Method And Apparatus For Manufacturing An Aerosol Generating Article
20210251301 · 2021-08-19
Assignee
Inventors
Cpc classification
B65B29/00
PERFORMING OPERATIONS; TRANSPORTING
A24D3/17
HUMAN NECESSITIES
A24D1/20
HUMAN NECESSITIES
B65B61/207
PERFORMING OPERATIONS; TRANSPORTING
B65B7/2842
PERFORMING OPERATIONS; TRANSPORTING
International classification
B65B1/04
PERFORMING OPERATIONS; TRANSPORTING
B65B61/20
PERFORMING OPERATIONS; TRANSPORTING
Abstract
A method for manufacturing an aerosol generating article comprises: (i) providing a plant-based aerosol generating material; (ii) providing an inductively heatable susceptor element; (iii) providing a cup comprising a bottom wall, a side wall and a flange at an open end; (iv) depositing a layer of plant-based aerosol generating material in the cup; (v) placing the inductively heatable susceptor element on the deposited layer of plant-based aerosol generating material; (vi) optionally repeating step (iv) only or steps (iv) and (v); and (vii) providing a closure and affixing the closure on the flange.
Claims
1. A method for manufacturing an aerosol generating article, the method comprising: (i) providing a plant-based aerosol generating material; (ii) providing an inductively heatable susceptor element; (iii) providing a cup comprising a bottom wall, a side wall and a flange at an open end; (iv) depositing a layer of plant-based aerosol generating material in the cup; (v) placing the inductively heatable susceptor element on the deposited layer of plant-based aerosol generating material; (vi) optionally repeating step (iv) only or steps (iv) and (v); (vii) providing a closure and affixing the closure on the flange.
2. The method according to claim 1, wherein step (iv) comprises dosing and depositing the plant-based aerosol generating material as granules, pellets, shreds, strands, particles, gel, strips, loose leaves, cut leaves, cut filler, porous material, foam material or sheets or combinations thereof.
3. The method according to claim 1, wherein the method further comprises the step of flattening the deposited layer of plant-based aerosol generating material.
4. The method according to claim 1, wherein step (ii) comprises providing a metal foil and cutting the metal foil to form a ring-shaped susceptor element or a plurality of ring-shaped susceptor elements.
5. The method according to claim 1, wherein the cup includes a cup axis extending between the open end and the bottom wall and step (vi) includes positioning respectively second and third inductively heatable susceptor elements in the cup at even distances from respectively the first and second inductively heatable susceptor elements in the direction of the cup axis.
6. The method according to claim 1, wherein step (vii) comprises affixing the closure on the flange by gluing or welding.
7. The method according to claim 1, wherein step (vii) comprises affixing the closure on the flange by a snap-fit connection.
8. The method according to claim 1, wherein the cup includes a positioning member for receiving the inductively heatable susceptor element and step (v) includes positioning the inductively heatable susceptor element by the positioning member.
9. The method according to claim 8, wherein the positioning member comprises a retaining surface extending continuously in a circumferential direction of an inside wall of the cup or at least two separate retaining surfaces at circumferentially spaced locations inside the cup and, step (v) comprises positioning the inductively heatable susceptor element on the retaining surface or surfaces.
10. The method according to claim 8, wherein the cup includes a cup axis extending between the open end and the bottom wall and at least two of said positioning members at different locations along the cup axis, preferably wherein the positioning member located along the cup axis nearest to the open end is closer to an inside wall of the cup than the other positioning member(s).
11. The method according to claim 8, wherein the cup further comprises a stopper extending from the side wall in a radially inward direction.
12. The method according to claim 11, wherein the side wall includes a step which includes the stopper and the positioning member.
13. An apparatus for manufacturing an aerosol generating article according to the method of claim 1, wherein the apparatus comprises: a cup holding unit for holding a plurality of cups; a first station comprising a dosing and depositing unit for depositing dosed layers of plant-based aerosol generating material in the cups; a second station comprising a foil receiving unit for receiving a metal foil and a cutting unit for cutting heatable inductively susceptor elements from the metal foil, the second station further comprising a placing unit for placing the inductively heatable susceptor elements in the cups; and a third station comprising a closure receiving unit and a sealing unit for affixing the closures on the flanges of the cups.
14. The apparatus according to claim 13, wherein the cutting unit comprises a punching unit configured for punching ring-shaped susceptor elements from the metal foil.
15. The apparatus according to claim 13, wherein the sealing unit comprises an adhesive applicator for applying a layer of adhesive between the closures and the flanges of the cups.
16. The apparatus according to claim 13, wherein the cup holding unit comprises a transport unit for moving the cups between the first, second and third stations.
17. The apparatus according to claim 13, wherein the cup holding unit comprises a sliding tray.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
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DETAILED DESCRIPTION OF EMBODIMENTS
[0073] Embodiments of the present disclosure will now be described by way of example only and with reference to the accompanying drawings.
[0074] Referring initially to
[0075] The cylindrical cup 10 is typically a paper cup, for example a moulded paper cup having a self-supporting moulded form. The bottom wall 12 is air-permeable and in the illustrated embodiment includes a plurality of openings or perforations 22. In some embodiments, the paper (or other material) from which the cup 10 is manufactured may have a porous structure which allows air to flow through the bottom wall 12 without the need for the openings or perforations 22.
[0076] The cup 10 contains a plant-based aerosol generating material 24, for example a solid or semi-solid material which has a powdered or crumbed form with a sieved particle size less than 1.7 mm. The plant-based aerosol generating material 24 also comprises an aerosol-former, such as glycerine or propylene glycol, which acts as a humectant. Typically, the plant-based aerosol generating material 24 may comprise an aerosol-former content of between approximately 30% and approximately 50% on a dry weight basis, and possibly approximately 40% on a dry weight basis. Upon being heated, the plant-based aerosol generating material 24 releases volatile compounds possibly including nicotine or flavour compounds such as tobacco flavouring.
[0077] The cup 10 also contains a plurality of ring-shaped inductively heatable susceptor elements 26. The inductively heatable susceptor elements 26 are arranged coaxially inside the cylindrical cup 10 with respect to a cup axis extending between the bottom wall 12 and the open end 16 and are spaced apart in the axial direction along the cup axis. When an alternating electromagnetic field is applied in the vicinity of the inductively heatable susceptor elements 26 during use of the article 1 in an aerosol generating device, heat is generated in the inductively heatable susceptor elements 26 due to eddy currents and magnetic hysteresis losses and the heat is transferred from the inductively heatable susceptor elements 26 to the plant-based aerosol generating material 24 to heat the plant-based aerosol generating material 24 without burning it and to thereby generate a vapour which cools and condenses to form an aerosol for inhalation by a user. The inductively heatable susceptor elements 26 are in contact over substantially their entire surfaces with the plant-based aerosol generating material 24, thus enabling heat to be transferred directly, and therefore efficiently, from the inductively heatable susceptor elements 26 to the plant-based aerosol generating material 24.
[0078] The closure 18 at the open end 16 retains the plant-based aerosol generating material 24 and the inductively heatable susceptor elements 26 inside the cup 10. It will be understood by one of ordinary skill in the art that the closure 18 needs to be air-permeable so that a vapour or aerosol generated due to heating of the plant-based aerosol generating material 24 can flow out of the cylindrical cup 10 during use of the aerosol generating article 1 in an aerosol generating device. In the example illustrated in
[0079] Referring now to
[0080] As best seen in
[0081] Referring now to
[0082] The aerosol generating article 2 comprises a closure 18 having a snap-fit connector 34. The snap-fit connector 34 comprises a circumferentially extending hook 36 forming a circumferential recess 38 in which the flange 20 can be securely located as shown in
[0083] Referring now to
[0084] The aerosol generating article 3 comprises a cup 210 having a flange 20 which projects in the radially inward direction and forms a snap-fit connector 42. In more detail, the snap-fit connector 42 comprises an upper circumferential flange portion 44 and a lower circumferential flange portion 46 which define therebetween a circumferential recess 48 in which the periphery of the closure 18 can be securely retained as shown in
[0085] Referring now to
[0086] In first, second and third steps S1, S2 and S3, the method comprises respectively providing plant-based aerosol generating material 24, providing an inductively heatable susceptor element 26 and providing a cup 10, 110, 210 comprising a bottom wall 12, a side wall 14 and a flange 20 at an open end 16. The inductively heatable susceptor element 26 in step S2 is preferably provided by punching a continuous susceptor element, preferably a metal foil, most preferably an aluminium foil, to form one or more ring-shaped susceptor elements 26 as described above with reference to
[0087] In a fourth step S4, a layer of the plant-based aerosol generating material 24 is deposited in the cup 10, 110, 210. The layer of plant-based aerosol generating material 24, which typically has a powdered or crumbed form as discussed above, is dosed (for example weighed) and deposited in the cup 10, 110, 210 to ensure that the deposited layer contains a predetermined amount (e.g. mass) of the aerosol generating material 24. In some embodiments, the mass of the aerosol generating material 24 in the deposited layer may be between 40 mg and 60 mg, for example approximately 50 mg. In an optional step, the method may comprise flattening the deposited layer of the plant-based aerosol generating material 12. The flattening is ideally carried out without pressing the deposited layer of the plant-based aerosol generating material 12 to avoid compaction of the aerosol generating material 12.
[0088] In a fifth step S5, an inductively heatable susceptor element 26 as provided in step S2 is placed on the layer of plant-based aerosol generating material 24 deposited in the cup in step S4.
[0089] In an optional step S6, a further layer of the plant-based aerosol generating material 24 can be dosed and deposited in the cup 10 (i.e. step S4 only can be repeated) or a further layer of the plant-based aerosol generating material 24 can be dosed and deposited in the cup 10 and an inductively heatable susceptor element 26 can be placed on the further layer of plant-based aerosol generating material 24 (i.e. both steps S4 and S5 can be repeated a desired number of times to provide a plurality of alternating layers of the plant-based aerosol generating material 24 and inductively heatable susceptor elements 26).
[0090] In a final step S7, a closure 18 is provided and the closure 18 is affixed on the flange 20, for example by gluing or welding the closure 18 on the flange 20 as described above with reference to
[0091] Referring now to
[0092] The steps 54a-c define a plurality of radially extending retaining surfaces 56a-c which extend continuously in a circumferential direction of the inside wall 58 of the cup 310. The retaining surfaces 56a-c act as positioning members 56 for positioning the inductively heatable susceptor elements 26 axially in the cup 310, along the cup axis, as will be described below with reference to
[0093] The steps 54a-c also define a plurality of axially extending abutment surfaces 60a-c which extend continuously in a circumferential direction of the inside wall 58 of the cup 310. The abutment surfaces 60a-c act as stoppers 60 for positioning the inductively heatable susceptor elements 26 radially in the cup 310, for example so that they are coaxial with the cup axis, as will be described below with reference to
[0094] Referring now to
[0095] The inductively heatable susceptor element 26a contacts the retaining surface 56a and the abutment surface 60a and is thereby positioned in predetermined axial and radial positions inside the cup 310.
[0096] Further layers of plant-based aerosol generating material 24b-d and further inductively heatable susceptor elements 26b-c are then placed in the cup 310 as shown in
[0097] In particular, a second layer 24b of plant-based aerosol generating material 24 is dosed and deposited in the cup 310 as shown in
[0098] A third layer 24c of plant-based aerosol generating material 24 is then dosed and deposited in the cup 310 as shown in
[0099] A fourth and final layer 24d of plant-based aerosol generating material 24 is then dosed and deposited in the cup 310 as shown in
[0100] Referring now to
[0101] The steps 64a-c define a plurality of radially extending retaining surfaces 66a-c which act as positioning members 66 for positioning the inductively heatable susceptor elements 26a-c axially in the cup 410, along the cup axis, as described above with reference to
[0102] Referring now to
[0103] After the pins 72 have been inserted through the openings 22 in the bottom wall 12, a first layer 24a of plant-based aerosol generating material 24 is dosed and deposited in the cup 310 as shown in
[0104] Further layers of plant-based aerosol generating material 24b-d and further inductively heatable susceptor elements 26b-c are then placed in the cup 510 as shown in
[0105] After the fourth and final layer 24d of plant-based aerosol generating material 24 has been dosed and deposited in the cup 510 as shown in
[0106] Referring now to
[0107] The first station 84 comprises a dosing and depositing unit for depositing dosed layers of plant-based aerosol generating material 24 in the cups held by the cup holding unit 82. The second station 86 comprises a foil receiving unit for receiving a metal foil and a cutting unit, for example a punching unit, for punching the metal foil to form ring-shaped inductively heatable susceptor elements 26 as described above. The second station 86 also comprises a placing unit for placing the ring-shaped inductively heatable susceptor elements 26 in the cups held by the cup holding unit 82. The third station 88 comprises a closure receiving unit and a sealing unit, such as an adhesive applicator for applying a layer of adhesive between the closures 18 and the flanges 20 of the cups to enable the closures 18 to be affixed on the flanges 20 of the cups.
[0108] The apparatus 80 comprises a controller (not shown) configured for controlling the operation of the transport unit, and for thereby controlling the movement of the sliding tray between the first, second and third stations 84, 86, 88. The controller is also configured for controlling the operation of the first, second and third stations 84, 86, 88.
[0109] In operation, the cup holding unit 82 loaded with cups is positioned at the first station 84 by the transport unit so that a first layer of plant-based aerosol generating material 24 can be dosed and deposited in the cups in accordance with step S4 described above. The cup holding unit 82 is then moved by the transport unit under the operation of the controller to the second station 86 so that inductively heatable susceptor elements 26 can be placed in the cups in accordance with step S5 described above. The cup holding unit 82 can, if desired, be moved by the transport unit under the action of the controller back to the first station 84 so that a second layer of plant-based aerosol generating material 24 can be dosed and deposited in the cups in accordance with step S4 described above. The cup holding unit 82 can be moved back and forth between the first and second stations 84, 86 by the transport unit, under the action of the controller, a desired number of times to provide a desired number of layers of the plant-based aerosol generating material 24 and a desired number of the inductively heatable susceptor elements 26 in the cups. Finally, the cup holding unit 82 is moved by the transport unit under the action of the controller to the third station 88 where a closure 18 is affixed on the flange 20 of each of the cups in the cup holding unit 82 to thereby provide a plurality of aerosol generating articles which can then be removed from the cup holding unit 82.
[0110] 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.
[0111] 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.
[0112] 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”.