Patent Application
20240245098
The present invention relates to a method for producing a plurality of aerosol-generating articles comprising a substrate section with an aerosol-forming substrate and a susceptor element. The present invention further relates to a system configured for producing the plurality of individual aerosol-generating articles. The present invention further relates to an aerosol-generating article comprising a substrate section with aerosol-forming substrate and a susceptor element.
A lot of aerosol-generating articles, in particular heat-not-burn articles comprise a substrate section comprising aerosol-forming substrate and additional susceptor material. The susceptor is able to heat the aerosol-forming substrate to a temperature below combustion temperature of the substrate when subjected to an alternating electromagnetic field. During the production of the aerosol-generating articles a continuous substrate section including multiple individual substrate sections is produced, also containing a continuous band of susceptor material integrated within the aerosol-forming substrate. When cutting the continuous substrate sections in order to produce the individual substrate sections for the aerosol-generating articles, a rotating cutting tool often impinges on the continuous substrate section with great momentum. This great momentum is necessary in order to cut simultaneously through the aerosol-forming substrate and the continuous band of susceptor material, which is often a metal or a metal alloy. This however can lead to a deformation or dislocation of the band of susceptor material within the individual aerosol-generating articles. In a substrate section having a length of 12 mm, the impact of the rotating cutting tool can move the susceptor band around 1.8 mm and can lead to deformations of up to 1 mm. These deformations and dislocations might impact the ability of the susceptor material to be heated when subjected to the alternating electromagnetic field. Additionally, the susceptor also may touch the wrapping paper surrounding the substrate section. This may result in the susceptor burning the wrapping paper during use, which may be undesirable. A dislocated susceptor protruding from the end faces of the substrate section furthermore may impact the connection process of further sections, such as filter plugs or hollow filter plugs to the substrate section. Operating the cutting tools with higher impact can also affect the service life of the cutting tools.
It would be desirable to provide a method for producing a plurality of aerosol-generating articles and a system configured for producing the plurality of individual aerosol-generating articles, which are able to avoid or alleviate a deformation or dislocation of the susceptor element. Furthermore, it would be desirable to provide a method and a system for producing aerosol-generating articles which can increase the service life of the cutting tools.
According to an embodiment of the present invention a method for producing individual aerosol-generating articles each article comprising an individual substrate section and the substrate section comprising aerosol-forming substrate with a susceptor is provided. The method may comprise a method step A) of providing a continuous band of susceptor material. The method may comprise a method step B) of partially cutting the continuous band of susceptor material at a predetermined precut position to produce a partially cut band of susceptor material. A method step C) may be included. This method step C) may comprise producing the aerosol-generating articles employing the partially band of susceptor material, wherein the precut position separates individual aerosol-generating articles from each other.
According to another embodiment of the present invention, a method for producing individual aerosol-generating articles is provided. Each aerosol-generating article comprises an individual substrate section and the substrate section comprises aerosol-forming substrate with a susceptor element. The method comprises the method steps of:
The partially cut band of susceptor material may more easily be separated by a cutting tool at the precut position. This may be due to the partial cut introduced at the precut position. Completely cutting the partially cut band of susceptor material at the precut position may require less momentum of the cutting tool. This may reduce the danger of deformations or dislocations of the susceptor material within the substrate section.
At least two precut positions may be formed in method step B). The positions of the precuts on the continuous band of susceptor material may be set in such a way that one individual substrate section is located between adjacent precut positions. Analogously one individual susceptor element corresponding to one individual substrate section may be located between adjacent precut positions.
This may enable the easy formation of individual substrate sections by cutting adjacent precut positions on the partially cut band of susceptor material. In particular, one individual substrate section may comprise one individual susceptor element. One individual susceptor element may be located between adjacent precut positions.
A plurality of precut positions may be formed on the continuous band of susceptor material. If one individual susceptor element is located between adjacent precut positions, the plurality of precut positions may allow the easy formation of a plurality of individual susceptor elements by cutting the band of susceptor material at the plurality of precut positions.
The plurality of precut positions may separate at least 50 individual susceptor elements, preferably between 10 and 50 individual susceptor elements from each other. Most preferably the plurality of precut positions separates 10 individual susceptor elements from each other
During method step C) the aerosol-forming substrate may be positioned around the partially cut band of susceptor material in a first embodiment. This may produce a continuous substrate section comprising the partially cut band of susceptor material. Subsequently the continuous substrate section may be cut at the precut position in order to produce individual aerosol-generating articles.
A continuous substrate section comprising the partially cut band of susceptor material may be easier to cut at the precut positions compared to a continuous substrate section, including a continuous band of susceptor material without a precut.
During method step B) a plurality of precuts may be formed. During method step C) the continuous substrate section may then be cut at all precut positions. This may produce a plurality of individual substrate sections, wherein each individual substrate section may comprise an individual susceptor element.
Otherwise during method step C) the continuous substrate section may be cut at some precut positions. This may provide a plurality of multiple substrate sections. These multiple substrate sections may be further processed in order to produce aerosol-generating articles. The multiple substrate sections may each comprise a band of susceptor material, which still may include precut positions. One multiple substrate section may contain at least two, more preferably at least 5, or at least 10 individual substrate sections.
In another embodiment of the method of the invention during method step C) the partially cut band of susceptor material may be completely cut at the predetermined precut position. This may produce individual susceptor elements. Subsequently the aerosol-forming substrate may be positioned around the individual susceptor elements. This may produce a continuous substrate section including individual susceptor elements. The individual susceptor elements may be spaced apart from each other. The individual susceptor elements therefore may not contact each other in the continuous substrate section.
During method step C) the individual susceptor elements in the continuous substrate section may each be spaced apart by gaps. Subsequently the continuous substrate section may be cut between the gaps of individual susceptor bands, thereby producing individual substrate sections.
Such a continuous substrate section with individual susceptor elements may also ease the final cutting of the continuous substrate section. In particular, a cutting tool may only be required to cut through the aerosol-forming substrate in the continuous substrate section between individual susceptor elements without simultaneously cutting through the band of susceptor material. This may ease the cutting process and may not require as much force as cutting through the aerosol-forming substrate and the band of susceptor material. This may therefore reduce the risk of deformations and dislocations of the individual susceptor elements within the individual substrate sections. This may also increase the service life of the cutting tool.
During method step B) the continuous band of susceptor material may be partially cut by introducing incisions at the edge of the band. Subsequently during method step C) the partially cut band may be completely cut in a central part of the band adjacent to the incisions to produce the individual susceptor elements.
This may enable completely cutting the continuous band of susceptor material in order to produce individual susceptor elements. This method in particular may require less force applied by the cutting tool compared to a method wherein the continuous band of susceptor material is completely cut in one step. This method may avoid deformations of the individual susceptor elements. The individual susceptor elements subsequently then may be incorporated into the continuous substrate section comprising the individual susceptor elements.
The method of the present invention in general may provide two different alternative embodiments. One preferred first embodiment may be provided, wherein the partially cut band of susceptor material with the precuts is incorporated into aerosol-forming substrate. This produces a continuous substrate section comprising the partially cut band of susceptor material. This continuous substrate section can easily be further cut into individual substrate sections due to the precut positions.
The other embodiment of the method of the present invention may provide a method wherein the partially cut band of susceptor material may be cut completely at the precut positions into individual susceptor elements. These individual susceptor elements subsequently may be incorporated into aerosol-forming substrate. This may produce a continuous substrate section comprising the individual susceptor elements. This method also enables an easy cutting of continuous substrate section since the cutting tool only may have to cut the aerosol forming substrate of the substrate section located between the individual susceptor elements. This method of the invention may not cut through susceptor material.
Individual susceptor elements produced by completely cutting the partially cut band of susceptor material may have a susceptor element length being smaller than the substrate section length of the finished individual substrate sections.
For example, the susceptor element length may be around 5 percent, or around 10 percent smaller than the substrate section length. This may enable positioning individual susceptor elements within the aerosol-forming substrate of the substrate section without any susceptor material being present at the end faces of the individual substrate sections. The individual susceptor elements therefore may be centrally positioned within the aerosol-forming substrate of the substrate section.
This may enable the production of substrate sections incorporating less susceptor material. This also may produce less waste after consumption of the aerosol-generating articles.
In the embodiment of method of the invention, where the partially cut band of susceptor material is completely cut at the precut position in order to produce individual susceptor elements before incorporation of the susceptor elements in the aerosol-forming substrate, the method may further comprise increasing a gap between adjacent susceptor elements. This may be done by transporting the individual susceptor elements on an accelerating belt. In particular, the partially cut band of susceptor material may be transported on a first belt and the individual susceptor elements may be transported on an accelerating belt as a second belt. The velocity of the second belt may be higher than the velocity of the first belt. The velocity of the second belt may be between 10 percent and 30 percent, preferably 20 percent higher than the velocity of the first belt. This may increase the gaps between individual adjacent susceptor elements.
If the gaps between individual adjacent susceptor elements are increased, it may be easier to produce the individual substrate sections by cutting through the gaps of the individual adjacent susceptor elements after they have been integrated into a continuous substrate section. In particular, if the gaps are larger, the positioning of the cutting tool relative to the continuous substrate section for cutting through the gaps may not be so critical. In the case of some misalignments between the later complete cut in method step C) to produce individual substrate sections and the final cut of the continuous substrate section larger gaps between the individual adjacent susceptor elements within the continuous substrate section may still enable a reliable cutting of the continuous substrate section through the gaps.
Partially cutting in method step B) may comprise one or more of: producing perforations in the continuous band of susceptor material, producing incisions at one or both edges of the continuous band of susceptor material, or producing a plurality of recesses in the band of susceptor material.
These methods for partially cutting the continuous band of susceptor material may be particularly suitable in order to weaken the susceptor material at the precut positions. This may further alleviate providing the final cut at the precut positions with reduced force.
The continuous band of susceptor material may comprise a width. The continuous band of susceptor material may comprise a central longitudinal axis. The continuous band of susceptor material may extend along its central longitudinal axis. The precut or the plurality of precuts may be produced in the band in between a quarter and half of the width of the continuous band of susceptor material. Preferably, the precut may be produced at opposing edges of the continuous band of susceptor material and may extend towards the central longitudinal axis of the band.
During method step C) the continuous substrate portion may be overwrapped with wrapping material, preferably paper.
Providing the wrapping material around the continuous substrate section may produce a rod-shaped continuous substrate section, wherein the wrapping material stabilizes the substrate section. As already mentioned above, the continuous substrate section may either contain a continuous partially cut band of susceptor material or individual susceptor elements, which may be spaced apart within the continuous substrate section.
During method step C) one of the partially cut continuous band of susceptor material or the individual susceptor elements may be transported through a funnel shaped guide element. The guide element may be configured for positioning the aerosol-forming substrate around the one of the partially cut continuous band or the individual susceptor elements.
The funnel shaped guide element may be configured for compressing aerosol-forming substrate around one of the partially cut continuous band of susceptor material or the individual susceptor elements. This may produce a continuous substrate section, which either may comprise the partially cut continuous band of susceptor material or the individual susceptor elements.
During one or both of methods steps B) and method step C) one of the partially cut continuous band of susceptor material or the individual susceptor elements may be transported on a transport device. The transport device may comprise a belt, preferably a toothed belt, more preferably a U-shaped toothed belt.
Such a belt, preferably the toothed belt may be particularly well suited in order to transport either the partially cut continuous band of susceptor material or the individual susceptor elements. These special belts also may be particularly well configured for transporting the continuous substrate section after the band of susceptor material or the individual susceptor elements have been incorporated into the aerosol-forming substrate.
The toothed belt may include U-shaped grooves which may run parallel to the transport direction of the toothed belt. These U-shaped grooves may be configured to accommodate the continuous substrate section, in particular a rod-shaped continuous substrate section.
The toothed belt may be produced from flexible polymers, such as rubber or other flexible polymers such as nylon or aramid-fibers.
During method step B) the continuous band of susceptor material may be guided through at least one rotating knife drum or rotating drums with punching tools. This may allow for a partial cutting of the continuous band of susceptor material.
In particular, at least one of the rotating knife drum or rotating drums with punching tools may be able to partially cut the continuous band of susceptor material at a predetermined precut position. This predetermined precut position may be at the opposing edges of the band or at predetermined positions on the band. For example, a rotating knife drum or rotating drums with punching tools may be located on the opposing edges of the band configured for producing the precuts in the opposing edges of the band of susceptor material. These precuts may, as already described above, only cover a small part of the width of the band of susceptor material, for example between a quarter and half of the width. Alternatively, the precut may extend along a large part or over the complete length of the width of the band of susceptor material. For example, a perforating line may be formed in the continuous band of susceptor material. This may be done by employing rotating drums with punching tools.
During method step C) the individual susceptor elements may remain positioned centrally within the individual substrate sections after cutting.
In particular, an individual substrate section may include an individual central longitudinal axis. The individual substrate section may be rod-shaped. Similarly, the continuous substrate section may include a continuous central longitudinal axis. The individual susceptor elements may be positioned in such a way within the continuous substrate section that the individual susceptor elements are arranged along the continuous central longitudinal axis, preferably wherein the individual susceptor elements may be located in a plane, wherein the continuous central longitudinal axis also runs within that plane.
Owing to the precut positions, individual substrate sections can be produced by completely cutting the continuous substrate section either through the gaps between adjacent individual susceptor elements or at the precuts without applying too much force. Thus, individual susceptor elements may remain positioned centrally within the individual substrate sections after cutting.
Consequently, individual susceptor elements within an individual substrate section may retain their position after cutting. Therefore, and individual susceptor element after cutting may be located in a plane, wherein the individual central longitudinal axis of the substrate section also may run within that plane.
Individual susceptor elements which are located centrally within the individual substrate sections may easier and more reliably be heated by applying an external alternating electromagnetic field.
During method step B) flat regions on opposing edges of the continuous band of susceptor material may be removed as partial cuts. This may create a central linking part connecting different adjacent parts of the partially cut band of susceptor material.
This may create precuts in the partially cut band of susceptor material which may occupy a larger area on the partially cut band. In case of a misalignment between the precut and the final cut, the final cut may still cut through the central linking part. Thus, creating precuts occupying a larger area on the partially cut band may allow for a greater tolerance of misalignments between the precuts and the final cuts.
During method step C) a detection device may be employed for detection of one of the positions of the precuts on the continuous band of susceptor material or for the position of the gaps between the plurality of individual susceptor elements. The detection device may be selected from a group consisting of: x-ray device, induction sensor, infrared camera analyzer, device for measuring impedance.
These detection devices may be configured to detect the precut positions either on the continuous band of susceptor material incorporated into the continuous substrate section or the gaps between the plurality of individual susceptor elements in the continuous substrate section. Alternatively note detection device may be present. Instead, the main machine drive of a system for producing the aerosol-generating articles may allow for synchronization of the precuts with the final cuts.
During method step C) the continuous substrate section may be cut by a rotating blade. This may enable the cutting in order to produce either multiple substrate sections, which may contain for example up to 10 individual substrate sections. Alternatively, the rotating blade may cut the continuous substrate section into individual substrate sections containing individual susceptor elements.
The continuous band of susceptor material may have an elongate, flat shape. In particular, the continuous band of susceptor material may comprise a continuous band with opposing edges. The individual susceptor elements cut from the continuous band of susceptor material also may have an elongate, flat shape. The individual susceptor elements may have with and may have a length. The ratio of the length to the width in the individual susceptor elements may be between 1.5 to 4.5, preferably between 1.8 to 3.5, more preferably between 1.9 to 2.5. In one embodiment, the length of an individual susceptor element may be between 9 mm to 12 mm and the width may be between 3 mm to 6 mm, preferably the length may be between 10 to 12 mm and the width may be between 4 to 5 mm.
The length of the substrate section may be between 10 to 15 mm, preferably 12 mm. A multiple substrate section containing 10 individual substrate sections therefore may have a length of 120 mm, if one single substrate section has a length of 12 mm.
In general, the susceptor element comprises or is made of a material that is capable of generating heat, when penetrated by an alternating magnetic field. If the susceptor element is conductive, then typically eddy currents are induced by the alternating magnetic field. If the susceptor element is magnetic, then typically another effect that contributes to the heating is commonly referred to hysteresis losses. Hysteresis losses occur mainly due to the movement of the magnetic domain blocks within the material of the susceptor element, because the magnetic orientation of these will align with the magnetic induction field, which alternates. Another effect contributing to the hysteresis loss is when the magnetic domains will grow or shrink within the material of the susceptor element. Commonly all these changes in the material of the susceptor element that happen on a nano-scale or below are referred to as “hysteresis losses”, because they produce heat in the material of the susceptor element. Hence, if the susceptor is both magnetic and electrically conductive, both hysteresis losses and the generation of eddy currents will contribute to the heating of the susceptor element. If the material of the susceptor element is magnetic, but not conductive, then hysteresis losses will be the only means by which the susceptor element will heat, when penetrated by an alternating magnetic field. According to the invention, the material of the susceptor element may be magnetic and electrically conductive.
The susceptor material may for example comprise a ferromagnetic material. Preferably the susceptor material may comprise a ferromagnetic alloy. More preferably the susceptor material may comprise ferritic iron, in particular a ferromagnetic steel or stainless steel.
The susceptor element comprising the susceptor material may heat the aerosol-forming substrate surrounding the susceptor element.
As used herein, the term ‘aerosol-forming substrate’ relates to a substrate capable of releasing one or more volatile compounds that can form an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. An aerosol-forming substrate may conveniently be part of an aerosol-generating article or smoking article.
The aerosol-forming substrate may be a solid aerosol-forming substrate. The aerosol-forming substrate may comprise both solid and liquid components. The aerosol-forming substrate may comprise a tobacco-containing material containing volatile tobacco flavour compounds which are released from the substrate upon heating. The aerosol-forming substrate may comprise a non-tobacco material. The aerosol-forming substrate may comprise an aerosol former that facilitates the formation of a dense and stable aerosol. Suitable aerosol-formers are well known in the art and include, but are not limited to: polyhydric alcohols, such as triethylene glycol, 1,3-butanediol and glycerine; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetra-decanedioate. Aerosol formers may be polyhydric alcohols or mixtures thereof, such as triethylene glycol, 1,3-butanediol and glycerine. The aerosol-former may be propylene glycol. The aerosol former may comprise both glycerine and propylene glycol.
In a method step D) after method step C) one or both of filter sections and hollow plug sections may be connected to one of: individual substrate sections or multiple substrate sections. This method step D) may result in a final aerosol-generating article. This aerosol-generating article may comprise a substrate section including aerosol-forming substrate with the susceptor element and additionally one or both of a filter section and a hollow plug section.
Preferably, the filter section and the hollow plug section are located downstream of the substrate section in the aerosol-forming article. If both of a filter section and a hollow plug section are present, the hollow plug section may be located between the filter section and the substrate section in the aerosol-forming article. Alternatively, the aerosol-forming article may be formed of only the substrate section.
The aerosol-forming article may be inserted into the cavity of an aerosol-generating device. The aerosol-generating device furthermore may comprise a heating element. The heating element may include an inductive coil for heating the susceptor material via inductive heating.
Inductive heating may be more efficient if the susceptor element included in the substrate section of the aerosol-forming article is not deformed and is positioned centrally within the aerosol-forming substrate of the substrate section. In particular, eddy currents induced in the susceptor element by the inductive coil also depend on the shape of the susceptor element and its position relative to the heating element of the aerosol-generating device. Therefore, producing an aerosol-generating article including a susceptor element with a uniform shape and position within the substrate section may greatly enhance the efficiency of the inductive heating.
As used herein, the terms “upstream”, and “downstream”, are used to describe the relative positions of components, or portions of components, of the aerosol-generating article or the aerosol-generating device in relation to the direction in which air flows through the aerosol-generating article or aerosol-generating device during use thereof along the air flow path. Aerosol generating articles according to the invention comprise a proximal end through which, in use, an aerosol exits the device. The proximal end of the aerosol generating article may also be referred to as the mouth end or the downstream end. The mouth end is downstream of the distal end. The mouth end may comprise a mouthpiece. The distal end of the aerosol generating article may also be referred to as the upstream end. Components, or portions of components, of the aerosol generating article may be described as being upstream or downstream of one another based on their relative positions with respect to the airflow path through the aerosol generating article.
The invention also provides a method for producing individual aerosol-generating articles each comprising an individual substrate section, the substrate section comprising aerosol-forming substrate with a susceptor element, the method comprising the method steps of:
Such a method may provide the advantage that a continuous substrate section may easily be cut completely at the predetermined precut positions.
This method may be combined with any of the further method features disclosed herein.
In one embodiment of this method, during method step C) the individual susceptor elements in the continuous substrate sections may each be spaced apart by gaps and subsequently the continuous substrate sections may be cut between the gaps of individual susceptor elements. This may produce individual substrate sections.
In a further embodiment of this method, during method step B) flat regions on opposing edges of the continuous band of susceptor material may be removed as partial cuts. This may create a central linking part connecting different parts of the partially cut band of susceptor material.
The invention also provides a system configured for producing individual aerosol-generating articles, each article comprising an individual substrate section with a susceptor element. The system may comprise a precut device configured for partially cutting a continuous band of susceptor material to produce a precut position on the continuous band of susceptor material. The precut position may separate individual aerosol-generating articles from each other. The system may comprise a substrate section forming device configured for producing aerosol-generating articles. The substrate section forming device may employ the partially cut band of susceptor material for producing the aerosol-generating articles. The system may also comprise a transport device configured for transporting the continuous band of susceptor material between the precut device and the substrate section forming device.
According to another embodiment, the invention provides a system configured for producing individual aerosol-generating articles, each article comprising an individual substrate section with a susceptor element. The system comprises a precut device configured for partially cutting a continuous band of susceptor material to produce a precut position on the continuous band of susceptor material, wherein the precut position separates individual aerosol-generating articles from each other. The system furthermore comprises a substrate section forming device configured for producing aerosol-generating articles employing the partially cut band of susceptor material. The system also comprises a transport device configured for transporting the continuous band of susceptor material between the precut device and the substrate section forming device.
Such a system is well suited in order to produce aerosol-generating articles including susceptor elements with a uniform shape and well determined position within the substrate section in order to ease the inductive heating.
The precut device of the system furthermore may be configured to produce at least two precuts. In particular the precut device may be further configured to set the position of the at least two precuts on the continuous band of susceptor material in such a way that one single individual substrate section is located between adjacent precut positions. The single individual substrate section may correspond to one single susceptor element located between the adjacent precut positions.
The precut device may comprise one of: a knife, a rotating drum with punching tools or a rotating knife drum. The rotating knife drum may comprise a plurality of knifes located on the circumference of the drum. Preferably, the pitch between adjacent knifes on the knife drum or between adjacent punching tools on the rotating drum is the same as the distance of adjacent precuts on the partially cut band of susceptor material. For example, the pitch may be 12 mm if the distance between two adjacent precuts is 12 mm.
According to one first embodiment of the invention, the substrate section forming device may be configured for producing a continuous substrate section comprising the partially cut band of susceptor material. The system for producing aerosol-generating articles further may comprise a substrate cutting device for cutting the continuous substrate section at the precut position.
In this embodiment, the continuous band of susceptor material is only partially cut to produce the partially cut band of susceptor material. This partially cut band of susceptor material may subsequently be incorporated into a continuous substrate section. The continuous substrate section afterwards may be cut at the precut positions of the partially cut band of susceptor material for producing individual or larger substrate sections.
This may allow a reliable production of individual substrate section including individual susceptor elements with greater reliability.
The substrate cutting device may comprise a cutting tool for cutting the continuous substrate section at the precut positions. This may enable the cutting of the aerosol-forming substrate located at the precut position and additionally also may cut the partially cut continuous band of susceptor material at the precut position for producing the individual substrate sections.
The substrate cutting device may be configured to impinge on the continuous substrate section with lesser momentum in order to avoid or reduce deformations or dislocations of susceptor elements of the individual substrate sections.
The substrate cutting device may comprise a rotating knife. The rotating knife can for example be a stainless steel knife. At a transport speed of 200 m/min. the rotating knife may be operated with a rotational speed of around 800 rpm. The rotating knife may cut the continuous substrate section with an inclination of 45°.
In an alternative embodiment of the invention, the system for producing individual aerosol-generating articles apart from a precut device also may comprise a susceptor cutting device. The susceptor cutting device may be configured for cutting the partially cut band of susceptor material into individual susceptor elements. The substrate section forming device may then be configured for producing a continuous substrate section comprising the individual susceptor elements.
In this alternative embodiment of the invention, the partially cut band of susceptor material is further cut into individual susceptor elements. Owing to the lower impact of the susceptor cutting device, deformations of the individual susceptor elements may be avoided. The susceptor cutting device may comprise a rotating blade.
In this alternative embodiment of the invention, the system furthermore may comprise a substrate cutting device which may be configured for cutting the continuous substrate section between the individual susceptor elements.
The substrate cutting device may operate with reduced impact owing to the fact that it only may have to cut through the aerosol-forming substrate in between adjacent individual susceptor elements incorporated in the continuous substrate section, but not through the susceptor material. The transport device may also be configured to transport the partially cut band of susceptor material from the precut device to the susceptor cutting device. In both the first and the second embodiment, the transport device furthermore may be configured to transport the continuous substrate section from the substrate section forming device to the substrate cutting device.
Systems for producing individual aerosol-generating articles furthermore may comprise a bobbin configured for unwinding the continuous band of susceptor material. The bobbin may be operated at the speed sufficient for unwinding the continuous band of susceptor material and feed it through the transport device.
The transport device may comprise a belt. Preferably the transport device may comprise a toothed belt, more preferably a U-shaped toothed belt.
The belt may be operated at the speed sufficiently to transport the continuous band of susceptor material between the precut device and the substrate section forming device. The speed may be between 150 m/min. and 400 m/min., preferably between 200 m/min. and 300 m/min.
The substrate section forming device may comprise a funnel shaped guide element for positioning the aerosol-forming substrate around one of: the partially cut continuous band of susceptor material or the plurality of individual susceptor elements.
The substrate section forming device may compress the aerosol-forming substrate around the partially cut band of susceptor material or around the individual susceptor elements for producing the continuous substrate section.
The system for producing individual aerosol-generating articles may comprise a modified commercially available device. The commercially available device may be modified by including a precut device. Additionally, the commercially available device may be modified by including a susceptor cutting device. One commercially available device which may be modified according to the invention could be a Hauni KDF, manufactured by Hauni Maschinenbau GmbH.
The invention furthermore provides an aerosol-generating article comprising a substrate section comprising aerosol-forming substrate and a susceptor element. The susceptor element may comprise a first and a second susceptor end face. At least one of the first and the second susceptor end face may have a tapered shape.
The first and second susceptor end face having a tapered shape may result from cutting the central linking part between adjacent susceptor elements in the partially cut band of susceptor material. This central linking part may be formed when flat regions on opposing edges of the continuous band of susceptor material are removed in order to create precuts employing a larger area.
An aerosol-generating article including such a susceptor element may be easier to heat via inductive heating owing to the absence of deformations in the susceptor element.
The susceptor element of the aerosol-generating article may comprise a flat elongated shape. Such a susceptor element embedded in the aerosol-forming substrate may allow a uniform heating of the aerosol-forming substrate upon inductive heating of the susceptor element.
One or both of the first and the second susceptor end face may comprise rounded edges. The rounded edges may result from removing larger flat areas from opposing edges of the continuous band of susceptor material when producing the precuts.
The susceptor element may comprise a flat surface. The surface of the susceptor element may not have been bent owing to the reduced impact of the substrate cutting device or the susceptor cutting device owing to the precuts.
The aerosol-generating article may comprise a first article end face and an opposing second article end face. The first and second susceptor end face may be spaced apart from these first and second article end faces.
A susceptor comprising such a first and second susceptor end face may not be deformed. Such a susceptor may not have been bent during the cutting of the continuous substrate section. The first and second susceptor end face may be spaced apart from the respective article end faces because in the continuous substrate section aerosol-forming substrate is located between adjacent individual susceptor elements. Cutting between adjacent individual susceptor elements may result in an aerosol-generating article wherein susceptor end faces are then spaced apart from the respective article end faces.
The susceptor element may be positioned centrally within the substrate section of the aerosol-generating article. The aerosol-generating article may comprise a tubular elongated shape. The aerosol-generating article may comprise a central longitudinal axis. The susceptor elements may be positioned in such a way within the substrate section that the susceptor element is arranged along the continuous central longitudinal axis, preferably wherein the susceptor element may be located in a plane, wherein the continuous central longitudinal axis also runs within that plane.
Such a centrally positioned susceptor element may be able to reliably and uniformly heat the surrounding aerosol-forming substrate. Additionally, any harm to the user which may result from dislocations of the susceptor element may be avoided.
The aerosol-generating article may generate an aerosol by heating the aerosol-forming substrate to a temperature below combustion temperature via inductive heating. Such an aerosol-generating article may also be referred to as a “heat-not-burn product”.
The invention also provides an aerosol-generating article produced according to any of the methods described herein.
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.
Example A: Method for producing individual aerosol-generating articles each comprising an individual substrate section, the substrate section comprising aerosol-forming substrate with a susceptor element, the method comprising the method steps of:
Example B: Method according to Example A, wherein at least two precut positions are formed in method step B) and wherein the positions of the precuts on the continuous band of susceptor material are set in such a way that one individual substrate section is located between adjacent precut positions.
Example C: Method according to any of the preceding examples, wherein during method step C) the aerosol-forming substrate is positioned around the partially cut band of susceptor material, thereby producing a continuous substrate section comprising the partially cut band, and wherein subsequently the continuous substrate section is cut at the precut position.
Example D: Method according to the preceding example, wherein during method step B) a plurality of precuts is formed and wherein during method step C) the continuous substrate section is cut at all precut positions, thereby producing a plurality of individual substrate sections or wherein during method C) the continuous substrate section is cut at some precut positions, thereby providing a plurality of multiple substrate sections, preferably wherein one multiple substrate section contains at least two, more preferably at least 5 or at least 10 individual substrate sections.
Example E: Method according to Example A or Example B, wherein during method step C) the partially cut band of susceptor material is completely cut at the predetermined precut position, thereby producing individual susceptor elements, and wherein subsequently the aerosol-forming substrate is positioned around the individual susceptor bands, thereby producing a continuous substrate section including individual susceptor elements.
Example F: Method according to the preceding example, wherein during method step C) the individual susceptor elements in the continuous substrate section are each spaced apart by gaps and wherein subsequently the continuous substrate section is cut between the gaps of the individual susceptor bands, thereby producing individual substrate sections.
Example G: Method according to any of the preceding Example E or Example F, wherein during method step B) the continuous band of susceptor material is partially cut by producing incisions at the edges of the band, and wherein during method step C) the partially cut band is completely cut in a central part of the band adjacent to the incisions to produce the individual susceptor elements.
Example H: Method according to any of the preceding examples, wherein partially cutting in method step B) comprises one or more of: producing perforations in the band, producing incisions at one or both edges of the band, producing a plurality of recesses in the band.
Example I: Method according to any of the preceding examples, wherein during method step C) the continuous substrate section is overwrapped with wrapping material, preferably paper.
Example J: Method according to any of the preceding examples, wherein during method step C) one of the partially cut continuous band or the individual susceptor elements are transported through a funnel shaped guide element for positioning the aerosol-forming substrate around the one of the partially cut continuous band or the individual susceptor elements.
Example K: Method according to any of the preceding examples, wherein during one or both of method step B) and method step C) one of the partially cut continuous band or the individual susceptor elements are transported on a belt, preferably a toothed belt, more preferably a U-shaped toothed belt.
Example L: Method according to any of the preceding examples, wherein during method step B) the continuous band of susceptor material is guided through at least one rotating knife drum or rotating drums with punching tools for partially cutting the continuous band of susceptor material.
Example M: Method according to any of the preceding examples, wherein during method step C) the individual susceptor elements remain positioned centrally within the individual substrate sections after cutting.
Example N: Method according to any of the preceding examples, wherein during method step B) flat regions on opposing edges of the continuous band of susceptor material are removed as partial cuts, thereby creating a central linking part connecting different parts of the partially cut band of susceptor material.
Example O: Method according to any of the preceding examples, wherein during method step C) a detection device is employed for detection of one of the positions of the precuts on the partially cut band of susceptor material or for the positions of the gaps between the plurality of individual susceptor elements within the continuous substrate section, preferably wherein the detection device is selected from a group consisting of: X-ray device, induction sensor, IR camera analyzer, device for measuring impedance.
Example P: Method according to any of the preceding examples, wherein during method step C) the continuous substrate section is cut by a rotating blade, preferably wherein the rotating blade is controlled by the detection device of Example O.
Example Q: Method according to any of the preceding examples, wherein the susceptor material comprises a ferromagnetic material, preferably a ferromagnetic alloy, more preferably ferritic iron, a ferromagnetic steel or stainless steel.
Example R: Method according to any of the preceding examples, wherein in a method step D) after method step C) one or both of filter sections and hollow plug sections are connected to one of: individual substrate sections or multiple substrate sections.
Example S: System configured for producing individual aerosol-generating articles each comprising an individual substrate section, the substrate section comprising aerosol-forming substrate with a susceptor element, comprising:
Example T: System according to the preceding example, wherein the precut device is configured to produce at least two precuts, wherein the precut device is further configured to set the position of the at least two precuts on the continuous band of susceptor material in such a way that one single individual substrate section is located between adjacent precut positions.
Example U: System according to any of the preceding Example S or Example T, wherein the substrate section forming device is configured for producing a continuous substrate section comprising the partially cut band of susceptor material, the device further comprising a substrate cutting device for cutting the continuous substrate section at the precut position.
Example V: System according to the preceding Example S or Example T, the device further comprising a susceptor cutting device for cutting the partially cut band of susceptor material into individual susceptor elementsat the plurality of precut positions, further wherein the substrate section forming device is configured for producing a continuous substrate section comprising the individual susceptor elements.
Example W: System according to the preceding example, further comprising a substrate cutting device for cutting the continuous substrate section between the individual susceptor elements.
Example X: System according to any of the preceding Example S to Example W, further comprising a bobbin configured for unwinding the continuous band of susceptor material.
Example Y: System according to any of the preceding Example S to Example X, wherein the transport device comprises a belt, preferably a toothed belt, more preferably a U-shaped toothed belt.
Example Z: System according to any of the preceding Example S to Example Y, wherein the substrate section forming device comprises a funnel shaped guide element for positioning the aerosol-forming substrate around one of: the partially cut continuous band or the plurality of individual susceptor elements.
Example AA: System according to any of the preceding Example S to Example Z, wherein the precut device comprises knife drums, a knife or drums with punching tools for providing partial cuts.
Example AB: System according to any of the preceding Example S to Example AA, wherein one or both of the susceptor cutting device or the substrate cutting device comprises a rotating blade.
Example AC: Aerosol-generating article comprising:
Example AD: Aerosol-generating article according to the preceding example, wherein one or both of the first and a second susceptor end face comprises rounded edges.
Example AE: Aerosol-generating article according to any of the preceding claim 29 or 30, wherein the susceptor element comprises a flat surface, preferably wherein the surface is not bend.
Example AF: Aerosol-generating article according to any of the preceding Example AC to Example AE, wherein the susceptor element is positioned centrally within the substrate section.
Example AG: Aerosol-generating article produced according to a method of any of the Example A to Example R.
Features described in relation to one embodiment may equally be applied to other embodiments of the invention.
The invention will be further described, by way of example only, with reference to the accompanying drawings in which:
In the following the same elements are marked with the same reference numerals throughout all the figures.
| Number | Date | Country | Kind |
|---|---|---|---|
| 21176558.1 | May 2021 | EP | regional |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/EP2022/064205 | 5/25/2022 | WO |
