EP4358751A2

EP4358751A2 - Apparatus and methods for manufacturing articles for use as or in an aerosol provision system

Info

Publication number: EP4358751A2
Application number: EP22736336.3A
Authority: EP
Inventors: Jeonghwan Park; Daniel Bray; Gary Fallon; Sam WHIFFEN; Arnold HERHOLDT; James Kim
Original assignee: Nicoventures Trading Ltd
Current assignee: Nicoventures Trading Ltd
Priority date: 2021-06-24
Filing date: 2022-06-22
Publication date: 2024-05-01
Also published as: US20240389637A1; CN117750890A; GB202109084D0; KR20240021977A; JP2024524187A; WO2022269253A3; WO2022269253A2

Abstract

The disclosure relates to apparatus and methods for manufacturing articles for use as or in an aerosol provision system. The disclosure also relates to an apparatus and methods for applying a substance in liquid form to a substrate, such as a sheet material wrapper for an article for use as or in an aerosol provision system. In one embodiment the apparatus comprises a rod forming portion (120) which forms one or more portions of sheet material into a rod. A first applicator (150) applies a first substance in liquid form to the one or more portions of sheet material. An air flow nozzle (140) also supplies a heated flow of air to the rod forming portion (120). In another embodiment, a substance in liquid form is applied to a substrate with an apparatus (210) comprising a conduit (211) and at least one nozzle (212). The conduit and/or nozzle are heated to a temperature greater than the melting point of the substance.

Description

Apparatus and Methods for Manufacturing Articles for Use as or in an Aerosol Provision

System

Technical Field

The present invention relates to apparatus and methods for manufacturing articles for use as or in an aerosol provision system. The present invention also relates to an apparatus and methods for applying a substance in liquid form to a substrate, such as a sheet material wrapper for an article for use as or in an aerosol provision system.

Background

It is known to provide articles for use as or in an aerosol provision system. Aerosol provision systems can be combustible or non-combustible, as defined further below.

Summary of the Invention

In accordance with a first aspect, the invention provides an apparatus for manufacturing a rod for articles for use as or in an aerosol provision system, comprising: a rod forming portion configured to receive one or more portions of sheet material and to form said one or more portions into a rod; a first applicator configured to apply a first substance in liquid form to the one or more portions of sheet material; an air flow nozzle configured to supply a flow of air to the rod forming portion; and a heating arrangement configured to heat the flow of air supplied to the rod forming portion.

In some embodiments, the sheet material may be at least partially formed from at least one of paper, reconstituted tobacco material, tobacco sheets, band cast tobacco, extruded tobacco, tobacco paper, hemp, flax, cotton, polylactic acid, and/or dry gel sheets.

In some embodiments, the apparatus includes a cutter configured to separate the rod into rod segments. The heating arrangement configured to heat the flow of air supplied to the rod forming portion may be located in or adjacent to the apparatus or may be remotely located, such that a heated flow of air is supplied to the apparatus via a supply pipe for example.

The heating arrangement in some embodiments is configured to heat the flow of air supplied to the rod forming portion to a temperature greater than the temperature of the ambient air external to the rod forming portion. In some embodiments, the temperature of the air supplied to the rod forming portion is greater than the melting point of the first substance. For example, the air supplied to the rod forming portion may be heated to a temperature which is at least 5, 10, 15 or 20 degrees C greater than the melting point of the first substance. The temperature of the air supplied to the rod forming portion may be greater than 20 degrees C, 30 degrees C, 40 degrees C, or 50 degrees C. The temperature of the air supplied to the rod forming portion may be in the range of 20-80 degrees C, 30-70 degrees C, 40-70 degrees C, 40-60 degrees C, or about 50 degrees C.

The rod forming portion in some embodiments comprises a funnel having an inlet to receive the one or more portions of sheet material and a narrowing width in the longitudinal direction to form said one or more portions of sheet material into a rod, wherein the air flow nozzle is configured to supply the flow of air to the funnel inlet. The funnel may be considered to have a longitudinal axis. The one or more portions of sheet material may move generally in a feed direction, parallel to the longitudinal axis, from the funnel inlet through the rod forming portion. The air flow nozzle may also be considered to have a longitudinal axis. The air flow nozzle may for example be circular or cylindrical. The air flow nozzle may be configured to supply the air to the funnel in a longitudinal direction, parallel to the longitudinal axis of the funnel. The air flow nozzle may be centred on the longitudinal axis of the funnel so that it is located at the centre of the funnel inlet. The sheet material may enter the funnel inlet around the outside of the air flow nozzle. The funnel in some embodiments comprises a funnel portion and a stem portion, and the apparatus further comprises an air inlet configured to supply a flow of air to the stem portion.

In some embodiments, the apparatus has a heating arrangement configured to heat the flow of air supplied to the stem portion.

The temperature of the air supplied to the stem portion may be greater than the temperature of the ambient air external to the stem portion. The temperature of the air supplied to the stem portion may be any of the temperatures or ranges described above for the air supplied to the rod forming portion (e.g. via the air flow nozzle, to the funnel inlet). The temperature of the air supplied to the stem portion may be the same as or different from the temperature of the air supplied to the rod forming portion.

The apparatus in some embodiments further comprises a second applicator configured to apply a second substance in liquid form to the one or more portions of sheet material in the stem portion, downstream of the first applicator.

In some embodiments, the first and second substances are flavours. The first substance may be menthol and the second substance may be menthol or another flavour.

The first applicator in some embodiments includes a nozzle having an aperture through which the first substance in liquid form is supplied. The nozzle aperture may have a dimension of up to about 10mm, up to about 5.0mm, or up to about 1.0mm. The nozzle aperture may have a dimension in the range of about O.Ol-lOmm, 0.1-5.0mm, 0.2- 1.0mm, 0.5-1.0mm, 0.2-0.8mm, 0.3-0.7mm, or 0.4-0.6mm, or a dimension of about 0.5mm. Dimension may refer to a width of the aperture. When the aperture is circular or substantially circular, dimension may refer to the diameter of the aperture.

The first applicator in some embodiments comprises a shaft extending into the rod forming portion with the nozzle located at the distal end. When the rod forming portion comprises a funnel having a funnel portion and a stem portion, the shaft may extend through the funnel portion and into the stem portion such that the nozzle is located in the stem portion. The shaft may have a length of up to about 1000mm, up to about 500mm or up to about 300mm depending on the application. The shaft may have a length range of about 0.01mm to 1000mm, 0.01-500mm, 0.01-300mm, 10mm to 1000mm, 10mm to 500mm or 10mm to 300mm.

In some embodiments, the longitudinal axis of the shaft is coaxial with the longitudinal axis of the funnel. The longitudinal axis of the shaft may alternatively or in addition be coaxial with the longitudinal axis of the air flow nozzle.

The first applicator may be heated and may include a heating element. In some embodiments the first applicator is heated to a temperature greater than the melting point of the first substance. For example, the first applicator may be heated to a temperature which is at least 5, 10, 15 or 20 degrees C greater than the melting point of the first substance. The first applicator may be heated to a temperature greater than 20 degrees C, 30 degrees C, 40 degrees C, or 50 degrees C. The first applicator may be heated to a temperature in the range of 20-80 degrees C, 30-70 degrees C, 40-70 degrees C, 40-60 degrees C, or about 50 degrees C.

In accordance with a second aspect, the invention provides apparatus for applying a substance in liquid form to a substrate, the apparatus comprising a conduit and at least one nozzle through which the substance in liquid form is supplied to the substrate, wherein the conduit is configured to supply the substance in liquid form to the nozzle, and wherein the nozzle has an aperture with a dimension in the range of O.Ol-lOmm and the conduit and/or nozzle is heated to a temperature greater than the melting point of the substance.

In some embodiments, the nozzle aperture has a dimension in the range of up to about 10mm, up to about 5.0mm, or up to about 1.0mm. The nozzle aperture may have a dimension in the range of about 0.01-10mm, 0.1-5.0mm, 0.2-1.0mm, 0.5-1.0mm, 0.2- 0.8mm, 0.3-0.7mm, or 0.4-0.6mm, or a dimension of about 0.5mm. Dimension may refer to a width of the aperture. When the aperture is circular or substantially circular, dimension may refer to the diameter of the aperture. A plurality of nozzles may be provided, for example 2, 3, 4, 5 or more.

In this aspect, the conduit and/or nozzle is heated to a temperature greater than the melting point of the substance. For example, the conduit and/or nozzle may be heated to a temperature which is at least 5, 10, 15 or 20 degrees C greater than the melting point of the substance. The conduit and/or nozzle may be heated to a temperature greater than 20 degrees C, 30 degrees C, 40 degrees C, or 50 degrees C. The conduit and/or nozzle may be heated to a temperature in the range of 20-80 degrees C, 30-70 degrees C, 40-60 degrees C, or about 50 degrees C.

In some embodiments, the substance applied in liquid form to the substrate is a flavour such as menthol.

The apparatus of the second aspect may be employed to apply a substance in liquid form to a substrate, the substrate then being supplied to an apparatus of the first aspect for wrapping the rod. In that case, the apparatus of the first aspect may further comprise a wrapping section configured to wrap a substrate around the rod, wherein the substrate includes a substance applied by the apparatus of the second aspect.

In accordance with a third aspect, the invention provides apparatus for applying a substance in liquid form to a sheet material wrapper for an article for use as or in an aerosol provision system, the apparatus comprising: at least one nozzle through which the substance in liquid form is supplied to the wrapper; a conduit for supplying the substance to the nozzle; a rod forming portion for receiving aerosol-generating substrate material and forming the aerosol-generating substrate material into a rod; and a wrapping portion for using the sheet material wrapper to wrap the aerosol-generating substrate material.

The substrate employed in the second or third aspects may be or may contain paper.

The invention extends to methods carried out by the apparatuses described above. In accordance with a fourth aspect, the invention provides a method of manufacturing a rod for articles for use as or in an aerosol provision system, comprising: receiving one or more portions of sheet material in a rod forming portion to form said one or more sheet material portions into a rod; applying a first substance in liquid form to the one or more portions of sheet material; and supplying a heated flow of air to the rod forming portion.

The method may further comprise applying a second substance in liquid form to the one or more portions of sheet material, downstream of the first substance. The first substance in liquid form may be supplied by a first applicator which is heated. The first substance may be heated before supply to the first applicator. While the first substance may be a flavour such as menthol, the second substance may be menthol or another flavour. The method may further comprise the step of cutting the rod into separate rod segments.

The invention extends to a rod for articles for use as or in an aerosol provision system manufactured by the method of the fourth aspect and to an article for use as or in an aerosol provision system including such a rod.

In accordance with a fifth aspect, the invention provides a method of applying a substance in liquid form to a substrate with an apparatus comprising a conduit and at least one nozzle, the method comprising: heating the conduit and/or nozzle to a temperature greater than the melting point of the substance; supplying the substance in liquid form from the conduit to the nozzle, and applying the substance in liquid form to the substrate from the nozzle.

In this aspect, the substance applied to the substrate may be a flavour such as menthol and the substrate may be paper or may contain paper.

The method of the fourth aspect may further comprise the step of wrapping a substrate around the rod, wherein the substrate includes a substance applied by the method of the fifth aspect. The method of the fourth aspect may further comprise the step of cutting the rod into separate rod segments after the wrapping step.

The invention extends to a substrate including a substance in liquid form applied by the method of the fifth aspect and to an article for use as or in an aerosol provision system including such a substrate.

In accordance with a sixth aspect, the invention provides a method of applying a substance in liquid form to a sheet material wrapper for an article for use as or in an aerosol provision system, the method employing an apparatus comprising a conduit and at least one nozzle, the method comprising: supplying the substance in liquid form from the conduit to the nozzle; applying the substance in liquid form to the sheet material wrapper from the nozzle; forming a rod of aerosol-generating substrate material; and wrapping the aerosol-generating substrate material rod using the sheet material wrapper.

The invention extends to a sheet material wrapper for an article for use as or in an aerosol provision system including a substance in liquid form applied by the method of the sixth aspect, and to an article for use as or in an aerosol provision system including such a sheet material wrapper.

Brief Description of the Drawings

Embodiments of the invention will now be described by way of example only and with reference to the accompanying drawings, in which:

Fig. 1 shows a schematic perspective view of an apparatus for producing wrapped tobacco rod segments in accordance with a first embodiment of the invention;

Fig. 2 shows a schematic cross-sectional view of a rod forming portion employed in the apparatus of Fig. 1;

Fig. 3 shows an enlarged schematic cross-sectional view of the first applicator nozzle; Fig. 4 shows a schematic side view of an apparatus for applying a substance in liquid form to a substrate in accordance with a second embodiment of the invention; and Fig. 5 shows a schematic plan view of the applicator of Fig. 4.

Detailed Description of Embodiments of the Invention

The aerosol provision system described herein can be implemented as a combustible aerosol provision system or a non-combustible aerosol provision system.

Combustible aerosol provision systems include cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or for make-your-own cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smokable material).

Non-combustible aerosol provision systems release compounds from an aerosol generating material without combusting the aerosol-generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems to generate aerosol using a combination of aerosol-generating materials.

According to the present disclosure, a "combustible" aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is combusted or burned during use in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a combustible aerosol provision system, such as a system selected from the group consisting of a cigarette, a cigarillo and a cigar.

In some embodiments, the disclosure relates to a component for use in a combustible aerosol provision system, such as a filter, a filter rod, a filter segment, a tobacco rod, a spill, an aerosol-modifying agent release component such as a capsule, a thread, or a bead, or a paper such as a plug wrap, a tipping paper or a cigarette paper. According to the present disclosure, a "non-combustible" aerosol provision system is one where a constituent aerosol-generating material of the aerosol provision system (or component thereof) is not combusted or burned in order to facilitate delivery of at least one substance to a user.

In some embodiments, the delivery system is a non-combustible aerosol provision system, such as a powered non-combustible aerosol provision system.

In some embodiments, the non-combustible aerosol provision system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol-generating material is not a requirement.

In some embodiments, the non-combustible aerosol provision system is an aerosol generating material heating system, also known as a heat-not-burn system. An example of such a system is a tobacco heating system.

In some embodiments, the non-combustible aerosol provision system is a hybrid system to generate aerosol using a combination of aerosol-generating materials, one or a plurality of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may comprise, for example, tobacco or a non-tobacco product.

Typically, the non-combustible aerosol provision system may comprise a non-combustible aerosol provision device and a consumable for use with the non-combustible aerosol provision device.

In some embodiments, the disclosure relates to consumables comprising aerosol generating material and configured to be used with non-combustible aerosol provision devices. These consumables are sometimes referred to as articles throughout the disclosure.

In some embodiments, the non-combustible aerosol provision system, such as a non combustible aerosol provision device thereof, may comprise a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source comprises a carbon substrate which may be energised so as to distribute power in the form of heat to an aerosol-generating material or to a heat transfer material in proximity to the exothermic power source.

In some embodiments, the non-combustible aerosol provision system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter and/or an aerosol-modifying agent.

In some embodiments, the consumable for use with the non-combustible aerosol provision device may comprise aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol generation area, a housing, a wrapper, a filter, a mouthpiece, and/or an aerosol-modifying agent.

In some embodiments, the substance to be delivered (such as the first substance and/or the second substance as described herein) may comprise one or more active constituents, one or more flavours, one or more aerosol-former materials, and/or one or more other functional materials.

In some embodiments, the substance to be delivered comprises an active substance.

The active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may for example be selected from nutraceuticals, nootropics, psychoactives. The active substance may be naturally occurring or synthetically obtained. The active substance may comprise for example nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may comprise one or more constituents, derivatives or extracts of tobacco, cannabis or another botanical.

In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin or vitamin B12.

As noted herein, the active substance may comprise or be derived from one or more botanicals or constituents, derivatives or extracts thereof. As used herein, the term "botanical" includes any material derived from plants including, but not limited to, extracts, leaves, bark, fibres, stems, roots, seeds, flowers, fruits, pollen, husk, shells or the like. Alternatively, the material may comprise an active compound naturally existing in a botanical, obtained synthetically. The material may be in the form of liquid, gas, solid, powder, dust, crushed particles, granules, pellets, shreds, strips, sheets, or the like. Example botanicals are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice (liquorice), matcha, mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, clove, cinnamon, coffee, aniseed (anise), basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, beefsteak plant, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab or any combination thereof. The mint may be chosen from the following mint varieties: Mentha Arventis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v. and Mentha suaveolens

In some embodiments, the active substance comprises or is derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is tobacco. In some embodiments, the active substance comprises or derived from one or more botanicals or constituents, derivatives or extracts thereof and the botanical is selected from eucalyptus, star anise, cocoa and hemp.

In some embodiments, the substance to be delivered comprises a flavour.

As used herein, the terms "flavour" and "flavourant" refer to materials which, where local regulations permit, may be used to create a desired taste, aroma or other somatosensorial sensation in a product for adult consumers. They may include naturally occurring flavour materials, botanicals, extracts of botanicals, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice (liquorice), hydrangea, eugenol, Japanese white bark magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (anise), cinnamon, turmeric, Indian spices, Asian spices, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, piment, ginger, coriander, coffee, hemp, a mint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, beefsteak plant, curcuma, cilantro, myrtle, cassis, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chive, carvi, verbena, tarragon, limonene, thymol, camphene), flavour enhancers, bitterness receptor site blockers, sensorial receptor site activators or stimulators, sugars and/or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharine, cyclamates, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath freshening agents. They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, liquid such as an oil, solid such as a powder, or gas.

In some embodiments, the flavour comprises menthol, spearmint and/or peppermint. In some embodiments, the flavour comprises flavour components of cucumber, blueberry, citrus fruits and/or redberry. In some embodiments, the flavour comprises eugenol. In some embodiments, the flavour comprises flavour components extracted from tobacco.

In some embodiments, the flavour comprises flavour components extracted from cannabis.

In some embodiments, the flavour may comprise a sensate, which is intended to achieve a somatosensorial sensation which are usually chemically induced and perceived by the stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or in place of aroma or taste nerves, and these may include agents providing heating, cooling, tingling, numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether and a suitable cooling agent may be, but not limited to eucolyptol, WS-3.

Aerosol-generating material is a material that is capable of generating aerosol, for example when heated, irradiated or energized in any other way. Aerosol-generating material may, for example, be in the form of a solid, liquid or gel which may or may not contain an active substance and/or flavourants. In some embodiments, the aerosol generating material may comprise an "amorphous solid", which may alternatively be referred to as a "monolithic solid" (i.e. non-fibrous). In some embodiments, the amorphous solid may be a dried gel. The amorphous solid is a solid material that may retain some fluid, such as liquid, within it. In some embodiments, the aerosol-generating material may for example comprise from about 50wt%, 60wt% or 70wt% of amorphous solid, to about 90wt%, 95wt% or 100wt% of amorphous solid.

The aerosol-generating material may comprise one or more active substances and/or flavours, one or more aerosol-former materials, and optionally one or more other functional material. The aerosol-former material may comprise one or more constituents capable of forming an aerosol. In some embodiments, the aerosol-former material may comprise one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

The one or more other functional materials may comprise one or more of pH regulators, colouring agents, preservatives, binders, fillers, stabilizers, and/or antioxidants.

The material may be present on or in a support, to form a substrate. The support may, for example, be or comprise paper, card, paperboard, cardboard, reconstituted material, a plastics material, a ceramic material, a composite material, glass, a metal, or a metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or either side of the material.

A consumable is an article comprising or consisting of aerosol-generating material, part or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generation area, a housing, a wrapper, a mouthpiece, a filter and/or an aerosol-modifying agent. A consumable may also comprise an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate aerosol in use. The heater may, for example, comprise combustible material, a material heatable by electrical conduction, or a susceptor.

A susceptor is a material that is heatable by penetration with a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically-conductive material, so that penetration thereof with a varying magnetic field causes induction heating of the heating material. The heating material may be magnetic material, so that penetration thereof with a varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both electrically-conductive and magnetic, so that the susceptor is heatable by both heating mechanisms. The device that is configured to generate the varying magnetic field is referred to as a magnetic field generator, herein.

An aerosol-modifying agent is a substance, typically located downstream of the aerosol generation area, that is configured to modify the aerosol generated, for example by changing the taste, flavour, acidity or another characteristic of the aerosol. The aerosol modifying agent may be provided in an aerosol-modifying agent release component, that is operable to selectively release the aerosol-modifying agent

The aerosol-modifying agent may, for example, be an additive or a sorbent. The aerosol modifying agent may, for example, comprise one or more of a flavourant, a colourant, water, and a carbon adsorbent. The aerosol-modifying agent may, for example, be a solid, a liquid, or a gel. The aerosol-modifying agent may be in powder, thread or granule form. The aerosol-modifying agent may be free from filtration material.

An aerosol generator is an apparatus configured to cause aerosol to be generated from the aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to heat energy, so as to release one or more volatiles from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to cause an aerosol to be generated from the aerosol-generating material without heating. For example, the aerosol generator may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

With reference to Fig. 1, a schematic perspective view of an apparatus 100 for producing a component or consumable for use in a combustible or non-combustible aerosol provision system is shown. An aerosol-generating material or substrate 10 is supplied from a roll 11 to a cutter 110 comprising a plurality of cutter discs 111. The cutter discs are configured with their cutting edges parallel to a feed direction F so that they cut the substrate 10 into a plurality of strands 12.

The plurality of strands 12 are fed into a rod forming portion 120 which will be described in more detail below. The rod forming portion 120 gathers the strands 12 to form a rod 13 in which all of the strands are substantially parallel to the axis of the rod. The rod 13 is fed to a wrapping/cutting section 180 to form a wrapped rod segment 30 comprising a rod segment 14 wrapped by a wrapping material segment 21.

The aerosol-generating substrate 10 may comprise a tobacco or non-tobacco material. The tobacco material may be, for example, but not limited to, reconstituted tobacco, tobacco sheets, band cast tobacco, extruded tobacco, tobacco paper. Alternatively, the aerosol-generating substrate 10 may comprise an aerosol forming material. The aerosol forming material may comprise one or more of glycerine, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-Erythritol, ethyl vanillate, ethyl laurate, a diethyl suberate, triethyl citrate, triacetin, a diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

The material used for wrapping material segment 21 may comprise tobacco paper, paper, laminated paper such as Alufoil or two different types of paper glued together, hemp, flax, cotton, polylactic acid (also referred to as polylactide or PLA) or other specialised biodegradable sheets material or starch based materials, dry gel sheets comprising menthol, glycerol, or another flavour, a plastic sheet, such as, for example, cellophane, natureflex, cellulose acetate, and HDPE, or a combination of one or more materials. The paper may be bleached, unbleached, coated, or treated, and may be impregnated with speciality fibres, such a Lyocell fibres, or with speciality additives, such as Carbon Paper. The material may be 100% non-woven materials, such as Lyocell, Airlaid, Cotton, Rayon, or Biocomponent fibres. Fig. 2 shows a schematic cross-sectional view of rod forming portion 120 in more detail. The strands 12, rod 13 and rod segment 14 have been omitted for clarity.

Rod forming portion 120 comprises a funnel 130 and a wrapping section 181. The cutting section is not shown in this figure. Funnel 130 comprises a funnel portion or inlet cone 131 and a stem portion 132 (also known as a "stuffer jet").

The purpose of the funnel portion 131 is to collect and guide the strands 12 to form a compacting rod around the longitudinal axis L of the funnel 130. The stem portion further compacts the rod 13 to a determined density. The angle of the sides of the funnel portion 131 relative to the longitudinal axis L is greater than the angle of the sides of the stem portion 132.

A flow of air A through the funnel 130 is provided from nozzle 140 to assist with the movement of the strands 12 through the apparatus. Nozzle 140 is generally circular with its axis being coaxial with the longitudinal axis L of the funnel 130. The air is supplied from air line 141.

As discussed above, the flow of air A is heated in order to maintain the substance, such as a flavour, in liquid form as it is being applied to the strands 12 downstream, within the funnel 130. Example values and ranges for the temperature of the air have been given, however one value for use in practice with the application of menthol has been found to be about 50 degrees C.

A first applicator 150 is provided for applying the flavour, such as menthol, to the strands 12 in the funnel 130. First applicator 150 comprises a conduit 151 which receives a supply of liquid flavour from line 152, which may or may not be pressurised, and which supplies the flavour to a hollow shaft 153. Shaft 153 extends from the conduit axially along the longitudinal axis L of the funnel 130 through the funnel portion 131 and terminates in a nozzle 154 at the distal end, which may be located just inside the stem portion 132 in some embodiments. The first applicator, which in some embodiments can be regarded as probe-like, and the heated flow of air A individually or in combination help to reduce contamination of the apparatus and to reduce wastage of the applied substance, such as menthol. The first applicator more accurately directs the liquid to where it needs to be applied, for example to the centre of the forming rod, than techniques such as spraying or atomising for example. By supplying heated air to the funnel 130, the substance is maintained in liquid form which reduces or prevents solidification or crystallisation of the liquid on any surfaces of the apparatus so that a build-up of solid substance is avoided. Any substance which does land on a surface of the apparatus will remain liquid and can therefore run or drip off, possibly back onto the forming rod.

Nozzle 154 is shown in more detail in Fig. 3 and has an aperture 155 through which the menthol is supplied to the strands 12. Aperture 155 has a diameter D indicated by the arrows. Example values and ranges for the diameter of the aperture are discussed above, however one value for use in practice with the application of menthol has been found to be about 0.5mm.

In some embodiments, the nozzle is configured to supply a substantially constant stream of liquid as opposed to a spray or drips. This ensures a substantially continuous application to the forming rod and avoids atomisation. The dose applied by the nozzle to the strands 12 can be controlled by the size of the nozzle and/or the pressure of liquid supplied to the nozzle.

As discussed above, the first applicator 150 is heated. Any, some or all of the conduit 151, shaft 153 and nozzle 154 may be heated. Heating may be provided by an electric heater. Example values and ranges for the temperature of the first applicator or its components are discussed above, however one value for use in practice with the application of menthol has been found to be about 50 degrees C. Heating the first applicator provides control of the temperature of the substance as it leaves the nozzle and helps to maintain the substance in liquid form in the apparatus. The stem portion 132 is provided with air inlets 160 which supply a second flow of air B to the stem portion. This flow of air acts as an "air bearing" to further carry the forming rod through the apparatus. In order to maintain the menthol applied upstream to the strands in liquid form, this air is also heated in some embodiments. As discussed above, this air is may be heated to the same temperature as the air supplied to the funnel portion 131, and may conveniently be supplied from the same source.

A second applicator 170 is provided downstream of the air inlets 160 for applying a second substance in liquid form, such as an additional flavour, to the rod, if desired. Second applicator 170 has a nozzle 171 through which the second substance is applied. The heated air supplied through inlets 160 upstream helps to prevent the second substance from solidifying or crystallising on any surfaces of the apparatus so that a build-up of solid substance is avoided. Also, the heated air supplied through inlets 160 helps to prevent the first substance applied upstream by the first applicator 150 from solidifying or crystallising in this area, either as the first substance contacts the second applicator 170 (or the nozzle 171) or as the first substance contacts the second substance. Again therefore, contamination of the apparatus by means of a solid build-up in this area is reduced or prevented.

Wrapping section 181 receives the formed rod 13 from the stem portion 132 and at this point, wrapping material web 20 is supplied by conveyor 182 to engage with and wrap the rod 13. Subsequently, the combined rod and wrapping material are cut into the finished wrapped rod segment 30, which may then be processed further or packaged.

Some features of the embodiments describe above have been found to be useful in applying a substance in liquid form to a substrate. With reference to Fig. 4, a schematic side view of an apparatus 200 for applying a substance in liquid form, such as a flavour, to a substrate, such as a paper web 22, is shown. Fig. 5 shows a schematic plan view of the apparatus of Fig. 4.

The paper web 22 is tensioned between web tension rollers 201. An applicator 210 is located adjacent the paper web has a conduit 211 and a plurality of nozzles 212. The conduit receives a supply of liquid flavour, such as menthol, from a line (not shown), which may or may not be pressurised, and supplies the liquid flavour to the nozzles for application to the paper web 22 as the web moves past the applicator.

In the example arrangement, the applicator has three nozzles as shown, arranged transversely across the width of the web. The applicator may apply the flavour in a continuous manner, across all or part of the width of the web, or the flavour may be applied intermittently in the longitudinal direction. An example area 23 of applied menthol is shown.

Each nozzle has an aperture (not shown). Example values and ranges for the diameter of the aperture are discussed above, however one value for use in practice with the application of liquid menthol has been found to be about 0.5mm.

Either or both of the conduit 211 and nozzles 212 may be heated. Heating may be provided by an electric heater. Example values and ranges for the temperature of the conduit or nozzles are discussed above, however one value for use in practice with the application of menthol has been found to be about 50 degrees C.

The treated paper web 22 of this embodiment of the invention may be employed as the wrapping material web 20 of the previous embodiments.

The various embodiments described herein are presented only to assist in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments only, and are not exhaustive and/or exclusive. It is to be understood that advantages, embodiments, examples, functions, features, structures, and/or other aspects described herein are not to be considered limitations on the scope of the invention as defined by the claims or limitations on equivalents to the claims, and that other embodiments may be utilised and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of, appropriate combinations of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions not presently claimed, but which may be claimed in future.

Claims

1. Apparatus for manufacturing a rod for articles for use as or in an aerosol provision system, comprising: a rod forming portion configured to receive one or more portions of sheet material and to form said one or more portions into a rod; a first applicator configured to apply a first substance in liquid form to the one or more portions of sheet material; an air flow nozzle configured to supply a flow of air to the rod forming portion; and a heating arrangement configured to heat the flow of air supplied to the rod forming portion.

2. The apparatus of claim 1, wherein the rod forming portion comprises a funnel having an inlet to receive the one or more portions of sheet material and a narrowing width in the longitudinal direction to form said one or more portions of sheet material into a rod, wherein the air flow nozzle is configured to supply the flow of air to the funnel inlet.

3. The apparatus of claim 2, wherein the funnel comprises a funnel portion and a stem portion and the apparatus further comprises an air inlet configured to supply a flow of air to the stem portion.

4. The apparatus of claim 3, further comprising a heating arrangement configured to heat the flow of air supplied to the stem portion.

5. The apparatus of claim 3 or 4, wherein the apparatus further comprises a second applicator configured to apply a second substance in liquid form to the one or more portions of sheet material in the stem portion, downstream of the first applicator.

6. The apparatus of any of claims 1 to 5, wherein the first applicator includes a nozzle having an aperture through which the first substance in liquid form is supplied.

7. The apparatus of claim 6, wherein the aperture has a dimension in the range of 0.01-10mm, 0.1-5. Omm, 0.2-1. Omm, 0.2-0.8mm, 0.3-0.7mm, or 0.4-0.6mm, or a dimension of about 0.5mm.

8. The apparatus of claim 6 or 7, wherein the first applicator comprises a shaft extending into the rod forming portion with the nozzle located at the distal end.

9. The apparatus of claim 8, wherein the rod forming portion comprises a funnel having a funnel portion and a stem portion, and the shaft extends through the funnel portion and into the stem portion such that the nozzle is located in the stem portion.

10. The apparatus of claim 9, wherein the longitudinal axis of the shaft is coaxial with the longitudinal axis of the funnel.

11. The apparatus of any of claims 8 to 10, wherein the longitudinal axis of the shaft is coaxial with the longitudinal axis of the air flow nozzle.

12. The apparatus of any of claims 1 to 11, wherein the first applicator is heated.

13. The apparatus of claim 12, wherein the first applicator includes a heating element.

14. The apparatus of any of claims 1 to 13, wherein the first substance is menthol.

15. The apparatus of claim 5, wherein the second substance is menthol or another flavour.

16. Apparatus for applying a substance in liquid form to a substrate, the apparatus comprising a conduit and at least one nozzle through which the substance in liquid form is supplied to the substrate, wherein the conduit is configured to supply the substance in liquid form to the nozzle, and wherein the nozzle has an aperture with a dimension in the range of 0.01-10mm and the conduit and/or nozzle is heated to a temperature greater than the melting point of the substance.

17. The apparatus of claim 16, wherein the nozzle aperture has a dimension in the range of 0.1-5. Omm, 0.2-1. Omm, 0.2-0.8mm, 0.3-0.7mm, or 0.4-0.6mm, or a dimension of about 0.5mm.

18. The apparatus of claim 16 or 17, comprising a plurality of nozzles.

19. The apparatus of any of claims 16 to 18, wherein the conduit and/or nozzle is heated to a temperature greater than 20 degrees C, 30 degrees C, 40 degrees C, or 50 degrees C.

20. The apparatus of any of claims 16 to 19, wherein the conduit and/or nozzle is heated to a temperature in the range of 20-80 degrees C, 30-70 degrees C, 40-60 degrees C, or is about 50 degrees C.

21. The apparatus of any of claims 16 to 20, wherein the substance is menthol.

22. The apparatus of any of claims 1 to 15, wherein the apparatus further comprises a wrapping section configured to wrap a substrate around the rod, wherein the substrate includes a substance applied by the apparatus of any of claims 16 to 21.

23. Apparatus for applying a substance in liquid form to a sheet material wrapper for an article for use as or in an aerosol provision system, the apparatus comprising: at least one nozzle through which the substance in liquid form is supplied to the wrapper; a conduit for supplying the substance to the nozzle; a rod forming portion for receiving aerosol-generating substrate material and forming the aerosol-generating substrate material into a rod; and a wrapping portion for using the sheet material wrapper to wrap the aerosol generating substrate material.

24. The apparatus of any of claims 16 to 23, wherein the substrate is or contains paper.

25. A method of manufacturing a rod for articles for use as or in an aerosol provision system, comprising: receiving one or more portions of sheet material in a rod forming portion to form said one or more sheet material portions into a rod; applying a first substance in liquid form to the one or more portions of sheet material; and supplying a heated flow of air to the rod forming portion.

26. The method of claim 25, wherein the temperature of the air supplied to the funnel is greater than the melting point of the first substance.

27. The method of claim 25 or 26, wherein the temperature of the air supplied to the funnel is greater than 20 degrees C, 30 degrees C, 40 degrees C, or 50 degrees C.

28. The method of any of claims 25 to 27, wherein the temperature of the air supplied to the funnel is in the range of 20-80 degrees C, 30-70 degrees C, 40-60 degrees C, or is about 50 degrees C.

29. The method of any of claims 25 to 28, wherein the rod forming portion comprises a funnel having an inlet to receive the one or more portions of sheet material and a narrowing width in the longitudinal direction to form said one or more portions of sheet material into a rod, wherein the heated flow of air is supplied to the funnel inlet.

30. The method of claim 29, wherein the funnel comprises a funnel portion and a stem portion and the method further comprises supplying a flow of air to the stem portion.

31. The method of claim 30, wherein the temperature of the air supplied to the stem portion is greater than the temperature of the ambient air external to the stem portion.

32. The method of claim 30 or 31, wherein the temperature of the air supplied to the stem portion is the same as the temperature of the air supplied to the rod forming portion.

33. The method of any of claims 30 to 32, wherein the method further comprises applying a second substance in liquid form to the one or more portions of sheet material in the stem portion, downstream of the first substance.

34. The method of any of claims 25 to 33, wherein the first substance in liquid form is supplied by a first applicator, the method further comprising the step of heating the first applicator.

35. The method of claim 34, wherein the first applicator is heated to a temperature greater than the melting point of the first substance.

36. The method of claim 34 or 35, wherein the first applicator is heated to a temperature greater than 20 degrees C, 30 degrees C, 40 degrees C, or 50 degrees C.

37. The method of any of claims 34 to 36, wherein the first applicator is heated to a temperature in the range of 20-80 degrees C, 30-70 degrees C, 40-60 degrees C, or is about 50 degrees C.

38. The method of any of claims 34 to 37, further comprising the step of heating the first substance before supply to the first applicator.

39. The method of any of claims 25 to 38, wherein the first substance is menthol.

40. The method of claim 33, wherein the second substance is menthol or another flavour.

41. The method of any of claims 25 to 40, further comprising the step of cutting the rod into separate rod segments.

42. A method of applying a substance in liquid form to a substrate with an apparatus comprising a conduit and at least one nozzle, the method comprising: heating the conduit and/or nozzle to a temperature greater than the melting point of the substance; supplying the substance in liquid form from the conduit to the nozzle, and applying the substance in liquid form to the substrate from the nozzle.

43. The method of claim 42, wherein the conduit and/or nozzle is heated to a temperature greater than 20 degrees C, 30 degrees C, 40 degrees C, or 50 degrees C.

44. The method of claim 42 or 43, wherein the conduit and/or nozzle is heated to a temperature in the range of 20-80 degrees C, 30-70 degrees C, 40-60 degrees C, or is about 50 degrees C.

45. The method of any of claims 42 to 44, wherein the apparatus comprises a plurality of nozzles.

46. The method of any of claims 42 to 45, wherein the substance is menthol.

47. The method of any of claims 42 to 46, wherein the substrate is or contains paper.

48. The method of any of claims 25 to 41, further comprising the step of wrapping a substrate around the rod, wherein the substrate includes a substance applied by the method of any of claims 42 to 47.

49. The method of claim 48, further comprising the step of cutting the rod into separate rod segments after the wrapping step.

50. A method of applying a substance in liquid form to a sheet material wrapper for an article for use as or in an aerosol provision system, the method employing an apparatus comprising a conduit and at least one nozzle, the method comprising: supplying the substance in liquid form from the conduit to the nozzle; applying the substance in liquid form to the sheet material wrapper from the nozzle; forming a rod of aerosol-generating substrate material; and wrapping the aerosol-generating substrate material rod using the sheet material wrapper.

51. A rod for articles for use as or in an aerosol provision system manufactured by the method of any of claims 25 to 41.

52. An article for use as or in an aerosol provision system including the rod of claim 51.

53. A substrate including a substance in liquid form applied by the method of any of claims 42 to 49.

54. An article for use as or in an aerosol provision system including the substrate of claim 53.

55. A sheet material wrapper for an article for use as or in an aerosol provision system including a substance in liquid form applied by the method of claim 50.

56. An article for use as or in an aerosol provision system including the sheet material wrapper of claim 55.