AEROSOL-GENERATING ARTICLE AND METHOD FOR MANUFACTURING SUCH AEROSOL-GENERATING ARTICLE; AEROSOL-GENERATING DEVICE AND SYSTEM

Abstract

An aerosol-generating article has a longitudinal extension and includes aerosol-generating substrate extending along the longitudinal extension and susceptor material extending along the longitudinal extension. The aerosol-forming substrate and the susceptor material form an extrudate having a same cross-sectional shape along a length of the extrudate. Additionally, an aerosol-generating device includes a device housing comprising a support element extending from a proximal end of the device housing. The support element is adapted for receiving an aerosol-generating article including aerosol-forming substrate and susceptor material. A mouthpiece of the device includes a cavity to accommodate the support element including aerosol-generating article mounted on the support element. An inductor may be inductively coupled to the susceptor material of the aerosol-generating article during use.

Claims

1. A method for manufacturing an inductively heatable aerosol-generating article, the method comprising: coaxially extruding aerosol-forming substrate and susceptor material through a die opening of an extrusion device to form a hollow extrudate comprising the aerosol-forming substrate and the susceptor material.

2. The method according to claim 1, further comprising coaxially extruding a continuous string material together with the aerosol-forming substrate and the susceptor material.

3. The method according to claim 2, wherein the continuous string material is arranged radially outside of the susceptor material.

4. The method according to claim 2, wherein the continuous string material is arranged between the susceptor material and the aerosol-forming substrate.

5. The method according to claim 2, wherein the continuous string material comprises fibres.

6. The method according to claim 2, wherein the continuous string material is a thread.

7. The method according to claim 2, wherein the continuous string material has a tensile strength such that an elongation of the continuous string material is below 1 millimeter per meter under a load of 20 Newton.

8. The method according to claim 1, wherein the susceptor material is a sheet-like material.

9. The method according to claim 1, wherein the susceptor material comprises ferromagnetic material.

10. The method according to claim 1, wherein the susceptor material is a hollow tube.

11. The method according to claim 1, wherein the susceptor material is a continuous band.

12. The method according to claim 11, wherein the continuous band is positioned helicoidally along an extrusion axis of the extrusion device.

13. The method according to claim 1, wherein the hollow extrudate has a wall thickness between 1 millimeter and 7 millimeter.

14. The method according to claim 13, wherein the wall of the hollow extrudate is a structured wall.

15. The method according to claim 14, wherein the structured wall is a wavy wall.

16. The method according to claim 1, further comprising covering the hollow extrudate at least partly with a cover material.

17. The method according to claim 16, wherein the covering includes covering an inside or an outside of the hollow extrudate with the cover material or covering both the inside and the outside of the hollow extrudate with the cover material.

18. The method according to claim 16, wherein the cover material is a porous material layer.

19. The method according to claim 1, wherein the die opening of the extrusion device is formed in between an inner tube and an outer tube, the inner tube and the outer tube being coaxially arranged.

20. The method according to claim 19, wherein a circumference of the inner tube and the outer tube describe a wavy line.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0127] The invention is further described with regard to embodiments, which are illustrated by means of the following drawings, wherein:

[0128] FIG. 1 shows a first embodiment of a tubular aerosol-generating article with susceptor foil;

[0129] FIG. 2 shows a second embodiment of a tubular aerosol-generating article with porous susceptor sheet;

[0130] FIG. 3 is a cross section of the article of FIG. 1 or FIG. 2;

[0131] FIG. 4 shows an extrusion die form for manufacturing a structured tubular extrudate;

[0132] FIG. 5 shows a first embodiment of an aerosol-generating article for segmented heating;

[0133] FIG. 6 shows a second embodiment of an aerosol-generating article for segmented heating;

[0134] FIG. 7,8,9 show three embodiments of aerosol-generating articles: plain (FIG. 7), with cover layer (FIG. 8) and with envelope (FIG. 9);

[0135] FIG. 10 shows a star-shaped aerosol-generating article (plain);

[0136] FIG. 11 shows the article of FIG. 10 with envelope;

[0137] FIG. 12-14 show a support element and tubular aerosol-generating article in separate (FIG. 12 and FIG. 13) and assembled position (FIG. 14);

[0138] FIG. 15 are exploded and an assembled view of an embodiment of an aerosol-generating system;

[0139] FIG. 16 illustrates the system of FIG. 15 in operation.

DETAILED DESCRIPTION

[0140] In FIG. 1 and FIG. 2 aerosol-generating articles 10 in the shape of hollow tubes are shown. The articles 10 consist of an extrudate comprising a susceptor material 30,31 in between aerosol-forming substrate 20,21. For better illustration, the inner components of the article 10 are shown by way of a stepwise cut-away of outer components. In the real article, all such cutaway components extend along the entire length of the article 10.

[0141] In FIG. 1 the susceptor material 30 is a susceptor foil, for example a metallic foil. The foil forms a physical barrier between the inner 21 and the outer 20 aerosol-forming substrate during and after extrusion.

[0142] In FIG. 2 the susceptor material 31 is a susceptor mesh or grid, for example made of non-woven metallic fibers such as stainless steel fibers. The mesh allows that aerosol-forming substrate may surround the fibers during and after extrusion of the article.

[0143] A string element 4 in the form of a thread is arranged between the outer aerosol-forming substrate 20 and the susceptor material 30,31. The string element 4 extends in longitudinal direction in a straight line along the extrudate. The string element 4 has a minimum tensile strength to limit elongation of the article 10 during the extrusion process. A minimum tensile strength may, for example be 110 MPa.

[0144] Preferably both aerosol-forming substrate 20,21 are tobacco containing substrates. They may be identical such that one tobacco slurry only may be prepared for the manufacture of the articles 10.

[0145] In FIG. 3 a cross section through the article 10 of FIG. 1 and FIG. 2 is shown. An inner diameter 101 of the hollow tube is in a range between 4 mm and 7 mm. An outer diameter 102 of the hollow tube is in a range between 5 mm and 7 mm. Accordingly, a wall thickness 100 of the tube is in a range between 1 mm and 3 mm. Inner and outer aerosol-forming substrate 21,20 may have a same thickness and the susceptor 30,31 may be arranged in the middle of the wall when seen in radial direction.

[0146] FIG. 4 shows an extrusion die for extruding aerosol-generating articles having a structured wall. The die comprises an outer circular tube 51 coaxially arranged with an inner tube 50 having an undulating wall structure. In this embodiment, the otherwise flat round walls of a tubular shaped extrusion die form a regular circumferentially running wave. The circumference of the shape of a hollow tube manufactured by such an extrusion die describes a wavy line.

[0147] A side wall of a tubular shaped aerosol-generating article, may be flat as, for example shown in FIG. 1 and FIG. 2, or may be structured. Preferably, the form of the susceptor material is adapted to the corresponding structure of the side wall.

[0148] Preferably, a structure is adapted to the size of the tube.

[0149] In FIG. 5 and FIG. 6 tubular aerosol-generating articles 10 are shown that are adapted for a segmented heating, for example for being sequentially heated.

[0150] In FIG. 5 the susceptor material is provided in the form of several tubular-shaped susceptor segments 300. The individual segments 300 are equidistantly arranged along the length of the article and are separated by gaps 33. Each segment 300 may be heated separately for a given time according to a desired sequence. The gap 33 provides that heat is not dispersed into the surrounding area but is limited to the portion of the article next to and corresponding to the heated susceptor segment 300. The gap 33 may also prevent that an area between segments is overheated, which might negatively influence the quality of a consuming experience and related aerosol delivery. At the same time waste may be minimized by heating a portion only required for a desired aerosol formation. In the embodiment of FIG. 5, the string element 4 may support the equidistant positioning of the distinct susceptor segments 300 upon extrusion of the article 10.

[0151] In FIG. 6 the susceptor material has the form of a helix arranged along the article 10. The susceptor material is a susceptor band 32 that may during the extrusion process continuously be unwound from a bobbin and positioned helicoidally along the extrusion axis (corresponding to the longitudinal axis of the extruded article). The continuous gap 34 formed in between the wound susceptor band 32 provides a certain thermal separation between the individual windings of the band 32. While still a certain heat transfer is possible along the band, this embodiment simplified the extrusion process and reduces costs of the product.

[0152] In this embodiment, the string element 4 may additionally support a regular positioning of the susceptor band 32.

[0153] In FIG. 7 an aerosol-generating article 10 being a hollow tube and consisting of an extrudate of a coextruded susceptor material and aerosol-forming substrate is shown. The length of the article 10, in this case corresponding to the length of the extrudate, preferably lies in a range between 4 mm and 14 mm.

[0154] In FIG. 8 the aerosol-generating article of FIG. 7 is provided with a cover layer 60. The cover layer 60 covers the outside of the article 11 or the extrudate, respectively. Depending on an application process of the cover layer, the cover layer 60 may cover or not cover end sides 600 of the hollow tube. Preferably, the cover layer is a thin porous material, for example a “tea bag” paper. Preferably, the cover layer 60 is tightly arranged around the outside of the extrudate. The cover layer 60 may be applied while an aerosol-forming substrate has not yet dried after an extrusion process.

[0155] In FIG. 9 the aerosol-generating article of FIG. 7 is provided with an envelope 61. The envelope 61 is a loose wrapping and covers the outside of the article or the extrudate, respectively. The envelope is a sheet of porous material that is folded into the inner space of the tube on each end of the tube. By this, the envelope 61 automatically covers the end sides 600 of the hollow tube. The sheet material for the envelope is provided with incisions such that each end portion of the tube is provided with a plurality of inwardly directing flaps 610. Preferably, an envelope 61 is loosely arranged around the extrudate and is attached to the extrudate through the folding of the envelope 61.

[0156] A loose envelope 61 may be marked, for example for branding, without using ink, for example by embossing the envelope material.

[0157] The length of the article 12 including the envelope preferably lies in a range between 5 mm and 17 mm.

[0158] Preferably, the envelope 61 is a thin porous material, for example a “tea bag” paper.

[0159] Aerosol-generating articles manufactured through extrusion do not necessarily have to be of hollow tubular shape.

[0160] FIG. 10 and FIG. 11 show examples of aerosol-generating articles 13, 14 manufactured through extrusion and having a star-shaped cross section. Three susceptor material strips form a star-shaped susceptor 35 with a center 350 and six susceptor flaps extending radially from the center. The susceptor strips are covered on both sides with aerosol-forming substrate 25.

[0161] In FIG. 11 the star-shaped aerosol-forming article 13 of FIG. 10 is provided with an envelope 61 as described above and with reference to FIG. 9. The envelope 61 gives the article 14 a cylindrical tubular shape.

[0162] FIG. 12 shows a support element 8 for holding and centering a hollow tubular-shaped aerosol-forming article. In this example, the aerosol-forming article as shown in FIG. 13 in a cross-sectional view is provided with an envelope 61. The support element 8 is designed to hold the article 12 on the support element and to position the article 12 in an aerosol-generating device. The support element 8 is arranged in the device, preferably extending from a proximal end of a device housing.

[0163] The support element 8 is basically pin-shaped having an extended middle section 80. The middle section 80 is shaped to allow smooth application of the aerosol-generating article 12 onto the support element. A cross section of the extended middle section has a varying radius and is leaf-like having four “leafs”. The leafs are arranged symmetrically around the longitudinal axis of the support element 8.

[0164] The shape of the support element 8, in particular the extended middle section 80 allows an air-flow to pass in between the support element 8 and the article 12. It becomes obvious that also different numbers of leafs (for example, only three or five or more leafs) may be provided to perform the described function of the middle section.

[0165] The support element 8 has a pointed tip 81 and a foot portion 81. The tip 81 facilitates a mounting and holding of the article 12 on the support element. The tip 81 also serves centering purposes of a mouthpiece as will be explained in more detail below. FIG. 14 shows the article 12 and the support element 8 in an assembled state. The folded flaps 610 of the envelope 61 of the article 12 slip below an undercut of the tip 81. The foot portion 82 has a conical shape and provides an end stop for the article 12 when being slid over the support element 8.

[0166] For non-hollow aerosol-generating articles, such as for example shown and described in FIGS. 10 and 11, the design of the support element may be adapted accordingly. For example, the support element may be provided with longitudinally extending pins extending in between the flaps or other radially extending elements of an aerosol-generating article.

[0167] FIG. 15 are exploded and an assembled view of an embodiment of an aerosol-generating system with an aerosol-generating article 12 as shown in FIG. 9 and FIG. 13. The aerosol-generating device of the system has a general tubular form and comprises a main housing 70 and a mouthpiece 71. The main housing 70 mainly comprises a battery and a power management system (not shown).

[0168] The device housing 70 comprises a support element 8 extending from the proximal end of the device housing 70. The support element 8 has been described in detail with reference to FIG. 12 and FIG. 14.

[0169] The mouthpiece 71 forms the proximal or most downstream element of the device. The mouthpiece 71 comprises a tubular hollow distal portion 710 forming and surrounding a cavity 701. The cavity 701 is provided for receiving and covering the aerosol-forming article 12 when the system is in the assembled state.

[0170] The mouthpiece 71 comprises an inductor in the form of an induction coil 703, for inductively heating susceptor material in the aerosol-generating article 12 mounted on the support element 8. The induction coil 703 is embedded in the walls of the tubular distal portion 710.

[0171] If an aerosol-generating article for segmented heating is provided, for example as shown in FIG. 5 or 6, the induction coil may be comprised of several induction coils 73,74,75 as indicated in the bottom drawing of FIG. 15. Preferably each induction coil is then provided for heating one segment of the susceptor material.

[0172] The mouthpiece 71 comprises an airflow alteration element 705 for a defined airflow management. The airflow alteration element 705 is arranged in the mouthpiece 71. In the mounted position of the mouthpiece, the airflow alteration element 705 assures self-centering and positioning of the mouthpiece 71 on the support element 8. The airflow alteration element comprises a centrally arranged indentation 708 at is distal end, which cooperates with the pointed tip 81 of the support element. Thereby, mouthpiece 71 and support element 8 and aerosol-generating article 12 accordingly, are mutually retained and positioned.

[0173] The airflow alteration element 705 is a cone influencing the airflow 91 and the mixing of the airflow 91 in the mixing chamber 704 of the mouthpiece 71. The airflow alteration element 705 is attached to the mouthpiece by fins 706.

[0174] The airflow alteration element 705 comprises passageways 707 through the airflow alteration element.

[0175] The mouthpiece 71 is further provided with radially arranged air-inlet channels 702 at a distal end of the mouthpiece to allow air 90 from the environment to enter the device and pass between aerosol-generating article 12 and mouthpiece wall as well as within the aerosol-generating article 12. Thereby, the air 90 picks up aerosol formed by heating the aerosol-forming substrate of the article 12. The aerosol containing air 91 continuous further downstream. An air-flow passing through the inside of the aerosol-generating article 12 passes through the passageways 707 in the airflow alteration element 705. An airflow passing along the outside of the aerosol-generating article 12 passes along the outside of the airflow alteration element 705. In the mixing chamber 704, the portion of the airflow passing through the inside of the article 12 and through the passageways 707 in the airflow alteration element 705 combines with the portion of the airflow passing the outside of the article 12 and the outside of the airflow-alteration element 705. The thoroughly mixed aerosol containing airflow 91 then leaves the mouthpiece 71 through the outlet opening 711 at the proximal end of the mouthpiece, which airflow 90, 91 is illustrated in FIG. 17.

[0176] For preparing the system for use, the mouthpiece 71 is removed from the housing 70, such as to provide open access to the support element 8.

[0177] After mounting the aerosol-forming article 12 onto the support element 8, the previously removed mouthpiece 71 may be repositioned on the housing 70, such that the device is now ready for use.