EA043868B1 - METHOD FOR PROCESSING AEROSOL-GENERATING PRODUCT - Google Patents

Description

Field of technology

The invention generally relates 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 relate in particular to a method for processing an aerosol generating article that uses a non-liquid aerosol generating material and an induction heated current collector.

Prerequisites for creating the invention

Devices that heat, rather than burn, non-liquid aerosol-generating material to produce an inhalable aerosol have become popular with consumers in recent years.

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 utilizes an induction heating system. In such a device, an induction coil is provided with the device and an induction heated current collector is also provided. Electricity is supplied 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 non-liquid aerosol-generating material, and when the aerosol-generating material is heated, an aerosol is generated.

It may be convenient to provide the non-liquid aerosol generating material and the induction heated current collector in the form of an aerosol generating article that can be inserted by a user into the aerosol generating device. Therefore, it is necessary to reduce the problems associated with the disposal of such aerosol-generating products after they have been used or if they do not meet specifications.

The essence of the invention

According to a first aspect of the present invention, there is provided a method for processing an aerosol generating article containing a non-liquid aerosol generating material and an induction heated current collector, the method comprising:

(i) grinding the aerosol generating article to separate the non-liquid aerosol generating material and the induction heated current collector; and (ii) separating the induction heated current collector and the non-liquid aerosol generating material.

According to a second aspect of the present invention, there is provided a method for manufacturing an aerosol generating article, the method including positioning a separated induction heated current collector obtained by the method according to the first aspect adjacent to a subsequent non-liquid aerosol generating material to form an aerosol generating article.

According to a third aspect of the present invention, there is provided a method for manufacturing an aerosol generating article, the method comprising separating an induction heated current collector and a non-liquid aerosol generating material in a used or out-of-spec aerosol generating article; and positioning the separated induction heated current collector adjacent to the next non-liquid aerosol generating material to form an aerosol generating article.

An aerosol generating article is intended for use with an aerosol generating device to heat a non-liquid aerosol generating material without burning the non-liquid aerosol generating material to vaporize at least one component of the aerosol generating material, and thereby generate steam that is cooled and condenses to form an aerosol for inhalation by the user of the aerosol generating device.

In general terms, 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 decreasing the temperature, while an aerosol is a suspension of small solid particles or liquid droplets in the air or other gas. However, it should be noted that the terms aerosol and vapor may be used interchangeably in this specification, particularly with respect to the form of the inhalable medium that is generated for inhalation by the user.

The induction heated pantograph may contain a single pantograph or may contain multiple elements in the form of a pantograph.

The induction heated current collector may comprise at least one of a metal material, a metal alloy material, a ceramic material, a carbon material, and a polymer fiber material coated with the metal material. The induction heated pantograph may comprise, but is not limited to, one or more of aluminum, iron, nickel, stainless steel, and alloys thereof, such as nichrome or cupro-nickel.

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The methods of the present invention help reduce the environmental impact associated with the disposal of a used or non-conforming aerosol generating product by allowing the induction heated current collector to be separated from the non-liquid aerosol generating material and then reused or further recycled. The methods of the present invention may also help reduce manufacturing costs associated with manufacturing an aerosol generating article by reusing the separated induction heated current collector.

Step (i) may include grinding the non-liquid aerosol-generating material. This may facilitate separation of the induction heated current collector and the non-liquid aerosol-generating material.

The induction heated current collector may be a continuous current collector and may comprise at least one of a mesh material and a fibrous fabric material. In some embodiments, the continuous current collector may comprise at least one of a metal mesh laminate and a metal fiber web laminate. Step (i) may include shredding the continuous pantograph. This may facilitate separation of the induction heated current collector and the non-liquid aerosol-generating material.

In embodiments in which the induction heated pantograph comprises multiple elements in the form of a pantograph, the induction heated pantograph may comprise particulate pantograph material. For example, the particulate susceptor material may comprise at least one of a granular material, a powder material, or a fiber material. The particulate susceptor material may be distributed throughout the non-liquid aerosol-generating material. Step (i) may thus involve comminuting only the non-liquid aerosol-generating material.

Step (ii) may include vibrating the crushed aerosol-generating article to separate the induction-heated current collector and the non-liquid aerosol-generating material. The use of vibration may provide a convenient method for separating the induction heated current collector and the non-liquid aerosol-generating material. Step (ii) may include placing the crushed aerosol-generating article on a vibrating screen assembly with holes therein to separate the induction heated susceptor and the non-liquid aerosol-generating material. The openings in the vibrating screen assembly may be sized to permit passage of non-liquid aerosol-generating material and to retain an inductively heated current collector on its holding surface.

Step (ii) may include subjecting the particulate aerosol-generating article to a magnetic force to separate the induction-heated current collector from the non-liquid aerosol-generating material. Since the induction heated current collector contains a magnetic material, it may be convenient to use a magnetic force to separate the induction heated current collector and the non-liquid aerosol generating material. Step (ii) may involve applying magnetic force using a magnet, for example using an electromagnet. The magnet may be positioned above the aerosol-generating shredded article such that the inductively heated current collector is attracted to the magnet in a generally upward direction.

The above examples are not limiting, and step (ii) may, for example, involve using a robotic arm to remove the inductively heated current collector from the non-liquid aerosol-generating material.

Step (ii) may include placing the particulate aerosol-generating article on a vibrating screen assembly having openings sized to permit passage of the non-liquid aerosol-generating material and retaining an inductively heated current collector on its holding surface; and subjecting the induction heated pantograph held on the surface of the vibrating screen unit to a magnetic force to remove the induction heated pantograph from the surface.

The application of both vibration and magnetic force can help ensure reliable separation of the induction heated current collector and the non-liquid aerosol-generating material.

The aerosol generating article may comprise one or more of a paper wrapper and a filter, and step (i) may include shredding the paper wrapper and/or filter. This allows the aerosol generating article to open during the grinding step to allow separation of the induction heated current collector and the non-liquid aerosol generating material. The filter may contain cellulose acetate fibers. The filter may be abutted coaxially aligned with the non-liquid aerosol-generating material.

The holes in the vibrating screen assembly may be sized to retain shredded paper wrapper and/or shredded filter on the holding surface. This allows the paper wrapper and/or filter to be separated from the induction heated current collector and non-liquid

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The method may further include cleaning the separated induction heated current collector. This may allow the separated induction heated current collector to be reused in subsequent production of the aerosol generating product or for another purpose.

The method may further include analyzing the separated induction heated current collector to determine one or more of its mechanical and electrical properties. The result of the analysis can be advantageously used to determine whether the separated induction heated current collector is suitable for reuse in subsequent production of the aerosol generating product or is better suited for another purpose.

The step of analyzing the separated induction heated pantograph may be performed after the step of cleaning the separated induction heated pantograph. This may allow for more reliable analysis.

The non-liquid aerosol-generating material may be any type of solid or semi-solid material. Examples of the types of aerosol-generating solids include powder, granules, grains, shavings, filaments, particles, gel, strips, shredded leaves, cut leaves, cut litter, porous material, foam or sheets. The non-liquid aerosol generating material may contain material of plant origin and, in particular, may contain tobacco. It may advantageously contain reconstituted tobacco.

The non-liquid aerosol generating material may contain an aerosol generating agent. Examples of aerosol-forming substances include polyhydric alcohols and mixtures thereof, such as glycerin or propylene glycol. Typically, the non-liquid aerosol generating material may have an aerosol generating agent content of from about 5 to about 50% on a dry weight basis. In some embodiments, the non-liquid aerosol generating material may have an aerosol generating agent content of from about 10% to about 20% on a dry weight basis, and possibly about 15% on a dry weight basis.

When heated, the non-liquid aerosol-generating material can release volatile compounds. Volatile compounds may include nicotine or flavoring compounds such as tobacco flavoring.

The aerosol generating article may be oblong and may be substantially cylindrical. The aerosol generating article may be substantially in the shape of a stick. The cylindrical shape of the aerosol generating article with its circular cross-section may advantageously facilitate insertion of the aerosol-generating article into a heating compartment of an induction heating unit of the aerosol generating device, for example, in which the induction heating unit includes a helical induction coil having a circular cross-section.

Brief description of graphic materials

Fig. 1 is a schematic cross-sectional view of an example of an aerosol generating system comprising an aerosol generating device and an aerosol generating article;

fig. 2 is a flow chart illustrating an example of a processing method for an aerosol generating article such as illustrated in FIG. 1;

fig. 3 is a schematic side view of an example of an apparatus for processing an aerosol generating article and suitable for performing the example method illustrated in FIG. 2.

Detailed Description of Embodiments

Embodiments of the present invention will now be described by way of example only and with reference to the accompanying drawings.

First with reference to FIG. 1, an example of an aerosol generating system 1 is schematically shown. The aerosol generating system 1 includes an aerosol generating device 10 and an aerosol generating article 24. The aerosol generating device 10 has a proximal end 12 and a distal end 14, and also includes a device housing 16 that contains a power supply 18 and a controller 20 that may be configured to operate at high frequency. The power source 18 typically contains one or more batteries, which may, for example, be inductively rechargeable.

The aerosol generating device 10 is generally cylindrical in shape and includes a generally cylindrical aerosol generating cavity 22, for example in the form of a heating compartment accessible from a proximal end 12 of the aerosol generating device 10. The cylindrical cavity 22 is configured to accommodate a generally cylindrical or rod-shaped aerosol generating article 24 of appropriate shape containing a non-liquid aerosol generating material 26 and an induction heated current collector 28. The induction heated current collector 28 is a single continuous current collector, but in other (not In the illustrated embodiments, the induction heated pantograph 28 may comprise multiple pantograph elements and, for example, may comprise particulate pantograph material.

The aerosol generating article 24 is a disposable article, and the non-liquid aerosol generating material 26 is typically a solid or semi-solid material. Examples of suitable solid aerosol forms include powder, granules, particles, gel, strips, crushed leaves, cut litter, pellets, powder, shavings, filaments, foam and sheets.

The aerosol generating material 26 typically contains material of plant origin, and in particular contains tobacco.

The aerosol generating material 26 typically contains an aerosol generating agent such as glycerin or propylene glycol. Typically, the aerosol generating material 26 may have an aerosol generating agent content of from about 5 to about 50% on a dry weight basis. When heated, the aerosol generating material 26 releases volatile compounds, possibly containing nicotine or flavoring compounds such as tobacco flavoring.

The aerosol generating article 24 has first and second ends 30, 32 and includes a paper wrapper 34 surrounding the aerosol generating material 26. The aerosol generating article 24 also includes a filter 36 at the first end 30 that extends from the device housing 16 at the proximal end 12. The filter 36 functions as a mouthpiece and includes an air-permeable plug, such as one containing cellulose acetate fibers. The aerosol generating article 24 also includes a vapor cooling region 38 located between the aerosol generating material 26 and the filter 36.

The aerosol generating device 10 includes a helical induction coil 40 that has a circular cross-section and extends around a cylindrical cavity 22. The induction coil 40 may be powered by a power supply 18 and a controller 20. The controller 20 includes, among other electronic components, an inverter that configured to convert direct current from power source 18 into high frequency alternating current for induction coil 40. Aerosol generating device 10 also includes one or more air inlet openings 42 in device housing 16 that allow ambient air to flow into cavity 22.

As will be appreciated by one skilled in the art, when the induction coil 40 is energized using the aerosol generating system 1, an alternating and time-varying electromagnetic field is generated. It interacts with the induction heated pantograph 28 and generates eddy currents and/or magnetic hysteresis losses in the induction heated pantograph 28, causing it to heat up. Heat is then transferred from the induction heated current collector 28 to the aerosol generating material 26, such as by conduction, radiation, and convection.

The induction heated pantograph 28 may be in direct or indirect contact with the aerosol generating material 26 such that, when induction heating of the pantograph 28 occurs by the induction coil 40, heat is transferred from the pantograph 28 to the aerosol generating material 26 to heat the aerosol generating material 26 , and thereby obtaining steam. Evaporation of aerosol generating material 26 is aided by the addition of ambient air through air inlets 42. The steam generated by heating the aerosol generating article 26 passes through a steam cooling region 38 where it cools and condenses to form an aerosol that a user of the device 10 can inhale through a filter 36. The flow of air and steam/aerosol passing through the vapor/aerosol generating article 24 aerosol is promoted by the negative pressure created by the user drawing air through the filter 36.

Now with reference to FIG. 2 illustrates a method for processing the aerosol generating article 24 illustrated in FIG. 1, or any other example of an aerosol generating article comprising a non-liquid aerosol generating material 26 and an induction heated current collector 28. As noted above, it may be desirable to recycle a used aerosol generating article 24 in which the aerosol generating material 26 has been consumed. as a result of use, or recycle the aerosol generating product 24 that does not meet specifications.

In the first step S1, the method includes grinding the aerosol generating article 24 to separate the non-liquid aerosol generating material 26 and the induction heated pantograph 28. In the second step S2, the method includes separating the induction heated pantograph 28 and the non-liquid aerosol generating material 26.

In more detail and with reference to FIG. 3, which shows an example of an apparatus for performing the processing method illustrated in FIG. 2, a plurality of used and/or out-of-spec aerosol generating products 24 may be collected and placed on the first conveyor 50. The apparatus may include a grinding unit 52 located above the first conveyor 50, which may be configured to perform method step S1 , described above with reference to FIG. 2, namely to grind the aerosol generating products 24 located on the first conveyor 50 to separate the non-liquid aerosol generating material 26 and the induction heated current collector 28.

In the illustrated and non-limiting example, the grinding unit 52 includes a grinding roller 54, which may include a plurality of circumferentially arranged grinding rollers.

- 4 043868 elements 56 configured to open and crush the aerosol generating products 24 located on the first conveyor 50. The grinding elements 56 may be configured to grind at least the aerosol generating material 26, and possibly shred paper wrappers 34 and filters 36. In the illustrated embodiment, in which the induction heated pantographs 28 are continuous pantographs, the induction heated pantographs 28 are not crushed by the grinding elements 56 and remain intact. In other (not illustrated) embodiments in which the induction heated pantographs 28 are continuous pantographs, the grinding elements 56 may also be configured to grind the induction heated pantographs 28. Alternatively, as noted above, each of the induction heated pantographs 28 may contain particulate susceptor material distributed throughout the aerosol generating material 26 that is not crushed by the grinding elements 56.

The apparatus further includes a vibrating screen unit 60 in the form of a vibrating screen conveyor 62 (second conveyor), which may be configured to perform step S2 of the method described with reference to FIG. 2, namely the separation of the induction heated current collectors 28 and the aerosol generating material 26. In more detail, the vibrating screen conveyor 62 is configured to receive separated components of the aerosol-generating crushed articles 24 from the first conveyor 50, namely, the aerosol-generating crushed material 26, inductively heated current collectors 28, paper wrappers 34, and filters 36. In the illustrated example, the vibrating the screen conveyor 62 contains a plurality of holes (not shown) sized to allow a portion of the non-liquid aerosol-generating material 26 to pass through and to hold on the upper holding surface 64 the remainder of the aerosol-generating material 26, along with induction-heated pantographs 28, paper wrappers 34 and filters 36. As one skilled in the art will appreciate, vibration applied to the vibrating screen conveyor 62 causes the appropriately sized non-liquid aerosol generating material 26 to pass through the openings into a manifold (not shown) that may be located below the vibrating conveyor 62 roar.

The apparatus includes a third conveyor 70 located above and partially overlapping the vibrating screen conveyor 62, which may be configured to perform step S2 of the method described with reference to FIG. 2, namely the separation of the induction heated current collectors 28 and the aerosol generating material 26. In more detail, the third conveyor 70 includes a plurality of electromagnets 72 that can be individually and selectively activated or deactivated. When the individual electromagnet 72 is activated, it becomes magnetized and generates a magnetic force of attraction. Conversely, when the individual electromagnet 72 is deactivated, it enters a demagnetized state and does not generate magnetic attractive force. Activated (magnetized) electromagnets 72 are identified in FIG. 3 by the presence of shading, while deactivated (demagnetized) electromagnets 72 are identified by the absence of shading.

The apparatus is designed so that the electromagnets 72 located directly above the vibrating screen conveyor 62 are activated and become magnetized. This causes the induction heated pantographs 28 on the upper holding surface 64 of the vibrating screen conveyor 62 to be attracted in an upward direction towards the magnetized electromagnets 72. The crushed induction heated pantographs 28 are then carried by the third conveyor 70 and placed on the fourth conveyor 80, which is located under the third conveyor 70 and partially overlaps his. To place the separated induction heated pantographs 28 on the fourth conveyor 40, the electromagnets 72 are simply deactivated to place them in a demagnetized state so that the induction heated pantographs 28 can fall from the third conveyor 70 onto the surface of the fourth conveyor 80.

After the induction heated current collectors 28 have been removed from the upper holding surface 64 of the vibrating screen conveyor 62 by the electromagnets 72 on the third conveyor 70, the aerosol generating material 26, along with the paper wrappers 34 and filters 36 remaining on the upper holding surface 64, is discarded from the end of the vibrating conveyor 62 screen and can be collected for disposal and/or further processing.

Likewise, inductively heated current collectors 28 that were placed on the surface of the fourth conveyor 80 may be ejected from the end of the fourth conveyor 80. Again with reference to FIG. 2, in some embodiments, the induction heated current collectors 28 may be cleaned in step S3, for example, washed to remove deposits and/or other contaminants. Thus, the induction heated current collectors 28 can be analyzed in step S4 to determine their mechanical and/or electrical properties. Depending on the result of the analysis, one or more of the induction heated current collectors 28 may be reused in an optional step S5 for subsequent production of aerosol generating articles, or may be further processed and/or subjected to further processing operations.

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Claims (13)

Although exemplary embodiments have been described in the preceding paragraphs, it should be understood that various modifications may be made to these embodiments without departing from the scope of the appended claims. Thus, the degree of protection and scope of the claims should not be limited by the above-described illustrative embodiments. The present invention embraces any combination of the above-described features in all possible variations thereof, unless otherwise stated herein or otherwise clearly contrary to context. Unless the context clearly indicates otherwise, throughout the entire description and claims the expressions contain, containing, etc. should be considered in an inclusive rather than an exclusive or exhaustive sense, that is, in the sense of including but not limiting. CLAIM 1. A method for processing an aerosol generating article (24) containing a non-liquid aerosol generating material (26) and an induction heated current collector (28), the method comprising: (i) grinding (S1) the aerosol generating article (24) to separate the non-liquid aerosol generating material (26) and the induction heated current collector (28); and (ii) separating (S2) the induction heated current collector (28) and the non-liquid aerosol generating material (26). 2. The method according to claim 1, characterized in that the induction heated pantograph (28) is a continuous pantograph and step (i) includes grinding the continuous pantograph. 3. Method according to claim 1, characterized in that the inductively heated pantograph (28) contains particulate pantograph material. 4. A method according to any of the preceding claims, characterized in that step (ii) includes vibrating the crushed aerosol-generating article (24) to separate the induction-heated current collector (28) and the non-liquid aerosol-generating material (26). 5. The method according to any of the previous claims, characterized in that step (ii) includes placing the crushed aerosol-generating article (24) on a vibrating screen block (60) with holes therein to separate the induction heated current collector (28) and the non-liquid material (26), generating an aerosol. 6. The method according to claim 5, characterized in that the holes in the vibrating screen block (60) are of such dimensions as to allow the passage of non-liquid material (26) generating an aerosol through them, and to hold an induction heated current collector on its holding surface (64) (28). 7. A method according to any of the preceding claims, wherein step (ii) includes exposing the crushed aerosol-generating article (24) to a magnetic force to separate the induction-heated current collector (28) from the non-liquid aerosol-generating material (26). 8. The method according to claim 7, characterized in that step (ii) includes applying a magnetic force using a magnet, preferably using an electromagnet (72). 9. Method according to claim 8, characterized in that the magnet is positioned above the aerosol-generating crushed article (24), so that the inductively heated current collector (28) is attracted to the magnet in a generally upward direction. 10. The method according to any of the previous claims, characterized in that step (ii) includes placing the crushed aerosol-generating article (24) on a vibrating screen block (60) having holes of such dimensions as to allow the passage of non-liquid material (26) ), generating an aerosol, and an induction heated current collector (28) is held on its holding surface (64); and subjecting the induction heated pantograph (28) held on the surface (64) of the vibrating screen unit (60) to a magnetic force to remove the induction heated pantograph (28) from the surface (64). 11. The method according to any of the previous claims, characterized in that the aerosol generating article (24) contains one or more of a paper wrapper (34) and a filter (36), and step (i) includes shredding the paper wrapper (34) and /or filter (36). 12. The method according to claim 11, in the case of any of claims 5, 6 or 10, characterized in that the holes in the vibrating screen block (60) are sized to retain shredded paper wrapper (34) and/or shredded filter (36) on the holding surface (64). 13. The method according to any of the previous claims, characterized in that the method further includes cleaning (S3) of the separated induction heated current collector (28). -