APPLYING AN ADDITIVE UPON SHAPING SHEET MATERIAL INTO A ROD INCORPORATING A HEATABLE SUSCEPTOR

Abstract

A device (1) for producing an aerosol-generating rod (2) includes a converging device (3), a conveyor system (13), a susceptor guide (15), and an additive dispensing pipe (21). The conveyor system is configured to convey sheet material (11) through the converging device. The susceptor guide is configured to guide a susceptor (9). The susceptor guide extends into the converging device along an axial direction and comprises an exit opening (19) for the susceptor within the converging device. The additive dispensing pipe has an end section (29) extending within the converging device in parallel with the susceptor guide. The end section comprises a dispensing opening (31) to dispense an additive through the dispensing opening.

Claims

1-22. (canceled)

23. A device for producing an aerosol-generating rod, comprising: a converging device; a conveyor system configured to convey sheet material through the converging device; a susceptor guide configured to guide a susceptor, the susceptor guide extending into the converging device along an axial direction and comprising an exit opening for the susceptor within the converging device; an additive dispensing pipe having an end section, the end section extending within the converging device in parallel with the susceptor guide and comprising a dispensing opening to dispense an additive through the dispensing opening; an additive tank storing the additive; and a pump configured to supply the additive from the additive tank to the additive dispensing pipe.

24. The device according to claim 23, wherein the dispensing opening at least partially lies radially outside of the exit opening of the susceptor guide.

25. The device according to claim 23, wherein the end section of the additive dispensing pipe circumferentially surrounds the susceptor guide.

26. The device according to claim 23, wherein the dispensing opening and the exit opening are concentrically arranged.

27. The device according to claim 23, wherein the dispensing opening is provided in a circumferential surface of the additive dispensing pipe.

28. The device according to claim 23, wherein the dispensing opening faces in a radial direction.

29. The device according to claim 23, wherein the dispensing opening is located upstream of the exit opening, or essentially at the position of the exit opening, with respect to the axial direction.

30. The device according to claim 23, wherein the dispensing opening is located downstream of the exit opening with respect to the axial direction.

31. The device according to claim 23, wherein the end section of the additive dispensing pipe comprises at least two, or at least three, or at least four, or at least six, or at least eight, or at least ten, or more than ten dispensing openings to dispense the additive through the dispensing openings.

32. A method for producing a rod for an aerosol-generating device, with the steps of: conveying a susceptor through a converging device, the susceptor being heatable by exposing the susceptor to an alternating magnetic field; shaping a sheet material into a rod-shape incorporating the susceptor by conveying the sheet material through the converging device; and dispensing an additive through a dispensing opening within the converging device at an injection location inside the rod-shape upon shaping the sheet material into the rod-shape, wherein the susceptor is guided through a susceptor guide and exits the susceptor guide through an exit opening of the susceptor guide within the converging device along an axial direction; wherein the dispensing opening at least partially lies radially outwards of the exit opening of the susceptor guide; and wherein the additive is supplied by a pump from an additive tank to an additive dispensing pipe comprising the dispensing opening.

33. The method according to claim 32, wherein the additive is dispensed into interspaces of the sheet material.

34. The method according to claim 32, wherein the additive is dispensed along the axial direction or along a radial direction.

35. The method according to claim 32, wherein the dispensing opening is provided in a circumferential surface of the additive dispensing pipe.

36. The method according to claim 32, wherein the sheet material comprises plant material.

37. The method according to claim 32, wherein the additive is configured to form aerosol, supplementary to an aerosol formed by the sheet material, when the rod is heated in an aerosol-generating device by means of the susceptor.

38. The method according to claim 32, wherein the sheet material is crimped sheet material.

39. The method according to claim 32, wherein the additive is dispensed as a liquid.

40. An aerosol-generating rod, comprising a susceptor that is configured to be heated by exposing the susceptor to an alternating magnetic field; a sleeve of sheet material, the sleeve surrounding the susceptor to form a rod incorporating the susceptor; and an aerosol-generating additive provided within the sleeve on the sheet material, wherein a concentration of the aerosol-generating additive decreases in a direction radially away from the axially extending susceptor.

41. The aerosol-generating rod according to claim 40, wherein the sheet material is crimped sheet material.

42. Use of a dispensing opening to dispense an additive within a funnel-shaped converging device, wherein a susceptor that is heatable by electromagnetic induction is conveyed through an exit opening of a susceptor guide within the funnel-shaped converging device and a sheet material is shaped into a rod-shape incorporating the susceptor within the converging device, wherein the additive is supplied by a pump from an additive tank to an additive dispensing pipe comprising the dispensing opening, and wherein the additive is dispensed through the dispensing opening along a direction that is parallel to a direction in which the susceptor exits the susceptor guide, or along a direction that is perpendicular to a direction in which the susceptor exits the susceptor guide.

43. The use according to claim 42, wherein the additive is dispensed as a liquid.

Description

[0092] FIG. 1 shows a schematic sectional view of a device for producing an aerosol-generating rod according to an embodiment;

[0093] FIG. 2 shows a schematic sectional view of a device for producing an aerosol-generating rod according to another embodiment;

[0094] FIG. 3 shows a schematic sectional view of an aerosol-generating rod according to an embodiment;

[0095] FIG. 4 shows three variants of relative positioning between a dispensing opening of an additive dispensing pipe and an exit opening of a susceptor guide according to embodiments;

[0096] FIG. 5 schematically shows how the susceptor guide and the additive dispensing pipe may be assembled according to an embodiment;

[0097] FIG. 6 shows a sectional view of an assembly comprising a susceptor guide and an additive dispensing pipe according to an embodiment; and

[0098] FIG. 7 shows a perspective view of an assembly comprising a susceptor guide and an additive dispensing pipe according to an embodiment.

[0099] FIGS. 1 and 2 show a sectional view of a device 1 for producing an aerosol-generating rod 2 according to embodiments. The device 1 comprises a converging device 3. The converging device 3 is funnel-shaped and has a wall 5 defining a forming space 7 therein to produce an aerosol-generating rod 2.

[0100] A susceptor 9 and sheet material 11 are conveyed through the forming space 7 of the converging device 3.

[0101] The susceptor 9 is withdrawn from a supply roll 10 as a susceptor band. The susceptor 9 is configured to be heated by being exposed to alternating magnetic field. The susceptor 9 may be heated by means of induction heating. The susceptor 9 may, for example, be made of or comprise conductive material, such as metal or carbon.

[0102] The sheet material 11 may comprise reconstituted herbaceous material, such as reconstituted tobacco material, for example. The sheet material 11 may comprise cotton, for example. The sheet material 11 may be conveyed through the forming space 7 of the converging device 3 by a conveyor system 13 that is schematically shown in FIGS. 1 and 2. The conveyor system 13 may be configured to pull the sheet material 11 through the forming space 7 of the converging device 3. The conveyor system 13 may further be configured to convey the susceptor 9 through forming space 7 of the converging device 3, for example by pulling the susceptor 9.

[0103] A susceptor guide 15 extends into the forming space 7 of the converging device 3 along an axial direction 17. The susceptor guide 15 guides the susceptor 9. The susceptor 9 is conveyed through the susceptor guide 15. Within the forming space 7 of the converging device 3, the susceptor guide 15 comprises an exit opening 19 through which the susceptor 9 exits the susceptor guide 15 within the forming space 7 of the converging device 3.

[0104] A cross-sectional area of the forming space 7, in a sectional plane perpendicular to the axial direction 17, decreases along the axial direction 17. When the sheet material 11 is conveyed through the converging device 3, the sheet material 11 engages the wall 5 of the converging device 3 from inside the converging device 3 and is thereby shaped into a rod 2 incorporating the susceptor 9. Shaping the sheet material 11 into the rod 2 may comprise one or more of folding, bending and compressing the sheet material 11.

[0105] It is not required that the converging device 3, in particular the wall 5 of the converging device 3, is fully closed circumferentially along the axial direction 17. The converging device 3 may for example, be open at its lower side. Preferably, a support may be provided below the converging device 3, for example in the form of a garnish belt driven in the axial direction 17, and may support the sheet material 11 and the rod 2. It would, however, also be possible that the converging device 3 is fully closed circumferentially around the axial direction 17.

[0106] As shown in FIGS. 1 and 2, an additive dispensing pipe 21 is provided to supply an additive into the forming space 7 of the converging device 3. The additive dispensing pipe 21 is connected to an additive tank 23 storing the additive. A pump 25 is provided to supply the additive from the additive tank 23 to the additive dispensing pipe 21. Preferably, the additive is supplied as a liquid.

[0107] The additive may, for example, comprise aerosol-generating substances, such as one or more of glycerin, glycerol, and propylene glycol. The additive may comprise one or more flavorants, such as menthol, spearmint, peppermint, eucalyptus, vanilla, cocoa, chocolate, coffee, tea, spices (such as cinnamon, clove, and ginger), fruit flavorants, and combinations thereof. The additive may comprise nicotine. The additive may be pure menthol.

[0108] A viscosity regulator 27 may be provided to regulate a viscosity of the additive. In particular, the viscosity regulator 27 may control the viscosity of the additive to be below a threshold value. The threshold value may be 5000 millipascal-seconds, for example. In particular, the viscosity regulator 27 may regulate the viscosity of the additive by heating the additive. The viscosity of the additive may be reduced by heating the additive. The viscosity of the additive may be regulated by the viscosity regulator 27 to facilitate supplying the additive into the forming space 7 of the converging device 3 through the additive dispensing pipe 21. The viscosity regulator 27 may heat the additive to a predetermined temperature. The predetermined temperature may be above room temperature. The predetermined temperature may be between 30 degrees Celsius and 60 degrees Celsius, or between 30 degrees Celsius and 40 degrees Celsius, or between 40 degrees Celsius and 50 degree Celsius, for example. In the illustrated embodiments, the viscosity regulator 27 comprises a heater to heat the additive within the additive tank 23.

[0109] The additive is dispensed through the additive dispensing pipe 21 within the forming space 7 of the converging device 3 while the sheet material 11 is compressed around the susceptor 9 within the converging device 3. The additive is dispensed by the additive dispensing pipe 21 inside the rod-shape of the rod 2 upon shaping the rod 2.

[0110] FIG. 3 shows a sectional view of a rod 2 after production. At a radial center of the rod, 2 the susceptor 9 extends along the axial direction 17 (into the drawing plane). Along its extension in the axial direction 17, the susceptor 9 is surrounded by a sleeve 28 formed by the sheet material 11. The sheet material 11 is bent and folded, in particular in an irregular manner. Radially outside the sleeve 28 of sheet material 11, a wrapper 30 surrounds the sleeve 28 and forms an outer surface of the rod 2. The wrapper may optionally be wrapped around the sleeve 28 after or while the rod 2 exits the converging device 3. The wrapper 28 may, for example, be formed of a paper sheet.

[0111] As illustrated in FIGS. 1 and 2 and as explained in more detail hereunder, the additive is dispensed radially near the susceptor 9 upon forming the rod 2. This allows achieving a distribution of the additive within the final rod 2 that corresponds to a concentration of the aerosol-generating additive decreasing in a direction radially away from the axially extending susceptor 9 towards an outside.

[0112] According to the embodiments illustrated in FIGS. 1 and 2, the additive dispensing pipe 21 circumferentially surrounds the susceptor guide 15 within the forming space 7 of the converging device 3. This means that the susceptor guide 15 extends through the additive dispensing pipe 21.

[0113] FIG. 4 shows detailed views of the susceptor 9 leaving the exit opening 19 of the susceptor guide 15 and of an end section 29 of the liquid dispensing pipe 21 according to three different variants. According to each of the three variants, the end section 29 of the liquid dispensing pipe 21 extends in parallel to the susceptor guide 15 and comprise a dispensing opening 31 for dispensing the additive into the forming space 7 of the converging device 3. The dispensing opening 31 is provided in an end face of the liquid dispensing pipe 21. The susceptor guide 15 extends within the liquid dispensing pipe 21 along the axial direction 17. The susceptor guide 15 and the end section 29 of the liquid dispensing pipe 21 extend coaxially around the axial direction 17. For ease of illustration, the susceptor 9 in FIG. 4 is guided within the susceptor guide 15 with considerable play. The susceptor 9 could, however, also be guided more closely by the susceptor guide 15.

[0114] In the embodiment of part A of FIG. 4, the liquid dispensing pipe 21 and the susceptor guide end at the same position along the axial direction 17.

[0115] In the embodiment of part B of FIG. 4, the additive dispensing opening 31 of the end section 29 of the liquid dispensing pipe 21 is upstream, with respect to the axial direction 17, of the exit opening 19 through which the susceptor 9 exits the susceptor guide 15.

[0116] According to part C of FIG. 4, the additive dispensing opening 31 of the end section 29 of the additive dispensing pipe 21 is downstream, with respect to the axial direction 17, of the exit opening 19 through which the susceptor 9 exits the susceptor guide 15.

[0117] In each of the embodiments shown in FIG. 4, the additive is supplied to the additive dispensing opening 31 through a channel 33 between an outer surface of the susceptor guide 15 and an inner surface of the additive dispensing pipe 21.

[0118] FIG. 5 illustrates schematically how the susceptor guide 15 and the liquid dispensing pipe 21 may be assembled. According to the illustrated embodiment, the additive dispensing pipe 21 has, at its upstream end with respect to the axial direction 17, a base portion 35. The end section 29 of the additive dispensing pipe 21 extends from the base portion 35.

[0119] The susceptor guide 15 has a base portion 37 provided at its upstream end with respect to the axial direction 17. A guide portion 39 extends from the base portion 37 along the axial direction 17 to guide the susceptor 9. The guide portion 39 may circumferentially surround the susceptor 9.

[0120] As illustrated by the arrow in FIG. 5, the additive dispensing pipe 21 may be slipped onto the susceptor guide 15. Thereby, the end section 29 of the additive dispensing pipe 21 may slide over the guide portion 39 of the susceptor guide 15. The base portion 35 of the additive dispensing pipe 21 may abut the base portion 37 of the susceptor guide 15 in the assembled state.

[0121] The embodiments shown in FIGS. 1 and 2 differ from each other only in the way in which the additive is supplied from the tank 23 to the end section 29 of the additive dispensing pipe 21. In the embodiment of FIG. 1, the additive passes through a channel 41 in the base section 37 of the susceptor guide 15. In the embodiment of FIG. 2, the additive passes through a channel 43 provided in the base section 35 of the additive dispensing pipe 21.

[0122] FIG. 6 shows an alternative embodiment for the additive dispensing pipe 21 and the susceptor guide 15. The additive dispensing pipe 21 and the susceptor guide 15 shown in FIG. 6 could be used in the embodiments of FIGS. 1 and 2 instead of the additive dispensing pipe 21 and the susceptor guide 15 of the embodiments of FIGS. 1 and 2. In contrast to the embodiments of FIGS. 1, 2, 4 and 5, according to FIG. 6, the liquid dispensing pipe 21 does not concentrically surround the susceptor guide 15. Rather, the susceptor guide 15 is provided radially outside of the additive dispensing pipe 21 with respect to the axial direction 17 along which the susceptor 9 is guided through the susceptor guide 15. The end section 29 of the additive dispensing pipe 21 nevertheless extends in parallel to the susceptor guide 15 and in parallel to the axial direction 17. The additive dispensing pipe 21 is fixed to the susceptor guide 15. In particular, the base section of the additive dispensing opening 21 is fixed to the base section 37 of the susceptor guide 15.

[0123] FIG. 7 shows a further alternative embodiment for the additive dispensing pipe 21 and the susceptor guide 15. The additive dispensing pipe 21 and the susceptor guide 15 shown in FIG. 7 could be used in the embodiments of FIGS. 1 and 2 instead of the additive dispensing pipe 21 and the susceptor guide 15 of the embodiments of FIGS. 1 and 2. In the embodiment of FIG. 7, the end section 29 of the additive dispensing pipe 21 extends concentrically around the susceptor guide 15. In particular, the end section 29 of the additive dispensing pipe 21 extends concentrically around the axially extending guide portion 39 of the susceptor guide 15. The additive dispensing pipe 21 and the susceptor guide 15 may be combined by sliding the additive dispensing pipe 21 onto the susceptor guide 15.

[0124] In contrast to the embodiments of FIGS. 1, 2, 4, 5, and 6, according to FIG. 7, the additive dispensing pipe 21 is not open in the axial direction. Rather, an axial end face of the additive dispensing pipe 21 is closed. A plurality of additive dispensing openings 19 is arranged on a circumferential surface 51 of the end section 29 of the additive dispensing pipe 21. The additive dispensing openings 19 may be symmetrically arranged around a circumference of the end section 29. The additive is dispensed, in particular sprayed, onto the sheet material 11 through the additive dispensing openings 19. Any number of additive dispensing openings 19 may be arranged on the circumferential surface 51 of the end section 29, including in particular only one additive dispensing opening 19 or more than one additive dispensing openings 19.

[0125] A number of different additive dispensing pipes 21, for example two or more different additive dispensing pipes 21, may be provided to be used, one at a time, with the same susceptor guide 15. The additive dispensing pipes 21 may be of different types. The additive dispensing pipes 21 may have different arrangements and numbers of additive dispensing openings 19. The additive dispensing pipes 21 may have the same type of base portion 35 to ensure compatibility with the susceptor guide 15.

[0126] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified in all instances by the term “about”. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein. In this context, therefore, a number A is understood as A±10% of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.