Aerosol Generating Articles and Methods for Manufacturing the Same

Abstract

A method for manufacturing an aerosol generating article includes: (i) providing a first material containing a plant-based aerosol generating material; (ii) arranging a second material, constituting a mouthpiece, in line with the first material; and (iii) wrapping the first and second materials with a sheet to form a substantially cylindrical aerosol generating article. Step (i) includes: (a) providing the plant-based aerosol generating material as a foam material; or (b) providing a cylindrical cup and filling the cylindrical cup with the plant-based aerosol generating material and a third material.

Claims

1. A method for manufacturing an aerosol generating article, the method comprising: (i) providing a first material containing a plant-based aerosol generating material; (ii) arranging a second material, constituting a mouthpiece, in line with the first material; (iii) wrapping the first and second materials with a sheet to form a substantially cylindrical aerosol generating article; wherein step (i) comprises: (a) providing the plant-based aerosol generating material as a foam material; or (b) providing a cylindrical cup and filling the cylindrical cup with the plant-based aerosol generating material and a third material.

2. The method according to claim 1, wherein the cylindrical cup is a paper cup.

3. The method according to claim 1, wherein a bottom wall of the cylindrical cup is air-permeable.

4. The method according to claim 1, wherein the third material comprises an inductively heatable susceptor.

5. The method according to claim 4, wherein the inductively heatable susceptor comprises a plurality of substantially planar inductively heatable susceptor elements and step (b) comprises alternately positioning the plant-based aerosol generating material and the substantially planar inductively heatable susceptor elements in the cylindrical cup.

6. The method according to claim 4, wherein the inductively heatable susceptor is substantially tubular and step (b) comprises positioning the plant-based aerosol generating material and the tubular susceptor in the cylindrical cup so that the plant-based aerosol generating material is arranged both inside and outside the tubular susceptor.

7. The method according to claim 4, wherein the inductively heatable susceptor comprises a particulate susceptor material and step (b) comprises filling the cylindrical cup with a mixture of the plant-based aerosol generating material and the particulate susceptor material.

8. The method according to claim 1, wherein the step of filling the cylindrical cup with the plant-based aerosol generating material and the third material is carried out on a turntable.

9. The method according to claim 1, wherein the method further comprises, after the step of filling the cylindrical cup with the plant-based aerosol generating material and the third material, the step of closing an open end of the cylindrical cup with an air-permeable closure to retain the plant-based aerosol generating material in the cup.

10. The method according to claim 1, wherein the second material includes a filter material.

11. The method according to claim 1, wherein step (ii) comprises arranging two bodies of the second material, one of which constitutes the mouthpiece, in line with the first material so that the first material is positioned between the two bodies of the second material.

12. The method according to claim 1, wherein a hollow body is positioned between the first material and the second material.

13. The method according to claim 1, wherein the method is performed using an apparatus having a plurality of drums and each drum includes a plurality of axially extending and circumferentially arranged grooves which are adapted to perform the arranging of step (ii) or the wrapping of step (iii).

14. The method according to claim 1, wherein the foam material includes an inductively heatable susceptor.

15. An aerosol generating article comprising: a first cylindrical material containing a plant-based aerosol generating material; a second cylindrical material; wherein the first cylindrical material and the second cylindrical material are arranged in line and wrapped by a sheet; and wherein the first cylindrical material comprises a foam material or a cylindrical cup containing plant-based aerosol generating material and a third material.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0040] FIG. 1 is diagrammatic cross-sectional view of a first example of an aerosol generating article;

[0041] FIG. 2 is a schematic illustration of a method for manufacturing the first example of the aerosol generating article shown in FIG. 1;

[0042] FIG. 3 is a diagrammatic cross-sectional view of a second example of an aerosol generating article;

[0043] FIGS. 4a to 4e are diagrammatic cross-sectional views of part of the second example of the aerosol generating article of FIG. 3, showing different configurations of an inductively heatable susceptor;

[0044] FIG. 5 is a schematic illustration of a method for manufacturing the second example of the aerosol generating article shown in FIG. 3;

[0045] FIGS. 6a and 6b are schematic illustrations of an apparatus and method for manufacturing the second example of the aerosol generating article shown in FIG. 3 with the alternative susceptor configuration shown in FIG. 4a; and

[0046] FIG. 7 is a diagrammatic cross-sectional view of an aerosol generating system comprising an aerosol generating device and the second example of the aerosol generating article illustrated in FIG. 3.

DETAILED DESCRIPTION OF EMBODIMENTS

[0047] Embodiments of the present disclosure will now be described by way of example only and with reference to the accompanying drawings.

[0048] Referring initially to FIG. 1, there is shown a first example of an aerosol generating article 1 for use with an aerosol generating device, an example of which will be described later in this specification. The aerosol generating article 1 is elongate and substantially cylindrical. The circular cross-section facilitates handling of the article 1 by a user and insertion of the article 1 into a heating compartment of an aerosol generating device.

[0049] The aerosol generating article 1 comprises a first cylindrical material 10 containing a plant-based aerosol generating material 12. The plant-based aerosol generating material 12 comprises a foam material and, thus, has a semi-solid form. The plant-based aerosol generating material 12 typically comprises tobacco and, thus, may sometimes be referred to as a tobacco foam or a tobacco mousse.

[0050] The plant-based aerosol generating material 12 comprises an aerosol-former such as glycerine or propylene glycol. Typically, the plant-based aerosol generating material 12 may comprise an aerosol-former content of between approximately 5% and approximately 50% on a dry weight basis. Upon being heated, the plant-based aerosol generating material 12 releases volatile compounds possibly including nicotine or flavour compounds such as tobacco flavouring.

[0051] The plant-based aerosol generating material 12 includes an inductively heatable susceptor 14 in particulate form which is distributed throughout the plant-based aerosol generating material 12. When a time varying electromagnetic field is applied in the vicinity of the particulate inductively heatable susceptor 14 during use of the article 1 in an aerosol generating device, heat is generated in the particulate inductively heatable susceptor 14 due to eddy currents and magnetic hysteresis losses and the heat is transferred from the particulate susceptor material to the plant-based aerosol generating material 12 to heat the aerosol generating material 12 without burning it and to thereby generate an aerosol for inhalation by a user. The particulate inductively heatable susceptor 14 is typically distributed evenly throughout the plant-based aerosol generating material 12, thus enabling heat to be transferred directly, and therefore efficiently, from the particulate susceptor material to the plant-based aerosol generating material 12.

[0052] The aerosol generating article 1 comprises a second cylindrical material 16 arranged in line with the first cylindrical material 10. The second cylindrical material 16 includes a filter material, such as cellulose acetate fibres, and constitutes a mouthpiece 18 of the aerosol generating article 1 through which a user can inhale an aerosol generated during use of the article 1 in an aerosol generating device.

[0053] A hollow body 20, for example comprising cellulose acetate fibres defining a passage 22, is positioned in line with, and between, the first and second cylindrical materials 10, 16, i.e., between the plant-based aerosol generating material 12 and the mouthpiece 18. As heated aerosol flows through the passage 22 in the hollow body 20 from the plant-based aerosol generating material 12 towards the mouthpiece 18, the heated aerosol cools and condenses to form an aerosol having optimum characteristics, including temperature, for inhalation by a user through the mouthpiece 18.

[0054] In the illustrated embodiment, a further cylindrical body 24 of the second material is arranged in line with the first cylindrical material 10, on the opposite of side plant-based aerosol generating material 12 to the mouthpiece 18 and the hollow body 20. Thus, the plant-based aerosol generating material 12 is positioned between the second cylindrical material 16 constituting the mouthpiece 18 and the further cylindrical body 24 of the second material, and more particularly directly between the hollow body 20 and the further cylindrical body 24 of the second material.

[0055] The component parts of the aerosol generating article 1, namely the first cylindrical material 10 containing the plant-based aerosol generating material 12, the hollow body 20, the second cylindrical material 16 constituting the mouthpiece 18 and the further cylindrical body 24 of the second material, are wrapped by a sheet 26, typically in the form of a paper wrapper, which ensures that the component parts are held together in line with each other. In the illustrated embodiment, it will be seen that the hollow body 20 and the second cylindrical material 16 constituting the mouthpiece 18 are wrapped by a sheet 28, typically in the form of a paper wrapper, to hold the two component parts in line. With this arrangement, the sheet 26 circumscribes the sheet 28 along part of its length in an overlapping region and thereby holds the component parts of the article 1 in line with each other.

[0056] Referring now to FIG. 2, there is shown an example of a method for manufacturing the aerosol generating article 1 described above with reference to FIG. 1.

[0057] In a first step 30, the method comprises providing the first cylindrical material 10 containing the plant-based aerosol generating material 12 as a foam material. As explained above, the plant-based aerosol generating material 12 may comprise a particulate inductively heatable susceptor material 14 distributed throughout the foam material.

[0058] In a second step 32, the method comprises arranging the second cylindrical material 16 constituting the mouthpiece 18 in line with the first cylindrical material 10 containing the plant-based aerosol generating material 12. In the illustrated example of the second step 32, it will be noted that the second cylindrical material 16 constituting the mouthpiece 18 and the hollow body 20 have already been arranged in line and wrapped by the sheet 28 to secure their relative positions. The first cylindrical material 10 containing the plant-based aerosol generating material 12 is then positioned between, and in line with, the hollow body 20 (and hence the mouthpiece 18) and the further cylindrical body 24 of the second material.

[0059] In a third step 34, any gaps between the component parts of the article 1 are closed and both the first cylindrical material 10 containing the plant-based aerosol generating material 12 and the further cylindrical body 24 of the second material are wrapped by the sheet 26 to form the cylindrical aerosol generating article 1. Wrapping by the sheet 26 secures the first cylindrical material 10 containing the plant-based aerosol generating material 12 and the further cylindrical body 24 of the second material in line with each other and further secures the first cylindrical material 10 containing the plant-based aerosol generating material 12 and the further cylindrical body 24 of the second material to the previously wrapped second cylindrical material 16 constituting the mouthpiece 18 and the hollow body 20 by virtue of the overlapping region between the sheets 26, 28.

[0060] Referring now to FIG. 3, there is shown a second example of an aerosol generating article 2 which is similar to the aerosol generating article 1 described above with reference to FIGS. 1 and 2 and in which corresponding elements are designated using the same reference numerals.

[0061] In the aerosol generating article 2, the first cylindrical material 10 comprises a cylindrical cup 40 filled with the plant-based aerosol generating material 12 and a third material 42. In this example, the plant-based aerosol generating material 12 is typically a solid or semi-solid material. Examples of suitable aerosol forming solids include powder, shreds, strands, porous material, foam material and sheets. The plant-based aerosol generating material 12 comprises an aerosol former as described above and typically comprises tobacco.

[0062] The cylindrical cup 40 is typically a paper cup, for example a moulded paper cup. As best seen in FIG. 5, the cylindrical cup 40 has an open end 44, a closed end 46 defined by a substantially circular bottom wall 48 and a substantially cylindrical side wall 50. The bottom wall 48 is air-permeable and in the illustrated embodiment includes a plurality of openings or perforations 52.

[0063] The third material 42 comprises an inductively heatable susceptor 14. In the embodiment of FIG. 3, the inductively heatable susceptor 14 is a tubular inductively heatable susceptor 54 which extends fully along the length of the cylindrical cup 40 between the open and closed ends 44, 46. The plant-based aerosol generating material 12 is arranged both inside and outside of the tubular inductively heatable susceptor 54. When a time varying electromagnetic field is applied in the vicinity of the tubular inductively heatable susceptor 54 during use of the article 2 in an aerosol generating device, heat is generated in the tubular inductively heatable susceptor 54 due to eddy currents and magnetic hysteresis losses and the heat is transferred from the tubular inductively heatable susceptor 54 to the plant-based aerosol generating material 12 to heat the plant-based aerosol generating material 12 without burning it and to thereby generate an aerosol for inhalation by a user. The tubular inductively heatable susceptor 54 is in contact over substantially its entire inner and outer surfaces with the plant-based aerosol generating material 12, thus enabling heat to be transferred directly, and therefore efficiently, from the tubular inductively heatable susceptor 54 to the plant-based aerosol generating material 12.

[0064] FIGS. 4a to 4e are diagrammatic illustrations of the cylindrical cup 40 with different configurations of the inductively heatable susceptor 14.

[0065] In the example of FIG. 4a, the inductively heatable susceptor 14 comprises a plurality of substantially planar susceptor elements 56, such as discs or rings 56, which are arranged coaxially inside the cylindrical cup 40 and which are spaced apart in the axial direction between the open and closed ends 44, 46.

[0066] In the example of FIG. 4b, the inductively heatable susceptor 14 comprises a tubular susceptor 58 which is similar to the tubular susceptor 54 described above with reference to FIG. 3 but which extends only part way along the length of the cylindrical cup 40 between the open and closed ends 44, 46.

[0067] In the example of FIG. 4c, the inductively heatable susceptor 14 comprises a particulate susceptor material 60 which is distributed throughout the plant-based aerosol generating material 12. The cylindrical cup 40 may, for example, contain a mixture of the plant-based aerosol generating material 12 and the particulate susceptor material 60.

[0068] In the example of FIG. 4d, the inductively heatable susceptor 14 comprises a needle or plate susceptor 62 which is arranged axially in the cylindrical cup 40 so that it extends between the open and closed ends 44, 46.

[0069] In the example of FIG. 4e, the inductively heatable susceptor 14 comprises a plurality of susceptor strips or plates 64 which are distributed throughout the plant-based aerosol generating material 12.

[0070] It will be understood that the configurations of the inductively heatable susceptor 14 described above with reference to FIGS. 3 and 4a to 4e are given by way of example only and that other configurations, apparent to one of ordinary skill in the art, are entirely within the scope of the present disclosure.

[0071] Referring again to FIG. 3, the cylindrical cup 40 includes an air-permeable closure 66 at the open end 44 to retain the plant-based aerosol generating material 12 and the inductively heatable tubular susceptor 54 inside the cup 40. The cylindrical cup 40 is positioned in line with the hollow body 20 and the second cylindrical material 16 constituting the mouthpiece 18 with the closure 66 positioned adjacent to the hollow body 20. The cylindrical cup 40, the hollow body 20 and the second cylindrical material 16 constituting the mouthpiece 18 are wrapped by a sheet 68, typically in the form of a paper wrapper. It will be understood by one of ordinary skill in the art that the closure 66 needs to be air-permeable so that an aerosol generated upon heating of the plant-based aerosol generating material 12 can flow from the cylindrical cup 40, along the passage 22 and through the mouthpiece 18 during use of the aerosol generating article 2 in an aerosol generating device.

[0072] Referring now to FIG. 5, there is shown an example of a method for manufacturing the aerosol generating article 2 described above with reference to FIG. 3.

[0073] In first and second steps 70, 72, a cylindrical cup 40 as described above is provided and is filled with the plant-based aerosol generating material 12 and the third material 42, namely the inductively heatable tubular susceptor 54. In a third step 74, the open end 44 of the cylindrical cup 40 is closed with the air-permeable closure 66 to ensure that the plant-based aerosol generating material 12 and the tubular susceptor 54 are retained inside the cylindrical cup 40 irrespective of its orientation.

[0074] In a fourth step 76, the second cylindrical material 16 constituting the mouthpiece 18 is arranged in line with the cylindrical cup 40, with the air-permeable closure 66 positioned adjacent to the hollow body 20. In the illustrated example of the fourth step 76, it will be noted that the second cylindrical material 16 constituting the mouthpiece 18 and the hollow body 20 have already been arranged in line and wrapped by the sheet 28 to secure their relative positions.

[0075] In a fifth step 78, the cylindrical cup 40 and the previously wrapped hollow body 20 and second cylindrical material 16 (mouthpiece 18) are wrapped and secured in line relative to each other by the sheet 68 to form the cylindrical aerosol generating article 2. It will be noted that the sheet 68 extends only part way along the outer surface of the side wall 50 of the cylindrical cup 40, from the end sealed by the air-permeable closure 66 towards the closed end 46. This is sufficient to secure the component parts of the aerosol generating article 2 together, although in other embodiments the sheet 68 could extend further, and possibly fully, along the outer surface of the side wall 50 of the cylindrical cup 40, towards the closed end 46.

[0076] Referring now to FIGS. 6a and 6b, there is shown schematically an apparatus and method for manufacturing the second example of the aerosol generating article 2 described above with reference to FIG. 3 with the alternative susceptor configuration described above with reference to FIG. 4a. The apparatus and method is particularly suitable for the mass production of aerosol generating articles 2.

[0077] Referring initially to FIG. 6a, the apparatus comprises a turntable 80 (shown in plan view in FIG. 6a) having a plurality of recesses 82 for receiving a cylindrical cup 40 as described above. The turntable 80 is indexed, typically by a motor, in an anti-clockwise direction as shown by the arrow in FIG. 6a and each recess is thus indexed to a different rotational position. The operation of the turntable 80 in FIG. 6a is explained in relation to a single cylindrical cup 40 contained in a single recess 82 at different indexing positions denoted by the reference numerals 82a to 82j. It will, of course, be understood that each adjacent recess typically comprises a cylindrical cup 40 at different stages of preparation so that, in the illustrated embodiment, a plurality of cylindrical cups 40 are typically simultaneously prepared using the turntable 80.

[0078] In order to prepare a cylindrical cup 40 filled with the plant-based aerosol generating material 12 and the induction heatable susceptor discs/rings 56, an empty cylindrical cup 40 is initially located in the recess 82 at position 82a. The turntable 80 is then indexed in the anti-clockwise direction to position 82b where a first layer of the plant-based aerosol generating material 12 is positioned in the cylindrical cup 40. After that, the turntable 80 is indexed in the anticlockwise direction to position 82c where a first induction heatable susceptor disc/ring 56 is positioned on the previously deposited first layer of the plant-based aerosol generating material 12. Further indexed rotation of the turntable 80 in the anti-clockwise direction allows further layers of plant-based aerosol generating material 12 and further induction heatable susceptor discs/rings 56 to be positioned sequentially in the cylindrical cup 40: at position 82d, a second layer of plant-based aerosol generating material 12 is positioned in the cup 40; at position 82e, a second induction heatable disc/ring 56 is positioned in the cup 40 on the previously deposited second layer of plant-based aerosol generating material 12; at position 82f, a third layer of plant-based aerosol generating material 12 is positioned in the cup 40; at position 82g, a third induction heatable disc/ring 56 is positioned in the cup 40 on the previously deposited third layer of plant-based aerosol generating material 12; and at position 82h, a fourth and final layer of plant-based aerosol generating material 12 is positioned in the cup 40 to completely fill the cup 40.

[0079] To complete the preparation of the cylindrical cup 40, the turntable 80 is again indexed in the anti-clockwise direction to move the cup 40 to position 82i at which the air-permeable closure 66 is positioned on the open end 44 of the cup 40 to ensure that the plant-based aerosol generating material 12 and the induction heatable discs/rings 56 are retained in the cup 40. Finally, the turntable 80 is indexed in the anti-clockwise direction to move the cup to position 82j at which the prepared cup 40 is transferred to a plurality of drums 84a-g as shown in FIG. 6b. Each drum 84a-g includes a plurality of axially extending and circumferentially arranged grooves around its outer surface, and the drums 84a-g are arranged to assemble the various components described above to mass produce a plurality of the aerosol generating articles 2.

[0080] In more detail, in Step 1 each groove in the first drum 84a receives two axially spaced cups 40 from recesses 82 at position 82j on separate turntables 80. The axially spaced cups 40 are transferred from the first drum 84a to a second drum 84b as the first and second drums 84a, 84b rotate. Each of the grooves in a third drum 84c receives a second cylindrical material 16 as described above and a hollow body 20 positioned on each side of the second cylindrical material 16 in Step 2. The second cylindrical material 16 and the hollow bodies 20 have been previously wrapped by a sheet 28 to secure them in line relative to each other.

[0081] The second and third drums 84b, 84c are arranged so that the wrapped second cylindrical material 16 and the hollow bodies 20 are transferred from each groove of the third drum 84c into a groove of the second drum 84b, thus positioning the wrapped second cylindrical material 16 and the hollow bodies 20 from a groove in the third drum 84c into a groove in the second drum 84b in between the two cups 40 and forming a partially assembled article as denoted by Step 3. As the partially assembled articles are transported by the second and fourth drums 84b, 84d, the cylindrical cups 40 are pushed towards, and into contact with, the adjacent hollow bodies 20 in Step 4.

[0082] In Step 5, the partially assembled articles are each transported in the grooves of a fifth drum 84e and are wrapped by individual sheets 68 that are supplied by a sixth drum 84f. The cups 40 are pressed as they are wrapped by the sheets 68 and, thus, the use of paper cups 40 is particularly advantageous as the cups 40 are able to deform without being broken.

[0083] The partially assembled articles are finally transported by a seventh drum 84g where a cutter 86 is used to cut the second cylindrical material 16 at roughly its midpoint in Step 6. This results in the manufacture of two aerosol generating articles 2 in which the second cylindrical material 16 acts as the mouthpiece 18 for each article 2.

[0084] Referring now to FIG. 7, there is shown an aerosol generating system 90 for generating an aerosol to be inhaled. The aerosol generating system 90 comprises an aerosol generating device 92. The aerosol generating device 92 comprises a housing 94, a power source 96 and control circuitry 98 which may be configured to operate at high frequency. The power source 96 typically comprises one or more batteries which could, for example, be inductively rechargeable. The aerosol generating device 92 also includes an air inlet 100.

[0085] The aerosol generating device 92 comprises an induction heating assembly 102 for heating the plant-based aerosol generating material 12. The induction heating assembly 102 comprises a generally cylindrical heating compartment 104 which is arranged to receive a correspondingly shaped generally cylindrical aerosol generating article in accordance with aspects of the present disclosure.

[0086] FIG. 7 shows a third example of an aerosol generating article 3 positioned in the heating compartment 104. The aerosol generating article 3 is similar to the aerosol generating article 2 described above with reference to FIG. 3 and additionally comprises a further cylindrical body 24 of the second material 16 as shown in FIG. 1. The further cylindrical body 24 of the second material 16 provides a uniform distribution of air flowing into the heating compartment 104 through the air inlet 100 across the surface of the circular bottom wall 48 of the cylindrical cup 40.

[0087] The heating compartment 104 and the aerosol generating article 3 are arranged so that the second cylindrical material 16 constituting the mouthpiece 18 projects from the heating compartment 104 thus enabling a user to engage their lips with the mouthpiece 18 to inhale aerosol generated during operation of the system 90.

[0088] The induction heating assembly 102 comprises a helical induction coil 106, having first and second axial ends, which extends around the cylindrical heating compartment 104 and which can be energised by the power source 96 and control circuitry 98. Thus, the induction coil 106 defines a cavity, in the form of heating compartment 104, in which the aerosol generating article 3 is positioned. It will be noted that the heating compartment 104 and the aerosol generating article 3 each have a respective longitudinal axis and that the longitudinal axes are substantially aligned with each other when the aerosol generating article 3 is positioned inside the heating compartment 104.

[0089] The control circuitry 98 includes, amongst other electronic components, an inverter which is arranged to convert a direct current from the power source 96 into an alternating high-frequency current for the induction coil 106. As will be understood by those skilled in the art, when the induction coil 106 is energised by the alternating high-frequency current, an alternating and time-varying electromagnetic field is produced. This couples with the inductively heatable tubular susceptor 54 and generates eddy currents and/or magnetic hysteresis losses in the tubular susceptor 54 causing it to heat up. The heat is then transferred from the tubular susceptor 54 to the plant-based aerosol generating material 12, for example by conduction, radiation and convection, to heat the plant-based aerosol generating material 12 without burning and thereby produce an aerosol. The aerosolisation of the plant-based aerosol generating material 12 is facilitated by the addition of air from the surrounding environment through the air inlet 100. The aerosol generated by heating the plant-based aerosol generating material 12 flows through the air-permeable closure 66, along the passage 22 and through the mouthpiece 18 where it is typically inhaled by a user of the system 90.

[0090] 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.

[0091] 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.

[0092] 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”.