Method and apparatus for manufacturing heat-not-burn consumables for use with an aerosol generating device

Abstract

A method of manufacturing heat-not-burn consumables for use with an aerosol generating device comprises: receiving or manufacturing an aerosol generating substrate material in discrete particles (5); manufacturing a plurality of frames (2) each delimiting an inner cavity (3) and air passages (6, 7) in fluid communication with the inner cavity (3); filling each inner cavity (3) with a dose of the discrete particles (5); and then closing the inner cavities (3) to obtain a plurality of heat-not-burn consumables (1). After manufacturing the aerosol generating substrate material in discrete particles (5) and before closing the inner cavities (3), the method comprises: applying an additive (A) on the discrete particles (5).

Description

[0001] PMP1P43WO FTR4110PCT - 1 -

[0002] METHOD AND APPARATUS FOR MANUFACTURING HEAT-NOT-BURN CONSUMABLES FOR USE WITH AN AEROSOL GENERATING DEVICE

[0003] The present disclosure relates to a method and an apparatus for manufacturing heat-not-burn consumables for use with an aerosol generating device.

[0004] Aerosol generating articles or heat-not-burn consumables comprise an aerosolgenerating substrate that is heated rather than combusted. The aerosol-generating substrate is, for instance, a tobacco-free herbaceous or plant-based cast sheet or a biodegradable fibre-based material. Typically, in such heated aerosol-generating articles, an aerosol is generated by the transfer of heat from a heat source to a physically separate aerosol-generating substrate or material, which may be located in contact with, within, around or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are entrained in air drawn through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol.

[0005] Aerosol-generating articles appearing different from conventional cigarettes also are known.

[0006] For instance, document WO2021 / 105722A1 discloses a component for a noncombustible aerosol provision system. The component comprises a body defining an enclosed volume. The body comprises an inlet aperture and an outlet aperture, and an air flow path defined between the inlet aperture and the outlet aperture through the enclosed volume. The enclosed volume contains a source of aerosoli sable material in the form of a layer of amorphous solid material laminated on a carrier material. The material may also be in the form of crushed particles, granules, pellets, shreds, strips.

[0007] Document WO2024 / 133674A1 discloses an aerosol-generating article for use with an aerosol-generating device. The aerosol-generating article comprises a frame defining a cavity filled with an aerosol-forming substrate and provided with an air inlet and an air outlet. The aerosol-forming substrate may comprise one or more of particles, shreds, or a sheet of aerosol-forming substrate disposed within the cavity.

[0008] Document EP3903605B1 discloses abnormally shaped tobacco granules made of the tobacco granule bodies for the preparation of a heating non-burning tobacco product. The tobacco granules may include tobacco material, a flavour and a humectant.

[0009] Document US2018 / 295885A1 discloses an aerosol-generating article comprising an aerosol-generating pellet made of a plurality of compacted particles arranged in a casing. The aerosol-generating pellet is formed through the steps of providing a plurality of particles, filling the plurality of particles into a cavity of the casing and compacting the plurality ofPMP1P43WO FTR4110PCT - 2 -

[0010] particles in the cavity. A protection layer against environmental influence is applied to the pellet and ends of the casing are sealed. In use, piercing elements pierce the ends of the casing when the aerosol-generating article is housed in an aerosol-generating device. The inventor notes that the pellet of LIS2018 / 295885A1 is made of the plurality of particles stuck together and therefore, when the additive is applied on the pellet, the particles are no longer discrete particles and said additive is prevented from reaching all the particles of the pellet. The inventor notes that, when the aerosol-generating article is manufactured and the ends of the casing are sealed, no air passages and channels in communication with the pellet are present.

[0011] Document US2006 / 157070A1 discloses an apparatus and a method for forming cigarette filters. The apparatus comprises drums with flutes in which filter components fed from hoppers are aligned and spaced one from the other and then partially wrapped to form a filter assembly. Each partially wrapped filter assembly comprises a plurality of aligned and spaced components delimiting cavities between them. A metering drum delivers particles and additives from pockets in the drum to the cavities in the partially wrapped filter assembly. Another drum transfers further granules in the cavities to ensure that said cavities are filled. A further drum applies paper patches to close the cavities. The inventor notes that the filters are not heat-not-burn consumables.

[0012] Document US 2023 / 0165304 A1 discloses a method for preparing an aerosol generating material including an active substance and a volatile component incorporated in liquid for use in an apparatus for heating aerosol generating material. Menthol as one such volatile component is sprayed onto the surface of extruded tobacco granules.

[0013] In this technical field, it would be desirable to provide an improved method and an improved apparatus for manufacturing heat-not-burn consumables for use with an aerosol generating device, wherein the heat-not-burn consumables each comprises a frame filled with particles.

[0014] It would be desirable to provide a method and an apparatus for manufacturing heat-not-burn consumables, wherein the method and the apparatus are capable of adding an additive or more additives to the particles such that the additive / s is / are properly and evenly distributed on the particles in the final heat-not-burn consumables and provide the desired effects to the end consumer.

[0015] It would be desirable to provide a method and an apparatus for manufacturing heat-not-burn consumables capable of accurately adding the additive or additives to the particles such to limit migration or dispersion of the additive / s along the manufacturing line and / or on other parts of the frames.PMP1P43WO FTR4110PCT - 3 -

[0016] The present disclosure relates to a method of manufacturing heat-not-burn consumables for use with an aerosol generating device, the method comprising: receiving or manufacturing an aerosol generating substrate material in discrete particles; manufacturing a plurality of frames each delimiting an inner cavity and air passages in fluid communication with the inner cavity; filling each inner cavity with a dose of said discrete particles; and then closing the inner cavities to obtain a plurality of heat-not-burn consumables; wherein, after receiving or manufacturing the aerosol generating substrate material in discrete particles and before closing the inner cavities, the method comprises: applying an additive on the discrete particles. Optionally, the aerosol generating substrate material in discrete particles is received from a supplier or from another factory.

[0017] The method may be carried out through an apparatus for manufacturing heat-not-burn consumables for use with an aerosol generating device. The apparatus may comprise: a first station configured for receiving or manufacturing the aerosol generating substrate material in discrete particles; a second station configured for manufacturing the plurality of frames each delimiting the inner cavity and the air passages in fluid communication with the inner cavity; a filling station operatively placed downstream of the first station and the second station; the filling station being positioned and arranged to receive the discrete particles from the first station and the frames from the second station and to fill each inner cavity with a dose of said discrete particles; a closing station operatively placed downstream of the filling station and configured for closing the inner cavities and obtaining the plurality of heat-not-burn consumables; wherein the apparatus further comprises at least one applicator connected to a source of the additive and positioned downstream of the first station and upstream of the closing station to apply the additive on the discrete particles.

[0018] The present disclosure also relates to an apparatus for manufacturing heat-not-burn consumables for use with an aerosol generating device, the apparatus comprising: a first station configured for receiving or manufacturing an aerosol generating substrate material in discrete particles; a second station configured for manufacturing a plurality of frames each delimiting an inner cavity and air passages in fluid communication with the inner cavity; a filling station operatively placed downstream of the first station and the second station; the filling station being positioned and arranged to receive the discrete particles from the first station and the frames from the second station and to fill each inner cavity with a dose of said discrete particles; a closing station operatively placed downstream of the filling station and configured for closing the inner cavities and obtaining a plurality of heat-not-burn consumables; wherein the apparatus further comprises at least one applicator connected to a source of an additive and positioned downstream of the first station and upstream of the closing station to apply the additive on the discrete particles. Optionally, thePMP1P43WO FTR4110PCT - 4 -

[0019] first station is a container configured to receive the aerosol generating substrate material in discrete particles from a supplier or from another factory.

[0020] The apparatus may be configured to carry out a method of manufacturing heat-not-burn consumables for use with an aerosol generating device. The method may comprise: receiving or manufacturing the aerosol generating substrate material in discrete particles; manufacturing the plurality of frames each delimiting the inner cavity and the air passages in fluid communication with the inner cavity; filling each inner cavity with the dose of said discrete particles; and then closing the inner cavities to obtain the plurality of heat-not-burn consumables; wherein, after receiving or manufacturing the aerosol generating substrate material in discrete particles and before closing the inner cavities, the method comprises: applying the additive on the discrete particles.

[0021] The present disclosure also relates to a heat-not-burn consumable for use with an aerosol generating device manufactured according to the method of manufacturing heat-not-burn consumables for use with an aerosol generating device or through the apparatus for manufacturing heat-not-burn consumables for use with an aerosol generating device.

[0022] The inventor found that the disclosed method and apparatus allow to add one or more additives to the particles such that the additive / s is / are properly and evenly distributed on the particles housed in the frames of the final heat-not-burn consumables.

[0023] The inventor found that the disclosed method and apparatus allow to easily and quickly change the additive or additives and to tailor the additive / s to specific materials, design, and process features of the particles and of the heat-not-burn consumables.

[0024] The inventor found that the disclosed method and apparatus assures that the physical and chemical properties of the additive / s are maintained during application and also once that the additive / s are part of the final heat-not-burn consumables.

[0025] The inventor also found that the disclosed method and apparatus allow to add the additive / s to the particles such to prevent or limit dispersion of the additive / s along the manufacturing line and / or to prevent or limit migration of the additive / s on other parts of the frames in which the particles are housed.

[0026] The additive may be a mixture of several compounds.

[0027] The additive may comprise at least one of: a flavoring agent, an aerosol forming agent (e.g. propylene glycol) or a mixture thereof or a binder. The flavoring agent may also serve as a binder.

[0028] The additive may have a viscosity from 10 mPa*s to 60 mPa*s. The additive may have a flashpoint from 30°C to 110°C. The additive may have a density from to 0.5 g / cm3to 1.6 g / cm3, optionally from 0.7 g / cm3to 1.5 g / cm3. The additive may be applied on the discretePMP1P43WO FTR4110PCT - 5 -

[0029] particles with an application rate (weight of additive I weight of discrete particles) from 0.5 to 2.0, optionally from 0.7 to 1.7. The additive may be fluid, optionally the additive is liquid.

[0030] In some embodiments, the additive comprises a mixture of flavoring agents dissolved in a solvent and an additional solvent. The solvent and the additional solvent may be propylene glycol, and / or ethanol, and / or benzyl alcohol. The additive may also comprise an acid, like lactic acid or malonic acid.

[0031] The additive may also comprise glycerin.

[0032] The inventor found that the addition of glycerin as additive on the particles helps in increasing the overall content of the same as aerosol former in the consumable. Indeed, when manufacturing the particles, it is advisable that the amount of glycerin in the particles does not exceed a certain limit, for example 18% to 24%, otherwise the particles become too sticky and difficult to dose. Thus, higher levels of glycerin in the consumable, for instance 30%, are achieved by later adding glycerin as additive.

[0033] In some embodiments, the additive is applied in at least two sequential steps on the same discrete particles.

[0034] The inventor fund that dosing the additive or components of the additive in sequential steps allows to improve solubilization, as, for instance, the flavoring mix may not be soluble with the glycerin or compatible with the acid.

[0035] In some embodiments, applying the additive comprises: injecting said additive onto the discrete particles. The at least one applicator may comprise an injector for injecting droplets of the additive on the discrete particles. The injector may comprise at least one of: a jet-valve, a peristaltic pump, a diaphragm pump, a solenoid valve, a coaxial solenoid valve, a needle valve. Jet-valves provide precise, high-speed control for liquid injections, rapid response and accurate dosing. Peristaltic pumps allow handling a wide range of viscosities. Diaphragm pumps can handle viscous fluids effectively and are suitable for applications requiring precise control and cleanliness. Solenoid valves can handle fluids with viscosities up to 50 mPa*s and are useful for automated systems. Needle valves provide fine control over the flow of liquid. Coaxial solenoid valves are designed to handle highly viscous fluids and provide efficient and precise flow control.

[0036] A nozzle of the injector may be positioned 10 centimeters (cm) to 30 centimeters (cm) from a surface formed by the discrete particles. The inventor found that this distance helps ensuring an even coverage and proper adhesion of the additive / s on the discrete particles.

[0037] Injecting may comprise: depositing at least one droplet of the additive on the discrete particles. Injecting may comprise: depositing a plurality of droplets of the additive on the discrete particles, optionally 1 to 15 droplets, optionally 1 to 5 droplets.PMP1P43WO FTR4110PCT - 6 -

[0038] A radius of the droplet or droplets may be from 0.2 mm to 2 mm. These droplet sizes ensure proper additive distribution within the discrete particles, preventing spotting and leakage and help avoiding transfer of the additive to adjacent parts of the frame and cover.

[0039] The inventor found that injection allows an accurate flow control and dosing, proper adhesion of the additive / s to the particles and allows to manage a wide range of additive viscosities. Indeed, the injection can be adjusted based on the process parameters, which depend on properties of the additives being used, such as their chemical composition and physical measurements, like viscosity and density. Multiple droplet injections for each cavity guarantees an even additive application.

[0040] In some other embodiments, applying the additive comprises: spraying said additive onto the discrete particles. The at least one applicator may comprise a sprayer for spraying the additive on the discrete particles.

[0041] An air pressure for spraying may be from 1 bar to 5 bar. A spraying flow rate may be from 0.1 liters per minute to 1.0 liters per minute.

[0042] The inventor found that spraying produces a fine atomization and ensures an even coating without excessive fluid application.

[0043] A nozzle of the sprayer may be positioned 1 centimeters (cm) to 20 centimeters (cm) from a surface of the discrete particles. A spray angle with respect to a surface formed by the discrete particles may be between 80° and 100°, optionally 90°.

[0044] After receiving or manufacturing the aerosol generating substrate material in discrete particles, the discrete particles may be fed to a filling station where each inner cavity is filled with the dose.

[0045] In some embodiments, applying the additive is carried out before filling each inner cavity with a dose. Applying the additive may be carried out while the discrete particles are fed to the filling station.

[0046] The inventor found that applying the additive before filling each inner cavity streamlines the process at the filling station and limits the structural complexity of said filling station.

[0047] In some embodiments, applying the additive is carried out after filling each inner cavity with a dose. The additive may be applied on the discrete particles in each inner cavity. The at least one applicator may be positioned at the filling station or the at least one applicator may be positioned between the filling station and the closing station.

[0048] The inventor found that applying the additive / s at this stage, i.e. after dosing in the frame inner cavities, allows to differentiate the final product at the last stage, limiting brand mix possibilities as well limiting maintenance operations when it comes to brand change (when cleaning of the additive application system is required).PMP1P43WO FTR4110PCT - 7 -

[0049] Add itional ly , the inventor found that applying the additive / s at this stage provides more freedom in selecting additive / s and allows to handle a wide range of viscosities and flashpoints as well as to reduce the risk of loss / degradation of the additive / s during the manufacturing process.

[0050] The inventor also found that application in the inner cavities, just before closing said inner cavities, avoids part of the additive to be lost along the processing path and allows to keep a major part of the additive inside the consumables.

[0051] In some embodiments, the at least one applicator comprises a plurality of applicators arranged in sequence between the first station and the closing station and configured to apply the additive in sequential steps.

[0052] The additive may be applied simultaneously on the discrete particles of a plurality of inner cavities. The additive may be applied in a single point or in multiple points of each inner cavity.

[0053] Filling each inner cavity may comprise: preparing the doses and dispensing each dose in one of the inner cavities. A weight of one dose may be from 150 mg to 200 mg of discrete particles, optionally of 180 mg of discrete particles.

[0054] Applying the additive may be carried out before or after preparing the doses or applying the additive may be carried out when preparing the doses.

[0055] In some embodiments, the filling station comprises: a dispensing conveyor provided with pockets, each pocket being movable between a loading position and a dispensing position. In the loading position the pocket may receive the dose (i.e. a set quantity) of the discrete particles and in the dispensing position the pocket may face one of the inner cavities to fill said inner cavity with the dose of the discrete particles.

[0056] In some embodiments, a cleaning device is coupled to the dispensing conveyor to clean the pockets downstream of the dispensing position and upstream of the loading position.

[0057] In some embodiments, the at least one applicator is located at the dispensing conveyor to apply the additive on the discrete particles in the pockets.

[0058] In some embodiments, a dosing chamber is sized to hold the dose of the discrete particles. In the loading position the pocket may face the dosing chamber.

[0059] In some embodiments, the at least one applicator is located at the dosing chamber to apply the additive on the discrete particles in said dosing chamber.

[0060] The inventor found that applying the additive at the dosing chamber simplifies the process by combining two steps into one (dosing of discrete particles and additive application), provides a consistent and repeatable dosing process and streamlines the process by treating the discrete particles before they enter the dispensing conveyor.PMP1P43WO FTR4110PCT - 8 -

[0061] After application of the additive, the discrete particles of the dose may be mixed. A mixer may be operatively active in the dosing chamber or downstream of the dosing chamber to mix the discrete particles of the dose. The inventor found that mixing allows to make the distribution of the additive in the discrete particles more homogeneous.

[0062] In some embodiments, before closing the inner cavity, the particles are conditioned to promote drying and / or curing of the additive. Conditioning may comprise changing or making homogeneous the moisture content of the discrete particles through air and / or steam.

[0063] In some embodiments, a hopper has an upper opening to receive the discrete particles from the first station and a lower opening communicating with the dosing chamber or facing the pockets of the dispensing conveyor. In some embodiments, a feeder is used to feed the discrete particles from the hopper to the dosing chamber or to the dispensing conveyor.

[0064] In some embodiments, the dispensing conveyor comprises a wheel rotating about an axis thereof. The pockets may be located on a peripheral portion of the wheel and may open radially outwards. A motor may be coupled to the wheel to rotate said wheel about the axis to move the pockets between the loading position and the dispensing position.

[0065] The inventor found that this design ensures that each pocket and then each cavity is filled consistently and accurately.

[0066] The wheel may comprise a vacuum device operatively active in the pockets or a mechanical barrier to retain the discrete particles in said pockets while moving towards the dispensing position. The vacuum device may be configured to release the discrete particles from the pocket in the dispensing position.

[0067] The inventor found that the vacuum device or the mechanical barrier helps the discrete particles to stay securely in the pockets until they reach the discharge point.

[0068] In some embodiments, the axis is horizontal and the pocket in the dispensing position is located in a lower part of the wheel.

[0069] The inventor found that, in this design, dispensing is mainly due to gravity force which is a simple and reliable solution.

[0070] In some embodiments, the dosing chamber is located on a side of the wheel and faces the peripheral portion of the wheel. In some embodiments, the at least one applicator faces the peripheral portion of the wheel. The at least one applicator may be located above the wheel.

[0071] In some embodiments, a frame conveyor extends between the filling station and the closing station for supporting and carrying the frames from the filling station to the closing station. The at least one applicator may be positioned at the frame conveyor to apply thePMP1P43WO FTR4110PCT - 9 -

[0072] additive on the discrete particles in the inner cavities. The at least one applicator may be positioned above the frame conveyor. The at least one applicator may comprise at least one nozzle facing the frame conveyor. Optionally, the at least one applicator comprises a plurality of nozzles placed side by side to apply simultaneously the additive on the discrete particles of a single inner cavity or of a plurality of inner cavities. Optionally, the at least one applicator is moveable to apply the additive in multiple points of a single inner cavity or of a plurality of inner cavities. The inventor found that this solution allows to cover most of the particles with additive.

[0073] In some embodiments, a first conveyor extends between the first station and the filling station for feeding the discrete particles to the filling station. The at least one applicator may be positioned at the first conveyor to apply the additive on the discrete particles fed towards the filling station. In some embodiments, a second conveyor extends between the second station and the filling station for feeding the frames to the filling station.

[0074] A control unit may be operatively connected at least to the filling station and to the at least one applicator. The control unit mat be configured and / or programmed to control the filling station to fill each inner cavity with the dose of the discrete particles and to control the at least one applicator to apply the additive on the discrete particles. The control unit may be operatively connected to the dispensing conveyor and to the frame conveyor. The control unit may be configured and / or programmed to advance the frame conveyor step by step, to move the dispensing conveyor step by step and to fill at least one of the inner cavities with the dose of the discrete particles per each step.

[0075] The inventor found that the step by step motion ensures the discrete particle to be released in the inner cavities accurately.

[0076] According to embodiments, the discrete particles are made through an extrusion process. According to embodiments, the discrete particles are made through a spray granulation process. The discrete particles may comprise: water, an aerosol forming agent (e.g. glycerin), a binder (e.g. carboxymethylcellulose (CMC) or hydroxypropylmethylcellulose (HPMC)), tobacco or a tobacco or tobacco free herbaceous or plant-based material. The discrete particles may have an average size from 0.8 mm to 2.0 mm, optionally greater than 1 mm, optionally from 1 mm to 1.7 mm. The discrete particles may have a water content from 5% to 15%, optionally from 7% to 12%. The discrete particles may comprise granules or pellets. A bulk density of the discrete particles inside the cavities may be 500 g / L to 600 g / L.

[0077] According to embodiments, the frame is shaped like a tablet. According to embodiments, the frame is box-shaped. The frame may have a rectangular, circular, oval, symmetric or asymmetric outline. The frame may be made of paper or paperboard. ThePMP1P43WO FTR4110PCT - 10 -

[0078] frame may have a length from 25 mm to 35 mm, optionally 30 mm. The frame may have a width from 8 mm to 14 mm, optionally 11 mm. The frame may have a thickness from 0.5 mm to 4 mm, optionally from 2 mm to 3 mm, optionally 3 mm. The inner cavity may have a length from 10 mm to 20 mm, optionally 15 mm. The inner cavity may have a width from 5 mm to 10 mm, optionally 8 mm. The inner cavity may have a depth from 0.3 mm to 3 mm, optionally 3 mm, optionally 1.5 mm. The air passages may comprise: a first channel connecting the inner cavity to one end of the frame and opening on said one end. The air passages may comprise: a second channel connecting the inner cavity to an opposite end of the frame and opening on said opposite end. A cross section of the first channel and / or of the second channel may be rectangular. The cross section of the first channel and / or of the second channel may have a width from 3 mm to 5 mm, optionally 4 mm. The cross section of the first channel and / or of the second channel may have a height from 0.3 mm to 3 mm, optionally 1 mm. The average size of the discrete particles should be enough to prevent said particles from escaping from the first channel and / or from second channel.

[0079] With respect to a longitudinal extension of the frame, the inner cavity may be shifted towards one of two ends of said frame.

[0080] In some embodiments, the inner cavity is a recess on one face of the frame. Closing the inner cavity may comprise: applying a cover, optionally a foil or sheet, to said one face and on the recess. The cover may be glued on the frame. An opposite face of the frame may be made of a further cover. The cover and / or the further cover may be made of paper, optionally of a non-porous paper. The non-porous paper prevents or limits additive transfer from the discrete particles to the cover, to the further cover or to other parts of the frame.

[0081] According to embodiments, the plurality of frames are organized in frame assemblies, each frame assembly being then cut into several discrete frames.

[0082] According to embodiments, manufacturing the plurality of frames comprises: manufacturing frame assemblies each comprising several frames and then cutting each frame assembly into discrete frames before or after filling each inner cavity with the dose of the discrete particles or before or after closing the inner cavities.

[0083] As used in the present description, the term “aerosol generating substrate material” means a material capable of releasing volatile compounds when heated, which compounds are then entrained in air drawn through the aerosol-generating article.

[0084] As used in the present description, the term “discrete particles” means a plurality of individual particles that may have different shapes, such as granules or pellets, and sizes.

[0085] As used in the present description, the term “size” referred to a discrete particle means a diameter of a sphere in which the discrete particle is inscribed. An “average size” is the average of the diameters of a plurality of discrete particles.PMP1P43WO FTR4110PCT - 11 -

[0086] As used in the present description, the term “frame” means a body which may have different shapes and may be of different materials and is provided with an inner cavity to store the aerosol generating substrate material in discrete particles. The frame is sized and configured to be placed inside an aerosol generating device.

[0087] As used in the present description, the term “aerosol-generating device” is an electric device, usually an electronic device, comprising a casing delimiting a seat to accommodate an aerosol generating article and comprising a heater disposed and configured to heat the aerosol generating substrate material in discrete particles of the aerosol generating article placed in said seat.

[0088] As used in the present description, the terms “upstream” and “downstream” are used to describe the relative positions of components, or portions of components, of the apparatus in relation to the direction in which a material or materials passes through the apparatus along a given path.

[0089] The invention is defined in the claims. However, 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.

[0090] EX1. A method of manufacturing heat-not-burn consumables for use with an aerosol generating device, the method comprising: receiving or manufacturing an aerosol generating substrate material in discrete particles; manufacturing a plurality of frames each delimiting an inner cavity and air passages in fluid communication with the inner cavity; filling each inner cavity with a dose of said discrete particles; and then closing the inner cavities to obtain a plurality of heat-not-burn consumables; wherein, after receiving or manufacturing the aerosol generating substrate material in discrete particles and before closing the inner cavities, the method comprises: applying an additive on the discrete particles. Optionally, the aerosol generating substrate material in discrete particles is received from a supplier or from another factory.

[0091] EX2. The method according to EX1, wherein the additive is fluid, optionally liquid. EX3. The method according to EX1 or EX2, wherein applying the additive comprises: injecting said additive onto the discrete particles.

[0092] EX4. The method according to EX3, wherein injecting comprises: depositing at least one droplet of the additive on the discrete particles; optionally depositing a plurality of droplets of the additive on the discrete particles, optionally 1 to 15 droplets, optionally 1 to 5 droplets; optionally a radius of the droplet or droplets is from 0.2 mm to 2 mm.

[0093] EX5. The method according to EX1 or EX2, wherein applying the additive comprises: spraying said additive onto the discrete particles.PMP1P43WO FTR4110PCT - 12 -

[0094] EX6. The method according to EX5, wherein an air pressure for spraying is from 1 bar to 5 bar and a spraying flow rate is from 0.1 liters per minute to 1.0 liters per minute.

[0095] EX7. The method according to any of EX1 to EX6, wherein applying the additive is carried out before filling each inner cavity with a dose.

[0096] EX8. The method according to any of EX1 to EX7, wherein applying the additive is carried out after filling each inner cavity with a dose or wherein the additive is applied on the discrete particles in each inner cavity.

[0097] EX9. The method according to EX8, wherein the additive is applied simultaneously on the discrete particles of a plurality of inner cavities.

[0098] EX10. The method according to EX8 or EX9, wherein the additive is applied in a single point or in multiple points of each inner cavity.

[0099] EX11. The method according to any of EX1 to EX10, wherein filling each inner cavity comprises: preparing the doses and dispensing each dose in one of the inner cavities; optionally a weight of one dose is from 150 mg to 200 mg of discrete particles, optionally of 180 mg of discrete particles.

[0100] EX12. The method according to EX11, wherein applying the additive is carried out before or after preparing the doses.

[0101] EX13. The method according to EX11 or EX12, wherein applying the additive is carried out when preparing the doses.

[0102] EX14. The method according to any of EX11 to EX13, wherein, after application of the additive, the discrete particles of the dose are mixed; optionally, before closing the inner cavity, the particles are conditioned to promote drying and / or curing of the additive; optionally conditioning comprises: changing moisture of the particles through air and / or steam.

[0103] EX15. The method according to any of EX1 to EX14, wherein, after receiving or manufacturing the aerosol generating substrate material in discrete particles, the discrete particles are fed to a filling station where each inner cavity is filled with the dose.

[0104] EX16. The method according to EX15, wherein applying the additive is carried out while the discrete particles are fed to the filling station.

[0105] EX17. The method according to any of EX1 to EX16, wherein the discrete particles are made through an extrusion process.

[0106] EX18. The method according to any of EX1 to EX16, wherein the discrete particles are made through a spray granulation process.

[0107] EX19. The method according to any of EX1 to EX18, wherein the discrete particles comprise: water, an aerosol forming agent (e.g. glycerin), a binder (e.g.PMP1P43WO FTR4110PCT - 13 -

[0108] carboxymethylcellulose (CMC) or hydroxypropylmethylcellulose (HPMC)), tobacco or a tobacco or tobacco free herbaceous or plant-based material.

[0109] EX20. The method according to any of EX1 to EX19, wherein the discrete particles have an average size from 0.8 mm to 2.0 mm, optionally greater than 1 mm, optionally from 1 mm to 1.7 mm.

[0110] EX21. The method according to any of EX1 to EX20, wherein the discrete particles have a water content from 5% to 15%, optionally from 7% to 12%; optionally a bulk density of the discrete particles inside the cavities may be 500 g / L to 600 g / L.

[0111] EX22. The method according to any of EX1 to EX21 , wherein the discrete particles comprise granules or pellets.

[0112] EX23. The method according to any of EX1 to EX22, wherein the frame is shaped like a tablet; and / or the frame is box-shaped; and / or the frame has a rectangular, circular, oval, symmetric or asymmetric outline.

[0113] EX24. The method according to any of EX1 to EX23, wherein the frame is made of paper or paperboard.

[0114] EX25. The method according to any of EX1 to EX24, wherein the frame has a length from 25 mm to 35 mm, optionally 30 mm; a width from 8 mm to 14 mm, optionally 11 mm; a thickness from 0.5 mm to 4 mm, optionally from 2 mm to 3 mm, optionally 3 mm.

[0115] EX26. The method according to any of EX1 to EX25, wherein the inner cavity has a length from 10 mm to 20 mm, optionally 15 mm; a width from 5 mm to 10 mm, optionally 8 mm; a depth from 0.3 mm to 3 mm, optionally 3 mm, optionally 1.5 mm.

[0116] EX27. The method according to any of EX1 to EX26, wherein the air passages comprise: a first channel connecting the inner cavity to one end of the frame and opening on said one end.

[0117] EX28. The method according to EX27, wherein the air passages comprise: a second channel connecting the inner cavity to an opposite end of the frame and opening on said opposite end.

[0118] EX29. The method according to EX27 or EX28, wherein a cross section of the first channel and / or of the second channel is rectangular.

[0119] EX30. The method according to EX29, wherein the cross section of the first channel and / or of the second channel has a width from 3 mm to 5 mm, optionally 4 mm, and a height from 0.3 mm to 3 mm, optionally 1 mm.

[0120] EX31. The method according to any of EX1 to EX30, wherein, with respect to a longitudinal extension of the frame, the inner cavity is shifted towards one of two ends of said frame.PMP1P43WO FTR4110PCT

[0121] EX32. The method according to any of EX1 to EX31, wherein the inner cavity is a recess on one face of the frame.

[0122] EX33. The method according to EX32, wherein closing the inner cavity comprises: applying a cover, optionally a foil or sheet, to said one face and on the recess; wherein, optionally, an opposite face of the frame is made of a further cover.

[0123] EX34. The method according to EX32, wherein the cover is glued on the frame. EX35. The method according to EX32 or EX33, wherein the cover and / or the further cover is / are made of paper, optionally of a non-porous paper.

[0124] EX36. The method according to any of EX1 to EX35, wherein the additive is a mixture of several compounds.

[0125] EX37. The method according to any of EX1 to EX36, wherein the additive comprises at least one of: a flavoring agent, an aerosol forming agent (e.g. propylene glycol) or a mixture thereof or a binder.

[0126] EX38. The method according to any of EX1 to EX37, wherein the additive has a viscosity from 10 mPa*s to 60 mPa*s.

[0127] EX39. The method according to any of EX1 to EX38, wherein the additive has a flashpoint from 30°C to 110°C.

[0128] EX40. The method according to any of EX1 to EX39, wherein the additive has a density from 0.5 g / cm3to 1.6 g / cm3, optionally from 0.7 g / cm3to 1.5 g / cm3.

[0129] EX41. The method according to any of EX1 to EX40, wherein the additive comprises a mixture of flavoring agents dissolved in a solvent and an additional solvent.

[0130] EX42. The method according to EX41, wherein the solvent and the additional solvent is propylene glycol, and / or ethanol, and / or benzyl alcohol.

[0131] EX43. The method according to any of EX1 to EX42, wherein the additive comprises an acid, like lactic acid or malonic acid.

[0132] EX44. The method according to any of EX1 to EX43, wherein the additive comprises glycerin.

[0133] EX45. The method according to any of EX1 to EX44, wherein the additive is applied in at least two sequential steps on the same discrete particles.

[0134] EX46. The method according to any of EX1 to EX45, wherein the additive is applied on the discrete particles with an application rate (weight of additive I weight of discrete particles) from 0.5 to 2.0, optionally from 0.7 to 1.7.

[0135] EX47. The method according to any of EX1 to EX46, wherein the plurality of frames are organized in frame assemblies, each frame assembly being then cut into several discrete frames; or wherein manufacturing the plurality of frames comprises: manufacturing frame assemblies each comprising several frames joined one to another and then cuttingPMP1P43WO FTR4110PCT - 15 -

[0136] each frame assembly into discrete frames before or after filling each inner cavity with the dose of the discrete particles or before or after closing the inner cavities.

[0137] EX48. An apparatus for manufacturing heat-not-burn consumables for use with an aerosol generating device, the apparatus comprising: a first station configured for receiving or manufacturing an aerosol generating substrate material in discrete particles; a second station configured for manufacturing a plurality of frames each delimiting an inner cavity and air passages in fluid communication with the inner cavity; a filling station operatively placed downstream of the first station and the second station; the filling station being positioned and arranged to receive the discrete particles from the first station and the frames from the second station and to fill each inner cavity with a dose of said discrete particles; a closing station operatively placed downstream of the filling station and configured for closing the inner cavities and obtaining a plurality of heat-not-burn consumables; wherein the apparatus further comprises at least one applicator connected to a source of an additive and positioned downstream of the first station and upstream of the closing station to apply the additive on the discrete particles. Optionally, the first station is a container configured to receive the aerosol generating substrate material in discrete particles from a supplier or from another factory.

[0138] EX49. The apparatus according to EX48, wherein the at least one applicator is positioned at the filling station.

[0139] EX50. The apparatus according to EX48, wherein the at least one applicator is positioned between the filling station and the closing station.

[0140] EX51. The apparatus according to any of EX48 to EX50, wherein the at least one applicator comprises a plurality of applicators arranged in sequence between the first station and the closing station and configured to apply the additive in sequential steps.

[0141] EX52. The apparatus according to any of EX48 to EX51 , wherein the filling station comprises: a dispensing conveyor provided with pockets, each pocket being movable between a loading position and a dispensing position; optionally a cleaning device is coupled to the dispensing conveyor to clean the pockets downstream of the dispensing position and upstream of the loading position.

[0142] EX53. The apparatus according to EX52, wherein in the loading position the pocket receives the dose (i.e. a set quantity) of the discrete particles and in the dispensing position the pocket faces one of the inner cavities to fill said cavity with the dose of the discrete particles.

[0143] EX54. The apparatus according to EX46, wherein the at least one applicator is located at the dispensing conveyor to apply the additive on the discrete particles in the pockets.PMP1P43WO FTR4110PCT - 16 -

[0144] EX55. The apparatus according to EX53 or EX54, comprising a dosing chamber sized to hold the dose of the discrete particles; wherein in the loading position the pocket faces the dosing chamber.

[0145] EX56. The apparatus according to EX55, wherein the at least one applicator is located at the dosing chamber to apply the additive on the discrete particles in said dosing chamber.

[0146] EX57. The apparatus according to EX56, wherein a mixer is operatively active in the dosing chamber or downstream of the dosing chamber to mix the discrete particles of the dose.

[0147] EX58. The apparatus according to any of EX53 to EX57, comprising a hopper having an upper opening to receive the discrete particles from the first station and a lower opening communicating with the dosing chamber or facing the pockets of the dispensing conveyor; optionally a feeder is used to feed the discrete particles from the hopper to the dosing chamber or to the dispensing conveyor.

[0148] EX59. The apparatus according to any of EX53 to EX58, wherein the dispensing conveyor comprises a wheel rotating about an axis thereof; the pockets being located on a peripheral portion of the wheel; optionally the pockets opening radially outwards.

[0149] EX60. The apparatus according to EX59, comprising a motor coupled to the wheel to rotate said wheel about the axis to move the pockets between the loading position and the dispensing position.

[0150] EX61. The apparatus according to EX59 or EX60, wherein the wheel comprises a vacuum device operatively active in the pockets or a mechanical barrier to retain the discrete particles in said pockets while moving towards the dispensing position.

[0151] EX62. The apparatus according to EX61, wherein the vacuum device is configured to release the discrete particles from the pocket in the dispensing position.

[0152] EX63. The apparatus according to any of EX59 to EX62, wherein the axis is horizontal and the pocket in the dispensing position is located in a lower part of the wheel.

[0153] EX64. The apparatus according to any of EX59 to EX63 when EX59 is according to any of EX55 to EX57, wherein the dosing chamber is located on a side of the wheel and faces the peripheral portion of the wheel.

[0154] EX65. The apparatus according to any of EX59 to EX64, wherein the at least one applicator faces the peripheral portion of the wheel.

[0155] EX66. The apparatus according to EX65 when according to EX63, wherein the at least one applicator is located above the wheel.PMP1P43WO FTR4110PCT - 17 -

[0156] EX67. The apparatus according to any of EX48 to EX66, comprising a frame conveyor extending between the filling station and the closing station for supporting and carrying the frames from the filling station to the closing station.

[0157] EX68. The apparatus according to EX67, wherein the at least one applicator is positioned at the frame conveyor to apply the additive on the discrete particles in the inner cavities.

[0158] EX69. The apparatus according to EX67, wherein the at least one applicator is positioned above the frame conveyor.

[0159] EX70. The apparatus according to EX68 or EX69, wherein the at least one applicator comprises at least one nozzle facing the frame conveyor.

[0160] EX71. The apparatus according to EX70, wherein the at least one applicator comprises a plurality of nozzles placed side by side to apply simultaneously the additive on the discrete particles of a single inner cavity or of a plurality of inner cavities; or wherein the at least one applicator is moveable to apply the additive in multiple points of a single inner cavity or of a plurality of inner cavities.

[0161] EX72. The apparatus according to any of EX48 to EX71, comprising: a first conveyor extending between the first station and the filling station for feeding the discrete particles to the filling station.

[0162] EX73. The apparatus according to EX72, comprising: a second conveyor extending between the second station and the filling station for feeding the frames to the filling station.

[0163] EX74. The apparatus according to EX72 or EX73, wherein the at least one applicator is positioned at the first conveyor to apply the additive on the discrete particles fed towards the filling station.

[0164] EX75. The apparatus according to any of claims EX48 to EX74, wherein the at least one applicator comprises an injector for injecting droplets of the additive on the discrete particles; optionally the injector comprises at least one of: a jet-valve, a peristaltic pump, a diaphragm pump, a solenoid valve, a coaxial solenoid valve, a needle valve; optionally a nozzle of the injector is positioned 10 centimeters (cm) to 30 centimeters (cm) from a surface of the discrete particles.

[0165] EX76. The apparatus according to any of claims EX48 to EX74, wherein the at least one applicator comprises a sprayer for spraying the additive on the discrete particles; optionally a nozzle of the sprayer is positioned 1 centimeters to 20 centimeters from a surface of the discrete particles; optionally a spray angle with respect to a surface formed by the discrete particles is between 80° and 100°, optionally 90°.

[0166] EX77. The apparatus according to any of EX48 to EX76, comprising a control unit operatively connected at least to the filling station and to the at least one applicator, thePMP1P43WO FTR4110PCT - 18 -

[0167] control unit being configured and / or programmed to control the filling station to fill each inner cavity with the dose of the discrete particles and to control the at least one applicator to apply the additive on the discrete particles.

[0168] EX78. The apparatus according to EX77 when according to any of EX52 to EX66 and to any of EX67 to EX71, wherein the control unit is operatively connected to the dispensing conveyor and to the frame conveyor; wherein the control unit is configured and / or programmed to advance the frame conveyor step by step, to move the dispensing conveyor step by step and to fill at least one of the inner cavities with the dose of the discrete particles per each step.

[0169] EX79. The method according to any of EX1 to EX47 which is carried out by the apparatus according to any of EX48 to EX78.

[0170] EX80. The apparatus according to any of EX48 to EX78 which is configured to perform the method according to any of EX1 to EX47.

[0171] EX81. Heat-not-burn consumable for use with an aerosol generating device, wherein the heat-not-burn consumable is manufactured according to the method of any EX1 to EX47 or through the apparatus of any of EX48 to EX78.

[0172] Examples will now be further described with reference to the figures in which:

[0173] Figure 1 shows a heat-not-burn consumable;

[0174] Figure 2A is an exploded view of the heat-not-burn consumable of Figure 1 ;

[0175] Figure 2B shows the exploded view of Figure 2A with some elements removed to better show other parts;

[0176] Figure 3 is a cross section of the heat-not-burn consumable of Figures 1 , 2A and 2B; Figure 4 shows a schematic cross section of an aerosol generating device coupled to the heat-not-burn consumable of the previous Figures;

[0177] Figure 5 shows an apparatus for manufacturing heat-not-burn consumables;

[0178] Figure 6 is a variant embodiment of the apparatus of Figure 5;

[0179] Figure 7 is another variant embodiment of the apparatus of Figure 5;

[0180] Figure 8 is a further variant embodiment of the apparatus of Figure 5;

[0181] Figure 9 shows a step of a method of manufacturing heat-not-burn consumables; Figure 10 shows the step of Figure 9 according to a variant of the method;

[0182] Figure 11 shows another step of the method of manufacturing heat-not-burn consumables;

[0183] Figure 12 shows heat-not-burn consumables with different outlines;

[0184] Figure 13 is a flowchart showing an example of the method of manufacturing heat-not-burn consumables.PMP1P43WO FTR4110PCT - 19 -

[0185] A heat-not-burn consumable 1 is shown in Figures 1 , 2A, 2B and 3. The heat-not-burn consumable 1 comprises a frame 2 shaped like a parallelepiped and made of paper or paperboard. The frame 2 is shaped like a tablet with a length and a width much greater than a thickness. For instance, the frame 2 has a length of 30 mm, a width of 11 mm and a thickness of 3 mm. An outline of the frame 2 of the attached Figure 1 along the length and the width thereof is rectangular. Figure 12 shows variant embodiments of the heat-not-burn consumable 1 with different outlines of the frame 2: circular, oval, trapezoidal, symmetric or asymmetric.

[0186] The frame 2 has an upper face provided with a recess defining an inner cavity 3 (Figure 2B). Figure 12 shows some kinds of recesses, rectangular or circular, centered or off-center with respect to the frame 2. The recess may have a length of 15 mm, a width of 8 mm and a depth of 3 mm.

[0187] A cover 4 made of a foil or sheet of non-porous paper is applied and glued to said upper face to close the recess and delimit said inner cavity 3. A lower face of the frame 2 may be defined by a further cover 4A, as shown in Figure 3, of the same material of the cover 4. The further cover delimits a bottom surface of the recess.

[0188] The inner cavity 3 is filled with an aerosol generating substrate material made of a plurality of discrete particles 5 consisting in granules or pellets (Figure 2A). The discrete particles 5 comprises an aerosol forming agent (e.g. glycerin), a binder (e.g. carboxymethylcellulose (CMC) or hydroxypropylmethylcellulose (HPMC)), tobacco or a tobacco or tobacco free herbaceous or plant-based material. The discrete particles have usually an average size from 0.8 mm to 2.0 mm, e.g. from 1 mm to 1.7 mm, and a water content from 5% to 15%, e.g. from 7% to 12%. The discrete particles 5 are made through an extrusion process or a spray granulation process.

[0189] As better shown in Figure 3, a first channel 6 connects the inner cavity 3 to one end of the frame 2 and opens on said one end and a second channel 7 connects the inner cavity 3 to an opposite end of the frame 2 and opens on said opposite end. The first channel 6 and the second channel 7 of the example embodiment here disclosed have rectangular cross sections (Figures 1 , 2A and 2B). For instance, the cross section of the first 6 channel and / or of the second channel 7 has a width of 4 mm and a height of 1 mm.

[0190] Figure 4 shows an aerosol generating device 8 coupled to the heat-not-burn consumable 1. The aerosol generating device 8 comprises a battery 9, a controller 10, a first heater 11 and a second heater 12 located within a housing 13. The battery 9 provides electric power to the controller 10 and the first heater 11 and second heater 12. The controller 10 controls the power to the first heater 11 and second heater 12 and the temperature of said heaters 11, 12.PMP1P43WO FTR4110PCT - 20 -

[0191] The housing 13, the first heater 11 and the second heater 12 delimits a seat sized and shaped to accommodate the heat-not-burn consumable 1 which, when properly placed in said seat, protrudes from the aerosol generating device 8 as shown in Figure 4. The aerosol generating device 8 comprises an air inlet 14 defining an air-flow path configured to allow air to flow into the seat from outside the aerosol generating device 8.

[0192] When the heat-not-burn consumable 1 is accommodated in the seat, the first channel 6 faces the air inlet 14 which therefore is in fluid communication with said air inlet 14, with the cavity and with the second channel 7 through the discrete particles 5. In use, the first heater 11 and the second heater 12 heat up the aerosol generating substrate material and generate aerosol in the inner cavity 3. Inhalation of the user through the second channel 7 draws air through the air inlet 14, the first channel 6, the inner cavity 3 full of the discrete particles 5 and of aerosol and the second channel 7. The aerosol generated in the inner cavity 3 is inhaled by the user through the second channel 7.

[0193] Figure 5 shows an embodiment of an apparatus 15 for manufacturing the heat-not-burn consumable 1 detailed above. The apparatus 15 comprises a first station 16 configured for manufacturing the aerosol generating substrate material in discrete particles 5 and a second station 17 configured for manufacturing a plurality of frames 2. The first station 16 and the second station 17 are represented only schematically in Figure 5. The first station 16 may be an extruder or a spray granulation machine. The second station 17 may comprise devices for handling continuous sheet materials of paper or paperboard, for supplying adhesive, for cutting through continuous sheet materials, for folding and / or joining continuous sheet materials in order to manufacture the frames 2. The first station 16 may also be a container configured to receive the aerosol generating substrate material in discrete particles 5 from a supplier or from another factory.

[0194] The apparatus 15 comprises a frame conveyor 18. The frame conveyor 18 comprise an upper surface moved by a motor, not shown, along a conveying direction “C”. The upper surface is configured to support and convey along said conveying direction “C” the frames 2 manufactured in the second station 16 and then transported to a loading end 18A of the frame conveyor 18 through a second conveyor 200, represented schematically through an arrow. In Figure 3, the frames 2 are positioned one after the other on the upper surface and conveyed in sequence with the upper faces and the recesses 3 thereof facing upwards.

[0195] The apparatus 15 comprises a filling station 19 operatively placed downstream of the first station 16 and the second station 17. The filling station of Figure 5 is positioned on the frame conveyor 18, downstream of the loading end 18A, and comprises a hopper 20, a dosing chamber 21 and a dispensing conveyor 22 shaped like a wheel rotated, through a motor not shown, about a horizontal axis “X-X” perpendicular to the conveying direction “C”.PMP1P43WO FTR4110PCT - 21 -

[0196] The wheel comprises a plurality of pockets 23 located on a peripheral portion thereof and opening radially outwards. The dosing chamber 21 delimits an inner volume sized to hold a dose of the discrete particles 5 corresponding to a volume of the inner cavity 3 of the frame 2. The dosing chamber 21 is located on a side of the wheel and faces the peripheral portion of the wheel. The hopper 20 is positioned above the dosing chamber 21 and presents an upper opening 24 to receive the discrete particles 5 transported through a first conveyor 100 (represented schematically through an arrow) from the first station 16 and a lower opening 25 communicating with the dosing chamber 21. An outlet 26 of the dosing chamber 21 faces the peripheral portion of the wheel. The wheel comprises a vacuum device 27, represented schematically in Figure 5, which is operatively active in the pockets 23 to generate a suction in said pockets 23 and retain the discrete particles 5. The vacuum device may be a vacuum pump connected to each pocket 23 through pipes located inside the wheel and provided with electro-valves. Alternatively, each pocket may be provided with a mechanical barrier to prevent the discrete particles 5 from falling.

[0197] The dosing chamber 21 defines a loading position for the pockets 23, since the pocket 23 in said position can be loaded with one dose of the discrete particles 5 dispensed by the dosing chamber 21 through the outlet 26 thereof. A lower part of the wheel facing the upper surface of the frame conveyor 18 defines a dispensing position, since the pocket 23 in said position can be filled with one dose of the discrete particles 5 unloaded from the pocket 23.

[0198] A control unit of the apparatus 15, for instance an electronic control unit, is operatively connected to the filling station 19 and to the frame conveyor 18. The control unit is configured and / or programmed to advance step by step the upper surface of the frame conveyor 18 along the conveying direction “C” and to bring and stop each frame 2 under the lower part of the wheel.

[0199] The control unit is configured and / or programmed to rotate step by step the dispensing conveyor 22 (wheel) about the horizontal axis “X-X” to bring and stop each pocket 23 in the loading position in front of the outlet 26 of the dosing chamber 21 and then in the dispensing position above the recess of each frame 2. In the example embodiment of Figure 5, the wheel comprises eight pockets 23 angularly equi-spaced around the horizontal axis “X-X”. The wheel is rotated clockwise. A rotation angle of the wheel from the loading position to the dispensing position is 135°.

[0200] The control unit controls the dosing chamber 21 to feed a dose of the discrete particles 5 into the pocket 23 in the loading position and to activate the vacuum device 27 such that the dose is retained in the pocket 23 while rotates from the loading position to the dispensing position. In the dispensing position, the vacuum device 27 in said pocket 23 is disabled and the discrete particles 5 fall by gravity into the recess and fill the inner cavity 3. In the examplePMP1P43WO FTR4110PCT - 22 -

[0201] of Figure 5, one pocket 23 is filled in the loading position and one inner cavity 3 is filled in the dispensing position at each step. A weight of one dose is usually from 150 mg to 200 mg of discrete particles 5, e.g. of 180 mg of discrete particles 5. A bulk density of the discrete particles 5 inside the cavities may be 500 g / L to 600 g / L.

[0202] The apparatus 15 further comprises a closing station 28 which is represented schematically in Figure 5 and is configured to feed a plurality of the above-mentioned covers 4 (sheets of non-porous paper) and to apply and glue each cover 4 on one of the frames 2 filled with one dose of discrete particles 5. The frame conveyor 18 extends to the closing station 28. The closing station 28 is configured to apply one cover 4 to the upper face of each frame 2, to close the recess housing the discrete particles 5, thus forming one heat-not-burn consumable 1.

[0203] The apparatus of Figure 5 further comprises an applicator 29 connected to a source 30 of an additive “A”, such as a reservoir, and positioned between the filling station 19 and the closing station 28 and above the frame conveyor 18. The additive “A” may comprise a flavoring agent (e.g. menthol) or an aerosol forming agent (e.g. propylene glycol) ora binder or a mixture thereof.

[0204] The additive could be in general a mixture of several compounds, such as: 1) a flavoring mix (which is itself a mixture of different flavor compounds dissolved in a solvent such as propylene glycol and / or ethanol, and / or benzyl alcohol, etc.); 2) a solvent, such as propylene glycol and / or ethanol, and / or benzyl alcohol, etc.; 3) an acid to reduce harshness, such lactic acid or malonic acid; 4) glycerin which could help to increase the glycerin as aerosol former in the consumable. For instance, the amount of glycerin in the discrete particles 5 is from 18% to 24% and further glycerin is added as additive to reach 30% of glycerin in the aerosol generating substrate material of heat-not-burn consumable 1.

[0205] The additive “A” in the reservoir is a fluid, typically in liquid form.

[0206] The applicator 29 of Figure 5 is a sprayer having a nozzle 31 facing the upper surface of the frame conveyor 18. The applicator 29 is positioned between the wheel and the closing station 28. The control unit is configured and / or programmed to control the frame conveyor 18 such that each frame 2 filled with the discrete particles 5 is stopped below the applicator 29 and to command the applicator 29 to spray the additive “A” on the discrete particles 5 in each inner cavity 3. For instance, an air pressure for spraying is from 1 bar to 5 bar and a spraying flow rate is from 0.1 liters per minute to 1.0 liters per minute. For instance, the nozzle 31 of the sprayer is positioned 1 to 20 centimeters from a surface of the discrete particles 5 with a spray angle with respect to said surface between 80° and 100°. In Figure 5 the spray angle is 90°.PMP1P43WO FTR4110PCT - 23 -

[0207] The apparatus 15 may also comprise a conditioning unit, not shown, placed downstream of the applicator 29 and upstream of the closing station 28. The conditioning unit is for instance a conditioning chamber which is crossed by the frame conveyor 18 carrying the frames 2. The conditioning unit comprises devices that feed into the conditioning chamber air and / or steam to change moisture of the discrete particles 5 and to promote drying and / or curing of the additive “A”.

[0208] The embodiment of Figure 6 differs from the one of Figure 5 in that the applicator 29 (which is still a sprayer) is positioned at the filling station 19 and faces the peripheral portion of the wheel just upstream, with respect to a direction of rotation of said wheel, of the dispensing position. The additive “A” is sprayed on the discrete particles 5 housed in the pocket 23 just before being unloaded into one recess.

[0209] The embodiment of Figure 7 differs from Figure 5 and Figure 6 in that the applicator 29 is placed above the wheel and still faces the peripheral portion of said wheel. The additive “A” is sprayed on the discrete particles 5 housed in the pocket 23 at the top of the wheel, i.e. before filling each inner cavity 3 with a dose.

[0210] The embodiment of Figure 8 differs from Figures 5, 6 and 7 in that the applicator 29 is located at the dosing chamber 21 to apply the additive “A” on the discrete particles 5 housed in said dosing chamber 21. Thus, the additive “A” is applied to the discrete particles 5 after preparing a dose and before filling each pocket 23 with the dose. The nozzle 31 of the applicator 29 is, for instance, installed inside the dosing chamber 21 or the dosing chamber 21 is provided with an aperture facing the nozzle 31 of the applicator 29. Furthermore, a cleaning device 300 is coupled to the dispensing conveyor 22 to clean the pockets 23 downstream of the dispensing position and upstream of the loading position. The cleaning device 300 may be a dispenser of water or other substance that sprays such substance in the empty pocket 23 leaving the dispensing position. A variant embodiment of the one of Figure 8 may also comprise a mixer which is operatively active in the dosing chamber 21 or downstream of the dosing chamber 21 and upstream of the wheel to mix the discrete particles 5 and the additive “A” of the dose.

[0211] In other embodiments, not shown in the drawings, the applicator 29 is installed at the first conveyor 100, to apply the additive “A” on the discrete particles 5 while said discrete particles 5 are fed to the filling station 19, or the applicator 29 is installed above the hopper 20 to apply the additive “A” to the discrete particles 5 in said hopper 20. In other embodiments, not shown in the drawings, the hopper 20 is placed above the wheel and the lower opening 25 of the hopper 20 faces the pockets 23 to fill each pocket 23 with a dose, i.e. the hopper 20 works also as a metering device. In other embodiments, not shown in the drawings, a feeder, like a screw conveyor, is placed between the hopper 20 and the dosingPMP1P43WO FTR4110PCT - 24 -

[0212] chamber21 or between the dosing chamber 21 and the dispensing conveyor 19 and is used to feed the discrete particles 5 from the hopper 20 to the dosing chamber 21 or to the dispensing conveyor 19.

[0213] Figures 9 and 10 show another type of applicator 29 applying the additive “A” on a frame assembly 300. The frame assembly 300 comprises three joined frames 2 which are cut in single discrete frames 2 along cutting lines 301 after of before applying the cover 4.

[0214] The applicator 29 is an injector having a nozzle 32 positioned 10 cm to 30 cm from a surface of the discrete particles 5 housed in the recess. The injector is controlled for instance by the control unit and is configured to inject droplets 33 of the additive “A” on the discrete particles 5. Exemplary applicable technologies for liquid injections are: jet-valves, peristaltic pumps, diaphragm pumps, solenoid valves, needle valves, coaxial solenoid valves.

[0215] In the embodiment of Figure 9, the injector is only one and applies the additive “A” in one recess at a time after being filled with the discrete particles 5. In the embodiment of Figure 10, the applicator 29 comprises three injectors with three nozzles 32 placed side by side and capable of applying the additive “A” simultaneously in three recess 3 filled with the discrete particles 5. The applicator 29 of Figures 5 and 7 is represented as a sprayer. Anyway, said applicator 29 may a be an injector, like the one of Figures 9 or 10.

[0216] Figure 11 shows examples of points of drop application on the discrete particles 5 in the frame assembly 300. On the left, two drops 33 have been applied side by side and aligned along the conveying direction “C”. In the center, three drops 33 have been applied aligned along a line slanted with respect to a line perpendicular to the conveying direction “C”. On the right, three drops 33 have been applied aligned along a line perpendicular to the conveying direction “C”. The multiple drop application in a single inner cavity 3 may be performed by a plurality of applicators 29 similar to the applicator assembly shown in Figure 10 or by a single applicator 29 moved by respective devices in different points of the single inner cavity 3.

[0217] A plurality of droplets 33, for instance five droplets, may also be applied one after the other in a single point of the discrete particles 5. Each droplet may have a radius from 0.2 mm to 2 mm.

[0218] The following Table 1 contains some parameters related to the injection (drop application) of the additive “A”.

[0219] Table 1

[0220]

[0221] PMP1P43WO FTR4110PCT - 25 -

[0222]

[0223] Figure 13 is a flowchart of an example of a method of manufacturing heat-not-burn consumables 1 which may be carried out through the apparatus 15 of the appended Figures. The method comprises: manufacturing in the first station 16 the aerosol generating substrate material in the discrete particles 5, manufacturing the plurality of frames 2 in the second station 17, filling each inner cavity 3 of the frames 2 with the dose of said discrete particles 5, applying the additive on the discrete particles 5 and closing the inner cavities 3 to obtain the plurality of heat-not-burn consumables 1.

[0224] In other embodiments, a plurality of applicators 29 are arranged in sequence between the first station 16 and the closing station 28 and are configured to apply the additive in sequential steps on a same group of discrete particles.

[0225] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term "about". Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A ± 5 percent of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.

Claims

PMP1P43WO FTR4110PCT - 26 -CLAIMS1. A method of manufacturing heat-not-burn consumables for use with an aerosol generating device, the method comprising:receiving or manufacturing an aerosol generating substrate material in discrete particles (5);manufacturing a plurality of frames (2) each delimiting an inner cavity (3) and air passages (6, 7) in fluid communication with the inner cavity (3), wherein the air passages (6, 7) comprise a first channel (6) connecting the inner cavity (3) to one end of the frame (2) and opening on said one end and a second channel (7) connecting the inner cavity (3) to an opposite end of the frame (2) and opening on said opposite end;filling each inner cavity (3) with a dose of said discrete particles (5); and then closing the inner cavities (3) to obtain a plurality of heat-not-burn consumables (1); wherein, after receiving or manufacturing the aerosol generating substrate material in discrete particles (5) and before closing the inner cavities (3), the method comprises: applying an additive (A) on the discrete particles (5).

2. Method according to claim 1 , wherein the inner cavity (3) is a recess on one face of the frame (2) and wherein closing the inner cavity (3) comprises: applying a cover (4) to said one face and on the recess.

3. Method according to claim 1 or 2, wherein applying the additive (A) is carried out before or after filling each inner cavity (3) with a dose.

4. Method according to any of claims 1 to 3, wherein filling each inner cavity (3) comprises:preparing the doses; anddispensing each dose in one of the inner cavities (3);wherein applying the additive (A) is carried out before or after preparing the doses or when preparing the doses.

5. Method according to any of claims 1 to 4, wherein, after receiving or manufacturing the aerosol generating substrate material in discrete particles (5), the discrete particles (5) are fed to a filling station (19) where each inner cavity (3) is filled with the dose; whereinPMP1P43WO FTR4110PCT - 27 -applying the additive (A) is carried out while the discrete particles (5) are fed to the filling station (19).

6. Method according to any of claims 1 to 5, wherein the discrete particles (5) are made through an extrusion process or through a spray granulation process; wherein the discrete particles (5) comprise: water, an aerosol forming agent, a binder, a tobacco or tobacco free herbaceous or plant-based material; wherein the discrete particles (5) have an average size from 0.8 mm to 2.0 mm; wherein the additive (A) comprises at least one of: a flavoring agent, an aerosol forming agent, a binder.

7. An apparatus for manufacturing heat-not-burn consumables for use with an aerosol generating device, the apparatus being configured to carry out the method of claim 1 , the apparatus comprising:a first station (16) configured for receiving or manufacturing the aerosol generating substrate material in discrete particles (5);a second station (17) configured for manufacturing the plurality of frames (2) each delimiting the inner cavity (3) and the air passages (6, 7) in fluid communication with the inner cavity (3);a filling station (19) operatively placed downstream of the first station (16) and the second station (17); the filling station (19) being positioned and arranged to receive the discrete particles (5) from the first station (16) and the frames (2) from the second station (17) and to fill each inner cavity (3) with the dose of said discrete particles (5);a closing station (28) operatively placed downstream of the filling station (19) and configured for closing the inner cavities (3) and obtaining the plurality of heat-not-burn consumables (1);wherein the apparatus (15) further comprises at least one applicator (29) connected to a source (30) of the additive (A) and positioned downstream of the first station (16) and upstream of the closing station (28) to apply the additive (A) on the discrete particles (5).

8. Apparatus according to claim 7, wherein the at least one applicator (29) is positioned at the filling station (19) or between the filling station (19) and the closing station (28).

9. Apparatus according to claim 7 or 8, wherein the filling station (19) comprises:a dispensing conveyor (22) provided with pockets (23), each pocket (23) being movable between a loading position and a dispensing position, wherein in thePMP1P43WO FTR4110PCT - 28 -loading position the pocket (23) receives the dose of the discrete particles (5) and in the dispensing position the pocket (23) faces one of the inner cavities (5) to fill said inner cavity with the dose of the discrete particles;wherein the at least one applicator (29) is located at the dispensing conveyor (22) to apply the additive on (A) the discrete particles (5) in the pockets (23).

10. Apparatus according to claim 9, comprising a dosing chamber (21) sized to hold the dose of the discrete particles (5); wherein in the loading position the pocket (23) faces the dosing chamber (21); wherein the at least one applicator (29) is located at the dosing chamber (21) to apply the additive (A) on the discrete particles (5) in said dosing chamber (21).

11. Apparatus according to claim 9 or 10, comprising a hopper (20) having an upper opening (24) to receive the discrete particles (5) from the first station (16) and a lower opening (25) communicating with the dosing chamber (21) or facing the pockets (23) of the dispensing conveyor (22).

12. Apparatus according to any of claims 9 to 11 , wherein the dispensing conveyor (22) comprises a wheel rotating about an axis (X-X) thereof; the pockets (23) being located on a peripheral portion of the wheel and opening radially outwards; a motor coupled to the wheel to rotate said wheel about the axis (X-X) to move the pockets (23) between the loading position and the dispensing position; wherein the wheel comprises a vacuum device (27) operatively active in the pockets (23) to retain the discrete particles (5) in said pockets (23) while moving towards the dispensing position; wherein the at least one applicator (29) faces the peripheral portion.

13. Apparatus according to any of claims 7 to 12, comprising a frame conveyor (18) extending between the filling station (19) and the closing station (28) for supporting and carrying the frames (2) from the filling station (19) to the closing station (28), wherein the at least one applicator (29) is positioned at the frame conveyor (18) to apply the additive (A) on the discrete particles (5) in the inner cavities (3).

14. Apparatus according to any of claims 7 to 13, comprising:a first conveyor (100) extending between the first station (16) and the filling station (19) for feeding the discrete particles (5) to the filling station (19);PMP1P43WO FTR4110PCT - 29 -a second conveyor (200) extending between the second station (17) and the filling station (19) for feeding the frames (2) to the filling station (19); wherein the at least one applicator (29) is positioned at the first conveyor (100) to apply the additive (A) on the discrete particles (5) fed towards the filling station (19).

15. Apparatus according to any of claims 7 to 14, wherein the at least one applicator (29) comprises an injector for injecting droplets of the additive (A) on the discrete particles (5) or a sprayer for spraying the additive (A) on the discrete particles (5).

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