Tobacco plug with corrugated susceptor

Abstract

The invention relates to a tobacco plug for an inductively heatable aerosol-generating article. The tobacco plug comprises a paper wrapper. The tobacco plug comprises sensorial media. The tobacco plug comprises a band-shaped susceptor. The band-shaped susceptor is arranged within the sensorial media. The paper wrapper encloses the sensorial media and the band-shaped susceptor. The band-shaped susceptor has a transversal corrugation with respect to a longitudinal axis of the tobacco plug.

Description

[0001] New PCT Patent Application July 30, 2025 Philip Morris Products S.A. 46069- PCT

[0002] -1-

[0003] TOBACCO PLUG WITH CORRUGATED SUSCEPTOR

[0004] The present invention relates to a tobacco plug, an inductively heatable aerosol generating article comprising said tobacco plug, and a method for manufacturing said tobacco plug.

[0005] Aerosol-generating articles including at least one aerosol-forming substrate that is capable to form an inhalable aerosol when heated are generally known. For heating the substrate, the article may be received within an aerosol-generating device which comprises an electrical heater. The heater may be an inductive heater comprising an induction source. The induction source is configured for generating an alternating electromagnetic field to inductively heat a susceptor by at least one of eddy currents and hysteresis losses, depending on the electrical and magnetic properties of the susceptor. The susceptor may be integral part of the article and arranged such as to be in thermal proximity or direct physical contact with the substrate to be heated. In operation of the device, volatile compounds are released from the heated aerosol-forming substrate in the article and entrained in an airflow that is drawn through the article during a user's puff. As the released compounds cool, they condense to form an aerosol.

[0006] In the manufacturing of inductively heatable aerosol-generating articles, in particular Heat-not-Burn consumables (HnB consumables), a sensorial media and a band of susceptor material is wrapped in a wrapper material to form a continuous rod. This continuous rod is subsequently fed to a cutting device for cutting the continuous rod into a plurality of individual tobacco plugs of defined length.

[0007] A challenge in tobacco plug manufacturing is achieving precise susceptor positioning within the tobacco plugs. Knives used during a cutting step may exert bending loads on the susceptor, leading to misalignment of the susceptor within the aerosol-forming substrate. This issue may be more pronounced with cut filler material due to its soft and less rigid nature compared to other aerosol-forming substrates used in manufacturing of HnB products. Cut filler's flexibility allows greater movement of the susceptor within the rod, making precise positioning and mechanical interlocking of the susceptor more difficult.

[0008] It would be desirable to provide a method for manufacturing tobacco plugs that avoids or reduces susceptor misalignment and inadequate mechanical interlocking with the substrate in tobacco-based HnB-consumables, particularly those using cut filler as the aerosol-forming substrate.

[0009] It would be desirable to provide tobacco plugs that are more resistive to transversal forces during manufacturing. New PCT Patent Application July 30, 2025 Philip Morris Products S.A. 46069- PCT

[0010] -2-

[0011] It would be desirable to provide tobacco plugs that allow for manufacturing aerosolgenerating articles with a more consistent aerosolization performance.

[0012] It would further be desirable to provide a method of manufacturing such aerosolgenerating articles.

[0013] According to an embodiment of the invention there is provided a tobacco plug for an inductively heatable aerosol-generating article. The tobacco plug may comprise a paper wrapper. The tobacco plug may comprise sensorial media. The tobacco plug may comprise a band-shaped susceptor. The band-shaped susceptor may be arranged within the sensorial media. The paper wrapper may enclose the sensorial media and the band-shaped susceptor. The band-shaped susceptor may have a transversal corrugation with respect to a longitudinal axis of the tobacco plug.

[0014] According to an embodiment of the invention there is provided a tobacco plug for an inductively heatable aerosol-generating article. The tobacco plug comprises a paper wrapper. The tobacco plug comprises sensorial media. The tobacco plug comprises a band-shaped susceptor. The band-shaped susceptor is arranged within the sensorial media. The paper wrapper encloses the sensorial media and the band-shaped susceptor. The band-shaped susceptor has a transversal corrugation with respect to a longitudinal axis of the tobacco plug.

[0015] In this context, "band-shaped" may refer to the susceptor being in the form of a strip or ribbon that is arranged within the sensorial media of the tobacco plug. The susceptor is configured to be inductively heated by an alternating electromagnetic field generated with an induction source. As such the susceptor is a key component of an inductive heating mechanism. The band-shaped susceptor may comprise transversal corrugations to enhance its functionality in uniformly heating the tobacco during use and increase its resistance to transversal forces during manufacturing.

[0016] In this context a "transversal corrugation" may refer to the cross-sectional pattern of the band of susceptor material. Such pattern may be obtained by forming one or more parallel ridges or grooves that run along the length of the band-shaped susceptor. In a transversal direction, or in other words, in a direction orthogonal to the longitudinal direction of the bandshaped susceptor, such susceptor has a cross-section with a transversal corrugation. A “transversal corrugation” is a corrugation that runs perpendicular to the longitudinal axis of the band-shaped susceptor. Corrugations may be geometric features, preferably characterized by a series of parallel ridges or grooves. Using a corrugated susceptor may increase the contact area between the susceptor and the substrate. Increasing the contact area between the susceptor and the substrate may enhance the efficiency of heat transfer and may ensure more uniform heating of the tobacco plug. New PCT Patent Application July 30, 2025 Philip Morris Products S.A. 46069- PCT

[0017] -3-

[0018] Besides improving the heat transfer the transversal corrugations may contribute to the structural stability of the band-shaped susceptor. The corrugated pattern may add rigidity and resistance to deformation under mechanical stress. This enhanced stability may help maintain the integrity and proper positioning of the susceptor within the sensorial media, ensuring consistent performance of the inductively heatable aerosol-generating article. The susceptor may become more resistant to transversal forces during manufacturing, such as those exerted by knives during a cutting step. Without this stability, bending loads applied by the knives could cause misalignment of the susceptor within the aerosol-forming substrate.

[0019] A method for manufacturing tobacco plugs that avoids or reduces susceptor misalignment and inadequate mechanical interlocking with the substrate in tobacco-based HnB-consumables, particularly those using cut filler as the aerosol-forming substrate, is provided.

[0020] A tobacco plug that is more resistive to transversal forces during manufacturing is provided.

[0021] A tobacco plug that allows for manufacturing aerosol-generating articles with a more consistent aerosolization performance is provided.

[0022] A method of manufacturing such as aerosol-generating articles is provided.

[0023] The modifications of the susceptor in form of a transversal corrugation with respect to a longitudinal axis of the tobacco plug may enhance the mechanical anchoring and interlocking dynamics between the susceptor and the cut filler, enhancing stability and consistent performance of the susceptor. By integrating the modified susceptor within the cut filler, preferably centred and aligned parallel to the longitudinal axis of the tobacco plug, a multitude of contact points may be established, fostering a robust connection.

[0024] The transversal corrugation of the susceptor may be provided such that the susceptor has a curved cross-section.

[0025] A susceptor having a "curved cross-section" may have a transversal corrugation in which the cross-sectional profile of the ridges or grooves is rounded or arched, rather than flat or angular.

[0026] An advantage of a curved cross-section may be that it distributes mechanical and thermal stresses more evenly, reducing the risk of stress concentrations that could lead to bending during the cutting process. The susceptor may maintain its structural integrity and proper alignment within the aerosol-forming substrate. This stability may ensure that the heat generated during the inductive heating process is distributed more uniformly across the tobacco plug. Consequently, the overall efficiency and performance of the inductively heated tobacco plug may be enhanced, as the heat is not localized or uneven, which could otherwise New PCT Patent Application July 30, 2025 Philip Morris Products S.A. 46069- PCT

[0027] -4- lead to inconsistent heating and reduced effectiveness of the aerosol-generating article. The transversal corrugation of the susceptor may be S-shaped.

[0028] An "S-shaped susceptor" may refer to a susceptor comprising a cross-sectional profile resembling the letter "S."

[0029] An advantage of an S-shaped susceptor may be its ability to enhance heat distribution and maintain a more centered cross-sectional arrangement. The S-shaped design may allow for more uniform distribution of mechanical stresses, effectively accommodating expansion and contraction. This may reduce the risk of deformation or damage during the cutting process. As a result, the susceptor may provide improved durability and consistent performance in heating the tobacco plug, ensuring a more efficient and reliable inductive heating process.

[0030] The transversal corrugation of the susceptor may be multi S-shaped.

[0031] A "multi S-shaped susceptor" may refer to a generally S-shaped susceptor, wherein the susceptor comprises more than two arches. A multi S-shaped susceptor may have multiple curved arches along its width.

[0032] An advantage of a multi S-shaped susceptor may be its ability to distribute thermal mechanical stresses over a larger area. This configuration not only enhances the flexibility and adaptability of the susceptor but also increases the surface area for heat exchange, leading to more uniform and efficient heating of the tobacco plug. The multi S-shaped structure may also provide additional mechanical stability, making the susceptor more resistant to deformation.

[0033] The multi S-shape may take the form of sinusoidal curves, semi-circles, or combinations thereof. An advantage of a multi-S-shaped susceptor over a single S-shaped susceptor lies in its superior ability to distribute mechanical stresses and enhance heat distribution.

[0034] The transversal corrugation of the susceptor may comprise one or more edges.

[0035] An advantage of an edge in the transversal corrugation may be that it contributes to the structural integrity and durability of the susceptor. The edge may help maintaining the shape of the corrugation, ensuring that the susceptor retains its configured profile under mechanical stress. This stability may improve a consistent and efficient heat transfer, enhancing the overall performance and reliability of the inductively heated tobacco plug.

[0036] The transversal corrugation of the susceptor may have a Z-shaped or a W-shaped cross-section.

[0037] An advantage of Z-shaped or W-shaped cross-sections lies in their ability to enhance the structural rigidity and stability of the susceptor. These shapes may better withstand mechanical and thermal stresses due to their geometrical complexity, which distributes stress more evenly across the structure. New PCT Patent Application July 30, 2025 Philip Morris Products S.A. 46069- PCT

[0038] -5-

[0039] The Z-shape may provide flexibility and resilience, allowing the susceptor to expand and contract without significant deformation. This may lead to more consistent heating and better performance during mechanical stress.

[0040] The W-shape may further increase the surface area for heat exchange and may add additional structural strength, making the susceptor more robust and durable. The multiple peaks and valleys in the W-shape may ensure more uniform heat distribution across the tobacco plug, improving overall efficiency and reliability.

[0041] Both shapes may contribute to the longevity and efficiency of the inductively heated tobacco plug by maintaining structural integrity and enhancing heat transfer capabilities.

[0042] The transversal corrugation of the susceptor may have a zig-zag-shaped cross-section, which corresponds to a multi Z-shaped cross section, analogous to the multi S-shaped cross section.

[0043] The susceptor may be positioned centrally and parallel to the longitudinal axis of the tobacco plug.

[0044] The advantage of positioning the susceptor centrally and parallel to the longitudinal axis of the tobacco plug may be optimized heat distribution and rigidity. By placing the susceptor at the center and parallel to the plug's axis, heat can be evenly radiated throughout the tobacco material, ensuring uniform heating and consistent performance. This alignment helps prevent hotspots and promotes effective aerosol generation through controlled and thorough heat dispersion within the plug. Additionally, this positioning may enhance the overall stability and balance of the heating process, leading to improved user experience and product efficacy.

[0045] The susceptor material may comprise a metal alloy.

[0046] As used herein, the term ‘susceptor material’ may refer to a material that is capable to convert electromagnetic energy into heat. When located in an alternating electromagnetic field, typically eddy currents are induced and hysteresis losses may occur in the susceptor causing heating of the susceptor. As the susceptor material is located in thermal contact with the sensorial medium, the sensorial medium is heated by the susceptor material.

[0047] The susceptor material may be formed from any material that can be inductively heated to a temperature sufficient to heat the sensorial medium. Preferred susceptor materials comprise metal or carbon. A preferred susceptor material may comprise or consist of a ferrous or ferromagnetic material, for example ferritic iron, a ferromagnetic alloy, such as ferromagnetic steel, stainless steel or aluminium. The susceptor material preferably comprises more than 5 percent, preferably more than 20 percent, preferably more than 50 percent or 90 percent of ferromagnetic or paramagnetic materials. Preferred susceptors may be heated to a New PCT Patent Application July 30, 2025 Philip Morris Products S.A. 46069- PCT

[0048] -6- temperature between about 150 degrees Celsius and about 300 degrees Celsius. Preferably, the susceptors may be heated to a temperature between about 200 degrees Celsius and about 270 degrees Celsius, for example 235 degrees Celsius.

[0049] Preferably, a band of susceptor material is a metallic elongate material.

[0050] Preferably, a band of susceptor material is a stainless steel band. However, susceptor materials may also comprise or be made of graphite, molybdenum, silicon carbide, aluminum, niobium, Inconel alloys (austenite nickel-chromium-based superalloys), metallized films, ceramics such as for example zirconia, transition metals such as for example Iron, Cobalt, Nickel, or metalloids components such as for example Bor, Carbon, Silicium, Phosphor, Aluminum.

[0051] The susceptor material may have the form of a band. Preferably, the band has a basic rectangular shape having a width preferably between about 2 millimeters and about 8 millimeters, more preferably, between about 3 millimeters and about 5 millimeters, for example 4 millimeters and a thickness preferably between about 0.03 millimeters and about 1 millimeter, more preferably between about 0.05 millimeters and about 0.5 millimeters, for example between about 0.07 millimeters and about 0.2 millimeters. The width of the band of susceptor material is smaller than a width or diameter of a plug the susceptor material is arranged in.

[0052] The susceptor material also may comprise one or more of ferrous metals, alloys, aluminum, iron-chromium-aluminum (FeCrAI) alloys, copper, and ceramic-coated metals.

[0053] The advantage of having a choice of materials such as ferrous metals, alloys, aluminum, FeCrAI alloys, copper, and ceramic-coated metals for the susceptor lies in their diverse properties and characteristics that can be tailored to specific requirements.

[0054] Due to their magnetic properties, ferrous metals are suitable for inductive heating applications, enabling efficient energy transfer and heat generation.

[0055] Metal alloy compositions may be customized to achieve desired properties like strength, conductivity, and resistance to corrosion, enhancing the durability and performance of the susceptor.

[0056] Susceptors made from aluminum may be lightweight and may possess good thermal conductivity. Such aluminum susceptors may facilitate quick and uniform heat distribution within the susceptor.

[0057] Iron-chromium-aluminum (FeCrAI) alloys may have a high resistance to oxidation and corrosion, what makes them suitable for high-temperature applications like inductive heating.

[0058] Susceptors made from copper may have excellent electrical conductivity, enhancing the efficiency of energy transfer and heat generation in the susceptor.

[0059] Ceramic-coated metals may provide added protection against wear, corrosion, and high temperatures, extending the lifespan of the susceptor. New PCT Patent Application July 30, 2025 Philip Morris Products S.A. 46069- PCT

[0060] -7-

[0061] By offering a variety of material options, the susceptor may be tailored to meet specific performance requirements, ensuring optimal heat generation, durability, and efficiency in the inductive heating process of the tobacco plug.

[0062] The sensorial media may be tobacco-based material. The sensorial media may be cut filler tobacco material.

[0063] The cut filler tobacco material may comprise one or more of tobacco leaf, reconstituted tobacco, tobacco substitute blends, processed tobacco materials, herbs and botanicals, alternative plant materials, flavor enhancers and additives.

[0064] The tobacco material may be adjusted to create unique and customizable blends that cater to different preferences and requirements.

[0065] The tobacco plug may have a length of between 10 to 100 millimeters. The tobacco plug may have a length of between 20 to 60 millimeters. The tobacco plug may have a length of between 40 to 50 millimeters.

[0066] The tobacco plug may have a diameter of between 2 to 20 millimeters. The tobacco plug may have a diameter of between 4.5 to 17 millimeters. The tobacco plug may have a diameter of between 6 to 9 millimeters.

[0067] According to an embodiment of the invention there is provided an inductively heatable aerosol-generating article that may comprise the described tobacco plug. The tobacco plug may comprise a paper wrapper. The tobacco plug may comprise sensorial media. The tobacco plug may comprise a band-shaped susceptor. The band-shaped susceptor may be arranged within the sensorial media. The paper wrapper may enclose the sensorial media and the bandshaped susceptor. The band-shaped susceptor may have a transversal corrugation with respect to a longitudinal axis of the tobacco plug. The transversal corrugation may comprise a described pattern.

[0068] According to an embodiment of the invention there is provided a method for manufacturing a tobacco plug for an inductively heatable aerosol-generating article, wherein the tobacco plug comprises a paper wrapper, sensorial media, and a band-shaped susceptor, wherein the method comprises feeding a band of susceptor material, a wrapper material, and sensorial media into a rod maker, wherein, upstream from the rod maker, the band of susceptor material is guided through a set of rollers configured for providing to the band of susceptor material a transversal corrugation with respect to a longitudinal axis of the tobacco plug.

[0069] The method for manufacturing the tobacco plug for the aerosol-generating article comprises feeding the band of susceptor material, the wrapper material, and the sensorial media into a rod maker machine.

[0070] Before the band of susceptor material is fed into the rod maker, it undergoes a bending or manipulation process to achieve the desired shape or pattern. For this purpose, the band of New PCT Patent Application July 30, 2025 Philip Morris Products S.A. 46069- PCT

[0071] -8- susceptor material may be guided through a roller gap formed between two rollers. These rollers may be configured to impart a transversal corrugation onto the band of susceptor material. The rollers may comprise roller surfaces having a shape that corresponds to desired shape that is to be imparted to the susceptor material. In an embodiment a plurality of ridges or grooves is formed along the longitudinal axis of the band of susceptor material. By providing longitudinally running ridges or grooves a corrugated band of susceptor material is obtained. Thereby the band of susceptor material is provided with a transversal corrugation. The transversal corrugation may enhance both the heat distribution capabilities and the structural stability of the susceptor element.

[0072] The rollers may have a corresponding geometrical shape configured to provide a desired transversal corrugation to the band of susceptor material.

[0073] The rollers in the manufacturing process are configured with specific geometrical shapes to create a precise transversal corrugation on the susceptor material. Each roller's geometry corresponds to the desired corrugation pattern, ensuring consistency and accuracy in shaping the material. This approach may enhance quality control and promotes uniformity in the corrugation process, ultimately improving the structural integrity and heat distribution efficiency of the susceptor material in the tobacco plug.

[0074] The geometrical shape of the roller surfaces may be curved, S-shaped, or multi-S- shaped. The geometrical shape of the roller surfaces may be triangular, Z-shaped, W-shaped or zig-zag-shaped.

[0075] By introducing S-shaped or zig-zag-shaped susceptor geometries, mechanical interlocking with the sensorial media is enhanced. This may ensure that the susceptor remains securely positioned during the manufacturing process. By modifying the cross-sectional geometry of the susceptor, stable and consistent heating performance is ensured. The secure positioning of the susceptor within the consumable allows for uniform heat generation when exposed to electromagnetic radiation, thereby enhancing the overall quality and functionality of the tobacco product. Further, undesirable deformations during the cutting process may be prevented or reduced.

[0076] Before being fed into the rod maker, the band of susceptor material may receive a thermal treatment. This treatment may involve subjecting the material to controlled heating or other thermal processes. A heat treatment may assist in shaping the susceptor material.

[0077] The method may further comprise the cutting of the continuous tobacco plug to receive a plurality of tobacco plugs with a defined length.

[0078] This cutting step may transform the continuous tobacco plug into discrete units that may be incorporated in individual aerosol-generating articles. New PCT Patent Application July 30, 2025 Philip Morris Products S.A. 46069- PCT

[0079] -9- ln the rod maker the wrapper material may be wrapped around the cut filler tobacco material and the corrugated band of susceptor material to form a continuous tobacco rod. In the rod maker the wrapper material may be simultaneously wrapped around the cut filler tobacco material and the corrugated band of susceptor material to form the continuous tobacco rod. The continuous tobacco rod may be cut to receive a plurality of tobacco plugs with a defined length. The corrugated band of susceptor material of the continuous tobacco rod may be a continuous corrugated band of susceptor material. The corrugated band of susceptor material may be circumscribed by the cut filler tobacco material in the rod maker.

[0080] The transversal corrugations may contribute to the structural stability of the bandshaped susceptor. The corrugated pattern may add rigidity and resistance to deformation under mechanical stress. The susceptor may become more resistant to transversal forces during manufacturing, such as those exerted by knives during a cutting step. Without this stability, bending loads applied by the knives could cause misalignment of the susceptor within the aerosol-forming substrate. Cutting the continuous tobacco rod including the corrugated band of susceptor material may improve manufacturing simplicity. Cutting the continuous tobacco rod including the corrugated band of susceptor material may improve manufacturing efficiency.

[0081] The described method effectively may address variability issues within the manufacturing process of tobacco consumables by mitigating the problem of susceptor misalignment. This adjustment may ensure a more consistent quality and performance of the final product, thereby leading to more reliable and predictable consumer experiences.

[0082] A particular benefit of this method may be observed in the context of tobacco consumables that utilize cut filler as the substrate. Cut filler, distinguished by its loose and soft nature, may present challenges in maintaining the correct positioning of the susceptor during manufacture. The present method may introduce modified susceptor geometries, which significantly enhance mechanical anchoring and interlocking with the cut filler. These geometries, such as S-shaped and zig-zag-shaped profiles, may improve the stability of the susceptor within the loose matrix of the cut filler, optimizing the use of this substrate.

[0083] Below, there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

[0084] Example A: Tobacco plug for an inductively heatable aerosol-generating article, the tobacco plug comprising: a paper wrapper, New PCT Patent Application July 30, 2025 Philip Morris Products S.A. 46069- PCT

[0085] -10- sensorial media, and a band-shaped susceptor, wherein the band-shaped susceptor is arranged within the sensorial media, wherein the paper wrapper encloses the sensorial media and the band-shaped susceptor, and wherein the band-shaped susceptor has a transversal corrugation with respect to a longitudinal axis of the tobacco plug.

[0086] Example B: The tobacco plug according to example A, wherein the transversal corrugation of the susceptor comprises a curved cross-section.

[0087] Example C: The tobacco plug according to any one of the preceding examples, wherein the transversal corrugation of the susceptor is S-shaped.

[0088] Example D: The tobacco plug according to any one of the preceding examples, wherein the transversal corrugation of the susceptor is multi S-shaped.

[0089] Example E: The tobacco plug according to any one of the preceding examples, wherein the transversal corrugation of the susceptor comprises an edge.

[0090] Example F: The tobacco plug according to any one of the preceding examples, wherein the transversal corrugation of the susceptor has a Z-shaped or a W-shaped crosssection.

[0091] Example G: The tobacco plug according to any one of the preceding examples, wherein the transversal corrugation of the susceptor has a zig-zag-shaped cross-section.

[0092] Example H: The tobacco plug according to any one of the preceding examples, wherein the susceptor is positioned centrally and parallel to the longitudinal axis of the tobacco plug.

[0093] Example I: The tobacco plug according to any one of the preceding examples, wherein the susceptor material comprises a metal alloy.

[0094] Example J: The tobacco plug according to any one of the preceding examples, wherein the susceptor material comprises one or more of ferrous metals, alloys, aluminum, iron-chromium-aluminum (FeCrAI) alloys, copper, and ceramic-coated metals.

[0095] Example K: The tobacco plug according to any one of the preceding examples, wherein the sensorial media is cut filler tobacco material.

[0096] Example L: The tobacco plug according to any one of the preceding examples, wherein the cut filler tobacco material, comprises one or more of tobacco leaf, reconstituted tobacco, tobacco substitute blends, processed tobacco materials, herbs and botanicals, alternative plant materials, flavor enhancers and additives.

[0097] Example M: The tobacco plug according to any one of the preceding examples, wherein the tobacco plug has a length of between 10 to 100 millimeters, wherein the tobacco New PCT Patent Application July 30, 2025 Philip Morris Products S.A. 46069- PCT

[0098] -11- plug has a length of between 20 to 60 millimeters, wherein the tobacco plug has a length of between 40 to 50 millimeters.

[0099] Example N: The tobacco plug according to any one of the preceding examples, wherein the tobacco plug has a diameter of between 2 to 20 millimeters, wherein the tobacco plug has a diameter of between 4.5 to 17 millimeters, wherein the tobacco plug has a diameter of between 6 to 9 millimeters.

[0100] Example O: An inductively heatable aerosol-generating article comprising a tobacco plug according to any one of the preceding examples.

[0101] Example P: A method for manufacturing a tobacco plug for an inductively heatable aerosol-generating article, wherein the tobacco plug comprises a paper wrapper, sensorial media, and a band-shaped susceptor, wherein the method comprises feeding a band of susceptor material, a wrapper material, and sensorial media into a rod maker, wherein, upstream from the rod maker, the band of susceptor material is guided through a set of rollers configured for providing to the band of susceptor material a transversal corrugation with respect to a longitudinal axis of the tobacco plug.

[0102] Example Q: The method for manufacturing a tobacco plug according to example P, wherein the rollers have a corresponding geometrical shape configured to provide a desired transversal corrugation to the band of susceptor material.

[0103] Example R: The method for manufacturing a tobacco plug according to any one of examples P or Q, wherein the geometrical shape of the roller surfaces is curved, S-shaped, or multi-S-shaped.

[0104] Example S: The method for manufacturing a tobacco plug according to any one of examples P to R, wherein the geometrical shape of the roller surfaces is triangular, Z-shaped, W-shaped or zig-zag-shaped.

[0105] Example T: The method for manufacturing a tobacco plug according to any one of examples P to S, wherein upstream of the rod maker, the band of susceptor material receives a thermal treatment.

[0106] Example II: The method for manufacturing a tobacco plug according to any one of examples P to T, wherein the method further comprises:

[0107] • Cutting the continuous tobacco plug to receive a plurality of tobacco plugs with a defined length.

[0108] Example V The method for manufacturing a tobacco plug according to any one of examples P to T, wherein the sensorial media is cut filler tobacco material, wherein in the rod maker the wrapper material is wrapped around the cut filler tobacco material and the corrugated band of susceptor material to form a continuous tobacco rod, New PCT Patent Application July 30, 2025 Philip Morris Products S.A. 46069- PCT

[0109] -12- wherein the continuous tobacco rod is cut to receive a plurality of tobacco plugs with a defined length.

[0110] Example W. A tobacco plug for an inductively heatable aerosol-generating article manufactured by the method according to any one of examples P to V.

[0111] Example X. A method for manufacturing an inductively heatable aerosol-generating article comprising assembling the inductively heatable aerosol-generating article from a plurality of components, wherein the plurality of components comprises the tobacco plug according to example W.

[0112] Example Y. An inductively heatable aerosol-generating article manufactured by the method according to example X.

[0113] Features described in relation to one embodiment may equally be applied to other embodiments of the invention.

[0114] The invention will be further described, by way of example only, with reference to the accompanying drawings in which:

[0115] Fig. 1 shows a consumable of the state of the art;

[0116] Fig. 2 shows an exemplary embodiment of a susceptor with a S-shaped transversal corrugation;

[0117] Fig. 3a and 3b shows susceptors having a multi-S-shaped and a zig-zag-shaped transversal corrugation;

[0118] Fig. 4 illustrates the manufacturing process of a tobacco plug; and

[0119] Fig. 5a and 5b show different roller designs.

[0120] In Figure 1 , a state of the art inductively heated aerosol-generating article is depicted. The article has a generally tubular shape and comprises a plurality of distinct components. These components include a mouthpiece 1 , a tubular spacer 2, a hollow acetate tube 3 enveloped in paper wrapping 4, a tobacco plug 5 with a band-shaped internal susceptor 6, and a front plug 7. Paper wrappers 8, 9 are used to wrap the individual elements and to combine these elements to a rod-shaped article.

[0121] The susceptor 6 is configured to facilitate the heating process within the tobacco plug 5. Achieving precise alignment and mechanical interlocking of the susceptor 6 within the consumable is a key manufacturing challenge, particularly during cutting and shaping processes, where the susceptibility to misalignment is heightened due to the bending loads exerted on the susceptor 6. New PCT Patent Application July 30, 2025 Philip Morris Products S.A. 46069- PCT

[0122] -13-

[0123] The susceptor 6 of Fig. 1 possesses a flat and quadratic shape and is preferably positioned centrally within the tobacco plug 5 to ensure uniform and consistent heating.

[0124] The knives used to cut the continuous tobacco rod into individual portions exert bending loads on the susceptor 6, making it susceptible to misalignment and imprecise positioning within the tobacco plug 5. In the embodiment of Fig. 1 a cast leaf tobacco material is used as sensorial media of the tobacco plug 5. This material is comparably rigid and lends structural stability to the tobacco plug 5.

[0125] When cut filler tobacco material is used as sensorial media, misalignment or improper positioning of the susceptor 6 within the tobacco plug 5 may occur during manufacturing. Cut filler may have a more loose and softer composition than cast leaf. This may provide a higher degree of freedom for the susceptor 6 to move within the rod. As a result, maintaining precise positioning and mechanical interlocking between the susceptor 6 and cut filler tobacco material becomes increasingly challenging.

[0126] In Figure 2 a cross-section of an aerosol-generating article of the present invention is depicted. The aerosol-generating article comprises a sensorial media portion with a susceptor 20, which is wrapped by a paper wrapper 8. The sensorial media is cut filler tobacco material 10, which has a softer and looser nature compared to cast leaf tobacco material.

[0127] The susceptor 20 has a S-shaped cross-section incorporating interconnected arches 22, 24.

[0128] The transversal corrugation of the S-shaped susceptor 20 defines multiple points of contact between the susceptor 20 and the sensorial media.

[0129] These modifications ensure enhanced mechanical anchoring and interlocking between the susceptor 20 and the cut filler tobacco material 10. The configuration of the susceptor 20 offers improved stability and consistent performance. Moreover, the S-shaped susceptor 20 is integrated within the cut filler tobacco material 10, such that the susceptor 20 is positioned centrally and parallel to the longitudinal axis of the aerosol-generating article. The susceptor 20 intimately interacts with the cut filler tobacco material 10, which also enhances heat transfer to the tobacco material.

[0130] In Figure 3a a similarly shaped susceptor 26 is depicted. Instead of the two arches of the S-shaped susceptor of Fig. 2, the susceptor 26 depicted in Fig. 3a comprises three arches. The susceptor 26 depicted in Fig. 3a may be referred to as a “multi-S-shaped susceptor”.

[0131] The multi-S-shaped susceptor of Fig. 3a defines even more points of contacts between the susceptor 26 and the surrounding cut filler tobacco material 10, such that in this configuration the advantages of the S-shaped susceptor of Fig. 3a are even enhanced.

[0132] Figure 3b shows a zig-zag-shaped susceptor 28 with sharp angular bends that create a pattern resembling interconnected "Z" or "W1shapes when viewed in cross-section within New PCT Patent Application July 30, 2025 Philip Morris Products S.A. 46069- PCT

[0133] -14- the tubular consumable. This configuration also allows mechanical anchoring and interlocking between the susceptor 28 and the surrounding cut filler tobacco material 10 to ensure precise positioning and efficient heat transfer during use.

[0134] Figure 4 schematically depicts a manufacturing process for manufacturing a continuous tobacco rod. Wrapping paper 8 and a band of susceptor material 40 are fed into a rod maker. Simultaneously, cut filler tobacco material 10 is gravity-fed onto the wrapping paper 8 alongside the band of susceptor material 40. The vertical feeding mechanism ensures an even distribution of the cut filler tobacco material 10 along the entire length of the continuous tobacco rod.

[0135] Upstream of the rod maker the band of susceptor material 40 is manipulated to obtain the desired geometrical shape. The manipulation process is performed by guiding the band of susceptor material 40 through a roller gap defined between two cylindrical rollers 34. The rollers 34 have corresponding roller surfaces 38 to bring the initially flat band of susceptor material 40 into the desired geometrical pattern.

[0136] In the rod maker the wrapping paper 8 is wrapped around the cut filler tobacco material 10 and the corrugated band of susceptor material to form a continuous tobacco rod. In a subsequent processing step (not shown in Fig. 4) the continuous tobacco rod, may be cut into individual tobacco plugs. These tobacco plugs may be incorporated in an aerosol-generating article.

[0137] In Figure 5 two different configurations of roller pairs suitable to manipulate the band of susceptor material 40 are depicted. In Fig. 5a the rollers 34 comprise curved roller surfaces 36 that are designed to provide the susceptor material 40 with a S-shaped cross-section. The rollers 34 are capable of rotation around their longitudinal axes. As the band of susceptor material 40 progresses through the roller gap defined between these rollers 34, the rollers 34 apply controlled pressure and bending forces onto the band of susceptor material 40. Thereby the band of susceptor material 40 is formed into the intended S-shaped pattern. In Fig. 5b the rollers 34 comprise zig-zag-shaped roller surfaces 38 that are designed to provide the susceptor material 40 with a zig-zagged cross-section. As the band of susceptor material 40 progresses through the roller gap defined between these rollers 34, the rollers 34 apply controlled pressure and bending forces onto the band of susceptor material 40. Thereby the band of susceptor material 40 is formed into the intended zig-zag shaped pattern.

Claims

New PCT Patent Application July 30, 2025 Philip Morris Products S.A. 46069- PCT-15-CLAIMS1. A method for manufacturing a tobacco plug for an inductively heatable aerosolgenerating article, wherein the tobacco plug comprises, a paper wrapper, sensorial media, and a band-shaped susceptor, wherein the sensorial media is cut filler tobacco material, wherein the method comprises feeding a band of susceptor material, a wrapper material, and cut filler tobacco material into a rod maker, wherein, upstream from the rod maker, the band of susceptor material is guided through a set of rollers configured for providing to the band of susceptor material a transversal corrugation with respect to a longitudinal axis of the tobacco plug.

2. The method for manufacturing a tobacco plug according to claim 1 , wherein the rollers have a corresponding geometrical shape configured to provide a desired transversal corrugation to the band of susceptor material.

3. The method for manufacturing a tobacco plug according to any one of claims 1 or 2, wherein the geometrical shape of the roller surfaces is curved, S-shaped, or multi-S- shaped.

4. The method for manufacturing a tobacco plug according to any one of claims 1 to 3, wherein the geometrical shape of the roller surfaces is triangular, Z-shaped, W-shaped or zig-zag-shaped.

5. The method for manufacturing a tobacco plug according to any one of claims 1 to 4, wherein the method further comprises:• Cutting the continuous tobacco plug to receive a plurality of tobacco plugs with a defined length.

6. The method for manufacturing a tobacco plug according to any one of claims 1 to 4, wherein in the rod maker the wrapper material is wrapped around the cut filler tobacco material and the corrugated band of susceptor material to form a continuous tobacco rod, wherein the continuous tobacco rod is cut to receive a plurality of tobacco plugs with a defined length.New PCT Patent Application July 30, 2025 Philip Morris Products S.A. 46069- PCT-16-7. A tobacco plug for an inductively heatable aerosol-generating article manufactured by the method according to any one of claims 1 to 6.

8. A method for manufacturing an inductively heatable aerosol-generating article comprising assembling the inductively heatable aerosol-generating article from a plurality of components, wherein the plurality of components comprises the tobacco plug according to claim 7.

9. An inductively heatable aerosol-generating article manufactured by the method according to claim 8.

Images