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 substrate, without burning the aerosol generating substrate, to volatise at least one component of the aerosol generating substrate 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. Because the aerosol generating strips are formed during step (iii) without cutting the at least one susceptor patch, wear during the cutting step (e.g., on a cutting unit) is minimised. The combination of aerosol generating strips and a susceptor (formed without cutting the susceptor patch into strips) in aerosol generating articles produced by the method according to the present disclosure provides effective heat transfer from the susceptor 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.

Accurate and consistent positioning of the at least one susceptor patch along the centre line of the substantially flat surface of the continuous web of aerosol generating substrate further helps to ensure that aerosol generating articles manufactured by the method according to the present disclosure have consistent and repeatable characteristics.

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 exposed regions of the continuous web of aerosol generating substrate to form the plurality of aerosol generating strips. The use of a rotary cutter unit allows continuous, and high-speed, manufacture of aerosol generating articles to be readily achieved.

The first cutting drum and the second cutting drum may define therebetween a non-cutting region. The non-cutting region may accommodate the at least one susceptor patch and a part of the aerosol generating substrate to which the at least one susceptor patch is applied during step (ii). The provision of a non-cutting region ensures that the susceptor patch and underlying part of the aerosol generating substrate (which acts as an elongate carrier strip for the susceptor patch) are not cut whilst assuring that high-speed manufacture is obtained.

The first cutting drum may be formed without the first cutting formations in the non-cutting region. For example, the first cutting drum may include a circumferentially extending recess in its surface in the non-cutting region. The second cutting drum may be formed without the second cutting formations in the non-cutting region. For example, the second cutting drum may include a circumferentially extending recess in its surface in the non-cutting region. In some embodiments, both of the first and second cutting drums may be formed respectively without the first and second cutting formations in the non-cutting region. In some embodiments, at least part of the at least one susceptor patch may be accommodated in the circumferentially extending recess. These arrangements reliably ensure that the susceptor patch and underlying part of the aerosol generating substrate (i.e., the elongate carrier strip) are not cut during step (iii) and that high-speed manufacture is obtained.

Each of the plurality of aerosol generating strips has a width of between approximately <NUM> and <NUM>, possibly between approximately <NUM> and <NUM>. Each of the plurality of aerosol generating 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 a suitable number of aerosol generating 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 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 substantially flat 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 susceptor patch does not move relative to the continuous web of aerosol generating substrate. This in turn may help to ensure that only the exposed regions of the continuous web of aerosol generating substrate are cut during step (iii) to form the aerosol generating strips.

Step (ii) may comprise consecutively applying a plurality of susceptor patches to the substantially flat 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 exposed regions of the continuous web of aerosol generating substrate to form a plurality of aerosol generating strips on each side of the susceptor patches. Step (iv) may comprise forming the plurality of aerosol generating strips and the susceptor patches into a continuous rod. 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>, 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 at least one susceptor patch. Thus, step (v) may comprise cutting the continuous rod to form a plurality of individual aerosol generating articles each comprising at least one 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 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 susceptor patch and, thus, that the aerosol generating articles are consistent and repeatable. Also, because the susceptor patches 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 adjacent susceptor patches. In this way, the susceptor is spaced inwardly from both ends of the resultant aerosol generating article and is 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. Furthermore, the susceptor is fully embedded in the aerosol generating substrate (i.e., aerosol generating strips) of the resultant aerosol generating article, and this may allow an aerosol or vapour to be generated more effectively because the whole of the susceptor is surrounded by the aerosol generating strips and, therefore, heat transfer from the susceptor to the aerosol generating strips is maximised.

Each susceptor patch 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 material 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 and may be in coaxial alignment with an aerosol generating substrate constituted by the plurality of aerosol generating strips. One or more vapour collection regions, cooling regions, and other structures may also be included in some designs. For example, the aerosol generating article may include at least one tubular segment upstream of the filter segment. The tubular segment may act as a vapour cooling region. The vapour cooling region may advantageously allow the heated vapour generated by heating the aerosol generating strips to cool and condense to form an aerosol with suitable characteristics for inhalation by a user, for example through the filter segment.

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 (i.e., 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 example of 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 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 and 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 an elongate second strip <NUM> comprising an inductively heatable susceptor material. The elongate second strip <NUM> can, therefore, be regarded as a strip-shaped or blade-shaped elongate susceptor <NUM> which is also substantially oriented in the longitudinal direction of the aerosol generating article <NUM>. As can be clearly seen in <FIG>, each of the elongate first strips <NUM> has a width which is less than a width of the elongate second strip <NUM>.

The aerosol generating article <NUM> comprises at least one elongate carrier strip <NUM> having first and second major surfaces 17a, 17b. The elongate carrier strip <NUM> comprises an aerosol generating material and, thus, also constitutes an aerosol generating strip <NUM>. The elongate carrier strip <NUM> is substantially oriented in the longitudinal direction of the aerosol generating article <NUM>. The elongate carrier strip <NUM> has 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 strip <NUM> is adhered to the elongate carrier strip <NUM> and, as can be clearly seen in <FIG>, the elongate carrier strip <NUM> has a width which is greater than the width of the elongate second strip <NUM>. The elongate second strip <NUM> has first and second opposite faces 13b, 13c. The second face 13c is adhered to the second major surface 17b of the elongate carrier strip <NUM> and is covered in its entirety by the elongate carrier strip <NUM>, and more particularly by the second major surface 17b.

The elongate first strips <NUM>, the elongate second strip <NUM> and the elongate carrier strip <NUM> are arranged to form a substantially rod-shaped aerosol generating article <NUM> and the elongate first strips <NUM> 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. The elongate second strip <NUM> and the elongate carrier strip <NUM> are positioned roughly centrally within the cross-section of the aerosol generating substrate <NUM>, and hence the aerosol generating article <NUM>. Such an arrangement helps to ensure that there is uniform heat transfer from the elongate second strip <NUM> to the elongate first strips <NUM>.

As best seen in <FIG>, the centrally positioned elongate carrier strip <NUM> and the elongate second strip <NUM> adhered thereto define first and second regions <NUM>, <NUM> within the cross-section of the aerosol generating substrate <NUM> and, hence, within the cross-section of the aerosol generating article <NUM>. The first region <NUM> faces the first major surface 17a of the elongate carrier strip <NUM> and the second region <NUM> faces the second major surface 17b of the elongate carrier strip <NUM>. The first and second regions <NUM>, <NUM> both include a plurality of elongate first strips <NUM>.

As best seen in <FIG>, each of the plurality of elongate first strips <NUM> has a distal end 15a and the elongate second strip <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 strip <NUM> is shorter than the elongate first strips <NUM> and the elongate carrier strip <NUM>. The distal end 13a of the elongate second strip <NUM> is positioned inwardly from the distal ends 15a of the elongate first strips <NUM>. The distal end 13a of the elongate second strip <NUM> (i.e., the elongate susceptor <NUM>) is, 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 the elongate carrier strip <NUM> typically comprise plant derived material, such as tobacco. The elongate first strips <NUM> and the elongate carrier strip <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 the elongate carrier strip <NUM> typically comprise an aerosol-former such as glycerine or propylene glycol. Typically, the elongate first strips <NUM> and the elongate carrier strip <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 the elongate carrier strip <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 strip <NUM> during use of the article <NUM> in an aerosol generating device, heat is generated in the elongate second strip <NUM> due to eddy currents and magnetic hysteresis losses. The heat is transferred from the elongate second strip <NUM> to the elongate first strips <NUM> and the elongate carrier strip <NUM> to heat the elongate first strips <NUM> and the elongate carrier strip <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 with a centre line <NUM> 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>. As will become apparent from the description below, each susceptor patch <NUM> corresponds to the elongate second strip <NUM> (i.e., the elongate susceptor <NUM>) in the finished aerosol generating article <NUM> described above with reference to <FIG> and <FIG>.

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 flat surface of the continuous web <NUM> of aerosol generating substrate <NUM> substantially along the centre line <NUM>. Exposed side regions <NUM> of the continuous web <NUM> of aerosol generating substrate are thereby formed on both sides of the susceptor patches <NUM> (see <FIG>) because, as noted above, the continuous web <NUM> of aerosol generating substrate <NUM> is substantially wider than the susceptor patches <NUM>. Adjacent susceptor patches <NUM> are also spaced apart in the direction of travel of the continuous web <NUM> of aerosol generating substrate <NUM> 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 flat 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 flat surface is fed to the strip cutting unit <NUM>. The strip cutting unit <NUM> cuts only the exposed side regions <NUM> of the continuous web <NUM> of aerosol generating substrate <NUM>, without cutting the susceptor patches <NUM>, to form a plurality of continuous aerosol generating strips <NUM> alongside the susceptor patches <NUM>. In an embodiment, the strip cutting unit <NUM> cuts the exposed side regions <NUM> of the continuous web <NUM> of aerosol generating substrate <NUM> to form aerosol generating strips <NUM> having a strip width of approximately <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 exposed side regions <NUM> of the continuous web <NUM> of aerosol generating substrate <NUM> in the direction of travel of the continuous web <NUM> to form the continuous aerosol generating strips <NUM>, and specifically to form the elongate first strips <NUM> illustrated in <FIG> and <FIG>.

In order to provide for cutting of only the exposed side regions <NUM> of the continuous web <NUM> of aerosol generating substrate <NUM> to form the elongate first strips <NUM>, the first and second cutting drums <NUM>, <NUM> define therebetween a non-cutting region <NUM> which accommodates the susceptor patch <NUM> and the part of the continuous web <NUM> of aerosol generating substrate <NUM> to which the susceptor patch <NUM> is adhered. In the illustrated embodiment, the first cutting drum <NUM> is formed without the first cutting formations <NUM> in the non-cutting region <NUM>. Similarly, the second cutting drum <NUM> is also formed without the second cutting formations <NUM> in the non-cutting region <NUM>. Furthermore, the first cutting drum <NUM> includes a circumferentially extending recess <NUM> in its surface in the non-cutting region <NUM>, so that at least part of the susceptor patch <NUM> can be accommodated in the circumferentially extending recess <NUM> during cutting of the exposed side regions <NUM> of the continuous web <NUM> of aerosol generating substrate <NUM>. It will, thus, be understood that when the exposed side regions <NUM> of the continuous web <NUM> of aerosol generating substrate <NUM> are cut to form the elongate first strips <NUM> by virtue of the cooperation between the first and second cutting formations <NUM>, <NUM> on the first and second cutting drums <NUM>, <NUM> respectively, the central portion of the continuous web <NUM> of aerosol generating substrate <NUM> that is accommodated in the non-cutting region <NUM> and that is not cut into strips constitutes the elongate carrier strip <NUM> described above with reference to <FIG>.

The aerosol generating strips <NUM> formed by cutting the exposed side regions <NUM> of the continuous web <NUM> of aerosol generating substrate <NUM>, the elongate carrier strip <NUM> and the adhered susceptor patches <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 patches <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 edges of the susceptor patches <NUM>. In this way, the susceptor patches <NUM> are not cut by the rod cutting unit <NUM>, thereby reducing wear on the cutting elements. Further, because the susceptor patches <NUM> are shorter than the aerosol generating strips <NUM>, the ends of the individual susceptor patches <NUM> (i.e., the elongate second 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>), the continuous web (<NUM>) including a substantially flat surface having a centre line (<NUM>);
(ii) applying at least one susceptor patch (<NUM>) to the substantially flat surface substantially along the centre line (<NUM>) to leave an exposed region (<NUM>) of the continuous web (<NUM>) of aerosol generating substrate (<NUM>) on each side of the at least one susceptor patch (<NUM>);
(iii) cutting the exposed regions (<NUM>) of the continuous web (<NUM>) of aerosol generating substrate (<NUM>) to form a plurality of aerosol generating strips (<NUM>, <NUM>) on each side of the at least one susceptor patch (<NUM>); and
(iv) forming the plurality of aerosol generating strips (<NUM>, <NUM>) and the at least one susceptor patch (<NUM>) into a continuous rod (<NUM>);
wherein each of the plurality of aerosol generating strips (<NUM>, <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>.