Method for Manufacturing Aerosol Generating Articles

Abstract

A method for continuously manufacturing aerosol generating articles includes: (i) providing a continuous web of an aerosol generating substrate, the continuous web including a substantially flat surface having a centre line; (ii) applying at least one susceptor patch to the substantially flat surface substantially along the centre line to leave an exposed region of the continuous web of aerosol generating substrate on each side of the at least one susceptor patch; (iii) cutting the exposed regions of the continuous web of aerosol generating substrate to form a plurality of aerosol generating strips on each side of the at least one susceptor patch; and (iv) forming the plurality of aerosol generating strips and the at least one susceptor patch into a continuous rod.

What is claimed is: 
     
         1 . An aerosol generating article for use with an aerosol generating device which employs an induction heating system, the aerosol generating article comprising:
 an aerosol generating substrate;   a filter segment at a proximal end of the aerosol generating article;   at least one tubular segment upstream of the filter segment; and   a wrapper enclosing the aerosol generating substrate and the filter segment; wherein the aerosol generating substrate comprises:   a plurality of elongate first strips comprising aerosol generating material and substantially oriented in a longitudinal direction of the aerosol generating article;   an elongate second strip configured as a strip-shaped or blade-shaped susceptor and comprising an inductively heatable susceptor material, the elongate second strip substantially oriented in the longitudinal direction of the aerosol generating article; and   an elongate carrier strip comprising an aerosol generating material, the elongate carrier strip being substantially oriented in the longitudinal direction of the aerosol generating article, having first and second major surfaces and having a same length as the elongate first strips;   wherein the elongate first strips, the elongate second strip and the elongate carrier strip are arranged to form a substantially rod-shaped aerosol generating article and, wherein a cross-section of the aerosol generating substrate includes a first region facing the first major surface of the elongate carrier strip and a second region facing the second major surface of the elongate carrier strip, each of the first and second regions including some of the plurality of the elongate first strips, and the elongate second strip and the elongate carrier strip being positioned roughly centrally within the cross-section of the aerosol generating substrate; wherein each of the plurality of elongate first strips has a width of between 0.1 mm and 5.0 mm; or   wherein the elongate second strip has a length of between 5 mm and 50 mm.   
     
     
         2 . The aerosol generating article of  claim 1 , wherein the elongate second strip is adhered to the elongate carrier strip using an adhesive. 
     
     
         3 . The aerosol generating article of  claim 1 , wherein the elongate carrier strip has a width greater than the width of the elongate second strip. 
     
     
         4 . The aerosol generating article of  claim 1 , wherein the elongate second strip is fully embedded in the aerosol generating substrate and is not visible at either end of the aerosol generating substrate. 
     
     
         5 . The aerosol generating article of  claim 1 , wherein the elongate first strips and the elongate carrier strip are made from a same continuous web of the aerosol generating substrate. 
     
     
         6 . The aerosol generating article of  claim 1 , wherein the elongate second strip has a width between 0.1 mm and 7 mm, a thickness between 1 μm and 500 μm. 
     
     
         7 . The aerosol generating article of  claim 1 , wherein the inductively heatable susceptor material comprises one or more of aluminium, iron, nickel, stainless steel, carbon steel, or alloys thereof including Nickel Chromium and Nickel Copper. 
     
     
         8 . The aerosol generating article of  claim 1 , wherein the plurality of elongate first strips and the elongate carrier strip comprise tobacco. 
     
     
         9 . The aerosol generating article of  claim 1 , wherein the plurality of elongate first strips and the elongate carrier strip comprise at least one of glycerine or propylene glycol. 
     
     
         10 . The aerosol generating article of  claim 1 , wherein the plurality of elongate first strips and the elongate carrier strip comprise at least one of nicotine, flavour compounds, or tobacco flavouring. 
     
     
         11 . The aerosol generating article of  claim 1 , wherein the aerosol generating article has a total length between 30 mm and 100 mm, a diameter between 5 mm and 10 mm, and the aerosol generating substrate has a total length between 5 mm and 50 mm. 
     
     
         12 . An aerosol generating article for use with an aerosol generating device which employs an induction heating system, the aerosol generating article comprising:
 an aerosol generating substrate;   a filter segment at a proximal end of the aerosol generating article;   at least one tubular segment upstream of the filter segment; and   a wrapper enclosing the aerosol generating substrate and the filter segment; wherein the aerosol generating substrate comprises:   a plurality of elongate first strips comprising aerosol generating material and substantially oriented in a longitudinal direction of the aerosol generating article; and   an elongate second strip configured as a strip-shaped or blade-shaped susceptor and comprising an inductively heatable susceptor material, the elongate second strip substantially oriented in the longitudinal direction of the aerosol generating article;   wherein the elongate first strips and the elongate second strip are arranged to form a substantially rod-shaped aerosol generating article and, wherein a cross-section of the aerosol generating substrate includes a first region facing a first surface of the elongate second strip and a second region facing a second surface of the elongate second strip, each of the first and second regions including some of the plurality of the elongate first strips, and the elongate second strip being positioned centrally within the cross-section of the aerosol generating substrate;   wherein each of the plurality of elongate first strips has a width of between 0.1 mm and 5.0 mm; or   wherein the elongate second strip has a length of between 5 mm and 50 mm.   
     
     
         13 . The aerosol generating article according to  claim 12 , further comprising an elongate carrier strip comprising an aerosol generating material, the elongate carrier strip being substantially oriented in the longitudinal direction of the aerosol generating article. 
     
     
         14 . The aerosol generating article according to  claim 13 , wherein the elongate carrier strip has first and second major surfaces and have a same length as the elongate first strips. 
     
     
         15 . The aerosol generating article according to  claim 13 , wherein the elongate carrier strip is positioned centrally within the cross-section of the aerosol generating substrate.