CN118102898A

CN118102898A - Aerosol-generating article comprising an insulating sleeve

Info

Publication number: CN118102898A
Application number: CN202280068919.7A
Authority: CN
Inventors: R·N·R·A·巴蒂斯塔; S·卡波
Original assignee: Philip Morris Products SA
Current assignee: Philip Morris Products SA
Priority date: 2021-10-21
Filing date: 2022-10-20
Publication date: 2024-05-28
Also published as: JP2024537071A; WO2023067039A1; EP4418886A1; KR20240093641A

Abstract

An aerosol-generating article (1) adapted to be electrically heated in an aerosol-generating device. The aerosol-generating article comprises an inner matrix core (3) comprising an aerosol-generating matrix. The aerosol-generating article further comprises an insulating sleeve (5) surrounding the matrix core and an outer wrapper (7) surrounding the insulating sleeve. A method for manufacturing an aerosol-generating article, an apparatus for manufacturing an aerosol-generating article, and use of an acetate tow for encapsulating an aerosol-generating substrate of an aerosol-generating article.

Description

Aerosol-generating article comprising an insulating sleeve

The present invention relates to an aerosol-generating article. The invention also relates to a method for manufacturing an aerosol-generating article, an apparatus for manufacturing an aerosol-generating article and the use of an acetate tow for encapsulating an aerosol-generating substrate of an aerosol-generating article.

WO 2018/206615 A2 discloses an aerosol-generating article comprising a matrix core having a non-circular outer cross section and a filler sleeve surrounding the matrix core.

According to a first aspect of the present invention there is provided an aerosol-generating article adapted to be electrically heated in an aerosol-generating device. The aerosol-generating article comprises an inner matrix core. The inner matrix core comprises an aerosol-generating matrix. The aerosol-generating article comprises an insulating sleeve surrounding a matrix core. The aerosol-generating article comprises an outer wrapper surrounding the insulating sleeve.

To generate an aerosol, the aerosol-generating substrate may be heated by a heating element disposed within the substrate core. The insulating sleeve reduces the heat dissipated from the heating element to the outer surface of the aerosol-generating article. Thus, the higher portion of the generated heat remains in the matrix core and is available for generating aerosols from the aerosol-generating matrix. Preferably, more than 90% of the heat energy that would otherwise be dissipated radially remains inside the inner matrix core due to the insulating sleeve. Thus, the amount of energy consumed by the heating element may be reduced due to a lower heating temperature or shorter heating cycles of the heating element. Preferably, the heating temperature of the heating element may be reduced by 20% compared to the heating temperature of a heating element of an aerosol-generating article without an insulating sleeve or an aerosol-generating article made entirely of an aerosol-generating substrate. In particular, the heating temperature of the heating element may be set to a temperature at which aerosol is preferably released from the aerosol-generating substrate. Thus, the energy storage device (e.g. a battery) in the aerosol-generating device may be reduced in size or may be used for a longer time than an aerosol-generating device suitable for use with an aerosol-generating article without an insulating sleeve or an aerosol-generating article made entirely of an aerosol-generating substrate. The surface of the aerosol-generating article may be kept at a low temperature and may prevent possible overheating of adjacent surfaces or consumer interfaces. In particular, the surface of the aerosol-generating article may be maintained at a lower temperature than an aerosol-generating article without the insulating sleeve. The aerosol-generating article may be at least partially inserted into or connected with an aerosol-generating device and together form a "heated non-burning" system in which the aerosol-generating material is heated to release but not burn the aerosol. In particular, the cavity or side wall of the aerosol-generating device in which the aerosol-generating article may be inserted is protected from high temperatures. The outer wrapper may cover the insulating sleeve and provide the consumer with a preferably tactile and optical impression of the aerosol-generating article. The outer wrapper may provide additional stability to the aerosol-generating article. Due to the insulating sleeve, a wider range of materials for the outer wrapper may be possible, as more heat sensitive materials may also be used.

The insulating sleeve may comprise a porous material. The porous material may comprise a multitude of open or closed pores, in particular cavities filled with ambient air. Due to the low thermal conductivity of air, porous materials may provide increased thermal insulation compared to non-porous materials. Preferably, 50% of the volume of the insulating sleeve may be holes. The porous material may comprise air channels which may extend from the inner surface to the outer surface of the insulating sleeve and thus provide fluid exchange, in particular air exchange, between the region surrounded by the insulating sleeve (e.g. the inner matrix core) and the region outside the insulating sleeve. Furthermore, the air channels may extend from the interior of the insulating sleeve to the surface without extending through the entire insulating sleeve. Due to the reduced density, porous materials can have reduced weight and reduced material requirements compared to non-porous materials having the same volume. The porous material may have an elasticity which may allow deformation during insertion of the aerosol-generating article into the aerosol-generating device in order to establish a substantially airtight seal along a circumferential region of the aerosol-generating article by the receiving portion of the aerosol-generating device.

The insulating sleeve may comprise a fibrous material. By arranging the fibres accordingly, the fibre material may allow the elasticity of the insulating sleeve to be adapted to the preferred direction. The elasticity may be higher or lower in the direction of the fibers than in the perpendicular direction. Thus, the fibers may be arranged to be aligned primarily in one direction. Alternatively, the fibers may be arranged without any preferred direction to restore substantially constant elasticity in all directions. The fibrous material may comprise a greater number of air passages than the non-fibrous material and may thus provide a correspondingly higher air exchange between the inner and outer regions of the insulating sleeve. Thus, the longitudinal air flow through the inner matrix core may be supplemented by the air flow through the insulating sleeve in a substantially transverse or radial direction from the outside of the insulating sleeve into the inner matrix core. This may be useful for mixing the heated front-to-back airflow with ambient air. The longitudinal direction is defined as the direction along the longest extent of the aerosol-generating article. The radial or transverse direction is defined as the direction perpendicular to the longitudinal direction.

The fibrous material may comprise fibres extending mainly in the longitudinal direction of the aerosol-generating article. By this arrangement of the fibres, the insulating sleeve can be easily stretched in the longitudinal direction, which may be beneficial during the production process, but still provide stability in the circumferential direction. The air flow may be established within the insulating sleeve in a longitudinal direction parallel to the heated air flow through the inner matrix core, wherein the two air flows may merge at predetermined locations outside the inner matrix core (e.g. in the cooling section or the mouthpiece section). The heated aerosol-containing gas stream and the ambient gas stream may be mixed downstream of the inner matrix core. Thus, for example, a cooling airflow may be achieved at the mouthpiece without adversely affecting aerosol generation within the inner matrix core.

The insulating sleeve may have the same or higher elasticity than the inner matrix core. This may result in a stable structure of the aerosol-generating article and at the same time in elasticity at the outer surface. The elasticity at the outer surface may be able to establish a gas-tight seal with the receiving portion of the aerosol-generating device and additionally provide a pleasant tactile sensation to the consumer. Furthermore, it is possible to tightly encapsulate the inner matrix core by the insulating sleeve during production.

The insulating sleeve may comprise acetate tow. Acetate tow is a porous and stretchable material that can be processed to include advantageous thickness and elasticity. The acetate tow is thermally insulated.

The acetate tow may be a multi-directional expanded acetate tow web. The acetate tow may be stored and delivered in compressed form and expanded during the manufacturing process. After expansion to the desired thickness and elasticity, the inner matrix core may be encapsulated with acetate tow.

The insulating sleeve may have a radial layer thickness that varies less than 10% from its average radial thickness, i.e. the radial layer thickness may be in the range of 90% to 110% of the average radial thickness. Preferably, the radial layer thickness of the insulating sleeve may vary less than 5% from its average radial thickness. The insulating sleeve may have a substantially constant circumferential layer thickness. Preferably, the heat insulating sleeve may be circular in cross section. Furthermore, the cross-section of the insulating sleeve may be oval or rectangular. Preferably, in the case of oval or rectangular, the insulating sleeve may have a maximum variability of the layer thickness within the above specified ranges. The layer of material forming the insulating sleeve may encapsulate the matrix core without any overlap regions. The insulating sleeve may provide substantially equal insulation in all radial directions, i.e. in a direction perpendicular to the longitudinal direction. Furthermore, the mechanical stability, e.g. stiffness or elasticity, may be substantially equal in all radial directions.

The insulating sleeve may be tubular. In particular, the insulating sleeve may be a hollow tube extending in the longitudinal direction of the aerosol-generating article. This may provide symmetrical mechanical stability in all radial directions. The insulation may be substantially constant in all radial directions. Furthermore, the aerosol-generating article may be formed as a strip that may be inserted in a corresponding receptacle of the aerosol-generating device without the need for radial alignment or orientation.

The insulating sleeve and the matrix core may be coaxially aligned. The aerosol-generating article may be symmetrical in all radial directions. Thus, the insulation may be constant in all radial directions. Furthermore, symmetrical mechanical stability may be provided to the matrix core.

The matrix core may have an outer cross-section with a major diameter less than 5% longer than its minor diameter, and the insulating sleeve has an inner cross-section corresponding to the outer cross-section of the matrix core. The matrix core may have a circular outer cross-section and the insulating sleeve may have a circular inner cross-section corresponding to the circular outer cross-section of the matrix core.

The matrix core may have an elliptical cross-section, wherein the major axis of the ellipse is greater than 5%, and preferably less than 30%, of the minor axis. The insulating sleeve may have an oval inner cross-section corresponding to the outer oval cross-section of the matrix core.

The inner matrix core may be in contact with the insulating sleeve around its circumference, which may provide mechanical stability to the aerosol-generating article. The insulation may be uniform in all radial directions. Furthermore, the air exchange through the porous insulating sleeve may be uniform in all radial directions.

The aerosol-generating article may have a diameter of between 4.5 mm and 9 mm, preferably between 6 mm and 8 mm.

The susceptor may be arranged in the matrix core. The susceptor may be any material in which an electric current (in particular an eddy current) may be induced by magnetic induction and thus cause heating of the material. The material may be electrically conductive, in particular a ferromagnetic material, in particular iron, aluminium or steel. The excitation coil and the energy source may be provided in an aerosol-generating device in which the aerosol-generating article may be inserted during use. Thus, it is not necessary to insert an external heating element into the matrix core. Furthermore, after use, the aerosol-generating article may be arranged to comprise a susceptor. Thus, in contrast to the re-use of external heating elements, each susceptor is only used for one aerosol-generating article, which may prevent degradation of the susceptor.

The susceptor may be made of sheet material. Sheet material may be advantageous for inducing current by magnetic induction. Furthermore, a large surface can be created. Due to the extended contact area of the susceptor with the aerosol-generating substrate, a large surface may be beneficial in order to distribute heat into the substrate core. Susceptors formed as sheet materials may be relatively rigid with respect to bending forces that may occur during manufacture or handling for consumption of aerosol-generating articles.

The susceptor may have a width of between 2.5 mm and 6mm, preferably between 3.5 mm and 5.5 mm. The width of the susceptor may correspond to the diameter of the inner matrix core.

The susceptor may have a thickness of between 0.075 and 0.4 mm, preferably between 0.1 and 0.3 mm.

The susceptor may be a plate, strip, sheet, tape or foil. These shapes provide a flat and elongated surface, which may lead to an advantageous contact area with the aerosol-generating substrate. Furthermore, these shapes facilitate material handling during the manufacturing process, in particular for processing the susceptor material into a continuous strip or web. Thus, the susceptor may be flexible in the longitudinal direction, the transverse direction (or both the longitudinal and transverse directions).

The susceptor may be in contact with the insulating sleeve. This may stabilize the position of the susceptor, in particular preventing lateral movement of the susceptor. Thus, the susceptor remains fixed at the predetermined position. This may enable the susceptor to be reliably positioned at the location in the aerosol-generating device where the magnetic field of the magnetic induction coils is most dense or most uniform or both when the aerosol-generating article is arranged in the aerosol-generating device. This may enable efficient heating of the susceptor or uniform temperature distribution in the susceptor or both. Thus, points at the susceptor where the temperature exceeds the target temperature value are avoided and the aerosol-generating material can be heated at the intended predetermined temperature. The susceptor may have a width which substantially corresponds to the diameter of the circular inner cross-section of the inner matrix core or the insulating sleeve. Since the aerosol-generating substrate is present in the inner substrate core, rotation of the susceptor may be prevented. Thus, the susceptor may be positioned along the diameter of the inner matrix core of the respective insulating sleeve and intersect the central longitudinal axis of the aerosol-generating article.

The matrix core may have a diameter of between 3.5 mm and 7 mm, preferably between 4.5 mm and 6 mm. The susceptor may have a corresponding width. This may stabilize the position of the susceptor, in particular preventing lateral movement of the susceptor. Alternatively, the susceptor may have a width that is up to 20% smaller than the diameter of the matrix core. Thus, there may be a gap between the susceptor and the insulating sleeve or wrapper enveloping the matrix core.

The matrix core may comprise agglomerated tobacco material. The tobacco material may comprise one or more of the following: a powder, granule, pellet, chip, strand, ribbon or sheet comprising one or more of tobacco leaf, tobacco stem segment, reconstituted tobacco, homogenized tobacco, extruded tobacco and puffed tobacco. Optionally, the tobacco rod may contain additional tobacco or non-tobacco volatile flavour compounds that are released upon heating of the tobacco rod. Optionally, the tobacco rod may also contain a pouch, for example, comprising additional tobacco or non-tobacco volatile flavour compounds. Such capsules may melt during heating of the tobacco rod. Alternatively or additionally, such capsules may be crushed before, during or after heating the tobacco rod.

Where the tobacco rod comprises homogenized tobacco material, the homogenized tobacco material may be formed by agglomerating particulate tobacco. The homogenized tobacco material may be in the form of a sheet. The homogenized tobacco material may have an aerosol former content of greater than 5 percent on a dry weight basis. The homogenized tobacco material may alternatively have an aerosol former content of 5 wt.% to 30 wt.% based on dry weight. A sheet of homogenized tobacco material may be formed from particulate tobacco obtained by agglomerating one or both of tobacco lamina and tobacco leaf stems by grinding or otherwise pulverizing; alternatively or additionally, the sheet of homogenized tobacco material may include one or more of tobacco dust, tobacco scraps, and other particulate tobacco byproducts formed during, for example, handling, disposal, and shipping of tobacco. The sheet of homogenized tobacco material may include one or more intrinsic binders (i.e., tobacco endogenous binders), one or more extrinsic binders (i.e., tobacco exogenous binders), or a combination thereof to aid in coalescing the particulate tobacco. Alternatively or additionally, the sheet of homogenized tobacco material may include other additives including, but not limited to, tobacco and non-tobacco fibers, aerosol formers, humectants, plasticizers, flavorants, fillers, aqueous and non-aqueous solvents, and combinations thereof. The sheet of homogenized tobacco material is preferably formed by a casting process of the type generally comprising: casting a slurry comprising particulate tobacco and one or more binders onto a conveyor belt or other support surface; drying the cast slurry to form a sheet of homogenized tobacco material; and removing the sheet of homogenized tobacco material from the support surface.

The matrix core may comprise crimped and agglomerated tobacco material. The crimped tobacco material may be a crimped deciduous sheet. The crimped tobacco material may provide additional stability to the aerosol-generating article. The susceptor may be stably positioned within the crimped tobacco material in the inner matrix core.

The matrix core may comprise shredded tobacco material. Thus, the susceptor may be included in the inner matrix core during the production process without having to follow a certain orientation of the tobacco material. The same applies to the insertion of the external heating element just before the consumer consumes the aerosol-generating article.

The matrix core may comprise a fibrous sensory medium, preferably having fibers extending in a longitudinal direction. This may advantageously affect the air flow, as the air channels may be formed by the fibrous sensory medium. The air channels may be formed by correspondingly extending fibres in the longitudinal direction.

The overwrap may be formed of a pliable sheet material. This may facilitate a tight envelope of the insulating sleeve. Thus, the overwrap can be prevented from moving relative to the insulating sleeve. In particular, the outer wrapper can be prevented from sliding off the insulating sleeve. Preferably, the connection of the insulating sleeve and the outer wrapper may be free of adhesive.

The overwrap may be formed of paper or metal foil or plastic foil or a combination thereof. The paper material is lightweight, easy to process and can be easily imprinted on the outer surface. The metal foil may reflect heat from the inner matrix core. The metal foil may prevent accidental ignition of the aerosol-generating article by a match or lighter. The plastic foil may comprise an elasticity so as to wrap tightly around the insulating sleeve. A combination of two or more materials and thus an outer wrapper comprising two or more layers may be advantageous for combining the respective advantages.

The overwrap may be made of a porous material. This may facilitate air exchange from or into the insulating sleeve. Thus, an air flow through the outer package and through the insulating sleeve can be established. Thus, the airflow through the insulating sleeve may be radial and into the inner matrix core, or in the longitudinal direction to the cooling section or mouthpiece section. Thus, the heated fluid or air in the inner matrix core or cooling section or mouthpiece section may be mixed with ambient air.

The aerosol-generating article may comprise an inner wrapper disposed between and surrounding the matrix core and the insulating sleeve. This may additionally stabilize the inner matrix core, in particular during the production process.

The inner wrapper may be formed from paper or metal foil or plastic foil or a combination thereof. The materials may be selected to further adjust thermal insulation or air permeability or both. The paper material may provide an additional closure and thus stabilize the inner matrix core while maintaining breathability. The metal foil may provide thermal insulation. The metal foil prevents air exchange from the inner matrix core through the insulating sleeve even if an open porous material is used for the insulating sleeve. Combinations of two or more materials for an inner wrapper comprising two or more layers may combine the aforementioned characteristics.

The inner wrapper may be made of a porous material. This may allow the inner wrapper to be breathable and may provide adjustability to the breathability.

According to a second aspect of the present invention, there is provided a method for manufacturing an aerosol-generating article. The method comprises the following steps: transporting the aerosol-generating substrate in a transport direction through a sleeve converging means; supplying insulation material to the sleeve converging means such that the insulation material is arranged circumferentially around the aerosol-generating substrate in the sleeve converging means; and converging the insulating material to form an insulating sleeve around the aerosol-generating substrate. The method steps may be performed in this order. The method steps may be performed at least partially in parallel. The method may be performed in a continuous process, in particular producing an annular or continuous aerosol-generating article, which may be cut into individual aerosol-generating articles of a desired length in the following method steps. An aerosol-generating article comprising at least two coaxially aligned layers may thus be produced efficiently in a continuous production process. Preferably, the tubular strip may be produced continuously.

The method may include the step of wrapping the insulating sleeve with an outer wrapper. Thus, a three-layer aerosol-generating article having a coaxial layer may be produced in a continuous manner. This step may include applying an adhesive to hold the outer wrapper fixedly wrapped around the insulating sleeve. In particular, the outer wrapper may be wrapped around the insulating sleeve and have an overlap where the two overlapping ends of the outer wrapper are glued together. Alternatively, the outer wrapper may be glued directly onto the insulating sleeve, whereby the overlapping portion of the outer wrapper may be omitted.

The insulating material may comprise or consist of acetate tow. The acetate tow may include beneficial insulating properties. In addition, the acetate tow is a flexible material and can be processed in a continuous production process.

The method may comprise the steps of: the insulating material is equally circumferentially distributed in the sleeve converging means to form an insulating sleeve of substantially constant thickness. The same shaped aerosol-generating article, i.e. an aerosol-generating article symmetrical in the radial direction, may be formed. Preferably, the aerosol-generating article may be formed as a tubular strip. Thus, the insulation properties may be constant along the circumference of the aerosol-generating article.

The insulation material may be supplied to the sleeve converging means in one single stream of insulation material. Thus, continuous production of aerosol-generating articles is possible. The single stream may be fanned out for subsequent laying around the aerosol-generating substrate.

The insulation material may be supplied to the sleeve converging means in two or more separate streams of insulation material. Thus, the insulating sleeve may be formed by placing the separate flows together in a converging device. Thus, it may be sufficient to fan out the individual separate streams only to a small extent. One stream may be placed over a first half of the aerosol-generating substrate and the other stream may be placed over a second half of the aerosol-generating substrate.

The step of supplying the insulation material may comprise guiding the insulation material along a guiding system. This allows the insulation material to be in a preferred form and position, particularly in the shape of a truncated cone, hollow tube or the like. These shapes can still open along one side in the longitudinal direction, in particular in the conveying direction. This shape may then be laid around the aerosol-generating substrate in the sleeve converging device, wherein it completely encloses the aerosol-generating substrate, i.e. the inner substrate core.

The insulating material may be guided along a guiding surface of the guiding system, wherein the guiding surface faces away from the aerosol-generating substrate. In particular, the normal vector of the guiding surface does not intersect the aerosol-generating substrate. Thus, the guiding surface provides a counter force against the insulation material away from the aerosol-generating substrate. Thus, the insulating material may be guided around the aerosol-generating substrate and subsequently encapsulate the aerosol-generating substrate. The insulation material may be guided under tension along a guiding surface of the guiding system. This guiding may include stretching of the insulation material. The tension in the insulation material may be reduced in the sleeve convergence means. This may result in the aggregation of the insulating material such that it circumferentially surrounds the matrix core. The aggregated insulating material may provide insulation.

The method may comprise the steps of: a susceptor, in particular in the form of a continuous profile, is arranged in the aerosol-generating substrate. Thus, a continuous or annular aerosol-generating article may be produced comprising a heating element for heating an aerosol-generating substrate. The annular aerosol-generating article may then be cut into aerosol-generating articles having a length as used by a consumer.

The method may comprise the steps of: a susceptor, in particular in the form of a single susceptor segment, is arranged in the aerosol-generating substrate. The arrangement of the susceptors in the form of individual susceptor segments in the aerosol-generating substrate enables the susceptors to be positioned laterally and longitudinally within the inner substrate core. The susceptor segment may comprise a length less than the longitudinal length of the inner matrix core. The susceptor segments may thus be arranged at a distance from each other in the continuous aerosol-generating substrate. The continuous aerosol-generating article may be cut into segments of individual aerosol-generating articles, wherein each segment comprises one susceptor segment. The susceptor segment may have a longitudinal length less than the inner matrix core.

The method may comprise the steps of: converging the aerosol-generating material and the susceptor to form said aerosol-generating substrate with the susceptor embedded. The aerosol-generating substrate may be an inner substrate core of the aerosol-generating article. By arranging the susceptor in the aerosol-generating material and converging both the susceptor and the aerosol-generating material, the susceptor may be placed at a preferred position in the aerosol-generating material and this position may be stably maintained. Since the susceptor does not have to be inserted in the aerosol-generating substrate in a subsequent production step or before the consumer uses the aerosol-generating article, the aerosol-generating material is not negatively affected, e.g. misplaced by the insertion step.

The method may comprise the steps of: the aerosol-generating material is packaged with an inner wrapper. This may support the structure and shape of the aerosol-generating material, preferably comprising a susceptor. This step may include applying an adhesive to hold the inner wrapper fixedly wrapped around the aerosol-generating material. In particular, the inner wrapper may be wrapped around the aerosol-generating material and have an overlap where the two overlapping ends of the inner wrapper are glued together. Alternatively, the inner wrapper may be glued directly to the aerosol-generating material, whereby the overlapping portion of the inner wrapper may be omitted.

According to a third aspect of the present invention there is provided an apparatus for manufacturing an aerosol-generating article comprising a guidance system for forming an insulating sleeve of insulating material, and sleeve converging means for enveloping an aerosol-generating substrate with the insulating sleeve. Thus, an aerosol-generating article comprising an inner matrix core of aerosol-generating material coaxially surrounded by an insulating sleeve may be produced. The guiding system may guide the insulation material around the aerosol-generating substrate. The guiding system may comprise a section of increasing diameter in the conveying or production direction and a section of decreasing diameter in the conveying or production direction relative to the central longitudinal axis. The apparatus may be adapted to manufacture aerosol-generating articles in a continuous process. Furthermore, the device can produce a continuous, in particular annular, strip. The continuous strip may then be cut into aerosol-generating articles having a length for consumer use.

The apparatus may further comprise a wrapper supply means for supplying an outer wrapper to be wrapped around the insulating sleeve. Thus, an aerosol-generating article is obtained comprising an inner matrix core and two concentric layers, namely an insulating sleeve and an outer wrapper. The wrapper supply means may supply the outer wrapper into the sleeve converging means such that both the wrapping of the matrix core with the insulating sleeve and the wrapping with the outer wrapper are at least partly performed by the sleeve converging means.

The guiding system may comprise a guiding element providing a guiding surface along which the insulation material forming the insulation sleeve is guided, wherein the guiding surface extends around an angle of at least 180 degrees. Thus, the insulation material may be positioned around at least half of the strands of aerosol-generating material. The subsequent device may then encapsulate the aerosol-generating material by converging the insulating material. The guiding system may be formed to be convex with respect to the central longitudinal axis. The guiding system may be formed to be convex with respect to the strands of aerosol-generating material extending substantially along the central longitudinal axis.

The guiding system may comprise a first guiding element and a second guiding element, each guiding element providing a respective guiding surface along which the insulation material forming the insulation sleeve is guided. The two guiding elements may be arranged such that the insulating sleeve enters a position substantially surrounding the strands of aerosol-generating material. The two guiding elements may be arranged at laterally opposite sides of the strand of aerosol-generating material. The strands of aerosol-generating material may be arranged between the first and second guiding elements. The first guide element and the second guide element may be at a distance from each other. Either or both of the first guide element and the second guide element may have the shape of a tear drop, pear, water drop, or shoulder.

The sleeve converging means may comprise a funnel. The funnel may guide the thermally insulated sleeve into the sleeve converging means.

The apparatus may comprise a substrate converging means for forming the aerosol-generating substrate in the form of a strip. The substrate converging means may be adapted to curl the fallen leaf sheet of tobacco and form a rod. The substrate converging means may be adapted to form a rod of gathered tobacco. The substrate converging means may be adapted to form a strip of aerosol-generating substrate comprising a susceptor arranged within the substrate.

The matrix converging means may comprise a funnel. The funnel may direct the aerosol-generating substrate into the substrate converging means.

The apparatus may comprise an expansion device comprising a first pair of expansion rollers adapted to direct the insulation material through a nip between the first pair of rollers. This may apply a force to the insulation web from opposite sides to expand the insulation. Thus, the insulation material may expand to an increased thickness. The insulating material may be in a compressed state prior to the expansion device. The expansion device may further comprise a second pair of expansion rolls adapted to guide the insulation material through the nip between the pair of second rolls, wherein the second pair of expansion rolls may be arranged continuously to the first pair of expansion rolls for expanding the web of insulation material. Thus, the expansion may be performed in a two-step process. In addition, tension may be applied between the first pair of expansion rollers and the second pair of expansion rollers, for example by different rotational speeds of the first pair of expansion rollers relative to the second pair of expansion rollers. Thus, a high expansion level of the heat insulating material can be achieved.

The expansion roll may be a forming roll to form a profile into the web of insulation material.

According to a fourth aspect of the present invention there is provided the use of an acetate tow for encapsulating an aerosol-generating substrate of an aerosol-generating article to reduce heat dissipation from a heating element in the aerosol-generating substrate to an outer surface of the aerosol-generating article. Thus, the energy consumption of the heating element can be reduced. Furthermore, the outer surface of the aerosol-generating article may be prevented from reaching a temperature that is uncomfortable for the consumer or detrimental to e.g. adjacent materials of the aerosol-generating device in which the aerosol-generating article is inserted during use.

The heating element may be a susceptor as part of the aerosol-generating article. Thus, no external heating element needs to be inserted and the aerosol-generating material does not displace prior to use.

The heating element may be a heating blade arranged as part of a separate heating device, wherein the heating blade is inserted in the aerosol-generating substrate for heating the aerosol-generating article. The inner matrix core may be devoid of susceptors. This may simplify the production process of the aerosol-generating article, as no susceptor needs to be embedded in the inner matrix core.

The aerosol-generating article according to the first aspect of the invention may be manufactured by a method according to the second aspect of the invention. The apparatus for manufacturing an aerosol-generating article according to the third aspect of the invention may be used to manufacture an aerosol-generating article according to the first aspect of the invention. The apparatus for manufacturing an aerosol-generating article according to the third aspect of the invention may be used in a method according to the second aspect of the invention. The use of the acetate tow according to the fourth aspect of the invention may be used in an aerosol-generating article according to the first aspect of the invention.

The invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

Example Ex1: an aerosol-generating article adapted to be electrically heated in an aerosol-generating device, wherein the aerosol-generating article comprises an inner matrix core comprising an aerosol-generating matrix, an insulating sleeve surrounding the matrix core, and an outer wrapper surrounding the insulating sleeve.

Example Ex2: an aerosol-generating article according to example Ex1, wherein the insulating sleeve comprises a porous material.

Example Ex3: an aerosol-generating article according to any of examples Ex1 to Ex2, wherein the insulating sleeve comprises a fibrous material.

Example Ex4: an aerosol-generating article according to example Ex3, wherein the fibrous material comprises fibres extending predominantly in the longitudinal direction of the aerosol-generating article.

Example Ex5: the aerosol-generating article of any of examples Ex1 to Ex4, wherein the insulating sleeve has the same or higher elasticity than the inner matrix core.

Example Ex6: the aerosol-generating article of any of examples Ex1 to Ex5, wherein the thermally insulating sleeve comprises an acetate tow.

Example Ex7: the aerosol-generating article of example Ex6, wherein the acetate tow is a multi-directional expanded acetate tow web.

Example Ex8: an aerosol-generating article according to any of examples Ex1 to Ex7, wherein the insulating sleeve has a radial layer thickness that varies by less than 10%.

Example Ex9: an aerosol-generating article according to any of examples Ex1 to Ex8, wherein the insulating sleeve is tubular.

Example Ex10: an aerosol-generating article according to any of examples Ex1 to Ex9, wherein the insulating sleeve and the matrix core are coaxially aligned.

Example Ex11: an aerosol-generating article according to any of examples Ex1 to Ex10, wherein the matrix core has an outer cross-section, the major diameter of the outer cross-section being less than 5% longer than its minor diameter, and the insulating sleeve has an inner cross-section corresponding to the outer cross-section of the matrix core.

Example Ex12: an aerosol-generating article according to any of examples Ex1 to Ex11, wherein the aerosol-generating article has a diameter of between 4.5 mm and 9 mm, preferably between 6 mm and 8 mm.

Example Ex13: the aerosol-generating article according to any of examples Ex1 to Ex12, wherein the susceptor is arranged in the matrix core.

Example Ex14: an aerosol-generating article according to example Ex13, wherein the susceptor is made of sheet material.

Example Ex15: an aerosol-generating article according to any of examples Ex13 to Ex14, wherein the susceptor has a width of between 2.5 mm and 6 mm, preferably between 3.5 mm and 5.5 mm.

Example Ex16: an aerosol-generating article according to any of examples Ex13 to Ex15, wherein the susceptor has a thickness of between 0.075 mm and 0.4 mm, preferably between 0.1 mm and 0.3 mm.

Example Ex17: an aerosol-generating article according to any of examples Ex13 to Ex16, wherein the susceptor is a plate, strip, sheet, tape or foil.

Example Ex18: an aerosol-generating article according to any of examples Ex13 to Ex17, wherein the susceptor is in contact with the insulating sleeve.

Example Ex19: an aerosol-generating article according to any of examples Ex1 to Ex18, wherein the matrix core has a diameter of between 3.5 mm and 7 mm, preferably between 4.5 mm and 6 mm.

Example Ex20: an aerosol-generating article according to any of examples Ex1 to Ex19, wherein the matrix core comprises an aggregated tobacco material, preferably a crimped and aggregated tobacco material.

Example Ex21: an aerosol-generating article according to any of examples Ex1 to Ex20, wherein the matrix core comprises shredded tobacco material.

Example Ex22: an aerosol-generating article according to any of examples Ex1 to Ex21, wherein the matrix core comprises a fibrous sensory medium, preferably with fibres extending in the longitudinal direction.

Example Ex23: an aerosol-generating article according to any of examples Ex1 to Ex22, wherein the outer wrapper is formed from a pliable sheet material.

Example Ex24: the aerosol-generating article of any of examples Ex1 to Ex23, wherein the outer wrapper is formed from paper or metal foil or plastic foil, or a combination thereof.

Example Ex25: an aerosol-generating article according to any of examples Ex1 to Ex24, wherein the outer wrapper is made of a porous material.

Example Ex26: an aerosol-generating article according to any of examples Ex1 to Ex25, further comprising an inner wrapper disposed between and surrounding the matrix core and the insulating sleeve.

Example Ex27: an aerosol-generating article according to example Ex26, wherein the inner wrapper is formed from paper or metal foil or plastic foil or a combination thereof.

Example Ex28: an aerosol-generating article according to any of examples Ex26 to Ex27, wherein the inner wrapper is made of a porous material.

Example Ex29: a method for manufacturing an aerosol-generating article, the method comprising the steps of:

Transporting the aerosol-generating substrate in a transport direction through a sleeve converging means;

supplying insulation material to the sleeve converging means such that the insulation material is arranged circumferentially around the aerosol-generating substrate in the sleeve converging means; and

The insulating material is converged to form an insulating sleeve around the aerosol-generating substrate.

Example Ex30: the method of example Ex29, comprising the step of wrapping the insulating sleeve with an overwrap.

Example Ex31: the method of any of examples Ex29 to Ex30, wherein the insulating material comprises acetate tow.

Example Ex32: the method of any one of examples Ex29 to Ex31, comprising the steps of: the insulating material is equally circumferentially distributed in the sleeve converging means to form an insulating sleeve of substantially constant thickness.

Example Ex33: the method of any of examples Ex 29-Ex 32, wherein the insulation material is supplied to the sleeve converging device in one single stream of insulation material.

Example Ex34: the method of any of examples Ex29 to Ex33, wherein the insulation material is supplied to the sleeve converging device in two or more separate streams of insulation material.

Example Ex35: the method of any one of examples Ex 29-Ex 34, wherein the step of supplying the insulation material comprises guiding the insulation material along a guiding system.

Example Ex36: the method of example Ex35, wherein the insulation material is guided along a guiding surface of the guiding system, wherein the guiding surface faces away from the aerosol-generating substrate.

Example Ex37: the method of any one of examples Ex29 to Ex36, comprising the steps of: a susceptor, in particular in the form of a continuous profile, is arranged in the aerosol-generating substrate.

Example Ex38: the method of any one of examples Ex29 to Ex36, comprising the steps of: a susceptor, in particular in the form of a single susceptor segment, is arranged in the aerosol-generating substrate.

Example Ex39: the method of any one of examples Ex29 to Ex38, comprising the steps of: converging the aerosol-generating material and the susceptor to form said aerosol-generating substrate with the susceptor embedded.

Example Ex40: a method according to any one of examples Ex29 to Ex39, comprising the step of wrapping the aerosol-generating material with an inner wrapper.

Example Ex41: apparatus for manufacturing an aerosol-generating article, comprising

A guiding system for forming an insulating sleeve of insulating material, and

Sleeve converging means for enveloping an aerosol generating substrate with the thermally insulating sleeve.

Example Ex42: the apparatus of example Ex41, further comprising a wrapper supply device for supplying an outer wrapper to be wrapped around the insulating sleeve.

Example Ex43: the apparatus of any of examples Ex 41-Ex 42, wherein the guiding system comprises a guiding element providing a guiding surface along which the insulation material for forming the insulation sleeve is guided, wherein the guiding surface extends around an angle of at least 180 degrees.

Example Ex44: the apparatus of any of examples Ex 41-Ex 43, wherein the guiding system comprises a first guiding element and a second guiding element, each guiding element providing a respective guiding surface along which the insulation material forming the insulation sleeve is guided.

Example Ex45: the apparatus of any of examples Ex 41-Ex 44, wherein the sleeve converging device comprises a funnel.

Example Ex46: the apparatus of any one of examples Ex41 to Ex44, further comprising a matrix converging device for forming the aerosol-generating matrix in a strip form.

Example Ex47: the apparatus of example Ex46, wherein the matrix converging device comprises a funnel.

Example Ex48: the apparatus of any one of examples Ex 41-Ex 47, further comprising an expansion device comprising a first pair of expansion rollers adapted to direct the insulation material through a nip between the pair of first expansion rollers.

Example Ex49: the apparatus of example Ex48, wherein the expansion device further comprises a second pair of expansion rollers arranged consecutively to the first pair of expansion rollers for expanding the web of insulation material.

Example Ex50: the apparatus of any of examples Ex 48-Ex 49, wherein the expansion roller is a forming roller to form a profile into the web of insulation material.

Example Ex51: use of an acetate tow for encapsulating an aerosol-generating substrate of an aerosol-generating article to reduce heat dissipation from a heating element in the aerosol-generating substrate to an outer surface of the aerosol-generating article.

Example Ex52: the use of example Ex51, wherein the heating element is a susceptor disposed as part of the aerosol-generating article.

Example Ex53: use according to example Ex51, wherein the heating element is a heating blade provided as part of a separate heating device, wherein the heating blade is inserted in the aerosol-generating substrate for heating the aerosol-generating article.

Several examples will now be further described with reference to the accompanying drawings.

Fig. 1 shows a perspective view of an aerosol-generating article.

Fig. 2 shows a perspective view of an aerosol-generating article with further longitudinal elements.

Fig. 3 shows an apparatus for manufacturing an aerosol-generating article.

Fig. 4 shows a schematic view of a one-piece guidance system.

Fig. 5 shows a schematic view of a two-piece guidance system.

Fig. 1 shows an aerosol-generating article 1 comprising an inner matrix core 3, an insulating sleeve 5 surrounding the inner matrix core 3, and an outer wrapper 7 surrounding the insulating sleeve 5. The aerosol-generating article 1 has an outer surface 8. A susceptor 9 is arranged in the inner matrix core 3 for heating the aerosol-generating substrate 11. An inner wrapper 13 is arranged between the inner matrix core 3 and the insulating sleeve 5, said inner wrapper surrounding the inner matrix core 3. The aerosol-generating article 1 has a tubular strip shape and defines a longitudinal direction 100 along its longest extension and a radial direction 200 perpendicular to the longitudinal direction 100 and extending radially outwards from a central axis 300. The aerosol-generating article 1 has a diameter 400 and the inner matrix core 3 has a diameter 500. Thus, the insulating sleeve 5 has a circumference Xiang Cenghou degrees 600. The circular outer cross-section of the inner matrix core 3 defined by the diameter 500 of the inner matrix core 3 is equal to the circular inner cross-section of the insulating sleeve 5. Susceptor 9 has a width 701, a thickness 702, and a longitudinal length 703. The susceptor is formed of sheet material and has a longitudinal length 703 that is greater than its width 701. The susceptor has a width 701 that is greater than its thickness 702. The inner wrapper 13 and the outer wrapper 7 are made of a relatively thin material, such as a paper material, compared to the insulating sleeve 5 or the inner matrix core 3. The insulating sleeve 5 has a substantially constant circular layer thickness 600.

Fig. 2 shows a perspective view of an aerosol-generating article 1 having a plurality of longitudinal elements 801, 802, 803, 804, 805. The aerosol-generating article 1 comprises a longitudinal element 801 comprising an inner matrix core 3 encapsulated with an insulating sleeve 5 and comprising a susceptor 9 arranged within the inner matrix core 3. In this example, the width 701 of the susceptor 9 is equal to the diameter 500 of the inner matrix core 3 and is thus in contact with the insulating sleeve 5. A longitudinal element 802 is provided on the left side of element 801. The element 802 is formed as a hollow cylindrical tube and may serve as a spacer for the bottom surface of the housing of the aerosol-generating device in which the aerosol-generating article 1 is inserted. Furthermore, the element 802 may limit the airflow through the aerosol-generating article 1 according to its inner diameter. Element 803 is disposed on the right side of element 801. Element 803 is another hollow tube element formed, for example, from an acetate tow. The element 803 serves as a cooling element to cool the heated air flow from the aerosol-generating substrate 11 of the element 801. Element 803 may comprise a porous structure and mix the heated air stream with ambient air. The mouthpiece element 804 and the filter element 805 abut the right side of the element 803. The mouthpiece element 804 is preferably formed of a moisture resistant material. The filter element 805 is preferably formed from acetate tow and filters the air stream.

Fig. 3 shows an apparatus 31 for manufacturing an aerosol-generating article 1 comprising a guiding system 33 for forming an insulating sleeve 5 of an insulating material 35, and a sleeve converging device 37 for enveloping an aerosol-generating substrate 11 with the insulating sleeve 5. The guiding system 33 comprises a first guiding element 39 having a first guiding surface 41 and a second guiding element 43 having a second guiding surface 45. The insulating material 35 is guided along the outer first guiding surface 41 and the second guiding surface 45 for forming the insulating sleeve 5 around the aerosol-generating substrate 11. Accordingly, the heat insulating material 11 is continuously conveyed through the expansion device 47 in the conveying direction 900. The expansion device 47 comprises a first pair of expansion rolls 49, 51 and a second pair of expansion rolls 53, 55 arranged consecutively to the first pair of expansion rolls 49, 51 for expanding the web of insulation material 35. The insulation 35 is led through a nip 56 between the first pair of expansion rollers 49, 51 and between the second pair of expansion rollers 53, 55.

The device 31 further comprises a matrix converging means 57 for forming the aerosol-generating matrix 11 in the form of a strip. The aerosol-generating substrate 11 may initially be present as a defoliated sheet 59 and crimped together by the substrate converging means 57. The susceptor 9 of the continuous profile is fed by a susceptor feed means 61 into the aerosol-generating substrate 11, respectively into the deciduous sheets 59. In the substrate converging means 57, the susceptor 9 is arranged in the aerosol-generating substrate 11 and thus in the inner substrate core 3 of the final aerosol-generating article 1. The first pack supply device 63 supplies the outer pack 7 to wrap around the heat insulating sleeve 5 in the sleeve converging device 37. The second wrapper supply means 65 supplies the inner wrapper 13 to wrap around the inner matrix core 3 in the aerosol-generating substrate 11, the substrate converging means 57, respectively. The adhesive supply 67 applies adhesive to the inner wrapper 13 and the outer wrapper 7. Thus, the inner wrapper 13 is fixed to the aerosol-generating substrate 11 and the outer wrapper 7 is fixed to the insulating sleeve 5.

The sleeve converging means 37 and the matrix converging means 57 each comprise a funnel 69 to guide the material into the means 37, 57.

Fig. 4 shows a schematic view of a one-piece guiding system 33 comprising only one first guiding element 39. The first guiding element 39 extends at an angle of 180 degrees or more around the aerosol-generating substrate 11 in order to guide the insulating material 35 around the aerosol-generating substrate 11 and form the insulating sleeve 5. The insulating sleeve 5 will also converge in a sleeve converging means 37, into which it is additionally guided by a funnel 69. The insulation 35 is expanded by rollers 49, 51, 53, 55 of the expansion device 47 upstream of the guiding system 33.

Fig. 5 shows a schematic view of a two-piece guiding system 33 comprising a first guiding element 39 with a first guiding surface 41 and a second guiding element 43 with a second guiding surface 45. The guiding elements 39, 43 are arranged as an upper guiding element and a lower guiding element at a distance from each other and from the aerosol-generating substrate 11. The cross-section of the guiding element 43 increases first and then tapers towards the sleeve converging means 37, wherein the increase in cross-section is higher than the decrease. Either or both of the first guide element 39 and the second guide element 43 may have the shape of a tear drop, pear, water drop, or shoulder.

For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing quantities, amounts, percentages, and so forth, are to be understood as being modified in all instances by the term "about". Moreover, all ranges include the disclosed maximum and minimum points, and include any intervening ranges therein that may or may not be specifically enumerated herein. Thus, in this context, the number a is understood to be a±10% a. In this context, the number a may be considered to include values within a general standard error for the measurement of the property of the modification of the number a. In some cases, as used in the appended claims, the number a may deviate from the percentages recited above, provided that the amount of deviation a does not materially affect the basic and novel characteristics of the claimed invention. Moreover, all ranges include the disclosed maximum and minimum points, and include any intervening ranges therein that may or may not be specifically enumerated herein.

Claims

1. An aerosol-generating article adapted to be electrically heated in an aerosol-generating device, the aerosol-generating article comprising

An inner matrix core comprising an aerosol-generating substrate,

A thermally insulating sleeve surrounding the matrix core, and

An outer wrapper surrounding the insulating sleeve,

Wherein a susceptor is arranged in said matrix core and said susceptor is in contact with said insulating sleeve,

Wherein the susceptor is made of sheet material.

2. An aerosol-generating article according to claim 1, wherein the insulating sleeve comprises a fibrous material.

3. An aerosol-generating article according to any one of claims 1 to 2, wherein the insulating sleeve has a radial layer thickness that varies by less than 10%.

4. An aerosol-generating article according to any one of claims 1 to 3, wherein the matrix core has an outer cross-section, the major diameter of the outer cross-section being less than 5% longer than its minor diameter, and the insulating sleeve has an inner cross-section corresponding to the outer cross-section of the matrix core.

5. A method for manufacturing an aerosol-generating article, the method comprising the steps of:

The aerosol-generating substrate is transported in a transport direction through the sleeve converging means,

Supplying insulation material to the sleeve converging means such that the insulation material is arranged circumferentially around the aerosol-generating substrate in the sleeve converging means, and

6. A method according to claim 5, wherein the step of converging the insulating material to form an insulating sleeve around the aerosol-generating substrate is performed in parallel with the step of conveying the aerosol-generating substrate through the sleeve converging means in the conveying direction.

7. The method according to any one of claims 5 to 6, comprising the steps of: the insulating material is equally circumferentially distributed in the sleeve converging means to form an insulating sleeve of substantially constant thickness.

8. The method of any of claims 5 to 7, wherein the step of supplying insulation comprises guiding the insulation along a guiding system.

9. A method according to claim 8, wherein the insulating material is guided along a guiding surface of the guiding system, wherein the guiding surface faces away from the aerosol-generating substrate.

10. The method according to any one of claims 5 to 9, comprising the steps of: converging the aerosol-generating material and the susceptor to form said aerosol-generating substrate with the susceptor embedded.

11. Apparatus for manufacturing an aerosol-generating article, comprising

A guiding system for forming an insulating sleeve of insulating material, and

12. The apparatus of claim 11, wherein the sleeve converging means comprises a funnel.

13. The apparatus of any one of claims 11 to 12, further comprising a wrapper supply means for supplying an outer wrapper to be wrapped around the insulating sleeve.

14. The apparatus of any one of claims 11 to 13, wherein the guiding system comprises a first guiding element and a second guiding element, each guiding element providing a respective guiding surface along which the insulating material forming the insulating sleeve is guided.

15. The apparatus of any one of claims 11 to 14, further comprising an expansion device comprising a first pair of expansion rollers adapted to direct the insulation material through a nip between the pair of first expansion rollers.

16. Use of an acetic acid tow for encapsulating an aerosol-generating substrate of an aerosol-generating article to reduce heat dissipation from a heating element in the aerosol-generating substrate to an outer surface of the aerosol-generating article, wherein a susceptor is arranged in the substrate and the susceptor is in contact with the acetic acid tow, wherein the susceptor is made of sheet material.