Patent Description:
The popularity and use of reduced-risk or modified-risk devices (also known as aerosol generating devices or vapour generating devices) has grown rapidly in recent years as an alternative to the use of traditional tobacco products. Various devices and systems are available that heat or warm aerosol generating substances to generate an aerosol for inhalation by a user.

A commonly available reduced-risk or modified-risk device is the heated substrate aerosol generating device, or so-called heat-not-burn device. Devices of this type generate an aerosol or vapour by heating an aerosol generating substrate to a temperature typically in the range <NUM> to <NUM>. Heating the aerosol generating substrate to a temperature within this range, without burning or combusting the aerosol generating substrate, generates a vapour which typically cools and condenses to form an aerosol for inhalation by a user of the device.

Currently available aerosol generating devices can use one of a number of different approaches to provide heat to the aerosol generating substrate. One such approach is to provide an aerosol generating device which employs an induction heating system. In such a device, an induction coil is provided in the device and an inductively heatable susceptor is provided to heat the aerosol generating substrate. Electrical energy is supplied to the induction coil when a user activates the device which in turn generates an alternating electromagnetic field. The susceptor couples with the electromagnetic field and generates heat which is transferred, for example by conduction, to the aerosol generating substrate and an aerosol is generated as the aerosol generating substrate is heated.

It can be convenient to provide both the aerosol generating substrate and the inductively heatable susceptor together, e.g., as described in <CIT>, in the form of an aerosol generating article which can be inserted by a user into an aerosol generating device. As such, there is a need to provide a method which facilitates the manufacture of aerosol generating articles, and in particular which enables aerosol generating articles to be mass-produced easily and consistently.

According to the present invention, there is provided a method for continuously manufacturing aerosol generating articles, as defined in claim <NUM>, the method comprising:.

Aerosol generating articles produced by the method are for use with an aerosol generating device for heating the aerosol generating strips, without burning the aerosol generating strips, to volatise at least one component of the aerosol generating strips and thereby generate a heated vapour which cools and condenses to form an aerosol for inhalation by a user of the aerosol generating device. The aerosol generating device is a hand-held, portable, device.

In general terms, a vapour is a substance in the gas phase at a temperature lower than its critical temperature, which means that the vapour can be condensed to a liquid by increasing its pressure without reducing the temperature, whereas an aerosol is a suspension of fine solid particles or liquid droplets, in air or another gas. It should, however, be noted that the terms 'aerosol' and 'vapour' may be used interchangeably in this specification, particularly with regard to the form of the inhalable medium that is generated for inhalation by a user.

The method according to the present disclosure facilitates the manufacture of aerosol generating articles and in particular enables aerosol generating articles to be mass produced consistently and with relative ease. The combination of aerosol generating strips and susceptor strips in aerosol generating articles produced by the method according to the present disclosure provides effective heat transfer from the susceptor strips to the aerosol generating strips during use of the aerosol generating articles in an aerosol generating device. This in turn provides effective and uniform heating of the aerosol generating strips and, thus, reliable vapour generation.

Step (iii) may comprise simultaneously cutting the continuous web of aerosol generating substrate and the at least one susceptor patch applied to the surface thereof. The provision of a single, combined, cutting step may facilitate the mass production of aerosol generating articles.

Step (iii) may be performed using a rotary cutter unit. The rotary cutter unit may include a first cutting drum and a second cutting drum. The first cutting drum may have circumferentially extending first cutting formations. The second cutting drum may have circumferentially extending second cutting formations. The first and second cutting formations may cooperate to cut the continuous web of aerosol generating substrate and the at least one susceptor patch applied to the surface thereof to form the plurality of aerosol generating strips and the plurality of susceptor strips. The use of a rotary cutter unit allows continuous, and high-speed, manufacture of aerosol generating articles to be readily achieved.

Each of the plurality of aerosol generating strips and each of the plurality of susceptor strips has a width of between approximately <NUM> and <NUM>, possibly between approximately <NUM> and <NUM>. Each of the plurality of aerosol generating strips and each of the plurality of susceptor strips may have a width of <NUM>. These width dimensions ensure that aerosol generating articles manufactured using the method according to the present disclosure contain an optimum number of aerosol generating strips and susceptor strips to allow uniform airflow through the aerosol generating article and the generation of an acceptable quantity of vapour or aerosol. If the width of the aerosol generating strips and/or susceptor strips is too low, the strength of the strips may be reduced and, consequently, mass production of aerosol generating articles may become difficult.

Step (ii) may comprise adhering the at least one susceptor patch to the surface of the continuous web of aerosol generating substrate using an adhesive. A good bond between the susceptor patch and the continuous web of aerosol generating substrate is thereby achieved, ensuring that the continuous web of aerosol generating substrate and the adhered susceptor patch can be cut effectively and reliably during step (iii) to form the aerosol generating strips and the susceptor strips.

The method may comprise, after step (ii) and prior to step (iii), heating the adhesive to cure or set the adhesive. This may help to strengthen the bond between the susceptor patch and the continuous web of aerosol generating substrate. A trade-off is, however, needed because excessive heating may initiate the release of one or more volatile components from the aerosol generating substrate, whereas the aim is that volatile components should only be released during heating of aerosol generating articles manufactured by the method in an aerosol generating device. On the other hand, insufficient heating may not cure or set the adhesive. The heating temperature must, therefore, be carefully selected based on the characteristics of both the aerosol generating substrate and the adhesive.

The continuous web of aerosol generating substrate provided in step (i) may include a substantially flat surface which may have a centre line. Step (ii) may comprise applying the at least one susceptor patch to the substantially flat surface substantially along the centre line. Accurate and consistent positioning of the susceptor patch along the centre line ensures that aerosol generating articles manufactured by the method according to the present disclosure have consistent and repeatable characteristics.

Step (ii) may comprise consecutively applying a plurality of susceptor patches to the surface of the continuous web of aerosol generating substrate with a predefined and constant spacing between each successive susceptor patch. The predefined and constant 'spacing' between each successive susceptor patch is the shortest distance between successive (i.e., adjacent) susceptor patches, i.e., the distance or gap between the edges of successive (i.e., adjacent) susceptor patches. Step (iii) may comprise cutting the continuous web of aerosol generating substrate and the plurality of susceptor patches applied to the surface thereof to form a plurality of aerosol generating strips and a plurality of susceptor strips. The mass production of aerosol generating articles is thereby readily achieved.

The at least one susceptor patch has a length between <NUM> and <NUM>, preferably between <NUM> and <NUM>. The at least one susceptor patch may have a width between <NUM> and <NUM>, preferably between <NUM> and <NUM>. The at least one susceptor patch may have a thickness between <NUM> and <NUM>, preferably between <NUM> and <NUM>, and possibly approximately <NUM>. Susceptor patches with these dimensions are particularly suitable for the manufacture of aerosol generating articles.

The method may further comprise (v) cutting the continuous rod to form a plurality of individual aerosol generating articles. Each individual aerosol generating article may comprise a plurality of susceptor strips formed in step (iii) by cutting a single susceptor patch. Continuous and mass production of aerosol generating articles is, thereby, readily achieved.

Step (v) may comprise cutting the continuous rod at a position between the susceptor strips formed in step (iii) by cutting adjacent susceptor patches. Cutting the continuous rod in this way ensures that the individual aerosol generating articles formed by cutting the continuous rod each comprise a plurality of susceptor strips formed from an individual susceptor patch and, thus, that the aerosol generating articles are consistent and repeatable. Also, because the susceptor strips are not cut during step (v), wear during the cutting step (e.g., on a cutting unit) is minimised.

Step (v) may comprise cutting the continuous rod substantially at a midpoint between the susceptor strips formed in step (iii) by cutting adjacent susceptor patches. In this way, the ends of the susceptor strips are spaced inwardly from both ends of the resultant aerosol generating article and are not visible at either end of the aerosol generating article. This may improve the user acceptance of aerosol generating articles manufactured by the method according to the present disclosure by ensuring that the susceptor strips are not visible at a distal end of the aerosol generating articles. Furthermore, because the susceptor strips are fully embedded in the aerosol generating substrate of the resultant aerosol generating article, this may allow an aerosol or vapour to be generated more effectively because the susceptor strips are fully surrounded by the aerosol generating strips and, therefore, heat transfer from the susceptor strips to the aerosol generating strips is maximised.

The at least one susceptor patch that is cut during step (iii) to form the susceptor strips may comprise an inductively heatable susceptor material, such as one or more, but not limited, of aluminium, iron, nickel, stainless steel, carbon steel, and alloys thereof, e.g. Nickel Chromium or Nickel Copper. With the application of an electromagnetic field in its vicinity during use of the aerosol generating article in an aerosol generating device, the susceptor strips may generate heat due to eddy currents and magnetic hysteresis losses resulting in a conversion of energy from electromagnetic to heat.

The aerosol generating substrate may be any type of solid or semi-solid material. Example types of aerosol generating solids include powder, granules, pellets, shreds, strands, particles, gel, strips, loose leaves, cut leaves, cut filler, porous material, foam material or sheets. The aerosol generating substrate may comprise plant derived material and in particular, may comprise tobacco. It may advantageously comprise reconstituted tobacco, for example including tobacco and any one or more of cellulose fibres, tobacco stalk fibres and inorganic fillers such as CaCO3.

Consequently, the aerosol generating device with which the aerosol generating articles are intended for use may be referred to as a "heated tobacco device", a "heat-not-burn tobacco device", a "device for vaporising tobacco products", and the like, with this being interpreted as a device suitable for achieving these effects. The features disclosed herein are equally applicable to devices which are designed to vaporise any aerosol generating substrate.

The continuous rod may be circumscribed by a paper wrapper. Thus, the method may further comprise wrapping the continuous rod with a paper wrapper.

The aerosol generating article may be formed substantially in the shape of a stick, and may broadly resemble a cigarette, having a tubular region with an aerosol generating substrate arranged in a suitable manner. The aerosol generating article may include a filter segment, for example comprising cellulose acetate fibres, at a proximal end of the aerosol generating article. The filter segment may constitute a mouthpiece filter. The filter segment may be in coaxial alignment with the aerosol generating substrate. One or more vapour collection regions, cooling regions, and other structures may also be included in some designs.

The aerosol generating substrate may comprise an aerosol-former. Examples of aerosol-formers include polyhydric alcohols and mixtures thereof such as glycerine or propylene glycol. Typically, the aerosol generating substrate may comprise an aerosol-former content of between approximately <NUM>% and approximately <NUM>% on a dry weight basis. In some embodiments, the aerosol generating substrate may comprise an aerosol-former content of between approximately <NUM>% and approximately <NUM>% on a dry weight basis, and possibly approximately <NUM>% on a dry weight basis.

Upon heating, the aerosol generating substrate, and in particular the aerosol generating strips, may release volatile compounds. The volatile compounds may include nicotine or flavour compounds such as tobacco flavouring.

Referring initially to <FIG> and <FIG>, there is shown an aerosol generating article <NUM> for use with an aerosol generating device that comprises an induction heating system to inductively heat the aerosol generating article <NUM> and thereby generate an aerosol for inhalation by a user of the device. Such devices are known in the art and will not be described in further detail in this specification. The aerosol generating article <NUM> is elongate, having a distal end 11a and a proximal end (or mouth end) 11b, and is substantially cylindrical. The circular cross-section facilitates handling of the article <NUM> by a user and insertion of the article <NUM> into a cavity or heating compartment of an aerosol generating device.

The aerosol generating article <NUM> comprises an aerosol generating substrate <NUM> having first and second ends 10a, 10b and an inductively heatable susceptor <NUM>. The aerosol generating substrate <NUM> and the inductively heatable susceptor <NUM> are positioned in, and enclosed by, a wrapper <NUM>. The wrapper <NUM> comprises a material which is substantially non-electrically conductive and non-magnetically permeable. In the illustrated example, the wrapper <NUM> is a paper wrapper and may comprise cigarette paper.

The aerosol generating article <NUM> may have a total length, measured between the distal end 11a and the proximal (mouth) end 11b, between <NUM> and <NUM>, preferably between <NUM> and <NUM>, possibly approximately <NUM>. The aerosol generating substrate <NUM> may have a total length, measured between the first and second ends 10a, 10b, between <NUM> and <NUM>, preferably between <NUM> and <NUM>, possibly approximately <NUM>. The aerosol generating article <NUM> may have a diameter between <NUM> and <NUM>, preferably between <NUM> and <NUM>, possibly approximately <NUM>.

The aerosol generating substrate <NUM> comprises a plurality of elongate first strips <NUM> comprising an aerosol generating material. The plurality of elongate first strips <NUM> constitute aerosol generating strips <NUM> and are substantially oriented in a longitudinal direction of the aerosol generating article <NUM>. The elongate first strips <NUM> are typically foldless in the longitudinal direction to ensure that the air flow route is not interrupted and that a uniform air flow through the article <NUM> can be achieved.

The inductively heatable susceptor <NUM> comprises a plurality of elongate second strips <NUM> comprising an inductively heatable susceptor material. The plurality of elongate second strips <NUM> constitute susceptor strips <NUM> and are also substantially oriented in the longitudinal direction of the aerosol generating article <NUM>. The elongate second strips <NUM> are foldless in the longitudinal direction to prevent hot spots in the aerosol generating substrate <NUM>.

The aerosol generating article <NUM> comprises a plurality of elongate third strips <NUM> (see <FIG>) comprising an aerosol generating material. The elongate third strips <NUM> also constitute aerosol generating strips <NUM> and are substantially oriented in the longitudinal direction of the aerosol generating article <NUM>. The elongate third strips <NUM> have the same length as the elongate first strips <NUM>, and thus the aerosol generating strips <NUM> within the aerosol generating article <NUM> all have the same length. The elongate second strips <NUM> are adhered to the elongate third strips <NUM>, and the elongate second strips <NUM> and the elongate third strips <NUM> have the same width. In preferred embodiments, the elongate first strips <NUM> also have the same width as the elongate second strips <NUM> and the elongate third strips <NUM>.

The elongate first strips <NUM>, the elongate second strips <NUM> and the elongate third strips <NUM> are arranged to form a substantially rod-shaped aerosol generating article <NUM> and can be randomly distributed throughout the cross-section of the rod-shaped aerosol generating article <NUM> such that they have a plurality of different orientations within the cross-section of the aerosol generating article <NUM>. Although not apparent from <FIG>, a sufficient number of elongate first strips <NUM> are provided to substantially fill the cross-section of the aerosol generating substrate <NUM>, and it will be understood that a smaller number of elongate first strips <NUM> are shown merely for illustration purposes. It should also be noted that any suitable number of elongate second strips <NUM> can be positioned in the aerosol generating substrate <NUM>, depending on the heating requirements. Each of the elongate second strips <NUM> is advantageously surrounded by elongate first strips <NUM> thereby ensuring that heat transfer to the elongate first strips <NUM> is maximised and that the likelihood of contact between the elongate second strips <NUM> is minimised.

As best seen in <FIG>, each of the plurality of elongate first strips <NUM> has a distal end 15a and each of the plurality of elongate second strips <NUM> has a distal end 13a. The distal ends 15a of the elongate first strips <NUM> form the first end 10a of the aerosol generating substrate <NUM> and, correspondingly, the distal end 11a of the aerosol generating article <NUM>. The elongate second strips <NUM> are shorter than the elongate first strips <NUM> and the elongate third strips <NUM>. The distal ends 13a of the elongate second strips <NUM> are positioned inwardly from the distal ends 15a of the elongate first strips <NUM>. The distal ends 13a of the elongate second strips <NUM> are, therefore, not visible at the distal end 11a of the aerosol generating article <NUM>.

The aerosol generating article <NUM> comprises a mouthpiece segment <NUM> positioned downstream of the aerosol generating substrate <NUM>. The aerosol generating substrate <NUM> and the mouthpiece segment <NUM> are arranged in coaxial alignment inside the wrapper <NUM> to hold the components in position to form the rod-shaped aerosol generating article <NUM>.

In the illustrated embodiment, the mouthpiece segment <NUM> comprises the following components arranged sequentially and in co-axial alignment in a downstream direction, in other words from the distal end 11a to the proximal (mouth) end 11b of the aerosol generating article <NUM>: a cooling segment <NUM>, a center hole segment <NUM> and a filter segment <NUM>. The cooling segment <NUM> comprises a hollow paper tube 22a having a thickness which is greater than the thickness of the paper wrapper <NUM>. The center hole segment <NUM> may comprise a cured mixture containing cellulose acetate fibres and a plasticizer, and functions to increase the strength of the mouthpiece segment <NUM>. The filter segment <NUM> typically comprises cellulose acetate fibres and acts as a mouthpiece filter. As heated vapour flows from the aerosol generating substrate <NUM> towards the proximal (mouth) end 11b of the aerosol generating article <NUM>, the vapour cools and condenses as it passes through the cooling segment <NUM> and the center hole segment <NUM> to form an aerosol with suitable characteristics for inhalation by a user through the filter segment <NUM>.

The elongate first strips <NUM> and elongate third strips <NUM> typically comprise plant derived material, such as tobacco. The elongate first strips <NUM> and elongate third strips <NUM> can advantageously comprise reconstituted tobacco including tobacco and any one or more of cellulose fibres, tobacco stalk fibres and inorganic fillers such as CaCO3.

The elongate first strips <NUM> and elongate third strips <NUM> typically comprise an aerosol-former such as glycerine or propylene glycol. Typically, the elongate first strips <NUM> and elongate third strips <NUM> comprise an aerosol-former content of between approximately <NUM>% and approximately <NUM>% on a dry weight basis. Upon heating, the elongate first strips <NUM> and elongate third strips <NUM> release volatile compounds possibly including nicotine or flavour compounds such as tobacco flavouring.

When a time varying electromagnetic field is applied in the vicinity of the elongate second strips <NUM> during use of the article <NUM> in an aerosol generating device, heat is generated in the elongate second strips <NUM> due to eddy currents and magnetic hysteresis losses. The heat is transferred from the elongate second strips <NUM> to the elongate first strips <NUM> and elongate third strips <NUM> to heat the elongate first strips <NUM> and elongate third strips <NUM> without burning them to release one or more volatile compounds and thereby generate a vapour. As a user inhales through the filter segment <NUM>, the heated vapour is drawn in a downstream direction through the article <NUM> from the first end 10a of the aerosol generating substrate <NUM> towards the second end 10b of the aerosol generating substrate <NUM>, and towards the filter segment <NUM>. As noted above, as the heated vapour flows through the cooling segment <NUM> and the center hole segment <NUM> towards the filter segment <NUM>, the heated vapour cools and condenses to form an aerosol with suitable characteristics for inhalation by a user through the filter segment <NUM>.

Apparatus <NUM> and methods suitable for manufacturing aerosol generating articles according to the present disclosure, such as the aerosol generating article <NUM> described above with reference to <FIG> and <FIG>, will now be described.

Referring to <FIG>, there is shown a diagrammatic illustration of an apparatus <NUM> and method for manufacturing the aerosol generating article <NUM> described above with reference to <FIG> and <FIG>. <FIG> is a plan view of an aerosol generating substrate <NUM> and susceptor patches <NUM> as they move through the apparatus <NUM>, in the direction of the arrow in <FIG>.

The apparatus <NUM> comprises a substrate supply reel <NUM> (e.g. a first bobbin) which carries a continuous web <NUM> of an aerosol generating substrate <NUM> having a substantially flat surface and first feed rollers <NUM> for controlling the feed of the continuous web <NUM> of aerosol generating substrate <NUM>. The apparatus <NUM> may also include a web tension regulator and a web edge control system as will be understood by one of ordinary skill in the art, but these additional components are not essential in the context of the present disclosure and have, therefore, been omitted for the sake of simplicity.

The apparatus <NUM> comprises a susceptor supply reel <NUM> (e.g. a second bobbin) which carries a continuous web <NUM> of susceptor material, feed rollers <NUM>, <NUM> for controlling the feed of the continuous web <NUM> of susceptor material, an adhesive applicator unit <NUM>, and a susceptor cutting unit <NUM>.

The apparatus <NUM> further comprises an optional heater <NUM>, a strip cutting unit <NUM>, feed rollers <NUM>, a rod forming unit <NUM>, and a rod cutting unit <NUM>.

In operation, a continuous web <NUM> of aerosol generating substrate <NUM> is continuously supplied from the substrate supply reel <NUM>. At the same time, a continuous web <NUM> of susceptor material is continuously supplied from the susceptor supply reel <NUM>, via the feed rollers <NUM>, <NUM>, to the adhesive applicator unit <NUM>. The adhesive applicator unit <NUM> applies an adhesive <NUM> to a surface of the continuous web <NUM> of susceptor material. In the illustrated example, the adhesive applicator unit <NUM> applies the adhesive <NUM> to the surface of the continuous web <NUM> of susceptor material intermittently, and across the full width of the web <NUM>. In this way, discrete adhesive areas <NUM> (see <FIG> and <FIG>) are formed on the surface of the continuous web <NUM> of susceptor material, with adhesive-free areas <NUM> being formed between adjacent adhesive areas <NUM> in the direction of travel of the continuous web <NUM> of susceptor material.

The continuous web <NUM> of susceptor material is supplied from the adhesive applicator unit <NUM> to the susceptor cutting unit <NUM> which continuously cuts the continuous web <NUM> of susceptor material to form a plurality of susceptor patches <NUM>. As best seen in <FIG>, the continuous web <NUM> of susceptor material, and hence the susceptor patches <NUM>, have a width which is substantially less than a width of the continuous web <NUM> of aerosol generating substrate <NUM>. For example, the continuous web <NUM> of aerosol generating substrate <NUM> can have a width of approximately <NUM> whereas the continuous web <NUM> of susceptor material, and hence the susceptor patches <NUM>, can have a width of between approximately <NUM> and <NUM>. The susceptor patches <NUM> have a length of between approximately <NUM> and <NUM> in the direction of travel of the continuous web <NUM> of susceptor material and can have a thickness of between approximately <NUM> and <NUM>.

In order to minimise soiling of the susceptor cutting unit <NUM> by the adhesive <NUM> applied to the continuous web <NUM> of susceptor material by the adhesive applicator unit <NUM>, the susceptor cutting unit <NUM> cuts the continuous web <NUM> of susceptor material in the adhesive-free areas <NUM>, that is at positions between the adhesive areas <NUM> on the surface of the continuous web <NUM> of susceptor material. This can be achieved by synchronising the operation of the susceptor cutting unit <NUM> with the movement of the continuous web <NUM> of susceptor material.

Referring to <FIG>, the susceptor cutting unit <NUM> comprises a rotary cutting unit <NUM> comprising a support drum <NUM> and a cutting drum <NUM>. The support drum <NUM> supports the continuous web <NUM> of susceptor material around its periphery and includes a plurality of circumferentially spaced recesses <NUM> around its periphery. The support drum <NUM> is typically a suction drum and the continuous web <NUM> of susceptor material and susceptor patches <NUM> are supported around the periphery of the suction drum by a suction force applied through suction ports <NUM>. The cutting drum <NUM> includes a plurality of circumferentially spaced cutting elements <NUM>, for example projecting cutting blades, around its periphery and the cutting elements <NUM> cooperate with (e.g., extend into) the circumferentially spaced recesses <NUM> during synchronised rotation of both the support drum <NUM> and the cutting drum <NUM> in opposite directions as shown by the arrows in <FIG>. This results in continuous shear cutting of the continuous web <NUM> of susceptor material to form a plurality of susceptor patches <NUM>.

The susceptor patches <NUM> provided by the susceptor cutting unit <NUM> can be applied to the surface of the continuous web <NUM> of aerosol generating substrate <NUM> so that there is a constant and predetermined spacing <NUM> between the edges of each successive susceptor patch <NUM>, for example as shown in <FIG> and <FIG>. The constant and predetermined spacing <NUM> may, for example, be between <NUM> and <NUM>. In order to generate the constant and predetermined spacing <NUM> between the edges of adjacent susceptor patches <NUM>, the susceptor cutting unit <NUM> permits relative movement between the continuous web <NUM> of susceptor material and the support drum <NUM> for a predetermined period of time immediately after the continuous web <NUM> of susceptor material carried by the support drum <NUM> has been cut by the cutting drum <NUM> to form a susceptor patch <NUM>. This relative movement allows the continuous web <NUM> of susceptor material to remain stationary or to travel at a reduced speed for a short period of time after a susceptor patch <NUM> has been cut from the continuous web <NUM> of susceptor material. The relative movement between the continuous web <NUM> of susceptor material and the support drum <NUM> can be achieved by, for example, reducing the suction force applied to the continuous web <NUM> of susceptor material by the support drum <NUM>, whilst at the same time maintaining an adequate suction force between the already cut susceptor patches <NUM> and the support drum <NUM> to ensure that there is no relative movement between the susceptor patches <NUM> and the support drum <NUM>. In this way, a susceptor patch <NUM> that has been cut from the continuous web <NUM> of susceptor material by the susceptor cutting unit <NUM> is conveyed for a short period of time at a greater speed than the continuous web <NUM> of susceptor material from which the susceptor patch <NUM> has been cut, thereby generating the desired constant and predetermined spacing <NUM> between the edges of adjacent susceptor patches <NUM>.

The susceptor patches <NUM> with the adhesive <NUM> applied thereto are continuously and consecutively adhered to the surface of the continuous web <NUM> of aerosol generating substrate <NUM> substantially along a centre line of the continuous web <NUM>. Adjacent susceptor patches <NUM> are spaced apart in the direction of travel of the continuous web <NUM> of aerosol generating substrate by the constant and predetermined spacing <NUM> between the edges of the susceptor patches <NUM> that is generated when the susceptor patches <NUM> are formed in the susceptor cutting unit <NUM>. In order to ensure that there is adequate adhesion between the susceptor patches <NUM> and the substantially flat surface of the continuous web <NUM> of aerosol generating substrate <NUM>, the susceptor patches <NUM> can be pressed onto the substantially flat surface by a cam roller <NUM>, shown diagrammatically in <FIG>. The rotation of the cam roller <NUM> is synchronized with the movement of the continuous web <NUM> of aerosol generating substrate <NUM> so that a pressing force is applied to consecutive susceptor patches <NUM>, but not to the spaced regions between consecutive susceptor patches <NUM>.

Depending on the properties of the adhesive <NUM> applied to the continuous web <NUM> of susceptor material (and hence to the susceptor patches <NUM>) by the adhesive applicator unit <NUM>, the continuous web <NUM> of aerosol generating substrate <NUM> and the susceptor patches <NUM> adhered to the surface thereof can be heated by the optional heater <NUM>. This may help to cure or set the adhesive <NUM>, and thereby ensure a good bond between each susceptor patch <NUM> and the surface of the continuous web <NUM> of aerosol generating substrate <NUM>. The heating temperature must be carefully selected based on the characteristics of both the aerosol generating substrate <NUM> and the adhesive <NUM>, to ensure that sufficient heating is achieved to cure or set the adhesive <NUM>, whilst at the same time avoiding or at least minimising the release of volatile components from the aerosol generating substrate <NUM>.

The continuous web <NUM> of aerosol generating substrate <NUM> with the spaced susceptor patches <NUM> adhered to its surface is fed to the strip cutting unit <NUM> (best seen in <FIG>) which simultaneously cuts the continuous web <NUM> of aerosol generating substrate <NUM> and the susceptor patches <NUM> to form a plurality of continuous aerosol generating strips <NUM> and a plurality of susceptor strips <NUM>. In an embodiment, the strip cutting unit <NUM> cuts the continuous web <NUM> of aerosol generating substrate <NUM> and the susceptor patches <NUM> to form aerosol generating strips <NUM> and susceptor strips <NUM> having a strip width of approximately <NUM>. Thus, if the susceptor patches <NUM> have a width of <NUM> as discussed above, it will be understood that five susceptor strips <NUM> are formed by cutting each susceptor patch <NUM>.

The ends of the susceptor strips <NUM> formed by cutting the susceptor patches <NUM> are longitudinally spaced by the same predetermined and constant spacing <NUM> that was present between the edges of adjacent susceptor patches <NUM>. As shown in <FIG> and <FIG>, the strip cutting unit <NUM> is a rotary cutter unit <NUM> and comprises first and second cutting drums <NUM>, <NUM>. The first cutting drum <NUM> includes circumferentially extending first cutting formations <NUM> and the second cutting drum <NUM> includes circumferentially extending second cutting formations <NUM>. The first and second cutting formations <NUM>, <NUM> cooperate (e.g., intermesh) to shear cut the continuous web <NUM> of aerosol generating substrate <NUM> and the susceptor patches <NUM> in the direction of travel of the continuous web <NUM> to form the plurality of aerosol generating strips <NUM> and the plurality of susceptor strips <NUM>. As will be appreciated from <FIG> and <FIG>, the aerosol generating strips <NUM> formed by cutting the central region of the continuous web <NUM> of aerosol generating substrate <NUM> with susceptor patches <NUM> adhered to its surface have susceptor strips <NUM> (i.e., elongate second strips <NUM>) adhered to them, and it is the aerosol generating strips <NUM> formed by cutting this central region that constitute the elongate third strips <NUM>. On the other hand, the aerosol generating strips <NUM> formed by cutting the side regions of the continuous web <NUM> of aerosol generating substrate <NUM>, on opposite sides of the susceptor patches <NUM>, do not have susceptor strips <NUM> adhered to them and it is the aerosol generating strips <NUM> formed by cutting these side regions that constitute the elongate first strips <NUM>.

The aerosol generating strips <NUM> and the susceptor strips <NUM> are conveyed to the rod forming unit <NUM> where they are formed into a continuous rod <NUM>. If desired, a continuous sheet of wrapping paper (not shown) can be supplied to the rod forming unit <NUM> from a supply reel (not shown) or can be supplied to a separate wrapping unit (again from a supply reel) which can be positioned downstream of the rod forming unit <NUM>. As the sheet of wrapping paper is transported and guided through the rod forming unit <NUM> or the separate wrapping unit, it can be wrapped around the aerosol generating strips <NUM> and the susceptor strips <NUM> so that the continuous rod <NUM> is circumscribed by a wrapper <NUM>.

The continuous rod <NUM> (optionally circumscribed by a wrapper <NUM>) is then transported to the rod cutting unit <NUM> where it is cut at appropriate positions into predetermined lengths to form multiple aerosol generating articles <NUM>. The aerosol generating articles <NUM> formed by the rod cutting unit <NUM> may have a length between <NUM> and <NUM>, preferably between <NUM> and <NUM>. It will be understood that this length corresponds to the length of the aerosol generating substrate <NUM> described above with reference to <FIG> and <FIG>. The continuous rod <NUM> is preferably cut repeatedly by the rod cutting unit <NUM> substantially at a midpoint between the ends of the susceptor strips <NUM> formed by cutting consecutive susceptor patches <NUM>. In this way, the susceptor strips <NUM> are not cut by the rod cutting unit <NUM>, thereby reducing wear on the cutting elements. Further, because the susceptor strips <NUM> are shorter than the aerosol generating strips <NUM>, the ends of the susceptor strips <NUM> are not visible at either end of the aerosol generating articles <NUM> formed by the rod cutting unit <NUM>. It will be understood that this type of method is particularly suitable for the mass production of aerosol generating articles <NUM>.

Further units (not shown) may be arranged downstream of the rod cutting unit <NUM> and may be configured to provide one or more additional components such as the mouthpiece segment <NUM> described above and to assemble these with the individual aerosol generating articles <NUM> formed by the rod cutting unit <NUM> to form finished aerosol generating articles <NUM>, for example of the type illustrated in <FIG>. In this case, a separate wrapping unit may be provided downstream of the rod cutting unit <NUM> so that the assembled components can be simultaneously wrapped to form the finished aerosol generating articles <NUM>. The further units may form part of the apparatus <NUM> or may be separate, stand-alone, units forming part of a final assembly line.

Although exemplary embodiments have been described in the preceding paragraphs, it should be understood that various modifications may be made to those embodiments without departing from the scope of the appended claims. Thus, the breadth and scope of the claims should not be limited to the above-described exemplary embodiments.

Claim 1:
A method for continuously manufacturing aerosol generating articles (<NUM>), the method comprising:
(i) providing a continuous web (<NUM>) of an aerosol generating substrate (<NUM>);
(ii) applying at least one susceptor patch (<NUM>) to a surface of the continuous web (<NUM>) of aerosol generating substrate (<NUM>);
(iii) cutting the continuous web (<NUM>) of aerosol generating substrate (<NUM>) and the at least one susceptor patch (<NUM>) applied to the surface thereof to form a plurality of aerosol generating strips (<NUM>) and a plurality of susceptor strips (<NUM>); and
(iv) forming the plurality of aerosol generating strips (<NUM>) and the plurality of susceptor strips (<NUM>) into a continuous rod (<NUM>);
wherein each of the plurality of aerosol generating strips (<NUM>) and each of the plurality of susceptor strips (<NUM>) has a width of between <NUM> and <NUM>; or
wherein the at least one susceptor patch (<NUM>) has a length of between <NUM> and <NUM>.