of the present invention may include a supply unit for housing a bobbin of a sheet of aerosol-generating material and for unwinding the sheet of aerosol-generating material from the bobbin, for supplying the sheet along the transport path.

[0025] In some other embodiments described herein, a sheet of aerosol-generating material is provided that is wound on a bobbin, the sheet including a plurality of parallel elongated strips of aerosol-generating material extending along the length of the sheet.

[0026] A plurality of parallel elongated strips may be formed into individual cut sections spaced apart from one another along the length of the sheet.

[0027] The sheet of aerosol-generating material may comprise a laminate of two or more layers, one of which may be a gel, which may contain or be formed from a flavorant such as menthol.

[0028] In some other embodiments described herein, a consumable product is provided that includes a sheet of aerosol-generating material formed into a packaged rod and having a distal end for insertion into an aerosol-generating device that includes a heating element, the heating element being contained within the aerosol-generating material at the distal end of the rod, and a portion of the sheet of aerosol-generating material at the distal end of the rod is cut into strips that extend from the distal end of the packaged rod. As described above, the sheet of aerosol-generating material may include a laminate. One layer of the laminate may be a gel or may be formed from or include a flavorant, such as menthol.

[0029] In another aspect of the present invention, there is provided a non-combustion based aerosol delivery system comprising the consumable of the present invention and an aerosol generating device including a heating element, the aerosol generating device configured to receive the consumable such that the heating element is received within the aerosol-generating material at the distal end of a rod.

[0030] In some other embodiments described herein, a method for cutting a sheet of aerosol-generating material is provided, the method including conveying the sheet of aerosol-generating material along a conveying path and scoring the sheet using a laser emitted by a laser generator as the sheet is conveyed along the conveying path.

[0031] The method of the present invention may include using a control unit to control the laser generator to score the sheet to form a plurality of continuous, parallel, elongated strips of aerosol-generating material extending in a direction along the transport path.

[0032] The method of the present invention may include using a control unit to control a laser generator to cut the sheet to form individual cut sections spaced apart from one another in a direction extending along the transport path, each individual cut section comprising a plurality of parallel elongated strips of aerosol-generating material.

[0033] The present invention also provides a sheet of aerosol-generating material cut by the above-described method.

[0034] In some other embodiments described herein, a method for manufacturing a consumable product for generating an aerosol from a sheet of aerosol-generating material is provided, the method including conveying the sheet of aerosol-generating material along a conveying path, cutting the sheet of aerosol-generating material using a laser emitted by a laser generator as the sheet of aerosol-generating material is conveyed along the conveying path, and forming the cut sheet into a consumable product in a consumable product forming unit.

[0035] A method of manufacturing an aerosol-generating consumable of the present invention may include cutting a sheet using a laser generator to form individual cut sections spaced apart from one another in a direction extending along a transport path, each individual cut section including a plurality of parallel elongated strips of aerosol-generating material.

[0036] Forming the cut sheets into consumables may include forming the sheets into rods, wrapping the rods in packaging material, and cutting the rods into individual cut rods.

[0037] The method may include cutting the rod into individual rods such that individual cut sections extend from the end of each rod.

[0038] The present invention also provides a consumable aerosol-generating product produced by the above-described method.

[0039] Another aspect of the present invention provides a sheet of aerosol-generating material that is cut using a laser emitted by a laser generator as the sheet is transported along a transport path.

[0040] In a further aspect of the present invention there is provided an aerosol-generating consumable product formed from a sheet of aerosol-generating material according to the present invention. [Brief explanation of the drawings]

[0041] Some embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Figure 1] 1 is a schematic diagram of an embodiment of an apparatus for manufacturing a consumable product in accordance with an embodiment of the present invention. [Figure 2] 1 is a schematic diagram of an embodiment of an apparatus for producing a consumable product according to another embodiment of the present invention. [Figure 3] 1 is a schematic diagram of an embodiment of an apparatus for producing a consumable product according to yet another embodiment of the present invention. [Figure 4A] 2 shows a sheet of aerosol-generating material before being cut using the apparatus of FIG. 1 and formed into consumables. [Figure 4B] 3 shows a sheet of aerosol-generating material before being cut using the apparatus of FIG. 2 and formed into consumables. [Figure 4C] 4 shows a sheet of aerosol-generating material before being cut using the apparatus of FIG. 3 and formed into consumables. [Figure 5] 1 illustrates an aerosol delivery device containing a consumable product according to an embodiment of the present invention; and [Figure 6] FIG. 1 is a flow diagram illustrating a method for manufacturing a consumable for an aerosol delivery device according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0042] 1 is a schematic diagram of an embodiment of an apparatus 1 for producing an aerosol-generating consumable from a sheet 2 of aerosol-generating material according to a first embodiment. The manufacturing apparatus 1 of the present invention includes a cutting device 3 for cutting the sheet 2 of aerosol-generating material before conveying the sheet 2 of aerosol-generating material into a consumable-forming unit 4 of the manufacturing apparatus 1.

[0043] In various embodiments of the present invention, the sheet of aerosol-generating material 2 is a tobacco material, such as a reconstituted tobacco material, formed into a continuous web or sheet. However, it should be noted that the aerosol-generating material 2 may alternatively be a non-tobacco-based material.

[0044] The manufacturing apparatus 1 includes a feeder 5 having a spool or bobbin 7 of aerosol-generating material mounted thereon. The feeder 5 is configured to feed a sheet 2 of aerosol-generating material as a continuous sheet along a conveying path 6. The sheet 2 may be fed along the conveying path 6 by any suitable mechanism, such as a drive belt or a plurality of rollers (not shown), at least one of which is driven.

[0045] The consumable formation unit 4 of the manufacturing apparatus 1 is configured to receive the sheet 2 of aerosol-generating material as it is conveyed along the conveying path 6. The consumable formation unit 4 is configured to form the sheet 2 into a consumable 8. In this example, the consumable formation unit 4 is configured to gather or form the sheet 2 of aerosol-generating material into a long continuous rod in a rod formation unit 9, wrap the continuous rod with packaging material in a packaging unit 10, and then cut the long wrapped rod into individual rod sections 8 in a rod cutter 11, each rod section forming an individual consumable 8, as shown in FIG.

[0046] In some consumables, the sheet 2 is in the form of strips or strands extending longitudinally along the length of the consumable 8 and in the direction that it extends along the conveying path during manufacture. To enable this configuration, it is known to cut the sheet 2 into a plurality of longitudinally extending strips or strands of the order of 1 mm width using a cutting cylinder that acts on the sheet 2 to gather and form the strips into a rod, cutting the sheet before it enters the consumable forming unit 4, which wraps the rod into packaging material.

[0047] A problem with the above-mentioned cutting techniques is the generation of a significant amount of tobacco dust. The dust coats or adheres to both the strands and the device. Sometimes this problem is alleviated by providing a dust extraction system to suck or blow the dust away from the strands and strips. However, this complicates the device, and some dust remains. Dust may also be blown locally around the device. Also, the cutting blades do not cut precisely, and individual strands may break off due to inconsistencies in the thickness of the sheet.

[0048] To reduce or substantially eliminate the above problems, the sheet 2 is cut into strips using a laser generator 3, which provides a more precise and cleaner cut, thereby eliminating or minimizing dust generation. The tendency for individual strands to snap or break is also avoided or reduced because the strands maintain greater tensile strength when cut by the laser emitted by the laser generator 3.

[0049] In one embodiment, the laser generator 3 is positioned between the feeder 5 and the consumable formation unit 4 above the aerosol-generating sheet 2 so that a laser emitted by the laser generator 3 cuts the sheet 2 of aerosol-generating material as it is conveyed along the conveying path 6 and before it reaches the consumable formation unit 4. The laser generator 3 may be positioned to cut the sheet 2 into strands immediately after the sheet 2 is unwound from a bobbin 7 attached to the feeder 5. Alternatively, the sheet 2 may be cut further downstream, i.e., just before it enters the consumable formation unit 4. A suitable laser generator is a TechR 2x400W, model MLS-G 2-800 or MPS-M4-800, manufactured by Micro Laser.

[0050] The sheet 2 may be cut into strands online, i.e., as the sheet 2 is unwound from the bobbin 7 and fed into the consumable forming unit 4 of the consumable manufacturing apparatus 1. However, it is of course also possible to pre-cut the sheet 2, i.e., to form the cut in the sheet 2 as an integral part of the sheet manufacturing process. In this case, the manufactured sheet 2 is cut immediately after production and before being wound onto the bobbin 7, which is then subsequently loaded into the supply unit 5 of the apparatus 1 for manufacturing consumables. The sheet 2 is therefore wound onto the bobbin 7 in its cut form, and a cutting device including a laser generator 3 according to an embodiment of the present invention can be located between the sheet manufacturing apparatus 1 and the device for winding the sheet onto the bobbin 7.

[0051] The sheet 2 may be cut in a separate process in a dedicated cutting machine. For example, an uncut sheet 2 wound on a spool 7 after manufacture may be subsequently loaded into a cutting machine that unwinds the sheet from the spool 7 and uses a laser generator to cut the cut sheet 2 before it is rewound onto another spool 7. The laser generator 3 for cutting the sheet 2 may be mounted such that the laser generator cuts the portion of the sheet 2 that is between two spools 7.

[0052] It will also be appreciated that in an alternative embodiment, the feeder 5 may feed individual sheets 2 of aerosol-generating material along the transport path 6, with the laser generator 3 positioned to cut into each sheet rather than into a continuous length of aerosol-generating material unwound from a bobbin 7.

[0053] The rod-forming unit 9 of the consumable forming unit 4 is configured to gather the sheets 2 of aerosol-generating material cut by the laser generator 3 into rods having a generally circular cross-section, although other cross-sectional shapes are contemplated. The rod-forming unit 9 may include a funnel or cone (not shown) configured to gather the strips together and allow them to exit the funnel or cone as rods.

[0054] The packaging unit 10 is downstream of the rod-forming unit 9 and is configured to encase the gathered strips of aerosol-generating material in a wrapper. The packaging unit may include a garniture (not shown), which is configured to receive the rod of gathered strips and encase the strips in a wrapper. The wrapper may be fed as a continuous web on a garniture belt and through the garniture, the web being configured to wrap around the rod of strip as the belt, wrapper, and strip pass through the narrow cone or tongue of the garniture. The wrapper may then be secured in place using adhesive applied or pre-applied to the edges of the wrapper.

[0055] The consumable forming apparatus 4 may also include a rod cutter 11 located downstream of the packaging unit 10. The rod cutter 11 is configured to cut the continuous wrapped rod into individual rods 8 of aerosol-generating material. The individual rods 8 produced by the rod cutter 11 may be single-length, double-length, or longer.

[0056] The laser generator 3 may have an array of laser generating heads mounted in fixed positions to simultaneously cut the sheet 2 into a plurality of strips as the sheet 2 is conveyed along the conveying path 6, the strips extending in a direction along the conveying path 6. However, one or more of the laser generating heads may be movable to scan across the sheet. It is envisioned that the sheet 2 continues to move along the conveying path 6. However, it is also possible for the sheet 2 to move intermittently and be held stationary while the sheet is cut by the laser generator 3.

[0057] The apparatus 1 may include a control unit 12 operable to control the activation of the laser generator 3. In some embodiments, such as that shown in FIG. 1, the control unit 12 may control the laser generator 3 to remain activated to continuously cut the sheet 2 as it moves along the transport path 6. FIG. 4A illustrates a plan view of a portion of a sheet 2 of aerosol-generating material cut into a series of continuous, longitudinally extending, parallel strips 13 by the laser generator 3 of FIG. 1. In FIG. 4A, six cuts 14 are cut into the sheet, forming five strips 13. However, it will be appreciated that the sheet 2 may be cut into any number of strips 13, including across the entire width of the sheet 2. In alternative embodiments, the control unit 12 may be omitted altogether, and the laser generator 3 may be controlled manually, i.e., via an on / off switch, or may operate in conjunction with the operation of the supply unit 5.

[0058] In another embodiment, and as shown in the plan view of a portion of a sheet 2 of aerosol-generating material in FIG. 4B , the control unit 12 may continuously start or stop the laser generator 3 of FIG. 1 as the sheet 2 continues to move along the transport path 6, thereby intermittently cutting the sheet 2 to form discrete cut sections 15 spaced apart from one another in a direction extending along the transport path 6. In FIG. 4B , each discrete cut section 15 includes four spaced-apart, parallel cuts 16, forming three strips 17. As in FIG. 4A , each discrete cut section 15 may include any number of cuts 16 adjacent to one another and extending across the width of the sheet 2. A sheet 2 provided with discrete cut sections 15 as shown in FIG. 4B is preferred when the sheet 2 is cut before being wound onto a bobbin 7, because such intermittent cut sections 15 further strengthen and maintain the overall integrity of the sheet 2, facilitating unwinding when the bobbin 7 is loaded onto the consumable manufacturing machine 1. If the sheet is pre-cut into individual cut sections 15, the laser generator 3 may be used to cut registration marks 18 into the sheet 2 between or adjacent to the individual cut sections 15, as shown in the plan view of a portion of the sheet 2 of aerosol-generating material in Figure 4C.

[0059] When sheet 2 is then unwound and fed along transport path 6 to consumable forming unit 4, additional cuts are cut into the web to form continuous longitudinal strips 13, so that sheet 2 resembles that shown in FIG. 4A. These additional cuts may be made using laser generator 3 or by a conventional cutting blade. While the use of a conventional cutting blade generates some dust, the extent of the cuts that need to be made is much shorter than any cuts made in the previous uncut sheet, and therefore the amount of dust is also substantially reduced. The operation of laser generator 3 or conventional cutting blade may be controlled in response to signals received from a scanner 19 (see FIG. 2) located upstream of the cutter that reads registration markings 18 on sheet 2 and operates cutter 3 to complete the cuts between the individual cut sections 15.

[0060] The registration marks 18 may be a pattern or image readable by a scanner 19 of the manufacturing apparatus 1 which can send a signal to control the cutter 3 to complete the cuts between the individual cut sections 15 of the sheet 2 before the sheet 2 enters the consumable forming unit 4. The registration marks 18 may be formed using a laser 3 which is used at a low intensity so as not to penetrate the sheet 2 completely and / or intermittently to form a series of perforations in the sheet 2.

[0061] 4C, the registration marks 18 are located between the individual cut sections 15 and comprise a series of interlocking triangles, however, the registration marks 18 may be formed from any individual shape or combination of shapes. The registration marks 18 may be located anywhere, i.e., adjacent to the individual cut sections 15 or offset to one side of the area between the individual cut sections 15.

[0062] As the sheet 2 moves along the transport path 6, a scanner 19 reads or recognizes the registration marks 18 and sends a signal to a control unit 12 which starts or stops a cutter, which may be a laser generator 3 or a conventional cutting blade, to complete the cuts between the individual cut sections 15 before the strip enters the consumable forming unit 4 to form a plurality of continuous longitudinally extending strips as shown in FIG. 4A.

[0063] In another embodiment, the individual cut sections 15 and registration marks 18 may be cut into the sheet 2 using a laser generator 3, as shown in FIG. 3, and there may be no further cuts in the sheet 2 between the individual cut sections 15 before the sheet 2 enters the rod forming unit 9. In this embodiment, the control unit 12 may instead be configured to control the rod cutter 11, which cuts the rod into individual rod sections 8, in dependence on signals received from a scanner 19 that reads the registration marks 18. In particular, the rod cutter 11 may be controlled so that the rod is cut into individual rod sections 8, with the individual cut sections 15 extending from one end of each individual rod section 8 that forms the distal end of the consumable, i.e., the end of the consumable opposite the mouth end that, during use, is inserted into an aerosol-generating device 20 (see FIG. 5) for heating of the consumable aerosol-generating material.

[0064] If the sheet of aerosol-generating material 2 is pre-cut to have the individual cut sections 15 and registration marks 18, the laser generator 3 may be omitted entirely from the embodiment shown in Figure 3. The scanner 19 then recognizes the registration marks 18 as described in the previous paragraph, and the control unit 12 controls the rod cutter 11.

[0065] If the aerosol generating device 20 (see FIG. 5) into which the consumable 8 is inserted has a heating element 21 in the form of a pin or blade that is inserted into the distal end of the consumable 8, the individual cut sections 15 extending from that end of the consumable 8 facilitate insertion of the heating element 21. The individual cut sections 15 may be the same length as the heating element 21 into which they are inserted. Alternatively, each individual cut section 15 may be shorter or longer than the heating element 21.

[0066] In the above embodiment, the scanner 19 may be positioned above the sheet of aerosol-generating material 2 either perpendicular to the transport path 6 or at an angle to the transport path 6. The scanner 19 may include a camera. Any suitable model of camera may be used, for example, a Keyence CA-HL02MX camera. The camera is configured to image the sheet of aerosol-generating material 2 as it moves along the transport path 4 and detect the presence of registration indicia 18.

[0067] 5, the aerosol-generating device 20 is a non-combustion-based aerosol-generating device 20. The aerosol-generating system includes a consumable product 8 according to an embodiment of the present invention together with the aerosol-generating device 20. The aerosol-generating material 2, gathered into a rod shape and wrapped in a packaging material 23 as represented by the dashed line in FIG. 5, has individual cut sections 15 extending from the end of the consumable product 8 that is inserted into the aerosol-generating device 20, such that a heating element 21 within the device 20 is housed in the aerosol-generating material formed by the individual cut sections 15.

[0068] 6, there is shown a flow chart illustrating a method 25 for manufacturing a consumable 8 for an aerosol delivery device 20. The method 25 of the present invention includes providing a sheet 2 of aerosol-generating material along a conveying path (step S1), cutting the sheet of aerosol-generating material 2 using a laser emitted by a laser generator 3 as the sheet of aerosol-generating material 2 is conveyed along the conveying path (step S2), and forming the cut sheet 2 into a consumable 8 in a consumable forming unit 4 (step S3).

[0069] The step of cutting the sheet 2 of aerosol-generating material using the laser generator 3 (step S2) may include cutting the sheet to form individual cut sections 15 spaced apart from one another in a direction extending along the conveying path 6, each individual cut section 15 comprising a plurality of parallel elongated strips of aerosol-generating material 2.

[0070] The process of forming the cut sheet into consumables 8 in a consumables forming unit 4 (step S3) includes forming the sheet 2 into a rod shape, wrapping the rod in packaging material, and cutting the rod into individual cut rods in a rod cutter 11.

[0071] The step of forming consumables 8 from the cut sheets in a consumable forming unit 4 (step S3) may also include cutting the rods into individual rods 8 using a rod cutter 11 so that individual cut sections 15 extend from one end of each rod.

[0072] In this disclosure, the terms "aerosol-generating device" and "aerosol-generating system" refer to non-combustion aerosol delivery devices and non-combustion aerosol-generating systems, respectively.

[0073] For purposes of this disclosure, a "non-combustion based" aerosol delivery device or system is one that facilitates delivery of at least one substance to a user without burning or combusting the constituent aerosol-generating materials (or components thereof) of the aerosol delivery system.

[0074] In some embodiments, the non-combustion based aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0075] In some embodiments, the non-combustion based aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system.

[0076] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which can be heated. Each of the aerosol-generating materials may or may not contain nicotine. The aerosol-generating materials may include, for example, tobacco or non-tobacco products.

[0077] In some embodiments, the non-combustion aerosol delivery device may include a power source and a controller. The power source may be, for example, an electrical power source or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon substrate that is energized to deliver power in the form of heat to an aerosol-generating material or a thermally conductive material proximate to the heat-generating power source.

[0078] In some embodiments, the non-combustion aerosol delivery device may include a region for containing a consumable product, an aerosol generator, an aerosol-generation region, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0079] In some embodiments, a consumable 8 for use with a non-combustion-based aerosol delivery device may include, in addition to an aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol-generating area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0080] In some embodiments, the substance being dispensed may be an aerosol-generating material or a material not intended to be aerosolized, either of which may optionally include one or more active ingredients, one or more flavoring agents, one or more aerosol-forming materials, and / or one or more other functional materials.

[0081] In some embodiments, the substance delivered comprises an active agent.

[0082] The active substance used in the present invention is a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, and psychotropic drugs. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or components, derivatives, or mixtures thereof. The active substance may also include one or more components, derivatives, or extracts of tobacco, cannabis, or other plants.

[0083] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0084] As described herein, the active substance may include one or more components, derivatives or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0085] As described herein, an active agent may include or be derived from a plant or its components, derivatives, or extracts. The term "plant" as used herein includes, but is not limited to, any material derived from a plant, such as extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruit, pollen, husks, and pods. Alternatively, the material may include active compounds naturally occurring in the plant or synthetically derived. The material may be in the form of a liquid, gas, solid, powder, dust, comminuted particles, granules, pellets, chips, strips, sheets, and the like. Examples of plants include tobacco, eucalyptus, holly, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay leaf, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, Lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, sedge, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiento, oregano, olive, lemon balm, lemon basil, chives, fennel, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. The mint may be selected from the following mint species: mentha piperita, Moroccan mint, Egyptian mint, peppermint, eau de cologne mint, candy mint, curly mint, Kentucky kernel mint, horse mint, pineapple mint, pennyroyal mint, English spearmint, and malva.

[0086] In some embodiments, the active agent may comprise or be derived from a plant or one or more of its components, derivatives, or extracts, and the plant is tobacco.

[0087] In some embodiments, the active agent may comprise or be derived from one or more plants or components, derivatives or extracts thereof, wherein the plants are selected from eucalyptus, celery, cocoa, and hemp.

[0088] In some embodiments, the composition may comprise or be derived from a plant or one or more of its components, derivatives or extracts, wherein the plant is selected from rooibos and fennel.

[0089] In some embodiments, the substance comprises a flavoring agent.

[0090] As used herein, the terms "flavorant" and "flavoring agent" are used to produce a taste, odor, or other somatosensory stimulus that is permitted by local regulations and desired by an adult consumer.They may be naturally occurring flavoring materials, plants, plant extracts, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, Roots, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey extract, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, Sage, fennel, wasabi, pimento, ginger, coriander, coffee, hemp, peppermint oil from any species of the genus Mentha, eucalyptus, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay leaf, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, sedge, curcuma, cilantro, myrtle, black currant, valerian, pimento, melon These additives may include but are not limited to: sucralose, damien, oregano, olive, lemon balm, lemon basil, chives, fennel, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, mannitol, etc.), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.They may be mimetics, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example a liquid such as an oil, a solid such as a powder or a gas.

[0091] In some embodiments, the flavorant comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavorant comprises cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavorant comprises eugenol. In some embodiments, the flavorant comprises flavor components extracted from tobacco. In some embodiments, the flavorant comprises flavor components extracted from cannabis.

[0092] In some embodiments, the flavoring agent may include a sensory agent, which is chemically induced and recognized by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of aroma or taste nerves, and may include agents that produce heating, cooling, tingling, or numbing sensations. A suitable heating agent is, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent is, but is not limited to, eucalyptol, WS-3.

[0093] An aerosol-generating material is a material that can generate an aerosol when excited, for example, by heating, irradiation, or in some other way. The aerosol-generating material may contain, for example, an active agent and / or a flavoring agent. In some embodiments, the aerosol-generating material may comprise an "amorphous solid," alternatively referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that retains a fluid, such as a liquid, within its interior. In some embodiments, the aerosol-generating material comprises from about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0094] The aerosol-generating material 2 may be a laminate of two or more layers. One layer may be a gel layer and may contain or consist of a substance or flavoring such as menthol. The laminate may be formed as part of a band casting process such that the laminate is wound onto a bobbin.

[0095] The aerosol-generating material may include one or more active agents and / or flavorants, one or more aerosol-forming materials, and one or more other functional materials, if desired.

[0096] The aerosol forming material may include one or more components capable of forming an aerosol, and in some embodiments, the aerosol forming material may include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0097] The one or more functional materials may include one or more of a pH regulator, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0098] A consumable is an article containing or consisting of an aerosol-generating material that is intended to be consumed, in part or in whole, by a user during use. A consumable may also include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transport component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater, that radiates heat so that the aerosol-generating material generates an aerosol upon use. The heater may include, for example, a combustion-based material, a material heatable by electrical conduction, or a susceptor.

[0099] The susceptor is a material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material, and the penetration of the varying magnetic field may result in induction heating of the heating material. The heating material may be an electrically conductive material, and the penetration of the varying magnetic field may result in magnetic hysteresis heating of the heating material. The susceptor may be both electrically conductive and magnetic, such that the heating material can be heated by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0100] An aerosol modifier is a substance that is typically located downstream of the aerosol-generation region and configured to modify the generated aerosol, for example by altering the taste, flavor, acidity, or another characteristic of the aerosol. The aerosol modifier may be provided within an aerosol modifier-releasing member that is operable to selectively release the aerosol modifier.

[0101] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavorant, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, liquid, or gel. The aerosol modifier may be a powder, string, or granule. The aerosol modifier may not include a filter material.

[0102] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to expose the aerosol-generating material to thermal energy, causing one or more volatile substances to be released from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to expose the aerosol-generating material to one or more of vibration, high pressure, or electrostatic energy.

[0103] The various embodiments described herein are provided merely to aid in understanding and teaching the claimed features. These embodiments are merely representative examples and are not intended to be comprehensive or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects of the present disclosure should not be construed as limiting the disclosure to the exact scope of the claims or to the equivalents of the claims, and that other embodiments may be utilized or modified without departing from the scope and / or spirit of the present disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of the disclosed elements, components, features, parts, steps, means, or other combinations. The present disclosure also encompasses other inventions not currently claimed but which may be claimed in the future.

Claims

1. a laser generator configured to cut the sheet of aerosol-generating material with a laser emitted by the laser generator as the sheet of aerosol-generating material is conveyed along the conveyance path; a control unit configured to control the laser generator; An apparatus for cutting a sheet of aerosol-generating material, characterized in that the control unit is configured to control the laser generator to intermittently cut the sheet of aerosol-generating material to form individual cut sections spaced apart from one another in a direction extending along the conveying path.

2. 10. The apparatus of claim 1, wherein the control unit is configured to control the laser generator to cut the sheet of aerosol-generating material into a plurality of continuous, parallel, elongated strips of aerosol-generating material extending in a direction along the transport path.

3. 10. The apparatus of claim 1, wherein each individual cut section comprises a plurality of parallel, elongated strips of aerosol-generating material extending in a direction along the transport path.

4. 4. The apparatus of claim 1 or 3, wherein the control unit is configured to control the laser generator to form registration marks on the sheet of aerosol-generating material.

5. 5. The apparatus of claim 4, wherein the registration mark is at least one cut or perforation in the sheet spaced from the individual cut sections.

6. 6. The apparatus of claim 5, wherein each registration mark is a pattern of cuts, perforations, or other indicia formed in the sheet.

7. 6. The apparatus of claim 5, wherein the control unit is configured to form registration marks between or adjacent to the individual cut sections.

8. 4. An apparatus for producing a sheet of aerosol-generating material, comprising a device for cutting a sheet of aerosol-generating material according to any one of claims 1 to 3.

9. 9. The apparatus of claim 8, further comprising a unit for producing a sheet of aerosol-generating material and a winding unit for winding the produced sheet onto a bobbin, wherein the device for cutting the sheet of aerosol-generating material is configured to cut the sheet before winding it onto the bobbin using the winding unit.

10. a conveyor for conveying a sheet of aerosol-generating material along a conveying path; a laser generator configured to emit a laser to cut the sheet of aerosol-generating material as the sheet is conveyed along the conveying path; a consumable forming unit configured to receive the cut sheets of aerosol-generating material as they are conveyed along a conveying path and form them into rods; and a control unit configured to control the laser generator to intermittently cut the sheet to form individual cut sections, each cut section being spaced apart from an adjacent cut section in a direction extending along a conveying path.

11. 11. The apparatus of claim 10, further comprising a control unit configured to control the laser generator to cut the sheet into a plurality of parallel, elongated strips of aerosol-generating material extending longitudinally along the transport path.

12. 11. The apparatus of claim 10, wherein each individual cut section comprises a plurality of parallel, elongated strips of aerosol-generating material extending in a direction along the transport path.

13. 13. Apparatus according to claim 10 or 12, characterized in that the control unit is arranged to control the laser generator to form registration marks on the sheet.

14. 14. The apparatus of claim 13, including a scanner configured to read the registration indicia and transmit a signal to the control unit indicative of the presence of the registration indicia.

15. 15. Apparatus according to claim 14, characterized in that the control unit is adapted to control the consumable forming unit in dependence on said signal.

16. 16. The apparatus of claim 15, wherein the consumable forming unit includes a garniture for wrapping the rod-shaped sheet in a wrapper to form a packaged rod, and a cutter for cutting the packaged rod into individual rod sections.

17. 17. The apparatus of claim 16, wherein the control unit is configured to control the cutter to cut the wrapped rod into individual rod sections dependent on the signal indicating the presence of registration marks.

18. conveying a sheet of aerosol-generating material along a conveying path; scoring the sheet using a laser emitted by a laser generator as the sheet is conveyed along a conveying path; A method for cutting a sheet of aerosol-generating material, comprising: controlling a laser generator by a control unit to intermittently cut the sheet to form individual cut sections, each cut section being spaced apart from an adjacent cut section in a direction extending along a conveying path.

19. conveying a sheet of aerosol-generating material along a conveying path; intermittently cutting the sheet of aerosol-generating material to form discrete cut sections using a laser emitted by a laser generator as the sheet of aerosol-generating material is conveyed along the conveying path, each cut section being spaced apart from an adjacent cut section in a direction extending along the conveying path; and forming the cut sheet into a consumable in a consumable-forming unit.

20. 20. The method of claim 19, further comprising cutting the sheet using a laser generator to form individual cut sections spaced apart from one another in a direction extending along the transport path, each individual cut section comprising a plurality of parallel elongated strips of aerosol-generating material.

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