Susceptor heating element extraction

Abstract

An assembly for facilitating removal of a susceptor heating element from an aerosol-generating article includes a cutting tool having (i) a body defining a passageway through which the aerosol-generating article can pass, and (ii) a cutting element extending into the passageway. The cutting element includes a cutting edge arranged to cut the aerosol-generating article as it passes through the passageway. The assembly may include a heating element removal tool with a tip configured to magnetically attract the susceptor heating element. Alternatively, the cutting element may include a magnet for attracting the susceptor heating element as the aerosol-generating article passes the cutting element as it passes through the passageway.

Description

Technical Field

[0005] ,

[0004] , ,

[0001] The present disclosure relates to methods, tools, and assemblies for extracting susceptor heaters from aerosol-generating articles.

Background Art

[0002] Some aerosol-generating systems include an aerosol-generating device having a cavity configured to receive an induction heater and an aerosol-generating article. The aerosol-generating article comprises an aerosol-forming substrate and a susceptor heater. The susceptor heater is positioned such that an induction heater of the aerosol-generating device can heat the susceptor heater when the aerosol-generating article is received within the cavity. Heating of the susceptor heater causes heating of the aerosol-forming substrate and generates an aerosol.

[0003] Removing the susceptor heater from the aerosol-generating article can be difficult. Since the susceptor heater is typically within the interior of the aerosol-generating article, it may be necessary to access the interior of the aerosol-generating article. In some cases, the susceptor heater may be embedded within the aerosol-forming substrate.

[0004] According to aspects of the present invention, an assembly is provided that facilitates removal of a susceptor heater from an aerosol-generating article. The assembly includes a cutting tool. The cutting tool comprises a body defining a passage through which the aerosol-generating article can pass and a cutting element extending within the passage. The cutting element includes a cutting edge arranged to cut the aerosol-generating article as the aerosol-generating article passes through the passage. The assembly also includes a heater removal tool having a tip configured to magnetically attract the susceptor heater and remove the heater from an aerosol-generating element that has been cut by the cutting tool when the tip is positioned proximate to the susceptor heater.

[0005] The use of assembled components may enable the recovery and recycling of the susceptor heating element. In some aerosol-generating articles containing a susceptor heating element, the susceptor heating element may be the sole non-biodegradable element, or one of a limited number of non-biodegradable elements. Therefore, the removal and recycling of the susceptor heating element may be environmentally beneficial.

[0006] Furthermore, since susceptor material can be a valuable resource, it may be advantageous to recover the susceptor heating element. The recycled susceptor heating element may be used in any suitable manner. For example, the recycled susceptor heating element may be reused, reused, or its components may be recovered. [Overview of the project]

[0007] The assembly of the present invention may be advantageously arranged to enable the safe cutting of aerosol-generating articles. For example, the cutting edge of the cutting element may be positioned within a passage. Such positioning can prevent accidental contact of the cutting edge of the cutting element by the user.

[0008] The heating element removal tool may be retained relative to the passage of the cutting tool. Such a configuration may be convenient for the consumer. For example, if the heating element removal tool is retained relative to the passage of the cutting tool, the space occupied by the assembly may be reduced compared to storing each tool separately. Retaining the heating element removal tool relative to the cutting tool may also allow the tools to be stored together so that both tools are available when needed by the consumer.

[0009] According to an aspect of the present invention, a tool is provided for facilitating the removal of a susceptor heating element from an aerosol-generating article. The tool includes a body that defines a passage through which the aerosol-generating article can pass. The tool also includes a cutting element extending into the passage. The cutting element includes a cutting blade arranged to cut the aerosol-generating article as it passes through the passage. The cutting element includes a magnet and is configured to magnetically attract the susceptor heating element.

[0010] The cutting element may be configured to be inserted into and removed from the passage. When the cutting element is removed from the passage and the susceptor heating element is magnetically attracted to the cutting element, the susceptor heating element may be removed from the passage. The removed susceptor heating element may be recycled.

[0011] The tools of the present invention may be advantageously arranged to enable the safe cutting of aerosol-generating articles. For example, the cutting edge of the cutting element may be positioned within a passage to cut the aerosol-generating article. Such positioning can prevent accidental contact of the cutting edge of the cutting element by the user during use of the tool.

[0012] According to an aspect of the present invention, a method is provided for removing a susceptor heating element from an aerosol generating article. The method includes passing the aerosol generating article through a passage of a cutting tool. The cutting tool comprises a body defining the passage and a cutting element extending within the passage. The cutting element includes a cutting blade arranged to cut the aerosol generating article as it passes through the passage. The method includes removing the susceptor heating element from the cut aerosol generating article. The removed susceptor heating element may be recycled.

[0013] The tools and assemblies of the present invention can be used to carry out the methods of the present invention.

[0014] The methods, tools, and assemblies of the present invention can be used to extract a susceptor heating element from any suitable aerosol generating article. The aerosol generating article may be of any suitable size and shape. For example, the aerosol generating article may form an elongated cylindrical rod. The aerosol generating article may include a mouth end and a distal end upstream from the mouth end. In use, the user may inhale the aerosol generated by the aerosol generating article by sucking at the mouth end. The aerosol generating article may include an aerosol-forming substrate located at or toward the distal end.

[0015] The aerosol-forming substrate may be solid, liquid, or may contain both solid and liquid components. The aerosol-forming substrate preferably contains nicotine. In some preferred embodiments, the aerosol-forming substrate contains tobacco. For example, the aerosol-forming substrate may contain a homogenized tobacco sheet. The aerosol-forming substrate may also contain a non-tobacco-containing aerosol-forming material. For example, the aerosol-forming material may contain a sheet containing a nicotine salt and an aerosol-forming agent.

[0016] The aerosol-forming substrate may be in the form of a plug containing an aerosol-forming material surrounded by paper or other wrappers.

[0017] The aerosol generating article includes a susceptor heating element, which is arranged to sufficiently heat an aerosol-forming substrate to generate an aerosol when the susceptor heating element is heated by a derivative of the aerosol generating device. Preferably, the susceptor heating element, the aerosol generating device, or the susceptor heating element and the aerosol generating device are configured such that the susceptor heating element sufficiently heats the aerosol-forming substrate to generate an aerosol without burning the aerosol-forming substrate.

[0018] The susceptor heating element is in thermal contact with the aerosol-forming substrate. The susceptor element may be in direct physical contact with the aerosol-forming substrate. The susceptor heating element may be embedded inside the aerosol-forming substrate or outside of it. It is preferable that the susceptor heating element is embedded in the aerosol-forming substrate. When embedded in the aerosol-forming substrate, the susceptor heating element may be positioned along the longitudinal axis of the aerosol-forming substrate or offset from the longitudinal axis of the aerosol-forming substrate.

[0019] The susceptor heating element may be in the form of a thin, elongated, substantially rectangular member. The susceptor heating element may also be in the form of a sheet. The susceptor heating element may extend along any suitable portion of the length of the aerosol-forming substrate within the article. For example, the susceptor heating element may extend along 60% or more of the length of the aerosol-forming substrate in the article.

[0020] The susceptor heating element may contain any material that can be inductively heated to a temperature sufficient to generate an aerosol from the aerosol-forming substrate. For example, the susceptor heating element may contain metal or carbon. The susceptor heating element may contain a ferromagnetic material. The ferromagnetic material may include ferrite iron, ferromagnetic steel, or stainless steel. The susceptor heating element may contain aluminum.

[0021] A susceptor heating element may comprise a non-metallic core having a metal layer disposed on top of the non-metallic core. For example, a susceptor heating element may include a metal track formed on the surface of a ceramic core.

[0022] The susceptor heating element may include a protective outer layer. For example, the susceptor heating element may include a protective ceramic layer or protective glass layer enclosing the susceptor material. The susceptor heating element may also have a protective coating formed of glass, ceramic, or inert metal on the core of the susceptor material.

[0023] At least a portion or component of the susceptor heating element is magnetically attracted.

[0024] The aerosol-generating article may contain a single susceptor heating element or multiple susceptor heating elements. The methods, tools, and assemblies described herein may be used to recover multiple susceptor heating elements from an aerosol-generating article if the article contains multiple susceptor heating elements.

[0025] The aerosol-generating article may include a support element. The support element may be located downstream of the aerosol-forming substrate. The support element may be adjacent to the aerosol-forming substrate. The support element may include a hollow tubular element. In one preferred embodiment, the support element includes a hollow cellulose acetate tube or a paper tube.

[0026] The aerosol generating article may include an aerosol cooling element. The aerosol cooling element may be located downstream of the aerosol forming substrate. The aerosol cooling element may be located downstream of the support element. The aerosol cooling element may be adjacent to the support element. The aerosol cooling element may function as a heat exchanger. Preferably, the aerosol cooling element has sufficient surface area and thermal conductivity to cool the heated aerosol generated from the aerosol forming substrate. Preferably, the aerosol cooling element does not substantially affect the resistance to drawing out the aerosol generating article. The aerosol cooling element may include a plurality of longitudinally extending channels. The aerosol cooling element may contain polylactic acid.

[0027] The aerosol generating article may include a mouthpiece. The mouthpiece may be located at the oral end of the aerosol generating article. In some preferred embodiments, an aerosol cooling element is located between a support element and the mouthpiece. The mouthpiece may include a filter. The filter may contain cellulose acetate.

[0028] An aerosol-generating article may include a housing in which components such as an aerosol-forming substrate and susceptor heater, a support element, an aerosol cooling element, and a mouthpiece are arranged. The housing may include a wrapper that surrounds the components of the aerosol-generating article. The wrapper may be formed of any suitable material. For example, the wrapper may include cigarette paper.

[0029] The aerosol-generating article may have any suitable overall length. For example, the length of the aerosol-generating article may be from 30 millimeters to 100 millimeters, preferably from 30 millimeters to 60 millimeters.

[0030] The aerosol-generating article may have any suitable outer diameter. Preferably, the outer diameter of the aerosol-generating article is suitable for the distal end of the aerosol-generating article that is received within the cavity of an electrically-operated aerosol-generating device. In some embodiments, the outer diameter of the aerosol-generating article is from 5 millimeters to 12 millimeters, preferably from 6 millimeters to 8 millimeters.

[0031] The cutting tool of the present invention includes a body that defines a passage through which an aerosol-generating article can pass. For example, the inner diameter of the cutting tool defined by the passage may be larger than the outer diameter of the aerosol-generating article. It is preferred that the inner diameter of the cutting tool is not substantially larger than the outer diameter of the aerosol-generating article. For example, the inner diameter of the cutting tool may be less than 5 millimeters larger than the outer diameter of the aerosol-generating article, or less than 2 millimeters larger than the outer diameter of the aerosol-generating article, or less than 1 millimeter larger than the outer diameter of the aerosol-generating article, or less than 0.5 millimeters larger than the outer diameter of the aerosol-generating article. In some preferred embodiments, the inner diameter defined by the passage of the cutting tool is from 5 millimeters to 15 millimeters, for example, from 7 millimeters to 10 millimeters.

[0032] The inner diameter defined by the passage of the cutting tool may be uniform or may vary along its length. Preferably, the inner diameter defined by the passage of the cutting tool is uniform or substantially uniform over 50 percent or more of the passage's length, such as 80 percent or more of the passage's length. For example, the inner diameter defined by the passage of the cutting tool may be considered substantially uniform if it varies by 10 percent or less along its length, or by 5 percent or less along its length. Having a substantially uniform inner diameter can provide stability for cutting aerosol-generating articles passing through the passage, particularly when the inner diameter of the passage is similar to the outer diameter of the aerosol-generating article.

[0033] The cutting tool may include an inlet funnel having an opening that communicates with a passage. For example, the inlet funnel may form a chamfered inlet to the passage. The chamfered inlet may help guide the aerosol-generating article into the passage. The cutting tool may include multiple inlet funnels. For example, the cutting tool may include inlet funnels that communicate with each end of the passage.

[0034] The passage of the cutting tool may have any suitable length. Preferably, the passage is shorter than the length of the aerosol-generating article. Preferably, the length of the passage allows the aerosol-generating article to be pushed into the passage from one end and pulled out of the passage from the opposite end. For example, the passage may be less than 80 percent of the length of the aerosol-generating article, such as less than 50 percent of the length of the aerosol-generating article or less than 20 percent of the length of the aerosol-generating article.

[0035] The aerosol-generating article used with the cutting tool may have a length of 1 centimeter or more that is longer than the passage of the cutting tool. For example, the aerosol-generating article may have a length of 2 centimeters or more that is longer than the passage, 3 centimeters or more that is longer than the passage, 10 centimeters or more that is longer than the passage, or 20 centimeters or more that is longer than the passage.

[0036] The length of the cutting tool's passage may be longer than the length of the susceptor heating element. Alternatively, the length of the passage may be shorter than the length of the susceptor heating element.

[0037] In some preferred embodiments, the cutting tool has a length of 20 to 50 millimeters.

[0038] The body of the cutting tool may have any suitable thickness. In some preferred embodiments, the body of the cutting tool has a thickness of 2 mm to 20 mm, such as 4 mm to 10 mm.

[0039] The body of the cutting tool can be made of any suitable material or combination of materials. For example, the body of the cutting tool may be made of one or more plastic materials such as metal and hard plastic materials. For example, the body of the cutting tool may be made of polycarbonate, polyetheretherketone, high-density polyethylene, polypropylene, polyvinyl chloride, acrylonitrile butadiene styrene, stainless steel, aluminum or aluminum alloy, iron or iron alloy, and combinations thereof. In some embodiments, the body of the cutting tool includes a magnetic material. For example, the body may include a ferromagnetic material, a rare-earth magnetic material, or a ferromagnetic material and a rare-earth magnetic material. The entire body may be ferromagnetic, or one or more parts of the body may be ferromagnetic.

[0040] The cutting tool comprises a cutting element extending into the passage. The cutting element includes a cutting blade positioned to cut the aerosol-generating article as it passes through the passage. The cutting tool may comprise any suitable cutting element.

[0041] The cutting element may include a blade, a wire, or any other structure having a blade suitable for cutting aerosol-generating articles as the article passes through the passage. The blade may have a sharp cutting edge for cutting aerosol-generating articles. The blade may be made from any suitable material. For example, the blade may be made from one or more of the following: metal and plastic materials such as rigid plastic materials. For example, the blade may include one or more of the following: polycarbonate, polyetheretherketone, high-density polyethylene, polypropylene, polyvinyl chloride, acrylonitrile butadiene styrene, stainless steel, aluminum or aluminum alloys, iron or iron alloys, titanium or titanium alloys, obsidian, ceramics, etc.

[0042] The blade may extend within the passage only a distance sufficient to cut the aerosol-generating article as it passes through the passage. The blade may extend across the passage entirely or partially. For example, the blade may extend within the passage for a distance equal to 20 percent to 100 percent of the passage's diameter. In some preferred embodiments, the cutting edge of the blade extends within the passage for a distance equal to 30 percent to 50 percent of the passage's diameter.

[0043] The wire may be thin enough to cut the aerosol-generating material. Preferably, the wire extends across the passage and is fixed at two positions in the passage. The positions in the passage to which the wire is fixed may be opposite positions in the passage or non-opposing positions in the passage. Fixing the wire at non-opposing positions in the passage may allow the wire to cut the aerosol-generating material off-center. Cutting the aerosol-generating material off-center may help ensure that the wire does not cut or come into contact with the susceptor heating element as the aerosol-generating material passes through the passage of the cutting tool.

[0044] The cutting tool may include a wire formed from any suitable material. For example, the wire may be made from one or more plastic materials such as metals and rigid plastic materials. For example, the blade may be made from polycarbonate, polyether ether ketone, high-density polyethylene, polypropylene, polyvinyl chloride, acrylonitrile butadiene styrene, stainless steel, aluminum or aluminum alloys, iron or iron alloys, titanium or titanium alloys, carbon, ceramics, and combinations thereof. The wire may be in the form of a filament, braided wire, stranded wire, braided stranded wire, or similar.

[0045] The cutting element may pass through or extend toward the geometric center of the passage, or it may be offset from the geometric center of the passage. For example, the cutting edge may be offset from the geometric center of the passage by a distance ranging from 10 to 20 percent of the passage diameter. Cutting the aerosol-generating article off-center can help ensure that the cutting element does not cut or come into contact with the susceptor heating element or other parts or components of the aerosol-generating article as the aerosol-generating article passes through the passage of the cutting tool.

[0046] The cutting element may comprise one or more cutting blades. For example, the cutting element may comprise a first cutting blade positioned and arranged to cut the aerosol-generating article as it passes through the passage from a first end to a second end, and a second cutting blade positioned and arranged to cut the aerosol-generating article as it passes through the passage from a second end to a first end. The first blade may face a first opening. The second end may face a second opening. In such an arrangement, the cutting tool can be used to cut the aerosol-generating article regardless of the direction in which the aerosol-generating article passes through the passage.

[0047] The cutting tool may include multiple cutting elements. Each cutting element may extend within the passage. Each cutting element may have a cutting edge positioned to cut the aerosol-generating article as it passes through the passage. The cutting elements may be spaced circumferentially around the passage. The cutting elements may be spaced evenly apart from each other, or unevenly apart from each other.

[0048] The cutting element may be offset longitudinally within the passage.

[0049] The cutting elements may be offset longitudinally within the passage and circumferentially. Such arrangements may allow for the initiation of a second cutting of the aerosol-generating article at different angles to the article at a later stage, after the article has passed through the passage.

[0050] The cutting tool may have multiple cutting elements, each cutting element including a blade. The blades may be spaced circumferentially around the passage, with each blade extending into the passage. The blades may be spaced evenly apart from each other, or unevenly apart from each other.

[0051] The blade may be offset longitudinally within the passage. The blade may be offset longitudinally and circumferentially within the passage.

[0052] A cutting tool may have multiple cutting elements, each of which includes a wire. A cutting tool may have one or more cutting elements, at least one of which includes a blade, and at least one of which includes a wire.

[0053] The cutting tool may include a cutting element that includes a magnet configured to magnetically attract a susceptor heating element. As the aerosol-generating article passes through the passage of the cutting tool, the cutting edge of the cutting element cuts the aerosol-generating article. When the susceptor heating element passes in close proximity to the magnet of the cutting element, the magnet may attract and hold the susceptor heating element.

[0054] The cutting element, or a portion thereof, may be insertable into and removable from the passage. When inserted into the passage, the cutting element is positioned to cut the aerosol-generating article as it passes through the passage. When removed from the passage, the cutting element is configured to remove a magnetically attracted susceptor heating element.

[0055] In some preferred embodiments, the cutting element includes a blade and a magnet. For example, the magnet may be positioned on the side of the blade. When an aerosol-generating article passes through the blade, the cutting edge of the blade cuts through the aerosol-generating article. When a susceptor heating element passes through the cutting edge of the blade, the susceptor heating element is magnetically attracted to the magnet positioned on the side of the blade. The blade may include a magnetic material. The blade may include a magnetizable material.

[0056] The body of the cutting tool may include a slot configured to receive a cutting element such that when the cutting element is received in the slot, the cutting edge is positioned to cut the aerosol-generating article as it passes through the passage. The cutting element may be removable from the slot. After the aerosol-generating article has passed through the passage of the cutting tool, if the susceptor heating element is magnetically attracted to and held by the cutting element, the susceptor heating element can be removed by removing the cutting element from the slot.

[0057] The cutting tool may be configured such that the cutting element can magnetically attract susceptor heating elements from multiple aerosol-generating articles before removing the cutting element and the multiple magnetically attracted susceptor heating elements. For example, the cutting tool may be configured such that the cutting element can hold a first susceptor heating element from a first aerosol-generating article that has passed through the passage away from the cutting tool, while simultaneously cutting a second aerosol-generating article and holding a second susceptor heating element as the second aerosol-generating article passes through the passage.

[0058] The cutting tool may comprise a plurality of cutting elements, each containing a magnet or magnetizable material, wherein the cutting elements are offset circumferentially. The cutting tool may be oriented such that the passage of a first aerosol-generating article attracts a susceptor heat source from the first aerosol-generating article to the first cutting element. The cutting tool may then be oriented such that the passage of a second aerosol-generating article attracts a susceptor heat source from the second aerosol-generating article to the second cutting element.

[0059] If the cutting element includes a magnetic or magnetizable material and is removable from the cutting tool to allow the removal of a magnetically attracted susceptor heating element, the length of the passage may be longer than the length of the susceptor heating element configured for removal by the cutting tool. A passage longer than the susceptor heating element can serve to hold the susceptor heating element within the passage to avoid accidental contact with the susceptor heating element by the user. Alternatively, the passage may be shorter than the length of the susceptor heating element. Having a passage shorter than the susceptor heating element can facilitate the removal of the susceptor heating element from the cutting tool without removing the cutting element from the cutting tool.

[0060] The cutting element may include any suitable magnet or magnetizable material. For example, the cutting element may include a ferromagnetic material or a rare-earth magnet. Preferably, the cutting element includes a rare-earth magnet. Examples of suitable rare-earth magnets include neodymium magnets and samarium magnets.

[0061] The cutting tool may include an alignment indicator that can be aligned with an indicator on the aerosol-generating article. The indicator on the aerosol-generating article may be positioned relative to the susceptor heating element. Alignment between the indicator on the aerosol-generating article and the alignment indicator on the cutting tool can orient the aerosol-generating article relative to the cutting element so that the cutting element avoids the susceptor heating element as the aerosol-generating article passes through the passage of the cutting tool. Depending on the type of susceptor heating element, the cutting element may not be able to cut through the susceptor heating element. Therefore, orienting the aerosol-generating article relative to the cutting tool in a way that avoids contact between the susceptor heating element and the cutting element can allow the aerosol-generating article to pass freely through the passage of the cutting tool. Such an arrangement can also reduce blade wear.

[0062] If the cutting element includes a magnet or magnetizable material, the alignment of the indicator on the aerosol-generating article using the cutting tool's alignment indicator can orient the aerosol-generating article relative to the cutting element such that the magnet or magnetizable material of the cutting element is positioned sufficiently close to the susceptor heating element as the aerosol-generating article passes through the passage, and the magnet or magnetizable material attracts and holds the susceptor heating element.

[0063] The cutting tool may include any suitable alignment indicator. The indicator may include embossed markings, debossed markings, colored markings, or similar.

[0064] The present invention includes an assembly comprising a cutting tool and a heat element removal tool. The heat element removal tool includes a magnet for attracting the susceptor heat element. For example, the heat element removal tool may have a tip configured to magnetically attract the susceptor heat element. The tip of the heat element removal tool may be positioned close to the susceptor heat element after the aerosol generating article has been cut and optionally separated. The magnetic attraction between the tip of the heat element removal tool and the susceptor heat element allows the tip to engage with the susceptor heat element, facilitating its removal from the cut aerosol generating article.

[0065] The tip of the heating element may contain any suitable magnetic material. For example, the tip may contain a ferromagnetic material, a rare-earth magnetic material, or both. Preferably, the tip contains a rare-earth magnetic material. Examples of suitable rare-earth magnetic materials include neodymium magnets and samarium magnets.

[0066] The tip of the heating element removal tool may have any suitable shape. Preferably, the tip is conical. A conical magnet can provide an enhanced magnetic field gradient focused at the tip of the conical portion.

[0067] The tip of the heating element removal tool may be insertable into and removable from the passage of the cutting tool. Therefore, the tip may have a diameter smaller than the diameter of the passage.

[0068] The heating element removal tool may be retained within the passage. For example, the tip of the heating element removal tool may be inserted into the passage, and at least a portion of the heating element removal tool may be retained within the passage. The heating element removal tool may be retained within the passage in any suitable manner. For example, the tip of the heating element removal tool may be magnetically attracted to a portion of the cutting element or the body of the cutting tool. The magnetic attraction may retain the heating element removal tool within the passage until a force sufficient to overcome the magnetic attraction is applied to remove the heating element removal tool or the portion of the heating element removal tool from the passage. In addition, or alternatively, the cutting tool may include a magnet to magnetically attract a portion of the heating element removal tool. For example, a portion of the body of the cutting tool defining the passage may have a magnet. In addition, or alternatively, the heating element removal tool may be retained within the passage via an interfering fit, a screw engagement, a snap fit, or similar.

[0069] Holding at least a portion of the heating element removal tool in the passage of the cutting tool allows for more compact storage of both the cutting tool and the heating element removal tool, and also prevents the tools from separating, ensuring that both tools are available to the user when needed.

[0070] The heating element removal tool may include the distal end of the magnetic tip. The distal end, or the portion of the heating element removal tool between the distal end and the magnetic tip, preferably has an outer diameter larger than the diameter of the passage of the cutting tool. The portion of the heating element removal tool having a diameter larger than the passage diameter preferably abuts against the body of the cutting tool adjacent to the opening of the passage. Preferably, the shape and size of the portion of the heating element removal tool abutting against the body of the cutting tool adjacent to the opening of the passage are identical or substantially identical to the shape and size of the body cutting tool. Such a matched shape and size can reduce the possibility of accidental separation of the heating element removal tool and the cutting tool due to the formation of a substantially continuous outer surface between the two tools.

[0071] The assembly, including the heating element removal tool and the cutting tool, may further include a separation tool. The separation tool may be configured to assist in separating a portion of the cut aerosol-generating article from the opposing portion of the aerosol-generating article along the cut. Separation of the opposing portion of the aerosol-generating article may provide better access to the susceptor heating element, which may facilitate the removal of the susceptor heating element using the heating element removal tool.

[0072] The separation tool may include a spreader. The separation tool may comprise a first arm having a free end and a second arm having a free end. The tool may be configured such that the application of an inward force, such as a clamping force, to the intermediate portions of the first and second arms separates the free ends of the first and second arms. For example, the separation tool may include a debarricator.

[0073] The separation tool or portion of the separation tool is preferably insertable into and removable from the passage of the cutting tool. The separation tool may be retained within the passage. For example, the end of the separation tool may be inserted into the passage, and at least a portion of the separation tool may be retained within the passage. The separation tool may be retained within the passage in any suitable manner. For example, the end of the separation tool configured to be inserted into the passage of the cutting tool may be magnetically attracted to the cutting element or a portion of the body of the cutting tool. The magnetic attraction may retain the separation tool within the passage until a force sufficient to overcome the magnetic attraction is applied to remove the separation tool or portion of the separation tool from the passage. In addition, or alternatively, the cutting tool may be equipped with a magnet to magnetically attract a portion of the separation tool. For example, a portion of the body of the cutting tool defining the passage may be equipped with a magnet. In addition, or alternatively, the separation tool may be retained within the passage via an interfering fit, a screw-in engagement, a snap-fit, or similar.

[0074] Holding at least a portion of the separation tool in the passage of the cutting tool allows for compact storage of both the cutting and separation tools and prevents the tools from separating, ensuring that both tools remain available to the user when needed.

[0075] The separation tool may have a distal end of an end configured to be inserted into the passage. The distal end, or the portion of the separation tool between the distal end and the end configured to be inserted into the passage, preferably has an outer diameter larger than the diameter of the passage of the cutting tool. The portion of the separation tool having a diameter larger than the diameter of the passage preferably abuts against the body of the cutting tool adjacent to the opening of the passage. Preferably, the shape and size of the portion of the separation tool abutting against the body of the cutting tool adjacent to the opening of the passage are identical or substantially identical to the shape and size of the body cutting tool. Such a matched shape and size may provide a smooth appearance and may reduce the possibility of accidental separation of the separation tool and the cutting tool due to the formation of a substantially continuous outer surface between the two tools.

[0076] In some preferred embodiments, the separation tool is configured to be inserted into the passage through a first opening defined by the body of the cutting tool, and the heating element removal tool is configured to be inserted into the passage through a second opening defined by the body of the cutting tool. Preferably, the separation tool and the heating element removal tool are retainable within the passage.

[0077] The tools and assemblies of the present invention can be used in any suitable manner to remove a susceptor heating element from an aerosol generating article.

[0078] Furthermore, the singular forms “a,” “an,” and “the” as used herein also include embodiments that have plural objects, unless otherwise clearly defined by the context.

[0079] The terms “preferred” and “preferred” refer to embodiments of the present invention that may provide certain advantages under specific circumstances. However, other embodiments may also be preferred under the same or other circumstances. Furthermore, the enumeration of one or more preferred embodiments does not imply that other embodiments are unhelpful, nor is it intended to exclude other embodiments from the scope of this disclosure, including the claims.

[0080] As used herein, the term “aerosol-forming substrate” means a substrate having the ability to release volatile compounds capable of forming aerosols upon heating. The aerosols generated from the aerosol-forming substrates of the aerosol-generating articles described herein may be visible or invisible and may include vapors (e.g., fine particles of a substance in a gaseous state, which is normally a liquid or solid at room temperature) as well as droplets of gas and condensed vapor.

[0081] As used herein, the terms “upstream” and “downstream” describe the relative position of an element or part of an aerosol generating article with respect to the direction of the airflow through the aerosol generating article when the user inhales through the mouth end of the aerosol generating article.

[0082] As used herein, the term "susceptor" refers to a material capable of converting electromagnetic energy into heat. When located within a fluctuating electromagnetic field, induced eddy currents within a susceptor cause the susceptor to heat up.

[0083] As used herein, “longitudinal direction” means the direction along the length of the article or tool being referenced. The term “transverse direction” is used to describe the direction perpendicular to the longitudinal direction.

[0084] As used herein, “diameter” refers to the maximum lateral dimension of the reference article or tool.

[0085] Non-limiting examples are provided below without exhaustion. One or more features of these examples may be combined with one or more features of other examples, embodiments, or aspects described herein.

[0086] Example 1: An assembly for facilitating the removal of a susceptor heating element from an aerosol-generating article, comprising: (i) a main body defining a passage through which an aerosol-generating article can pass; and (ii) a cutting element extending within the passage, wherein the cutting element has a cutting blade arranged to cut the aerosol-generating article as it passes through the passage; and a heating element removal tool having a tip configured to magnetically attract the susceptor heating element. Example 2: The assembly according to Example 1, wherein the cutting element includes a first blade. Example 3: The assembly according to Embodiment 2, wherein the cutting tool comprises one or more blades in addition to a first blade, each of which extends into the passage and is arranged to cut the aerosol-generating article as it passes through the passage. Example 4: The assembly described in Example 3, in which the blades are spaced circumferentially around the passage. Example 5: The assembly according to Example 3 or 4, wherein the blades are spaced evenly apart from one another. Example 6: The assembly according to Example 3 or 4, wherein the blades are spaced unevenly apart from one another. Example 7: The assembly according to Example 1, wherein the cutting element includes a wire. Example 8: The assembly described in Example 7, wherein the wire extends across the passageway. Example 9: The assembly according to Example 8, wherein the wire extends through the geometric center of the passage. Example 10: The assembly described in Example 8, wherein the wire is offset from the geometric center of the passage. Example 11: The assembly described in Example 10, wherein the wire is offset from the geometric center of the passage by a range of 10 to 20 percent of the passage diameter. Example 12: The assembly according to Embodiment 1, wherein the cutting tool includes a plurality of cutting elements, each cutting element extending into a passage, and each cutting element having a cutting blade arranged to cut the aerosol-generating article as the aerosol-generating article passes through the passage. Example 13: An assembly according to any one of Examples 1 to 12, wherein the cutting tool comprises an alignment indicator configured to align with an indicator on an aerosol-generating article. Example 14: An assembly according to any one of Examples 1 to 13, wherein the tip of the heating element removal tool can be inserted into the passage. Example 15: The assembly according to Example 14, wherein the heating element removal tool can be held within the passageway. Example 16: The assembly according to Example 15, wherein the heating element removal tool is magnetically held within the passage. Example 17: The assembly according to Example 16, wherein the tip of the heating element removal tool is magnetically attracted to a cutting element in order to magnetically hold the heating element removal tool within the passage. Example 18: The assembly according to Example 16, wherein the cutting tool comprises magnets positioned around at least a portion of the passage, and the heating element removal tool is attracted to the magnets, thereby magnetically holding the heating element removal tool within the passage. Example 19: The assembly described in Example 18, wherein the main body that defines the passage includes a magnet. Example 20: The assembly according to Example 15, wherein the heating element removal tool can be retained in the passage via interference fit, screw engagement, or snap fit. Example 21: An assembly according to any one of Examples 1 to 20, comprising a separation tool configured to help separate a portion of a cut aerosol-generating article from an opposing portion of the aerosol-generating article that has been cut along the cut. Example 22: The assembly described in Example 21, wherein the separation tool includes a spreader. Example 23: The assembly according to Example 21 or 22, wherein at least a portion of the separation tool is configured to be inserted into the passage. Example 24: An assembly according to any one of Examples 21 to 23, wherein the separation tool can be held within the passage. Example 25: The assembly according to Example 24, wherein the separation tool is magnetically held within the passage. Example 26: The assembly according to Example 25, wherein a portion of the separation tool is magnetically attracted to the blade, thereby magnetically holding the separation tool within the passage. Example 27: The assembly according to Example 25, wherein the separation tool is configured to be magnetically held in the passage via magnetic attraction to the tip of the heating element removal tool. Example 28: The assembly according to Example 25, wherein the cutting tool comprises magnets positioned around at least a portion of the passage, and the separating tool is attracted to the magnets, thereby magnetically holding the separating tool within the passage. Example 29: The assembly described in Example 28, wherein the main body that defines the passage includes a magnet. Example 30: The assembly according to Example 24, wherein the separation tool can be retained in the passage via interference mating, screw engagement, or snap mating. Example 31: Use of any one of the assemblies described in Examples 1 to 30 for removing the susceptor heating element from an aerosol generating article. Example 32: A tool for facilitating the removal of a susceptor heating element from an aerosol-generating article, wherein the tool comprises a body that defines a passage through which the aerosol-generating article can pass, and a cutting element extending within the passage, the cutting element having a cutting blade arranged to cut the aerosol-generating article as it passes through the passage, and the cutting element including a magnet and configured to magnetically attract the susceptor heating element. Example 33: The tool according to Example 32, wherein the cutting element includes a blade. Example 34: The tool according to Example 32 or 33, wherein the cutting element is configured to be inserted into and removed from the passage. Example 35: The tool according to Embodiment 34, wherein the main body defines a slot configured to receive a cutting element such that when the cutting element is received in the slot, the cutting blade is positioned to cut the aerosol-generating article as the article passes through the passage. Example 36: The tool according to Example 35, wherein the cutting element is removable from the slot so that when the cutting element is removed, the susceptor heating element is removed when the cutting element is magnetically attracted to the cutting element. Example 37: Use of any one of the tools described in Examples 32 to 36 for removing the susceptor heating element from an aerosol generating article. Example 38: A method for removing a susceptor heating element from an aerosol generating article, the method comprising: passing the aerosol generating article through a passage of a cutting tool, the cutting tool comprising (i) a body defining a passage and (ii) a cutting element extending within the passage, the cutting element including a cutting blade arranged to cut the aerosol generating article as the aerosol generating article passes through the passage; and removing the susceptor heating element from the cut aerosol generating article. Example 39: The method according to Example 38, wherein removing the susceptor heating element from a severed aerosol-generating article includes magnetically attracting the susceptor heating element to the tip of a heating element removal tool. Example 40: The method according to Example 39, comprising separating a portion of the cut aerosol-generating article from the opposing portion of the cut aerosol-generating article along the cut portion. Example 41: The method according to Example 38, wherein removing the susceptor heating element from the cut aerosol-generating article includes magnetically attracting the susceptor heating element to the cutting element. Example 42: The method according to Example 41, further comprising drawing out the cutting element and the magnetically attracted susceptor heating element from the passage. Example 43: The method according to any one of Examples 38 to 42, which includes placing the susceptor heating element in a trash can. Example 44: A kit comprising an aerosol-generating article configured to pass through a passage, comprising an assembly described in any one of Examples 1 to 32, or a tool described in any one of Examples 32 to 36. Example 45: The kit according to Example 44, wherein the passage is less than 80 percent the length of the aerosol-generating article. Example 46: The kit according to Example 44, wherein the passage is less than 50 percent the length of the aerosol-generating article. Example 47: The kit according to Example 44, wherein the passage has a length of less than 20 percent of the aerosol-generating article. Example 48: The kit according to Example 44, wherein the aerosol generating article has a length of 1 centimeter or more that is longer than the length of the passage. Example 49: The kit according to Example 44, wherein the aerosol generating article has a length of 2 centimeters or more that is longer than the passageway. Example 50: The kit according to Example 44, wherein the aerosol generating article has a length of 3 centimeters or more that is longer than the passageway. Example 51: The kit according to Example 44, wherein the aerosol generating article has a length of 10 centimeters or more longer than the passageway. Example 52: The kit according to Example 44, wherein the aerosol generating article has a length of 20 centimeters or more that is longer than the length of the passage. Example 53: An assembly, tool, use, method, or kit according to any one of Examples 1 to 52, wherein the aerosol generating article includes an aerosol forming substrate, and the susceptor heating element extends along 60% or more of the length of the aerosol forming substrate in the aerosol generating article.

[0087] An assembly, tool, method of use, or kit as described in any one of Examples 1 to 53, wherein the susceptor heating element is in the form of a thin, elongated, roughly rectangular component. The examples will be further described here with reference to the figures. [Brief explanation of the drawing]

[0088] [Figure 1] Figure 1 is a schematic cross-sectional view of an example of an aerosol-generating article. [Figure 2] Figure 2 is a schematic cross-sectional view of an example of an electrically operated aerosol generator for use with the aerosol generating article shown in Figure 1. [Figure 3] Figure 3 is a schematic cross-sectional view of the aerosol generating article shown in Figure 1, received inside the cavity of the aerosol generating device shown in Figure 2. [Figure 4] Figure 4 is a schematic cross-sectional view of an example of a cutting tool and an aerosol-generating article that can be cut by the cutting tool. [Figure 5] Figure 5 shows an example of a cross-sectional view of a cut aerosol-generating article and a heat-removing tool. [Figure 6] Figure 6 is an example of a cross-sectional view of a heat-generating tool that attracts a severed aerosol-generating article and a removed susceptor heat-generating element. [Figure 7] Figure 7 is a cross-sectional view of the cutting tool and the heating element removal tool inserted into the passage of the cutting tool. [Figure 8] Figure 8 is a cross-sectional view of a cutting tool, a heating element removal tool inserted into the passage of the cutting tool, and a separation tool inserted into the passage of the cutting tool. [Figure 9] Figure 9 is a schematic diagram of an example of a separation tool. [Figure 10] Figure 10 is a flowchart showing one embodiment of the method according to the present invention. [Modes for carrying out the invention]

[0089] Figure 1 shows an example of an aerosol generating article 10 that may be used with the tools, assemblies, uses, and methods of the present invention. The shown aerosol generating article 10 includes four elements arranged in coaxial alignment: an aerosol forming substrate 20, a support element 30, an aerosol cooling element 40, and a mouthpiece 50. Each of these four elements is substantially cylindrical and has substantially the same diameter. These four elements are arranged in a continuous manner and surrounded by an outer wrapper 60 to form a cylindrical rod. A blade-shaped susceptor heating element 25 is located within the aerosol forming substrate 20 and is in direct physical contact with the aerosol forming substrate 20. The susceptor heating element 25 has a length approximately equal to the length of the aerosol forming substrate 20 and is located along the longitudinal axis of the aerosol generating article 10.

[0090] The susceptor heating element 25 is made of ferrite iron material and has a length of 12 mm, a width of 4 mm, and a thickness of 1 mm. The ends of the susceptor heating element 25 are oriented to facilitate insertion into the aerosol-forming substrate 20.

[0091] The aerosol generating article 10 has a proximal or oral end 70, which the user inserts into their mouth during use, and the distal end 80 is located on the opposite end of the aerosol generating article 10 from the oral end 70. The total length of the assembled aerosol generating article 10 is approximately 45 millimeters and the diameter is approximately 7.2 millimeters.

[0092] Figure 2 shows a schematic cross-sectional example of an electrically operated aerosol generator 200. The aerosol generator 200 includes an inductor 210 located adjacent to the distal portion 231 of the substrate receiving cavity 230. In use, the user inserts the aerosol generating article 10 into the substrate receiving cavity 230 of the aerosol generator 200 such that the aerosol-forming substrate 20 and susceptor heating element 25 of the aerosol generating article 10 are located adjacent to the inductor 210.

[0093] The aerosol generator 200 includes a battery 250 and an electronic circuit 260 that enable the activation of the inductor 210. This activation may be performed manually or may occur automatically in response to the user inhaling the aerosol generating article 10 inserted into the substrate receiving chamber 230 of the aerosol generator 200.

[0094] When activated, a high-frequency alternating current flows through the coil of wires forming part of the inductor 210, causing the inductor 210 to generate a fluctuating electromagnetic field within the distal portion 231 of the substrate receiving cavity 230. When the aerosol generating article 10 is correctly positioned within the substrate receiving cavity 230, the susceptor heating element 25 of the article 10 is located within this fluctuating electromagnetic field. The fluctuating electromagnetic field generates eddy currents within the susceptor material of the susceptor heating element 25, causing it to heat up. The heated susceptor heating element heats the aerosol-forming substrate 20 of the aerosol generating article 10 to a temperature sufficient to form an aerosol. The aerosol is drawn downstream through the aerosol generating article 10 and sucked in by the user. Figure 3 shows the aerosol generating article 10 received within the cavity 230 of the aerosol generator 200.

[0095] Figure 4 shows an aerosol-generating article 10 and a cutting tool 400. The cutting tool 400 has a body 410 that defines a passage 420 extending along the length of the cutting tool 400. The cutting tool 400 includes a blade 430 extending from the body 410 into the passage 420. The illustrated cutting tool 400 includes two cutting edges. One cutting edge faces the opening defined by the right body 410 in Figure 4, and the other cutting edge faces the opening defined by the left body 410 in Figure 4.

[0096] The aerosol-generating article 10 may pass through the passage 420 of the cutting tool 400 from right to left. However, since the blade 430 has opposing cutting edges, the aerosol-generating article 10 may also pass through the passage 420 from left to right. The diameter of the passage 420 is larger than the outer diameter of the aerosol-generating article 10, allowing the aerosol-generating article 10 to pass through the passage 420. The diameter of the passage 420 may be 8 millimeters, and the diameter of the aerosol-generating article 10 may be 7.2 millimeters.

[0097] After passing through the cutting tool 400, the aerosol-generating article 10 is cut.

[0098] Figure 5 shows a cut aerosol generating article 10, which has been cut along line 15 to expose its internal components, including the susceptor heating element 25. The susceptor heating element 25 may be removed from the aerosol generating article 10 using a heating element removal tool 700 having a magnetic tip 710. When the magnetic tip 710 is positioned close to the susceptor heating element 25, the susceptor heating element 25 may be attracted to the tip 710 and removed from the aerosol generating article 10 as shown in Figure 6.

[0099] Alternatively, the cutting element (e.g., the blade 430 shown in Figure 4) may be equipped with a magnet to attract the susceptor heating element as the aerosol-generating material passes through the passage of the cutting tool, and the cutting element and the attracted susceptor heating element may be removed from the cutting tool to recover the susceptor heating element (not shown).

[0100] Figure 7 shows the heating element removal tool 700 being inserted into the passage 420 of the cutting tool 400 for storage. The tip 710 of the heating element removal tool 700 is magnetic and attracted to the blade 430, and its magnetic attraction holds the heating element removal tool 700 in the passage of the cutting tool 400. The heating element removal tool 700 includes a shaft 720 that extends from a distal handle portion 730 to the magnetic tip 710. The distal handle portion 730 is larger than the diameter of the passage 420 but is substantially the same as the outer diameter of the body 410 of the cutting tool 400, providing a smooth transition between the outer surface of the cutting tool 400 and the heating element removal tool 700 when the heating element removal tool 700 is stored in the passage 420 of the cutting tool 400.

[0101] As shown in Figure 8, the separation tool 900 may also be inserted into and held within the passage 420 of the cutting tool 400. The tip of the separation tool 900 may be magnetic, attracted to the blade 430, or magnetically attracted to the tip 710 of the heating element removal tool 700. Magnetic attraction holds the separation tool 900 in the passage of the cutting tool 400. The separation tool 900 includes a shaft 920 extending from a distal handle portion 930 to its tip. The distal handle portion 930 has a diameter larger than the diameter of the passage 420, but is substantially the same as the outer diameter of the body 410 of the cutting tool 400 to provide a smooth transition between the outer surface of the cutting tool 400 and the separation tool 900 when the separation removal tool 900 is housed in the passage 420 of the cutting tool 400.

[0102] A schematic diagram of an example of the separation tool 900 is shown in Figure 9. The separation tool 900 includes a handle 930, a first arm 941 and a second arm 942 extending from the handle 930. An inward clamping force on the middle portions of arms 941 and 942 separates the free ends of arms 941 and 942. The free ends of arms 941 and 942 function as spreaders. When the free ends of arms 941 and 942 of the separation tool 900 are inserted into the cut portion of the aerosol-generating article (such as cut portion 15 depicted in Figure 5) and the middle portions of arms 941 and 942 are clamped, the free ends of the separation tool 900 separate, separating the opposing surfaces along the cut aerosol-generating article. Separating the opposing surfaces of the aerosol-generating article along the cut portion may provide access to a susceptor heating element that can be removed from the aerosol-generating article using a heating element removal tool.

[0103] Figure 10 is a flowchart illustrating an example of a method according to the present invention. This method includes passing an aerosol-generating article through the passage of a cutting tool to cut the aerosol-generating article (121). The method also includes removing the susceptor heating element from the cut aerosol-generating article (123).

[0104] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers representing amounts, quantities, percentages, etc., should be understood in all cases as being modified by the term “approximately.” Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges therewith, which may or may not be specifically listed herein. Thus, in this context, the number A is understood as A ± 2 percent of A. In this context, the number A may be considered to include a number that falls within the general standard error of the measurement of the characteristic modified by the number A. In some cases as used in the appended claims, the number A may deviate by the percentage listed above, provided that the amount of deviation does not substantially affect the basic and novel characteristics(s) of the claimed invention. Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges therewith, which may or may not be specifically listed herein.

Claims

1. An assembly that facilitates the removal of a susceptor heating element from an aerosol generating article, A cutting tool comprising (i) a body defining a passage through which the aerosol-generating article can pass, and (ii) a cutting element extending within the passage, wherein the cutting element is equipped with a cutting blade arranged to cut the aerosol-generating article as it passes through the passage, An assembly comprising a heating element removal tool, the tool having a tip configured to magnetically attract the susceptor heating element and to remove the susceptor heating element from the aerosol generating article that has been cut by the cutting tool when the tip is positioned in close proximity to the susceptor heating element.

2. The assembly according to claim 1, wherein the cutting element includes a first blade.

3. The assembly according to claim 1 or 2, wherein the heating element removal tool can be held within the passage.

4. The assembly according to claim 3, wherein the heating element removal tool is magnetically held within the passage.

5. The assembly according to claim 4, wherein the tip of the heating element removal tool is magnetically attracted to the cutting element, thereby magnetically holding the heating element removal tool within the passage.

6. The assembly according to any one of claims 1 to 5, comprising a separation tool configured to assist in separating a portion of the cut aerosol-generating article from an opposing portion of the cut aerosol-generating article along the cut portion.

7. The assembly according to claim 6, wherein the separation tool is retainable within the passage.

8. A tool for facilitating the removal of susceptor heating elements from aerosol-generating articles, A main body that defines a passage through which the aerosol-generating article can pass, A tool comprising: a cutting element extending within the passage, wherein the cutting element includes a cutting blade disposed to cut the aerosol generating article as the aerosol generating article passes through the passage, and the cutting element includes a magnet and is configured to magnetically attract the susceptor heating element.

9. The tool according to claim 8, wherein the cutting element includes a blade.

10. The tool according to claim 8 or 9, wherein the cutting element is configured to be inserted into and removed from the passage.

11. Use of the tool according to any one of claims 1 to 10 for removing the susceptor heating element from the aerosol generating article.

12. A method for removing a susceptor heating element from an aerosol generating article, wherein the method is The process involves passing the aerosol-generating article through a passage in a cutting tool, wherein the cutting tool comprises (i) a body defining the passage and (ii) a cutting element extending within the passage, the cutting element having a cutting blade arranged to cut the aerosol-generating article as it passes through the passage. This includes removing the susceptor heating element from the cut aerosol generating article, A method for removing the susceptor heating element from the cut aerosol-generating article, comprising magnetically attracting the susceptor heating element to the cutting tool.

13. The method according to claim 12, wherein removing the susceptor heating element from the cut aerosol generating article includes magnetically attracting the susceptor heating element to the tip of a heating element removal tool.

14. The method according to claim 13, comprising separating a portion of the cut aerosol-generating article from an opposing portion of the cut aerosol-generating article along the cut portion.

15. The method according to claim 12, wherein removing the susceptor heating element from the cut aerosol generating article includes magnetically attracting the susceptor heating element to the cutting element.

Images