Method and Apparatus for Manufacturing an Aerosol Generating Pod

Abstract

A method of manufacturing an aerosol generating pod includes providing aerosol generating material; positioning sheet material over opposite sides of the aerosol generating material; and punching the aerosol generating material and the sheet material from one of the opposite sides to form an aerosol generating pod including aerosol generating material covered by the sheet material. An apparatus for manufacturing an aerosol generating pod is also provided.

Claims

1. A method of manufacturing an aerosol generating pod, the method comprising: (i) providing aerosol generating material; (ii) positioning sheet material over opposite sides of the aerosol generating material; (iii) punching the aerosol generating material and the sheet material from one of the opposite sides to form an aerosol generating pod comprising the aerosol generating material covered by the sheet material.

2. The method according to claim 1, wherein: step (i) comprises supplying the aerosol generating material having a continuous profile; step (ii) comprises supplying the sheet material as continuous sheet material over the opposite sides of the continuous profile of the aerosol generating material; step (iii) comprises repeatedly punching the continuous profile of the aerosol generating material and the continuous sheet material from one of the opposite sides of the sheet material to form a plurality of aerosol generating pods comprising the aerosol generating material covered by the sheet material.

3. The method according to claim 1, further comprising: positioning an inductively heatable susceptor in the aerosol generating material.

4. The method according to claim 3, wherein the inductively heatable susceptor is an inductively heatable susceptor sheet.

5. The method according to claim 4, wherein the inductively heatable susceptor sheet includes an aperture.

6. The method according to claim 1, wherein step (i) comprises positioning the aerosol generating material between the sheet material and an inductively heatable susceptor sheet and/or between inductively heatable susceptor sheets.

7. The method according to claim 1, further comprising prior to step (iii): cutting the sheet material positioned on at least one of the opposite sides of the aerosol generating material to separate the sheet material from the remaining sheet material or creating a weakened region in the sheet material positioned on at least one of the opposite sides of the aerosol generating material to facilitate cutting and separation of the sheet material from the remaining sheet material during step (iii).

8. The method according to claim 1, wherein step (iii) comprises moving a punching element towards the sheet material positioned on one of the opposite sides of the aerosol generating material and into a cavity of a mould adjacent to the sheet material positioned on the other opposite side of the aerosol generating material.

9. The method according to claim 8, wherein step (iii) comprises moving the punching element towards the sheet material positioned on the one side of the aerosol generating material and pushing the sheet material positioned on the opposite side of the aerosol generating material into the cavity of the mould to thereby wrap exposed regions of the aerosol generating material with the sheet material.

10. The method according to claim 1, further comprising after step (iii): joining the sheet material positioned on the opposite sides of the aerosol generating material to secure the aerosol generating material inside the sheet material.

11. An apparatus for manufacturing an aerosol generating pod, the apparatus comprising: a first supply unit for supplying aerosol generating material; a second supply unit for positioning sheet material over opposite sides of the aerosol generating material; and a punching unit arranged to punch the aerosol generating material and the sheet material from one of the opposite sides to form an aerosol generating pod comprising the aerosol generating material covered by the sheet material.

12. The apparatus according to claim 11, further comprising a third supply unit for positioning an inductively heatable susceptor in the aerosol generating material.

13. The apparatus according to claim 11, wherein the punching unit comprises a punching element adjacent to the sheet material positioned on one of the opposite sides of the aerosol generating material and a mould having a cavity adjacent to the sheet material positioned on the opposite side of the aerosol generating material, the punching element being movable into the cavity of the mould to form the aerosol generating pod.

14. The apparatus according to claim 13, wherein the punching element includes a peripheral wall having a peripheral edge adapted to separate the sheet material positioned on the side of the aerosol generating material adjacent to the punching element from the remaining sheet material positioned on said side and to push the sheet material positioned on the opposite side of the aerosol generating material into the cavity of the mould to thereby wrap exposed regions of the aerosol generating material with the sheet material.

15. The apparatus according to claim 11, further comprising a joining unit adapted to join the sheet material positioned on the opposite sides of the aerosol generating material to secure the aerosol generating material inside the sheet material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0069] FIG. 1 is diagrammatic cross-sectional side view of part of a method and apparatus for manufacturing an aerosol generating pod, illustrating one way of positioning aerosol generating material and inductively heatable susceptor sheets between sheet material;

[0070] FIG. 2 is a diagrammatic cross-sectional side view of part of a method and apparatus for manufacturing an aerosol generating pod, illustrating another way of positioning aerosol generating material and inductively heatable susceptor sheets between sheet material;

[0071] FIGS. 3 to 12 are diagrammatic views of a further part of a method and apparatus for manufacturing an aerosol generating pod;

[0072] FIGS. 13 and 14 are top views of the method and apparatus illustrated in FIGS. 3 to 12, illustrating respectively first and second implementations;

[0073] FIG. 15 is a diagrammatic cross-sectional side view similar to FIG. 5 illustrating stretching of the sheet material on one side of the aerosol generating material;

[0074] FIG. 16a is a diagrammatic cross-sectional side view of an example of an aerosol generating pod manufactured using the method and apparatus illustrated in FIGS. 1 to 15; and

[0075] FIG. 16b is a cross-sectional view along the line A-A shown in FIG. 16a.

DETAILED DESCRIPTION OF EMBODIMENTS

[0076] Embodiments of the present disclosure will now be described by way of example only and with reference to the accompanying drawings.

[0077] Referring initially to FIG. 1, there is shown a first example of part of an apparatus for manufacturing an aerosol generating pod 1 as shown in FIGS. 16a and 16b. The aerosol generating pod 1 is for use in an aerosol generating device to generate an aerosol for inhalation by a user of the device. Suitable aerosol generating devices are known generally in the art and will not be described in further detail in this specification.

[0078] The apparatus comprises a first supply unit for supplying aerosol generating material 10, second supply units 12 for positioning sheet material 14 over opposite sides of the aerosol generating material 10 and third supply units 16 for positioning an inductively heatable susceptor 18 in the aerosol generating material 10. The horizontal arrow at the bottom of FIG. 1 illustrates the process flow direction, that is the direction of movement of the aerosol generating material 10, the sheet material 14 and the inductively heatable susceptor 18.

[0079] In more detail, each of the second supply units 12 comprises a supply roller 12a and a feed roller 12b which are arranged to position first sheet material 14a on one side of the aerosol generating material 10 and second sheet material 14b on an opposite side of the aerosol generating material 10. The first sheet material 14a and second sheet material 14b is intended to cover the aerosol generating material 10 in the aerosol generating pod 1 and, thus, typically comprises an air-permeable material which allows air and vapour to flow into and out of the aerosol generating pod 1 and through the aerosol generating material 10.

[0080] Each of the third supply units 16 comprises a supply roller 16a which is arranged to supply an inductively heatable susceptor sheet 18 and to position the inductively heatable susceptor sheet 18 in the aerosol generating material 10. In the illustrated embodiment, each of the inductively heatable susceptor sheets 18 includes a plurality of apertures 22 which are spaced uniformly along a longitudinal direction of the susceptor sheets 18. The apertures 22 facilitate the generation of eddy currents in the inductively heatable susceptor sheets 18 during use of the aerosol generating pod 1 in an inductively heatable aerosol generating device and/or facilitate the flow of air and vapour through the aerosol generating pod 1. It will, however, be understood by one of ordinary skill in the art that the apertures 22 are not essential and may be omitted.

[0081] The aerosol generating material 10 supplied by the first supply unit is positioned between adjacent inductively heatable susceptor sheets 18. The aerosol generating material 10 is also positioned by the first supply unit between the first sheet material 14a and the uppermost inductively heatable susceptor sheet 18 as viewed in FIG. 1 and between the second sheet material 14b and the lowermost inductively heatable susceptor sheet 18 as viewed in FIG. 1. This ensures that the aerosol generating material 10 is uniformly distributed throughout the aerosol generating pod 1 as best seen in FIG. 16a.

[0082] In the example of FIG. 1, the aerosol generating material 10 is typically a cut filler material, for example a plant derived cut filler material such as cut filler tobacco.

[0083] The aerosol generating material 10 may comprise an aerosol-former such as glycerine or propylene glycol. Typically, the aerosol generating material 10 comprises an aerosol-former content of between approximately 5% and approximately 50% on a dry weight basis. Upon heating, the aerosol generating material 10 releases volatile compounds possibly including nicotine or flavour compounds such as tobacco flavouring.

[0084] Referring now to FIG. 2, there is shown a second example of part of an apparatus for manufacturing an aerosol generating pod. The apparatus shares some similarities with the apparatus described above with reference to FIG. 1 and corresponding features are identified using the same reference numerals. Again, the horizontal arrow at the bottom of FIG. 2 illustrates the process flow direction, that is the direction of movement of the aerosol generating material 10, the sheet material 14 and the inductively heatable susceptor 18.

[0085] The apparatus comprises second supply units 12 for positioning sheet material 14 over opposite sides of the aerosol generating material 10 and third supply units 16 for positioning inductively heatable susceptor sheets 18 in the aerosol generating material 10. The second and third supply units 12, 16 are the same as those described above with reference to FIG. 1.

[0086] The apparatus also comprises first supply units 24 for supplying the aerosol generating material 10. Each of the first supply units 24 comprises a supply roller 24a which is typically arranged to supply aerosol generating material 10 having a continuous profile, for example in the form of an aerosol generating sheet 26. The aerosol generating material 10 typically comprises a reconstituted material, for example reconstituted tobacco including tobacco and any one or more of cellulose fibres, tobacco stalk fibres and inorganic fillers such as CaCO3.

[0087] Each of the first supply units 24 includes first cooperating rollers 24b (e.g. perforating rollers) which are adapted to perforate the aerosol generating sheet 26 as it passes through the rollers 24b to facilitate the flow of air and vapour through the aerosol generating sheets 26. Each of the first supply units 24 also includes second cooperating rollers 24c, for example calender rollers to provide a calendered aerosol generating sheet 26 or creping rollers to provide a creped aerosol generating sheet 26.

[0088] The aerosol generating material 10 supplied by each of the first supply units 24 is positioned between adjacent inductively heatable susceptor sheets 18. The aerosol generating material 10 is also positioned between the first sheet material 14a and the uppermost inductively heatable susceptor sheet 18 as viewed in FIG. 2 and between the second sheet material 14b and the lowermost inductively heatable susceptor sheet 18 as viewed in FIG. 2.

[0089] The apparatus of FIG. 2 includes a plurality of supply assemblies 28, each supply assembly 28 comprising two first supply units 24 and a third supply unit 16 which is arranged to position an inductively heatable susceptor sheet 18 in the aerosol generating material 10 supplied by the first supply units 24. It will be understood that the apparatus could comprise any suitable number of the supply assemblies 28, provided that a third supply unit 16 is positioned between adjacent supply assemblies 28 as shown in FIG. 2.

[0090] Referring now to FIGS. 3 to 14, there is shown a further part of the apparatus for manufacturing the aerosol generating pod 1 shown in FIGS. 16a and 16b and which is positioned downstream of the part of the apparatus illustrated in FIGS. 1 and 2. The apparatus includes a punching unit 30 for punching the aerosol generating material 10 and the sheet material 14 from one of the opposite sides of the sheet material 14 to form the aerosol generating pod 1 shown in FIGS. 16a and 16b.

[0091] In more detail, the punching unit 30 comprises a punching element 32 positioned adjacent to the first sheet material 14a and a cooperating mould 34 positioned adjacent to the second sheet material 14b. The punching element 32 is generally circular in cross-section and includes a peripheral wall 36 having a peripheral edge 38. The punching element 32 also includes an end wall 40 which, together with the peripheral wall 36, defines a hollow interior portion 42. The mould 34 includes a cavity 44 which also has a circular cross-section and into which the punching element 32 can be moved. The mould 34 includes first and second mould parts 34a, 34b which can be separated, for example as shown in FIG. 8.

[0092] The aerosol generating material 10, the inductively heatable susceptor sheets 18 positioned in the aerosol generating material 10 and the first and second sheet material 14a, 14b produced by the upstream part of the apparatus shown in FIGS. 1 and 2 are advanced by the first, second and third supply units to a punching position shown in FIG. 3. The apparatus includes a cutting unit 43 that is adapted to cut the second sheet material 14b when the second sheet material 14b is in the punching position, for example to separate it from the remaining second sheet material 14b (shown to the left of the cutting unit 43 in FIG. 3) or to create a weakened region 46 in the second sheet material 14b, for example comprising any one or more of a groove, score, perforations, a weakened line, or similar.

[0093] With the aerosol generating material 10, the inductively heatable susceptor sheets 18 and the first and second sheet material 14a, 14b in the punching position, the punching element 32 is moved towards the cavity 44 of the mould 34 as shown by the arrow in FIG. 4. The peripheral edge 38 of the punching element 32 cuts the first sheet material 14a, the aerosol generating material 10 and the inductively heatable susceptor sheets 18 via shearing as it moves towards the cavity 44. The cut portions of the first sheet material 14a, the aerosol generating material 10 and the inductively heatable susceptor sheets 18 are received inside the hollow interior portion 42 of the punching element 32 to form part of the aerosol generating pod 1 shown in FIGS. 16a and 16b.

[0094] Continued movement of the punching element 32 into the cavity 44 of the mould 34 as shown by the arrows in FIGS. 5 and 6 pushes a separated portion of the second sheet material 14b into the cavity 44 and wraps it around the exposed side regions of the aerosol generating material 10.

[0095] The punching element 32 is then withdrawn from the cavity 44 of the mould 34 as shown by the larger arrow in FIG. 7 and a joining unit 48 which in the illustrated embodiment has a circular shape, for example in the form of a sealing heater, is moved towards the mould 34 as shown by the smaller arrows in FIG. 7 so that it can apply heat to the peripheral edge of the cut portion of the first sheet material 14a and the upper peripheral edge of the separated portion of the second sheet material 14b where they contact each other. This seals the first sheet material 14a and the second sheet material 14b together, thereby forming an aerosol generating pod 1 in which the aerosol generating material 10 and the inductively heatable susceptor 18 is fully enclosed by the sheet material 14.

[0096] In some embodiments, the separated portion of the second sheet material 14b may be dimensioned so that there is substantially no excess second sheet material 14b projecting from the upper edge of the cavity 44 as shown in FIG. 6 and such that an upper peripheral edge of the separated portion of the second sheet material 14b contacts a peripheral edge of the cut portion of the first sheet material 14a. In practice, such accurate dimensioning of the separated portion of the second sheet material 14b may be difficult to achieve and the separated portion of the second sheet material 14b may instead be dimensioned so that there is a sufficient area of the second sheet material 14b to cover the exposed side regions of the aerosol generating material 10 and so that there is excess second sheet material 14b projecting from the upper edge of the cavity 44. In this case, any excess second sheet material 14b can be cut and removed after the first sheet material 14a and the second sheet material 14b have been sealed together by the joining unit 48 or can be left in situ as part of the aerosol generating pod 1.

[0097] After the first sheet material 14a and the second sheet material 14b have been heated to seal them together, the joining unit 48 is moved to its original position as shown by the small vertical arrows in FIGS. 8 and 9 and the first and second mould parts 34a, 34b are separated as shown by the horizontal arrows in FIG. 8 to release the aerosol generating pod 1 from the cavity 44 of the mould 34 as shown by the arrow in FIG. 9. The first and second mould parts 34a, 34b are then moved back to their original position, as shown by the arrows in FIG. 10.

[0098] The method described above is performed continuously to enable the mass production of aerosol generating pods 1. Thus, referring to FIG. 11, a further section of the second sheet material 14b is advanced to the punching position as denoted by the arrow so that it overlies the cavity 44 of the mould 34 as described above. Further sections of the first sheet material 14 and the aerosol generating material 10 including the inductively heatable susceptor sheets 18 are also moved to the punching position as shown by the arrows in FIG. 12. The cutting unit 43 is again operated to cut the second sheet material 14b or to create a weakened region 46 in the second sheet material 14b as discussed above. The steps described above are then repeated continuously to produce further aerosol generating pods 1.

[0099] In a first implementation shown in FIG. 13, the apparatus (in particular the supply units) is configured to move the first sheet material 14a, the aerosol generating material 10 and the inductively heatable susceptor sheets 18 by a smaller distance than the second sheet material 14b to transfer the first sheet material 14a, the second sheet material 14b and the aerosol generating material 10 including the inductively heatable susceptor sheets 18 to the punching position in the direction denoted by the arrow. As will be apparent from FIG. 13, in this first implementation the punching element 32 punches the first sheet material 14a, the aerosol generating material 10 and the inductively heatable susceptor sheets 18 in the manner described above thereby creating a series of holes 50 via shearing which are immediately adjacent to each other. A maximum usage of the first sheet material 14a, the aerosol generating material 10 and the inductively heatable susceptor sheets 18 is thereby achieved and the first implementation may thus provide a particularly efficient use of these materials, with minimum waste. As will be appreciated, the large circle denoted in FIG. 13 by the broken line corresponds to the weakened region 46 in the second sheet material 14b as described above whilst the large circles denoted by the solid lines indicate holes 52 in the second sheet material 14b that are formed due to separation of a portion of the second sheet material 14b by the punching element 32, as described above with reference to FIGS. 5 and 6.

[0100] In a second implementation shown in FIG. 14, the apparatus (in particular the supply units) is configured to move the first sheet material 14a, the second sheet material 14b, the aerosol generating material 10 and the inductively heatable susceptor sheets 18 by the same distance to transfer the first sheet material 14a, the second sheet material 14b and the aerosol generating material 10 including the inductively heatable susceptor sheets 18 to the punching position in the direction denoted by the arrow. As will be apparent from FIG. 14, in this second implementation the punching element 32 punches the first sheet material 14a, the aerosol generating material 10 and the inductively heatable susceptor sheets 18 in the manner described above thereby creating a series of holes 50 via shearing which are spaced apart from each other, leaving unused regions of the first sheet material 14a, the aerosol generating material 10 and the inductively heatable susceptor sheets 18 between the holes 50 as is clearly apparent in FIG. 14. Although the first sheet material 14a, the aerosol generating material 10 and the inductively heatable susceptor sheets 18 may be used less efficiently due to the presence of the unused regions between the holes 50, the second implementation allows the apparatus and method of manufacture to be simplified. As will be appreciated, the large circle denoted in FIG. 14 by the broken line corresponds to the weakened region 46 in the second sheet material 14b as described above whilst the large circles denoted by the solid lines indicate holes 52 in the second sheet material 14b that are formed due to separation of a portion of the second sheet material 14b by the punching element 32, as described above with reference to FIGS. 5 and 6.

[0101] FIG. 15 illustrates a variation of the method described above in which the second sheet material 14b is deformed, and in particular stretched, as it is pushed into the cavity 44 of the mould 34 by the punching element 32 as shown by the arrow in FIG. 15. With this variation of the method, the difference in the feed rate between the first sheet material 14a and the second sheet material 14b (as supplied by the corresponding second supply units 12) can be minimised because a smaller quantity of the second material 14b is required to cover the aerosol generating material 10 and inductively heatable susceptor sheets 18 during movement of the punching element 32 into the cavity 44 due to the elongation of the second sheet material 14b during the punching process.

[0102] The aerosol generating pod 1 manufactured by the above method and corresponding to the embodiment of FIG. 8 is shown in FIGS. 16a and 16b. The aerosol generating pod 1 comprises aerosol generating material 10 and a plurality of susceptor elements 18a which are formed by the cut portions of the inductively heatable susceptor sheets 18. The apertures 22 in the susceptor elements 18a facilitate the flow of air and vapour through the aerosol generating pod 1, for example towards an outlet (e.g. a mouthpiece) of an aerosol generating device. The aerosol generating material 10 and the susceptor elements 18a are fully enclosed by the sheet material 14 (first sheet material 14a and second sheet material 14b) to form a sealed aerosol generating pod 1.

[0103] 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.

[0104] For example, although the apparatus of FIGS. 1 and 2 include third supply units 16 for positioning an inductively heatable susceptor 18 in the aerosol generating material 10, the third supply units 16 may be omitted so that the resulting aerosol generating pod 1 comprises only aerosol generating material 10 covered by the sheet material 14. In this case, the aerosol generating pod 1 could be used with an aerosol generating device which employs a resistive heating system, for example in which a resistive heating element penetrates and/or is arranged proximate the aerosol generating pod 1 so that it can heat the aerosol generating material 10 within the aerosol generating pod 1 when the aerosol generating pod 1 is positioned in a heating compartment of the aerosol generating device. The aerosol generating pod 1 could equally be used with an aerosol generating device which employs an induction heating system, for example in which an inductively heatable susceptor penetrates and/or is arranged proximate the aerosol generating pod 1 so that it can heat the aerosol generating material 10 within the aerosol generating pod 1 when the aerosol generating pod 1 is positioned in a heating compartment of the aerosol generating device.

[0105] It is not strictly necessary to use a first sheet material 14a and a second sheet material 14b to cover the aerosol generating material 10 and the optional inductively heatable susceptor 18, and a single sheet material 14 could instead be used.

[0106] Any combination of the above-described features in all possible variations thereof is encompassed by the present disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.

[0107] Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise”, “comprising”, and the like, are to be construed in an inclusive as opposed to an exclusive or exhaustive sense; that is to say, in the sense of “including, but not limited to”.