RU2813318C1 - Susceptor and method of its manufacture - Google Patents

Abstract

FIELD: induction heated products.

SUBSTANCE: method for manufacturing a susceptor includes providing a strip of susceptor material, providing a compression stage comprising opposing compression elements, wherein in the first part of the compression stage the compression elements are arranged so as to form a gradually narrowing compression gap in the processing direction, and wherein in the second part of the compression stage the compression elements are arranged so as to form a constant compression gap between them in the processing direction, and wherein the oppositely located compression elements are configured to have matching surface structures, conducting the current-collecting material strip through the tapering compression gap of the compression stage so that the matching surface structures of the compression elements produce a deep drawing of the susceptor material strip.

EFFECT: current collector for an induction heated product that generates an aerosol.

15 cl, 21 dwg

Description

The present invention relates to a current collector (=susceptor) and to a method for making a current collector for use in an induction heated aerosol generating product.

Aerosol-generating products containing at least one aerosol-generating substrate capable of producing a respirable aerosol when heated are well known. To heat the substrate, the article may be placed in an aerosol generating device that contains 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 for inductive heating of the pantograph by at least one of eddy currents and hysteresis losses, depending on the electrical and magnetic properties of the pantograph (susceptor). The current collector 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. When the device operates, volatile compounds are released from the heated aerosol-forming substrate in the product and are entrained in the air stream drawn through the product during the user's puff. As the released compounds cool, they condense to form an aerosol.

The pantograph may contain or be composed of a metal sheet. Although such sheet-shaped pantographs can be easily manufactured and provide extensive heat dissipation due to their two-dimensional nature, the overall mass of such pantographs can often still be disproportionate to the heat dissipation surface. Thus, resources are used inefficiently.

Reducing the weight of pantographs, in particular reducing the thickness of the sheet material used in the manufacture of pantographs, places high demands on the manufacturing processes involved.

It would therefore be desirable to have a method for producing a susceptor for an induction heated aerosol generating article that provides high reliability and reproducibility even for very thin susceptor material.

In particular, it would be desirable to have a method of making a corrugated current collector for an induction heated aerosol generating article, wherein the current collector is made of a very thin current collector material.

In addition, it would be desirable to have a method for making pantographs in which a flavoring material is applied to the pantograph during the molding process.

In addition, it would be desirable to have a method of making pantographs that provides increased flexibility in the resulting heating profile of the pantographs.

In addition, it would be desirable to have a method that allows the flavoring material to be deposited in specified areas of the pantograph element.

The present invention relates to a method for manufacturing a susceptor for an induction heated aerosol generating article, the method comprising the steps of providing a strip of susceptor material and providing a compression stage comprising opposing compression elements. The compression stage has a first part in which the compression elements are arranged so as to form a gradually narrowing compression gap in the processing direction, and a second part in which the compression elements are arranged so as to form a constant compression gap between them in the processing direction, and at the same time oppositely located The compression elements are designed to have matching surface structures. The method further includes the step of passing the strip of current-collecting material through the tapering compression gap of the compression stage, such that the combined surface structures of the compression elements produce a deep drawing of the strip of current-collecting material.

The matching surface structures of the opposing compression elements can be designed such that the strip of current-receiving material is provided on at least one side with at least one recess. The surfaces of the compression elements may, for example, comprise protruding structures that interact with corresponding recessed structures of corresponding opposing compression elements. When the current-collecting material strip is passed through the opposing compression elements of the compression stage, the surface structures deeply draw the current-collecting material strip and modify the surface of the current-collecting material accordingly.

By gradually narrowing the compression gap in the processing direction, the current-receiving material is gradually given its final shape. This reduces the risk of damage to the material during the deep drawing process. In this way, even very thin strips of current-receiving material can be processed in a compression stage.

Advantageously, the first part of the compression stage, that is, the part forming a gradually narrowing compression gap in the processing direction, is located at the upstream end of the compression stage. The second part of the compression stage is advantageously located downstream of the first part of the compression stage. Thus, the strip of current-collecting material is first passed through the first part of the compression stage. In this part, the strip of current-receiving material is provided with recesses, which are given the desired shape.

In the subsequent second part of the compression stage, the final shape of the current-receiving material is confirmed. To this end, the compression elements of the second part of the compression stage form a constant compression gap in the processing direction and exert a constant pressure on the current-receiving material.

The compression elements may be in the form of bands, each of which runs over a plurality of guide rollers. The strips can be positioned opposite each other so that they form a compression gap through which the strip of current-receiving material is passed. In the first part of the compression stage, the guide rollers are further arranged so that the belts form a gradually narrowing compression gap in the processing direction. In the second part of the compression stage, the guide rollers are arranged so that the belts form a constant compression gap in the processing direction.

Each belt can be guided along a plurality of guide rollers. At least one of the guide rollers can be configured as a drive roller. The drive roller is a guide roller that is connected to the drive motor. The drive roller is used to drive the corresponding belt.

The belts may be toothed belts with a plurality of teeth protruding from the surface of the belt. The teeth can be positioned correctly at a constant pitch. Toothed belts can be arranged such that a tooth from one belt penetrates between two adjacent teeth located on an opposing belt. The use of two identical belts has the advantage that only one belt structure is used and therefore the number of different parts of the device is reduced. Additionally, the risk of using the wrong tapes is eliminated.

The belts can also be provided with alternately matching female and male teeth. The female teeth are formed with a recess that is large enough to receive the male teeth. Male and female teeth may be arranged alternately on each belt. In this configuration, both surfaces of the current-receiving material strip are alternately provided with projections and recesses.

The male teeth may also be located exclusively on one belt, while the female teeth may be located on another belt. In this configuration, only one surface of the strip of current-receiving material is provided with projections, while the other surface is provided with only recesses.

Tapes with matching female and male teeth may be advantageous in that the compression gap through which the strip of current-collecting material is passed is well defined. In this way, better control is achieved over the resulting recesses and projections that are provided on the strip of current-receiving material.

The teeth of the strips can have a wide variety of shapes, so that different surface patterns can be created on the surfaces of the strip of current-collecting material. The teeth can run across the entire width of the belts. The teeth can only extend part of the width of the belt. Consecutive teeth can be offset from each other. The teeth can be designed to produce transverse waves relative to the direction of movement of the strip of current-receiving material. The teeth may be arranged to form longitudinal or transverse recesses relative to the longitudinal direction of the strip of current collecting material, and may be distributed in any desired pattern. Belts can also be equipped with rows of parallel teeth. The configuration of the belt teeth determines the resulting shape of the surfaces of the strip of current-collecting material. When the recesses of the belts are subsequently filled with flavoring material, the evaporation characteristics of the flavoring material can be controlled, or at least influenced, by the design of the surface of the current collecting material.

The toothed belts can at the same time be used as toothed synchronization belts during the deep drawing process of a strip of current-collecting material. Thus, the tapes can promote strong tension on the strip of current-collecting material, and also help synchronize the movement of the tapes. Since the surface structures of the belts interact with each other during compression, these surface structures at the same time prevent sliding or any other unwanted relative movement between the belts.

Heat generating units can be used to assist the deep drawing process. These heat generation units can be used to heat the strip of current collector material before or during the compression stage shape changing process.

The compression elements can be designed as screw-shaped elements. The compression stage may comprise one or more pairs of helical-shaped elements arranged in series. In the first part of the compression stage, the screw-shaped elements may be formed and arranged such that threads provided on the outer circumference of the screw-shaped elements form a gradually narrowing compression gap in the processing direction. In the second part of the compression stage, the screw-shaped elements can be designed and arranged so that the screw-shaped elements form a constant compression gap in the processing direction.

When the strip of current-collecting material is passed through the compression gap formed by the opposing helical-shaped elements, the strip of current-collecting material is simultaneously stretched and gradually tightened into the desired corrugated shape. Thus, during the compression stage, no additional drive means are required for the strip of current-receiving material. Additionally, the compression stage has a fairly simple design, since it essentially consists only of helical-shaped elements.

Helical-shaped elements are essentially cylindrical elements. The outer circumference of the oppositely located screw-shaped elements is provided with a corresponding thread with a corresponding thread pitch. The axis of rotation of the helical-shaped elements can be oriented substantially parallel to the processing direction of the strip of current-receiving material.

To form a progressively narrowing gap in the processing direction, the screw-shaped elements can be arranged such that their longitudinal axes are slightly inclined towards each other so that the threads provided on the outer circumference of the screw-shaped elements form a gradually narrowing compression gap in the processing direction. This embodiment may be advantageous since the screw-shaped elements used are identical and have a regular cylindrical shape.

Screw-shaped elements can also be designed to have a gradually increasing diameter. In such an embodiment, the helical-shaped elements can be arranged such that their longitudinal axes are oriented parallel to each other. In this configuration, the threads provided on the outer circumference of the screw-shaped members again form a gradually narrowing compression gap in the processing direction. A parallel configuration of the longitudinal axes of helical-shaped elements may provide structural advantages. This, in particular, may be relevant in the case of using multiple sequential pairs of screw-shaped compression elements. It may be advantageous if all these compression elements have a common axis of rotation.

In the first part of the compression stage, which is in the part in which the screw-shaped elements form a gradually narrowing compression gap in the processing direction, the initially flat strip of current-receiving material is gradually stretched into a corrugated shape. Again, by gradually narrowing the compression gap in the cutting direction, the molding process is slow and smooth, reducing the risk of material failure.

In the second part of the compression stage, the screw-shaped elements form a compression gap, which has a constant size in the processing direction. The second part again helps to shape the strip of current collector material into the correct final corrugated or wavy shape.

The compression stage comprising helical-shaped compression elements may further comprise one or more guide elements. The guide elements may be screw-shaped guide elements. Helical-shaped guide elements may be located on top or bottom of a pair of helical-shaped compression elements. The helical-shaped guide members may be arranged in engagement with a pair of helical-shaped compression members. The guide elements may have a thread pitch that matches the thread pitch of the compression elements. In this way, the guide elements can engage the compression elements during rotation. The guide elements and the compression elements may share the same drive element and may be arranged to laterally form a compression gap between them.

The guide elements help guide the strip of current-receiving material. The guide elements can prevent the strip of current-receiving material from leaving the compression gap due to rotation of the compression elements. It is therefore particularly advantageous if the guide elements are designed and arranged in such a way as to limit the compression gap on the side. Advantageously, two guide elements are provided for each pair of screw-shaped compression elements.

The compression stage may comprise a third part in which the compression elements are arranged to form a gradually widening gap in the processing direction. The compression elements used in the third part of the compression stage may be generally configured similar to the compression elements in the first and second parts of the compression stage.

Thus, if the compression elements in the first part of the compression stage are provided in the form of opposing belts that are guided along the guide rollers, the compression elements of the third stage may equally be belts that are guided along the guide rollers. In the third part of the compression stage, the guide rollers are arranged so that the belts form a gradually widening gap in the processing direction.

If the compression elements in the first part of the compression stage are provided as opposite helical-shaped compression elements, the third stage compression elements can likewise be provided as helical-shaped compression elements. In the third part of the compression stage, the screw-shaped compression elements are arranged so that they form a gradually widening gap in the processing direction.

To form a gradually widening gap in the processing direction, the same considerations apply as discussed above with respect to the configuration of the screw-shaped elements used in the first part of the compression stage and which form a gradually narrowing compression gap in the processing direction. Thus, the helical-shaped elements can also be designed to have a gradually decreasing diameter, or the helical-shaped elements can be arranged such that their longitudinal axes are slightly inclined away from each other.

By providing a compression stage having a third compression stage in which the compression elements are configured to form a gradually widening gap in the processing direction, the compression elements are slowly disengaged from the newly formed strip of current-receiving material. This gradual release of the compression elements reduces the risk of potential damage to the molded strip of current-receiving material.

The third part of the compression stage, forming a gradually widening gap in the processing direction, is advantageously located at the downstream end of the compression stage.

The method may further include a flavoring material introduction step, in which the flavoring material may be introduced onto the strip of current collecting material. The flavoring material may be introduced into the recess of the strip of current collecting material.

The flavoring material may be introduced onto the strip of susceptor material using a separate injection device.

The insertion device may also be included in the compression step. Advantageously, the insertion device is included in the third part of the compression stage.

In embodiments in which the compression elements are provided in the form of opposing toothed bands that are guided along guide rollers, one or more teeth or projecting structure of the belts may be provided with a central hollow channel extending entirely through the belt and the projecting tooth element.

One or both toothed belts may be directed along the storage material to impart flavor under pressure. The flavoring material storage may have an opening facing the rear side of the toothed belt. The rear side of the toothed belt can generally cover the opening of the pressurized flavoring material storage, so that the pressurized flavoring material is prevented from leaking out of the flavoring material storage. The toothed belt may be directed along the flavoring material storage such that the central hollow channels of the teeth are brought into fluid communication with the pressurized flavoring material storage opening.

When the central hollow channel is in fluid communication with the pressurized flavoring material storage opening, an amount of the flavoring material flows through the central hollow channel and is delivered from the tip of the prong into a recess in the strip of current collecting material.

The amount of flavoring material supplied at each injection step can be adjusted as needed. The amount supplied may, for example, be adjusted by changing the pressure in the storage of the pressurized flavoring material, by changing the speed of the belts, or by changing the size of the channels in the teeth.

The insertion device may be stationary relative to the compression stage. The insertion device may be provided in the third part of the compression step. In the third part of the compression stage, the teeth of the tapes are gradually removed from the corrugations made on the strip of current-receiving material. The third part of the compression stage is optimal for introducing flavoring material because the gradual withdrawal of the teeth provides space for introducing flavoring material into the recesses of the strip of current collecting material.

Pressurizing the storage material to impart flavor may be achieved by any suitable means, such as a piston or pump. The pump may be a peristaltic pump or another type of pump suitable for interacting with the material to impart flavor.

If the compression elements in the first part of the compression stage are configured as opposing helical-shaped compression elements, introduction of the flavoring material can be achieved through one or more hollow radial channels that open on thread projections provided on the outer circumference of one or both of the helical-shaped compression elements . One or more hollow, radially arranged channels may be connected to a stationary storage of pressurized flavor material.

In particular, if more than one radial channel is provided, a corresponding helical-shaped compression member may be provided with a central axial channel which acts as a manifold for the plurality of radial channels. The central axial channel may be configured to connect to a storage material for flavoring. The central axial channel may be configured to be connected via a tube or any other transmission means to the flavor material storage.

Also in this embodiment, the radial channels are advantageously provided in the screw-shaped compression elements of the third part of the compression stage. As discussed earlier, in the third part of the compression stage, the protrusions of the helical-shaped compression members are gradually withdrawn from the corrugations formed on the current-receiving material strip. This again leaves sufficient space for the flavoring material in the corrugations of the strip of current collector material and is therefore an ideal time to introduce the flavoring material.

The amount of flavoring material introduced may be determined by the pressure of the flavoring material in the flavoring material storage, the diameter of the axial hollow channel, and the size and number of radially arranged hollow channels in the screw-shaped compression elements.

The present invention also relates to a method for making a susceptor for an induction heated aerosol generating article, the method including the steps of providing a strip of susceptor material and providing a cutting step comprising a periodically grooved blade. Using a periodically grooved blade, at least portions of the strip of susceptor material are cut and thinned so that the strip of susceptor material is provided with successive sections of smooth and sparse susceptor material.

The periodically grooved blade is made with a cutting blade with a periodically grooved profile. The exact shape of the grooved profile can be adapted to the desired characteristic of the rarefied part, which is formed from the cut parts. However, the corrugations must be formed so that the strip of current-collecting material is not completely cut across the entire width of the strip of current-collecting material. Instead, the strip of susceptor material should be provided with only partial cut lines, leaving uncut bridges of susceptor material between them.

The grooved profile may have a triangular or other polygonal shape, or may have a round shape, such as a sinusoidal shape.

As discussed above, the serrated blade is configured to partially cut the strip of current collector material along its width. The blade is at the same time also provided with a molding part which follows the design of the cutting blade and which stamps the cut part into a corrugated shape. Thus, the cut portion of the initially flat strip of current-receiving material is cut and thinned into a corrugated shape at the same time.

The cutting and dilution process is preferably a stepwise process. This means that between the individual stages of cutting and vacuuming, the strip of current-receiving material is fed forward by a predetermined amount. Additionally, the serrated blade may be periodically displaced laterally between successive cutting and vacuuming steps.

During the cutting and rarefaction process, an initially flat strip of susceptor material is fed step by step into the cutting stage, and the cutting blade reciprocates perpendicular to the feeding direction. In this way, the initially flat strip is provided with alternately offset cuts, which are used to form the corresponding sparse parts.

In this way, the entire strip of current-receiving material can be converted into a sparse strip of current-receiving material. It is also possible to create a strip with successive pieces of sparse and smooth current-receiving material.

During the rarefaction process, the cut portion of the strip of current-receiving material is cut in a cutting direction that is substantially perpendicular to the flat, uncut portions of the strip. The resulting strip is therefore provided with a ladder profile in the length direction.

After cutting and vacuuming, the processed strip can be flattened to prepare the current-receiving material for further processing. For this purpose, the strip of current-receiving material can be flattened by folding or stamping. In this way, a flat strip of current-receiving material with successively arranged smooth and sparse areas can be obtained.

A strip of current-receiving material having successively arranged smooth and rarefied parts opens up new possibilities regarding the induction heating process. Smooth parts have a larger surface area and volume for eddy currents than rarefied parts. Accordingly, more heat is generated in the smooth parts of the strip of current-receiving material sections than in the rarefied areas. This can be used to design the heating profile of the current collector element. This can also be used in making decisions about where flavoring materials should be placed in relation to the current collector.

The method may further include the step of providing a flavoring material to the strip of susceptor material. The step of providing the flavoring material to the strip of current collector material may be performed simultaneously with the cutting and vacuuming step. The step of providing the flavoring material to the strip of current collecting material may be performed such that the sparse areas are supplied with the flavoring material during the cutting and sparging step.

For this purpose, the cutting stage may be provided with a storage area for flavoring material. The flavor material storage may have an outlet that is adjacent to the area where the vacuum step is performed. The flavor release material storage may have an outlet positioned such that a strip of current collection material, which is subjected to vacuum by the cutting blade, is moved across the outlet opening. The flavoring material storage is configured such that the flavoring material is released during the vacuum of the current collecting material. In this way, the flavoring material can be directly captured in the rarefied parts during their manufacture. In particular, the flavoring material may be supplied to the pierced or exposed portions of the pantograph in rarefied regions such that the addition of the flavoring material does not result in any change in thickness.

The flavoring material storage may contain the material under pressure and may have a controllable valve that can be opened to release the flavoring material. The flavoring material store may also include a controllable piston that can change the volume of the flavoring material storage and which can force the flavoring material out of the outlet.

Both the valve and the piston can be synchronized with the movement of the cutting blade so that the material is released during the vacuum phase. The sparse portions are well suited for providing flavoring material thereon because, due to the open structure of the sparse portions, the evaporated flavoring material can be easily captured by the air flow passing by the current receiving material.

As used herein, the term "sparse susceptor material" refers to a type of susceptor material in which a plurality of areas of reduced strength have been created, in particular a plurality of perforations, and which have subsequently been stretched to form a regular pattern of holes resulting from the stretching of the plurality of areas of reduced strength, in particular many perforations. The current-receiving material can be thinned by piercing.

The use of a pantograph containing sparse pantograph material provides many advantages over other types of sheet-like pantographs.

Firstly, due to the specifics of the production process, the mass per unit area of the sparse current-receiving material is reduced compared to the current-receiving material without such holes. At the same time, the surface of the rarefied current-receiving material is still large enough to provide extensive heat generation. As a result, the proportional ratio of the total mass and heat radiation surface of a pantograph containing a sparse pantograph material is improved compared with a pantograph containing a pantograph material without any holes. This mainly helps to save resources for the manufacture of the product. In addition, reduced mass per unit area may also be beneficial in terms of reduced overall mass of the product.

Secondly, in comparison with a susceptor material containing holes that have been created by removing material, such as by punching, the production of a sparse susceptor material containing holes that have been created, as described above, by weakening, in particular perforating and stretching the susceptor material , is predominantly not associated with material loss. Also for this reason, the pantograph of the product according to the present invention advantageously saves materials and manufacturing costs and thus saves resources.

Third, the holes make the pantograph of the article of the present invention permeable, which improves the flow of air drawn through the article compared to an article containing an impermeable pantograph. In addition, the pantograph openings assist in the release and capture of material that evaporates from the heated aerosol-forming substrate into the air stream. Predominantly both aspects contribute to aerosol formation.

Fourth, a pantograph containing sparse pantograph material is stronger than an equivalent weight of welded or woven pantograph mesh because the pantograph material, although weakened, particularly perforated, and thinned, remains intact and thus retains its strength . At the same time, the sparse current-receiving material is more flexible and less rigid than the current-receiving material without any holes. Advantageously, this facilitates the supply of material during the manufacture of the aerosol generating article.

Fifth, the holes of the rarefied current-receiving material can be filled with an aerosol-forming substrate during the manufacture of the product. Advantageously, this can support fixation of the current collector within the aerosol-forming substrate. As a consequence, the accuracy and stability of the placement of the susceptor within the aerosol-forming substrate is significantly improved without affecting the overall thickness. The flavoring material does not protrude from the pantograph, making it easier to handle.

The method may further include the step of shaping the flattened strip of susceptor material into the shape of a corrugated strip of susceptor material, as described above. Preferably, the strip of current-receiving material is formed with periodically alternating smooth and sparse portions. In addition, it is preferable that the periodicity of these parts corresponds to the periodicity of the corrugations that form on the strip of current-receiving material. By adjusting the two periodicities to each other, a corrugated strip of current-receiving material is obtained in which the sparse and smooth parts are always provided in the same positions.

The smooth portions may be shaped into depressions, also referred to herein as dimples, and the sparse portions may be shaped into projections, herein also referred to as ridges, resulting in a corrugated strip of current-receiving material. Alternatively, the smooth parts can be shaped into ridges and the thin parts can be shaped into valleys of the resulting corrugated strip of current-receiving material.

The method may further include the step of providing two strips of current collecting material. The method may further include the step of applying two strips of current collecting material such that the sparse portions of one strip of current collecting material are adjacent to the smooth portion of the other strip of current collecting material. By superimposing two strips of current-receiving material in this manner, a sparse portion of one strip of current-receiving material is positioned adjacent to a smooth portion of the other strip of current-receiving material. This configuration improves heat transfer from the smooth parts to the rarefied parts, which in turn increases the evaporation capabilities of the current collector.

The present invention also relates to a susceptor for an induction heated aerosol generating article, the susceptor being provided as a strip of susceptor material comprising successive portions of smooth and rarefied susceptor material.

A strip of current-receiving material having successively arranged smooth and rarefied parts opens up new possibilities regarding the induction heating process. Smooth parts have a larger surface area and volume for eddy currents than rarefied parts. Accordingly, more heat is generated in the smooth parts of the strip of current-receiving material sections than in the rarefied areas. This can be used to design the heating profile of the current collector element. This can also be used in making decisions about where flavoring materials should be placed in relation to the current collector.

A portion of the rarefied current-receiving material may be filled with a flavoring material. The flavoring material may be located in the openings, pores, openings of the rarefied portion, and the flavoring material may not protrude from the thickness of the pantograph. A current collector, having successively arranged smooth and rarefied parts, has good heat capacity and at the same time good evaporation properties. The smooth parts are used to generate heat, which is easily transferred through conduction to the rarefied parts. The thin parts receive heat from the adjacent smooth parts so that the flavor material provided to the thin parts can evaporate. Due to the porous structure of the rarefied parts, the evaporating flavor material can interact with the air flow passing the drying side of the current receiving material, so that the overall aerosolization of the flavor material is enhanced.

A flat strip of current-receiving material having successively arranged smooth and sparse parts can be processed to provide it with corrugations. A flat strip of current-receiving material having successively arranged smooth and sparse parts can be processed to provide it with valleys and ridges. A flat strip of current collecting material having successive smooth and sparse portions can be processed to provide dimples and ridges such that the smooth portions are shaped like dimples and the sparse portions are shaped like ridges of the resulting corrugated strip of susceptor material.

The ridges of the current-receiving material extend into the air stream and are therefore good locations for evaporation to occur. Thus, this configuration is particularly advantageous when the sparse portions of the current-receiving material strip are provided with a flavoring material.

Alternatively or in addition, the depressions of the susceptor material that are formed in the parts of the smooth susceptor material may also be provided with a flavoring material. Since smooth susceptor material generates more heat during induction heating, it may be desirable for special flavoring materials to be provided on these smooth portions of the susceptor material strip.

As an example, the sparse pantograph may be made from a sheet having a thickness ranging from about 0.03 millimeter to about 1 millimeter, more preferably from about 0.05 millimeter to about 0.5 millimeter, for example from about 0.07 millimeter to approximately 0.2 millimeters. The openings in the rarefied region may have a general diamond or lozenge shape with a first diagonal ranging from 0.5 millimeters to 5 millimeters and a second diagonal ranging from 0.3 to 3 millimeters. The open area can be between 30 percent and 70 percent of the total area. The current-receiving material may be in the form of a strip. Preferably the strip has a simple rectangular shape, preferably having a width between about 2 millimeters and about 8 millimeters, more preferably between about 3 millimeters and about 5 millimeters, for example 4 millimeters.

The present invention further relates to a susceptor device for an induction heated aerosol generating article, the susceptor device comprising two strips of susceptor material as described herein. Two strips of current-receiving material are superimposed on each other so that the sparse ridged regions of one strip of current-receiving material are located adjacent to the smooth regions with depressions of the other strip of current-receiving material.

Such a current collector provides additional advantages. Since in this configuration, the sparse portion of one susceptor material strip is always adjacent to the smooth portion of the other susceptor material strip, the induction heat generated in the smooth portion can be directly transferred to the sparse portion of the other susceptor material strip. Since the thermal conduction path between adjacent pantographs is shorter and the thermal conduction surface between adjacent pantographs is larger, heat can be more efficiently conducted in this configuration.

Moreover, the ridges on both sides of the current collector are formed from sparse parts, so that optimal evaporation conditions are obtained on both sides of the current collector. In addition, the depressions are formed from the smooth parts of the pantograph and are located directly adjacent to the ridges of another pantograph. In this way, the heat generated in any depression can be easily conducted to the adjacent susceptor, which improves the overall evaporation efficiency of the susceptor device.

The current collector can be equipped with sinusoidal or triangular corrugations. Mostly, the periodicity of corrugation corresponds to the periodicity of successive smooth and sparse parts. As an example, the corrugations may have a crest-to-crest height of approximately 5 to 15 times the thickness of the flat strip before forming.

As discussed previously, the ridges of the susceptor device extend into the air flow generated in the aerosol generating article, so from this point of view it is advantageous for the ridges to be formed from rarefied portions of the susceptor material that carries the flavoring material.

However, in this case, the flavoring material may also be more susceptible to the negative effects of additional manufacturing steps performed during the further manufacture of the aerosol-forming articles. Thus, it may also be advantageous to form ridges from unfilled smooth material and form depressions from filled sparse material. To provide a more intense user experience, the sparse parts can be filled with additional material to impart flavor.

By providing triangular corrugations, the current collectors can be arranged so that the direction of diffusion of the vaporized flavoring material can be oriented. For example, the current collectors may be positioned such that the direction of diffusion of vaporized flavoring material is in the direction of air flow through the aerosol generating article and toward the mouth end of the article.

The present invention also relates to a method of supplying a flavoring material to a strip of susceptor material, wherein the strip of susceptor material is manufactured as described herein. The strip of susceptor material may be a corrugated strip of susceptor material, or may be a flat strip of susceptor material containing successive portions of smooth and sparse susceptor material.

The flavoring material may be provided to the susceptor material strip by dipping. For this purpose, a strip of current collecting material may be passed through a reservoir containing the flavoring material. The strip of susceptor material may be completely embedded in the flavoring material such that the entire surface of the strip of susceptor material is in contact with the flavoring material.

In order to guide the current collecting material strip through the flavoring material reservoir, a pair of guide rollers may be provided between which the current collecting material strip is clamped and transported through the flavoring material reservoir. A pair of such guide rollers may be provided at each end of the flavoring material reservoir. In this way, the movement of the strip of susceptor material through the reservoir of flavoring material can be well controlled.

This method may be particularly suitable for applying a flavoring material to a strip of susceptor material containing successive smooth and rarefied portions. The flavoring material may adhere better to sparse parts than to smooth parts. Accordingly, this method may be particularly suitable for applying flavoring material to thin portions of a strip of susceptor material.

The flavoring material may be provided to the strip of current collecting material by means of a coating roller. The surface of the coating roller may be provided with a flavoring material. By passing the strip of susceptor material over the coating roller, the flavoring material can be applied to the strip of susceptor material.

The strip of susceptor material may be lightly pressed against the cover roller so that sufficient contact is maintained between the strip of susceptor material and the cover roller. If the strip of current-receiving material is a corrugated strip, the strip can be passed through a roller gap formed between the cover roller and the support roller. The distance of this gap between the rollers may be less than the peak-to-peak distance of the corrugations. In this way, the back-up roller can help press the strip of current-receiving material against the cover roller. The back-up roller not only helps maintain sufficient contact pressure, but also increases the contact surface between the corrugated strip of susceptor material and the coating roller so that a larger area of the susceptor strip is supplied with flavoring material. This method may be particularly suitable for corrugated strips of current-receiving material having sinusoidal corrugations that are highly elastic.

If the strip of current collecting material is a corrugated strip, the cover roll contacts only the ridges of the strip of current collecting material. Accordingly, only the ridges of the corrugated strip are provided with flavoring material. The corrugated strip of current-receiving material may be formed such that the ridges are formed from sparse portions of the current-receiving material. The thin parts can hold the flavoring material better than the smooth parts, so in this configuration the application of the flavoring material is more effective.

The strip of current-receiving material may also be pressed against the cover roller by two tension rollers which are provided upstream and downstream of the cover roller. Tension rollers can be used to change the tension of a strip of current-collecting material in the vicinity of the cover roller. By varying the strip tension, the coating efficiency can be adjusted. The use of tension rollers can be especially useful if the strip of current collector material is a flat strip.

Tension rollers can also be used to change the arc of contact between the strip of current-receiving material and the cover roller. In this way, the contact time between the strip of current-receiving material and the coating roller can be changed. Adjustment of the arc of contact can be used to improve coating efficiency.

The coating roller may be in fluid communication with the flavor material storage. The coating roller may be positioned above the flavoring material storage at such a distance that the lower portion of the coating roller is immersed in the flavoring material provided in the flavoring material storage. The flavoring material may moisten the surface of the coating roller and may subsequently be applied to the strip of current collecting material.

The coating roller may be in direct fluid communication with the flavoring material storage. The coating roller may also be in indirect fluid communication with the flavoring material storage. Indirect fluid contact may be established by means of an intermediate roller which is in direct contact with the flavoring material and which transfers the flavoring material to the coating roller. One or more intermediate rollers may be provided between the flavoring material storage and the coating roller. By using one or more intermediate rollers, the amount of flavoring material that is provided to the coating roller and then to the strip of current collecting material can be more precisely controlled.

The flavoring material may be provided to the susceptor material strip by passing the susceptor material strip under the flavoring material storage. The flavoring material storage may have an opening at its bottom, which opening may be in contact with an upper surface of the current collecting material strip.

The strip of current-collecting material can be transported on an endless conveyor belt. The flavoring material storage opening may be positioned directly in contact with the top surface of the current collecting material strip.

This configuration may be advantageous for use with a strip of current-receiving material that is a flat strip containing successive smooth and sparse portions. When the smooth portion of the susceptor material strip is directly below the hole, the smooth portion actually seals the hole and prevents the flavoring material from flowing onto the susceptor material strip.

When the sparse portion of the strip of susceptor material is directly below the opening, the flavoring material is applied to the sparse portions that open to full capacity. In this way, only a limited amount of flavoring material is supplied to the strip of current collecting material.

An introduction device that uses a flavoring material storage that is provided above the susceptor material strip can also be used with a corrugated susceptor material strip. The opening at the bottom of the flavoring material storage may not necessarily be in contact with the strip of current collecting material. The flavoring material storage, however, can be used to supply the flavoring material to the concave concave portions of the current receiving material strip, which are transported under the opening of the flavoring material storage.

This insertion device may be used to apply the flavoring material to a corrugated strip of susceptor material in which the depressions are formed from smooth portions of the susceptor material and wherein the ridges are optionally formed from loose susceptor material.

Being made of a smooth susceptor material, the dimples can hold a significant amount of flavor material. Moreover, the amount of flavoring material supplied to each depression of the corrugated strip of the current receiving material can be kept constant. Each of the depressions can be filled with the same amount of material to impart flavor. If the ridges are formed from a sparse current-receiving material, these ridges may determine the maximum fill level for the flavoring material. The ridges can act as overflows to limit the amount of flavoring material delivered to the depressions. Thus, when the filling level in the recesses reaches the portions made of porous sparse material areas, any excess amount of flavoring material can be discharged through the porous sparse material.

The flavoring material storage opening can be opened and closed by suitable means known to one skilled in the art. For example, an opening valve may be provided that can be controlled depending on the frequency of discharging the flavoring material onto the strip of current collecting material. In this way, the flavoring material can be supplied exactly when the recess is located below the opening.

A pump, such as a peristaltic pump, may be provided to control the flow of the flavoring material or the pressure in the flavoring material storage. The pump can be synchronized with the valve. In this way, it can be ensured that a sufficient amount of flavoring material is supplied to each of the depressions of the corrugated strip of the current-receiving material.

The flavoring material may be provided to the corrugated strip of current collector material through an introduction device that uses the flavoring material in a solid state. The method may include advancing the flavoring material in a solid state toward a punch, cutting off an amount of the flavoring material, and dispensing that amount of the flavoring material into a recess of the corrugated strip of the current collector material.

The flavoring material may be easier to handle in a solid state than the liquid flavoring material. Feeding the flavoring material in a solid state ensures consistent and accurate dosing of the flavoring material. Thus, with this method, corrugated strips of current-receiving material can be produced in which all recesses are provided with the same and predetermined amount of flavoring material.

The method may further include the step of temporarily liquefying the amount of flavoring material that is supplied to the depressions of the corrugated strip of the current collector material.

Liquefaction of the amount of flavoring material may be assisted by temporarily heating the flavoring material after the flavoring material is introduced into the depressions of the corrugated strip of the current collecting material. Heating may be accomplished by any suitable heating device. A suitable heating device is a hot air gun. The hot air supplied from such a heat gun may be sufficient to reduce the viscosity of the material to impart flavor. The heated flavoring material can then become fluid and adhere to the walls of the recesses of the strip of current collecting material.

When heating the flavoring material, it may be advantageous if only the flavoring material is heated while heating the current collecting material is largely eliminated. In this case, the amount of heat required to liquefy the flavoring material can be minimized, and deformation of the susceptor material due to excess heat can be avoided. Moreover, the cooling process of the flavoring material is accelerated if the current-receiving material is heated as little as possible.

To further speed up the cooling process of the flavoring material, the strip of susceptor material may be transported through a cooling station. Cooling stations suitable for this process are known in the art. By accelerating the cooling process, rapid regelation of the material can be achieved to impart flavor. The strip of susceptor material can only continue to be processed after the flavoring material has cooled and sufficiently adhered to the susceptor material. Therefore, accelerating the cooling process can reduce the required time for the entire manufacturing process.

The corrugated strip of current-receiving material may be transported in stages through the insertion device. Each step may correspond to the pitch width of the corrugated strip of current-receiving material. After each step, the insertion device is activated. A predetermined amount of flavoring material is cut and fed into the cavity of the corrugated strip of current-receiving material.

The gradual movement of the corrugated strip of current-receiving material can be established using any suitable conveyor device. The conveyor device may comprise a toothed endless belt driven by a stepper motor. The toothed strip may have a periodicity that matches the periodicity of the corrugated strip of current-collecting material. In this way, each tooth of the toothed strip can engage with the depression of the corrugated strip of current-receiving material. By dividing the traction force into multiple engagement points, the stress at each individual engagement point can be reduced and deformation of the corrugated strip of current-collecting material can be avoided.

Advancing the flavoring material toward the cutting device and cutting off a predetermined amount of the flavoring material can be accomplished using suitable processes and devices known in the art. The advance mechanism may include a piston or clip that engages the solid state flavoring material and that serves to move the solid state flavoring material.

A hammer drill can be used to cut off a predetermined amount of material for flavoring. The punch may be movable perpendicular to the direction of advance of the flavoring material and may include a cutting blade at its front end. The puncher may be used to cut a predetermined amount of flavoring material and to force the cut flavoring material into a recess of the corrugated strip of current collector material located below the puncher.

The method can be used to fill depressions on only one side of a corrugated strip of current-receiving material. The method can also be used to fill depressions on either side of a corrugated strip of current collector material with a flavoring material. This can be done through a two-step process. In a first step, depressions on the first side of the corrugated strip of current collecting material may be filled with flavoring material. After the flavoring material has been cooled sufficiently such that the flavoring material sufficiently adheres to the depressions of the corrugated strip of current collector material, the strip can be unrolled to fill the depressions on the second side of the corrugated strip of current collector material with the flavoring material.

Because the flavoring material inside the cavity may adhere to the walls of the corrugated strip, the flavoring material must remain in place even when inverted. If the adhesion of the flavoring material is too weak, for example due to movement vibrations of the moving corrugated strip or due to the thixotropic property of the flavoring material, the viscosity or adhesion of the flavoring material may be increased. This can be done by further cooling the metal strip or by changing the composition of the material to impart flavor.

The flavoring material may be provided to the corrugated strip of current collector material through another injection device that uses liquid flavoring material. The liquid flavoring material may be provided to a flavoring material storage through which a corrugated strip of current collecting material is passed. The flavoring material storage may have at least one inlet for introducing an unloaded corrugated strip of current collecting material into the flavoring material storage. The flavoring material storage may have at least one outlet opening allowing the loaded corrugated strip of current collecting material to exit the flavoring material storage.

The outlet may be formed from two edges defining the distance between them. The distance between the edges may correspond to the peak-to-peak distance of the corrugated strip of current-collecting material.

The corrugated strip is passed through the internal volume of the flavoring material storage and is led to the exit from the flavoring material storage through the outlet.

The two edges defining the outlet may be elastic or pre-biased, or elastic and pre-biased such that each of the edges is slightly pressed against the corrugated strip of current-receiving material.

After passing the corrugated strip of susceptor material through the interior and outlet of the liquid material storage, liquid flavoring material is placed in each depression of the corrugated strip of susceptor material. The flavoring material is formulated such that the flavoring material received into each recess substantially adheres to the wall of the recesses of the corrugated strip after the corrugated strip leaves the flavoring material storage through the outlet.

Because the edges are pressed on each side of the corrugated strip, the edges effectively close the outlet so that excess flavoring material cannot escape from the flavoring material storage. To ensure reliable sealing, the edges may be of such length that at any moment each of the edges is in contact with at least two ridges of the corresponding side of the corrugated strip of current-receiving material.

The width of the edges can correspond to the width of the corrugated strip. The outlet of the flavoring material storage may be provided with a suitable sealing element for sealing the outlet on the sides of the corrugated strip.

The edges are preferably made of elastic material. In this way, differences in height between successive ridges of the corrugated strip can be compensated. Alternatively or additionally, the edges can be pre-biased towards each other using a suitable biasing device. In a simple design, such displacement can be achieved by means of a spring mechanism which is provided between each of the edges and the corresponding side surface of the flavor material storage.

Because the corrugated strip of susceptor material may be subject to varying pulling and pushing forces as it moves through the flavor material storage, the peak-to-peak distance of the corrugated strip may vary during the coating process. Such varying pulling and pushing forces may be caused by the viscosity of the flavoring material or by the friction of the corrugated strip against the surface of the two edges at the outlet. Thanks to the elastic configuration of the two edges or the pre-displacement of the edges, the distance between the two edges can be changed dynamically and can compensate for any changes in the dimensions of the corrugated strip. In this way, sealing of the outlet can be achieved and unwanted leakage of excess flavoring material can be prevented.

The expression "flavoring material" as used herein is understood to mean a material or mixture of materials capable of releasing volatile compounds into the air stream passing through the article in which the susceptor is located, preferably when the flavoring material is heated.

The flavoring material may be a gel. Providing a gel may be advantageous for storage and transport or during use, since the risk of leakage from the current collector of the aerosol-generating article or aerosol-generating device can be reduced.

Advantageously, the gel is solid at room temperature. "Solid" in this context means that the gel has a stable size and shape and does not flow. Room temperature in this context means 25 degrees Celsius.

The flavoring material may comprise an aerosol-forming agent. Ideally, the aerosol generating agent is substantially resistant to thermal degradation at the operating temperature of the pantograph. Suitable aerosol-forming agents are well known in the art and include, but are not limited to: polyhydric alcohols such as triethylene glycol, 1,3-butanediol and glycerol; polyhydric alcohol esters such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate. Polyhydric alcohols or mixtures thereof may be one or more of triethylene glycol, 1,3-butanediol and glycerol or polyethylene glycol.

Advantageously, the gel of the flavoring material, for example, contains a thermoreversible gel. This means that the gel will become pourable when heated to the melting temperature and will set to become a gel again at the gelation temperature. The gelation temperature may be at or above room temperature and atmospheric pressure. Atmospheric pressure means pressure equal to 1 atmosphere. The melting temperature may exceed the gelation temperature. The melting point of the gel may exceed 50 degrees Celsius, or 60 degrees Celsius, or 70 degrees Celsius, and may exceed 80 degrees Celsius. Melting point in this context means the temperature at which the gel is no longer solid and begins to flow.

Alternatively, in certain embodiments, the gel is a non-meltable gel that does not melt during use of the pantograph. In these embodiments, the gel may release the active agent at least partially at a temperature that is equal to or greater than the operating temperature of the pantograph in use, but below the melting temperature of the gel.

Preferably, the gel has a viscosity of from 50,000 to 10 pascals per second, preferably from 10,000 to 1000 pascals per second, to provide the desired viscosity.

The gel may contain a gelling agent. The gel may contain agar, or agarose, or sodium alginate, or gellan gum, or a mixture thereof.

The gel may contain water, for example the gel is a hydrogel. Alternatively, in certain embodiments, the gel is non-aqueous.

Preferably the gel contains an active substance. The active substance may contain nicotine (eg, in powder or liquid form), or a tobacco product, or other target compound, for example, for release into an aerosol. Nicotine may be included in the gel along with a substance to form an aerosol. Maintaining the nicotine in the gel at room temperature is desirable to prevent leakage of nicotine from the aerosol generating article.

The gel may contain solid tobacco material which releases flavor compounds when heated. The solid tobacco material may be one or more of powder, granules, pellets, pieces, thin tubes, strips or sheets containing one or more of plant material such as grass leaves, tobacco leaves, tobacco stem fragments, reconstituted tobacco, homogenized tobacco , extruded tobacco and expanded tobacco.

The gel may contain other flavorings, such as menthol. Menthol can be added either to the water or to the aerosol forming agent prior to formation of the gel.

In embodiments in which agar is used as a gelling agent, the gel may contain from 0.5 to 5 percent by weight, preferably from 0.8 to 1 percent by weight, agar. Preferably, the gel further contains from 0.1 to 2 percent by weight nicotine. Preferably, the gel further contains from 30 percent to 90 percent by weight (or from 70 to 90 percent by weight) glycerol. In certain embodiments, the remainder of the gel contains water and flavoring agents.

Preferably, the gelling agent is an agar, which has the property of melting at temperatures above 85 degrees Celsius and reverting to a gel at approximately 40 degrees Celsius. This property makes it suitable for hot environments. The gel will not melt at 50 degrees Celsius, which is useful if the system is left, for example, in a hot car in the sun. The liquid phase transition at approximately 85 degrees Celsius means the gel only needs to be heated to a relatively low temperature to cause aerosol formation, resulting in low energy consumption. It may be helpful to use only agarose, which is one of the ingredients in agar, instead of agar.

When gellan gum is used as the gelling agent, typically the gel contains 0.5 to 5 percent by weight gellan gum. Preferably, the gel further contains from 0.1 to 2 percent by weight nicotine. Preferably the gel contains from 30 percent to 99.4 percent by weight glycerol. In certain embodiments, the remainder of the gel contains water and flavoring agents.

In one example, the gel contains 2 percent by weight nicotine, 70 percent by weight glycerol, 27 percent by weight water, and 1 percent by weight agar.

In another example, the gel contains 65 percent by weight glycerol, 20 percent by weight water, 14.3 percent by weight tobacco, and 0.7 percent by weight agar.

In particular, the amount of gel per product may be set or adjusted depending on the expected nicotine delivery, and/or the total expected amount of aerosol generation, and/or the expected duration of the user session.

As used in this document, the term "susceptible material" refers to a material that is capable of converting electromagnetic energy into heat. When a pantograph is placed in an alternating electromagnetic field, eddy currents are typically induced and hysteresis losses may occur, causing the pantograph to heat up. Since the susceptor material is in thermal contact with the flavoring material, the flavoring material is heated by the susceptor material, releasing fluid from the susceptor material.

The current collecting material may be formed from any material that can be inductively heated to a temperature sufficient to release the material from the flavoring material. Preferred current collector materials include metal or carbon. A preferred current collector material may comprise or consist of a ferrous or ferromagnetic material, such as ferritic cast iron, a ferromagnetic alloy such as ferromagnetic steel, stainless steel or aluminum. The current collecting material preferably contains more than 5 percent, preferably more than 20 percent, preferably more than 50 percent, or 90 percent ferromagnetic or paramagnetic materials. Preferred pantographs can be heated to a temperature of from about 150 degrees Celsius to about 300 degrees Celsius. Preferably, the pantographs can be heated to a temperature of from about 200 degrees Celsius to about 270 degrees Celsius, for example 235 degrees Celsius.

Preferably, the strip of current collecting material is an oblong metal material.

Preferably, the strip of current collecting material is a strip of stainless steel. However, current collector materials may also contain graphite, molybdenum, silicon carbide, aluminum, niobium, Inconel alloys (austenitic nickel-chromium superalloys), metallized films, ceramics such as, for example, zirconia, transition metals such as, for example, iron, cobalt, nickel, or metalloid components such as, for example, boron, carbon, silicon, phosphorus, aluminum, or be made of them.

The current-receiving material has the shape of a strip. Preferably the strip has a simple rectangular shape with a width preferably from about 2 millimeters to about 8 millimeters, more preferably from about 3 millimeters to about 5 millimeters, for example 4 millimeters, and a thickness preferably from about 0.03 millimeters to about 1 millimeter, more preferably from about 0.05 millimeter to about 0.5 millimeter, for example from about 0.07 millimeter to about 0.2 millimeter. The width of the strip of current-receiving material is less than the width or diameter of the plug in which the current-receiving material is placed.

The following is a non-exhaustive list of non-limiting examples. Any one or more features of these examples can be combined with any one or more features of another example, embodiment, or aspect described herein.

Example A: A method of manufacturing a susceptor for an induction heated aerosol generating article, the method comprising the steps of:

• provision of a strip of current-collecting material,

• providing a compression stage comprising opposing compression elements, wherein in a first part of the compression stage the compression elements are arranged so as to form a gradually narrowing compression gap in the processing direction, and wherein in a second part of the compression stage the compression elements are arranged so as to form between themselves a constant compression gap in the processing direction, and wherein the opposing compression elements are designed to have matching surface structures,

• passing the strip of current-collecting material through the tapering compression gap of the compression stage, so that the combined surface structures of the compression elements produce a deep drawing of the strip of current-collecting material.

Example B: The method according to Example A, wherein the compression elements are belts which are guided along a plurality of guide rollers, wherein in the first part of the compression stage the guide rollers are arranged such that the belts form a gradually narrowing compression gap in the processing direction.

Example C: A method according to any of the previous examples, wherein the belts are provided with alternately arranged teeth such that a tooth on one belt penetrates between two adjacent teeth located on the opposite belt.

Example D: A method according to any of the previous examples, wherein the belts are provided with alternately arranged and combined raised and recessed structures, wherein the raised structures from one belt penetrate into the recessed structures of another belt, thereby producing a deep draw of a strip of current-collecting material carried between the belts.

Example E: The method according to Example A, wherein the compression elements are helical-shaped elements configured and arranged such that threads provided on the outer circumference of the helical-shaped elements form a gradually narrowing compression gap in the processing direction.

Example F: The method according to Example E, in which the compression elements are helical-shaped elements arranged so that their longitudinal axes are inclined towards each other, so that threads provided on the outer circumference of the helical-shaped elements form a gradually narrowing compression gap in the processing direction .

Example G: Method according to Example E, wherein the compression elements are helical elements having a gradually increasing diameter and arranged so that their longitudinal axes are parallel to each other, so that the threads provided on the outer circumference of the helical elements form a gradually narrowing gap compression in the processing direction.

Example H: The method according to any one of Examples E-G, wherein the compression stage comprises one or two helical-shaped guide elements that are located above or below the tapering compression gap and in engagement with the compression elements.

Example I: A method according to any of the preceding paragraphs, wherein the compression step further comprises a third part in which the compression elements are arranged to form a gradually widening gap in the processing direction.

Example J: The method according to any of the previous examples, wherein a portion of the compression stage forming a gradually narrowing compression gap is located at the upstream end of the compression stage.

Example K: The method according to any of the previous examples, in which a part of the compression stage forming a gradually widening gap is located at the downstream end of the compression stage.

Example L: The method according to any of the previous examples, wherein the method includes a flavoring material introduction step in which the flavoring material is introduced into a recess of the current collector material strip formed in the compression step.

Example M: The method according to any of the previous examples, wherein the tooth or projecting structure is provided with a central channel that is in fluid communication with the flavoring material storage, and wherein the flavoring material is provided into a recess of the current collecting material strip in the third part of the compression step , forming a gradually widening gap.

Example N: The method according to any of the previous examples, wherein the ridge of the helical-shaped compression elements, which are arranged to form a gradually widening gap, is provided with one or more central channels that are in fluid communication with the storage of the flavoring material, and wherein the material to impart flavor, a strip of current-receiving material is inserted into the recess of the strip in the third part of the compression stage, forming a gradually widening gap in the processing direction.

Example O: A method of manufacturing a susceptor for an induction heated aerosol generating article, the method comprising the steps of:

• provision of a strip of current-collecting material,

• providing a cutting step comprising a periodically grooved blade for cutting and sparging at least portions of the strip of susceptor material such that the strip of susceptor material is provided with successive portions of smooth and sparse susceptor material.

Example P: The method according to Example O, in which the cutting process is a step-by-step process in which, between individual cutting steps, a strip of current-collecting material is fed forward by a predetermined amount, and a periodically grooved blade reciprocates perpendicular to the direction of feed.

Example Q: The method according to any one of Examples O and P, wherein after the cutting process, the strip of current collector material is flattened by folding or stamping so as to obtain a flat metal strip with successively arranged smooth and sparse portions of the current collector material.

Example R: The method according to any one of Examples O-Q, wherein during the cutting and vacuuming process, a flavoring material is provided to the strip of current collector material, such that the rarefied portions are simultaneously supplied with a flavoring material.

Example S: The method of any one of Examples Q-R, wherein the flattened strip of current-receiving material is corrugated such that the smooth portions are shaped like dimples and the sparse portions shaped like ridges of the resulting corrugated strip.

Example T: The method of any one of Examples O-S, wherein two strips of susceptor material are superimposed on each other such that sparse portions of one strip of susceptor material are adjacent to smooth portions of another strip of susceptor material.

Example U: The method according to any one of Examples Q-R, in which the flavoring material is provided on the strip of current collector material after the flattening step.

Example V: The method according to any of the previous examples, wherein the flavoring material is provided as a gel in a reservoir and the treated susceptor material is passed through the reservoir of the flavoring material.

Example W: The method according to any of the previous examples, wherein the flavoring material is provided as a gel in a reservoir and the flavoring material is applied to the treated susceptor material by means of a coating roller, wherein the coating roller is in fluid communication with the flavoring material in tank.

Example X: The method according to any of the previous examples, wherein the flavoring material is provided in the form of a gel in a reservoir having a feed opening at its bottom, and wherein the treated susceptor material with successively arranged smooth and expanded areas is carried directly under and adjacent to the opening of the reservoir containing the flavoring material.

Example Y: The method according to any of the previous examples, wherein the flavoring material storage is pressurized so that the flavoring material exiting the flavoring material storage fills the sparse areas.

Example Z: The method according to any of the previous examples, in which the flavoring material reservoir is periodically pressurized so that the gel flows out of the flavoring material storage to fill the vacuum portions only when the vacuum portion passes adjacent to the opening of the flavoring material storage adding flavor.

Example ZA: The method according to any of the previous examples, wherein the flavoring material is provided to the susceptor material through an injection device, the flavoring material is a gel, and the flavoring material is discharged from the applicator under pressure onto a nearby strip.

Example ZB: The method according to any of the previous examples, in which the flavoring material is discarded continuously or periodically.

Example ZC: Method according to any of the previous examples, wherein the administration device comprises a pump, preferably a peristaltic pump, for supplying the flavoring material.

Example ZD: The method according to any of the previous examples, in which the strip of susceptor material is provided in the form of a corrugated strip, and in which the flavoring material is provided in the form of a gel strip in a solid state,

wherein the apparatus comprises an insertion device containing a advancement mechanism for the gel tape and a perforator for cutting off a certain amount of gel and for supplying this amount of gel into the cavity of the corrugated strip of the current-receiving material.

Example ZE: Method according to Example ZD, in which the amount of gel material supplied to the cavity is temporarily liquefied using a hot air gun.

Example ZF: Method according to Examples ZD or ZE, in which the corrugated strip material is conveyed step by step past the insertion device by means of a toothed belt driven by a stepper motor.

Example ZG: The method according to any of the previous examples, in which the depressions on both sides of the corrugated strip material are then filled with flavoring material.

Example ZH: The method according to any of the previous examples, wherein the strip of susceptor material is provided in the form of a corrugated strip, and wherein the flavoring material is provided in the form of a liquid gel provided in a reservoir, wherein on the side of the reservoir there is an opening formed from two pre- offset or elastic edges, and at the same time the corrugated strip is passed through the internal volume of the tank and removed from the reservoir through an opening formed by two previously offset or elastic edges.

Example ZI: Method according to example ZH, in which the length of the edges is such that the edges are at any time pressed against at least two ridges of the corrugated strip.

Example ZJ: A susceptor for an induction heated aerosol-generating article, wherein the susceptor is provided as a strip of susceptor material containing successive sections of smooth and rarefied susceptor material.

Example ZK: A susceptor according to Example ZJ, in which parts of the sparse susceptor material are provided with a flavoring material.

Example ZL: A pantograph according to any one of Examples ZJ or ZK, wherein the strip of pantograph material is corrugated such that the smooth portions are shaped like dimples and the sparse portions are shaped like ridges of the resulting corrugated strip.

Example ZM: A pantograph according to any one of Examples ZJ to ZL, in which the depressions formed in portions of the smooth pantograph material are provided with a flavoring material.

Example ZN: A susceptor device for an inductively heated aerosol-generating article, wherein the susceptor device comprises two susceptors according to any one of Examples ZJ-ZM, and wherein the two susceptors are superimposed on each other such that the flared ridge-shaped portions of one susceptor are adjacent to smooth parts in the form of depressions of another pantograph.

Example ZO: Current collector according to Example ZN, in which the current collector is equipped with sinusoidal or triangular corrugations, the periodicity of the corrugations corresponding to the periodicity of successive smooth and sparse parts.

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

in fig. 1 shows a method for forming a corrugated strip of current-receiving material;

in fig. 2 shows an embodiment of a toothed belt;

in fig. 3 shows strips of current-collecting material with different surface patterns;

in fig. 4 shows an embodiment of a toothed band including an insertion device;

in fig. 5 shows a method for forming a corrugated strip of current-receiving material;

in fig. 6 is a sectional view of the device shown in FIG. 5;

in fig. 7 illustrates a method for forming a corrugated strip of current-receiving material provided with a flavoring material;

in fig. 8 illustrates a method for cutting and thinning a flat strip of current-receiving material;

in fig. 9 shows the cutting and rarefaction stage;

in fig. 10 shows a flat strip of susceptor material having successive portions of smooth and sparse susceptor material;

in fig. 11 illustrates a method for supplying a strip of current-receiving material shown in FIG. 10 flavoring material;

in fig. 12 shows a corrugated strip of current-collecting material having successive portions of smooth and sparse current-collecting material, and corresponding current-collecting devices;

in fig. 13 shows a device for supplying flavoring material to the susceptor shown in FIG. 10;

in fig. 14 shows a device for supplying flavoring material to the susceptor shown in FIG. 10;

in fig. 15 shows a device for supplying flavoring material to a corrugated pantograph;

in fig. 16 shows a device for supplying flavoring material to the susceptor shown in FIG. 10;

in fig. 17 shows a device for supplying flavoring material to a corrugated pantograph;

in fig. 18 shows a method for forming a current collector;

in fig. 19 illustrates a method of introducing a solid state flavoring material into a corrugated current collector;

in fig. 20 illustrates a method of introducing a liquid flavoring material into a corrugated pantograph;

in fig. 21 is a detailed view of the outlet end of the flavoring material storage shown in FIG. 20.

In fig. 1 shows a first embodiment of an apparatus for carrying out the method of the present invention, in which an initially flat strip of current collector material 10 is processed into a corrugated strip of current collector material 11. The flat strip of current collector material 10 is a stainless steel strip having a width of approximately 5 millimeters and a thickness of approximately 0 .05 millimeters.

The flat strip of current collector material 10 is fed into a processing device 12 which performs a compression step 14 in which the strip of current collector material 10 is given the desired corrugation. For this purpose, opposing compression elements 16 are provided, which form a compression gap 18 between them.

The compression elements are toothed endless belts 16, each of which runs along guide rollers 20. One of the guide rollers 20 is designed as a drive roller 22, which is connected to a drive motor (not shown). The guide rollers 20 and the drive rollers 22 are arranged to define three different parts of the compression stage 14.

In the first part 24 of the compression stage 14, the guide rollers 20, 22 are arranged so that the compression elements 16 form a gradually narrowing compression gap 18'' in the processing direction. In the second part 26 of the compression stage 14, the guide rollers 20, 22 are arranged so that the compression elements 16 form a constant compression gap 18 between them in the processing direction. In the third part 28 of the compression stage 14, the guide rollers 20 are arranged such that the compression elements 16 form an expanding compression gap 18 in the processing direction.

The opposing toothed endless belts 16 are arranged such that a tooth 30 of one endless belt penetrates between two adjacent teeth 30 located on the opposite belt.

Initially, a flat strip of current-receiving material 10 is directed through the compression stage 14, with the strip 10 being fed into the tapering gap 18 of the first part 24 of the compression stage 14.

The matching surface structures, which are the mutually penetrating teeth 30 of the opposing compression elements 16, gradually engage with the strip of current-receiving material 10 and gradually produce a deep drawing of the material to a predetermined corrugated shape. In the second part 26 of the compression stage 14, the compression gap 18 remains unchanged in the processing direction. In this part of the compression stage 14, the compression elements 16 are used to secure the corrugated shape of the strip of current collector material 10.

At the downstream end of the compression stage 14, the compression elements 16, and in particular the teeth 30 of the endless belts 16, are gradually withdrawn from the corrugated strip of current collector material 11. This gradual withdrawal prevents any potential damage to the newly formed strip of current collector material 11.

In fig. 2 shows an alternative arrangement of toothed belt 16 having matching surface structures. The strips 16 are provided with alternately arranged matching female teeth 32 and male teeth 34. The male teeth 34 include a projection 36. The female teeth 32 are formed with a recess 38 that is large enough to receive the projection 36 of the male teeth 34. In use, the strip of current-receiving material 10 is guided between toothed belts 16 with female teeth 32 and male teeth 34. The combined surface structures of these toothed belts 16 form alternately spaced depressions in the strip of current-collecting material 10. In this way, the initially flat strip of current-collecting material 10 is transformed into a corrugated strip of current-collecting material 11.

In fig. 3 schematically shows corrugated strips of current-receiving material 11 with different surface patterns. In the left view of FIG. 3 shows a corrugated strip of current-receiving material 11 having a regular sinusoidal or wavy pattern. However, other patterns are also possible, as shown in the other two views shown in FIG. 3. In the middle view of FIG. 3 shows a pattern in which a plurality of longitudinal recesses 40 are formed on the strip of current-receiving material 11. In the right view of FIG. 3, a plurality of transverse recesses 42 are made on a strip of current-receiving material 11.

In fig. 4 shows a configuration in which the strip of current-receiving material 10 is provided with corrugations and in which, at the same time, a flavoring material 44 is introduced into each of the newly formed recesses 46. The serrated strips 16 shown in FIG. 4 correspond to tapes 16 in FIG. 2.

Each male tine 34 is provided with a central hollow channel 48 extending completely through the belt 16 and the male tine 34. The toothed belts 16 are guided along the pressurized flavor material storage 50. Each of the flavoring material stores 50 has an opening 52 that faces the rear side of a respective toothed belt 16. The belts 16 are oriented such that the rear side of each of the toothed belts 16 generally covers the opening 52 of a corresponding flavoring material store 50 underneath. pressure. However, when the male tine 34 with the central hollow channel 48 is guided past the opening 52 of the pressurized flavoring material storage 50, the flavoring material 50 can flow through the central hollow channel 48 and is fed from the tip of the male tine 34 into the recess 46 in the corrugated strip. current-receiving material 11.

The introduction step is carried out in the third part 28 of the compression stage 14. In this portion, the belts 16 are arranged to form an expanding compression gap 18 in the processing direction, causing the male teeth 34 to gradually withdraw from the female teeth 32. As the projections 36 of the male teeth 34 move out of the recesses 46, they make room for the insertion of material 44 for adding flavor.

The flavoring material 44 is provided in the form of a gel. The supplied amount of flavoring material gel 44 is controlled by changing the pressure in the pressurized flavoring material storage 50 and by varying the speed of the belts 16. Pressurization of the flavoring material storage 50 is achieved by means of a pump (not shown).

Fig. 5-7 relate to a further embodiment of the present invention, in which the method is carried out using compression elements in the form of screw-shaped elements 56. The helical-shaped elements 56 are essentially cylindrical elements. The outer circumference of the opposing screw-shaped elements 56 is provided with a corresponding thread 58 with a corresponding thread pitch.

As shown in FIG. 5, the screw-shaped elements 56 are arranged such that their longitudinal axes 60 are slightly inclined towards each other, so that the threads 58 provided on the outer circumference of the screw-shaped elements 56 form, in the processing direction, a gradually narrowing compression gap 18 relative to the processing direction 62. In fig. 5 only the first part 24 of the compression stage 14 is shown. In the first part 24 of the compression stage 14, an initially flat strip of current-receiving material 10 is gradually stretched into a strip having a corrugated shape 11. This first part 24 is followed by at least a second part 26 in which helical-shaped compression elements 56 are arranged to form in the direction processing constant compression gap 18.

In the embodiment of FIG. 6, the strip of current-receiving material 10 is further guided at the compression stage 14 by two guide elements 64. The guide elements 64 are also helical-shaped elements. Helical-shaped guide elements 64 are located above and below a pair of helical-shaped compression elements 56. The screw-shaped guide elements 64 also have external threads having a thread pitch that matches the thread pitch of the compression elements 56. Thus, the guide elements 64 engage in rotation with the compression elements 56. The guide members 64 and the lateral compression members 64 define a compression gap 18 through which the strip of current-receiving material 10 is guided.

In fig. 7 shows the third part 28 of the compression stage 14, in which the compression elements 16 are represented as opposing helical-shaped elements 56. The screw-shaped elements 56 are arranged so that they form, in the processing direction, a gradually widening compression gap 18 in the processing direction 62. The compression elements 56 are configured to deliver a flavoring material gel 44 to the strip of current collector material 11. To this end, the compression elements 56 comprise hollow radial channels 66 that open on the projections of threads formed on the outer circumference of one of the helical-shaped compression elements 56. Hollow radially arranged channels 66 extend into a central manifold channel 68, which in turn is connected to a stationary pressurized flavoring material storage (not shown). In fig. 7, the central axial channel manifold 68 is configured to receive an adapter 70 that is configured to connect to a pressurized flavoring material storage. Adapter 70 includes a longitudinal opening 72 that allows fluid communication with hollow, radially disposed channels 66. FIG. 7, the flavoring material introduction device is shown with the upper compression member 56 only. However, a corresponding device for introducing the flavoring material is also provided to the lower compression member 56, so that the flavoring material 44 is supplied from both sides of the corrugated strip of the current collector material 11.

On the right in Fig. 7 is a cross-sectional view of a compression element 56 containing fluid passages 66, 68. In this case, three equally spaced radial channels 66 are provided per thread revolution. Each of the radial channels 66 extends from the central axial channel 68 to the outer circumference of the helical-shaped compression element 56.

The amount of flavoring material 44 introduced into recess 46 is determined by the pressure in the flavoring material storage, the diameter of the axial hollow channel 68, and the size and number of radially spaced hollow channels 66 in the screw-shaped compression elements 56. The flavoring material 44 may be introduced continuously or intermittently. For this purpose, a controllable valve (not shown) may be provided which can be opened and closed to control the flow of flavoring material onto the strip of current collecting material 11.

Fig. 8-11 relate to a method for manufacturing a current collector for an induction heated aerosol-generating article. In this method, an initially flat strip of susceptor material is advanced in stages to a cutting step 80 comprising a periodically grooved blade 82. The periodically grooved blade 82 has a periodically trapezoidal shape and is configured such that the flat strip of susceptor material 10 is provided with partial cuts across its longitudinal axis.

The grooved blade 82 is at the same time also provided with a forming portion 83 which follows the structure of the cutting blade 82 and which stamps the cut portion into a corrugated shape defined by the grooved blade 82. Thus, the cut portion of the originally flat strip of current collector material 10 is cut and thinned to this corrugated shape at the same time.

The cutting and thinning process is a step-by-step process. The movement of the cutting blade 82 is a reciprocating movement, as indicated by a series of arrows in FIG. 8. In the top view of FIG. 8, the strip of current-receiving material 10 has already been advanced to the cutting stage 80 by a predetermined distance corresponding to the width of the cut of the cutting stage 80. As indicated by the arrow, the serrated blade 82 is moved to the right to the first cutting position.

In the second view of FIG. 8, the cutting blade 82 is in the first position and is moved downward to simultaneously cut and thin the strip of current collector material 10. The cutting blade 82 is then moved up and to the left by half the blade serration pitch to the second cutting position. The strip of current collector material 10 is again advanced one step and the cutting blade 82 is moved downward to make a second cut that is offset laterally with respect to the first cut. Similarly, the rarefaction occurs with a lateral displacement relative to the first stage of rarefaction. In the lowest view in Fig. 8, the cutting blade 82 is raised again and moved back to the first cutting position. Then the cutting process described above can be performed again. Thus, the initially flat strip of susceptor material 10 is provided with a sparse portion 86 extending at least part of the length of the strip of susceptor material 10.

During the rarefaction process, the cut portion of the strip of current-receiving material 10 is thinned in the cutting direction. The cutting direction is substantially perpendicular to the plane defined by the flat strip of current-receiving material 10. In FIG. 9, an initially flat strip of current collecting material 10 is provided with successive portions of smooth, or uncut, current collecting material 84 and sparse, or cut, susceptor material 86. Thus, the resulting partially sparse strip 88 has a staircase-like profile in the length direction, as depicted in the schematic as shown in Fig. 9.

After cutting and rarefaction, the strip 88 with successive smooth and rarefied portions 84, 86 may be flattened to prepare the strip of current collector material 88 for further processing. For this purpose, the strip of current-receiving material 88 is flattened using a stamping device (not shown). The resulting flat strip of current-receiving material 90 with successive smooth and sparse portions 84, 86 is shown in FIG. 10. As a result of the rarefaction process, the rarefied parts are provided with sunken openings bounded by sheet ribbons or straps. For example, the width of the ribbons or straps can be set to equal the thickness of the pantograph. The openings or perforations may have a maximum opening size greater than or at least equal to the thickness of the pantograph.

As shown in FIG. 11, the partially sparse strip of current collector material 88 is further provided with flavoring material 44. The flavoring material 44 is applied to the strip of susceptor material 88 during the cutting and vacuum process. To this end, the cutting stage 80 is provided with a flavoring material storage 50. The flavoring material storage 50 has an outlet 52 that is immediately adjacent to the cutting and vacuuming stage 80. During the cutting and vacuuming step, the portion 86 of the strip of susceptor material that is subjected to vacuum by the cutting blade 82 is moved past the outlet 52.

The flavoring material storage 50 is configured such that the flavoring material 44 is released during the vacuum of the strip of current collecting material 10. For this purpose, the flavoring material storage 50 includes a controllable piston 51 that forces the flavoring material 44 out of the outlet 52. The piston 51 is synchronized with the cutting blade 82 such that the flavoring material 44 is released during the downward movement of the cutting blade 82 during the vacuum step.

Gaps in the rarefied portion of the strip of susceptor material 86 are well suited for capturing flavor material 44. Moreover, the sparse portion 86 is open on both sides of the strip of susceptor material 88 so that the vaporized flavoring material 44 can be easily captured by the air flow passing by the susceptor in use.

The flattened strip of susceptor material 90 having successive smooth and sparse portions 84, 86 may be molded into a corrugated strip of susceptor material 11 as described above in FIG. 1 and 5. As shown in the topmost view of FIG. 12, the periodicity of the smooth and sparse parts 84, 86 can correspond to the periodicity of the corrugations, which are given to the strip of current-receiving material 11. In this way, a corrugated strip of current-receiving material 11 is obtained, in which the corrugations, in other words successive depressions and ridges, are formed from the smooth parts 84 and from the sparse portions 86, wherein the rarefied portions 86 are provided with flavoring material 44.

As shown in the additional views shown in FIGS. 12, two strips of current collector material 90 may be superimposed on each other to form a current collector device 100. In FIG. 12 shows three alternative arrangements illustrating how two corrugated strips of current collector material 90 may be superimposed on each other. The arrows in these views indicate the general direction of diffusion of flavor material 44 upon evaporation.

Two strips of current collector material 90 may be arranged such that on both sides the ridges of current collector device 100 are formed from sparse portions 86 of the corrugated strip of current collector material 90. When such current collector device 100 is used in an aerosol generating device, the device allows vaporized material to easily enter the path air flow, which is directed along the current collector 100.

Alternatively, the two corrugated strips of current collector material 90 may also be arranged such that on both sides the ridges of the current collector 100 are formed from smooth portions 84 of the corrugated strips of current collector material 90. The ridges formed from the smooth portions 84 may protect the filled sparse portions 86 from friction with additional material provided in the aerosol generating system in the vicinity of the current collector 100.

In the lowest view of Fig. 12 corrugated strips of current-receiving material 90 are provided with triangular corrugations. The corrugated strips of the current receiving material 90 are arranged such that the diffusion direction of the evaporated flavoring material is oriented. In fig. 12, the pantographs are positioned so that the direction of diffusion points to the right side. This direction may correspond to the direction of air flow through the aerosol-generating product being used.

The flavoring material 44 may also be applied to the flat or corrugated strip of current collector material 90, 11 in a subsequent, separate process step.

In fig. 13 is a strip of current-receiving material 90 as shown in FIG. 10 is provided with flavoring material 44 after the strip of current collector material 90 has been partially thinned and flattened. The strip of current collecting material 90 is directed through a flavoring material storage 50 containing flavoring material 44 in the form of a gel. The strip of current collecting material 90 is completely immersed in the material gel 44 to impart flavor.

In order to pass the strip of current collection material 90 through the flavoring material storage 52, a pair of guide rollers 92 are provided upstream and downstream of the flavoring material storage 50. In this way, the movement of the strip of current collecting material 90 through the flavoring material storage 50 is well controlled.

The flavoring material gel 44 adheres better to the thin portions 86 than to the smooth portions 84 of the strip of current collecting material 90. Accordingly, this method is particularly suitable for selectively applying the flavoring material 44 to the thin portions 86 of the strip of current collecting material 90.

As shown in FIG. 14 and 15, the flavoring material may also be applied to the strip of current collector material 90 via the coating roller 110.

In fig. 14 schematically illustrates a method for applying flavoring material 44 to a flat strip of susceptor material 90. The strip of susceptor material 90 is again configured as described in connection with FIG. 10. The strip of current collecting material 90 is guided over the coating roller 110. The coating roller 110 is connected to the flavoring material storage 50. By passing the strip of susceptor material 90 over the coating roller 110, the flavoring material 44 is applied to the strip of susceptor material 90.

In fig. 14, the coating roller 110 is in rolling contact with the intermediate roller 112, which in turn is immersed in a flavoring material storage 50 containing the flavoring material 44 in the form of a gel. The rotating intermediate roller 112 continuously picks up gel 44 onto its surface and delivers this gel 44 to the surface of the coating roller 110. From the coating roller 110, the gel 44 is supplied to the strip of current collecting material 90.

Because the gel 44 adheres really well to the thin portions 86 of the strip of current collector material 90, these portions are the ones that primarily absorb the gel 44 of the flavoring material. Gel that does not adhere to the strip of current-collecting material 90 remains on the coating roller 110 and is re-applied to the strip of current-collecting material 90 on the next rotation of the coating roller 110.

The strip of current collector material 90 is lightly pressed against the cover roller 110 so as to maintain sufficient contact force between the strip of current collection material 90 and the cover roller 110. In FIG. 14, the strip of current-collecting material 90 is pressed against the cover roller 110 by two tension rollers 114, which are provided downstream and upstream of the cover roller 110. The tension rollers 114 are arranged so that the tension of the strip of current-collecting material 90 in the vicinity of the cover roller 110 is maintained at a predetermined value. Tension rollers 114 regulate the tension of the strip, as well as the arc of contact between the strip of current-receiving material 90 and the covering roller 110.

In fig. 15 shows a similar method that may be primarily used to coat a corrugated strip of current-receiving material 11. The corrugated strip 11 is guided through a roller gap 117 formed between the coating roller 110 and the back-up roller 116. The size of this roller gap 117 is somewhat smaller. than the peak-to-peak corrugation distance 13 of the corrugated strip of current-collecting material 11. Thus, the back-up roller 116 presses the strip of current-collecting material 11 against the cover roller 110. Thus maintaining sufficient contact pressure and at the same time increasing the contact surface between the corrugated strip of current-collecting material 11 and a coating roller 110. In FIG. 15, the strip of current-receiving material 11 is designed as having a wavy shape. However, corrugated strips 11 having a corrugated profile of a different shape can be used.

The cover roller 110 contacts only the ridges of the strip of current collecting material. Accordingly, only the ridges of the corrugated strip are provided with the flavor imparting material 44. Therefore, this method may be particularly suitable for use with corrugated strips of susceptor material that include smooth portions 84 and sparse portions 86 and in which ridges are formed in the sparse portions of susceptor material 86, as shown in FIG. 15.

As shown in FIG. 16 and 17, the flavoring material 44 may be provided to the susceptor material strip 11, 90 by passing the susceptor material strip 11, 90 under the flavoring material storage 50. The flavoring material storage has an outlet 52 at its bottom.

In fig. 16, the flavoring material is provided onto a flat strip of susceptor material 90 containing successive portions of smooth and sparse susceptor material 84, 86, as described in connection with FIG. 10. The strip 90 is transported on an endless conveyor belt 120, which is guided by guide wheels 122. The outlet 52 of the flavoring material storage 50 is located directly above and contacts the top surface of the strip of current collector material 90.

When the smooth portion 84 of the strip of susceptor material 90 is directly below the outlet 52, the smooth portion 84 effectively seals the outlet 52 and prevents the flavoring material 44 from flowing onto the strip of susceptor material 90.

When the sparse portion 86 of the strip of susceptor material 90 is immediately below the outlet 92, flavoring material 44 is supplied to these sparse portions 86. Thus, only a limited amount of flavoring material 44 is selectively supplied to the strip of susceptor material 90. Flavoring material 44 located in the open area of the rarefied portion 86 so that the overall thickness does not increase after loading of the flavoring material. This makes further handling of the material easier.

In fig. 17 is a similar insertion device as in FIG. 16 is used to supply flavoring material 44 to the corrugated strip of susceptor material 11. In this configuration, the outlet 52 at the bottom of the flavoring material storage 50 does not necessarily contact the strip of susceptor material 11.

This insertion device is particularly useful for applying flavoring material 44 to a corrugated strip of susceptor material 11 in which recesses 94 are formed from smooth portions of susceptor material 84. The recesses 94 can accommodate a significant amount of flavoring material 44.

In fig. 17, the ridges 96 of the strip of current-receiving material 11 are formed from the sparse portions 86. These ridges 96 act as an overflow to limit the amount of flavoring material 44 supplied to the depressions 94. Thus, when the fill level in the depressions 94 reaches the ridges 96 formed from the portions 86 porous savory material, any excess amount of flavoring material 44 flows through the porous sacrificial material 86.

To limit the amount of flavoring material 44 supplied to the corrugated strip 11, the outlet 52 of the flavoring material storage 50 is provided with an electronically controlled valve (not shown). The opening of the valve is controlled depending on the frequency of filling the strip of current-receiving material 11 with material 44 to impart flavor. Thus, the flavoring material 44 is supplied precisely when the recess 94 is located below the outlet 52.

Strips of current-receiving material 11 provided with flavoring material 44 in the manner shown in FIG. 17 may be layered on top of each other to form a current collector device 100. A suitable assembly process for this purpose is shown in FIG. 18.

In the first step, two identical corrugated strips 11 are produced in which ridges 96 are formed from sparse portions of current collector material 86 and in which valleys 94 are formed from smooth portions of current collector material 84 and filled with flavoring material 44.

One of the strips 11 is turned upside down and shifted half a step to one side. The strips 11 are then superimposed on each other so that the sparse portions 86 of one strip 11 extend into the depressions 94 of a corresponding other strip 11. As can be seen in the bottommost view of FIG. 18, the vacuum portions 86 of one strip 11 cover the flavor material 44 provided into the recesses 94 of the other strip 11. At the same time, the porous vacuum portions 86 allow the passage of evaporated flavor material 44. The flavoring material 44 helps to glue the two corrugated strips of current collector material 11 together. Using the process illustrated in FIG. 18, a very reliable current collector 100 is obtained.

The flavoring material 44 may be supplied to the corrugated strip of current collector material 11 through an injection device 130 that uses the flavoring material 44 in a solid state. The corresponding method is shown schematically in FIG. 19. The solid-state flavoring material 44 is advanced toward the perforator 132 as indicated by arrow 134. The perforator 132 is a movable member that is configured to cut a specified amount of the flavoring material 44 and deliver that amount of the flavoring material 44 into the recess 94 corrugated strip of current-receiving material 11. The advancing mechanism is not shown in more detail in FIG. 19, but any suitable actuators known to one skilled in the art may be used.

The corrugated strip of current-receiving material 11 is transported past the insertion device 130 in stages. The step-by-step movement of the corrugated strip of current-collecting material 11 is carried out by means of a conveyor device 140 containing a toothed endless belt 142, which is driven by a stepper motor 144. The teeth 146 of the toothed belt 142 are provided with a periodicity that corresponds to the periodicity of the corrugated strip of current-collecting material 11. Thus, each tooth 146 of the toothed belt 142 engages with a groove 94 of the corrugated strip of current-collecting material 11 so that the toothed belt 142 transports the corrugated strip of current-collecting material 11.

Each step of the stepper motor 144 and the toothed belt 142, respectively, corresponds to a pitch width 148 of the corrugated strip of the current-receiving material 11, such that each of the depressions 94 of the corrugated strip 11 is sequentially placed under the insertion device 130. After each step, a perforator 132 is activated, cutting a predetermined amount of flavoring material 44 and delivering the predetermined amount into a recess 94 of the corrugated strip of the current-receiving material 11.

The method further includes the step of temporarily liquefying an amount of flavoring material 44 that is supplied to depressions 94 of the corrugated strip of current receiving material 11. For this purpose, a heat gun 136 is provided which is directed at the cut flavoring material 44 in the depression 94. Hot air reduces the viscosity of the material 44 to add flavor. The heated flavoring material 44 becomes fluid and adheres to the walls of the recesses 94 of the strip of current-receiving material 11.

Fig. 20 and 21 relate to a method of supplying a liquid flavoring material 44 to a corrugated strip of susceptor material 11. The liquid flavoring material 44 is provided in a flavoring material storage 50 through which the corrugated strip of susceptor material 11 is passed. Flavoring material storage 50 has an inlet (not shown) for introducing an unloaded corrugated strip of current-receiving material 11 into the flavoring material storage 50. The flavoring material storage 50 further has an outlet 53 for allowing the loaded corrugated strip of current collecting material 11 to exit from the flavoring material storage 50.

The outlet 53 is formed from two pre-displaced edges 150 defining a distance between them that corresponds to the peak-to-peak distance 13 of the corrugated strip of current-receiving material 11.

The corrugated strip 11 is passed through the interior volume of the flavoring material storage 50 and is directed to the exit of the flavoring material storage 50 through the outlet 53.

The two edges 150 forming the outlet 53 are made of an elastic material and are pre-biased so that each of the edges 150 is slightly pressed against the corrugated strip of the current-receiving material 11. The pre-bias is obtained by means of a spring mechanism 152, which is provided between each of the edges 150 and the corresponding side surface 154 storage 50 to add flavor.

Thanks to the elastic material of the edges 150 and the spring mechanism 152, the edges 150 are pressed tightly on each side to the corrugated strip of the current-receiving material 11. In this way, the difference in height between successive ridges of the corrugated strip 11 is compensated.

Since the edges 150 are pressed on each side of the corrugated strip 11, the edges 150 effectively close the outlet 53 so that excess flavoring material 44 is largely prevented from flowing out of the flavoring material storage 50. To ensure reliable sealing, the edges 150 are made with such a length 156 that at any given time each of the edges 150 is in contact with at least two ridges of the corresponding side of the corrugated strip of the current-receiving material 11.

The width of the edges 158 corresponds to the width of the corrugated strip 11. The outlet 53 of the flavoring material storage 50 is provided with a suitable sealing element (not shown) to seal the outlet 53 on the sides of the corrugated strip 11.

After the corrugated strip of current collecting material 11 is passed through the interior space and the outlet 53 of the liquid material storage 50, the liquid flavoring material 44 enters each depression 94 of the corrugated strip of current collecting material 11. The flavoring material 44 is configured such that the flavoring material 44 The flavor entering each recess 94 substantially adheres to the walls of the recesses 94 of the corrugated strip 11 after the corrugated strip 11 leaves the flavor material storage 50 through the outlet 53.

Claims (20)

1. A method for manufacturing a current collector for an induction heated product that generates an aerosol, wherein the method includes the steps: provision of a strip of current-collecting material, providing a compression stage comprising opposing compression elements, wherein in a first part of the compression stage the compression elements are arranged so as to form a gradually narrowing compression gap in the processing direction, and wherein in a second part of the compression stage the compression elements are arranged so as to form a constant between them a compression gap in the processing direction, and wherein the opposing compression elements are designed to have matching surface structures, passing the strip of current-collecting material through the tapering compression gap of the compression stage so that the combined surface structures of the compression elements produce a deep drawing of the strip of current-collecting material. 2. The method according to claim 1, characterized in that the compression elements are belts that are guided along a plurality of guide rollers, wherein in the first part of the compression stage the guide rollers are arranged so that the belts form a gradually narrowing compression gap in the processing direction. 3. The method according to claim 2, characterized in that the belts are equipped with alternately arranged teeth so that a tooth of one belt penetrates between two adjacent teeth located on the opposite belt. 4. The method according to claim 1, characterized in that the compression elements are helical-shaped elements made and arranged so that threads provided on the outer circumference of the helical-shaped elements form a gradually narrowing compression gap in the processing direction. 5. The method according to any of the previous claims, characterized in that the compression step further comprises a third part in which the compression elements are arranged so as to form a gradually widening gap in the processing direction. 6. The method as claimed in any one of the preceding claims, wherein the method includes a flavoring material injection step in which the flavoring material is injected into a recess of the current-receiving material strip formed in the compression step. 7. The method according to any of the preceding claims, wherein the tooth or projecting structure is provided with a central channel which is in fluid communication with the flavoring material storage, and wherein the flavoring material is provided into the recess of the current collecting material strip in the third part of the step compression, forming a gradually widening gap in the processing direction. 8. A method for manufacturing a current collector for an induction heated product that generates an aerosol, wherein the method includes the steps: provision of a strip of current-collecting material, providing a cutting step comprising a periodically grooved blade for cutting and sparging at least portions of the strip of susceptor material such that the strip of susceptor material is provided with successive portions of smooth and sparse susceptor material. 9. The method according to claim 8, characterized in that the cutting process is a step-by-step process in which, between individual cutting stages, a strip of current-receiving material is fed forward by a given amount, and the periodically grooved blade makes reciprocating movements perpendicular to the feeding direction. 10. Method according to any one of claims 8 to 9, characterized in that during the cutting and vacuuming process, a flavoring material is provided to the strip of current-receiving material, so that the rarefied areas are simultaneously supplied with a flavoring material. 11. The method according to any one of claims 8 to 10, characterized in that two strips of current-collecting material are superimposed on each other so that the sparse parts of one strip of current-collecting material are located adjacent to the smooth parts of the other strip of current-collecting material. 12. A susceptor for an induction heated aerosol generating article, wherein the susceptor is provided as a strip of susceptor material containing successive portions of smooth and sparse susceptor material, and wherein the sparse susceptor material contains a plurality of holes. 13. The current collector according to claim 12, characterized in that the parts of the rarefied current collecting material are provided with a material for imparting taste. 14. The pantograph according to claim 12 or 13, characterized in that the strip of pantograph material is corrugated in such a way that the smooth parts are formed into depressions and the rarefied parts are formed into ridges of the resulting corrugated strip. 15. A current collector device for an induction heated product that generates an aerosol, wherein the current collector device contains two current collectors according to any one of claims 12-14 and the two current collectors are superimposed on each other so that the rarefied sections in the form of ridges of one current collector are located adjacent to the smooth ones parts in the form of depressions of another pantograph.