RU2811897C2 - Induction heated aerosol generator containing segment of aerosol-generating rod (options) and method for manufacturing such segments of aerosol-generating rod - Google Patents

Abstract

FIELD: aerosol-generating systems.

SUBSTANCE: proposed group of inventions relates to an induction heated aerosol generating article for use with a device that generates an aerosol by induction heating, as well as to a method for manufacturing induction heated segments of an aerosol generating rod. The product contains a rod segment that forms an aerosol, having a cylindrical shape with a constant external cross-section. The aerosol-generating rod segment comprises an elongated susceptor element and an aerosol-generating substrate surrounding the susceptor element so as to form a cylindrical shape of the rod segment. The susceptor element comprises at least one narrower portion at each extreme end of the susceptor element and/or at least one narrower portion between both extreme ends of the susceptor element, wherein the corresponding narrower portion has a reduced cross-section compared to one or more portions along the length of the current-receiving element, having the maximum cross-section of the current-receiving element. A method of producing induction heated aerosol-generating rod segments in a continuous rod forming process involves using a continuous pantograph profile having a reduced cross-section at spaced locations along its length.

EFFECT: improved placement of the current-receiving element inside the substrate to ensure sufficient heating of the substrate and ensure sufficient consistency of the product.

18 cl, 17 dwg

Description

The present invention relates to an induction heated aerosol generating article comprising an aerosol generating rod segment, as well as a method for making such aerosol generating rod segments.

Aerosol-generating products containing an aerosol-generating substrate capable of generating a respirable aerosol when heated are well known (see, for example, the technical solutions disclosed in WO 2016184928 A1, WO 2015176898 A1 or WO 2017068094 A1). To heat the substrate, the article may be placed in an aerosol generating device containing an electrical heater. The heater may be an induction heater comprising an induction source. The induction source is configured to generate an alternating electromagnetic field that induces at least one of eddy currents generating heat or hysteresis losses in the current collecting element. The current collecting element itself may be an integral part of the product and is located so as to be in thermal proximity or in direct physical contact with the substrate that is to be heated. In particular, the product may comprise - among other elements - an aerosol-forming rod segment having a cylindrical shape with a constant cross-section. Within the rod segment, the aerosol-forming substrate surrounds the current collecting element so as to form a cylindrical shape of the segment. Such rod segments can be produced by a continuous rod formation process in which a continuous pantograph profile and a substrate web containing the aerosol-forming substrate are positioned relative to each other. The substrate web is then assembled around the susceptor profile to form a continuous rod-like core, which is ultimately cut into individual aerosol rod segments having a specific length.

It has been discovered that the position of the susceptor element within the aerosol-forming substrate can deviate from its desired position, for example, twist or move from the central position of the susceptor element relative to the central axis of the aerosol-forming rod segment. Such deviations may be caused by mechanical stresses during the manufacture of the rod segments, which cause the current-receiving element to shift from its desired position within the aerosol-forming substrate. In particular, when cutting a continuous rod-shaped strand into individual aerosol-forming rod segments as described above, the profile of the pantograph may be affected by the forces applied by the cutting tools, which may adversely affect placement accuracy. In addition, the current collector element can also move slowly within the aerosol-forming substrate, even after manufacturing processes. Moreover, positioning a continuous pantograph profile relative to the substrate web is sometimes a labor-intensive task due to the mechanical rigidity of the pantograph profile. It has also been discovered that particles can be cut off from the cutting tools and/or from the current collector during the cutting process and are unfavorably transported into the aerosol-forming substrate. In addition, it has been discovered that some elements of the aerosol generating product located in thermal proximity or thermal contact with the current collector may be adversely affected by overheating, in particular, charring.

However, the accuracy and stability of the placement of the current collector element within the rod segment is key to ensure sufficient heating of the substrate and thus to ensure sufficient consistency of the product.

Accordingly, it would be advantageous to have induction heated aerosol generating articles comprising an aerosol generating rod with a current collecting element, as well as a method for making such rod segments, that solve at least one of the above problems inherent in prior art solutions. In particular, it would be advantageous to have induction heated aerosol generating articles comprising an aerosol generating rod segment with a susceptor element and a method of manufacturing such rod segments that provides improved accuracy and stability of susceptor placement.

The present invention provides an induction heated aerosol generating article for use with an induction heating aerosol generating device. The article comprises an aerosol-forming rod segment, preferably having a cylindrical shape with a constant cross-section, in particular a constant outer cross-section forming a cylindrical shape. The aerosol generating rod segment contains an elongated current collecting element and an aerosol generating substrate surrounding the current collecting element. Preferably, the aerosol-forming substrate surrounds the current collecting element so as to form, in other words, shape or fill, in particular completely fill the cylindrical shape of the rod segment. The current collecting element comprises at least one narrower part along the length of the current collecting element, in particular at least one narrower part at each extreme end of the current collecting element and/or at least one narrower part between both extreme ends of the current collecting element. The corresponding narrower portion has a reduced cross-section compared to other portions along the length of the current collector, in particular compared to one or more portions of the current collector along the length of the current collector having a maximum cross-section of the current collector. Accordingly, the cross-section of the elongated susceptor element along its length is reduced, in other words, it is smaller compared to the cross-section, in particular the maximum cross-section of the elongated susceptor element at one or more other positions along its length. Preferably, the cross-section of the elongated susceptor element is at least in a corresponding position at each extreme end of the susceptor element and/or at least in a position between two extreme ends of the susceptor element reduced, in other words, it is smaller compared to the cross-section, in particular the maximum cross-section cross-section of the elongated current-receiving element at one or more other positions along its length.

These are some of the narrower parts with a reduced cross-section that can form recesses filled with an aerosol-forming substrate when the rod segment is manufactured. Advantageously, this provides better fixation of the current-receiving element within the aerosol-forming substrate, both in the direction along the central axis of the rod segment and in the direction across the central axis of the rod segment. As a consequence, the accuracy and stability of the placement of the pantograph profile inside the aerosol-forming substrate is significantly improved.

In addition, a susceptor element comprising one or more reduced cross-sectional portions exhibits reduced mechanical stiffness compared to susceptor elements having a constant cross-section. Advantageously, lower mechanical stiffness facilitates positioning of the current collector relative to the aerosol-forming substrate when producing the aerosol-forming rod. As a result, the accuracy of placement of the current collector in the substrate is further improved.

Moreover, when using a current-receiving element containing one or more parts with a reduced cross-section, a smaller part of the current-receiving element is in thermal proximity or in thermal contact with elements of the aerosol-generating product that need to be protected from overheating, in particular from charring. For example, the aerosol cooling element of the aerosol generating article may use PLA (polylactic acid) foil.

As used herein, the terms “narrower portion” and “reduced cross-section” are to be understood as reducing the size of the cross-sectional profile of the current collecting element in at least one transverse direction, in particular perpendicular to the length of the elongated current collecting element. In particular, a "reduced cross-section" comprises a reduced cross-sectional area of at least one narrower portion.

One or more portions of the susceptor element having a maximum cross-section of the susceptor element may extend over a major portion of the length of the susceptor element. In particular, one or more parts of the current collecting element having a maximum cross-section of the current collecting element may cover at least 70%, in particular at least 75%, preferably at least 80%, most preferably at least 85% or at least 90% of the length of the current collecting element. Of course, one or more parts of the current collecting element having a maximum cross-section of the current collecting element can cover less than 75%, in particular at least 15%, or at least 20%, or at least 25%, or at least 50 % of the length of the current-receiving element.

Likewise, the at least one narrower portion may span a maximum of 30%, in particular a maximum of 25%, preferably a maximum of 20%, most preferably a maximum of 15% or a maximum of 10% of the length of the current collecting element. Of course, at least one narrower part can cover more than 30%, in particular at most 85%, or at most 80%, or at most 75%, or at most 50%, of the length of the current collecting element.

Advantageously, the cross-sectional area of at least one narrower part is at most 90%, in particular at most 85%, or at most 80%, or at most 75%, or at most 70%, or at most 65%, or at most 60%, or at most 55% , or maximum 50%, or maximum 45%, or maximum 40%, or maximum 35%, or maximum 30%, or maximum 25%, or maximum 20%, preferably maximum 15% or maximum 10% of the maximum cross-sectional area, in particular, above at least 1%, preferably above at least 2%, or at least 5%, or at least 10%, or at least 15%, or at least 20%, or at least 25%, or at least 30%, or at least 35%, or at least 40%, or at least 45%, or at least 50%, or at least 55%, or at least 60 %, or at least 65%, or at least 70%, or at least 75%, or at least 80% of the length of the elongated current collecting element. Any of the above-mentioned relative values of the cross-sectional area of the at least one narrower portion may be combined with any of the above-mentioned relative values of the lengthwise extent of the at least one narrower portion along the lengthwise extent of the elongated current collecting element.

For example, the cross-sectional area of the at least one narrower portion is at most 50%, in particular at most 30%, preferably at most 15% of the cross-sectional area of the maximum cross-section over at least 1% of the length of the elongated current collecting element.

Likewise, the cross-sectional area of the at least one narrower portion is at most 90%, in particular at most 75%, preferably at most 50% of the maximum cross-sectional area over at least 5% of the length of the elongated current collecting element.

Alternatively, the cross-sectional area of the at least one narrower portion is at most 80%, in particular at most 75%, preferably at most 50% of the cross-sectional area of the maximum cross-section over at least 80% of the length of the elongated current collector element with a reduced cross-section along at least one narrower part.

The cross-sectional area of the maximum cross-section is in the range from 0.1 mm ² (square millimeters) to 5.0 mm ² (square millimeters), in particular from 0.15 mm ² (square millimeters) to 3 mm ² (square millimeters) , preferably from 0.2 mm ² (square millimeter) to 1.0 mm ² (square millimeter), most preferably from 0.2 mm ² (square millimeter) to 0.5 mm ² (square millimeter).

Preferably, the minimum cross-sectional size of the at least one narrower part is at most 90%, in particular at most 85%, or at most 80%, or at most 75%, or at most 70%, or at most 65%, or at most 60%, or maximum 55%, or maximum 50%, or maximum 45%, or maximum 40%, or maximum 35%, or maximum 30%, or maximum 25%, or maximum 20%, preferably maximum 15% or maximum 10% of the maximum section size elongated current-receiving element in other parts. In this case, the maximum section size is measured in the same direction as the minimum section size, across the length of the elongated current-receiving element. In other words, the minimum size of the reduced cross-section of the current collecting element is a maximum of 75%, in particular, a maximum of 50%, preferably a maximum of 30% of the maximum cross-sectional size of the elongated current collecting element at other positions along the length of the current collecting element, the maximum size of the non-reduced cross-section in other positions, measured in the same direction as the minimum dimension of the reduced cross-section extending transversely, in particular perpendicular to the length of the elongated pantograph. Preferably, the minimum size and maximum size are measured in a direction along the depth extent of the recess formed by the narrower portions of the current collecting element having a reduced cross-section.

The minimum cross-sectional size of the at least one narrower part may be in the range from 55% to 90%, in particular from 60% to 90%, preferably from 70% to 90%, even more preferably from 75% to 90% of the maximum size sections of the elongated current collecting element in one or more parts having a maximum cross-section, wherein the maximum cross-sectional dimension is measured in the same direction as the minimum cross-sectional dimension extending transversely to the length of the elongated current collecting element.

As mentioned above, some of the narrower portions with a reduced cross-section may define one or more lateral recesses or, conversely, may be formed by one or more lateral recesses.

Accordingly, the current collecting element may comprise at least one lateral recess in at least one narrower portion at each extreme end of the current collecting element and/or in at least one narrower portion between both extreme ends of the current collecting element. In other words, the current collecting element may comprise at least one side recess at at least some position between both extreme ends and/or at least one side recess at a corresponding position at each extreme end of the current collecting element. Advantageously, these one or more lateral recesses comprise edges facing in directions parallel and/or transverse, in particular perpendicular, to the length of the elongated current-receiving element. Thanks to these edges, the susceptor element and the substrate filling the recesses are mutually engaged, thus the susceptor element is fixed in the surrounding substrate, forming an aerosol.

It should be noted at this point that at least one narrower portion or recess located between both extreme ends of the current collecting element advantageously comprises at least two edges facing in opposite directions parallel to the lengthwise extension of the elongated current collecting element. Likewise, the at least one narrower portion or recess at one extreme end advantageously comprises at least one edge facing in a longitudinal direction that is opposite to the direction in which the at least one edge of the at least one narrower portion faces. parts or indentations at the other extreme end. Thanks to these opposing edges, the current collecting element is advantageously fixed in both directions parallel to its length.

Preferably, at least one narrower part has some symmetry, which is advantageous with respect to symmetrical fixation of the current collecting element in the aerosol-forming substrate. Accordingly, the current collecting element may include at least two lateral recesses on opposite sides of the elongated current collecting element in at least one narrower portion between both extreme ends of the current collecting element. Additionally or alternatively, the current collecting element may comprise at least two lateral recesses on opposite sides of the elongated current collecting element at at least one of both extreme ends of the current collecting element, in other words, in at least one of the narrower portions at the extreme ends of the current collecting element element. Preferably, the susceptor element comprises at least two lateral recesses on opposite sides of the elongated susceptor element at each extreme end, in other words, in corresponding narrower portions at each extreme end.

Likewise, the at least one side recess may extend entirely along the circumference of the elongated current collecting element across its length. This is also advantageous with regard to the symmetrical fixation of the current collecting element. For example, the at least one side recess may be a groove or recess extending around the entire circumference of the current collecting element across its length.

The shape of the at least one lateral recess - as seen in a longitudinal section of the current collector element along its length - is one of: at least partially trapezoidal, at least partially triangular, at least partially wedge-shaped, curved, at least partially circular in particular semi-circular, at least partially oval, in particular semi-oval, at least partially rectangular or polygonal. For example, the shape of one side recess - as seen in a longitudinal section of the current collecting element along its length - may be a section of a circle, such as a semicircle, or a section of an oval, such as a semi-oval, or a triangle, or a rectangle, or a square, or section of a trapezoid, or trapezoid.

The shape of the at least one side recess may also correspond to a combination of at least two of the above mentioned shapes. For example, the shape of one side recess - as seen in a longitudinal section of the current collector element along its length - may be a combination of a circle and a rectangle section.

In general, the elongated pantograph can be of any shape. For example, the pantograph element may be a pantograph strip, wherein the width of the pantograph strip is greater than the thickness of the pantograph strip. Preferably, the length of the pantograph strip substantially matches the length of the aerosol-forming rod segment. The length of the pantograph strip can, for example, be in the range from 8 millimeters to 16 millimeters, in particular from 10 millimeters to 14 millimeters, preferably 12 millimeters. The width of the pantograph strip in one or more parts that are not at least one narrower part can, for example, be in the range from 2 millimeters to 6 millimeters, in particular from 4 millimeters to 5 millimeters. The thickness of the pantograph strip in the one or more portions that are not at least one narrower portion is preferably in the range of 0.03 millimeters to 0.15 millimeters, more preferably 0.05 millimeters to 0.09 millimeters. Strip-shaped susceptor elements are advantageous because they can be easily manufactured at low cost. Preferably, the pantograph strip has one of a rectangular or oval cross-sectional profile in one or more portions that are not at least one narrower portion at each extreme end of the pantograph element and/or that are not at least one narrower portion between both extreme ends current-receiving element.

Alternatively, the current collector element may be a current collector rod. The rod-shaped current-receiving element advantageously enables symmetrical heating of the surrounding aerosol-forming substrate. Preferably, the pantograph rod has one of a rectangular, square, oval, round, triangular, star-shaped or polygonal cross-sectional profile in portions that are not at least one narrower portion at each extreme end of the pantograph element and/or between both extreme ends of the pantograph element. Similarly, the pantograph rod has a cross-sectional profile that is shaped like the Latin letters “T”, “X”, “U”, “C” or “I” (with or without serifs). In the case of a circular cross-section, the pantograph rod preferably has a width or diameter in the range of 1 millimeter to 5 millimeters.

Preferably, the length of the current collecting element substantially corresponds to the length of the aerosol-forming rod segment. The length of the current collecting element can, for example, be in the range from 8 millimeters to 16 millimeters, in particular from 10 millimeters to 14 millimeters, preferably 12 millimeters. Moreover, the current collecting element is surrounded by an aerosol-forming substrate along its entire length. In particular, the aerosol-forming substrate surrounds the current collecting element so as to form a cylindrical shape of the rod segment. In other words, the aerosol-forming substrate can completely fill the volume of the cylindrical rod segment, in addition to the volume occupied by the current collector element.

The article may further comprise various elements in addition to the aerosol rod segment: a support element containing a central air passage, an aerosol cooling element, and a filter element. The filter element preferably functions as a mouthpiece. As used herein, the term “mouthpiece” refers to the portion of the product that is placed in the user's mouth to directly inhale the aerosol from the product. The user of the aerosol-generating product may take a puff. Any of these elements, or any combination thereof, may be arranged in series with respect to the aerosol-forming rod segment. Preferably, the aerosol generating rod is located at the distal end of the article. Likewise, the filter element is preferably located at the proximal end of the product. In addition, these elements may have the same external cross-section as the aerosol rod segment.

The article may further comprise a wrapper surrounding at least a portion of the various segments and elements mentioned above so as to hold them together and maintain the desired cross-sectional shape of the article. Preferably, the wrapper forms at least part of the outer surface of the article. For example, the wrapper may be a paper wrapper, in particular a paper wrapper made from cigarette paper. Alternatively, the wrapper may be a foil, for example made from plastic. The wrapper may be fluid permeable to allow vaporized aerosol-forming substrate to be released from the article or to allow air to be drawn into the article through its circumference. In addition, the wrapper may contain at least one volatile substance that is subject to activation and release from the wrapper upon heating. For example, the wrapper may be impregnated with a flavor volatile.

Preferably, the induction heated aerosol generating article of the present invention has a circular or elliptical or oval cross-section. However, the product may also have a square, or rectangular, or triangular, or polygonal cross-section.

Particularly with respect to cross-sections of a susceptor element having a well-defined width and/or thickness, in particular rectangular, square, oval or circular cross-sections, the present invention provides an induction heated aerosol generating article for use with an aerosol generating device by induction heating. The article comprises an aerosol-forming rod segment, preferably having a cylindrical shape with a constant cross-section, in particular a constant outer cross-section forming a cylindrical shape. The aerosol-generating rod segment includes an elongated susceptor element, such as a susceptor strip or susceptor rod, and an aerosol-generating substrate surrounding the susceptor element. Preferably, the aerosol-forming substrate surrounds the current collecting element so as to form, in other words, shape or fill, in particular completely fill the cylindrical shape of the rod segment. The current collecting element comprises at least one narrower part along the length of the current collecting element, in particular at least one narrower part at each extreme end of the current collecting element and/or at least one narrower part between both extreme ends of the current collecting element. The corresponding narrower portion has a reduced width and/or reduced thickness compared to other portions along the length of the current collector, in particular compared to one or more portions of the current collector along the length of the current collector having a maximum cross-section of the current collector.

All of the features and advantages described above with respect to an aerosol generating article comprising a current collecting element which has at least one narrow section with a reduced cross-section also apply to the above mentioned aerosol generating article comprising a current collecting element which has at least one a narrow part with reduced width and/or thickness. Therefore, these features and benefits will not be repeated.

The present invention also relates to an aerosol generating system comprising an induction heated aerosol generating article according to the present invention and as described herein. The system further includes a device that generates an aerosol by induction heating for use with the product. The aerosol generating device contains a receiving cavity for at least partial placement of the product therein. The aerosol-generating device further comprises an induction source including an induction coil for generating an alternating, in particular high-frequency, electromagnetic field inside the receiving cavity for the purpose of inductively heating the current-receiving element of the product when the product is placed in the receiving cavity.

The device may additionally contain a power supply and a controller for powering and controlling the heating process. As mentioned herein, the alternating, in particular high frequency, electromagnetic field can be in the range from 500 kHz to 30 MHz, in particular from 5 MHz to 15 MHz, preferably from 5 MHz to 10 MHz.

The aerosol generating device may be, for example, a device as described in WO 2015/177256 A1.

In use, the aerosol generating article is engaged with the aerosol generating device such that the susceptor assembly is placed in the fluctuating electromagnetic field generated by the inductor.

Additional features and advantages of the aerosol generating system of the present invention have been described in relation to the aerosol generating article and will not be repeated.

The present invention also provides a method for manufacturing an induction heated aerosol generating article. This method includes the steps:

- providing a rod segment containing a substrate that forms an aerosol, wherein the rod segment has a cylindrical shape with a constant cross-section;

- providing a current collecting element according to the present invention and as described herein;

- placing the current-receiving element in the rod segment, in particular, in the substrate forming an aerosol.

Preferably, the step of placing the susceptor element in the rod segment includes moving the susceptor element and the rod segment relative to each other, thereby advancing the susceptor element into the aerosol-forming substrate contained in the rod segment.

Additional features and advantages of this method of manufacturing an induction heated aerosol generating article have been described with respect to the aerosol generating article of the present invention and will not be repeated.

The present invention also relates to a method for producing induction heated aerosol rod segments in a continuous rod forming process. This method includes the steps:

- providing a continuous profile of the pantograph, containing narrower parts having a reduced cross-section, located at places at certain intervals along its length;

- providing a substrate web containing an aerosol-forming substrate;

- placement of the pantograph profile and the substrate web relative to each other;

- gathering the substrate web around the pantograph profile so as to form a continuous rod-shaped core having a cylindrical shape with a constant cross-section;

- cutting a continuous rod-shaped core into individual segments of the aerosol-forming rod having a length that is equal to or greater than the length of the interval between narrower parts located at certain intervals.

The method according to the present invention provides many advantages, which in part have already been described above in relation to the aerosol generating product. First, the use of a pantograph profile comprising spaced narrower portions of reduced cross-section makes it easier to position the pantograph relative to the aerosol-forming substrate before collecting the substrate around the pantograph. This is caused by the reduced mechanical rigidity of the pantograph profile, which results from the arrangement of narrower parts at certain intervals. Secondly, cutting the continuous rod-shaped strand into individual aerosol-forming rod segments having a length that is equal to or greater than the length of the interval between narrower portions spaced at specified intervals ensures that each rod segment contains a current-collecting element (which is the result of cutting continuous profile) containing at least one narrower part with a reduced cross-section. As further described above with respect to the aerosol generating article of the present invention, this at least one narrower portion provides better fixation of the current collecting element within the aerosol generating substrate in a direction along the central axis of the aerosol generating rod segment, as well as in a transverse direction. the central axis of the rod segment forming the aerosol. The improved placement capability, as well as improved retention of the susceptor element, significantly improves the accuracy and stability of placement of the susceptor within the aerosol-forming substrate and thus helps ensure adequate product consistency.

Moreover, the use of a susceptor profile containing narrower parts located at certain intervals along its length allows the production of induction heated aerosol-generating products in which only a reduced part of the susceptor element (obtained by cutting a continuous profile) is in thermal proximity or in thermal contact with other elements of the aerosol-generating product, which must be protected from overheating.

The steps of providing a continuous profile of the pantograph and the substrate web, positioning the pantograph profile and the substrate web relative to each other, gathering the substrate web around the pantograph profile and cutting the continuous rod-shaped core into separate segments of the rod forming an aerosol can in principle be implemented in different ways, in particular with using one of the methods and/or devices described in documents WO 2016/184928 A1 or WO 2016/184929 A1.

According to one aspect of the method, the step of providing a continuous profile of a pantograph comprising narrower portions having a reduced cross-section located at intervals along its length includes the steps of:

- ensuring a continuous profile of the pantograph with a constant cross-section;

- creating lateral recesses in the pantograph in places located at certain intervals along its length to form a continuous profile of the pantograph containing narrower parts located at certain intervals.

Preferably, the step of creating side recesses in the pantograph occurs before positioning the pantograph profile and the substrate web relative to each other. Advantageously, this makes it possible to clean the pantograph from particles that may be cut off from the pantograph material when creating side recesses in the pantograph. In this way, the risk of subsequent migration of particles into the aerosol-forming substrate can be reduced.

The step of creating side recesses in the pantograph may be part of the overall process of forming a continuous rod. In particular, lateral recesses can be created in the pantograph profile as it is fed to the steps of relative placement and gathering of the substrate web around the pantograph profile.

Advantageously, the step of creating side recesses in the pantograph profile may involve the use of a cutting device. The cutting device may comprise, for example, at least one of a cutting blade, opposing cutting blade rollers, shears, a milling cutter, or a hammer drill.

Alternatively, spaced narrower portions may be created before the pantograph profile is submitted to the continuous rod forming process.

According to another aspect of the method, the step of cutting the continuous rod-shaped strand may include cutting the continuous rod-shaped strand at narrower portions so as to form individual aerosol-forming rod segments having a length corresponding to the length of the interval between the narrower portions spaced at specific intervals.

According to this aspect of the method, it will be appreciated that when cutting a continuous rod-shaped strand, the relative angular orientation of the pantograph profile within the rod-shaped strand is uncertain, such that the cutting angle between the pantograph strip and the cutting device used for the cutting process is also uncertain. The disadvantage of this is that it may degrade the quality of the cut and also cause some change in the position of the pantograph in the finished rod segment. The present invention achieves a significant improvement in this situation by locally reducing the cross-section of the pantograph profile at locations located at regular intervals along its length. Advantageously, this makes it possible to cut a continuous rod-shaped strand in well-defined thin areas. Although the angular position of the pantograph profile is still uncertain, cutting the pantograph profile into narrower parts becomes less problematic. In this case, the narrower parts can be considered narrow weakened ligaments between parts with an unreduced cross-section, which can be easily cut. In this way, the mechanical forces applied during cutting can be significantly reduced, which in turn makes the specific angular position of the pantograph profile less important. As a result, the accuracy and stability of placement of the pantograph in the finished rod-shaped segment is further improved.

In addition, cutting the pantograph profile at the weakened ligaments between the non-reduced sections advantageously increases the service life of the cutting tools used for this step of the process.

Moreover, cutting at weakened, narrower portions and applying less mechanical force during cutting advantageously reduces the risk of moving particles into the aerosol-forming substrate. This particle movement may be caused by particles being cut off from the current collector and/or cutting tools during the cutting process.

To ensure that a continuous rod-shaped strand is cut into individual rod segments at desired positions of narrower portions, the method may further comprise the steps of:

- tracking the trajectory of the pantograph profile as it passes through the process of forming a continuous rod;

- determination - based on the tracked trajectory of the pantograph profile and the length of the interval between places of reduced cross sections located at certain intervals - the moment in time when the corresponding narrower part of the pantograph profile arrives at the cutting position in the process of forming a continuous rod, where the step of cutting the continuous rod-shaped core into individual segments of the aerosol-forming rod; And

- initiating the stage of cutting a continuous rod-shaped core at a time specified for the corresponding narrower part.

Advantageously, the trajectory of the pantograph profile can be tracked by a controller. The controller may be capable of determining the speed of the pantograph profile throughout the continuous rod formation process, the point in time when the corresponding narrower portion of the pantograph profile passes a particular reference position during the continuous rod formation process. Preferably, the control position is located upstream of the step of placing the pantograph profile and the substrate web relative to each other. The time point at which the corresponding narrower portion of the pantograph profile arrives at the cutting position can be determined from the speed of the pantograph profile, the time point of passage of the reference position, and the predetermined distance between the reference position and the cutting position. The controller may comprise a sensor, in particular an optical sensor such as a camera, for determining the time of passage of the reference position. The controller may be a controller used to control the overall process of forming the continuous rod.

According to a further aspect of this method, the method may include the step of corrugating the substrate web before positioning the pantograph profile and the substrate web relative to each other. In particular, the substrate web can be corrugated longitudinally. In other words, the substrate web may be provided with a longitudinal folding structure along the longitudinal axis of the continuous sheet, in other words, along the transport direction of the substrate web. Preferably, the longitudinal folding structure provides the substrate with a zigzag or wavy cross-section. Advantageously, corrugating the substrate web facilitates the step of assembling the substrate web transversely relative to its longitudinal axis into the final rod shape. In particular, the longitudinal folding structure ensures proper folding of the aerosol-forming substrate around the susceptor. This turns out to be advantageous for the production of aerosol rods with reproducible characteristics. Moreover, the corrugation of the substrate web advantageously facilitates precise placement of the pantograph profile having narrower portions at regular intervals in the substrate web. As a result, the accuracy and stability of the placement of the pantograph profile within the aerosol-forming substrate is significantly improved.

The aerosol generating rod segments can be used to form an induction heated aerosol generating article, particularly an aerosol generating article according to the present invention and as described herein. In particular, the article may further comprise - in addition to the aerosol generating rod - at least one of a support element, an aerosol cooling element and a filter element. Any of these elements, or any combination thereof, may be arranged in series with respect to the aerosol-forming rod segment. These elements may have the same external cross-section as the aerosol-forming rod segment. In particular, the aerosol rod segment and any of the foregoing elements or any combination thereof may be arranged in series and surrounded by an outer wrap to form a rod-shaped article.

Additional features and advantages of the method for making induction heated aerosol generating rod segments have been described above with respect to the aerosol generating article of the present invention and will not be repeated.

In general and with respect to all aspects of the present invention, the term "aerosol generating article" - as used herein - refers to an article containing an aerosol generating substrate to be used by an aerosol generating device. The aerosol-generating article may be a consumable item, in particular a consumable item that must be discarded after a single use. The aerosol generating product may be a tobacco product. In particular, the product may be a rod-shaped product resembling conventional cigarettes.

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

The susceptor element or susceptor profile may be formed from any material that can be inductively heated to a temperature sufficient to generate an aerosol from the aerosol-forming substrate. Preferred pantograph profiles contain metal or carbon. A preferred pantograph profile may comprise or be composed of a ferromagnetic material, such as a ferromagnetic alloy, ferritic iron, or ferromagnetic steel, or stainless steel. Another suitable pantograph profile may be or contain aluminum. Preferred pantograph profiles can be heated to temperatures in excess of 250 degrees Celsius. The current collector profile may also comprise a non-metallic core with a metal layer deposited on the non-metallic core, for example, with metal tracks formed on the surface of the ceramic core. According to another example, the pantograph profile may comprise a protective outer layer, for example a protective ceramic layer or a protective glass layer, enveloping the pantograph profile. The pantograph may comprise a protective coating formed of glass, ceramic, or inert metal formed over a core of pantograph material.

The pantograph profile may be a pantograph consisting of several materials. In particular, the pantograph profile may comprise a first pantograph material and a second pantograph material. The first pantograph material is preferably optimized with respect to heat loss and thus heating efficiency. For example, the first pantograph material may be aluminum or a ferrous metal such as stainless steel. In contrast, the second pantograph material is preferably used as a temperature marker. For this purpose, the material of the second pantograph is selected in such a way as to have a Curie temperature corresponding to the specified heating temperature of the pantograph assembly. The magnetic properties of the second current collector at its Curie temperature change from ferromagnetic to paramagnetic, which is accompanied by a temporary change in its electrical resistance. Thus, by observing the corresponding change in the electric current absorbed by the induction source, it can be determined when the second susceptor material has reached its Curie temperature and thus when the predetermined heating temperature has been reached. The second susceptor material preferably has a Curie temperature that is below the ignition point of the aerosol-forming substrate, in other words, preferably below 500 degrees Celsius. Suitable materials for the second pantograph material may include nickel and certain nickel alloys.

Preferably, the pantograph profile is dimensionally stable. For this purpose, the shape and material of the pantograph profile can be selected in such a way as to ensure sufficient dimensional stability. Advantageously, this ensures that the initially desired heating susceptor profile is maintained throughout the core formation process, which in turn reduces product performance variability. Accordingly, the step of gathering the substrate web around the pantograph profile is performed such that the pantograph profile remains substantially undeformed after passing through the rod formation process. This means that preferably any deformation of the pantograph profile remains elastic such that the pantograph profile returns to its intended shape when the deforming force is removed.

As used herein, the term “aerosol-forming substrate” means a substrate formed from or containing an aerosol-forming material that is capable of releasing volatile compounds when heated to generate an aerosol. The aerosol-forming substrate is designed to be heated rather than burned to release the volatile compounds that form the aerosol. Preferably, the aerosol-forming substrate is a tobacco aerosol-forming substrate, in other words, a tobacco-containing substrate. The aerosol-forming substrate may contain volatile tobacco flavor compounds that are released from the substrate when heated. The aerosol-forming substrate may contain or consist of a cut blended tobacco filler, or may contain homogenized tobacco material. Homogenized tobacco material can be formed by agglomeration of tobacco particles. The aerosol-forming substrate may further comprise a non-tobacco material, such as a homogenized plant-based material other than tobacco.

Preferably, the aerosol-forming substrate may comprise a tobacco web, preferably a corrugated web. The tobacco web may contain tobacco material, fiber particles, a binder material and an aerosol forming agent. Preferably the tobacco leaf is a molded sheet. A molded sheet is a form of reconstituted tobacco that is formed from a pulp containing tobacco particles, fiber particles, an aerosol forming agent, a binder, and also, for example, flavoring agents. The tobacco particles may be in the form of tobacco dust having particle sizes on the order of 30 micrometers to 250 micrometers, preferably on the order of 30 micrometers to 80 micrometers or 100 micrometers to 250 micrometers, depending on the required sheet thickness and casting gap. The casting gap affects the sheet thickness. The fiber particles may include tobacco stem materials, petioles or other tobacco plant material, and other cellulose-based fibers, such as, for example, wood fibers, preferably wood fibers. The fiber particles may be selected based on the need to provide sufficient tensile strength to the molded sheet relative to a low inclusion rate, for example, an inclusion rate of about 2 percent to 15 percent. Alternatively, fibers such as plant fibers, including hemp and bamboo, can be used either together with the above fiber particles or as an alternative thereto. The aerosol-forming agents included in the pulp forming the molded sheet or used in other aerosol-forming tobacco substrates may be selected based on one or more characteristics. From a functional point of view, the aerosol forming agent provides a mechanism that allows it to vaporize and deliver nicotine or flavor or both into an aerosol when heated to a temperature above a specific vaporization temperature of the aerosol forming agent. Different substances usually evaporate at different temperatures to form an aerosol. The aerosol forming agent may be any suitable known compound or mixture of compounds which, when used, facilitates the formation of a stable aerosol. The stable aerosol is substantially resistant to thermal degradation at the operating temperature for heating the aerosol-forming substrate. The aerosol generating agent may be selected based on its ability, for example, to remain stable at or near room temperature, but be capable of vaporization at higher temperatures, for example, 40 degrees Celsius to 450 degrees Celsius.

The aerosol-forming agent may also have humectant-type properties that help maintain a desired level of moisture in the aerosol-forming substrate when the substrate consists of a tobacco-based product, particularly one containing tobacco particles. In particular, some aerosol-forming agents are a hygroscopic material that functions as a humectant, in other words, a material that helps keep the humectant-containing tobacco substrate moist.

One or more aerosol-forming agents may be combined to obtain an advantage due to one or more properties of the combined aerosol-forming agents. For example, triacetin can be combined with glycerin and water to obtain the benefit of triacetin's ability to transfer the active components and moisturizing properties of glycerin.

The aerosol-forming agents may be selected from: polyols, glycol ethers, polyol esters, esters and fatty acids, and may contain one or more of the following compounds: glycerol, erythritol, 1,3-butylene glycol, tetraethylene glycol, triethylene glycol, triethyl citrate, propylene carbonate, ethyl laurate, triacetin, meso-erythritol, diacetin-based mixture, diethyl suberate, triethyl citrate, benzyl benzoate, benzyl phenylacetate, ethyl vanillate, tributyrin, lauryl acetate, lauric acid, myristic acid and propylene glycol.

The aerosol-forming substrate may contain other additives and ingredients such as flavoring agents. The aerosol-forming substrate preferably contains nicotine and at least one aerosol-forming agent. A current collector that is in thermal proximity to, or in thermal or physical contact with, the aerosol-forming substrate provides effective heating.

The corrugated tobacco sheet of the present invention, such as a molded sheet, may have a thickness ranging from about 0.05 millimeters to about 0.5 millimeters, preferably from about 0.08 millimeters to about 0.2 millimeters, and most preferably from about 0 .1 millimeter to approximately 0.15 millimeter.

At least one of an aerosol-forming substrate within an aerosol-forming rod of an article of the present invention or an aerosol-forming substrate within an aerosol-forming rod produced by a method of the present invention or a substrate web containing an aerosol-forming substrate for collection around the pantograph profile in accordance with the method according to the present invention may have a density of at least 500 milligrams per cubic centimeter, in particular at least 600 milligrams per cubic centimeter, or at least 700 milligrams per cubic centimeter, or at least at least 800 milligrams per cubic centimeter, or at least 900 milligrams per cubic centimeter, or at least 1000 milligrams per cubic centimeter, or at least 1100 milligrams per cubic centimeter. Preferably this density is a maximum of 2000 milligrams per cubic centimeter, in particular a maximum of 1700 milligrams per cubic centimeter, preferably a maximum of 1500 milligrams per cubic centimeter. In this case, the use of a susceptor having at least one part with a reduced cross-section is particularly advantageous, since as the density increases, precise placement of the susceptor within the substrate becomes more problematic.

Thus, according to a first aspect of the present invention, there is provided an induction heated aerosol generating article for use with an induction heated aerosol generating device, the article comprising an aerosol generating rod segment having a cylindrical shape with a constant outer cross section, including an elongated current collecting element and an aerosol-forming substrate surrounding the susceptor element so as to form a cylindrical shape of the rod segment, wherein the susceptor element is a susceptor strip, wherein the width of the susceptor strip exceeds the thickness of the susceptor strip, wherein the susceptor element includes at least one narrower portion per each extreme end of the pantograph element, and the narrower portion at each extreme end has a reduced cross-section compared to one or more portions of the pantograph element along the length of the pantograph having a maximum cross-section of the pantograph element, the minimum cross-sectional size of said at least , one narrower part is in the range between 55% and 90%, in particular between 60% and 90%, preferably between 70% and 90%, even more preferably between 75% and 90%, of the maximum cross-sectional dimension of the elongated current collector element in said one or more portions containing a maximum cross-section, wherein the maximum cross-sectional dimension is measured in the same direction as the minimum cross-sectional dimension extending transversely to the length of the elongated susceptor member.

Preferably, the pantograph element further comprises at least one narrower portion between both extreme ends of the pantograph element, wherein the narrower portion between both extreme ends has a reduced cross-section compared to one or more portions of the pantograph element along the length of the pantograph element having a maximum cross-section of the current-receiving element.

According to a second aspect of the present invention, there is provided an induction heated aerosol generating article for use with an aerosol generating device by induction heating, the article comprising an aerosol generating rod segment having a cylindrical shape with a constant external cross section, including an elongated current collecting element and a substrate forming an aerosol surrounding the susceptor element so as to form a cylindrical shape of the rod segment, wherein the susceptor element is a pantograph strip, wherein the width of the pantograph strip exceeds the thickness of the pantograph strip, wherein the pantograph element comprises at least one narrower portion at each extreme end a pantograph element and/or at least one narrower portion between both extreme ends of the pantograph element, and the corresponding narrower portion has a reduced cross-section compared to one or more portions of the pantograph element along the length of the pantograph having a maximum cross-section of the pantograph element, wherein the minimum cross-sectional size of at least one narrower part is in the range between 55% and 90%, in particular between 60% and 90%, preferably between 70% and 90%, even more preferably between 75% and 90%, of the maximum cross-sectional dimension of the elongated susceptor element in one or more portions containing the maximum cross-section, the maximum cross-sectional size being measured in the same direction as the minimum cross-sectional dimension extending transversely to the lengthwise extent of the elongated susceptor element, and one or more portions of the current collecting element having a maximum cross-section of the current collecting element span at least 70% of the length of the current collecting element.

According to a third aspect of the present invention, there is provided an induction heated aerosol generating article for use with an aerosol generating device by induction heating, the article comprising an aerosol generating rod segment having a cylindrical shape with a constant external cross section, including an elongated current collecting element and a substrate forming an aerosol surrounding the susceptor element so as to form a cylindrical shape of the rod segment, the susceptor comprising at least one narrower portion at each extreme end of the susceptor element and/or at least one narrower portion between both extreme ends of the susceptor element, wherein a corresponding the narrower portion has a reduced cross-section compared to one or more portions of the current collector element along the length of the pantograph having a maximum cross-section of the current collector element, wherein the minimum cross-sectional size of the at least one narrower portion is in the range of between 55% and 90%, in particular between 60% and 90%, preferably between 70% and 90%, even more preferably between 75% and 90%, of the maximum cross-sectional dimension of the elongated current collecting element in one or more parts containing the maximum cross-section , wherein the maximum cross-sectional size is measured in the same direction as the minimum cross-sectional size extending across the length of the elongated pantograph element, and the pantograph element is a pantograph strip, wherein the width of the pantograph strip is greater than the thickness of the pantograph strip and the thickness of the pantograph strip is greater than one or more parts that are not at least one narrower part, is in the range from 0.03 millimeters to 0.15 millimeters.

Preferably, the minimum cross-sectional size of the at least one narrower portion is at most 90%, in particular at most 75%, preferably at most 50%, most preferably at most 25% of the maximum cross-sectional size of the elongated current collecting element in one or more parts having a maximum cross-section , wherein the maximum cross-sectional dimension is measured in the same direction as the minimum cross-sectional dimension extending across the length of the elongated current-receiving element.

Preferably, over at least 1% of the length of the elongated current collecting element, the cross-sectional area of the at least one narrower part is at most 50%, in particular at most 30%, preferably at most 15% of the cross-sectional area of the maximum cross-section.

Preferably, over at least 5% of the length of the elongated current collecting element, the cross-sectional area of the at least one narrower part is at most 90%, in particular at most 75%, preferably at most 50% of the cross-sectional area of the maximum cross-section.

Preferably, over at least 80% of the length of the elongated current collecting element, the reduced cross-section of the at least one narrower part is at most 80%, in particular at most 75%, preferably at most 50% of the cross-sectional area of the maximum cross-section.

Preferably, the maximum cross-sectional area is in the range from 0.1 square millimeters to 5.0 square millimeters, in particular from 0.15 square millimeters to 3 square millimeters, preferably from 0.2 square millimeters to 1.0 square millimeters, most preferably from 0.2 square millimeters to 0.5 square millimeters.

Preferably, one or more parts of the current collecting element having a maximum cross-section of the current collecting element covers at least 75%, in particular at least 80%, preferably at least 90% of the length of the current collecting element.

Preferably, the current collecting element comprises at least one side recess in at least one narrower part at each extreme end of the current collecting element and/or at least one side recess in at least one narrower part between both extreme ends of the current collecting element.

Preferably, the current collecting element comprises at least two side recesses on opposite sides of the elongated current collecting element in at least one narrower portion between both extreme ends of the current collecting element and/or at least two side recesses on opposite side sides of the elongated current collecting element in at least one narrower portion at the extreme ends of the current collecting element.

Preferably, the shape of the at least one lateral recess - as seen in a longitudinal section of the current collecting element along its length - is one of trapezoidal, triangular, wedge-shaped, curved, circular, oval, rectangular or polyhedral.

According to a fourth aspect of the present invention, there is provided a method for producing induction heated aerosol rod segments in a continuous rod forming process, the method comprising the steps of:

providing a continuous pantograph profile comprising narrower portions having a reduced cross-section at intervals along its length compared to one or more portions of the pantograph profile having a maximum cross-section of the pantograph element;

providing a substrate web containing an aerosol-forming substrate;

placing the pantograph profile and the substrate web relative to each other;

collecting the substrate web around the pantograph profile so as to form a continuous rod-shaped core having a cylindrical shape with a constant cross-section;

cutting a continuous rod-shaped strand into individual aerosol-forming rod segments having a length that is equal to or greater than the length of the interval between narrower portions spaced at specified intervals.

Preferably, the step of providing a continuous pantograph profile having a periodically reduced cross-section includes the steps of:

ensuring a continuous profile of the pantograph having a constant cross-section;

creating lateral recesses in the pantograph profile in places located at certain intervals along its length to form a continuous pantograph profile containing narrower parts located at certain intervals.

Preferably, the step of creating side recesses in the profile of the pantograph includes the use of a cutting device, wherein the cutting device comprises at least one of a cutting blade, counter rollers with cutting blades, shears, a milling cutter or a hammer drill.

Preferably, the step of cutting the continuous rod-shaped strand includes cutting the continuous rod-shaped strand at specified locations of the narrower portions so as to form individual aerosol-forming rod segments having a length corresponding to the length of the interval between the narrower portions spaced at specific intervals.

Preferably, the method further includes the steps of:

tracking the trajectory of the pantograph profile as it passes through the process of forming a continuous rod;

determination - based on the tracked trajectory of the pantograph profile and the length of the interval between places of reduced cross sections located at certain intervals - the moment in time when the corresponding narrower part of the pantograph profile arrives at the cutting position in the process of forming a continuous rod, where the stage of cutting the continuous rod-shaped core into individual aerosol-forming rod segments; And

initiating the step of cutting the continuous rod-shaped core at a time determined for the corresponding narrower part.

The present invention will be further described by way of example only with reference to the accompanying drawings, in which:

fig. 1 is a schematic diagram of an induction heated aerosol generating article comprising a current collecting element according to a first exemplary embodiment of the present invention;

fig. 2 is a schematic diagram of an exemplary embodiment of an aerosol generating system comprising an aerosol generating device and an aerosol generating article, as shown in FIG. 1;

fig. 3-8 illustrate additional illustrative embodiments of a susceptor element that may be used to form an aerosol generating article according to FIG. 1;

fig. 9-12 are schematic illustrations of an embodiment of the method of the present invention for producing aerosol generating rod segments that can be used to form an aerosol generating article according to FIG. 1; And

fig. 13-17 are schematic illustrations of another method for making aerosol rod segments.

In fig. 1 schematically shows a first exemplary embodiment of an induction heated aerosol generating article 1 according to the present invention. The aerosol generating article 1 is substantially rod-shaped and contains four elements sequentially coaxially aligned: an aerosol generating rod segment 10 containing a current collector element 20 and an aerosol generating substrate 30, a support element 40 containing a central air passage, an element 50, a cooling aerosol, and a filter element 60 that functions as a mouthpiece. The aerosol generating rod 10 is located at the distal end 2 of the article 1, while the filter element 60 is located at the distal end 3 of the article 1. Each of these four elements is a substantially cylindrical element, all of which have substantially the same diameter . In addition, the four elements are surrounded by an outer wrapper 70 in order to hold the four elements together and maintain the desired circular cross-sectional shape of the rod-shaped product 1. The wrapper 70 is preferably made of paper. Further details of the product, in particular the four elements - in addition to the features of the current collecting element 20 in the rod segment 10 - are disclosed in WO 2015/176898 A1.

As shown in FIG. 2, the aerosol generating article 1 is configured for use with the aerosol generating device 80 by induction heating. Together, device 80 and article 1 form an aerosol generating system 90. The aerosol generating device 80 includes a cylindrical receiving cavity 82 formed within a distal portion of the device housing 81 to accommodate at least a distal portion of the article 1. The device 80 further includes an induction source including an induction coil 83 for generating an alternating current, such as high frequency electromagnetic field. In the present embodiment, the induction coil 83 is a helical coil surrounding the cylindrical receiving cavity 82 in a circumferential manner. The coil 83 is positioned such that the current collecting element 20 of the aerosol generating article 1 is exposed to an electromagnetic field when the article 1 is engaged with the device 80. Thus, when the induction source is activated, the current collecting element 20 is heated due to eddy currents and/or hysteresis losses, which are caused by an alternating electromagnetic field, depending on the magnetic and electrical properties of the material of the current collector. The susceptor element 20 is heated until it reaches a temperature sufficient to vaporize the substrate 30 to form an aerosol surrounding the susceptor element 20 within the rod segment.

Device 80 additionally contains a power supply 85 and a controller 84 (shown only schematically in FIG. 2) for powering and controlling the heating process. Preferably, the induction source is at least partially an integral part of the controller 84.

According to the present invention, the aerosol rod segment 10 has a cylindrical shape with a constant cross-section, such as a circular cross-section. As mentioned above, the aerosol-forming substrate 30 surrounds the current collecting element 20 so as to form an overall cylindrical shape of the rod segment 10. The elongated current collecting element 20 is located along the central axis of the rod segment 10 and has a length L approximately the same as the length of the aerosol-forming substrate 30.

In the present embodiment, the elongated pantograph element 20 is a pantograph strip having a rectangular cross-sectional profile, the thickness of the pantograph strip being less than the width W, which in turn is less than the length L.

The aerosol-forming substrate 30 comprises an assembled sheet of corrugated homogenized tobacco material surrounded by a wrapper 70. The corrugated sheet of homogenized tobacco material contains glycerin as an aerosol-forming agent.

According to the present invention, the current collecting element 20 includes at least one narrower portion to improve the fixation of the current collecting element 20 within the substrate 30. With respect to the embodiment shown in FIG. 1, the current collector element 20 includes a narrower portion 22 at each of its outer ends 21. In other words, the narrower portions 22 have a reduced cross-section compared to one or more portions 25 of the current collector element 20 along its length that have a maximum cross-sectional area. cross-section of the current-receiving element. Each of the narrower portions 22 at the extreme ends 21 are formed by two lateral recesses 23 on opposite sides of the elongated current collecting member 20. In the present embodiment, the recesses are partially circular in shape as seen in a longitudinal section of the current collecting member 20 along its length. In other words, the shape of each recess 23 corresponds to a section of a circle, in particular a quarter of a circle. Due to the edges of the four recesses 23 - which advantageously face in both directions along the lengthwise extent, as well as in opposite directions across the lengthwise extent of the current collecting element 20 - the surrounding aerosol-forming substrate 30 and the current collecting element 20 are mutually engaged so as to substantially improve the fixation of the current-receiving element 20 inside the substrate 30.

In fig. 3-8 schematically illustrate additional illustrative embodiments of a current collector element 20 that may be used alternatively to form an aerosol generating rod segment 10 for an aerosol generating article, according to FIG. 1.

In fig. 3, the current collector element 120 also includes a narrower portion 122 at each of its outer ends 121. According to this embodiment, the narrower portions 122 are formed by recesses 123 having a triangular shape as seen in a longitudinal section of the current collector element 120 along its length. As a result, the extreme ends have a conical, tapering or pointed shape. This may be advantageous for inserting the current collecting element into the substrate, as will be described later in relation to the method depicted in FIG. 13-17.

The current collecting element 220 according to FIG. 4 also includes a narrower portion 222 at each of its extreme ends 221. In the present case, the narrower portions 222 are formed by recesses 223 that are partially trapezoidal in shape, as seen in a longitudinal section of the current collector element 220 along its length. Such recesses 223 can be obtained using a method described in more detail in relation to FIGS. 9-12.

As an alternative to a corresponding narrower portion at each extreme end, the current collector element 320 according to FIG. 5 includes one narrower portion 322 between both of its outer ends 321. In this embodiment, the narrower portion 322 is formed by two side recesses 323 located on opposite sides of the elongated current collector element 320. The recesses 323 are located approximately midway between both extreme ends 321, in in the same longitudinal position relative to the lengthwise extent of the elongated current collector member 320. The recesses 323 are semicircular in shape as seen in a longitudinal section of the current collector member 320 along its lengthwise extent. Similar to the arrangement of the recesses shown in FIG. 1, 3 and 4, semicircular recesses 323 according to FIG. 4 include edges facing in both directions along the length, as well as in opposite directions across the length of the current collector element 320. Accordingly, this configuration also improves the fixation of the current collector element 320 within the substrate.

In fig. 6 depicts another embodiment of current collector element 420 similar to the embodiment depicted in FIG. 5. However, instead of one narrower portion, the current collector 420 of FIG. 6 includes two narrower portions 422 between both of its outer ends 421, each of which is formed by a pair consisting of two lateral semicircular recesses 423 located on opposite sides of the elongated current collector element 420. The two corresponding recesses 423 of each pair are located in the same longitudinal position relative to the lengthwise extent of the current collecting element 420. Advantageously, this arrangement further improves the fixation of the current collecting element 420 within the substrate, which generally increases with the number of recesses.

Moreover, as shown in FIG. 7, current collector 520 may also include narrower portions having a different shape. The current collecting element 520 according to the embodiment of FIG. 7 contains a combination of narrower parts from the embodiments of FIG. 4 and fig. 5, in other words, a narrower portion 524 at each extreme end 521 formed by two opposing recesses 525 having a partially trapezoidal shape, and one narrower portion 522 between both extreme ends 521 formed by two opposing recesses 523 having a semicircular shape.

Of course, as shown in FIG. 8, the current collector element may also include a narrower portion 622 defined by only one recess 623. This single recess may be located, for example, on one side of the elongated current collector element 620. Although this narrower portion is less pronounced compared to the narrower portions of the current collector element element shown in Fig. 3-7, it still improves the placement stability of the current collector element 620 within the substrate.

In fig. 9-13 schematically show, at least in part, an illustrative embodiment of the method of the present invention for producing induction heated aerosol generating rod segments that can be used to form an aerosol generating article similar to or in accordance with FIG. 1. The method basically implements a process of forming a continuous rod, which begins by providing a continuous pantograph profile 225 having a constant cross-section, for example, a rectangular cross-section (see FIG. 9). In the next step, side recesses 226 are created in the continuous profile of the pantograph 225 at locations 227 spaced along its length to form a continuous pantograph profile 228 containing spaced narrower portions 229. In the present embodiment, the recesses 226 are created on opposite sides of the continuous pantograph 225. The recesses 226 are substantially trapezoidal in shape, as seen in a longitudinal section of the pantograph profile 228 along its length (see FIG. 10). In addition to providing a continuous pantograph profile 225 and creating side recesses 226, a substrate web containing the aerosol-forming substrate is fed into a continuous rod forming process (not shown). In the next step, the pantograph profile 228 with the spaced recesses 226 and the substrate web 231 are placed relative to each other (not shown), after which the substrate web 231 is assembled around the pantograph profile 228 so as to form a continuous rod-like core 215 having a cylindrical shape with a constant cross-section, for example, circular cross-section (see Fig. 11). In this case, narrower parts 229 located at certain intervals lead to a decrease in the mechanical rigidity of the pantograph profile 228, which in turn facilitates the placement of the pantograph relative to the substrate web. Finally, the continuous rod-like core 215 is cut at specified locations 227 of the narrower portions 229 so as to form individual aerosol-forming rod segments 210 having a length L corresponding to the length P of the interval between the narrower portions 229 spaced at specified intervals (see FIG. 12). Cutting the core 215, in particular the pantograph profile 228, in narrower parts 229 becomes less problematic, in particular requiring significantly less mechanical effort. As a result, the pantograph elements 220 produced by cutting the pantograph profile 228 have improved placement accuracy and stability within the finished rod segment 210. At the same time, the service life of the cutting tools used for the cutting process is significantly increased. Moreover, by cutting the core 215 into narrower portions 229, the risk of particles moving into the aerosol-forming substrate caused by particles being cut off from the current collector and/or cutting tools is also reduced.

As described above, rod segments 210 can be used to form an induction heated aerosol generating article, particularly an aerosol generating article according to the present invention and as described herein.

In fig. 13-17 schematically illustrate an alternative method for making individual induction heated aerosol rod segments that can be used to form an aerosol generating article in accordance with the present invention. The method includes the step of providing a susceptor element according to the present invention and as described herein, for example, a susceptor element 20 as shown in FIG. 1 and fig. 2. The step of providing such a susceptor element may also begin by providing a continuous susceptor profile 825 having a constant cross-section, for example, a constant rectangular cross-section (see FIG. 13). In the next step, side recesses 826 are created in the continuous pantograph profile 825 at spaced locations 827 along its length to form a continuous pantograph profile 828 containing spaced narrower portions 829. In the present embodiment, the recesses 826 have a substantially semi-circular shape as seen in a longitudinal section of pantograph profile 828 along its length (see FIG. 14). The pantograph profile 828 is then cut at specified locations of the narrower portions 829 so as to form individual pantograph members 820 having a length corresponding to the spacing length P of the narrower portions 829 spaced at specified intervals (see FIG. 15). The susceptor elements 820 resulting from this process correspond to the susceptor element 20 shown in FIG. 1 and fig. 2.

Before, after, or in parallel with providing the current collector elements 820, the method includes the step of providing a substrate rod segment 835 containing an aerosol-forming substrate 830. The substrate rod segment 835 has a cylindrical shape with a constant cross-section and a length substantially corresponding to the length L of the susceptor element 820. The susceptor element 820 is then positioned in the rod segment 835, particularly by moving the susceptor element 820 and the substrate rod segment 835 relative to each other, thereby thereby propelling the current collector element 820 into the substrate 830, forming an aerosol contained in the substrate rod segment 835 (see FIG. 16). The resulting process results in an inductively heated aerosol rod segment 810, as shown in FIG. 17. Rod segment 810 corresponds to rod segment 10 of the aerosol generating article shown in FIG. 1 and 2.

Claims (28)

1. An induction heated aerosol generating article for use with a device that generates an aerosol by induction heating, the article comprising an aerosol generating rod segment having a cylindrical shape with a constant outer cross section, including an elongated susceptor element and an aerosol generating substrate surrounding the susceptor element so as to form a cylindrical shape of the rod segment, wherein the susceptor element is a pantograph strip, wherein the width of the pantograph strip exceeds the thickness of the pantograph strip, wherein the pantograph element includes at least one narrower portion at each extreme end of the pantograph element, and the narrower portion at each extreme end has a reduced cross-section compared to one or more portions of the current collector element along the length of the pantograph having a maximum cross-section of the current collector element, wherein the minimum cross-sectional dimension of the at least one narrower portion is at in the range between 55% and 90%, in particular between 60% and 90%, preferably between 70% and 90%, even more preferably between 75% and 90% of the maximum cross-sectional dimension of the elongated current collecting element in said one or more parts, containing a maximum cross-section, wherein the maximum cross-sectional dimension is measured in the same direction as the minimum cross-sectional dimension extending transversely to the length of the elongated current collecting element. 2. The product of claim 1, wherein the susceptor element further comprises at least one narrower portion between both extreme ends of the susceptor element, wherein the narrower portion between both extreme ends has a reduced cross-section compared to one or more portions of the susceptor element along the length of the pantograph, having the maximum cross-section of the pantograph element. 3. An induction heated aerosol generating article for use with a device that generates an aerosol by induction heating, the article comprising an aerosol generating rod segment having a cylindrical shape with a constant outer cross section, including an elongated susceptor element and an aerosol generating substrate surrounding the susceptor element so as to form a cylindrical shape of the rod segment, wherein the susceptor element is a pantograph strip, wherein the width of the pantograph strip exceeds the thickness of the pantograph strip, wherein the pantograph element comprises at least one narrower portion at each extreme end of the pantograph element and/ or at least one narrower portion between both extreme ends of the susceptor element, and the corresponding narrower portion has a reduced cross-section compared to one or more portions of the susceptor element along the length of the susceptor having a maximum cross-section of the susceptor element, wherein the minimum size cross-section of at least one narrower part is in the range between 55% and 90%, in particular between 60% and 90%, preferably between 70% and 90%, even more preferably between 75% and 90% of the maximum cross-sectional size of the elongated current-collecting element in one or more parts containing a maximum cross-section, wherein the maximum cross-sectional size is measured in the same direction as the minimum cross-sectional size extending transversely to the length of the elongated current-collecting element, and one or more parts of the current-collecting element elements having a maximum cross-section of the current collecting element cover at least 70% of the length of the current collecting element. 4. An induction heated aerosol generating article for use with a device that generates an aerosol by induction heating, the article comprising an aerosol generating rod segment having a cylindrical shape with a constant outer cross section, including an elongated susceptor element and an aerosol generating substrate surrounding the susceptor element so as to form a cylindrical shape of the rod segment, wherein the pantograph comprises at least one narrower portion at each extreme end of the pantograph element and/or at least one narrower portion between both extreme ends of the pantograph element, wherein the corresponding narrower portion has a reduced cross-section compared to one or more portions of the pantograph element along the length of the pantograph having a maximum cross-section of the pantograph element, wherein the minimum cross-sectional size of at least one narrower portion is in the range between 55% and 90%, in particular between 60% and 90%, preferably between 70% and 90%, even more preferably between 75% and 90% of the maximum cross-sectional dimension of the elongated current collecting element in one or more parts containing the maximum cross-section, wherein the maximum cross-sectional dimension section is measured in the same direction as the minimum cross-sectional dimension extending transversely to the length of the elongated pantograph element, and the pantograph element is a pantograph strip, wherein the width of the pantograph strip is greater than the thickness of the pantograph strip and the thickness of the pantograph strip in one or more parts, which are not at least one narrower part, is in the range from 0.03 millimeters to 0.15 millimeters. 5. An article according to any of the preceding claims, wherein the minimum cross-sectional dimension of the at least one narrower part is a maximum of 90%, in particular a maximum of 75% of the maximum cross-sectional dimension of the elongated current-collecting element in one or more parts having a maximum cross-section, with In this case, the maximum cross-sectional dimension is measured in the same direction as the minimum cross-sectional dimension extending across the length of the elongated current-receiving element. 6. Product according to any of the previous claims, wherein for at least 1% of the length of the elongated current-receiving element the cross-sectional area of at least one narrower part is a maximum of 50%, in particular a maximum of 30%, preferably a maximum of 15% of the cross-sectional area maximum cross section. 7. Product according to any one of paragraphs. 1-5, wherein over at least 5% of the length of the elongated current-receiving element the cross-sectional area of at least one narrower part is at most 90%, in particular at most 75%, preferably at most 50% of the cross-sectional area of the maximum cross-section. 8. Product according to any of the previous claims, wherein over at least 80% of the length of the elongated current-receiving element the reduced cross-section of at least one narrower part is at most 80%, in particular at most 75%, preferably at most 50% of the area maximum cross section. 9. Product according to any of the preceding claims, wherein the maximum cross-sectional area is in the range from 0.1 square millimeters to 5.0 square millimeters, in particular from 0.15 square millimeters to 3 square millimeters, preferably from 0.2 square millimeter to 1.0 square millimeter, most preferably from 0.2 square millimeter to 0.5 square millimeter. 10. Product according to any of the previous claims, wherein one or more parts of the current collecting element having a maximum cross-section of the current collecting element cover at least 75%, in particular at least 80%, preferably at least 90% of the length current-receiving element. 11. The product according to any of the previous paragraphs, in which the current collecting element contains at least one side recess in at least one narrower part at each extreme end of the current collecting element and/or at least one side recess in at least one narrower part parts between both extreme ends of the current collecting element. 12. The product according to any of the previous paragraphs, in which the current collecting element contains at least two side recesses on opposite sides of the elongated current collecting element in at least one narrower part between both extreme ends of the current collecting element and/or at least two side recesses on opposite sides of the elongated current collecting element in at least one narrower portion at the extreme ends of the current collecting element. 13. The product of claim 11 or 12, wherein the shape of the at least one lateral recess - as seen in a longitudinal section of the current collecting element along its lengthwise extent - is one of trapezoidal, triangular, wedge-shaped, curved, round, oval, rectangular or multifaceted. 14. A method for producing induction heated segments of an aerosol-forming rod during the process of forming a continuous rod, the method comprising the steps of: providing a continuous pantograph profile comprising narrower portions at intervals along the length of the continuous pantograph profile, the narrower portions having a reduced cross-section compared to one or more pantograph profile portions having a maximum pantograph cross-section; providing a substrate web containing an aerosol-forming substrate; placement of the pantograph profile and the substrate web relative to each other; collecting the substrate web around the profile of the current collector so as to form a continuous rod-shaped core having a cylindrical shape with a constant cross-section; cutting a continuous rod-shaped strand into individual aerosol-forming rod segments, the rod segments having a length that is equal to or greater than the length of the interval between the narrower, spaced portions. 15. The method according to claim 14, wherein the step of providing a continuous profile of the pantograph having a periodically reduced cross-section includes the steps of: ensuring a continuous profile of the pantograph having a constant cross-section; creating lateral recesses in the pantograph profile at intervals along the length of the continuous pantograph profile to form a continuous pantograph profile containing narrower portions located at intervals. 16. The method according to claim 15, wherein the step of creating side recesses in the profile of the pantograph includes the use of a cutting device, wherein the cutting device comprises at least one of a cutting knife, opposing rollers with cutting knives, scissors, a milling cutter or a hammer drill. 17. Method according to any one of paragraphs. 14-16, wherein the step of cutting the continuous rod-shaped strand includes cutting the continuous rod-shaped strand at specified locations of the narrower portions so as to form individual segments of the aerosol-forming rod having a length corresponding to the length of the interval between the narrower portions located at intervals. 18. Method according to any one of paragraphs. 14-17, additionally including the steps: tracking the trajectory of the pantograph profile as it passes through the process of forming a continuous rod; determining - based on the tracked trajectory of the pantograph profile and the length of the interval between the spaced places of reduced cross sections - the point in time when the corresponding narrower part of the pantograph profile arrives at the cutting position in the process of forming a continuous rod, where the step of cutting the continuous rod-shaped core into individual segments occurs an aerosol-forming rod; And initiating the step of cutting the continuous rod-shaped core at a time determined for the corresponding narrower part.