U.S. patent application number 17/252441 was filed with the patent office on 2021-08-19 for method and apparatus for manufacturing an aerosol generating article.
This patent application is currently assigned to JT International S.A.. The applicant listed for this patent is JT International S.A.. Invention is credited to Mark Gill, Andrew Robert John Rogan.
Application Number | 20210251301 17/252441 |
Document ID | / |
Family ID | 1000005622012 |
Filed Date | 2021-08-19 |
United States Patent
Application |
20210251301 |
Kind Code |
A1 |
Rogan; Andrew Robert John ;
et al. |
August 19, 2021 |
Method And Apparatus For Manufacturing An Aerosol Generating
Article
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.
Inventors: |
Rogan; Andrew Robert John;
(Forres, GB) ; Gill; Mark; (London, GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
JT International S.A. |
Geneva |
|
CH |
|
|
Assignee: |
JT International S.A.
Geneva
CH
|
Family ID: |
1000005622012 |
Appl. No.: |
17/252441 |
Filed: |
July 5, 2019 |
PCT Filed: |
July 5, 2019 |
PCT NO: |
PCT/EP2019/068101 |
371 Date: |
December 15, 2020 |
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B65B 1/04 20130101; B65B
61/207 20130101; A24F 40/20 20200101; B65B 7/2842 20130101; A24F
40/70 20200101; A24F 40/465 20200101; B65B 7/2807 20130101 |
International
Class: |
A24F 40/70 20060101
A24F040/70; A24F 40/465 20060101 A24F040/465; A24F 40/20 20060101
A24F040/20; B65B 1/04 20060101 B65B001/04; B65B 7/28 20060101
B65B007/28; B65B 61/20 20060101 B65B061/20 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 26, 2018 |
EP |
18185821.8 |
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
TECHNICAL FIELD
[0001] The present disclosure relates generally to aerosol
generating articles, and more particularly to an aerosol generating
article for use with an aerosol generating device for heating the
aerosol generating article to generate an aerosol for inhalation by
a user. Embodiments of the present disclosure relate in particular
to a method for manufacturing an aerosol generating article and/or
to an apparatus for manufacturing an aerosol generating
article.
TECHNICAL BACKGROUND
[0002] Devices which heat, rather than burn, an aerosol generating
material to produce an aerosol for inhalation have become popular
with consumers in recent years.
[0003] Such devices can use one of a number of different approaches
to provide heat to the aerosol generating material. One such
approach is to provide an aerosol generating device which employs
an induction heating system and into which an aerosol generating
article, comprising aerosol generating material, can be removably
inserted by a user. In such a device, an induction coil is provided
with the device and an inductively heatable susceptor is provided
typically with the aerosol generating article. Electrical energy is
supplied to the induction coil when a user activates the device
which in turn generates an alternating electromagnetic field. The
susceptor couples with the electromagnetic field and generates heat
which is transferred, for example by conduction, to the aerosol
generating material and a vapour or aerosol is generated as the
aerosol generating material is heated.
[0004] It can be convenient to provide the aerosol generating
material in the form of an aerosol generating article which can be
inserted by a user into an aerosol generating device. As such,
there is a need to provide a method and apparatus which facilitates
the manufacture of aerosol generating articles.
SUMMARY OF THE DISCLOSURE
[0005] According to a first aspect of the present disclosure, there
is provided a method for manufacturing an aerosol generating
article, the method comprising: [0006] (i) providing a plant-based
aerosol generating material; [0007] (ii) providing an inductively
heatable susceptor element; [0008] (iii) providing a cup comprising
a bottom wall, a side wall and a flange at an open end; [0009] (iv)
depositing a layer of plant-based aerosol generating material in
the cup; [0010] (v) placing the inductively heatable susceptor
element on the deposited layer of plant-based aerosol generating
material; [0011] (vi) optionally repeating step (iv) only or steps
(iv) and (v); [0012] (vii) providing a closure and affixing the
closure on the flange.
[0013] The present disclosure provides a convenient method for
manufacturing aerosol generating articles comprising a plant-based
aerosol generating material and an inductively heatable susceptor
element, and in particular which facilitates the mass production of
aerosol generating articles.
[0014] The aerosol generating article is for use with an aerosol
generating device for heating the plant-based aerosol generating
material, without burning the aerosol generating material, to
volatise at least one component of the plant-based aerosol
generating material and thereby generate a vapour which cools and
condenses to form an aerosol for inhalation by a user of the
aerosol generating device.
[0015] In general terms, a vapour is a substance in the gas phase
at a temperature lower than its critical temperature, which means
that the vapour can be condensed to a liquid by increasing its
pressure without reducing the temperature, whereas an aerosol is a
suspension of fine solid particles or liquid droplets, in air or
another gas. It should, however, be noted that the terms `aerosol`
and `vapour` may be used interchangeably in this specification,
particularly with regard to the form of the inhalable medium that
is generated for inhalation by a user.
[0016] The use of an inductively heatable susceptor element
provides a convenient, effective and energy efficient way to heat
the plant-based aerosol generating material. When the aerosol
generating article is positioned in an aerosol generating device
and exposed to an alternating electromagnetic field, heat is
generated in the inductively heatable susceptor element due to eddy
currents and magnetic hysteresis losses resulting in a conversion
of energy from electromagnetic to heat. The heat generated in the
inductively heatable susceptor element is transferred to the
plant-based aerosol generating material whereupon it is heated to
generate a vapour which cools and condenses to form an aerosol with
the desired characteristics.
[0017] The inductively heatable susceptor element may comprise one
or more, but not limited, of aluminium, iron, nickel, stainless
steel and alloys thereof, e.g. Nickel Chromium or Nickel
Copper.
[0018] The inductively heatable susceptor element may comprise a
substantially planar inductively heatable susceptor element and may
comprise a substantially ring-shaped inductively heatable susceptor
element.
[0019] The cup may be a paper cup and may be a moulded paper cup. A
paper cup is cheap, easy to manufacture, compostable and is safe
for use even at high temperatures. The paper cup may have a
self-supporting moulded form. This enables the cup to retain its
shape and facilitates handling of the cup during manufacture of the
aerosol generating article.
[0020] The cup and/or closure may further contain tobacco and/or
flavour. The tobacco and/or flavour may improve or mask the taste
of paper and give it a more pleasant taste. The flavour may be
tobacco, fruit, plant, nut, flower and so on. The tobacco and/or
flavour may be contained as an ingredient of the paper. The tobacco
may be embedded in the paper or applied thereon such as by coating
or layering. The tobacco may be in the form particles, flakes, leaf
fragments, strip(s), layer(s) and combinations thereof.
[0021] The cup may be substantially cylindrical. The side wall may
be substantially cylindrical. The bottom wall may be substantially
circular. The closure may be substantially circular. A cup with a
cylindrical form, having a substantially circular cross-section,
may facilitate handling of the cup during manufacture of the
aerosol generating article. The cylindrical form of the resulting
aerosol generating article with its substantially circular
cross-section may facilitate packaging of multiple aerosol
generating articles and/or may facilitate insertion of the aerosol
generating article into a correspondingly shaped heating
compartment of an aerosol generating device. The cylindrical form
enables the insertion of several identical susceptor elements while
maintaining a homogeneous heating of the aerosol generating
material. Therefore, the manufacturing complexity is reduced while
the effectiveness of the system ensured.
[0022] The flange may extend outwardly away from the side wall.
Thus, the flange does not extend across the open end of the cup,
thereby allowing the plant-based aerosol generating material and
the inductively heatable susceptor element(s) to be easily
positioned in the cup during steps (iv), (v) and optionally during
step (vi). In embodiments in which the side wall is substantially
cylindrical, the flange may comprise a substantially circular
lip.
[0023] The bottom wall of the cup may be porous or perforated. For
example, the bottom wall may comprise a material which is porous to
allow air to flow through the bottom wall. Alternatively or in
addition, the bottom wall may include one or more openings or
perforations. In the latter case, the bottom wall may comprise a
material which is itself resistant to air such that the openings or
perforations are needed to allow air to flow through the bottom
wall. The provision of a porous or perforated bottom wall
advantageously promotes air flow through the aerosol generating
article thereby optimising aerosol generation and transfer to the
user, for example via a mouthpiece of an aerosol generating
device.
[0024] The closure may be porous or perforated. For example, the
closure may comprise a material having a porous structure to allow
air to flow through the closure. Alternatively or in addition, the
closure may include one or more openings or perforations. In the
latter case, the closure may comprise a material which is itself
resistant to air such that the openings or perforations are needed
to allow air to flow through the closure. In addition to retaining
the plant-based aerosol generating material in the cup, the porous
or perforated closure advantageously promotes air flow through the
aerosol generating article thereby optimising aerosol generation
and transfer to the user, for example via a mouthpiece of an
aerosol generating device.
[0025] By "air-resistant" is meant a material that is not
necessarily barrier to oxygen during storage but a material that at
least does not allow the flow of air and vapour during use.
[0026] Step (iv) may comprise 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.
The step of dosing the plant-based aerosol generating material may
comprise weighing the plant-based aerosol generating material.
Accurate dosing of the aerosol generating material is thereby
assured, in turn ensuring that an aerosol with the desired
characteristics is generated during use of the aerosol generating
article with an aerosol generating device.
[0027] The method may further comprise flattening the deposited
layer of plant-based aerosol generating material. The step of
flattening the deposited layer of aerosol generating material may
be performed after step (iv) and may be performed prior to step
(v). Flattening of the deposited layer of aerosol generating
material may facilitate placement of the inductively heatable
susceptor element on the deposited layer in step (v), in particular
when the aerosol generating material has a powdered or crumbed
form.
[0028] Step (ii) may comprise providing a metal foil and may
comprise cutting the metal foil, for example with a cutting member,
to form a ring-shaped susceptor element or a plurality of
ring-shaped susceptor elements. The use of a metal foil and cutting
member to form the susceptor element(s) may facilitate the
mass-production of aerosol generating articles. Cutting may include
punching, laser cutting, plasma cutting, water jet cutting or
etching (e.g. photoetching or chemical etching).
[0029] The cup may include a cup axis extending between the open
end and the bottom wall and step (vi) may include 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. A uniform distribution of the inductively heatable
susceptor elements throughout the plant-based aerosol generating
material is thereby obtained and this in turn ensures a uniform
transfer of heat from the inductively heatable susceptor elements
to the plant-based aerosol generating material during use of the
aerosol generating article with an aerosol generating device.
[0030] Step (vii) may comprise affixing the closure on the flange
by gluing or welding. Step (vii) may comprise affixing the closure
on the flange by a snap-fit connection. The closure can be securely
and reliably affixed to the flange, thereby ensuring that the
aerosol generating material and the inductively heatable susceptor
element(s) are retained in the cup and facilitating mass production
of aerosol generating articles.
[0031] The cup may include a positioning member for receiving the
inductively heatable susceptor element. Step (v) may include
positioning the inductively heatable susceptor element by the
positioning member. The inductively heatable susceptor element can
be easily and reliably positioned in the cup in a predetermined
position with respect to the aerosol generating material, thereby
ensuring that uniform heating of the aerosol generating material
can be achieved. The use of a positioning member can also help to
ensure that the inductively heatable susceptor element is correctly
positioned for coupling with an electromagnetic field during use of
the aerosol generating article with an aerosol generating device,
thereby ensuring that maximum heat generation is achieved in the
inductively heatable susceptor element.
[0032] The positioning member may comprise a retaining surface
which may extend continuously in a circumferential direction of an
inside wall of the cup. With this arrangement, the inductively
heatable susceptor element is reliably supported around its
periphery. The positioning member may comprise at least two,
preferably three or more, separate retaining surfaces at
circumferentially spaced locations inside the cup. With this
arrangement, the periphery of the inductively heatable susceptor
element is supported at discrete circumferential positions, thereby
increasing the contact area between the aerosol generating material
and the inductively heatable susceptor element around its periphery
and maximising the amount of heat transfer to the aerosol
generating material.
[0033] Step (v) may comprise positioning the inductively heatable
susceptor element on the retaining surface or surfaces.
[0034] The cup may include 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. The positioning
member located along the cup axis nearest to the open end may be
closer to an inside wall of the cup than the other positioning
member(s). The positioning members ensure that a uniform
distribution of the inductively heatable susceptor elements
throughout the plant-based aerosol generating material can be
achieved and this in turn ensures a uniform transfer of heat from
the inductively heatable susceptor elements to the plant-based
aerosol generating material during use of the aerosol generating
article with an aerosol generating device.
[0035] The cup may further comprise a stopper extending from the
side wall in a radially inward direction. The stopper facilitates
reliable and accurate positioning of the inductively heatable
susceptor element in the cup in a direction orthogonal to the cup
axis, for example in the radial direction.
[0036] The side wall of the cup may include a step which includes
the stopper and the positioning member. This provides a simple and
robust structure.
[0037] The cup may include a cup axis extending between the open
end and the bottom wall. Step (v) may include placing the
inductively heatable susceptor element in the cup substantially in
the direction of the cup axis by contacting the inductively
heatable susceptor element with a positioning member inside the
cup. The method may further comprise withdrawing the positioning
member from the cup after placing the inductively heatable
susceptor element in the cup. With this arrangement, the
positioning member does not form part of the cup. The cup may,
therefore, be easier and cheaper to manufacture than a cup in which
the positioning member forms part of the cup. Further, the
positioning member could be inserted through an existing opening in
the bottom wall (e.g. an opening intended to allow air to flow
through the bottom wall), thereby facilitating the insertion and
removal of the positioning member.
[0038] The plant-based aerosol generating material may be any type
of solid or semi-solid material capable of generating vapour and/or
aerosol upon heating. As noted above, the aerosol generating
material may include granules, pellets, shreds, strands, particles,
gel, strips, loose leaves, cut leaves, cut filler, porous material,
foam material or sheets or combinations thereof. The plant-based
aerosol generating material may comprise tobacco. It may
advantageously comprise reconstituted tobacco.
[0039] The foam material may comprise a plurality of fine particles
(e.g. tobacco particles). The tobacco particles may have a particle
size (D90) between 50 and 180 .mu.m, preferably between 60 and 140
.mu.m, further preferably between 65 and 125 .mu.m, even further
preferably between 70 and 110 .mu.m, particularly preferably
between 75 and 90 .mu.m, e.g. having a particle size (D90) of about
80 .mu.m. The particle size in volume (D90) is determined by dry
dispersion of the sample and laser refractometry using the Malvern
Mastersizer 3000.
[0040] The foam material may further comprise an aerosol forming
agent such as propylene glycol, glycerol and a combination thereof.
The aerosol forming agent can further comprise water. Water can be
contained in an amount of 0 to 15 wt. % of the weight of the foam
material, e.g. 5 to 10 wt. %. The foam material may further
comprise a solvent and/or an acid and/or an ester in an amount of
up to 15 wt. %, based on the total weight of the foam material,
preferably up to 5 wt. %. The foam material may further comprise a
foam forming agent such non-protein containing polysaccharide. The
foam material may further comprise a foam stabilizing agent such as
cellulose gum. The foam material may be porous, which is
open-pored, and may allow a flow of air and/or vapour through the
foam material.
[0041] The plant-based aerosol generating material may comprise an
aerosol-former. The aerosol former acts as a humectant. Examples of
aerosol-formers include polyhydric alcohols and mixtures thereof
such as glycerine or propylene glycol. The aerosol generating
material may comprise an aerosol-former content of between
approximately 5% and approximately 50% on a dry weight basis. In
some embodiments, the aerosol generating material 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.
[0042] Upon heating, the plant-based aerosol generating material
may release volatile compounds. The volatile compounds may include
nicotine or flavour compounds such as tobacco flavouring.
[0043] Steps (iv), (v) and (vii), and optional step (vi), may be
carried out on a turntable. The use of a turntable allows the
plant-based aerosol generating material and the inductively
heatable susceptor element(s) to be positioned accurately and
reliably in the cup. The use of a turntable may be particularly
advantageous in embodiments in which step (vi) is carried out to
alternately position layers of the plant-based aerosol generating
material and the inductively heatable susceptor elements in the
cup. In other possible embodiments, steps (iv), (v) and (vii), and
optional step (vi), may be carried out on a linear conveyor.
[0044] According to a second aspect of the present disclosure,
there is provided apparatus for manufacturing an aerosol generating
article according to the method defined above, wherein the
apparatus comprises: [0045] a cup holding unit for holding a
plurality of cups; [0046] a first station comprising a dosing and
depositing unit for depositing dosed layers of plant-based aerosol
generating material in the cups; [0047] 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 [0048] a third station comprising a closure receiving unit and
a sealing unit for affixing the closures on the flanges of the
cups.
[0049] The use of such apparatus facilitates mass production of the
aerosol generating articles, in particular by moving the cup
holding unit between the first, second and third stations.
[0050] The cutting unit may comprise a punching unit for punching
ring-shaped susceptor elements from the metal foil. The use of a
punching unit lends itself well to mass production. The cutting
unit may alternatively comprise a laser cutting unit, a plasma
cutting unit, a water jet cutting unit or an etching unit (e.g. a
photoetching unit or a chemical etching unit).
[0051] The sealing unit may comprise an adhesive applicator for
applying a layer of adhesive between the closures and the flanges
of the cups. The sealing unit ensures that the closures can be
reliably secured to the flanges of the cups.
[0052] The cup holding unit may comprise a transport unit for
moving the cups between the first, second and third stations. The
transport unit may be configured to move the cup holding unit back
and forth between the first and second stations a desired number of
times to deposit a plurality of layers of plant-based aerosol
generating material in the cups and to place a plurality of
inductively heatable susceptor elements in the cups.
[0053] The cup holding unit may comprise a sliding tray. The cups
can be moved easily by the sliding tray between the first, second
and third stations.
[0054] The cup holding unit may comprise a turntable. The cup
holding unit may comprise a tray moved by a linear conveyor.
[0055] The apparatus may comprise a controller which may be
configured to control the operation of one or more of the cup
holding unit, the first station, the second station and the third
station.
BRIEF DESCRIPTION OF THE DRAWINGS
[0056] FIG. 1 is diagrammatic cross-sectional side view of an
aerosol generating article comprising a first example of a cup
containing a plant-based aerosol generating material and a
plurality of ring-shaped inductively heatable susceptor
elements;
[0057] FIG. 2 is a plan view of one of the ring-shaped inductively
heatable susceptor elements;
[0058] FIG. 3a is a plan view of a second example of a cup;
[0059] FIG. 3b is a cross-sectional view along the line A-A in FIG.
3a;
[0060] FIG. 3c is a side view of the cup of FIGS. 3a and 3b;
[0061] FIG. 3d is a perspective view of the cup of FIGS. 3a to
3c;
[0062] FIGS. 4a and 4b are diagrammatic cross-sectional side views
of an aerosol generating article similar to that shown in FIG. 1,
showing a first example of a snap-fit connection between the cup
and a closure;
[0063] FIGS. 5a and 5b are diagrammatic cross-sectional side views
of an aerosol generating article similar to that shown in FIG. 1,
showing a second example of a snap-fit connection between the cup
and a closure;
[0064] FIG. 6 is a flowchart illustrating the steps of a method for
manufacturing an aerosol generating article;
[0065] FIGS. 7a and 7b are respectively a diagrammatic
cross-sectional side view and a diagrammatic plan view of a cup
including positioning members which extend continuously around the
inner surface of a side wall of the cup;
[0066] FIGS. 8a to 8h are schematic illustrations of an example of
a method for manufacturing an aerosol generating article using the
cup of FIGS. 7a and 7b;
[0067] FIG. 9a is a diagrammatic plan view of a cup including
positioning members at discrete circumferential locations around
the inner surface of the side wall of the cup;
[0068] FIGS. 9b and 9c are diagrammatic cross-sectional views
respectively along the lines A-A and B-B in FIG. 9a prior to
filling the cup with plant-based aerosol generating material and
inductively heatable susceptor elements;
[0069] FIGS. 10a and 10b are diagrammatic cross-sectional views
respectively along the lines A-A and B-B in FIG. 9a after filling
the cup with plant-based aerosol generating material and
inductively heatable susceptor elements;
[0070] FIGS. 11a and 11b are respectively a diagrammatic
cross-sectional side view and a diagrammatic plan view of a cup
including removable positioning members;
[0071] FIGS. 12a to 12i are schematic illustrations of an example
of a method for manufacturing an aerosol generating article using
the cup of FIGS. 11a and 11b; and
[0072] FIG. 13 is a schematic view of an apparatus for
manufacturing an aerosol generating article according to the method
of FIG. 6.
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 FIGS. 1 and 2, there is shown a first
example of an aerosol generating article 1 for use with an aerosol
generating device comprising an electromagnetic field generator
(e.g. an induction heating system comprising an induction coil).
The aerosol generating article 1 comprises a first example of a
cylindrical cup 10 having a substantially circular bottom wall 12,
a substantially cylindrical side wall 14 and a substantially
circular open end 16 sealed by a substantially circular closure 18
affixed to a flange 20 at the open end 16 of the cup 10.
[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
FIG. 1, the flange 20 comprises an outwardly extending circular lip
28 and the closure 18 is affixed to the circular lip 28 by an
adhesive or by welding, for example using an ultrasonic welding
technique or a hot press.
[0079] Referring now to FIGS. 3a to 3c, there is shown a second
example of a cylindrical cup 110 which is similar to the cup 10
described above with reference to FIG. 1 and in which corresponding
elements are designated using the same reference numerals.
[0080] As best seen in FIGS. 3a and 3b, the bottom wall 12
comprises a plurality of circumferentially spaced peripheral
openings 30 positioned around a central opening 32. The peripheral
openings 30 are substantially circular and have a diameter
typically between 0.5 mm and 1 mm. The central opening 32 is also
substantially circular and has a larger diameter than the
peripheral openings, typically between 1.2 mm and 2.5 mm.
[0081] Referring now to FIGS. 4a and 4b, 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. It will be noted that the
plant-based aerosol generating material 24 and the inductively
heatable susceptor elements 26 are not shown in FIGS. 4a and
4b.
[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 FIG. 4b. The hook 36 includes a tapered surface 40 which allows
it to slide past the flange 20 when the closure 18 is moved in the
direction of the cup axis from the position shown in FIG. 4a to the
position shown in FIG. 4b. It will be understood by one of ordinary
skill in the art that the side wall 14 of the cup 10 proximate the
open end 16 and/or the hook 36 may flex as the closure 18 is
pressed onto the flange 20 before one or both components return to
their original positions, to thereby allow the flange 20 to be
accommodated and securely retained in the circumferential recess 38
as shown in FIG. 4b.
[0083] Referring now to FIGS. 5a and 5b, there is shown a third
example of an aerosol generating article 3 which is similar to the
aerosol generating articles 1, 2 described above with reference to
FIGS. 1, 2, 4a and 4b and in which corresponding elements are
designated using the same reference numerals. It will again be
noted that the plant-based aerosol generating material 24 and the
inductively heatable susceptor elements 26 are not shown in FIGS.
5a and 5b.
[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 FIG. 5b. The
upper circumferential flange portion 44 includes a tapered surface
50 which facilitates movement of the closure 18 from the position
shown in FIG. 5a into the circumferential recess 48 as shown in
FIG. 5b. In particular, it will be understood by one of ordinary
skill in the art that the side wall 14 of the cup 210 proximate the
open end 16 may be caused to flex radially outwardly as the as the
closure 18 is pressed onto the tapered surface 50 and that the
upper circumferential flange portion 44 may also be deformed
outwardly and/or downwardly before both components return to their
original positions, to thereby allow the periphery of the closure
18 to be accommodated in the circumferential recess 48 as shown in
FIG. 5b.
[0085] Referring now to FIG. 6, there is shown an example of a
method for manufacturing an aerosol generating article, for example
the first example of the aerosol generating article 1 described
above with reference to FIGS. 1 and 2.
[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 FIGS. 1
and 2.
[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 FIGS. 1 to 3 or by a snap-fit connection as described above with
reference to FIGS. 4 and 5.
[0091] Referring now to FIGS. 7a and 7b, there is shown an example
of a cup 310 in which the side wall 14 has a stepped inner surface
52 comprising a plurality of steps 54a-c.
[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 FIGS. 8a-h. Due to the stepped configuration of the
inner surface 52, the retaining surface 56c positioned along the
cup axis nearest to the open end 16 is closer to the side wall 14
than the retaining surfaces 56a, 56b below it. Similarly, the
retaining surface 56b is closer to the side wall 14 than the
retaining surface 56a below it. In one embodiment, the retaining
surfaces 56a-c are spaced by a uniform distance.
[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 FIGS. 8a-h. Due to the stepped
configuration of the inner surface 52, the abutment surface 60c
positioned along the cup axis nearest to the open end 16 is closer
to the side wall 14 than the abutment surfaces 60a, 60b below it.
Similarly, the abutment surface 60b is closer to the side wall 14
than the abutment surface 60a below it.
[0094] Referring now to FIGS. 8a-h, a first layer 24a of
plant-based aerosol generating material 24 is dosed and deposited
in the cup 310 as shown in FIG. 8a and in accordance with step S4
described above. A first inductively heatable susceptor element 26a
is then placed on the deposited first layer 24a of plant-based
aerosol generating material 24a as shown in FIG. 8b and in
accordance with step S5 described above.
[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 FIGS. 8c to 8g in accordance
with step S6 described above.
[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 FIG. 8c and a second inductively heatable susceptor
element 26b is then placed in the cup 310 in contact with the
retaining surface 56b and the abutment surface 60b as shown in FIG.
8d. The second inductively heatable susceptor element 26b has a
larger outer diameter than the first inductively heatable susceptor
element 26a so that it can contact the surfaces 56b, 60b.
[0098] A third layer 24c of plant-based aerosol generating material
24 is then dosed and deposited in the cup 310 as shown in FIG. 8e
and a third inductively heatable susceptor element 26c is then
placed in the cup 310 in contact with the retaining surface 56c and
the abutment surface 60c as shown in FIG. 8f. The third inductively
heatable susceptor element 26c has a larger outer diameter than the
first and second inductively heatable susceptor elements 26a, 26b
so that it can contact the surfaces 56c, 60c.
[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 FIG. 8g so that the cup 310 is completely filled with
the plant-based aerosol generating material 24 and the inductively
heatable susceptor elements 26. The closure 18 is then affixed to
the flange 20 in accordance with step S7 described above to secure
the plant-based aerosol generating material 24 and the inductively
heatable susceptor elements 26 inside the cup 310 and thereby form
an aerosol generating article.
[0100] Referring now to FIGS. 9a to 9c and 10 to 10b, there is
shown an example of a cup 410 in which includes a plurality of
stepped segments 62 at circumferentially spaced locations inside
the cup. Each stepped segment 62 includes a plurality of steps
64a-c.
[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 FIGS. 8a-h and as shown in FIGS. 10a and 10b. The
steps 64a-c also define a plurality of axially extending abutment
surfaces 68a-c which act as stoppers 68 for positioning the
inductively heatable susceptor elements 26a-c radially in the cup
410, as also described above with reference to FIGS. 8a-h and as
shown in FIGS. 10a and 10b.
[0102] Referring now to FIGS. 11a and 11b, there is shown an
example of a cup 510 which uses removable positioning members 70
for positioning the inductively heatable susceptor elements 26
inside the cup 510 as shown in FIGS. 12a-i. The positioning members
70 comprise pins 72 which extend in the axial direction through
openings 22 in the bottom wall 12 that are intended to facilitate
air flow through the bottom wall 12 during use of the aerosol
generating article in an aerosol generating device. In the
illustrated example, three circumferential arrays of 72a-c of the
pins 72 are inserted through openings 22 in the bottom wall 12 so
that the ends of the pins 72 in each array 72a-c are located at
different axial and radial positions inside the cup 510. In the
illustrated example, each array 72a-c comprises four pins 72 as
best seen in FIG. 11b, but in practice each array could comprise
two or more pins 72.
[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 FIG. 12a and in accordance with step S4 described above. A
first inductively heatable susceptor element 26a is then placed on
the deposited first layer 24a of plant-based aerosol generating
material 26 as shown in FIG. 8b and in accordance with step S5
described above. The inductively heatable susceptor element 28a
contacts the ends of the pins 72 in the first array 72a and the
sides of the pins 72 in the second array 72b. The ends of the pins
72 in the first array 72a act as retaining surfaces and sides of
the pins 72 in the second array 72b act as abutment surfaces,
thereby positioning the first inductively heatable susceptor
element 26a in predetermined axial and radial positions inside the
cup 510.
[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 FIGS. 12c to 12g in
accordance with step S6 described above. The method is similar to
that described above with reference to FIGS. 8c to 8g and will not
be described in further detail.
[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 FIG. 12g, the closure 18 is affixed to the flange 20 in
accordance with step S7 described above to secure the plant-based
aerosol generating material 24 and the inductively heatable
susceptor elements 26 inside the cup 510. Finally, the
circumferential arrays 72a-c of pins 72 are withdrawn from the
openings 22 in the bottom wall 12 as shown in FIG. 12i to form an
aerosol generating article.
[0106] Referring now to FIG. 13, there is shown a schematic view of
an apparatus 80 for performing the methods described above. The
apparatus 80 comprises a cup holding unit 82 for holding a
plurality of cups, and first to third stations 84, 86, 88. The cup
holding unit 82 may comprise a sliding tray and a transport unit
(not shown) for moving the sliding tray between the first, second
and third stations 84, 86, 88 as shown schematically in FIG.
13.
[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".
* * * * *