Method for manufacturing aerosol-generating articles

Abstract

To provide a method for continuously manufacturing aerosol-generating articles.SOLUTION: A method for continuously manufacturing aerosol-generating articles 1 includes: (i) providing a continuous web 34 of an aerosol-generating substrate 10, the continuous web including a substantially flat surface having a center line 18; (ii) applying at least one susceptor patch 28 to the substantially flat surface substantially along the center line to leave an exposed region 90 of the continuous web of the aerosol-generating substrate on each side of the at least one susceptor patch; (iii) cutting the exposed regions of the continuous web of the aerosol-generating substrate to form a plurality of aerosol-generating strips 15, 16 on each side of the at least one susceptor patch; and (iv) forming the plurality of aerosol-generating strips and the at least one susceptor patch into a continuous rod 88.SELECTED DRAWING: Figure 2b

Description

[Technical Field]

[0001] The present disclosure relates generally to aerosol-generating articles, and more specifically to aerosol-generating articles for use in an aerosol-generating device for heating an aerosol-generating article to generate an aerosol for inhalation by a user. Embodiments of the present disclosure particularly relate to a method for continuously manufacturing aerosol-generating articles. The present disclosure is particularly applicable to the manufacture of aerosol-generating articles for use with portable (handheld) aerosol-generating devices. [Background Art]

[0002] In recent years, the popularity and use of risk-reducing devices or risk-modifying devices (also known as aerosol-generating devices or vapor-generating devices) have grown rapidly as an alternative to the use of conventional tobacco products. Various devices and systems are available that heat an aerosol-generating substance to generate an aerosol for inhalation by a user.

[0003] Commonly available risk-reducing devices or risk-modifying devices are substrate-heating aerosol-generating devices or so-called heat-not-burn devices. This type of device generates an aerosol or vapor by heating an aerosol-generating substrate to a temperature typically in the range of 150°C to 300°C. By heating the aerosol-generating substrate to a temperature within this range without burning or combusting the aerosol-generating substrate, vapor is generated, which typically cools and condenses to form an aerosol for inhalation by the user of the device.

[0004] Currently available aerosol generating devices can heat an aerosol generating substrate using one of several different methods. One such method is to provide an aerosol generating device that employs an induction heating system. In such a device, an induction coil is provided in the device, and an induction-heatable susceptor is provided to heat the aerosol generating substrate. When the user operates the device, electrical energy is supplied to the induction coil, which subsequently generates an alternating current electromagnetic field. The susceptor couples with this electromagnetic field to generate heat, which is transferred to the aerosol generating substrate, for example by conduction, and when the aerosol generating substrate is heated, an aerosol is generated.

[0005] It can be convenient to provide both an aerosol generating substrate and an induction-heatable susceptor together in the form of an aerosol generating article that can be inserted into an aerosol generating device by the user. Therefore, there is a need to provide a method that facilitates the manufacture of aerosol generating articles, and in particular, enables easy and consistent mass production of aerosol generating articles. [Overview of the project] [Means for solving the problem]

[0006] According to a first aspect of this disclosure, a method for continuously producing an aerosol-generating article is provided, comprising: (i) providing a continuous web of an aerosol-generating substrate, the continuous web comprising a substantially flat surface having a center line; (ii) Applying at least one susceptor patch to a substantially flat surface substantially along the centerline, leaving exposed areas of the continuous web of the aerosol-generating substrate on both sides of at least one susceptor patch, (iii) Cutting the exposed area of ​​the continuous web of the aerosol generating substrate to form multiple aerosol generating strips on both sides of at least one susceptor patch, (iv) Forming multiple aerosol generating strips and at least one susceptor patch on a continuous rod, A method including this is provided.

[0007] The aerosol generating article produced by this method is intended for use with an aerosol generating device to heat the aerosol generating substrate without burning it, thereby volatilizing at least one component of the aerosol generating substrate, and thereby generating heated vapor that cools and condenses to form an aerosol for inhalation by the user of the aerosol generating device. The aerosol generating device is a handheld portable device.

[0008] Generally speaking, vapor is a substance that is in the gaseous phase at temperatures below its critical temperature, meaning that vapor can be condensed into a liquid by increasing pressure without lowering the temperature. Aerosol, on the other hand, is a suspended mass of fine solid particles or droplets in the air or another gas. However, it should be noted that in this specification, the terms “aerosol” and “vapor” may be used synonymously, particularly with respect to the form of an inhalable medium generated for the user to inhale.

[0009] The method according to this disclosure facilitates the manufacture of aerosol-generating articles, and in particular enables the consistent and relatively easy mass production of aerosol-generating articles. Since the aerosol-generating strip is formed without cutting at least one susceptor patch in step (iii), wear during the cutting step (e.g., on a cutting unit) is minimized. The combination of the aerosol-generating strip and susceptor (formed without cutting the susceptor patch into a strip) in the aerosol-generating article manufactured by the method according to this disclosure provides effective heat transfer from the susceptor to the aerosol-generating strip during use of the aerosol-generating article in an aerosol-generating device. This provides effective and uniform heating of the aerosol-generating strip, and therefore reliable vapor generation.

[0010] Precise and consistent positioning of at least one susceptor patch along the centerline of a substantially flat surface of a continuous web of an aerosol-generating substrate further helps ensure that aerosol-generating articles produced by the method according to this disclosure have consistent and repeatable properties.

[0011] Step (iii) can be performed using a rotary cutter unit. The rotary cutter unit may include a first cutting drum and a second cutting drum. The first cutting drum may have a first cutting structure extending in the circumferential direction. The second cutting drum may have a second cutting structure extending in the circumferential direction. The first and second cutting structures can cooperate to cut exposed areas of a continuous web of aerosol-generating substrate to form multiple aerosol-generating strips. Using a rotary cutter unit makes it easy to achieve continuous and high-speed production of aerosol-generating articles.

[0012] A first cutting drum and a second cutting drum can define a non-cutting region between them. The non-cutting region can accommodate at least one susceptor patch and a portion of the aerosol-generating substrate to which at least one susceptor patch is applied during step (ii). Providing a non-cutting region ensures that the portion beneath the susceptor patch and the aerosol-generating substrate (which functions as an elongated carrier strip for the susceptor patch) is not cut, while simultaneously ensuring that high-speed manufacturing is achieved.

[0013] The first cutting drum can be formed without a first cutting structure in the non-cutting region. For example, the first cutting drum may include a circumferentially extending recess on the surface of its non-cutting region. The second cutting drum can be formed without a second cutting structure in the non-cutting region. For example, the second cutting drum may include a circumferentially extending recess on the surface of its non-cutting region. This is possible. In some embodiments, both the first and second cutting drums may have the first and second cutting structures formed in the non-cutting region, respectively. In some embodiments, at least a portion of at least one susceptor patch may be housed in a circumferentially extending recess. These configurations ensure that the portion beneath the susceptor patch and the aerosol generating substrate (i.e., the elongated carrier strip) is not cut during step (iii), and that high-speed manufacturing is achieved.

[0014] Each of the multiple aerosol-generating strips may have a width of approximately 0.1 mm to 5.0 mm, and in some cases, approximately 0.5 mm to 2.0 mm. Each of the multiple aerosol-generating strips may have a width of 1.0 mm. These width dimensions ensure that the aerosol-generating articles manufactured using the method according to this disclosure contain an appropriate number of aerosol-generating strips, allowing for a uniform airflow through the aerosol-generating articles and the generation of an acceptable amount of vapor or aerosol. If the width of the aerosol-generating strips is too small, the strength of the strips may be reduced, which may make mass production of aerosol-generating articles difficult.

[0015] Step (ii) may include adhering at least one susceptor patch to a substantially flat surface of the continuous web of the aerosol-generating substrate using an adhesive. This ensures a good bond between the susceptor patch and the continuous web of the aerosol-generating substrate and that the susceptor patch does not move relative to the continuous web of the aerosol-generating substrate. This may help ensure that only the exposed areas of the continuous web of the aerosol-generating substrate are cut during step (iii) to form aerosol-generating strips.

[0016] Step (ii) may include applying a plurality of susceptor patches sequentially to a substantially flat surface of a continuous web of aerosol-generating substrate at predetermined constant intervals between each sequential susceptor patch. The predetermined constant "interval" between each sequential susceptor patch is the shortest distance between sequential (i.e., adjacent) susceptor patches, i.e., the distance or gap between the edges of sequential (i.e., adjacent) susceptor patches. Step (iii) may include cutting the exposed areas of the continuous web of aerosol-generating substrate to form a plurality of aerosol-generating strips on both sides of the susceptor patches. Step (iv) may include forming the plurality of aerosol-generating strips and susceptor patches into a continuous rod. This facilitates mass production of aerosol-generating articles.

[0017] At least one susceptor patch may have a length of 5 mm to 50 mm, preferably 10 mm to 30 mm. At least one susceptor patch may have a width of 0.1 mm to 7 mm, preferably 1 mm to 5 mm. At least one susceptor patch may have a thickness of 1 μm to 500 μm, preferably 10 μm to 100 μm, and possibly 50 μm. Susceptor patches having these dimensions are particularly suitable for the manufacture of aerosol-generating articles.

[0018] The method may further include (v) cutting a continuous rod to form a plurality of individual aerosol-generating articles. Each individual aerosol-generating article may include at least one susceptor patch. Thus, step (v) may include cutting a continuous rod to form a plurality of individual aerosol-generating articles, each containing at least one susceptor patch. This facilitates the continuous mass production of aerosol-generating articles.

[0019] Step (v) may include cutting the continuous rod at a location between adjacent susceptor patches. By cutting the continuous rod in this manner, the individual aerosol-generating articles formed by cutting the continuous rod each include a susceptor patch, therefore This ensures that the aerosol-generating material is consistently reproducible. In addition, since the susceptor patch is not cut during step (v), wear during the cutting step (e.g., on the cutting unit) is minimized.

[0020] Step (v) may include cutting the continuous rod at a substantially midpoint between adjacent susceptor patches. In this way, the susceptors are spaced inward from both ends of the resulting aerosol-generating article and are not visible from either end of the aerosol-generating article. This can improve the user acceptability of the aerosol-generating article produced by the method according to the present disclosure. Furthermore, the susceptors are fully embedded in the aerosol-generating substrate (i.e., aerosol-generating strip) of the resulting aerosol-generating article, so that the entire susceptor is surrounded by the aerosol-generating strip, and thus heat transfer from the susceptor to the aerosol-generating strip is maximized, which can enable more efficient generation of aerosols or vapors.

[0021] Each susceptor patch may include, but is not limited to, an inductively heatable susceptor material such as aluminum, iron, nickel, stainless steel, carbon steel, and their alloys, such as nickel-chromium or nickel-copper. When an electromagnetic field is applied nearby during the use of an aerosol-generating article in an aerosol-generating device, the susceptor material can generate heat due to eddy currents and magnetic hysteresis losses, resulting in an energy conversion from the electromagnetic field to heat.

[0022] The aerosol-generating substrate can be any type of solid or semi-solid material. Examples of aerosol-generating solids include powders, granules, pellets, shredded, strands, particles, gels, strips, loose leaves, cut leaves, cut fillers, porous materials, foamed materials, or sheets. The aerosol-generating substrate may include plant-derived materials, particularly tobacco. It may include, for example, reconstituted tobacco comprising tobacco and one or more inorganic fillers such as cellulose fibers, tobacco stem fibers, and CaCO3.

[0023] Therefore, an aerosol generating device intended for use in conjunction with an aerosol generating article can be called a "heated tobacco device," a "heated non-combustion tobacco device," or a "tobacco product vaporization device," and is interpreted as a device suitable for achieving these effects. The features disclosed herein are equally applicable to devices designed to vaporize any aerosol generating substrate.

[0024] The continuous rod may be surrounded by a paper wrapper. Therefore, this method may further include wrapping the continuous rod with a paper wrapper.

[0025] The aerosol-generating article may be substantially formed in the shape of a stick, and may generally resemble a cigarette having a tubular region containing an aerosol-generating substrate arranged in a suitable configuration. The aerosol-generating article may comprise a filter segment, for example comprising cellulose acetate fibers, at the proximal end of the aerosol-generating article. The filter segment may constitute a mouthpiece filter, and may be coaxially aligned with the aerosol-generating substrate constituted by a plurality of aerosol-generating strips. Some designs may also include one or more vapor collection regions, cooling regions, and other structures. For example, the aerosol-generating article may include at least one tubular segment upstream of the filter segment. The tubular segment may function as a vapor cooling region. The vapor cooling region may advantageously allow the heated vapor generated by heating the aerosol-generating strip to be cooled and condensed to form an aerosol having suitable properties for inhalation by a user, for example through the filter segment.

[0026] The aerosol-generating substrate may comprise an aerosol former. Examples of the aerosol former include polyhydric alcohols such as glycerin or propylene glycol, and mixtures thereof. Typically, the aerosol-generating substrate may comprise an aerosol former content of from about 5% to about 50% by dry weight. In some embodiments, the aerosol-generating substrate may comprise an aerosol former content of from about 10% to about 20% by dry weight, optionally about 15% by dry weight.

[0027] Upon heating, the aerosol-generating substrate (i.e., the aerosol-generating strip) may release volatile compounds. The volatile compounds may comprise flavor compounds such as nicotine or tobacco flavorants. BRIEF DESCRIPTION OF THE DRAWINGS

[0028] [Figure 1a] It is a schematic side sectional view of an example of an aerosol-generating article. [Figure 1b] It is an enlarged schematic cross-sectional view taken along line A-A in Figure 1a. [Figure 2a] Figures 1a and 1b are schematic diagrams of the apparatus and method for manufacturing the aerosol-generating article shown. [Figure 2b] This is a plan view of the aerosol generating substrate and susceptor patch as they move through the apparatus shown in Figure 2a in the direction indicated by the arrows. [Figure 3] This is a plan view of a portion of a continuous web of susceptor material, showing the bonded and non-bonded areas. [Figure 4] Figure 2a is a functional diagram of part of the apparatus and method, schematically illustrating the formation of a susceptor patch from a continuous web of susceptor material and the application of the susceptor patch to the surface of a continuous web of an aerosol-generating substrate. [Figure 5] This is a schematic perspective view of the susceptor cutting unit. [Figure 6] This is a schematic diagram of a strip cutting unit. [Modes for carrying out the invention]

[0029] Herein, embodiments of the present disclosure will be described as merely examples, with reference to the attached drawings.

[0030] Referring first to Figures 1a and 1b, an example of an aerosol generating article for use with an aerosol generating device that includes an induction heating system for induction heating the aerosol generating article, thereby generating an aerosol for inhalation by the user of the device. Such devices are known in the art and will not be described in further detail herein. The aerosol generating article 1 is elongated and substantially cylindrical. The circular cross-section facilitates handling of the article 1 by the user and insertion of the article 1 into the cavity or heating compartment of the aerosol generating device.

[0031] The aerosol generating article 1 includes an aerosol generating substrate 10 having a first end 10a and a second end 10b, and an induction-heatable susceptor 12. The aerosol generating substrate 10 and the induction-heatable susceptor 12 are placed within and surrounded by a wrapper 14. The wrapper 14 comprises a substantially non-conductive and non-magnetic material. In the illustrated example, the wrapper 14 is a paper wrapper and may include cigarette wrapping paper.

[0032] The aerosol generating article 1 may have a total length of 30 mm to 100 mm, preferably 50 mm to 70 mm, and possibly about 55 mm, measured between the distal end 11a and the proximal (mouse) end 11b. The aerosol generating substrate 10 may have a total length of 5 mm to 50 mm, preferably 10 mm to 30 mm, measured between the first end 10a and the second end 10b. Therefore, it may be about 20 mm. The aerosol generating article 1 may have a diameter of 5 mm to 10 mm, preferably 6 mm to 8 mm, and in some cases about 7 mm.

[0033] The aerosol generating substrate 10 includes a plurality of elongated first strips 15 containing aerosol generating material. The plurality of elongated first strips 15 constitute an aerosol generating strip 16 and are substantially oriented in the longitudinal direction of the aerosol generating article 1. The elongated first strips 15 are typically foldless in the longitudinal direction, ensuring that the airflow path is not interrupted and that a uniform airflow can be achieved through the article 1.

[0034] The induction-heatable susceptor 12 includes an elongated second strip 13 containing induction-heatable susceptor material. Thus, the elongated second strip 13 can also be considered as an elongated susceptor 12 in the shape of a strip or blade, which is substantially oriented in the longitudinal direction of the aerosol-generating article 1. As is clearly seen in Figure 1b, each of the elongated first strips 15 has a width smaller than the width of the elongated second strip 13.

[0035] The aerosol generating article 1 includes at least one elongated carrier strip 17 having first and second main surfaces 17a, 17b. The elongated carrier strip 17 contains the aerosol generating material and therefore also constitutes the aerosol generating strips 16. The elongated carrier strip 17 is substantially oriented in the longitudinal direction of the aerosol generating article 1. The elongated carrier strip 17 has the same length as the elongated first strip 15, and therefore all the aerosol generating strips 16 in the aerosol generating article 1 have the same length.

[0036] The elongated second strip 13 is bonded to the elongated carrier strip 17, and as can be clearly seen in Figure 1b, the elongated carrier strip 17 has a width greater than the width of the elongated second strip 13. The elongated second strip 13 has first and second opposing surfaces 13b and 13c. The second surface 13c is bonded to the second main surface 17b of the elongated carrier strip 17, and the elongated carrier strip 17 covers the entire strip, more specifically the second main surface 17b.

[0037] The elongated first strip 15, the elongated second strip 13, and the elongated carrier strip 17 are arranged to form a substantially rod-shaped aerosol generating article 1, and the elongated first strips 15 can be randomly distributed across the entire cross-section of the rod-shaped aerosol generating article 1, so that they have multiple different orientations within the cross-section of the aerosol generating article 1. Although not evident from Figure 1b, it will be understood that there are enough elongated first strips 15 to substantially fill the cross-section of the aerosol generating substrate 10, and a smaller number of elongated first strips 15 are shown simply for illustrative purposes. The elongated second strip 13 and the elongated carrier strip 17 are positioned approximately in the center of the cross-section of the aerosol generating substrate 10, and therefore the aerosol generating article 1. Such arrangement helps to ensure uniform heat transfer from the elongated second strip 13 to the elongated first strip 15.

[0038] As best shown in Figure 1b, the centrally positioned elongated carrier strip 17 and the elongated second strip 13 bonded thereto define first and second regions 5 and 6 within the cross-section of the aerosol generating substrate 10, and therefore within the cross-section of the aerosol generating article 1. The first region 5 faces the first main surface 17a of the elongated carrier strip 17, and the second region 6 faces the second main surface 17b of the elongated carrier strip 17. Both the first and second regions 5 and 6 contain a plurality of elongated first strips 15.

[0039] As best shown in Figure 1a, each of the multiple elongated first strips 15 is far The elongated second strip 13 has a distal end 13a, with a first end 15a. The distal end 15a of the elongated first strip 15 forms the first end 10a of the aerosol generating substrate 10, and correspondingly forms the distal end 11a of the aerosol generating article 1. The elongated second strip 13 is shorter than the elongated first strip 15 and the elongated carrier strip 17. The distal end 13a of the elongated second strip 13 is positioned inward from the distal end 15a of the elongated first strip 15. Therefore, the distal end 13a of the elongated second strip 13 (i.e., the elongated susceptor 12) is not visible at the distal end 11a of the aerosol generating article 1.

[0040] The aerosol generating article 1 includes a mouthpiece segment 20 positioned downstream of the aerosol generating substrate 10. The aerosol generating substrate 10 and the mouthpiece segment 20 are arranged coaxially inside the wrapper 14 to hold the components in place, forming a rod-shaped aerosol generating article 1.

[0041] In the illustrated embodiment, the mouthpiece segment 20 includes the following components arranged sequentially and coaxially in a downstream direction, in other words, from the distal end 11a to the proximal (mouth) end 11b of the aerosol generating article 1: a cooling segment 22, a central hole segment 23, and a filter segment 24. The cooling segment 22 includes a hollow paper tube 22a having a thickness exceeding the thickness of the paper wrapper 14. The central hole segment 23 may contain a cured mixture containing cellulose acetate fibers and a plasticizer, which functions to increase the strength of the mouthpiece segment 20. The filter segment 24 typically contains cellulose acetate fibers and functions as a mouthpiece filter. As heated vapor flows from the aerosol generating substrate 10 toward the proximal (mouth) end 11b of the aerosol generating article 1, the vapor cools and condenses as it passes through the cooling segment 22 and the central hole segment 23 to form an aerosol with properties suitable for inhalation by the user via the filter segment 24.

[0042] The elongated first strip 15 and the elongated carrier strip 17 typically contain plant-derived materials such as tobacco. Advantageously, the elongated first strip 15 and the elongated carrier strip 17 may contain reconstituted tobacco, comprising tobacco and any one or more inorganic fillers such as cellulose fibers, tobacco stem fibers, and CaCO3.

[0043] The elongated first strip 15 and the elongated carrier strip 17 typically contain an aerosol former such as glycerin or propylene glycol. Typically, the elongated first strip 15 and the elongated carrier strip 17 contain an aerosol former content of about 5% to about 50% on a dry weight basis. When heated, the elongated first strip 15 and the elongated carrier strip 17 release volatile compounds, which may include flavor compounds such as nicotine or tobacco flavorings.

[0044] During use of article 1 in the aerosol generating device, when a time-varying electromagnetic field is applied near the elongated second strip 13, heat is generated in the elongated second strip 13 due to eddy currents and magnetic hysteresis losses. The heat is transferred from the elongated second strip 13 to the elongated first strip 15 and the elongated carrier strip 17, heating the elongated first strip 15 and the elongated carrier strip 17 without combustion, releasing one or more volatile compounds, thereby generating vapor. When the user inhales through the filter segment 24, the heated vapor is drawn downstream through article 1 from the first end 10a of the aerosol generating substrate 10 toward the second end 10b of the aerosol generating substrate 10, and toward the filter segment 24. As described above, the heated vapor passes through the cooling segment 22 and the central hole segment 23 toward the filter segment 24. As it flows, the heated vapor cools and condenses, forming an aerosol with properties suitable for inhalation by the user through the filter segment 24.

[0045] [Manufacturing of aerosol-generating articles] Here, with reference to Figures 1a and 1b, a suitable apparatus 30 and method for manufacturing an aerosol generating article according to this disclosure, such as the aerosol generating article 1 described above, will be explained.

[0046] Referring to Figure 2a, a schematic diagram of the apparatus 30 and method for manufacturing the aerosol-generating article 1 described above is shown with reference to Figures 1a and 1b. Figure 2b is a plan view of the aerosol-generating substrate 10 and susceptor patch 28 as they move through the apparatus 30 in the direction of the arrow in Figure 2b.

[0047] The apparatus 30 includes a substrate supply reel 32 (e.g., a first bobbin) that carries a continuous web 34 of an aerosol-generating substrate 10 having a substantially flat surface with a centerline 18, and a first feed roller 36 for controlling the feed of the continuous web 34 of the aerosol-generating substrate 10. The apparatus 30 may also include a web tension adjuster and a web edge control system, as will be understood by those skilled in the art, but these additional components are not essential in the context of this disclosure and are therefore omitted for simplicity.

[0048] The apparatus 30 includes a susceptor supply reel 38 (e.g., a second bobbin) for carrying a continuous web 40 of susceptor material, feed rollers 42, 44 for controlling the feeding of the continuous web 40 of susceptor material, an adhesive application unit 46, and a susceptor cutting unit 48.

[0049] The apparatus 30 further includes an optional heater 50, a strip cutting unit 52, a feed roller 54, a rod forming unit 56, and a rod cutting unit 58.

[0050] [Preparing the susceptor patch] During operation, the continuous web 34 of the aerosol generating substrate 10 is continuously supplied from the substrate supply reel 32. Simultaneously, the continuous web 40 of the susceptor material is continuously supplied from the susceptor supply reel 38 to the adhesive application unit 46 via feed rollers 42 and 44. The adhesive application unit 46 applies adhesive 47 to the surface of the continuous web 40 of the susceptor material. In the illustrated example, the adhesive application unit 46 applies the adhesive 47 intermittently to the surface of the continuous web 40 of the susceptor material, and across the entire width of the web 40. In this way, separate adhesive regions 60 (see Figures 3 and 4) are formed on the surface of the continuous web 40 of the susceptor material, and non-adhesive regions 62 are formed between adjacent adhesive regions 60 in the direction of movement of the continuous web 40 of the susceptor material.

[0051] A continuous web 40 of the susceptor material is supplied from an adhesive application unit 46 to a susceptor cutting unit 48 that continuously cuts the continuous web 40 of the susceptor material to form a plurality of susceptor patches 28. As best shown in Figure 2b, the continuous web 40 of the susceptor material, and therefore the susceptor patches 28, has a width substantially smaller than the width of the continuous web 34 of the aerosol generating substrate 10. For example, the continuous web 34 of the aerosol generating substrate 10 may have a width of about 140 mm, while the continuous web 40 of the susceptor material, and therefore the susceptor patches 28, may have a width of about 0.1 mm to 7 mm. In some embodiments, the susceptor patches 28 may have a length of about 5 mm to 50 mm in the direction of movement of the continuous web 40 of the susceptor material and a thickness of about 1 μm to 500 μm.

[0052] To minimize contamination of the susceptor cutting unit 48 by the adhesive 47 applied to the continuous web 40 of the susceptor material by the adhesive application unit 46, the susceptor cutting unit Unit 48 cuts the continuous web 40 of the susceptor material in the non-adhesive region 62, i.e., at a position between the adhesive regions 60 on the surface of the continuous web 40 of the susceptor material. This can be achieved by synchronizing the operation of the susceptor cutting unit 48 with the movement of the continuous web 40 of the susceptor material.

[0053] Referring to Figure 5, the susceptor cutting unit 48 includes a rotary cutting unit 64 comprising a support drum 66 and a cutting drum 68. The support drum 66 supports a continuous web 40 of susceptor material around it and includes a plurality of circumferentially spaced recesses 70 around it. The support drum 66 is typically a suction drum, and the continuous web 40 of susceptor material and susceptor patches 28 are supported around the suction drum by a suction force applied through a suction port 67. The cutting drum 68 includes a plurality of circumferentially spaced cutting elements 72, such as protruding cutting blades, around it, and the cutting elements 72 cooperate with (e.g., extend into) the circumferentially spaced recesses 70 during synchronous rotation of both the support drum 66 and the cutting drum 68 in the opposite direction, as indicated by the arrows in Figure 5. This results in continuous shear cutting of the continuous web 40 of susceptor material, forming a plurality of susceptor patches 28. As will become clear from the following description, each susceptor patch 28 corresponds to the elongated second strip 13 (i.e., elongated susceptor 12) of the completed aerosol generating article 1 described above with reference to Figures 1a and 1b.

[0054] [Application of susceptor patch] The susceptor patches 28 provided by the susceptor cutting unit 48 can be applied to the surface of the continuous web 34 of the aerosol generating substrate 10, so that a certain predetermined gap 74 exists between the edges of each continuous susceptor patch 28, as shown, for example, in Figures 2b and 4. The certain predetermined gap 74 may be, for example, 1 mm to 20 mm. To generate a certain predetermined gap 74 between the edges of adjacent susceptor patches 28, the susceptor cutting unit 48 allows relative movement between the continuous web 40 of the susceptor material and the support drum 66 for a predetermined period immediately after the continuous web 40 of the susceptor material, carried by the support drum 66, has been cut by the cutting drum 68 to form a susceptor patch 28. This relative movement allows the continuous web 40 of the susceptor material to remain stationary or move slowly for a short time after the susceptor patch 28 has been cut from the continuous web 40 of the susceptor material. The relative motion between the continuous web 40 of the susceptor material and the support drum 66 can be achieved, for example, by reducing the attractive force applied to the continuous web 40 of the susceptor material by the support drum 66, while at the same time maintaining an appropriate attractive force between the already cut susceptor patch 28 and the support drum 66 to ensure that there is no relative movement between the susceptor patch 28 and the support drum 66. In this way, the susceptor patch 28 cut from the continuous web 40 of the susceptor material by the susceptor cutting unit 48 is transported for a short time at a speed faster than the continuous web 40 of the susceptor material from which it was cut, thereby creating a desired constant predetermined gap 74 between the edges of adjacent susceptor patches 28.

[0055] The susceptor patches 28 coated with adhesive 47 are continuously bonded to the flat surface of the continuous web 34 of the aerosol generating substrate 10, substantially along the centerline 18. The exposed side regions 90 of the continuous web 34 of the aerosol generating substrate are thereby formed on both sides of the susceptor patches 28 (see Figure 2b), because, as described above, the continuous web 34 of the aerosol generating substrate 10 is substantially wider than the susceptor patches 28. Adjacent susceptor patches 28 are also spaced apart in the direction of movement of the continuous web 34 of the aerosol generating substrate 10 by a certain predetermined gap 74 between the edges of the susceptor patches 28, which occurs when the susceptor patches 28 are formed by the susceptor cutting unit 48.

[0056] The substantially flat surface of the continuous web 34 of the susceptor patch 28 and aerosol generating substrate 10 To ensure sufficient adhesion between them, the susceptor patches 28 can be pressed against a substantially flat surface by a cam roller 76 schematically shown in Figure 2a. The rotation of the cam roller 76 is synchronized with the movement of the continuous web 34 of the aerosol-generating substrate 10, so that pressing force is applied to the continuous susceptor patches 28 but not to the separated areas between the continuous susceptor patches 28.

[0057] Depending on the properties of the adhesive 47 applied to the continuous web 40 of the susceptor material (and therefore to the susceptor patches 28) by the adhesive application unit 46, the continuous web 34 of the aerosol generating substrate 10 and the susceptor patches 28 bonded to its surface can be heated by an optional heater 50. This helps to cure or solidify the adhesive 47, thereby ensuring good bonding between each susceptor patch 28 and the flat surface of the continuous web 34 of the aerosol generating substrate 10. The heating temperature should be carefully selected based on the properties of both the aerosol generating substrate 10 and the adhesive 47, ensuring that sufficient heating is achieved to cure or solidify the adhesive 47, while at the same time avoiding or at least minimizing the release of volatile components from the aerosol generating substrate 10.

[0058] [Strip cutting] The continuous web 34 of the aerosol generating substrate 10, to which the separated susceptor patches 28 are adhered to its flat surface, is fed to a strip cutting unit 52. The strip cutting unit 52 cuts only the exposed side regions 90 of the continuous web 34 of the aerosol generating substrate 10 without cutting the susceptor patches 28, thereby forming multiple continuous aerosol generating strips 16 along the susceptor patches 28. In one embodiment, the strip cutting unit 52 cuts the exposed side regions 90 of the continuous web 34 of the aerosol generating substrate 10 to form aerosol generating strips 16 having a strip width of approximately 1 mm.

[0059] As shown in Figures 2a and 6, the strip cutting unit 52 is a rotary cutter unit 78 and includes first and second cutting drums 80 and 82. The first cutting drum 80 includes a first cutting structure 84 extending in the circumferential direction, and the second cutting drum 82 includes a second cutting structure 86 extending in the circumferential direction. The first and second cutting structures 84 and 86 cooperate (e.g., interlock) to shear-cut the exposed side regions 90 of the continuous web 34 of the aerosol-generating substrate 10 in the direction of movement of the continuous web 34, thereby forming a continuous aerosol-generating strip 16, specifically the elongated first strip 15 shown in Figures 1a and 1b.

[0060] To cut only the exposed side region 90 of the continuous web 34 of the aerosol generating substrate 10 to form an elongated first strip 15, the first and second cutting drums 80, 82 define a non-cutting region 92 between them that accommodates the susceptor patch 28 and the portion of the continuous web 34 of the aerosol generating substrate 10 to which the susceptor patch 28 is adhered. In the illustrated embodiment, the first cutting drum 80 is formed in the non-cutting region 92 without a first cutting structure 84. Similarly, the second cutting drum 82 is also formed in the non-cutting region 92 without a second cutting structure 86. Furthermore, since the first cutting drum 80 includes a circumferentially extending recess 94 on the surface of the non-cutting region 92, at least a portion of the susceptor patch 28 can be accommodated in the circumferentially extending recess 94 during cutting of the exposed side region 90 of the continuous web 34 of the aerosol generating substrate 10. Therefore, when the exposed side regions 90 of the continuous web 34 of the aerosol generating substrate 10 are cut to form an elongated first strip 15 by the cooperation of the first and second cutting structures 84 and 86 on the first and second cutting drums 80 and 82, respectively, it will be understood that the central portion of the continuous web 34 of the aerosol generating substrate 10, which is contained in the uncut region 92 and has not been cut into strips, constitutes the elongated carrier strip 17 as described above, with reference to Figure 1b.

[0061] [Rod formation] The aerosol generating strip 16, elongated carrier strip 17, and bonded susceptor patch 28, formed by cutting the exposed side region 90 of the continuous web 34 of the aerosol generating substrate 10, are transported to the rod forming unit 56, where they are formed into a rod 88. If necessary, a continuous sheet of wrapping paper (not shown) can be supplied to the rod forming unit 56 from a supply reel (not shown) or to another wrapping unit located downstream of the rod forming unit 56 (again from the supply reel). Once the sheet of wrapping paper is transported and guided through the rod forming unit 56 or the separate wrapping unit, it can be wrapped around the aerosol generating strip 16 and susceptor patch 28 so that the continuous rod 88 is surrounded by the wrapper 14.

[0062] [Rod cutting] The continuous rod 88 (optionally surrounded by a wrapper 14) is then transferred to a rod cutting unit 58, where it is cut to predetermined lengths at appropriate positions to form multiple aerosol-generating articles 1. The aerosol-generating articles 1 formed by the rod cutting unit 58 can have a length of 5 mm to 50 mm, preferably 10 mm to 30 mm. This length will be understood to correspond to the length of the aerosol-generating substrate 10 described above with reference to Figures 1a and 1b. The continuous rod 88 is preferably repeatedly cut by the rod cutting unit 58 at substantially midpoints between the edges of the susceptor patches 28. In this way, the susceptor patches 28 are not cut by the rod cutting unit 58, thereby reducing wear on the cutting element. Furthermore, since the susceptor patches 28 are shorter than the aerosol-generating strips 16, the ends of the individual susceptor patches 28 (i.e., the elongated second strips 13) are not visible at any end of the aerosol-generating articles 1 formed by the rod cutting unit 58. It will be understood that this type of method is particularly suitable for the mass production of aerosol-generating article 1.

[0063] [Final assembly] Further units (not shown) can be positioned downstream of the rod cutting unit 58 to provide one or more additional components, such as the mouthpiece segments 20 described above, and configured to assemble with the individual aerosol generating articles 1 formed by the rod cutting unit 56 to form, for example, a completed aerosol generating article 1 of the type shown in Figure 1. In this case, a separate wrapping unit can be provided downstream of the rod cutting unit 58 to allow the assembled components to be wrapped simultaneously to form a completed aerosol generating article 1. The further units may form part of the apparatus 30, or they may be separate standalone units that form part of the final assembly line.

[0064] While the preceding paragraphs have described exemplary embodiments, it should be understood that various modifications can be made to these embodiments without departing from the scope of the attached claims. Therefore, the breadth and scope of the claims should not be limited to the exemplary embodiments described above.

[0065] Unless otherwise stated herein or unless clearly inconsistent with the context, any combination of the features described above in all possible variations is encompassed by this disclosure.

[0066] Unless the context clearly indicates otherwise, throughout this specification and the claims, words such as “includes” and “contains” should be interpreted comprehensively, that is, “includes but not limited,” as opposed to an exclusive or exhaustive meaning.

Claims

1. An aerosol generating article (1) for use with an aerosol generating device using an induction heating system, wherein the aerosol generating article (1) is Aerosol generating substrate (10) and A filter segment (24) at the proximal end (11b) of the aerosol generating article (1), At least one tubular segment (22, 23) located upstream of the filter segment (24), A wrapper (14) surrounds the aerosol generating substrate (10) and the filter segment (24). Includes, The aerosol generating substrate (10) is A plurality of elongated first strips (15) containing an aerosol generating material, which constitute an aerosol generating strip (16) substantially oriented in the longitudinal direction of an aerosol generating article (1), An elongated second strip (13) comprising an induction-heatable susceptor material and acting as an elongated strip-shaped or blade-shaped susceptor (12) substantially oriented in the longitudinal direction of the aerosol-generating article (1), An elongated carrier strip (17) containing an aerosol generating material, wherein the elongated carrier strip (17) is substantially oriented in the longitudinal direction of the aerosol generating article (1), has first and second main surfaces (17a, 17b), and has the same length as the elongated first strip (15). Includes, The elongated first strip (15), the elongated second strip (13), and the elongated carrier strip (17) are arranged to form a substantially rod-shaped aerosol generating substrate (10). The cross-section of the aerosol generating substrate (10) includes a first region (5) facing the first main surface (17a) of the elongated carrier strip (17) and a second region (6) facing the second main surface (17b) of the elongated carrier strip (17). The first and second regions (5, 6) each include a plurality of the elongated first strips (15), the elongated second strip (13) and the elongated carrier strip (17) are positioned approximately in the center of the cross-section of the aerosol generating substrate (10). Each of the plurality of aerosol generating strips (16) has a width of 0.1 mm to 5.0 mm. The elongated carrier strip (17) includes a single strip having a flat surface on which the elongated second strip (13) is arranged and supported. Aerosol-generating article (1).

2. The elongated second strip (13) is bonded to the elongated carrier strip (17) using an adhesive (47). The aerosol generating article (1) according to claim 1.

3. The elongated carrier strip (17) has a width greater than the width of the elongated second strip (13). The aerosol-generating article (1) according to claim 1 or 2.

4. The elongated second strip (13) is completely embedded within the aerosol generating substrate (10) and is not visible at any end of the aerosol generating substrate (10). an aerosol generating article (1) according to any one of claims 1 to 3.

5. Each of the elongated first strip (15) and the elongated carrier strip (17) contains the same aerosol generating material. an aerosol generating article (1) according to any one of claims 1 to 4.

6. The elongated second strip (13) has a width of 0.1 mm to 7 mm and a thickness of 1 μm to 500 μm, and includes an induction-heatable susceptor material. an aerosol generating article (1) according to any one of claims 1 to 5.

7. The induction-heatable susceptor material includes one or more of the following: aluminum, iron, nickel, stainless steel, carbon steel, and alloys thereof including nickel-chromium and nickel-copper. The aerosol generating article (1) according to claim 6.

8. The plurality of aerosol generating strips (16) and the elongated carrier strip (17) contain tobacco. an aerosol generating article (1) according to any one of claims 1 to 7.

9. The plurality of aerosol generating strips (16) and the elongated carrier strip (17) contain glycerin and / or propylene glycol. an aerosol generating article (1) according to any one of claims 1 to 8.

10. The plurality of aerosol generating strips (16) and the elongated carrier strip (17) contain nicotine and / or flavor compounds such as tobacco flavor. an aerosol generating article (1) according to any one of claims 1 to 9.

11. The aerosol generating article (1) has a total length of 30 mm to 100 mm and a diameter of 5 mm to 10 mm. The aerosol generating substrate (10) has a total length of 5 mm to 50 mm. an aerosol generating article (1) according to any one of claims 1 to 10.

12. An aerosol generating article (1) for use with an aerosol generating device using an induction heating system, wherein the aerosol generating article (1) is Aerosol generating substrate (10) and A filter segment (24) at the proximal end (11b) of the aerosol generating article (1), At least one tubular segment (22, 23) located upstream of the filter segment (24), A wrapper (14) surrounds the aerosol generating substrate (10) and the filter segment (24). Includes, The aerosol generating substrate (10) is A plurality of elongated first strips (15) containing an aerosol generating material, which constitute an aerosol generating strip (16) substantially oriented in the longitudinal direction of an aerosol generating article (1), An elongated second strip (13) comprising an induction-heatable susceptor material and acting as an elongated strip-shaped or blade-shaped susceptor (12) substantially oriented in the longitudinal direction of the aerosol-generating article (1), An elongated carrier strip (17) containing an aerosol generating material, wherein the elongated carrier strip (17) is substantially oriented in the longitudinal direction of the aerosol generating article (1), has first and second main surfaces (17a, 17b), and has the same length as the elongated first strip (15). Includes, The elongated first strip (15), the elongated second strip (13), and the elongated carrier strip (17) are arranged to form a substantially rod-shaped aerosol generating substrate (10). The cross-section of the aerosol generating substrate (10) includes a first region (5) facing the first main surface (17a) of the elongated carrier strip (17) and a second region (6) facing the second main surface (17b) of the elongated carrier strip (17). The first and second regions (5, 6) each include a plurality of the elongated first strips (15), the elongated second strip (13) and the elongated carrier strip (17) are positioned approximately in the center of the cross-section of the aerosol generating substrate (10). Each of the plurality of aerosol generating strips (16) has a width of 0.1 mm to 5.0 mm. The elongated carrier strip (17) has a width greater than the width of the elongated second strip (13). Aerosol-generating article (1).

13. In an aerosol generating article (1) described in any one of claims 1 to 12, The aerosol generating article (1) has an elongated second strip (13) having a length of 5 mm to 50 mm.

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