EA042655B1 - METHOD AND DEVICE FOR MANUFACTURING ARTICLE GENERATING AEROSOL - Google Patents

Description

Technical field

The present invention relates generally to aerosol generating articles, and in particular to an aerosol generating article for use with an aerosol generating device for heating the aerosol generating article to generate an aerosol for inhalation by a user. Embodiments of the present invention specifically relate to a method for manufacturing an aerosol generating article and/or an apparatus for manufacturing an aerosol generating article.

Background of the invention

In recent years, devices that heat rather than burn an aerosol generating material to produce an inhalable aerosol have become popular with consumers.

Such devices may use one of a number of different approaches to apply heat to the aerosol generating material. One such approach is to provide an aerosol generating device that uses an induction heating system and into which a user can retractably insert an aerosol generating article containing an aerosol generating material. In such a device, the device is provided with an induction coil, and the aerosol generating article is usually provided with an inductively heated current collector. Electricity is applied to the induction coil when the user activates the device, which in turn generates an alternating electromagnetic field. The current collector interacts with the electromagnetic field and generates heat, which is transferred, for example, by conduction, to the aerosol-generating material, and as the aerosol-generating material is heated, steam or aerosol is generated.

It may be desirable to provide the aerosol generating material in the form of an aerosol generating article that can be inserted into the aerosol generating device by a user. Accordingly, there is a need to provide a method and apparatus to facilitate the manufacture of aerosol generating articles.

The essence of the invention

According to a first aspect of the present invention, there is provided a method for manufacturing an aerosol generating article, the method comprising:

(i) providing an aerosol generating material from plant materials;

(ii) providing an inductively heated current collector;

(iii) providing a cup-shaped element containing a bottom wall, a side wall and a flange at the open end;

(iv) depositing a layer of plant-derived aerosol generating material in a cup-like element;

(v) placing an inductively heated susceptor on a deposited layer of aerosol-generating plant material;

(vi) if necessary, repeating only step (iv) or steps (iv) and (v);

(vii) providing the closure element and attaching the closure element to the flange.

According to the present invention, there is provided a convenient method for manufacturing an aerosol generating article which comprises an aerosol generating material from vegetable raw materials and an inductively heated current collector, the method in particular facilitating the mass production of aerosol generating articles.

The aerosol-generating article is intended for use with an aerosol-generating device for heating an aerosol-generating material from a plant material without burning the aerosol-generating material, in order to vaporize at least one component of the aerosol-generating material from the plant material and generate in the form of vapor that is cooled and condensed to form an aerosol for inhalation by the user of the aerosol generating device.

In general, vapor is a substance in the gas phase at a temperature that is below its critical temperature, which means that vapor can condense into a liquid by increasing its pressure without lowering its temperature, whereas an aerosol is a suspension of fine solid particles or liquid droplets in air. or other gas. However, it should be noted that the terms aerosol and vapor may be used interchangeably in this specification, particularly in relation to the form of inhalable medium that is generated for inhalation by the user.

The use of an inductively heated susceptor element provides a convenient, efficient, and energy-saving method for heating plant-derived aerosol-generating material. When the aerosol generating product is located in the aerosol generating device and is subjected to an alternating electromagnetic field, heat is generated in the inductively heated current collector due to eddy currents and magnetic hysteresis losses resulting in the conversion of electromagnetic energy into thermal energy. The heat generated in the inductively heated current collector is transferred to the aerosol generating plant material, which is heated to generate steam which cools and condenses to form an aerosol having the desired characteristics.

The inductively heated current collector may comprise one or more of, but not limited to, aluminum, iron, nickel, stainless steel, and their alloys, such as nichrome or nickel-copper alloy.

The inductively heated current collector may comprise a generally flat inductively heated current collector and may comprise a generally annular inductively heated current collector.

The cup may be a paper cup and may be a molded paper cup. The paper cup is cheap, easy to manufacture, biodegradable and safe to use even at high temperatures. The paper cup may have a self-supporting molded shape. This allows the cup to maintain its shape and facilitates handling of the cup during manufacture of the aerosol generating article.

The cup-shaped element and/or the closure element may additionally contain tobacco and/or flavoring. The tobacco and/or flavoring may enhance or mask the taste of the paper and make it more palatable. The flavoring may be tobacco, fruity, herbal, nutty, floral, and so on. Tobacco and/or flavor may be present as an ingredient in the paper. The tobacco may be embedded in or applied to the paper, for example by coating or layering. The tobacco may be in the form of particles, flakes, leaf fragments, strip(s), layer(s), and combinations thereof.

The cup-shaped element may be generally cylindrical. The side wall may be generally cylindrical. The bottom wall may be generally round. The closure element may be generally circular. A cylindrically shaped cup having a generally circular cross section can facilitate handling of the cup during manufacture of an aerosol generating article. The cylindrical shape of the resulting aerosol generating article, with its generally circular cross section, may facilitate the packaging of several aerosol generating articles and/or may facilitate insertion of the aerosol generating article into a suitably shaped heating compartment of the aerosol generating device. The cylindrical shape allows the insertion of several identical current collectors while still providing uniform heating of the aerosol generating material. Therefore, manufacturing complexity is reduced while ensuring system efficiency.

The flange may extend outward from the side wall. Thus, the flange does not pass through the open end of the cup, which makes it easy to place the aerosol-generating plant material and the inductively heated current-collecting element(s) in the cup in steps (iv), (v) and, if necessary, in step ( vi). In embodiments in which the side wall is generally cylindrical, the flange may include a generally circular projection.

The bottom wall of the cup may be porous or perforated. For example, the bottom wall may comprise a material that is porous to allow air to pass through the bottom wall. Alternatively or additionally, the bottom wall may comprise one or more holes or perforations. In the latter case, the bottom wall may comprise a material which is itself resistant to air, so that holes or perforations are needed to allow air to pass through the bottom wall. The provision of a porous or perforated bottom wall preferably facilitates the passage of air through the aerosol generating article and thereby optimizes aerosol generation and transmission to the user, for example through the mouthpiece of the aerosol generating device.

The closing element may be porous or perforated. For example, the closure may comprise a material with a porous structure to allow air to pass through the closure. Alternatively or additionally, the closure element may comprise one or more holes or perforations. In the latter case, the closure may comprise a material which is itself air resistant, such that holes or perforations are necessary to allow air to pass through the closure. In addition to retaining the aerosol-generating plant material in the cup-like element, the porous or perforated closure preferably facilitates the passage of air through the aerosol-generating article and thereby optimizes the generation and transmission of the aerosol to the user, for example, through the mouthpiece of the aerosol-generating device.

By air-resistant is meant a material which is not necessarily an oxygen barrier during storage, but which at least excludes the flow of air and vapor during use.

Step (iv) may include dosing and depositing the aerosol generating material from plant materials in the form of granules, pellets, chips, filaments, particles, gel, strips, split leaves, cut leaves, cut filler, porous material, foam or sheets or their combinations. The step of dosing the aerosol generating material from the plant material may include weighing the aerosol generating material from the plant material. As a result, it provides

- 2 042655 accurate dosing of the aerosol generating material, which in turn ensures that during use of the aerosol generating article with the aerosol generating device, an aerosol with the desired characteristics is generated.

The method may further include leveling the deposited layer of aerosol generating material from the plant material. The step of leveling the deposited layer of aerosol generating material may be performed after step (iv) and may be performed before step (v). Flattening the deposited layer of aerosol generating material can facilitate the placement of the inductively heated current collector on the deposited layer in step (v), particularly when the aerosol generating material is applied in powder or crumb form.

Step (ii) may include providing a metal foil and may include cutting the metal foil, for example by means of a cutting element, to form an annular susceptor or multiple annular susceptors. The use of a metal foil and a cutting member to form the current-collecting member(s) can facilitate the mass production of aerosol-generating articles. Carving may include punching, laser cutting, plasma cutting, waterjet cutting, or etching (eg, photoetching or chemical etching).

The cup-shaped element may comprise an axis of the cup-shaped element extending between the open end and the bottom wall, and step (vi) may include placing the second and third inductively heated current collectors in the cup-shaped element, respectively, at equal distances from the first and second inductively heated current-collecting elements, respectively, in the direction of the axis bowl element. As a result, uniform distribution of the inductively heated susceptor elements over the aerosol-generating plant material is provided, and this, in turn, ensures uniform heat transfer from the inductively heated susceptor elements to the aerosol-generating material from plant materials during use of the aerosol-generating article. aerosol, with an aerosol generating device.

Step (vii) may include attaching the closure to the flange by gluing or welding. Step (vii) may include snap-fitting the closure element to the flange. The closure member can be firmly and securely attached to the flange, thereby ensuring that the aerosol generating material and the inductively heated current-collecting member(s) are held in the cup member, and mass production of the aerosol generating articles is facilitated.

The bowl-shaped element may include a positioning element for receiving an inductively heated current-collecting element. Step (v) may include placing the inductively heated current-collecting element with the positioning element. The inductively heated current collector can be easily and securely positioned in the cup-shaped body at a predetermined position relative to the aerosol-generating material, and thereby it is ensured that uniform heating of the aerosol-generating material can be obtained. The use of a positioning element can also help ensure that the inductively heated current collector is positioned correctly to interact with the electromagnetic field during use of the aerosol generating article with the aerosol generating device, thereby ensuring that maximum generation is provided in the inductively heated current collector. heat.

The positioning element may comprise a support surface which may extend continuously in the circumferential direction of the inner wall of the cup-shaped element. With such a device, the inductively heated current-collecting element is provided with a reliable support along its periphery. The positioning element may comprise at least two, preferably three or more, separate support surfaces at circumferentially spaced locations within the cup-shaped element. With such an arrangement, the inductively heated current-collecting element along the periphery is supported at certain positions around the circumference, as a result of which the contact area between the aerosol-generating material and the inductively heated current-collecting element along its periphery is increased and the amount of heat transfer to the aerosol-generating material is maximized.

Step (v) may include placing the inductively heated current collector on the support surface or surfaces.

The cup-shaped element may contain the axis of the cup-shaped element, passing between the open end and the bottom wall, and at least two of these positioning elements in different places along the axis of the cup-shaped element. The positioning element located along the axis of the cup-shaped element closest to the open end may be closer to the inner wall of the cup-shaped element than the other positioning element (elements). The positioning elements make it possible to obtain a uniform distribution of the inductively heated current-collecting elements over the aerosol-generating material from vegetable raw materials, and this, in turn, ensures uniform heat transfer from the inductively heated current-collecting elements to the aerosol-generating material from vegetable raw materials. while using an aerosol generating product with an aerosol generating device.

The cup-shaped element may further comprise an abutment extending from the side wall in a radially inward direction. The abutment facilitates secure and accurate placement of the inductively heated current collector in the cup-shaped element in a direction perpendicular to the axis of the cup-shaped element, for example, in the radial direction.

The side wall of the cup-shaped element may include a step that contains a stop and a positioning element. This provides a simple and robust structure.

The cup-shaped element may contain the axis of the cup-shaped element, passing between the open end and the bottom wall. Step (v) may include placing the inductively heated susceptor in the cup as a whole in the direction of the axis of the cup by bringing the inductively heated susceptor into contact with the positioning element within the cup. The method may further include pulling the positioner out of the cup after placing the inductively heated susceptor in the cup. With such an arrangement, the positioning element does not form part of the cup-shaped element. Therefore, the cup-shaped element can be manufactured lighter and cheaper than a cup-shaped element in which the positioning element forms part of the cup-shaped element. In addition, the positioning element could be inserted through an existing opening in the bottom wall (eg, an opening designed to allow air to pass through the bottom wall), which facilitates insertion and removal of the positioning element.

The aerosol generating material from plant material can be any type of solid or semi-solid material capable of generating vapor and/or aerosol when heated. As noted above, aerosol generating material may include granules, pellets, chips, filaments, particles, gel, strips, plucked leaves, cut leaves, cut filler, porous material, foam or sheets, or combinations thereof. The aerosol-generating material from vegetable raw materials may contain tobacco. It may preferably contain reconstituted tobacco.

The foam may contain many small particles (eg, tobacco particles). The tobacco particles may have a particle size (D90) of 50 to 180 µm, preferably 60 to 140 µm, more preferably 65 to 125 µm, even more preferably 70 to 110 µm, particularly preferably 75 to 90 µm, e.g. particle size (D90) approximately 80 µm. Particle size by volume (D90) is determined using dry dispersion of the sample and laser refractometry using a Malvern Mastersizer 3000.

The foam may further comprise an aerosol generating agent such as propylene glycol, glycerol, and a combination thereof. The aerosol generating agent may further comprise water. Water may be present in an amount of 0 to 15% by weight of the foam, for example 5 to 10% by weight. The foam may further contain a solvent and/or an acid and/or an ester in an amount of up to 15% by weight based on the total weight of the foam, preferably up to 5% by weight. The foam may further comprise a foaming agent such as a protein-free polysaccharide. The foam may further comprise a foam stabilizing agent such as cellulose gum. The foam may be porous, such that it contains open cells and may allow air and/or vapor to pass through the foam.

An aerosol-generating material from a plant material may contain an aerosol generating agent. The aerosolizing agent acts as a humectant. Examples of aerosol forming agents include polyhydric alcohols and mixtures thereof, such as glycerol or propylene glycol. The aerosol generating material may contain from about 5% to about 50% by dry weight of the aerosol generating agent. In some embodiments, the aerosol generating material may contain from about 30 to about 50% dry weight, and possibly about 40% dry weight.

When heated, the aerosol-generating material from plant materials may release volatile compounds. The volatile compounds may contain nicotine or flavor compounds such as tobacco flavor.

Steps (iv), (v) and (vii), as well as the optional step (vi), can be performed on a turntable. The use of a turntable allows accurate and reliable positioning of the aerosol generating plant material and the inductively heated current-collecting element(s) in the cup-shaped element. The use of a turntable may be particularly advantageous in embodiments in which step (vi) is performed by interleaving layers of plant material aerosol generating material and induction heated current collectors located in the cup-like element. In other possible embodiments, steps (iv), (v) and (vii), as well as optional step (vi), may be performed on a linear conveyor.

According to a second aspect of the present invention, there is provided an apparatus for manufacturing an aerosol generating article according to the method discussed above, the apparatus comprising

- 4 042655 cup-shaped elements holding unit for holding several cup-shaped elements;

a first station comprising a metering and deposition unit for depositing metered layers of aerosol generating material from plant material in cup-shaped elements;

a second station comprising a foil receiving unit for receiving the metal foil and a cutting unit for cutting the inductively heated current collectors from the metal foil, the second station further comprising a housing unit for accommodating the inductively heated current collectors in the cup-like elements; and a third station comprising a closure receiving unit and a closure unit for attaching the closures to the flanges of the cups.

The use of such a device facilitates the mass production of aerosol generating articles, in particular by moving the cup holding unit between the first, second and third stations.

The cutting unit may include a punching unit for punching with a punch to form annular metal foil current collectors. The use of a die punching unit is well suited for mass production. Alternatively, the cutting unit may comprise a laser cutting unit, a plasma cutting unit, a waterjet cutting unit, or an etching unit (eg, a photo-etching unit or a chemical etching unit).

The closure unit may include an adhesive application device for applying a layer of adhesive between the closure elements and the flanges of the cup elements. The closure block allows the closure elements to be securely attached to the flanges of the cup elements.

The cup holding unit may include a transfer unit for moving the cups between the first, second, and third stations. The moving unit can be configured to move the cup-shaped elements holding unit back and forth between the first and second stations as many times as necessary with the deposition of several layers of aerosol-generating material from vegetable raw materials into the cup-shaped elements and with the placement of several inductively heated current-collecting elements in the cup-shaped elements.

The cup holding unit may include a sliding tray. The cup-shaped elements can be easily moved by means of a sliding tray between the first, second and third stations.

The cup holding unit may include a turntable. The cup holding unit may include a tray conveyed by a linear conveyor.

The apparatus may include a controller that may be configured to control the operation of one or more of the cup holding unit, the first station, the second station, and the third station.

Brief description of graphic materials

In FIG. 1 is a schematic side sectional view of an aerosol generating article which comprises a first example of a cup-shaped element containing an aerosol-generating plant material and a plurality of annular inductively heated current collector elements;

in fig. 2 is a top view of one of the annular inductively heated current collectors;

in fig. 3a is a plan view of a second example of a cup-like element;

in fig. 3b is a sectional view taken along line A-A in FIG. 3a;

in fig. 3c is a side view of the cup of FIG. 3a and 3b;

in fig. 3d is a perspective view of the cup of FIG. 3a-3c;

in fig. 4a and 4b are schematic side sectional views of an aerosol generating product which is similar to that shown in FIG. 1 showing a first example of a snap-on connection between a cup and a closure;

in fig. 5a and 5b are side sectional diagrams of an aerosol generating article similar to that shown in FIG. 1 showing a second example of a snap-on connection between a cup and a closure;

in fig. 6 is a flow chart showing the steps of a method for manufacturing an aerosol generating article;

in fig. 7a and 7b are respectively a side-sectional diagram and a top diagram of a cup-shaped element containing positioning elements that extend continuously around the inner surface of the side wall of the cup-shaped element;

in fig. 8a-8h are schematic representations of an example of a method for manufacturing an aerosol generating article using the cup-shaped element of FIG. 7a and 7b;

in fig. 9a is a schematic plan view of a cup-shaped element containing positioning elements in separate places around the circumference around the inner surface of the side wall of the cup-shaped element;

- 5 042655 in FIG. 9b and 9c are schematic sectional views, respectively, along lines A-A and B-B in FIG. 9a before filling the cup-like element with the aerosol-generating plant material and the inductively heated susceptor elements;

in fig. 10a and 10b are schematic sectional views, respectively, along lines AA and B-B in FIG. 9a after the cup-shaped element has been filled with plant-derived aerosol generating material and inductively heated susceptor elements;

in fig. 11a and 11b show respectively a schematic side view in section and a schematic top view of a cup-shaped element containing removable positioning elements;

in fig. 12a-12i are schematic representations of an example of a method for manufacturing an aerosol generating article using the cup of FIG. 11a and 11b and in FIG. 13 is a schematic representation of an apparatus for manufacturing an aerosol generating article according to the method of FIG. 6.

Detailed description of embodiments

Hereinafter, with reference to the accompanying drawings, embodiments of the present invention will be described by way of example only.

As seen first, in Fig. 1 and 2 show a first example of an aerosol generating article 1 for use with an aerosol generating device that contains an electromagnetic field generator (eg, an induction heating system comprising an induction coil). The aerosol generating article 1 comprises, as a first example, a cylindrical cup 10 having a generally circular bottom wall 12, a generally cylindrical side wall 14, and a generally circular open end 16 tightly closed by a generally circular closure member 18 attached to the flange. 20 at the open end 16 of the cup 10.

The cylindrical cup 10 is typically a paper cup, such as a molded paper cup with a self-supporting molded shape. The bottom wall 12 is air permeable and in the embodiment shown includes a plurality of holes or perforations 22. In some embodiments, the paper (or other material) from which the cup 10 is made may have a porous structure that allows air to pass through the bottom wall 12 without the need for holes or perforations 22.

The cup 10 contains a plant based aerosol generating material 24, for example a solid or semi-solid material in powder or crumb form with a particle size after sieving of less than 1.7 mm. The herbal aerosol generating material 24 also contains an aerosol generating agent, such as glycerin or propylene glycol, which acts as a humectant. Typically, plant-derived aerosol generating material 24 may have an aerosol generating agent content of from about 30 to about 50% by dry weight, and possibly by about 40% by dry weight. When heated, the plant material aerosol generating material 24 releases volatile compounds that may contain nicotinic or flavor compounds such as tobacco flavor.

The cup-shaped element 10 also contains several annular inductively heated current-collecting elements 26. The inductively heated current-collecting elements 26 inside the cylindrical cup-shaped element 10 are coaxial with respect to the axis of the cup-shaped element passing between the bottom wall 12 and the open end 16, and are spaced from each other in the axial direction along the axis bowl element. When an alternating electromagnetic field is applied in the vicinity of the inductively heated current collectors 26 during use of the product 1 in an aerosol generating device, heat is generated in the inductively heated current collectors 26 due to eddy currents and magnetic hysteresis losses, and heat is transferred from the inductively heated current collectors 26 to the plant material aerosol generating material 24, heating the plant material aerosol generating material 24 without burning it, and thereby generating steam, which is cooled and condensed to form an aerosol for inhalation by the user. The inductively heated susceptor elements 26 are in contact with the aerosol generating material 24 of the vegetable raw materials as a whole on all of their surfaces and thus allow direct, and therefore efficient, transfer of heat from the inductively heated susceptor elements 26 to the aerosol generating material 24 , from vegetable raw materials.

The closure member 18 at the open end 16 retains the aerosol generating plant material 24 and the inductively heated current collectors 26 within the cup 10. One skilled in the art will recognize that the closure member 18 must be air permeable to allow vapor or aerosol , generated by heating the plant material aerosol generating material 24, could exit the cylindrical cup 10 during use of the aerosol generating article 1 in the aerosol generating device. In the example shown in FIG. 1, the flange 20 includes an outwardly extending round protrusion 28,

- 6 042655 and the closure element 18 is attached to the round protrusion 28 by adhesive or welding, for example, using ultrasonic welding technology or a hot pressing press.

Further in FIG. 3a-3c show a second example of a cylindrical cup 110 which is similar to the cup 10 described above with reference to FIG. 1, and in which the respective elements are designated by the same reference numerals.

As best seen in FIG. 3a and 3b, the bottom wall 12 comprises a plurality of circumferentially spaced peripheral holes 30 arranged around a central hole 32. The peripheral holes 30 are generally circular, typically 0.5 to 1 mm in diameter. The central hole 32 is also generally circular with a diameter that is larger than that of the peripheral holes and is typically 1.2 to 2.5 mm.

Further in FIG. 4a and 4b show a second example of an aerosol generating article 2, which is similar to the aerosol generating article 1 described above with reference to FIGS. 1 and 2, and in which the respective elements are designated by the same reference numerals. It should be noted that the plant material aerosol generating material 24 and the inductively heated current collectors 26 in FIG. 4a and 4b are not shown.

The aerosol generating article 2 comprises a closure member 18 with a snap connector 34. The snap connector 34 includes a circumferentially extending hook member 36 forming an annular recess 38 in which the flange 20 can be firmly seated as shown in FIG. 4b. The hooked element 36 includes an inclined surface 40 which allows it to slide past the flange 20 when the closure element 18 is moved in the direction of the axis of the cup from the position shown in FIG. 4a to the position shown in FIG. 4b. One skilled in the art will appreciate that the side wall 14 of the cup 10 in the region proximate the open end 16 and/or the hooked member 36 may sag as the closure 18 is pressed against the flange 20 before one or both of the components return to the their original positions, so that the flange 20 can be placed and securely held in the annular recess 38, as shown in FIG. 4b.

Further in FIG. 5a and 5b show a third example of an aerosol generating article 3, which is similar to the aerosol generating articles 1, 2 described above with reference to FIGS. 1, 2, 4a and 4b, and in which the respective elements are designated by the same reference numerals. Again, it should be noted that the plant material aerosol generating material 24 and the inductively heated current collectors 26 in FIG. 5a and 5b are not shown.

The aerosol generating article 3 comprises a cup-shaped element 210 with a flange 20 which protrudes radially inward and forms a snap-in connector 42. In more detail, the snap-in connector 42 comprises an upper annular flange portion 44 and a lower annular flange portion 46, which between define an annular recess 48 in which the edges of the closure element 18 can be securely held, as shown in FIG. 5b. The upper annular portion 44 of the flange includes an inclined surface 50 which assists in moving the closure member 18 from the position shown in FIG. 5a into an annular recess 48 as shown in FIG. 5b. In particular, one skilled in the art will appreciate that the side wall 14 of the cup 210 in the region adjacent to the open end 16 may sag radially outward when the closure 18 is pressed against the sloped surface 50, and that the upper annular portion 44 of the flange may also deform. out and/or down before both components return to their original positions to thereby allow the edges of the closure 18 to be placed in the annular recess 48 as shown in FIG. 5b.

Further in FIG. 6 shows an example of a method for manufacturing an aerosol generating article, for example, an aerosol generating article 1, according to the first example, which is described above with reference to FIG. 1 and 2.

In the first, second, and third steps S1, S2, and S3, respectively, the method includes providing an aerosol-generating material 24 from plant materials, obtaining an inductively heated current-collecting element 26, and providing a cup-shaped element 10, 110, 210 containing a bottom wall 12, a side wall 14 and a flange 20 at the open end 16. The inductively heated current collector 26 in step S2 is preferably obtained by punching a solid current collector, preferably metal foil, most preferably aluminum foil, to form one or more of the annular current collectors 26 described above with reference to FIG. . 1 and 2.

In the fourth step S4, a layer of aerosol generating material 24 is deposited into the cup 10, 110, 210. A layer of aerosol-generating material 24, from plant materials, which is usually obtained in the form of powder or crumbs, as discussed above, is dosed (for example, weighed) and deposited in the cup-shaped element 10, 110, 210, ensuring that the deposited layer contains a predetermined amount of (eg, weight) of the aerosol generating material 24. In some embodiments, the mass of aerosol generating material 24 in the deposited layer may be between 40 and 60 mg, such as approximately 50 mg. On one

- 7 042655 optional step, the method may include leveling the deposited layer of material 12, generating aerosol, from vegetable raw materials. Leveling is carried out as far as possible without pressure on the deposited layer of aerosol-generating material 12 of plant material in order to avoid compaction of the aerosol-generating material 12.

In the fifth step S5, on the layer of the aerosol generating material 24 deposited in the cup-shaped member in step S4, the inductively heated current-collecting member 26 obtained in step S2 is placed.

In an optional step S6, an additional layer of plant material aerosol generating material 24 can be dosed and deposited in the cup 10 (that is, step S4 can simply be repeated); alternatively, an additional layer of plant material aerosol generating material 24 can be dosed and deposited in the cup 10 and an inductively heated current collector element 26 can be placed on the additional plant material aerosol generating material 24 (i.e., both steps S4 and S5 may be repeated as many times as necessary to provide multiple alternating layers of plant material aerosol generating material 24 and inductively heated current collectors 26).

In the last step S7, the closure 18 is provided and the closure 18 is secured to the flange 20, for example by gluing or welding the closure 18 to the flange 20 as described above with reference to FIG. 1-3, or by a snap-on connection as described above with reference to FIGS. 4 and 5.

Further in FIG. 7a and 7b show an example of a cup 310 in which the side wall 14 has a stepped inner surface 52 containing several steps 54a-c.

Steps 54a-c define a plurality of radially extending support surfaces 56a-c that extend continuously in the circumferential direction of the inner wall 58 of the cup 310. The support surfaces 56a-c serve as positioning elements 56 for accommodating the inductively heated current collectors 26 in the axial direction in the cup. 310 along the axis of the cup, as will be described below with reference to FIG. 8a-h. Due to the stepped design of the inner surface 52, the abutment surface 56c, located along the axis of the cup-shaped element closest to the open end 16, is closer to the side wall 14 than the abutment surfaces 56a, 56b located below it. Similarly, the support surface 56b is closer to the side wall 14 than the support surface 56a below it. In one embodiment, bearing surfaces 56a-c are equally spaced apart.

The steps 54a-c also define a plurality of axially extending abutment surfaces 60a-c which extend continuously in the circumferential direction of the inner wall 58 of the cup 310. The abutment surfaces 60a-c serve as abutments 60 for accommodating the inductively heated susceptor elements 26 radially in the cup. 310, for example, so that they are coaxial with the axis of the cup, as will be described below with reference to FIG. 8a h. Due to the stepped design of the inner surface 52, the abutment surface 60c located along the axis of the cup closest to the open end 16 is closer to the side wall 14 than the abutment surfaces 60a, 60b located below it. Similarly, the abutment surface 60b is closer to the side wall 14 than the abutment surface 60a below it.

As shown in FIG. 8a-h, the first layer 24a of plant material aerosol generating material 24 is dosed and deposited in the cup 310 as shown in FIG. 8a and according to step S4 described above. Then, on the deposited first layer 24a of plant material aerosol generating material 24a, the first inductively heated current collector 26a is placed as shown in FIG. 8b and according to step S5 described above. The inductively heated current collector 26a is in contact with the support surface 56a and the abutment surface 60a, and is therefore positioned within the cup 310 at predetermined axial and radial positions.

Next, other layers of aerosol generating plant material 24b-d and other inductively heated current-collecting elements 26b-c are placed in the bowl 310 as shown in FIG. 8c-8g according to step S6 described above.

In particular, the second layer 24b of the plant material aerosol generating material 24 is dosed and deposited in the cup 310 as shown in FIG. 8c, and the second inductively heated current collector 26b is then placed in the cup 310 in contact with the support surface 56b and the abutment surface 60b as shown in FIG. 8d. The second inductively heated current collector 26b has an outer diameter larger than that of the first inductively heated current collector 26a so that it can contact the surfaces 56b, 60b.

Then, a third layer 24c of plant material aerosol generating material 24 is dosed and deposited in the cup 310 as shown in FIG. 8e, and the third inductively heated current collector 26c is then placed in the cup 310 in contact with the support surface 56c and the abutment surface 60c as shown in FIG. 8f. The third inductively heated current collector 26c has an outer diameter larger than the first and second inductively heated current collectors 26a, 26b so that it can contact surfaces 56c,

60c.

The fourth and final layer 24d of plant material aerosol generating material 24 is then dosed and deposited in the cup 310 as shown in FIG. 8g so that the cup 310 is completely filled with vegetable aerosol generating material 24 and inductively heated current collectors 26. Then, the cover member 18 is attached to the flange 20 according to step S7 described above, with the vegetable aerosol generating material 24 secured. raw materials and inductively heated current-collecting elements 26 inside the cup-shaped element 310 and, therefore, to obtain an article that generates an aerosol.

Further in FIG. 9a-9c and 10-10b show an example of a cup 410 that includes a plurality of stepped segments 62 at circumferentially spaced locations within the cup. Each stepped segment 62 contains multiple steps 64a-c.

Steps 64a-c define a plurality of radially extending support surfaces 66a-c that serve as positioning elements 66 for accommodating inductively heated current-collecting elements 26a-c axially in the cup 410, along the axis of the cup, as described above with reference to FIG. 8a-h and as shown in FIG. 10a and 10b. The steps 64a-c also define a plurality of axially extending abutment surfaces 68a-c which serve as abutments 68 for receiving the inductively heated current collectors 26a-c radially in the cup 410, as also described above with reference to FIG. 8a-h and as shown in FIG. 10a and 10b.

Further in FIG. 11a and 11b show an example of a cup 510 in which retractable positioning members 70 are used to accommodate the inductively heated current collectors 26 within the cup 510, as shown in FIG. 12a-i. The positioning members 70 include pins 72 that extend axially through holes 22 in the bottom wall 12 that are designed to allow air to pass through the bottom wall 12 during use of the aerosol generating article in the aerosol generating device. In the example shown, three sets 72a-c of circumferential pins 72 are inserted through holes 22 in the bottom wall 12 such that the ends of the pins 72 in each set 72a-c are located at different axial and radial positions within the cup 510. In the shown example, each set 72a-c contains four pins 72, as best seen in FIG. 11b, but in practice each set could contain two or more pins 72.

After the pins 72 have been inserted through the holes 22 in the bottom wall 12, the first layer 24a of plant material aerosol generating material 24 is dosed and deposited in the cup 310 as shown in FIG. 12a and according to step S4 described above. Then, on the deposited first layer 24a of plant material aerosol generating material 26, the first inductively heated current collector 26a is placed as shown in FIG. 8b and according to step S5 described above. The inductively heated current collector 28a is in contact with the ends of the pins 72 in the first set 72a and with the sides of the pins 72 in the second set 72b. The ends of the pins 72 in the first set 72a serve as abutment surfaces, and the sides of the pins 72 in the second set 72b serve as abutment surfaces, thereby ensuring that the first inductively heated current collector 26a is positioned at predetermined axial and radial positions within the cup 510.

Then, other layers of aerosol-generating plant material 24b-d and other inductively heated current-collecting elements 26b-c are placed in the bowl 510 as shown in FIG. 12c-12g according to step S6 described above. The method is similar to that described above with reference to FIG. 8c-8g and will not be described in more detail.

After the fourth and final layer 24d of plant material aerosol generating material 24 is dispensed and deposited in the cup 510 as shown in FIG. 12g, the closure member 18 is attached to the flange 20 according to step S7 above, with the vegetal aerosol generating material 24 and the inductively heated current collectors 26 secured within the cup 510. Finally, the sets 72a-c of the circumferential pins 72 are pulled from holes 22 in bottom wall 12 as shown in FIG. 12i to form an aerosol generating article.

Further in FIG. 13 is a schematic representation of an apparatus 80 for performing the methods described above. The device 80 includes a cup holding unit 82 for holding multiple cups and first, second and third stations 84, 86, 88. The cup holding unit 82 may include a sliding tray and a transfer unit (not shown) for moving the sliding tray between the first, second and third stations 84, 86, 88, as shown schematically in FIG. 13.

The first station 84 includes a dosing and deposition unit for depositing metered layers of plant material aerosol generating material 24 in the cups held by the cup holding unit 82 . The second station 86 includes a foil receiving unit for

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Claims (18)

a metal foil receiving unit; and a cutting unit, such as a punching unit, for punching the metal foil with the punch to form the annular inductively heated current collectors 26 described above. The second station 86 also includes a hosting unit for accommodating the annular inductively heated current collectors 26 in the cups held by the cup holding unit 82 . The third station 88 includes a closure receiving unit and a closure unit such as an adhesive applicator for applying a layer of adhesive between the closures 18 and the cup flanges 20 to allow the closures 18 to be attached to the cup flanges 20. The device 80 includes a controller (not shown) configured to control the operation of the transfer unit and thereby control the movement of the sliding tray between the first, second and third stations 84, 86, 88. The controller is also configured to control the operation of the first, second and third stations 84, 86, 88. During operation, the cup holding unit 82 loaded with the cups is positioned by the transfer unit at the first station 84 so that the first layer of plant material aerosol generating material 24 can be dosed and deposited in the cups according to step S4 described above. The cup holding unit 82 is then moved by the movement unit under the control of the controller to the second station 86 so that the inductively heated current collectors 26 can be placed in the cups according to step S5 described above. The cup holding unit 82, if necessary, can be moved by the movement unit under the control of the controller back to the first station 84 so that a second layer of aerosol generating material 24 from plant material can be dispensed and deposited into the cups according to step S4 described above. The cup holding unit 82 can be moved back and forth by the movement unit under the control of the controller between the first and second stations 84, 86 as many times as necessary to provide the required number of layers of aerosol generating material 24 from vegetable raw materials in the cups and the required number of inductively heated current-collecting elements 26. Finally, the cup holding unit 82 is moved by the movement unit under the control of the controller to the third station 88, where a cover member 18 is attached to the flange 20 of each of the cups in the cup holding unit 82, thereby obtaining a plurality of aerosol generating articles, which are then can be removed from the cup holding unit 82 . While exemplary embodiments have been described in the preceding paragraphs, it should be understood that various changes may be made to such embodiments without departing from the scope of the appended claims. Thus, the scope and scope of the claims should not be limited by the exemplary embodiments described above. The present invention covers any combination of the above features in all their possible variations, unless otherwise indicated in this description or otherwise there is no clear contradiction to the context. Unless the context clearly implies otherwise, throughout the description and claims, the words contain, containing, etc. should be considered in an inclusive and not in an exclusive or exhaustive sense, that is, in the sense of inclusive, but without limitation. CLAIM 1. A method for manufacturing an aerosol generating article, the method comprising: (i) placing a layer of plant-derived aerosol-generating material in a cup-like element comprising a bottom wall, a side wall, and a circular radial protrusion at the open end; (ii) placing an inductively heated current-collecting element on a placed layer of an aerosol generating material from plant material; (iii) attaching a closure element to said protrusion. 2. The method according to claim 1, characterized in that step (i) includes dosing and dispensing an aerosol generating material from plant materials in the form of granules, pellets, chips, threads, particles, gel, strips, plucked leaves, cut leaves, cut filler, porous material, foam or sheets, or combinations thereof. 3. The method according to claim 1 or 2, characterized in that the method further includes the step of leveling the placed layer of aerosol generating material from plant material. 4. The method according to any one of the preceding claims, characterized in that the inductively heated current collector is obtained by cutting a metal foil to obtain an annular current collector or several annular current collectors. 5. The method according to any of the preceding paragraphs, characterized in that the method includes step (iv), on - 10 042655 where only step (i) or steps (i) and (ii) are repeated. 6. The method according to any one of the preceding claims, characterized in that the cup-shaped element comprises an axis of the cup-shaped element extending between the open end and the bottom wall, and stage (iv) includes placing, respectively, the second and third inductively heated current-collecting elements in the cup-shaped element at equal distances from respectively, the first and second inductively heated current-collecting elements in the direction of the axis of the cup-shaped element. 7. A method according to any one of the preceding claims, characterized in that step (iii) comprises attaching the closure element to said protrusion by gluing or welding. 8. A method according to any one of the preceding claims, characterized in that step (iii) comprises snap-fitting the closure element to said protrusion. 9. A method according to any one of the preceding claims, characterized in that the cup-shaped element comprises a positioning element for receiving an inductively heated current-collecting element and step (ii) comprising positioning the inductively heated current-collecting element with the positioning element. 10. The method according to claim 9, characterized in that the positioning element comprises a support surface extending continuously in the circumferential direction of the inner wall of the cup-shaped element, or at least two separate support surfaces at circumferentially spaced locations inside the cup-shaped element; and step (ii) includes placing the inductively heated current collector on the support surface or surfaces. 11. The method according to claim 9 or 10, characterized in that the cup-shaped element contains the axis of the cup-shaped element, passing between the open end and the bottom wall, and at least two of these positioning elements in different places along the axis of the cup-shaped element, while preferably positioning the element closest to the open end along the axis of the cup is closer to the inner wall of the cup than the other positioning element(s). 12. A method according to any one of claims 9 to 11, characterized in that the cup-shaped element further comprises an abutment extending from the side wall in a radially inward direction. 13. The method according to claim 12, characterized in that the side wall comprises a step which comprises a stop and a positioning element. 14. Device for the manufacture of products that generate aerosol, according to the method according to any one of the previous paragraphs, characterized in that the device contains a holding unit of cup-shaped elements for holding several specified cup-shaped elements; a first station comprising a metering and placement unit for accommodating metered layers of aerosol-generating plant material in cup-shaped elements; a second station comprising a foil receiving unit for receiving the metal foil and a cutting unit for cutting the inductively heated current collectors from the metal foil, the second station further comprising a housing unit for accommodating the inductively heated current collectors in the cup-like elements; and a third station comprising a closure receiving unit and a closure unit for attaching closures to said protrusions of the cup-shaped elements. 15. The device according to claim 14, characterized in that the cutting unit comprises a punching unit for punching with a punch to obtain annular metal foil current collectors. 16. A device according to claim 14 or 15, characterized in that the closure unit comprises an adhesive application device for applying a layer of adhesive between the closure elements and said protrusions of the cup-shaped elements. 17. Apparatus according to any one of claims 14 to 16, characterized in that the cup holding unit comprises a transfer unit for moving the cups between the first, second and third stations. 18. Device according to any one of claims 14 to 17, characterized in that the cup holding unit comprises a sliding tray. -