RU2812212C1 - Composite aerosol generating material - Google Patents

Abstract

FIELD: aerosol generating devices.

SUBSTANCE: invention is related to a composite aerosol generating material and a method for its manufacturing. The composite aerosol generating material (530) contains two sheets of support material (522A, 522B) with a gel (544) located between them. The method of making a composite aerosol generating material (530) includes providing a first continuous sheet of support material (522B) and dispensing a gel (544) onto the surface of the first continuous sheet of support material; providing a second continuous sheet of support material (522A) and placing said second continuous sheet of support material on said gel (544) to form a composite material with the gel disposed between the first continuous sheet of support material (522B) and the second continuous sheet of support material (522A). The method contains the additional step of dispensing a larger amount of gel to the central region proximal with respect to the longitudinal axis of the first continuous sheet of carrier material, compared to the amount of gel dispensed to the side region distal with respect to the longitudinal axis of the first continuous sheet of carrier material.

EFFECT: by accurately positioning the first continuous sheet and the second continuous sheet, stable manufacturing of the composite aerosol generating material can be ensured.

14 cl, 13 dwg

Description

The present invention relates to a composite aerosol generating material, methods for making such composite aerosol generating materials, and apparatus for such making. In addition, the present invention relates to aerosol generating rods containing said composite aerosol generating material, methods for making such rods, and apparatus for making such rods. The aerosol generating rod may be configured for use with an aerosol generating article. The aerosol generating article may be configured for use with an aerosol generating device. The present invention relates particularly, but not exclusively, to applying a gel in a layered configuration between an aerosol generating material, or support material. Preferably, the gel contains an active substance, for example flavoring agents, humectants, plasticizers or nicotine. Preferably, the gel contains a combination of active substances.

When manufacturing an aerosol generating rod, the procedure typically involves the following steps. A flat sheet of aerosol generating material is unwound from a reel of aerosol generating material. The aerosol-generating material is then typically sprayed along with liquid or powder components such as glycerin or flavoring agents. Finally, the aerosol-generating material is drawn through a funnel-shaped device, which collects the sheet into a continuous cylindrical rod of the required diameter. Said continuous rod is wrapped and cut to the required length before being combined with other rods in a line to form an aerosol generating article.

However, spraying liquid or powder components onto said sheet may have some disadvantages. For example, in the atomization process, typically only a portion of the material is sprayed and fixed onto a sheet of aerosol-generating material.

Therefore, it would be desirable to provide improved application of flavors and other components in which these disadvantages are eliminated. It would also be desirable to provide an aerosol-generating material for use in an aerosol-generating rod, and an apparatus and method for making said aerosol-generating material that reduces wastage of components to enable lower manufacturing costs and requires less cleaning work, which would save time.

According to a first aspect of the present invention, there is provided a method for manufacturing a composite aerosol generating material, comprising the following steps:

providing a first continuous sheet of support material;

dispensing the gel onto the surface of the first continuous sheet of carrier material;

providing a second continuous sheet of support material and placing said second continuous sheet of support material on said gel to form a composite material with the gel disposed between the first continuous sheet of support material and the second continuous sheet of support material; And

further comprising the step of dispensing more gel to a central region proximal to the longitudinal axis of the first continuous sheet of support material compared to the amount of gel dispensed to a side region distal to the longitudinal axis of the first continuous sheet of support material.

According to yet another aspect of the present invention, there is provided a composite aerosol generating material comprising:

- the first sheet of supporting material;

- second sheet of supporting material; And

- a gel located between the first sheet of support material and the second sheet of support material, wherein a greater amount of gel is applied to a central region proximal with respect to the longitudinal axis of the first continuous sheet of support material compared to the amount of gel applied to a lateral region distal to to the longitudinal axis of the first continuous sheet of support material.

The composite aerosol generating material of the present invention may be suitable for use in an aerosol generating rod or an aerosol generating article. In some embodiments, the composite aerosol generating material is for use in an aerosol generating rod.

The present invention provides a method of making a composite aerosol generating material for use in an aerosol generating rod, comprising the steps of: providing a first continuous sheet of support material; dispensing the gel onto the surface of the first continuous sheet of carrier material; providing a second continuous sheet of support material and placing the second continuous sheet of support material on said gel to form a composite material with the gel disposed between the first continuous sheet of support material and the second continuous sheet of support material. By accurately positioning the first continuous sheet and the second continuous sheet (support material), it is possible to stably manufacture the composite aerosol generating material.

Preferably, the method of making the composite aerosol generating material further includes a corrugating step. This may be corrugating the first continuous sheet of support material and/or the second continuous sheet of support material. Corrugation provides ease of manufacture due to the ease of assembly of the sheet in a subsequent manufacturing step, since as a result of the corrugation operation, the elasticity of the sheet of the supporting material is weakened and a plurality of ridges and corrugations are provided on the sheet. Said ridges and corrugations are regularly distributed at predetermined locations and extend substantially along the entire length of the sheet. Thus, corrugation helps the sheet to gather in a more defined manner. In addition, corrugation also allows more sheet material to be drawn through the funnel-shaped device to form an aerosol generating rod compared to non-corrugated sheets. In addition, the corrugation helps to create a uniform distribution of flow channels and maintain said flow channels by weakening the elasticity of the sheet of aerosol generating material. The speed of corrugation and the size and pattern of grooves or indentations may vary. This makes it possible to create a large number of different conditions for aerosol flow with a specific characteristic of retraction resistance. Preferably, the corrugating step is performed before dispensing the gel onto the first continuous sheet of support material or onto a portion of the surface of the first continuous sheet of support material. Crimping before dispensing simplifies manufacturing compared to crimping after dispensing the gel. This helps prevent gel extrusion during corrugation and thus reduces the risk of gel contact with production equipment. In addition, pre-dispensing corrugation also provides the advantage of being able to corrugate only one of the first or second sheet of carrier material instead of corrugating a composite aerosol generating material comprising at least two sheets of carrier material.

In specific embodiments, a method of making a composite aerosol generating material further includes the step of providing a first continuous sheet of support material and a second continuous sheet of support material from different respective sources of support material. By having a first continuous sheet of support material and a second continuous sheet of support material provided from different sources of support material or being different support materials, a large number of different materials and combinations of different support materials can be used. Thus, different composite aerosol-generating materials containing different combinations of carrier materials and/or aerosol-generating materials provide delivery of a large number of different aerosols.

In specific embodiments, a method of making a composite aerosol generating material further includes the step of providing both a first continuous sheet of support material and a second continuous sheet of support material from a single source of support material. This allows the manufacturing process to be simplified by having only one source of support material to produce the first and second continuous sheets of support material.

In specific embodiments, a method of making a composite aerosol generating material further includes the step of folding a continuous sheet from said one source of support material to form both a first continuous sheet of support material and a second continuous sheet of support material such that said first continuous sheet of support material and a second continuous sheet of support material sheets of supporting material were combined with each other along the fold line. Folding a sheet of the original support material to form first and second continuous sheets of support material provides ease of manufacture and efficient use of the material. It also prevents the dispensed gel from being squeezed out on one side.

Folding of the sheet of original support material can be accomplished by any suitable means known in the art, including the use of guides. Specific embodiments include the use of guides for folding a sheet of original support material. In specific embodiments, the guides used with the present invention may be roller type guides, such as a guide roller or a positioning roller; or a fixed guide with a curved surface; or any combination of guides of the types mentioned. Moving the sheet of original support material towards the folding means causes the sheet of original support material to fold until the folding process is completed and one side section of the continuous sheet of support material is completely folded over the contact point with the gel already dispensed onto the other side section. sheet of the original supporting material.

In specific embodiments, the method of making a composite aerosol generating material further includes the step of cutting a continuous sheet from one source of support material to form both a first continuous sheet of support material and a second continuous sheet of support material. By cutting the original support material to form the first continuous sheet and the second continuous sheet of support material, the material of the first continuous sheet of support material and the second continuous sheet of support material is ensured, for example, in terms of composition or thickness. In addition, by providing both sheets of support material from the same source, the material properties of the first continuous sheet of support material and the second continuous sheet of support material are ensured to be the same.

Typically, the width of the carrier material to be cut may range from 5 centimeters to 50 centimeters, preferably about 20-40 centimeters, more preferably about 25 centimeters.

When cutting a sheet of source support materials, cutting means are typically used, such as a cutting tool, one or more of a knife or blade, or a saw, or a cutting tool such as a hacksaw, or a rotary cutter, to produce a clean cut on the sheet of source support material, forming both first and second continuous sheets of support material. The cutting edge will typically face the incoming feed carrier material. Typically, but not necessarily, the cutting means will be an integral system that cuts the original support material into two sections along the longitudinal direction of the original support material sheet. The cutting means can cut the original carrier material into more than two sections, depending on the requirements. The first continuous sheet of support material and the second continuous sheet of support material are made separate. In those embodiments in which a second continuous sheet of support material is placed in contact with the gel, guide means and transport means will be required to position the second continuous sheet of support material in the desired position, ideally resting on the gel already applied to the first continuous sheet of support material . The gel is thus embedded in a layered configuration between two continuous sheets of support material. Typically, the first continuous sheet of support material obtained by cutting the support material extends along the same or similar path and in the same or similar direction as the support material being cut. The second continuous sheet of support material is guided by the guide means to be placed in contact with the gel dispensed onto the first continuous sheet of support material. Preferably, the sheet of carrier material is longitudinally cut in the sheet feed direction before dispensing the gel onto the first continuous sheet of carrier material. Cutting the sheet of original carrier material before dispensing the gel reduces the risk of the gel coming into contact with cutting agents, such as a cutting tool. This also reduces the risk of dust from cutting tools coming into contact with the gel or gel nozzles. Preferably, a distance is provided between the cutting location and the gel dispensing location to prevent dust generated at the cutting location from interfering with the dispensing of the gel. If the aerosol generating material is cut into more than two sections or sheets of support material, then each section or sheet can be used or removed in the same manner as explained for the first or second continuous sheet of support material. One cutting means can supply a first continuous sheet of support material and a second continuous sheet of support material to multiple devices for making a composite aerosol generating material. The composite aerosol generating material is then assembled together to form an aerosol generating rod. The sheet cutting means may have dust protection means, such as a vacuum source to collect dust from the cutting tool. Due to the presence of dust protection means, it is possible to reduce the distance between the cutting tool and the gel application site and thus the ability to speed up the production of the composite aerosol generating material and subsequent aerosol generating rods. The sequence of cutting and dispensing the gel is not essential to the practice of the present invention and, in principle, each of the steps of cutting and dispensing the gel can be performed before, after or simultaneously with another of them, depending on the embodiment. In some embodiments of the present invention, the gel is dispensed using gel dispensing means comprising at least one nozzle. The use of nozzles facilitates accurate gel dispensing, both in terms of the amount of gel dispensed and the placement of the gel dispensed. In some embodiments, in combination with other steps, the method of making a composite aerosol generating material further includes the step of adjusting the output amount of gel using a control system. The control system provides the ability to facilitate accurate gel dispensing, both in the amount of gel dispensed and the location of the gel dispensed. The gel dispensing means may have multiple nozzles creating multiple strips of gel on a first continuous sheet of carrier material. In some embodiments, not all nozzles will dispense gel at the same time. Alternatively, in some embodiments, all nozzles may dispense gel simultaneously. The control system may also record gel dispensing, including both the amount of gel dispensed and the location of the gel dispensed, so that the total amount of any ingredient in the gel can be calculated and tracked. The gel dispensing means, such as a dispensing device, may also have a gel temperature control system. Ideally, the gel dispensing means comprises a heater and/or temperature sensor. Preferably, such systems will also include a feedback loop for information processing. This system can make any necessary changes, for example, in the required amount of heat or in the rate of gel dispensing. Typically, an increase in temperature causes the viscosity of the gel to decrease and release becomes easier or faster. Some gels may require specific temperatures for optimal dispensing and storage. By keeping the gel at the required temperature before reaching the nozzles, it is possible to promote stable gel dispensing. The heater may be a resistive heater, although any suitable heater may be used. The dispensing means, eg a dispensing device, may also contain cooling means, eg a cooler. Coolants provide the ability to assist the setting of the gel when it is in the proper location. This reduces the risk of leakage. Alternatively or additionally, cooling agents, depending on the type of gel used, provide the ability to help hold the first and second continuous sheets of support material together. In some examples, cooling agents reduce the viscosity of the gel so that it remains in the same location after setting. In other examples, cooling agents speed up the setting of the gel. The gel dispensing means may also comprise one or more of flow meters, pumps, and actuated valves to enable precise control of the flow rate of the gel dispensed. This provides the advantage of being able to fine tune to maintain a stable gel flow rate. This is important because the gel can change over time during the manufacturing process. Many factors can cause changes in the gel, such as humidity and ambient temperature, as well as variations in the gel supplied. In preferred embodiments, each nozzle has a flow meter and an actuated valve that allows the flow of gel dispensed from the nozzle to be independently controlled. In some embodiments, the nozzles used to dispense gel onto the first continuous sheet of support material dispense the same type of gel onto each sheet of support material. Alternatively, the nozzles dispensing the gel onto the first continuous sheet of support material may dispense different types of gels. For example, in some embodiments, if the nozzles dispense different types of gels, then one or more nozzles may dispense a gel containing a flavoring agent. Alternatively, one or more nozzles may dispense a gel containing nicotine. Alternatively, one or more nozzles may dispense a gel containing glycerin. Alternatively, one or more nozzles may dispense a gel containing propylene glycol. Alternatively, one or more nozzles may dispense any combination of the types of gels mentioned. By having different nozzles for different types of gels, it is possible to precisely control and vary the gel ingredients. For example, a different end product may require more flavor, or a particular ingredient at a particular location on a sheet of aerosol generating material may be preferred.

In preferred embodiments, the gel dispensing means dispenses gel onto the same side of the first continuous sheet of carrier material. Preferably, this is the top side of the sheet so that, by gravity, the dispensed gel can be easily placed and fixed onto the sheet of carrier material for transport to a subsequent manufacturing step.

In some embodiments, a method of making a composite aerosol generating material further includes the step of dispensing a gel unevenly onto one surface of a first continuous sheet of support material.

In some embodiments, a method of making a composite aerosol generating material further includes the step of dispensing a greater amount of gel to a central region proximal to the longitudinal axis of the first continuous sheet of support material compared to the amount of gel dispensing to a side region distal to the longitudinal axis. the first continuous sheet of supporting material.

In some embodiments, the method of making a composite aerosol generating material further includes the step of dispensing at least 10% more mass of gel to a central region proximal to the longitudinal axis of the first continuous sheet of support material, compared to the mass of gel dispensed to the side region, distal with respect to the longitudinal axis of the first continuous sheet of supporting material. Alternatively, the method may include the step of dispensing at least 15 percent more gel mass to the central region. In other embodiments, the method includes dispensing at least 20 percent more gel mass to a central region, or at least 25 percent greater gel mass to a central region.

Controlling the amount of gel and the location of the gel on the first or second continuous sheet of support material or on the composite aerosol generating material provides the ability to reduce the risk of gel leakage from the composite aerosol generating material. Preventing gel leakage also provides the ability to promote uniform production of the composite aerosol generating material and thus the ability to ensure uniform performance of the final finished products.

In certain embodiments, a method of making a composite aerosol generating material further includes the step of providing a continuous strip of current collecting material. Preferably, the method of making the composite aerosol generating material includes placing a continuous strip of current collecting material on the gel. Preferably, a continuous strip of current collecting material is placed on the gel after dispensing the gel onto the first continuous sheet of carrier material. In some embodiments, the composite aerosol generating material comprises a current collecting material. The current-receiving material provides the possibility of induction heating. When a current-receiving material is placed in an electromagnetic field, eddy currents are induced in this current-receiving material and hysteresis losses occur, which leads to heating of the current-receiving material. In those embodiments in which the current-receiving material is located in thermal contact with or in close thermal proximity to the aerosol-generating material or gel, heating of said aerosol-generating material or gel occurs. Heating the aerosol-generating material or gel provides the ability to promote the release or generation of aerosols. Preferably, the current collecting material is in direct physical contact with the gel. However, in alternative embodiments, the current-receiving material may be located between sheets of support material without direct physical contact with the gel.

The current collector may be made of any material that is capable of being inductively heated to a temperature sufficient to generate or release an aerosol, such as a gel or aerosol-generating substrate, or a support material on which the aerosol-generating substrate or gel is placed. In some embodiments, the current collector contains carbon. A preferred current collector may comprise or be composed of a ferromagnetic material, such as a ferromagnetic alloy, ferritic iron or ferromagnetic steel, or stainless steel. Preferred current collector materials include metal, such as aluminum. Preferred pantographs can be heated to temperatures in excess of 50 degrees Celsius. More preferably, the pantographs may be heated to a temperature of from about 40 degrees Celsius to about 500 degrees Celsius, in particular from about 50 degrees Celsius to about 450 degrees Celsius, preferably from about 100 degrees Celsius to about 400 degrees Celsius . The current collector may also include a non-metallic core with a metal layer deposited on the non-metallic core, for example with metal tracks formed on the surface of the ceramic core.

The pantograph may have a protective outer layer, such as a protective ceramic layer or a protective glass layer surrounding the pantograph. The current collector may contain a protective coating of glass, ceramic or inert metal, made over the core of the current collecting material.

The current collector may consist of several materials. In particular, the pantograph may comprise a first pantograph material and a second pantograph material. The first current collector material is preferably optimized with respect to heat loss and thus heating efficiency. For example, the first current collector material may be aluminum or a ferrous metal such as stainless steel. In contrast, the second current-receiving material is preferably used as a temperature marker. To do this, the second current-receiving material is selected so that it has a Curie temperature corresponding to the specified heating temperature of the current-receiving unit. The magnetic properties of the second current collector at its Curie temperature change from ferromagnetic to paramagnetic, which is accompanied by a temporary change in its electrical resistance. Thus, by monitoring the change in electric current consumed by the induction source, it is possible to determine the moment at which the second current-receiving material has reached its Curie temperature and, thus, the moment at which said target heating temperature has been reached. The second current collecting material preferably has a Curie temperature that is below the ignition point of the aerosol-forming substrate, that is, preferably below 500 degrees Celsius. Suitable materials for the second current collector material may include nickel and certain nickel alloys. Nickel has a Curie temperature of 354 degrees Celsius to 360 degrees Celsius, depending on the nature of the impurities. A Curie temperature in this range is ideal because it is approximately the temperature to which the current collector must be heated to generate an aerosol from the aerosol-forming substrate, but is still low enough to avoid local overheating or burning of the aerosol-forming substrate.

If the pantograph is in the form of a strip, in particular a blade, plate, sheet, tape or foil, then the pantograph preferably has a substantially rectangular cross-section. In this case, the pantograph preferably has a width dimension larger than the thickness dimension, for example larger than twice the thickness dimension. Preferably, the strip pantograph has a width from about 2 millimeters to about 8 millimeters, more preferably from about 3 millimeters to about 5 millimeters, and a thickness from about 0.03 millimeters to about 0.15 millimeters, more preferably from about 0.05 millimeters to approximately 0.09 millimeters.

In specific embodiments, the method of making a composite aerosol-generating material further includes the steps of repeating the steps of making a composite aerosol-generating material and layering the composite aerosol-generating materials on top of each other. Therefore, the composite aerosol generating material may comprise a plurality of layers forming a multilayer composite aerosol generating material. The respective constituent layers of the composite aerosol generating material may be the same or different in terms of their composition or structure. A number of combinations can be achieved using different composite aerosol-generating materials and, additionally, in some embodiments, different support layers to make the final composite aerosol-generating material. This allows for the production of many different composite aerosol generating materials, potentially having many different properties and characteristics. In specific embodiments, a method of making a composite aerosol generating material includes the step of layering one composite aerosol generating material on top of another composite aerosol generating material. In certain embodiments, a method of making a composite aerosol-generating material includes the steps of layering one composite aerosol-generating material on top of another, and inserting a susceptor material between two layers of the composite aerosol-generating material. Composite aerosol generating materials or a multilayer composite material can be assembled and preferably wrapped to form a composite aerosol generating rod.

In specific embodiments, the device or manufacturing method further includes a layering system. The layering system is capable of layering composite aerosol generating materials, preferably one on top of the other. The description and examples provided are for illustrative purposes only, referring to a vertical orientation of the top and bottom sides, with the composite aerosol generating materials on top of each other, however, other embodiments may occur with other orientations characterized by placing the composite aerosol generating materials adjacent to each other, and they are included within the scope of the disclosure of the present invention herein. In preferred embodiments, the composite aerosol-generating materials are stacked such that the top and bottom surfaces of the layers of the stack of composite aerosol-generating materials are gel-free. In these particular embodiments, the outer faces of the individual composite aerosol generating materials preferably do not have a gel.

In some embodiments, the susceptor is located between layers of the composite aerosol generating material. In those embodiments in which there is no gel between the layers of the composite aerosol generating material (meaning there is no gel on the outer surfaces of the composite aerosol generating material) and the susceptor is located between the outer sides of the layers of the composite aerosol generating material, the susceptor may not be adjacent to the gel. However, the current collector can still heat the gel through layers of the composite aerosol-generating material. The presence of a current collector between the outer surfaces of the composite aerosol generating material provides the advantage of ease of manufacture. In alternative embodiments, the gel may be placed on or exposed to the outer surface of the layers of the composite aerosol-generating material, and thus, in these embodiments, the susceptor will be located adjacent to the gel when placing the susceptor between the outer surfaces of the composite aerosol-generating material.

Other embodiments may contain gel between the composite aerosol-generating materials, but ideally will not have gel on external surfaces that are not adjacent to another composite aerosol-generating material. Preferably, the gel is only on the internal surfaces, and thus any external surfaces are free of gel. This has the advantage of preventing contamination of the gel by reducing the risk of the gel contacting the wrapping material or contacting surfaces in the equipment, such as guide means, such as sheet placement guides and a funnel-shaped device for collecting the sheet to form a continuous cylindrical rod.

In specific embodiments, the layering system comprises at least one lateral movement system. Such a lateral movement system may move one material, such as one sheet of carrier material or composite aerosol generating material, laterally to a position above (or below) or parallel to another material, such as another sheet of carrier material or composite aerosol generating material. The manufacturing process or layering device or system may have multiple lateral movement systems. Typically, the number of lateral movement systems in a device or layering system or manufacturing process is equal to the number of sections minus one. Ideally, each lateral movement system works with one different starting section. For example, if a support material is cut into two pieces to form a first sheet of support material and a second continuous sheet of support material, then one lateral movement system is present to move one sheet, such as a second continuous sheet of support material, above (or below) the other. Preferably, the lateral movement system(s) place(s) all of the materials, eg sheets of composite aerosol generating support material, in a vertical stack, one above the other. As explained above, other orientations are possible in other embodiments.

In some preferred embodiments, the method of making a composite aerosol generating material further includes the step of pressing the composite aerosol generating material in a direction perpendicular to its flat surface. In a vertical stack of layers of composite aerosol generating material, for example, pressure from the pressing system acts along the height of the stack. Different pressures can be applied to a stack of material. The pressing system can have variable pressing force, depending on the desired effect or the size of the materials stacked. In specific embodiments, the manufacturing apparatus or manufacturing system comprises two press rollers that operate together to apply a pressing force as the composite aerosol generating material passes through the rollers. In specific embodiments, the manufacturing apparatus or manufacturing system comprises a single press roll. Ideally, the pressure in the pressing system is high enough to cause the material to adhere to the gel strips, but low enough to not cause structural damage to the sheet. Ideally, the gel strips are not pressed to a point where there is no air passage between the continuous sheets of support material and the layers of composite aerosol generating material.

The present invention further provides a composite aerosol generating material comprising: a first sheet of support material; a second sheet of supporting material; and a gel disposed between the first sheet of support material and the second sheet of support material.

In preferred embodiments, the composite aerosol generating material further comprises a current-receiving material located between the first sheet of support material and the second sheet of support material. The current-receiving material provides the possibility of induction heating. When a current-receiving material is placed in an electromagnetic field, eddy currents are induced in this current-receiving material and hysteresis losses occur, which leads to heating of the current-receiving material.

When making a composite aerosol generating material, the first sheet of support material and the second sheet of support material are preferably continuous sheets. However, if necessary, continuous sheets can be cut to a specific length so that they are no longer continuous.

In preferred embodiments, the gel contains one or more of a flavoring agent, an active agent, a plasticizer, a humectant, nicotine, glycerin, or propylene glycol.

In preferred embodiments, the sheet of carrier material contains tobacco material.

The present invention also relates to a composite aerosol generating rod containing a composite aerosol generating material described herein or manufactured by the steps described herein.

An apparatus for making a composite aerosol generating material for use in an aerosol generating rod comprises: means for supplying a first continuous sheet of carrier material; means for dispensing the gel onto the surface of the first continuous sheet of support material; a layering system for providing a second continuous sheet of support material and placing it on the gel to form a composite aerosol generating material.

An example of said feeding means is a feeding device.

In specific embodiments, in combination with other features, said device further comprises a cutting tool located upstream of the lamination system and configured to cut a sheet of the original support material along the longitudinal axis of the sheet of the original support material to form a first continuous sheet of support material and a second continuous sheet of supporting material.

In specific embodiments, in combination with other features, said device further comprises folding means, such as a folding device configured to fold at least a portion of a sheet of the original support material along the longitudinal axis of the sheet of the original support material to form a first continuous sheet of support material and a second continuous sheet of support material.

In specific embodiments, in combination with other features, said device additionally has a corrugating system. Preferably, the pleating system is located upstream of the gel dispensing system and the layering system.

The first continuous sheet of support material and/or the second continuous sheet of support material may be corrugated. If the composite aerosol generating material is multilayer, then any combination of corrugated and non-corrugated sheets of support material may be used to make the multilayer composite aerosol generating material.

The present invention also discloses a device that further comprises layering means configured to layer composite materials to form a multilayer composite aerosol generating material. This may be by layering the same composite aerosol-generating material on itself or by layering different composite aerosol-generating materials on top of each other. An example of layering means is a layering device.

In specific embodiments, said device further comprises a compression system in which the composite aerosol generating material and/or the multi-layer composite aerosol generating material is compressed using at least one compression roller. In preferred embodiments, said device further comprises means for collecting the composite aerosol generating material and/or the multilayer composite aerosol generating material. In preferred embodiments, said device further comprises means for wrapping the composite aerosol generating material or the multi-layer composite aerosol generating material after collection thereof. The wrapping means allows the composite aerosol generating material to be cut into aerosol generating rods. In some embodiments, the device includes a cutting tool for cutting the continuous length of the wrapped composite aerosol generating material into lengths of the required length. This allows the wrapped composite aerosol generating material to be easily transported during the manufacturing process. The apparatus of the present invention may include any feature described herein for making a composite aerosol generating material, such as gel dispenser, nozzles, controls, guides, rollers, compression system, or any combination thereof.

In certain embodiments, the sheet of support material comprises a porous material. In certain embodiments, the sheet of support material may be composed of a porous material. The porous material has the advantage that the material is able to securely hold the gel. The advantage of a porous carrier material is that it is able to hold the gel more securely than a non-porous carrier material. The pores of the porous material are capable of absorbing the gel and therefore allow the gel to be easily placed on and quickly adhere to the sheet of porous support material. The porous material is able to firmly fix the gel on the surface of the carrier sheet due to absorption through the pores. Thus, the porous material is able to prevent the gel from moving into the region adjacent to the porous material. The porous material used in the present invention helps reduce gel leakage from the composite aerosol generating material. A composite aerosol generating material made from a porous material helps reduce gel leakage and thus reduces contamination of equipment parts during the manufacturing process, for example, reducing contamination of the cutting blade of a cutting tool when a continuous length wrapped composite aerosol generating material must be cut into required lengths.

The porous material may be any suitable porous material capable of holding or fixing the gel. Ideally, the porous material is capable of allowing the gel to move within it. In specific embodiments, the porous material comprises natural materials, synthetics or semi-synthetics, or a combination of the above materials. In certain embodiments, the porous material comprises sheet material, foam or fibers, such as loose fibers, or a combination thereof. In specific embodiments, the porous material comprises woven, non-woven or extruded material, or combinations thereof. Preferably, the porous material contains, for example, cotton, paper, rayon, polylactic acid (PLA) or cellulose acetate, or combinations thereof. Preferably, the porous material comprises a sheet material such as cotton or cellulose acetate. The advantages of the porous material are that the gel is retained within the porous material and this provides the ability to facilitate the manufacture, storage or transport of the gel. This provides the ability to help maintain the desired gel shape, especially during manufacture, transport or use. The porous material used in the present invention may be corrugated or crushed. In specific embodiments, the porous material comprises corrugated porous material.

In some embodiments, the gel is at least partially absorbed into the porous material. The layered arrangement of the present invention using two porous support materials has the advantage that the two porous materials hold the gel in place, thereby providing improved or more secure anchorage of the gel compared to using only one porous material. Thus, the use of two porous materials in a layered arrangement according to the present invention is preferred to provide improved gel retention. Improved gel retention provides improved control of gel dispensing and less waste due to less gel movement and leakage. Allows precise placement of the gel with reduced movement or loss of the gel and additives or materials in the gel. In this way, it is possible to achieve improved control over the dosage of the gel and additives in the gel. Less gel leakage also means less equipment contamination and therefore less production downtime for equipment cleaning or repair.

In certain embodiments, the carrier material comprises an aerosol generating material. The carrier material may comprise, for example, tobacco, tobacco material, powdered tobacco, tobacco stalks, nicotine, tobacco leaves or molded leaf tobacco, or any combination of the above aerosol generating materials. The aerosol generating material may also be a porous material, with the advantage of retaining the gel. In specific embodiments, the carrier material may comprise an aerosol-generating material, and the gel may also contain an aerosol-generating substrate. In alternative embodiments, the gel or carrier material may comprise an aerosol-generating substrate.

In combination with certain embodiments, the gel comprises a gelling agent. In specific embodiments, the gel contains agar, or agarose, or sodium alginate, or gellan gum, or a mixture thereof.

In specific embodiments, the gel contains water; for example, the gel is a hydrogel. Alternatively, in certain embodiments, the gel is non-aqueous.

Preferably, the gel contains an active substance. In combination with certain embodiments, the active ingredient comprises nicotine. In certain embodiments, nicotine is included in the gel along with an aerosolizing agent to provide the required nicotine delivery. Fixing the nicotine in the gel at room temperature is desirable to prevent leakage.

In specific embodiments, the gel contains solid tobacco material that releases flavor compounds when heated. Depending on specific embodiments, the solid tobacco material is, for example, one or more of the following: powder, granules, pellets, pieces, thin tubes, strips or sheets containing one or more of the following: plant material, such as herbal leaves, tobacco leaves, tobacco stem fragments, reconstituted tobacco, homogenized tobacco, extruded tobacco and expanded tobacco.

The gel may contain any suitable gelling agent. For example, the gelling agent may include one or more biopolymers, such as two or three biopolymers. Preferably, if the gel contains more than one biopolymer, the biopolymers are present in substantially equal weight proportions. Biopolymers can be obtained from polysaccharides. Biopolymers useful as gelling agents include, for example, gellan gums (natural low acyl gellan gum, high acyl gellan gums, with low acyl gellan gum being preferred), xanthan gum, alginates (alginic acid), agar, guar gum and the like. Preferably the gel contains agar. Preferably, the gel contains only one gelling agent. Preferably, this one gelling agent is agar or guar.

As used herein, the term “aerosol-generating article” is used to describe an article capable of generating or emitting an aerosol.

As used herein, the term “aerosol generating device” describes a device that is to be used with an aerosol generating article to enable the generation of an aerosol, typically from the aerosol generating article. The aerosol generating device will often include a heater.

As used herein, the term “aerosol generating material” is used to describe a material, such as molded tobacco sheet, that promotes or is capable of generating an aerosol. The term also includes a material, such as an aerosol generating agent, that promotes the release of aerosols from an aerosol generating substrate.

As used herein, the term “aerosol generating substrate” is used to describe a substrate that is capable of generating an aerosol, such as cast tobacco leaf or nicotine.

As used herein, the term “support material” is used to describe a material that facilitates or is capable of carrying, storing or supporting an element. In the present invention this includes gel transfer. In particular, if the gel contains an aerosol-generating substrate. The term "carrier" also includes an aerosol-generating material, tobacco, cotton, or any material, such as a gel, that is capable of carrying an aerosol-generating substance. For example, the aerosol generating material may absorb the gel and/or is not destroyed by the gel.

As used herein, the term “composite aerosol generating material” is used to describe a material comprising two or more elements, at least one of which comprises an aerosol generating substrate or an aerosol generating material. It is not necessary for the composite aerosol generating material to have two or all of the elements generating aerosol.

As used herein, the term "corrugated" means a material having a plurality of substantially parallel ridges or corrugations. It also refers to the process of making corrugated material. These ridges may be longitudinal, transverse, angular, straight, wavy, continuous, intermittent, or any combination thereof. Longitudinal projections are preferred because they will enhance the formation of flow channels extending substantially the entire length of the sheet after the sheet has been collected. In addition, compared to non-corrugated or otherwise corrugated sheets, longitudinal ridges made by corrugation will also help to obtain a uniform distribution of flow channels across the cross-section of the formed aerosol generating rod, since the corrugation promotes the formation of flow channels at specified locations and ensures that each flow channel will have a relatively constant cross-sectional size. This makes it possible to achieve a relatively stable resistance to draw (RTD) for the aerosol generating rod.

For purposes of the present invention, as used herein, the term “diameter” or “width” refers to the maximum lateral dimension of the composite tubular aerosol generating material or the first and second continuous sheets of support material, a portion or portion thereof, an aerosol generating article, or an aerosol generating device. For example, "diameter" is the diameter of an object having a circular cross-section, or the length of the diagonal width of an object having a rectangular cross-section.

As used herein, the term "assembled" is used to describe a sheet that is rolled, folded, or otherwise compressed or tapered in a direction substantially transverse to the longitudinal axis of the composite aerosol generating material; or a first or second continuous sheet of support material; or a composite aerosol generating material.

As used herein, the term "gel" is used to describe a solid, jelly-like semi-solid material or mixture of materials, with a three-dimensional network capable of holding other materials and releasing materials into an aerosol.

As used herein, the term “longitudinal” is used to describe the direction between the downstream or proximal end and the opposite upstream or distal end of the aerosol generating article or aerosol generating material; or a composite aerosol generating material; or sheets of supporting material.

As used herein, the term "outer" with reference to a sheet of support material is used to describe that portion which lies closer to the longitudinal sides of the sheet of support material than to the middle of the cross-sectional region of the sheet of support material. Likewise, the term "inner" or "central" is used to describe (with reference to sheets of support material) that portion of the material that is located closer to the center of the cross-sectional region than to the longitudinal sides of the sheets of support material.

As used herein, the term "plasticizer" is used to describe a substance, usually a solvent, added to provide or enhance ductility or flexibility and to reduce friability.

As used herein, the term "rod" is used to describe a component, segment, or element for use in an aerosol generating article. The "continuous rod" is a precursor to the rod before being cut to the required length.

The term "porous material" as used herein is used to describe any material capable of holding, fixing or supporting a gel. Typically, a porous medium will have passages within its structure that can be filled to hold or hold fluid or semi-solid substances, for example to hold a gel. Preferably, the gel will also be able to pass or be transported along and through said passages within the porous material (to some extent).

As used herein, the term "susceptor" is used to describe an element containing a material that is capable of being inductively heated within an alternating electromagnetic field. This may result from at least one of hysteresis losses and eddy currents induced in the current collector, depending on the electrical and magnetic properties of the current collector material. Hysteresis losses occur in ferromagnetic or ferrimagnetic current collectors due to magnetization reversal of magnetic domains inside the material under the influence of an alternating electromagnetic field. Eddy currents can be induced if the pantograph is electrically conductive. In the case of an electrically conductive ferromagnetic current collector or an electrically conductive ferrimagnetic current collector, heat may be generated due to both eddy currents and hysteresis losses. Accordingly, the current collector may comprise a material that is at least one of electrically conductive and magnetic materials.

As used herein, the term resistance to draw (RTD) is used to describe the resistance of a fluid, such as a gas, to be drawn through a material. In the context of this document, pull-in resistance is expressed and measured according to ISO 6565:2002.

As used herein, the term "sheet" or "sheet material" is used to describe a generally flat plate-like element whose width and length are substantially greater than its thickness.

Any of the features or steps described herein with respect to one embodiment, aspect, or example of a composite aerosol generating material, a multilayer composite aerosol generating material, or an aerosol generating rod, or the manufacture (including apparatus) of any of them may be equally applicable to any other embodiment, aspect or example of any of a composite aerosol generating material, a multilayer composite aerosol generating material, an aerosol generating article or an aerosol generating rod, a method of making the same, or an apparatus for making the same.

Examples

Example 1 A method of making a composite aerosol generating material for use in an aerosol generating rod, comprising the steps of:

providing a first continuous sheet of support material;

dispensing the gel onto the surface of the first continuous sheet of carrier material;

providing a second continuous sheet of support material and placing the second continuous sheet of support material on the gel to form a composite material with the gel disposed between the first continuous sheet of support material and the second continuous sheet of support material.

Example 2 The method of manufacturing a composite aerosol generating material according to Example 1, further comprising the step of corrugating at least one of the first continuous sheet of support material and the second continuous sheet of support material.

Example 3 A method of making a composite aerosol generating material according to Example 1 or Example 2, further comprising the step of providing a first continuous sheet of support material and a second continuous sheet of support material from different respective sources of support material.

Example 4 A method of making a composite aerosol generating material according to Example 1 or Example 2, further comprising the step of providing both a first continuous sheet of support material and a second continuous sheet of support material from a single source of support material.

Example 5 The method of making a composite aerosol generating material according to Example 4, further comprising the step of folding a continuous sheet from one source of support material to form both a first continuous sheet of support material and a second continuous sheet of support material such that the first continuous sheet of support material and the second continuous sheet sheets of supporting material were combined with each other along the folding line.

Example 6 The method of making a composite support material according to Example 4, further comprising the step of cutting a continuous sheet from one source of support material to form both a first continuous sheet of support material and a second continuous sheet of support material.

Example 7 A method for making a composite aerosol generating material according to any one of Examples 1-6, 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 support material compared to the amount of gel dispensing to a side region, distal with respect to the longitudinal axis of the first continuous sheet of support material.

Example 8 A method of making a composite aerosol generating material according to any of Examples 1-7, further comprising the step of providing a continuous strip of current collecting material and placing the continuous strip of current collecting material on a gel after dispensing the gel onto a first continuous sheet of support material.

Example 9 A method for making a composite aerosol generating material according to any one of Examples 1 to 8, further comprising the step of pressing the composite aerosol generating material in a direction perpendicular to its flat surface.

Example 10 A method for making a composite aerosol generating material according to any one of Examples 1 to 9, wherein the gel contains a flavoring agent or an active agent or a plasticizer or a humectant or nicotine or glycerin or propylene glycol or any combination thereof.

Example 11 A method for producing a composite aerosol generating material according to any one of Examples 1 to 10, wherein the composite aerosol generating material contains tobacco material.

Example 12 Composite aerosol generating material containing:

- the first sheet of supporting material;

- a second sheet of supporting material and

- a gel located between the first sheet of support material and the second sheet of support material.

Example 13 The composite aerosol generating material of Example 12, further comprising a current-receiving material disposed between the first sheet of support material and the second sheet of support material.

Example 14 The composite aerosol generating material of Example 12 or 13, wherein the first continuous sheet of support material and/or the second sheet of support material comprises the aerosol generating material.

Example 15 Composite aerosol generating rod containing the composite aerosol generating material according to Examples 12-14; or containing a composite aerosol generating material made according to any of Examples 1-11.

Reference will now be made to drawings which depict one or more aspects described in the present invention. However, it should be understood that other aspects not depicted in the drawings fall within the scope of the present invention. Like numbers used in the figures refer to like components, steps, and the like. However, it should be understood that the use of a number to refer to a component in a given figure is not intended to limit a component in another figure designated by the same number. In addition, the use of different numbers to designate components in different figures is not intended to indicate that otherwise numbered components may not be the same or similar to other numbered components. The figures are presented for purposes of illustration and not limitation. The schematic drawings shown in the figures are not necessarily to scale.

In FIG. 1 is a schematic perspective view of a cutting system for cutting a sheet of a starting support material.

In FIG. 2 is a schematic perspective view of an exemplary system for dispensing a gel onto a sheet of starting carrier material having multiple nozzles.

In FIG. 3 shows a schematic top view of a layering system for making a stack of aerosol generating materials.

In FIG. 4 is a schematic side view of the layering system of FIG. 3.

In FIG. 5 is a schematic perspective view of a system for manufacturing an aerosol generating rod.

In FIG. 6 is a schematic cross-sectional view of a composite aerosol generating material according to an embodiment.

In FIG. 7 is a schematic cross-sectional view of a composite aerosol generating material according to yet another embodiment.

In FIG. 8 is a schematic cross-sectional view of a composite aerosol generating material according to a further embodiment.

In FIG. 9 is a schematic cross-sectional view of a composite aerosol generating material according to a further embodiment.

In FIG. 10 is a schematic cross-sectional view of a composite aerosol generating material containing a susceptor material according to an embodiment.

In FIG. 11 is a schematic cross-sectional view of a composite aerosol generating material comprising a susceptor material according to a further embodiment.

In FIG. 12 is a schematic cross-sectional view of a susceptor between two composite aerosol generating materials.

In FIG. 13 is a cross-sectional view of an aerosol generating rod in which a susceptor is positioned between the composite aerosol materials before collection.

In FIG. 1 shows an example of a cutting system 10 . The original sheet of carrier material 12 is initially unwound from a reel (not shown) and transported in the direction schematically shown by the arrows. The original sheet of support material 12 has a longitudinal axis in the longitudinal direction, and it has a specific width and a specific thickness. In certain embodiments, the starting support material 12 is preferably a tobacco cast leaf (TCL), however, in other embodiments, the starting support material 12 comprises other materials, such as cotton. The cutting system 10 preferably includes a cutting tool 20 , which in this example is in the form of an integral knife 10. In some embodiments, other cutting tools 20 are used, such as a rotary cutter or a rotary cutter.

The built-in knife 20 has a longitudinal axis perpendicular to the longitudinal axis of the sheet of the original support material 12 , so that the sharp edges of the knife 20 face in the direction of the incoming sheet of the original support material 12 . The sheet of original support material 12 is cut by the knife 20 into two sections 22A, 22B along the cutting line 24 . In certain embodiments, the sheet of original support material 12 is cut along its longitudinal axis such that both of the first section 22A and the second section 22B have the same width. In other embodiments, the sheet of original support material 12 is cut along an offset cutting line 24 such that the first section 22A has a width greater than the second section 22B , or so that the second section 22B has a width greater than the first section 22A. In other examples, a sheet of original support material 12 is cut into more than two sections 22A, 22B, for example, using more than one cutting tool 20 or using the same cutting tool 20 . The cutting process typically generates dust, so in some embodiments, the cutting system 10 also includes dust control measures in the cutting system 10 . For example, the dust protection means takes the form of an air suction system (not shown) so that the generated dust is at least partially evacuated in a controlled manner. By including dust controls, a higher percentage of dust is prevented from coming into contact with the gel 144 (see FIG. 2 ) or the original carrier material 12 , which would otherwise lead to contamination and quality problems. The two sections 22A, 22B form first and second continuous sheets of support material.

In FIG. 2 shows an example of a gel dispensing system 100 . The gel dispensing system 100 includes a gel dispensing station 140 having three gel dispensing nozzles 142 . Each nozzle 142 discharges gel 144 onto a portion of the surface of section 122 of the first continuous sheet 12 of support material. Three strips of gel 144 are applied to section 122 of the first continuous sheet of support material. Section 122 of the first continuous sheet of support material is transported in the direction schematically indicated by the arrows in this example. In certain embodiments , a different number of gel dispensing blocks 140 or nozzles 142 are used. 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 each other, however, in other examples, the strips 144 gels are not parallel to each other, for example they are wavy, offset or forming loops along the longitudinal direction of section 122 of the first continuous sheet of support material.

In some examples, the amount of gel 144 applied per strip and per dispensing system is calculated such that during the layering process and the pressing process (both will be described below), the gel 144 does not spread beyond the surface of the first continuous sheet of carrier material section 122 . This prevents the gel 144 from contacting (and thereby contaminating) the interior surface of the funnel device 490 (see FIG. 5 ) during the gathering process or the pressing process or the wrapping process (not shown).

In some examples, the gel dispensing system 100 includes a temperature control system (not shown) having a heater (not shown) and a temperature sensor (not shown) connected through a feedback loop. The temperature control system heats the gel 144 and controls its temperature so that it remains within a target temperature range before reaching the gel dispensing station(s) 140 . Optionally, the gel dispensing station 140 further includes, for example, flow meters, pumps, or actuated valves (not shown) that allow the flow rate at each nozzle 142 to be independently controlled or, alternatively or additionally, that allow the gel 144 to be delivered by different nozzles 142 , for example, at different locations in section 122 of the first continuous carrier sheet. This is particularly advantageous in that it facilitates the application of varying amounts of gel 144 and thus facilitates the manufacture of various composite aerosol generating materials. The amount of gel 144 dispensed may be varied by changing, for example, the flow rate of the nozzle or the length of time the gel 144 is dispensed from the nozzle. In some embodiments, the variability of the amount of gel 144 can be changed independently for each nozzle. This also allows the flow of gel 144 from each nozzle 142 to be adjusted depending on the location of the nozzle 142 ; for example, a nozzle 142 located proximate the longitudinal axis of the first continuous sheet of support material section 122 may be configured to dispense a greater amount of gel 144 compared to the amount dispensed by the nozzle 142 proximal to the edges of the first continuous sheet of support material section 122 to prevent spreading the gel 144 beyond the surface of the first continuous support material section 122 during the pressing process. The flow rate of the dispensed gel 144 , the length of time the dispensed gel 144 , or the pattern formed by the dispensed gel 144 varies in different examples. It should be understood that the order of the cutting step (of the original support material 12 ) and the gel application step is not significant. The cutting step of the original carrier material 12 preferably occurs before the gel dispensing step, however, in some embodiments, the cutting step occurs after the gel dispensing step or simultaneously with the gel application step.

In FIG. 3-4 illustrate an embodiment of a layering system 250, 350 for manufacturing an aerosol generating rod. The layering system 250, 350 places two sections 222A, 222B of the first continuous sheet of support material 222B and the second continuous sheet of support material 222A on top of each other to form a composite aerosol generating material 530 (as best shown in FIG. 6 ). Each of the first and second continuous sheets of support material 222B, 222A has a specific width. Each of the first and second continuous sheets of support material 222B, 222A has a certain thickness. The composite aerosol generating material 530 includes first and second continuous sheets of support material 222B , 222A and a gel 244 disposed between the first and second continuous sheets of support material 222B, 222A . The layering system 250, 350 includes a lateral movement system that places a second continuous sheet of support material 222A on the first continuous sheet of support material 222B . In this example, a second continuous sheet of support material 222A is placed on top, and a first continuous sheet of support material 222B is placed on the bottom. In other embodiments, the composite aerosol generating material 530 is made in other ways; for example, a second continuous sheet of support material 222A is placed underneath the first continuous sheet of support material 222B . The transverse movement system places the first and second continuous sheets of support material 222B, 222A in a vertical stack one above the other so that the second continuous sheet of support material 222A is positioned exactly above the first continuous sheet of support material 222B and parallel thereto. In other embodiments, the second continuous sheet of support material 222A and the first continuous sheet of support material 222B are offset from each other. The layering system 250, 350 shown in FIG. 3-4 includes one lateral movement system for placing first and second continuous sheets of support material 222B, 222A on top of each other. In other embodiments, the layering system 250, 350 includes multiple lateral movement systems, allowing the stack to be manufactured from more than two sheets of support materials 222A, 222B . In the example shown in FIG. 3-4 , the first continuous sheet of support material 222B and the second continuous sheet of support material 222A are unwound from separate reels (not shown) and fed to the cross-transfer system included in the lamination system 250, 350 , however, in other embodiments, a single sheet of original support material material 222 is unwound from the reel and then cut into separate sections, namely a first continuous sheet of support material 222B and a second continuous sheet of support material 222A. Rollers 252, 254, 256 and 258 assist in guiding the first continuous sheet of support material and/or the second continuous sheet of support material.

As best seen in FIG. 4 , the lateral movement system includes a feed roller 352, a guide roller 354 , and a pair of positioning rollers 356 . The first continuous sheet of carrier material 322B is transported on the feed roller 352. The second continuous sheet of carrier material 322A contacts the guide roller 354 on the side on which the gel 344 has not been placed to avoid contamination. The guide roller 354 is inclined such that movement of the second continuous sheet of support material 322A is redirected toward the first continuous sheet of support material 322B . The angle of the guide roller 354 is selected to save manufacturing space without imparting too much deformation to the second continuous sheet of support material 322A , which would otherwise cause the structure of the second continuous sheet of support material 322A to change. Both of the second continuous sheet of support material 322A and the first continuous sheet of support material 322B are then guided through positioning rollers 356 that are located at a location where the second continuous sheet of support material 322A is positioned adjacent the first continuous sheet of support material 322B . The distance from the first continuous sheet of support material 322B to the surface of the positioning roller 356 is approximately equal to the thickness of the second continuous sheet of support material 322A . This arrangement allows two continuous sheets of carrier material 322B, 322A to contact as they pass through positioning rollers 356 . The axis of rotation of the positioning rollers 356 is perpendicular to the feeding direction of the first sheet of aerosol generating material 322B . This aligns the second continuous sheet of support material 322A with the first continuous sheet of support material 322B , as shown in FIG. 3 .

In certain embodiments, the lamination system also includes a press system comprising two press rollers 358 through which a second continuous sheet of support material 322A and a first continuous sheet of support material 322B are further passed. As the first and second continuous sheets of support material 322B, 322A are fed through the press rollers 358 , the pressure applied by the press rollers 358 causes the second continuous sheet of support material 322A , the first continuous sheet of support material 322B , and the intervening gel 344 to be bonded together. Said pressure is calculated to be high enough to ensure adhesion of the first and second continuous sheets of support material 322B, 322A and gel 344 , but low enough so that the first and second continuous sheets of support material 322B, 322A are not subject to structural damage, and, further, such that the gel strips 344 are not pressed to a point where there is no air passage between the first and second continuous sheets of support material 322B, 322A . In this case, the first and second continuous sheets of support material 322B, 322A with gel 344 would create an airtight barrier without allowing aerosol or air to flow through it, which in some cases would affect the retraction performance. In some embodiments, the positioning rollers 356 are in the form of a single positioning roller acting on a surface. In certain embodiments, the press rollers 358 are in the form of a single press roller acting on a surface.

In FIG. 5 depicts an embodiment of a layering system 450 for manufacturing an aerosol generating rod. A sheet of tobacco leaf (TCL) 412 (an example of a source carrier material that is also an aerosol-generating material) is unwound from a reel (not shown) and crimped by a pair of crimp rollers 470A, 470B , creating ridges and grooves in the sheet of carrier material 412 source . The corrugated sheet 412 of the original support material is then cut into two sections to form first and second continuous sheets of support material 422B, 422A using a cutting tool 420 . In this example, the cutting tool 420 is an integral cutting tool and, more specifically, a rotary cutter. Please note that the corrugation step is optional. In some embodiments, the cutting step is replaced by the step of providing first and second continuous sheets of support material 422B, 422A from different reels or sources. The cutting step is provided so as to reduce the storage space required for a plurality of reels of first and second continuous sheets of carrier material 422B, 422A . Gel 444 is applied using a gel dispensing system 440 having three nozzles 442 , each of which discharges a strip of gel 444 onto the surface of a first continuous sheet of carrier material 422B . The second continuous sheet of support material 422A is directed by the redirect fork 452 toward that surface of the first continuous sheet of support material 422B to which the gel is dispensed, to form a composite aerosol generating material or "sandwich" having the first and second continuous sheets of support material 422B, 422A . with gel 444 positioned between first and second continuous sheets of support material 422B, 422A . In FIG. 5 shows a detailed cross-sectional view of a composite aerosol generating material in which three gel strips 444 of approximately equal width are disposed between a second continuous sheet of support material 422A and a first continuous sheet of support material 422B . The composite aerosol generating material of the first and second continuous sheets of support material 422B, 422A with the gel 444 at its core is then directed towards the inlet end of the funnel 490 where it is compressed to form a continuous rod 492 at the outlet end of the funnel 490 .

In FIG. 6 is a schematic cross-sectional view of a composite aerosol generating material 530 according to an embodiment. Composite aerosol generating material 530 includes a first sheet of support material 522B and a second sheet of support material 522A . Three strips of gel 544 are located between the first sheet of support material 522B and the second sheet of support 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 each side of the central gel strip 544B . In this embodiment, the gel strips 544A, 544B, 544C are the same width. Thus, it can be said that the gel strips 544A, 544B, 544C are evenly spaced. The gel strips 544A, 544C are preferably located on the inside of the outer edges of the first and second sheets of support material 522B, 522A to avoid gel getting on the equipment, for example, to avoid contamination of a funnel (not shown) due to gel leaks 544 . In other embodiments, the gel strips 544 are dispensed unevenly (see FIG. 7 ). The composite aerosol generating material 530 is made using the layering system 450 described herein with reference to FIG. 5 . In some embodiments, the first continuous sheet of support material 522B and the second continuous sheet of support material 522A are provided from the same sheet 512 , such as on a single reel (not shown), and are then cut into two pieces to form the first and second continuous sheets of support material 522B, 522A via cutting system 420 . In other embodiments, both of the first continuous sheet of support material 522B and the second continuous sheet of support material 522A are provided from different sources, for example, the first continuous sheet of support material 522B is provided on the first reel (not shown) and the second continuous sheet of support material 522A is provided on the other reel (not shown).

In FIG. 7 is a schematic cross-sectional view of a composite aerosol generating material 630 according to yet another embodiment. Composite aerosol generating material 630 includes a first sheet of support material 622B , a second sheet of support material 622A , and a third sheet of support material 622C . Three strips of gel 644 are located between the first sheet of support material 622B and the second sheet of support material 622A . A central gel strip 644B is located in a central region proximal to the longitudinal axis, and gel strips 644A, 644C are spaced apart in a lateral region on each side of the central gel strip 644B . In this embodiment, three additional gel strips 644 are located between the first sheet of support material 622B and the third sheet of support material 622C . The gel strips 644B in the central region are wider than the gel strips 644A, 644B in the side region. Thus, it can be said that the gel strips 644A, 644B, 644C are not uniformly distributed. In other examples, the distribution of the gel 644A, 644B, 644C between the first sheet of support material 622B and the second sheet of support material 622A is different from the distribution of the gel 644A, 644B, 644C between the first sheet of support material 622B and the third sheet of support material 622C . In some examples, gel 644 is uniformly distributed between the first sheet of support material 622B and the second sheet of support material 622A , and gel 644 is unevenly distributed between the first sheet of support material 622B and the third sheet of support material 622C . The gel strips 644A, 644C are preferably located on the inside of the outer edges of the first and second sheets of support material 622B, 622A to avoid gel contamination of the equipment, such as leakage of gel 644 into said funnel (not shown). More specifically, in this example, a greater amount of gel 644 is dispensed to the central region proximal to the longitudinal axis of the second sheet of support material 622A compared to the amount of gel 644 dispensed to the side region distal to the longitudinal axis of the second sheet of support material 622A. . Thus, the central gel strip 644B has a width greater than the gel strips 644A, 644C . This reduces the risk of contamination, such as leakage of gel 644 into said funnel (not shown). In specific embodiments, the central region is dispensed with 10 percent (%) more gel 644 by weight compared to the side region. In other embodiments, the central region delivers 20 percent (%) more gel 644 by weight compared to the side region of the aerosol generating material sheet.

The composite aerosol generating material 630 is made using the layering system 450 previously described herein with reference to FIG. 5 . In specific embodiments, preferably the first, second and third sheets of support material 622B, 622A, 622C are provided from the same support material source, such as on a single reel (not shown), and are then cut into three sections 622A, 622B, 622C by a cutting blade. systems 420 . In specific embodiments, the gel 644 is placed on both sides of the first continuous sheet of support material 622B , and the second and third continuous sheets of support material 622A, 622C are placed on the first sheet of support material 622B via a layering system 450 . In some embodiments, the composite aerosol generating material 630 is produced by providing first and third continuous sheets of support material 622B, 622C and applying gel strips 644 to the top side of each of the first and third continuous sheets of support material 622B, 622C. A first continuous sheet of support material 622B is placed on a third continuous sheet of support material 622C , and then a second continuous sheet of support material 622A is placed on the top side of the first continuous sheet of support material 622B . Preferably, the top and bottom surfaces of the composite aerosol generating material 630 do not have a gel 644 . In some embodiments, two of the three, namely first, second and third, continuous sheets of support material 622A, 622B, 622C are provided from the same source of support material, such as on a single reel (not shown), and are cut into two sections via cutting system 420 . In specific embodiments, each of the first, second and third continuous sheets of support material 622A, 622B, 622C is provided from a different source. More specifically, sheets 622A, 622B, 622C are unwound from different respective reels. In alternative embodiments, making a composite aerosol-generating material includes repeating the steps of making a composite aerosol-generating material and layering the composite aerosol-generating materials on top of each other. This provides a composite aerosol generating material with additional layers and/or a different number of layers.

The composite aerosol generating material 630 is produced by a device (not shown) having means for supplying a first continuous sheet of carrier material 622A . In one embodiment, said means for supplying the first continuous sheet of carrier material 622A is a bobbin (not shown). The device has a nozzle that delivers gel 644 to the surface of a first continuous sheet of support material 622A , and a layering system that delivers a second continuous sheet of support material 622B and places it on the gel 644 to form a composite aerosol generating material 630 . In another embodiment, the first continuous sheet of support material 622A is fed by a cutting tool. The cutting tool is located upstream of the lamination system. The cutting tool cuts the carrier material source sheet along its longitudinal axis to form a first continuous sheet of carrier material 622A and a second continuous sheet of carrier material 622B . In addition, in some examples, the device further includes folding means that fold a portion of the sheet of the original support material along its longitudinal axis to form a first continuous sheet of support material 622A and a second continuous sheet of support material 622B .

In FIG. 8 is 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 support material 722A , a second sheet of support material 722B , a third sheet of support material 722C , and a fourth sheet of support material 722D . Three gel strips 744 are placed between a first sheet of support material 722A and a second sheet of support material 722B . A central gel strip 744B is positioned in a central region proximal to the longitudinal axis, and gel strips 744A, 744C are spaced apart in a lateral region on each side of the central gel strip 744B . In this embodiment, the gel is not applied between the second sheet of support material 722B and the third sheet of support material 722C . Instead, three more gel strips 744 are disposed between the third sheet of carrier material 722C and the fourth sheet of carrier material 722D. Composite aerosol generating material 730 comprises two composite aerosol generating materials 722A, 722B and 722C, 722D . The gel strips 744B in the central region are wider than the gel strips 744A, 744C in the side region. Thus, it can be said that the gel strips 744A, 744B, 744C are not uniformly distributed. The gel strips 744A, 744C are preferably located on the inside of the outer edges of the first, second, third and fourth sheets of support material 722A, 722B, 722C, 722D to prevent contamination of the equipment, such as leakage of the gel 744 into the funnel (not shown). Specifically, in this example, more gel 744 is dispensed to the central region proximal to the longitudinal axis of section 722 compared to the amount of gel 744 dispensed to the side region distal to the longitudinal axis of section 722 . Thus, the central gel strip 744B is wider than the gel strips 744A, 744C . This reduces the risk of contamination, such as leakage of gel 744 into the specified funnel (not shown).

The composite aerosol generating material 730 is made using the layering system 450 described earlier herein with reference to FIG. 5 . In specific embodiments, preferably, one sheet is provided from a single source, such as on a single reel (not shown), and is then cut into four sections to form first, second, third, and fourth continuous sheets of carrier material 722A, 722B, 722C, 722D by a cutting shear. systems 420 . Preferably, the top and bottom surfaces of the composite aerosol generating material 730 do not have a gel 744 . In some embodiments, at least two of the first, second, third, or fourth continuous sheet of support material 722A, 722B, 722C, 722D are provided from the same sheet of original support material, such as on a single reel (not shown), and then cut into two sections using the 420 cutting system. In specific embodiments, each of the first, second, third and fourth continuous sheets of support material 722A, 722B, 722C, 722D is provided from a different source. More specifically, sheets 722A, 722B, 722C, 722D are unwound from different respective reels,

In FIG. 9 is a schematic cross-sectional view of a composite aerosol generating material 830 according to a further embodiment. In this embodiment, gel 844 is applied to sheet 812 (support material) and then sheet 812 is folded onto itself. As shown in the figures, this stops the gel 844 from being extruded from one side. As a result of folding the sheet 830 , two layers are created, namely first and second continuous sheets of support material, which are operably connected or integrated with each other. These two layers, namely the first and second continuous sheets of support material, are connected along a fold line (not shown).

In FIG. 10 is a schematic cross-sectional view of a composite aerosol generating material 930 according to an embodiment. Composite aerosol generating material 930 includes a first sheet of support material 922B and a second sheet of support material 922A . Two gel strips 944 are placed between the first sheet of support material 922B and the second sheet of support material 922A . The centrally located susceptor material 900 is located in a central region proximal to the longitudinal axis, and the gel strips 944 are spaced apart in a lateral region on either side of the centrally located susceptor material 900 . In this embodiment, the gel strips 944 are the same width. The gel strips 944 are preferably located on the inside of the outer edges of the first support material 922B and the second support material 922A to prevent gel leakage from the composite aerosol generating material 930 . The composite aerosol generating material 930 is made using the layering system 450 described herein with reference to FIG. 5 , with an additional mechanism for inserting current-receiving material 900 . In the embodiment of FIG. 10 , the first continuous sheet of support material 922B and the second continuous sheet of support material 922A are provided from the same sheet 512 , such as from one reel (not shown), and are then cut into two pieces to form the first continuous sheet of support material and the second continuous sheet of support material material. When manufactured according to FIG. 10 , the current collecting material 900 is inserted onto the first continuous sheet of support material 922B before dispensing the gel onto the surface of the first continuous sheet of support material 922B . The current collecting material 900 is shown not in direct contact with the gel strips 944 . However, the embodiment of FIG. 10 is shown before the aerosol generating composite material 930 is compressed. When compressed, the gel strips 944 may expand laterally between the first support material 922B and the second support material 922A such that they are in direct contact with the current collector material 900 .

In FIG. 11 is a schematic cross-sectional view of a composite aerosol generating material 930 according to yet another embodiment. Composite aerosol generating material 930 includes a first sheet of support material 922B , a second sheet of support material 922A , and a third sheet of support material 922C . Two gel strips 944 are located between the first sheet of support material 922B and the second sheet of support material 922A . A centrally located current collector material 900 is located in a central region proximal to the longitudinal axis of the composite aerosol generating material 930 between two gel strips 944 . In this embodiment, three more additional gel strips 944 are placed between the first sheet of support material 922B and the third sheet of support material 922C . Preferably, when compressing the composite aerosol generating material 930 according to the example of FIG. 11 , the current collecting material 900 may be in direct contact with the gel 944 .

In FIG. 12 is a schematic side view of a composite aerosol generating material 1030 containing two layers of composite aerosol generating materials. The first composite aerosol generating material comprises two continuous sheets of support materials 1022A and 1022B with a gel 1044A between two continuous support materials 1022A and 1022B. The second aerosol generating material comprises two continuous sheets of support material 1022C and 1022D , with gel 1044B between the two support materials 1022C and 1022D . A susceptor or continuous susceptor strip 1000 is placed between two layers of composite aerosol generating materials. In this illustrated embodiment, the pantograph 1000 is not in direct contact with the gel 1044A , 1044B . In use, heat from the current collector 1000 or continuous current collector strip 100 can still reach the gel through the support materials 1022B and 1022C . In this embodiment, all support materials are cotton. The gel contains nicotine. The current collecting strip is aluminum.

In FIG. 13 is a cross-sectional view along the longitudinal axis of the aerosol generating rod 1130 . As in FIG. 12 , an embodiment of the current collector strip 1100 was not placed adjacent to the gel 1144 , 1044A , 1044B between the continuous support materials 1122A and 1122B . In the embodiment of FIG. 13, a continuous current collection strip 1100 is positioned between the composite aerosol generating material immediately prior to collection of the composite aerosol generating material and the continuous current collection strip 1100 . The collected material is wrapped to form a continuous aerosol generating rod 1130 . In this embodiment of FIG. 13 carriers are flax. The current collecting strip is carbon. The gel contains nicotine. The gel additionally contains glycerin.

All scientific and technical terms used herein have the meanings commonly used in the art unless otherwise noted. The definitions provided in this document are intended to make it easier to understand certain terms that are frequently used in this document.

As used herein and in the claims, the singular form includes embodiments containing plural references unless the content clearly indicates otherwise.

As used in this specification and the appended claims, the conjunction “or” is generally used with its meaning to include “alternatively or additionally” unless the content clearly indicates otherwise.

As used herein, the words “have,” “having,” “include,” “including,” “contain,” “comprising,” or the like are used in their broadest sense and generally mean “including without limitation.” It should be understood that the expressions "consisting essentially of", "consisting of" and the like refer to the category of "comprising" and the like.

The words "preferred" and "preferably" refer to embodiments of the present invention that may provide certain advantages under certain circumstances. However, other embodiments may also be preferred under the same or different circumstances. Moreover, the description of one or more preferred embodiments is not intended to imply that other embodiments are not useful and is not intended to exclude other embodiments from the scope of the present invention, including the claims.

Any direction mentioned herein, such as "up", "down", "left", "right", "top", "bottom", and other directions or orientations are described herein for clarity and brevity and are not intended to to limit the actual device or system. The devices and systems described in this document may be used in a variety of directions and orientations.

The exemplified embodiments above are not limiting. Other embodiments consistent with the above-described embodiments will be apparent to those skilled in the art.

Claims (21)

1. A method for manufacturing a composite aerosol generating material, comprising the following steps: providing a first continuous sheet of support material; dispensing the gel onto the surface of the first continuous sheet of carrier material; providing a second continuous sheet of support material and placing said second continuous sheet of support material on said gel to form a composite material with the gel disposed between the first continuous sheet of support material and the second continuous sheet of support material; And further comprising the step of dispensing more gel to a central region proximal to the longitudinal axis of the first continuous sheet of support material compared to the amount of gel dispensed to a side region distal to the longitudinal axis of the first continuous sheet of support material. 2. The method of claim 1, further comprising the step of corrugating at least one of the first continuous sheet of support material and the second continuous sheet of support material. 3. The method of claim 1 or 2, further comprising the step of providing the first continuous sheet of support material and the second continuous sheet of support material from different respective sources of support material. 4. The method of claim 1 or 2, further comprising the step of providing both the first continuous sheet of support material and the second continuous sheet of support material from the same source of support material. 5. The method of claim 4, further comprising the step of folding a continuous sheet from one source of support material to form both a first continuous sheet of support material and a second continuous sheet of support material such that the first continuous sheet of support material and the second continuous sheet of support material are connected to each other along the folding line. 6. The method of claim 4, further comprising the step of cutting a continuous sheet from one source of support material to form both a first continuous sheet of support material and a second continuous sheet of support material. 7. The method of any one of the preceding claims, further comprising the step of providing a continuous strip of current collecting material and placing the continuous strip of current collecting material on the gel after dispensing the gel onto the first continuous sheet of support material. 8. The method of any one of the preceding claims, further comprising the step of pressing the composite aerosol generating material in a direction perpendicular to its flat surface. 9. The method according to any of the previous claims, wherein the gel contains a flavoring agent or an active agent, or a plasticizer, or a humectant, or nicotine, or glycerin, or propylene glycol, or any combination thereof. 10. The method according to any of the previous claims, wherein the composite aerosol generating material contains tobacco material. 11. Composite aerosol generating material containing: - the first sheet of supporting material; - a second sheet of supporting material and - a gel located between the first sheet of support material and the second sheet of support material, wherein a greater amount of gel is applied to a central region proximal with respect to the longitudinal axis of the first continuous sheet of support material compared to the amount of gel applied to a lateral region distal to to the longitudinal axis of the first continuous sheet of support material. 12. The material of claim 11 further comprising a current-receiving material located between the first sheet of support material and the second sheet of support material. 13. The material of claim 11 or 12, wherein the first continuous sheet of support material and/or the second sheet of support material comprises an aerosol generating material. 14. Composite aerosol generating rod containing a composite aerosol generating material according to claims. 11-13; or containing a composite aerosol generating material made according to any one of paragraphs. 1-10.

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