Abstract
A composite aerosol-generating material (530) comprising two sheets of carrier material (522A, 522B), with gel (544) interposed between. The method of manufacturing and apparatus for such manufacturing; a composite aerosol-generating material (530) comprising gel (544) interposed between two sheets of carrier material (522A, 522B). The gel (544) may carry an aerosol-generating substance, such as, nicotine.
Claims
1. A method of manufacturing a composite aerosol-generating material, comprising the steps of: providing a first continuous sheet of carrier material; dispensing gel to a surface of the first continuous sheet of carrier material; providing a second continuous sheet of carrier material and positioning the second continuous sheet of carrier material to the gel to form a composite material with gel interposed between the first continuous sheet of carrier material and the second continuous sheet of carrier material; and, further comprising the step of: dispensing a greater amount of gel to a central region proximal to the longitudinal axis of the first continuous sheet of carrier material relative to the amount of gel dispensed to a lateral region, distal to the longitudinal axis of the first continuous sheet of carrier material.
2. The method of manufacturing a composite aerosol-generating material according to claim 1, further comprising the step of: crimping, at least one of; the first continuous sheet of carrier material and the second continuous sheet of carrier material.
3. The method of manufacturing a composite aerosol-generating material according to claim 1, further comprising the step of: providing the first continuous sheet of carrier material and the second continuous sheet of carrier material from different respective sources of carrier material.
4. The method of manufacturing a composite aerosol-generating material according to claim 1, further comprising the step of: providing both the first continuous sheet of carrier material and the second continuous sheet of carrier material from a single source of carrier material.
5. The method of manufacturing a composite aerosol-generating material according to claim 4, further comprising the step of: folding a continuous sheet of the single source of carrier material to form both the first continuous sheet of carrier material and the second continuous sheet of carrier material such that the first continuous sheet of carrier material and the second continuous sheet of carrier are integral with each other via a folding line.
6. The method of manufacturing a composite carrier material according to claim 4, further comprising the step of: cutting a continuous sheet of the single source of carrier material to form both the first continuous sheet of carrier material and the second continuous sheet of carrier material.
7. The method of manufacturing of a composite aerosol-generating material according to claim 1, further comprises the step of providing a continuous band of susceptor material and positioning the continuous band of susceptor material to the gel after the gel is dispensed onto the first continuous sheet of carrier material.
8. The method of manufacturing a composite aerosol-generating material according to claim 1, further comprising the step of pressing the composite aerosol-generating material in a direction perpendicular to its planar surface.
9. The method of manufacturing a composite aerosol-generating material according to claim 1, wherein the gel comprises a flavour or an active agent or a plasticizer or a humectant or nicotine or glycerine or propylene glycol or any combination thereof.
10. The method of manufacturing a composite aerosol-generating material according to claim 1, wherein the composite aerosol-generating material comprises tobacco material.
11. A composite aerosol-generating material comprising: a first sheet of carrier material; a second sheet of carrier material; and gel wherein the gel is disposed between the first sheet of carrier material and the second sheet of carrier material, and wherein there is a greater amount of gel disposed on a central region proximal to the longitudinal axis of the first continuous sheet of carrier material relative to the amount of gel disposed on a lateral region, distal to the longitudinal axis of the first continuous sheet of carrier material.
12. A composite aerosol-generating material according to claim 11 further comprises a susceptor material positioned between the first sheet of carrier material and the second sheet of carrier material.
13. A composite aerosol-generating material according to claim 11, wherein the first continuous sheet of carrier material, or the second sheet of carrier material, or both the first and second sheets of carrier material, comprise an aerosol-generating material.
14. A composite aerosol-generating rod comprising: a composite aerosol-generating material according to claim 11.
15. A composite aerosol-generating rod comprising: a composite aerosol-generating material as manufactured according to claim 1.
Description
[0102] Reference will now be made to the drawings, which depict one or more aspects described in this disclosure. However, it will be understood that other aspects not depicted in the drawings fall within the scope of this disclosure. Like numbers used in the figures refer to like components, steps and the like. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number. In addition, the use of different numbers to refer to components in different figures is not intended to indicate that the different numbered components cannot be the same or similar to other numbered components. The figures are presented for purposes of illustration and not limitation. Schematic drawings presented in the figures are not necessarily to scale.
[0103] FIG. 1 is a schematic perspective view of a cutting system for cutting a sheet of source carrier material.
[0104] FIG. 2 is a schematic perspective view of example of a gel dispensing system with several nozzles for a sheet of source carrier material.
[0105] FIG. 3 illustrates a schematic top view of a layering system for manufacturing an aerosol-generating material stack.
[0106] FIG. 4 illustrates a schematic side view of the layering system of FIG. 3.
[0107] FIG. 5 is a schematic perspective view of a system for manufacturing an aerosol-generating rod.
[0108] FIG. 6 is a schematic cross-sectional view of a composite aerosol-generating material according to an embodiment.
[0109] FIG. 7 is a schematic cross-sectional view of a composite aerosol-generating material according to another embodiment.
[0110] FIG. 8 is a schematic cross-sectional view of a composite aerosol-generating material according to a further embodiment.
[0111] FIG. 9 is a schematic cross-sectional view of a composite aerosol-generating material according to a further embodiment.
[0112] FIG. 10 is a schematic cross-sectional view of a composite aerosol-generating material comprising a susceptor material according to an embodiment.
[0113] FIG. 11 is schematic cross-sectional view of a composite aerosol-generating material comprising a susceptor material according to a further embodiment.
[0114] FIG. 12 is a schematic drawing of a cross-sectional view of a susceptor between two composite aerosol-generating materials.
[0115] FIG. 13 is a cross-section view of an aerosol-generating rod where a susceptor is positioned between composite aerosol-generating materials before gathering.
[0116] FIG. 1 illustrates an example of a cutting system 10. A source sheet of carrier material 12 is initially unwound from a bobbin (not shown) and is transported in a direction generally indicated by the arrows. The source sheet of carrier material 12 has a longitudinal axis in the longitudinal direction and has a specified width and a specified thickness. In specific embodiments, the source carrier material 12 is preferably tobacco cast leaf (TCL), but in other embodiments, the source carrier material 12 comprise other materials, for example cotton. The cutting system 10 preferably comprises a cutter 20 which in this example takes the form of an inline knife 10. In certain embodiments, other cutters 20 are used, for example a circular knife or a rotary cutter.
[0117] The inline knife 20 has a longitudinal axis perpendicular to the longitudinal axis of the sheet of source carrier material 12 so that the sharp edges of the knife 20 points towards the incoming sheet of source carrier material 12. The sheet of source carrier material 12 is cut by the knife 20 into two sections 22A, 22B along the cutting line 24. In certain embodiments, the sheet of source carrier material 12 is cut along its longitudinal axis such that both the first section 22A and the second section 22B have the same width. In other embodiments, the sheet of source carrier material 12 is cut along a cutting line 24 offset from the longitudinal axis so that the first section 22A has a greater width relative to the second section 22B, or so that the second section 22B has a greater width relative to the first section 22A. In other examples, the sheet of source carrier material 12 is cut into more than two sections 22A, 22B, for example using more than one cutter 20, or using the same cutter 20. The cutting process typically produces dust, so in some embodiments, the cutting system 10 also comprises dust protection in the cutting system 10. For example, the dust protection takes the form of an air aspiration system (not shown) so that the dust produced is at least partially evacuated in a controller manner. By including dust protection, a higher proportion of dust is prevented from contacting the gel 144 (see FIG. 2) or the source carrier material 12, which would otherwise cause contamination and quality issues. The two sections 22A, 22B form the first and second continuous sheets of carrier material.
[0118] FIG. 2 illustrates an example of a gel dispensing system 100. The gel dispensing system 100 comprises a gel dispensing station 140 having three gel dispensing nozzles 142. Each nozzle 142 dispenses a gel 144 onto a surface-portion of the section 122 of a first continuous sheet 12 of carrier material. Three gel strips 144 are applied to the section 122 of the first continuous sheet of carrier material. The section 122 of the first continuous sheet of carrier material is transported along a direction generally indicated by the arrows in this example. In certain embodiments, a different number of gel dispensing stations 140 or nozzles 142 are employed. In such embodiments, a different number of gel strips 144 are produced. In this example, the gel strips 144 dispensed from the nozzles 142 are preferably parallel to one another, but in other examples, the gel strips 144 are non-parallel to one another, for example, wavy, offset or in loops along the longitudinal direction of the section 122 of the first continuous sheet of carrier material.
[0119] In some examples, the quantity of gel 144 applied per strip and per dispensing system is computed so that during the layering process and the pressing process (both as will be described), the gel 144 does not spread beyond the surface of the section 122 of the first continuous sheet of carrier material. This prevents the gel 144 from contacting (and therefore contaminating) the inner surface of the funnel shaped device 490 (see FIG. 5) during gathering or the pressing process or wrapping process (not shown).
[0120] In some examples, the gel dispensing system 100 includes a temperature control system (not shown) having a heater (not shown) and thermic sensor (not shown) coupled through a feedback loop. The temperature control system heats up the gel 144 and controls its temperature to remain within a target range of temperatures before reaching the gel dispensing station(s) 140. Optionally, the gel dispenser station 140 additionally comprises, such as, flowmeters, pumps or actuated faucets (not shown) which allow the flow of each nozzle 142 to be independently adjustable, or alternatively or in addition, which allow the type of gel 144 to be delivered by different nozzles 142, for example on different positions of section 122 of the first continuous sheet of carrier. This is particularly advantageous because it facilitates different amounts of gel 144 to be applied, and thus facilitates different composite aerosol-generating materials to be manufactured. The amount of gel 144 dispensed can be varied by altering, for example the flow rate of the nozzle or the length of time the gel 144 is dispensed from the nozzle. In certain embodiments, the variation of the amount of gel 144 can be altered for each nozzle independently. This also enables the flow of gel 144 from each nozzle 142 to be adjusted depending on the position of the nozzle 142, for example a nozzle 142 located near the longitudinal axis of the section 122 of the first continuous sheet of carrier material is adapted to dispense a greater amount of gel 144 relative to the amount dispensed by a nozzle 142 near the edges of the section 122 of the first continuous sheet of carrier material in order to prevent the spread of gel 144 beyond the surface of the section 122 of the first continuous carrier material during the pressing process. The flow rate of gel 144 dispensed, the duration of time gel 144 is dispensed, or the pattern formed by the gel 144 dispensed is altered in different examples. It should be appreciated that the sequence of the cutting step (of the source carrier material 12) and the gel application step is not relevant. The cutting step of the source carrier material 12 preferably takes place before the gel dispensing step, but in certain embodiments, the cutting step takes place after the gel dispensing step, or at the same time as the gel application step.
[0121] FIGS. 3-4 depict an embodiment of a layering system 250, 350 for manufacturing an aerosol-generating rod. The layering system 250, 350 places two sections 222A, 222B, a first continuous sheet of carrier material 222B and a second continuous sheet of carrier material 222A, on top of each other to form a composite aerosol-generating material 530 (as is better shown in FIG. 6). Each of the first and second continuous sheets of carrier material 222B, 222A have a specified width. Each of the first and second continuous sheets of carrier materials 222B, 222A has a specified thickness. The composite aerosol-generating material 530 comprises the first and second continuous sheets of carrier material 222B, 222A and a gel 244 interposed between the first and second continuous sheets of carrier material 222B, 222A. The layering system 250, 350 comprises a lateral moving system which places a second continuous sheet of carrier material 222A onto a first continuous sheet of carrier material 222B. In this example, the second continuous sheet of carrier material 222A is on the top and the first sheet continuous of carrier material 222B is on the bottom. In other embodiments, the composite aerosol-generating material 530 is configured in other ways, for example the second continuous sheet of carrier material 222A is placed beneath the first continuous sheet of carrier material 222B. The lateral moving system places the first and second continuous sheets of carrier material 222B, 222A into a vertical pile, one above the other such that the second continuous sheet of carrier material 222A is exactly above and parallel to the first continuous sheet of carrier material 222B. In other embodiments, the second continuous sheet of carrier material 222A and the first continuous sheet of carrier material 222B are offset from one another. The layering system 250, 350 depicted in FIGS. 3-4 illustrates one lateral moving system for placing the first and second continuous sheets of carrier material 222B, 222A on top of one another. In other embodiments the layering system 250, 350 comprises multiple lateral moving systems, enabling a stack of more than two sheets of carrier materials 222A, 222B to be manufactured. In the example illustrated in FIGS. 3-4, the first continuous sheet of carrier material 222B and the second continuous sheet of carrier material 222A are unwound from separate bobbins (not shown) onto the lateral moving system of the layering system 250, 350, but in other embodiments, a single sheet of source carrier material 222 is unwound from a bobbin, and then cut into separate sections, the first continuous sheet of carrier material 222B and the second continuous sheet of carrier material 222A. Rollers 252, 254, 256, and 258 assist in directing the first continuous sheet of carrier material or the second continuous sheet of carrier material, or both the first and second continuous sheets of carrier material.
[0122] As best seen in FIG. 4, the lateral moving system comprises a conveying roller 352, a directional roller 354 and a pair of positioning rollers 356. The first continuous sheet of carrier material 322B is transported on the conveying roller 352. The second continuous sheet of carrier material 322A is contacted by a directional roller 354 from a side which has not received gel 344 to avoid contamination. The directional roller 354 is angled so that the movement of the second continuous sheet of carrier material 322A is redirected towards the first continuous sheet of carrier material 322B. The angle of the directional roller 354 is chosen so that manufacturing space is saved, while not applying too high a strain onto the second continuous sheet of carrier material 322A which would otherwise cause the structure of the second continuous sheet of carrier material 322A to be altered. Both the second continuous sheet of carrier material 322A and the first continuous sheet of carrier material 322B are then directed through the positioning rollers 356 which is placed at a location where the second continuous sheet of carrier material 322A is disposed adjacent the first continuous sheet of carrier material 322B. The distance from the first continuous sheet of carrier material 322B to the surface of the positioning roller 356 is approximately equal to the thickness of the second continuous sheet of carrier material 322A. This arrangement allows the two continuous sheets of carrier material 322B,322A, to contact when they pass through the positioning rollers 356. The rotational axis of the positioning rollers 356 is perpendicular to the transporting direction of the first sheet of aerosol-generating material 322B. This aligns the second continuous sheet of carrier material 322A to the first continuous sheet of carrier material 322B, as is seen from FIG. 3.
[0123] In certain embodiments, the layering system also includes a pressing system having two pressing rollers 358 where the second continuous sheet of carrier material 322A and the first continuous sheet of carrier material 322B additionally pass through. When the first and second continuous sheets of carrier material 322B, 322A are transported through the pressing rollers 358, the pressure applied by the pressing rollers 358 allows the second continuous sheet of carrier material 322A, the first continuous sheet of carrier material 322B and the interposing gel 344 to adhere together. The pressure is computed to be high enough to facilitate adhesion of the first and second continuous sheets of carrier material 322B, 322A and gel 344, but low enough so that the first and second continuous sheets of carrier material 322B, 322A are not structurally damaged, and further so that the gel strips 344 are not pressed to a point where there is no air path between the first and second continuous sheets of carrier material 322B, 322A. In such instance, the first and second continuous sheets of carrier material 322B, 322A with gel 344 would create an air tight block without aerosol or air flowing through, which in some instances would affect resistance to draw properties. In certain embodiments, the positioning rollers 356 take the form of a single positioning roller acting on a surface. In certain embodiments the pressing rollers 358 take the form of a single pressing roller acting on a surface.
[0124] FIG. 5 depicts an embodiment of a layering system 450 for manufacturing an aerosol-generating rod. A tobacco cast leaf (TCL) sheet 412 (an example of a source carrier material being an aerosol-generating material as well) is unwound from a bobbin (not shown) and crimped by a pair of crimping rollers 470A, 470B, creating ridges and grooves in the sheet of source carrier material 412. The crimped sheet 412 of source carrier material is then cut into two sections, forming the first and second continuous sheets of carrier material 422B, 422A by a cutter 420. The cutter 420 in this example is an inline cutter and more specifically a circular knife. It should be envisaged that the step of crimping is optional. In certain embodiments, the step of cutting is replaced by providing the first and second continuous sheets of carrier material 422B, 422A from different bobbins or sources. The cutting step is provided so that storage space required for multiple bobbins of the first and second continuous sheets of carrier material 422B, 422A is reduced. A gel 444 is applied by a gel dispensing system 440 having three nozzles 442 that each dispenses a gel strip 444 onto a surface of the first continuous sheet of carrier material 422B. The second continuous sheet of carrier material 422A is directed by a redirecting fork 452 towards the gel dispensed surface of the first continuous sheet of carrier material 422B to form a composite aerosol-generating material or “sandwich” having the first and second continuous sheets of carrier material 422B, 422A, with a gel 444 disposed between the first and second continuous sheets of carrier material 422B, 422A. A cross-sectional detailed view of the composite aerosol-generating material is shown in FIG. 5, where three gel strips 444 of approximately equal width are disposed between the second continuous sheet of carrier material 422A and the first continuous sheet of carrier material 422B. The composite aerosol-generating material of the first and second continuous sheets of carrier material 422B, 422A with gel 444 at its core is then directed towards an input end of a funnel 490, where it is to be compressed into a continuous rod 492 shape at the output end of the funnel 490.
[0125] FIG. 6 depicts a schematic cross-sectional view of a composite aerosol-generating material 530 according to an embodiment. The composite aerosol-generating material 530 includes a first sheet of carrier material 522B and a second sheet of carrier material 522A. Three gel strips 544 are disposed between the first sheet of carrier material 522B and the second sheet of carrier material 522A. A central gel strip 544B is located in a central region proximal to the longitudinal axis, and gel strips 544A, 544C are spaced apart in a lateral region on either side of the central gel strip 544B. In this embodiment, the gel strips 544A, 544B, 544C have the same width. Thus, it can be said that the gel strips 544A, 544B, 544C are disposed uniformly. Gel strips 544A, 544C are preferably positioned inward from the outer edges of the first and second sheets of carrier material 522B, 522A to avoid the smear of gel on the machinery, for example avoid contamination of the funnel (not shown) by the leakage of gel 544. In other embodiments, gel strips 544 are dispensed non-uniformly (see FIG. 7). The composite aerosol-generating material 530 is produced using the layering system 450 as described hereinbefore with reference to FIG. 5. In certain embodiments, the first continuous sheet of carrier material 522B and the second continuous sheet of carrier material 522A are provided from the same sheet 512, for example, on a single bobbin (not shown), and then cut into two to form the first and second continuous sheets of carrier material 522B, 522A via the cutting system 420. In other embodiments, the first continuous sheet of carrier material 522B and second continuous sheet of carrier material 522A are each provided from a different source, for example, the first continuous sheet of carrier material 522B is provided on a first bobbin (not shown) and the second continuous sheet of carrier material 522A is provided on a different bobbin (not shown).
[0126] FIG. 7 depicts a schematic cross-sectional view of a composite aerosol-generating material 630 according to another embodiment. The composite aerosol-generating material 630 includes a first sheet of carrier material 622B, a second sheet of carrier material 622A and a third sheet of carrier material 622C. Three gel strips 644 are disposed between the first sheet of carrier materials 622B and the second sheet of carrier material 622A. A central gel strip 644B is located in a central region proximal to the longitudinal axis, and gel 644A, 644C are spaced apart in a lateral region on either side of the central gel strip 644B. In this embodiment, another further three gel strips 644 are disposed between the first sheet of carrier material 622B and the third carrier material 622C. The gel strips 644B in the central region have a greater width that the gel strips 644A, 644B in the lateral region. Thus, it can be said that the gel strips 644A, 644B, 644C are disposed non-uniformly. In other examples, the distribution of gel 644A, 644B, 644C between the first sheet of carrier material 622B and the second sheet of carrier material 622A is different from the distribution of gel 644A, 644B, 644C between the first sheet of carrier material 622B and the third sheet of carrier material 622C. In some examples, gel 644 is uniformly distributed between the first sheet of carrier material 622B and the second sheet of carrier material 622A, and gel 644 is non-uniformly distributed between the first sheet of carrier material 622B and the third sheet of carrier material 622C. Gel strips 644A, 644C are preferably positioned inward from the outer edges of the first and second sheets of carrier material 622B, 622A to avoid contamination of the machinery by the smear of gel, for example gel 644 leakage into the funnel (not shown). Specifically, in this example, more gel 644 is dispensed in the central region proximal to the longitudinal axis of the second sheet of carrier material 622A relative to the amount of gel 644 dispensed in a lateral region distal to the longitudinal axis of the second sheet of carrier material 622A. Thus, the central gel strip 644B has a greater width than the gel strips 644A, 644C. This reduces the risk of contamination, for example gel 644 leakage into the funnel (not shown). In specific embodiments, 10 percent (%) more gel 644 mass is dispensed in the central region relative to the lateral region. In other embodiments, 20 percent (%) more gel 644 mass is dispensed in the central region relative to the lateral region of a sheet of aerosol-generating material.
[0127] The composite aerosol-generating material 630 is produced using the layering system 450 as described hereinbefore with reference to FIG. 5. In specific embodiments, preferably the first, second and third sheets of carrier material 622B, 622A, 622C are provided from the same source of carrier material, for example, on a single bobbin (not shown), and then cut into three sections 622A, 622B, 622C via the cutting system 420. In specific embodiments, the gel 644 is placed on both sides of the first continuous sheet of carrier material 622B, and the second and third continuous sheets 622A, 622C of carrier material are placed on to the first sheet of carrier material 622B via the layering system 450. In certain embodiments, the composite aerosol-generating material 630 is constructed by providing the first and third continuous sheets of carrier material 622B, 622C and applying gel strips 644 on top of each of the first and third continuous sheets of carrier material 622B, 622C. The first continuous sheet of carrier material 622B is placed on the third continuous sheet of carrier material 622C and then the second continuous sheet of carrier material 622A is placed on top of first continuous sheet of carrier material 622B. Preferably, the top and bottom surfaces of the composite aerosol-generating material 630 do not have gel 644. In certain embodiments, two of the three—first, second or third continuous sheets of carrier material 622A, 622B, 622C are provided from the same source of carrier material, for example, on a single bobbin (not shown), and cut into two sections via the cutting system 420. In specific embodiments, each of the first, second and third continuous sheets of carrier material 622A, 622B, 622C are each provided from a different source. Namely, the sheets 622A, 622B, 622C are unwound from different respective bobbins. In alternative embodiments, the manufacture of the composite aerosol-generating material involves repeating the steps of manufacturing a composite aerosol-generating material and layering the composite aerosol-generating material one on top of the other. This provides a composite aerosol-generating material with additional layers and/or a different number of layers.
[0128] The composite aerosol-generating material 630 is manufactured by an apparatus (not shown) having a means to supply a first continuous sheet of carrier material 622A. In one embodiment, the means to supply the first continuous sheet of carrier material 622A is a bobbin (not shown). The apparatus has a nozzle that dispenses gel 644 onto the surface of the first continuous sheet of carrier material 622A, and a layering system that provides and positions a second continuous sheet of carrier material 622B onto the gel 644 to form a composite aerosol-generating material 630. In another embodiment, the first continuous sheet of carrier material 622A is supplied by a cutter. The cutter is located upstream of the layering system. The cutter cuts the sheet of a source of carrier material along its longitudinal axis to form the first continuous sheet of carrier material 622A and the second continuous sheet of carrier material 622B. Additionally, in some examples, the apparatus further comprises a folding means that folds a portion of a sheet of source carrier material along its longitudinal axis to form the first continuous sheet of carrier material 622A and the second continuous sheet of carrier material 622B.
[0129] FIG. 8 depicts a schematic cross-sectional view of a composite aerosol-generating material 730 according to a further embodiment. The composite aerosol-generating material 730 includes a first sheet of carrier material 722A, a second sheet of carrier material 722B, a third sheet of carrier material 722C and a fourth sheet of carrier material 722D. Three gel strips 744 are disposed between the first sheet of carrier material 722A and the second sheet of carrier material 722B. A central gel strip 744B is located in a central region proximal to the longitudinal axis, and gel strips 744A, 744C are spaced apart in a lateral region on either side of the central gel strip 744B. In this embodiment, no gel is disposed between the second sheet of carrier material 722B and the third sheet of carrier material 722C. Instead, another further three gel strips 744 are disposed between the third sheet of carrier material 722C and the fourth sheet of carrier material 722D. The composite aerosol-generating material 730 comprises two composite aerosol-generating materials, 722A, 722B and 722C, 722D. The gel strips 744B in the central region have a greater width than the gel strips 744A, 744C in the lateral region. Thus, it can be said that the gel strips 744A, 744B, 744C are disposed non-uniformly. Gel strips 744A, 744C are preferably positioned inward from the outer edges of the first, second, third and fourth sheets of carrier material 722A, 722B, 722C, 722D to avoid contamination of machinery, for example gel 744 leakage into the funnel (not shown). Specifically, in this example, more gel 744 dispensed in the central region proximal to the longitudinal axis of the section 722 relative to the amount of gel 744 dispensed in a lateral region distal to the longitudinal axis of the section 722. Thus, the central gel strip 744B has a greater width than the gel strips 744A, 744C. This reduces the risk of contamination, for example gel 744 leakage into the funnel (not shown).
[0130] The composite aerosol-generating material 730 is produced using the layering system 450 as described hereinbefore with reference to FIG. 5. In specific embodiments, preferably a single sheet is provided from a single source, for example, on a single bobbin (not shown), and then cut into four sections to form the first, second, third and fourth continuous sheets of carrier materials 722A, 722B, 722C, 722D via the cutting system 420. Preferably, the top and bottom surfaces of the composite aerosol-generating material 730 do not have gel 744. In certain embodiments, at least two of the first, second, third or fourth continuous sheets of carrier material 722A, 722B, 722C, 722D are provided from the same sheet of source carrier material, for example, on a single bobbin (not shown), and then cut into two sections via the cutting system 420. In specific embodiments, each of the first, second, third and fourth continuous sheets of carrier material 722A, 722B, 722C, 722D are each provided from a different source. Namely, the sheets 722A, 722B, 722C, 722D are unwound from different respective bobbins.
[0131] FIG. 9 depicts a schematic cross-sectional view of a composite aerosol-generating material 830 according to a further embodiment. In this embodiment, gel 844 is deposited on the sheet 812 (a carrier material) and then the sheet 812 is folded back onto itself. As illustrated, this stops gel 844 from being squeezed out from one side. The folding of the sheet 830 creates two layers, the first and second continuous sheets of carrier material which are operatively coupled or integrated with one another. The two layers, the first and second continuous sheets of carrier material are connected by a folding line (not shown).
[0132] FIG. 10 depicts a schematic cross-sectional view of a composite aerosol-generating material 930 according to an embodiment. The composite aerosol-generating material 930 includes a first sheet of carrier material 922B and a second sheet of carrier material 922A. Two gel strips 944 are disposed between the first sheet of carrier material 922B and the second sheet of carrier material 922A. A centrally positioned susceptor material 900 is located in a central region proximal to the longitudinal axis, and gel strips 944 are spaced apart in a lateral region either side of the centrally positioned susceptor material 900. In this embodiment the gel strips 944 have the same width. The gel strips 944 are preferably positioned inward from the outer edges of the first carrier material 922B and second carrier material 922A, to avoid gel leakage from the composite aerosol-generating material 930. The composite aerosol-generating material 930 is produced using the layering system 450 as described herein with reference to FIG. 5, with an additional susceptor material 900 insertion mechanism. In the FIG. 10 embodiment the first continuous sheet of carrier material 922B and the second continuous sheet of carrier material 922A are provided from the same sheet 512, for example, from a single bobbin (not shown) and then cut into two, to form the first continuous sheet of carrier material and the second continuous sheet of carrier material. In the manufacturing of the FIG. 10 embodiment the susceptor material 900 is inserted onto the first continuous sheet of carrier material 922B before dispensing of the gel to a surface of the first continuous sheet of carrier material 922B. The susceptor material 900 is shown not in direct contact with the gel strips 944. However, the FIG. 10 embodiment is shown before the composition aerosol-generating material 930 has been pressed. Once pressed the gel strips 944 may spread laterally between the first carrier material 922B and the second carrier material 922A to be in direct contact with the susceptor material 900.
[0133] FIG. 11 depicts a schematic cross-sectional view of a composite aerosol-generating material 930 according to another embodiment. The composite aerosol-generating material 930 includes a first sheet of carrier material 922B, a second sheet of carrier material 922A, and a third sheet of carrier material 922C. Two gel strips 944 are disposed between the first sheet of carrier material 922B and the second sheet of carrier materials 922A. A centrally positioned susceptor material 900 is located in a central region proximal to the longitudinal axis of the composite aerosol-generating material 930, and between the two gel strips 944. In this embodiment, another further three gel strips 944 are disposed between the first sheet of carrier material 922B and the third carrier material 922C. Preferably when the composite aerosol-generating material 930 of the FIG. 11 example is pressed the susceptor material 900 may be in direct contact with the gel 944.
[0134] FIG. 12 depicts a schematic side view of a composite aerosol-generating material 1030 comprising two layers of composite aerosol-generating materials. The first composite aerosol-generating material comprises two continuous sheets of carrier materials 1022A and 1022B, with gel 1044A between the two continuous carrier materials 1022A and 1022B. The second aerosol-generating material comprises two continuous sheets of carrier material 1022C and 1022D, with gel 1044B between the two carrier materials 1022C and 1022D. Between the two layers of composite aerosol-generating materials is positioned a susceptor or continuous band of susceptor 1000. In this illustrated embodiment the susceptor 1000 is not in direct contact with the gel 1044A, 1044B. In use the heat from the susceptor 1000 or the continuous band of susceptor 100 can still reach the gel though the carrier materials 1022B and 1022C. In this embodiment the carrier materials are all cotton. The gel comprises nicotine. The band of susceptor is aluminium.
[0135] FIG. 13 depicts cross-section view along the longitudinal axis of an aerosol-generating rod 1130. Like the FIG. 12 embodiment the band of susceptor 1100 was not positioned adjacent gel 1144, 1044A, 1044B, between continuous carrier materials 1122A and 1122B. In the FIG. 13 embodiment continuous band of susceptor 1100 is placed between composite aerosol-generating material just before gathering the composite aerosol-generating material and the continuous band of susceptor 1100. The gathered material is wrapped to produce a continuous aerosol-generating rod 1130. In this, FIG. 13 embodiment the carrier materials are linen. The band of susceptor is carbon. The gel comprises nicotine. The gel further comprises glycerin.
[0136] All scientific and technical terms used herein have meanings commonly used in the art unless otherwise specified. The definitions provided herein are to facilitate understanding of certain terms used frequently herein.
[0137] As used in this specification and the appended claims, the singular forms “a”, “an”, and “the” encompass embodiments having plural referents, unless the content clearly dictates otherwise.
[0138] As used in this specification and the appended claims, the term “or” is generally employed in its sense including, alternatively or in addition, unless the content clearly dictates otherwise.
[0139] As used herein, “have”, “having”, “include”, “including”, “comprise”, “comprising” or the like are used in their open-ended sense, and generally mean “including, but not limited to”. It will be understood that “consisting essentially of”, “consisting of”, and the like are subsumed in “comprising,” and the like.
[0140] The words “preferred” and “preferably” refer to embodiments of the invention that may afford certain benefits under certain circumstances. However, other embodiments may also be preferred under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and, is not intended to exclude other embodiments from the scope of the disclosure, including the claims.
[0141] Any direction referred to herein, such as “top,” “bottom,” “left,” “right,” “upper,” “lower,” and other directions or orientations are described herein for clarity and brevity are not intended to be limiting of an actual device or system. Devices and systems described herein may be used in a number of directions and orientations.
[0142] The embodiments exemplified above are not limiting. Other embodiments consistent with the embodiments described above will be apparent to those skilled in the art.
