CN111655057A

CN111655057A - Wrapper pattern for aerosol-generating article

Info

Publication number: CN111655057A
Application number: CN201980009881.4A
Authority: CN
Inventors: D·格拉夫; A·卢韦
Original assignee: Philip Morris Products SA
Current assignee: Philip Morris Products SA
Priority date: 2018-02-16
Filing date: 2019-01-29
Publication date: 2020-09-11
Also published as: EP3752012B1; US20200397036A1; KR20200119252A; JP2021514180A; WO2019158352A1; PL3752012T3; RU2020127492A; EP3752012A1; BR112020013860A2

Abstract

The present invention provides an aerosol-generating article comprising an outer packaging sheet which, when rolled about a longitudinal axis, forms an outer tubular element of an aerosol-generating article, the outer packaging sheet comprising a first edge comprising a proximal portion and a distal portion, wherein the proximal portion comprises a glued section, and wherein the distal portion extends from the proximal portion at an acute angle relative to the longitudinal axis.

Description

Wrapper pattern for aerosol-generating article

The present invention relates to a wrapper pattern for an aerosol-generating article having a collapsible heat source for heating an aerosol-forming substrate.

Aerosol-generating articles in which tobacco is heated rather than combusted are known in the art. One purpose of such "heated" articles is to reduce certain smoke constituents of the type produced in conventional cigarettes by the combustion and pyrolytic degradation of tobacco. In one known type of heated aerosol-generating article, an aerosol is generated from a combustible heat source which transfers heat to an aerosol-forming substrate, for example comprising tobacco. The aerosol-forming substrate may be located downstream of the combustible heat source. An outer packaging sheet of an aerosol-generating article may be used to enclose the aerosol-forming substrate and at least a portion of the combustible heat source contained within the inner packaging sheet. In use, volatile compounds released from the aerosol-forming substrate by heat transfer from the combustible heat source are entrained in air drawn through the heated aerosol-generating article. As the released compound cools, the compound condenses to form an aerosol.

Some combustible heat sources may be difficult to extinguish, or it may be desirable to extinguish the heat source before it self-extinguishes. It would be desirable to provide an aerosol-generating article that can cover a combustible heat source to extinguish or shield the heat source. Arranging the outer wrapper sheet to include an internal recess into which the combustible heat source may be drawn is one way of achieving this.

WO 2017/115196 discloses an aerosol-generating article having a foldable structure that retracts a heat source into an interior "void space". The disclosed structure comprises an inner tubular member comprising, in order from a distal tip towards a proximal mouthpiece end: a heat source, an aerosol-generating substrate, a first diffuser element, a void space, a second diffuser element and an aerosol-cooling element. In use, the inner tubular member is retained within a tubular body comprising a mouthpiece filter element. The outer wrap sheet may be adhered to the inner tubular member at the joint to form a tubular body that retains the inner tubular element within the tubular body. The inner tubular member includes a weakened area whereby the tip may be folded into the void space within the tubular body.

Aerosol-generating articles are typically manufactured in a back-to-back configuration by rolling a wrapping sheet over a rod formed from first and second inner tubular elements mounted to respective first and second mouthpiece filters. The mouthpiece filter may be combined to form a mouthpiece filter element. The wrapped rod may then be severed through the mouthpiece filter to produce two aerosol-generating articles. This arrangement allows for higher line speeds than packaging a single aerosol-generating article. During the manufacture of foldable aerosol-generating articles, it is proposed that two packages may be applied to the rod. The first package may be adhered to the strip at a proximal end of the strip. For example, the first wrapper may secure the wrapper sheet at the mouthpiece filter, and optionally at the proximal portion of the inner tubular element and the mouthpiece filter. The second package may secure the outer wrapper sheet to the first package. The second package may be secured along its length to the underlying first package. This may result in an outer tubular member that rigidly supports and protects the bar or inner tubular member, while allowing the inner tubular member to be collapsible within the outer tubular member, and thus collapsible when "pinched off.

However, the glue pattern proposed for adhering the outer package sheet first to the strip and then to itself does not fix the ends of the outer package sheet to the strip at all points (especially during the first package), since for this first package gluing over the whole outer package sheet area will reduce the foldability of the inner tubular element. It is therefore proposed to adhere the outer wrapper to only the mouthpiece filter and a portion of the first and second inner tubular members on the first wrapper. Rotating drums (including a vacuum to temporarily adhere the outer packaging sheet to the rotating drum) are typical methods of rolling such aerosol-generating articles. Since the adhesive is only applied to the central portion of the outer wrapper sheet for the portion that will form the first wrapper, only this central portion will be unambiguously attached to the strip. The tips of the outer wrap sheet do not adhere to the strips at this stage and accordingly will tend to remain attached to the rotating drum. Thus, the non-central portion of the outer wrapper sheet may remain attached to the rotating drum while the central portion is securely wrapped over the rod during the first circumferential wrapping, which may result in uneven wrapping of the outer wrapper sheet and formation of a conical aerosol-generating article.

It would be desirable to provide an aerosol-generating article having a structure comprising an outer sheet which neither results in a conical aerosol-generating article, but which retains a foldable portion. It is desirable to provide an aerosol-generating article that can be manufactured using existing manufacturing processes and can be produced at existing production speeds.

According to the present invention, there is provided an aerosol-generating article having a proximal end and a distal end, the aerosol-generating article comprising:

-an inner tubular member comprising an inner packaging sheet defining a combustible heat source located towards a distal end of the aerosol-generating article;

-an outer package sheet forming an outer tubular element of the aerosol-generating article when rolled around a longitudinal axis, the outer package sheet comprising a first edge comprising a proximal portion and a distal portion, wherein the proximal portion comprises a glued section, and wherein the distal portion extends from the proximal portion at an acute angle with respect to the longitudinal axis.

According to one aspect of the invention, there is provided a packaging sheet which, when rolled about a longitudinal axis, forms a tubular element of an aerosol-generating article. The packaging sheet comprises a first edge comprising a proximal portion and a distal portion. The proximal portion includes a glue segment. The distal portion extends from the proximal portion at an acute angle relative to the longitudinal axis.

The packaging sheet of the present invention advantageously provides an aerosol-generating article having a less tapered profile than the prior art. This is partly due to the glued section at the proximal end of the first edge first contacting the inner tubular element during the outer packaging process of forming the aerosol-generating article. The gluing section enables the packaging sheet to be tightly wrapped around the inner tubular element without any separation between the packaging sheet and the inner tubular element during the first circumferential packaging. In addition, the angled distal portion of the first edge provides traction between the packaging sheet and the inner tubular element when the packaging sheet is wrapped over the inner tubular element. This causes the wrapping sheet to be pulled towards the inner tubular element when it is wrapped thereon. This further reduces the possibility of any separation between the packaging sheet and the inner tubular member.

In some embodiments, the proximal portion of the first edge is substantially parallel to the longitudinal axis.

In some embodiments, the packaging sheet further comprises a second edge opposite the first edge. The second edge includes a second edge proximal portion and a second edge distal portion, wherein the first edge and the second edge define a width of the sheet. The second edge proximal portion may be substantially parallel to the proximal portion of the first edge. The second edge proximal portion may also be substantially the same length as the proximal portion of the first edge. The second edge distal portion may be substantially parallel to the distal portion of the first edge. The second edge distal portion may also be substantially the same length as the distal portion of the first edge. In some embodiments, the packaging sheet further comprises proximal and distal edges extending between the first and second edges at their respective proximal and distal ends. The distance between the first edge and the second edge may be constant along the length of the sheet. The proximal edge and the distal edge may extend substantially perpendicular to the longitudinal axis.

In some embodiments, the first region is defined by a region of the sheet between the first edge proximal portion and the second edge proximal portion. A first glue pattern comprising a gluing section is applied to the first area, thereby defining a tape across the width of the sheet in the proximal portion. The first glue pattern may be applied over the entire extent of the first area, for example as a continuous glue layer. The glue pattern may be discontinuous, such as a series of stripes, dots, etc. in a regular or irregular array.

In some embodiments, the second region is defined by a region of the sheet between the first edge distal portion and the second edge distal portion. The second zone is divided into a first zone adjacent the first edge and a second zone adjacent the second edge by a boundary line extending from the distal edge to the first zone. A second glue pattern is applied to the second zone. The second glue pattern may be applied over the entire extent of the second area. As with the first glue pattern, the second glue pattern may be applied as a continuous glue layer, or may be discontinuous, such as a series of stripes, dots, etc. in a regular or irregular array. Typically, no adhesive is applied to the first zone.

The boundary line may be substantially parallel to the first edge distal portion.

In some embodiments, the first zone extends a first distance from the proximal edge, wherein the first distance is in the range of 1mm to 60 mm. The first distance is preferably in the range of 5mm to 15 mm.

In some embodiments, the first zone extends a second distance from the distal portion of the first edge, wherein the second distance is in the range of 10mm to 40 mm. The second distance is preferably in the range of 10mm to 25 mm.

An aerosol-generating article having a proximal end and a distal end is disclosed. Aerosol-generating articles typically comprise a mouthpiece filter at the proximal end. The aerosol-generating article comprises an inner tubular member, typically having a heat source end located at a distal end of the aerosol-generating article. The inner tubular member typically comprises an inner packaging sheet defining a combustible heat source located towards the distal end of the aerosol-generating article. The inner wrapper sheet typically defines an aerosol-forming substrate downstream of the combustible heat source. The inner wrapper sheet may define a void space between the aerosol-forming substrate and the mouth end. The combustible heat source, aerosol-forming substrate and (where included) the void space are provided in a coaxial arrangement. The outer tubular element extends from the proximal end of the aerosol-generating article towards the distal end thereof. The outer tubular member typically defines at least a mouth end and a void space of the inner tubular member. The outer tubular member typically terminates downstream of the heat source. The outer tubular element comprises a packaging sheet according to the above aspect. The inner wrapper sheet may comprise a foldable portion surrounding at least the void space such that the distal end comprising the combustible heat source and the aerosol-forming substrate is slidable relative to the outer tubular member. The distal end is thus slidable from an extended position having a first article length to a retracted position having a second article length less than the first article length.

The width of the sheet between the first edge and the second opposite edge is typically at least equal to twice the circumference of the inner tubular member to be wrapped. The boundary line may be spaced from the distal portion of the first edge by a distance (i.e., a second distance) that is at least equal to the circumference of the inner tubular member to be wrapped.

The first distance may be selected such that, when rolled into the form of the outer tubular element, for a first circumferential package, the packaging sheet is adhesively joined at its proximal end only to the inner tubular element by means of the adhesive tape formed by the first glue pattern, and for a second package, adhered to itself along substantially the entire length by means of the second glue pattern of the second region and by means of the adjacent remaining portion of the adhesive tape formed by the first glue pattern, thereby forming a tight seal on the aerosol-generating article.

According to the present invention there is provided a method of manufacturing an aerosol-generating article, wherein the aerosol-generating article has a proximal end and a distal end, the method of manufacturing an aerosol-generating article comprising the steps of:

-providing an inner tubular member comprising an inner packaging sheet defining a combustible heat source located towards a distal end of the aerosol-generating article;

-providing an outer packaging sheet comprising a first edge comprising a proximal portion and a distal portion, wherein the proximal portion comprises a glued section, and wherein the distal portion extends from the proximal portion at an acute angle with respect to a longitudinal axis;

-overwrapping at least a portion of the inner tubular element with the overwrap sheet, starting from the first edge of the overwrap sheet, by:

-adhesively joining a first edge proximal portion to the inner tubular element by bringing the gluing section into contact with the proximal end of the inner tubular element; and the number of the first and second groups,

-wrapping the outer wrapping sheet on the inner tubular element by rolling.

According to one aspect of the invention, a method of making an aerosol-generating article is provided. The method comprises providing a packaging sheet according to the above aspect. The method further comprises providing an inner tubular member. The method further comprises overwrapping at least a portion of the inner tubular element with the packaging sheet starting from the first edge of the packaging sheet by: adhesively joining the first edge proximal portion to the inner tubular member; and the wrapping sheet is wrapped on the inner tubular element by rolling. Joining the first edge proximal portion to the inner tubular element is achieved by contacting the gluing section with the proximal end of the inner tubular element.

In some embodiments, the overwrapping process comprises applying the wrapping sheet using a rotating cylinder. The outer package may comprise rolling the inner tubular member through a press between a rotating drum to which the outer package sheet is temporarily attached and a stationary guide plate, the sheet being wrapped around the inner tubular member during its passage through the press.

In some embodiments, the method comprises back-to-back manufacturing a pair of aerosol-generating articles, comprising providing a single mouthpiece filter element having first and second edges corresponding to the first and second mouthpiece filters initially combined. Providing an inner tubular element comprises providing first and second inner tubular elements mounted to respective first and second ends of a single mouthpiece filter element. Simultaneously overwrapping the first inner tubular member and the second inner tubular member with a single wrapping sheet that is symmetric about the center of the mouthpiece filter element to form the first outer tubular member and the second outer tubular member that are initially joined. The method further comprises severing the bonded outer tubular element and the mouthpiece filter element to separate the bonded article into a first aerosol-generating article and a second aerosol-generating article.

In a particular embodiment, the method of manufacturing an aerosol-generating article further comprises providing an inner tubular member comprising a foldable portion. Ideally, the collapsible portion of the inner tubular element at least surrounds the void space of the aerosol-generating element.

All scientific and technical terms used herein have the meanings commonly used in the art unless otherwise indicated. The definitions provided herein are to facilitate understanding of certain terms used frequently herein.

As used herein, the term "aerosol-generating article" refers to an article comprising an aerosol-forming substrate capable of releasing (e.g. by heating, combustion or chemical reaction) volatile compounds that can form an aerosol.

As used herein, the term "aerosol-forming substrate" is used to describe a substrate capable of releasing volatile compounds that can form an aerosol. The aerosol generated from the aerosol-forming substrate of the aerosol-generating article according to the present invention may be visible or invisible and may comprise vapour (e.g. fine particles of a substance in the gaseous state, which is typically a liquid or solid at room temperature) as well as gas and liquid droplets of condensed vapour.

As used herein, the term "sheet" means a layered element having a width and length greater than its thickness.

The terms "upstream" and "downstream" refer to the relative positions of elements of an aerosol-generating article described with respect to the direction of the inhalation airflow as it is drawn through the body of the aerosol-generating article from the distal end to the mouthpiece end. In other words, "downstream" as used herein is defined with respect to the airflow during use of the aerosol-generating article, wherein the mouth end of the article via which air and aerosol are drawn is the downstream end. The end opposite the mouth end is the upstream end.

The words "preferred" and "preferably" refer to embodiments of the invention that may provide certain benefits under certain circumstances. However, other embodiments may be preferred under the same or other circumstances. Furthermore, the recitation of one or more preferred embodiments does not imply that other embodiments are not useful, and is not intended to exclude other embodiments from the scope of the disclosure, including the claims.

In the description and claims of this specification, the words "comprise" and "comprise", and variations of the words "comprise" and "comprising", mean "including but not limited to", and are not intended to (and do not) exclude other groups, additives, components, integers or steps. In the description and claims of this specification, the singular encompasses the plural unless the context otherwise requires. In particular, where the indefinite article is used, the specification is to be understood as contemplating plurality as well as singularity, unless the context requires otherwise.

Embodiments of the invention will be further described hereinafter with reference to the accompanying drawings, in which:

fig. 1 is a schematic view of a prior art strip and proposed outer wrapping sheet;

figure 2 is a schematic view of an exemplary aerosol-generating article;

FIG. 3 is a schematic illustration of a strip and an outer wrapping sheet according to the present invention;

FIG. 4 is a schematic view of an overwrap sheet partially wrapped over the strip; and

figure 5 shows a side view of an overwrap station for wrapping overwrap sheets on a strip.

The schematic drawings are not necessarily drawn to scale and are presented for illustrative, but not limiting, purposes. The figures depict one or more aspects described in the present disclosure. However, it should be understood that other aspects not depicted in the drawings fall within the scope of the present disclosure.

Fig. 1 is a schematic illustration of a prior art strip 16 and a proposed outer wrapping sheet 20. The rod 16 is arranged in a back-to-back configuration and comprises a first inner tubular element 15 ' having a distal end 12 ' and a mouth filter end 11 '. The mouthpiece filter 10 ' is mounted to the first inner tubular element 15 ' at the mouthpiece filter end 11 '. The strip 16 also includes a second inner tubular element 15 "which is a mirror image of the first inner tubular element 15', and like parts are indicated by like reference numerals but with a double prime (") suffix. Each of the first and second mouthpiece filters 10 ', 10 "has a proximal end, and the first and second mouthpiece filters 10', 10" are joined at their respective proximal ends to form the mouthpiece filter element 10. Each of the first inner tubular member 15' and the second inner tubular member 15 "comprises a heat source, an aerosol-forming substrate and a void (see figure 2). The proposed outer packaging sheet 20 is shown in fig. 1 as a substantially rectangular sheet having a first edge 21, a first glue area 25 and a second glue area 30. When the first edge 21 is in contact with the strip 16, the first area of adhesive 25 may adhere the outer wrapper sheet 20 to the first and second inner tubular members 15', 15 "and the mouthpiece filter element 10. However, the glue pattern only bonds the outer wrapper sheet 20 to the inner tubular members 15 ', 15 ", proximate to their respective mouthpiece filter ends 11', 11"; since the outer end of the sheet of outer packaging material is free from adhesive, at least for the initial stage of the packaging process, i.e. for at least the first package around the inner tubular members 15', 15 ".

When aerosol-generating articles are manufactured in a back-to-back configuration, a series of outer packaging sheets are temporarily attached to a rotating drum, typically by vacuum, for example, and the respective rod 16 is brought into contact with a first edge of an associated outer packaging sheet 20. As the rotating drum rotates, each strip 16 and the attached outer wrapping sheet 20 are brought in turn towards the fixed guide. The rotating drum and the fixed guide plate act as a press and friction between the unwrapped aerosol-generating article, the fixed guide plate and the rotating drum causes the outer wrapper sheet 20 to wrap over the rod 16, forming a wrapped aerosol-generating article. Since for the first package the outer wrapper sheet 20 is first wrapped on the strip 16, only the area of the outer wrapper sheet glued to the strip 16 by the first glue area 25 remains tightly glued to the strip 16. The remaining outer wrap sheet 20 does not adhere to the strip 16 and therefore may remain attached to the rotating drum. This may create a tension on the first edge 21, wherein the adhesive pulls the outer wrap sheet 20 towards the strip 16 and the rotating drum pulls the outer wrap sheet 20 away from the strip 16. Thus, the rolled aerosol-generating article may be formed into a conical profile, wherein the finished aerosol-generating article has a smaller diameter at the mouthpiece filter end 11 ', 11 "than at the distal ends 12', 12". This will be referred to hereinafter as the "cone effect". When produced in a back-to-back configuration, an outer package sheet member formed of two symmetrical outer package sheets 20 attached at respective proximal ends may be used to simultaneously form two joined outer tubular elements (as shown in figure 1). The joined outer tubular member may then be cut along the centre line 35 to form separate first and second aerosol-generating articles.

Fig. 2 is a schematic view of an exemplary aerosol-generating article 100 relating to aspects of the present disclosure. The aerosol-generating article 100 extends along a longitudinal axis 150 between the proximal end 102 and the distal end 104, and comprises an inner tubular member 105 having a mouth end 107 and an opposite heat source end at the distal end 104 of the aerosol-generating article 100. The inner tubular member 105 comprises an inner packaging sheet 109 defining: a combustible heat source 115 located towards the distal end 104 of the aerosol-generating article 100, an aerosol-forming substrate 120 located downstream of the combustible heat source 115, and a void space 125 between the aerosol-forming substrate 120 and the mouthpiece end 107. The combustible heat source 115, aerosol-forming substrate 120 and void space 125 (when present) are provided in a coaxial arrangement. The portion of the inner packaging sheet 109 that defines the void space may be considered a foldable portion 109 b. A mouthpiece filter 127 is disposed at the proximal end 102 and is shown mounted to the inner tubular member 105 at the mouthpiece end 107. A removable cap 110 may also be mounted at the distal end of the inner tubular element 105 to help retain the aerosol-forming substrate 115 by forming a seal at the distal end 104 of the inner tubular element 105.

The aerosol-generating article 100 is shown to further comprise an outer tubular member 130 extending from the proximal end 102 of the aerosol-generating article 100 towards the distal end 104 thereof. The outer tubular member 130 defines at least the mouth end 107 and the void space 125 of the inner tubular member 105 and is formed by wrapping an overwrap sheet 200 over the mouth filter 127 and a portion of the inner tubular member 105. The outer tubular member 130 terminates downstream of the heat source 115. The distal end 104 comprising the combustible heat source 115 and the aerosol-forming substrate 120 is slidable relative to the outer tubular member 130 from an extended position having a first article length, e.g., L1, to a retracted position having a second article length, e.g., L2, that is less than the first article length. The aerosol-generating article may have the length of a conventional cigarette. The aerosol-generating article may have the diameter of a conventional cigarette. Sliding distal end 104 from the extended position to the retracted position at least partially folds void space 125 into an axially collapsed configuration. The slidable distal end comprising the combustible heat source 115 and the aerosol-forming substrate 120 allows the slidable distal end to fold into the void space from the extended position to the retracted position. The retracted position may allow the heat source to be located within the outer tubular member. The retracted position may be achieved by applying pressure or force at the distal end of the aerosol-generating article 100, for example when performing a "pinching out" action. When in the axially contracted configuration, void space 125 does not have to be completely collapsed. As shown in fig. 2, the inner tubular member 105 further includes a first transfer element 121a and a second transfer element 121b located at the ends of the void space 125. The inner tubular element 105 may further comprise a further transfer element 117 arranged between the combustible heat source 115 and the aerosol-forming substrate 120. The void space 125 provides a recess into which the distal end may be folded to cover the combustible heat source 115. In embodiments, the void space need not be a void, but may instead include any compressible region.

Although the outer tubular element 130 of the aerosol-generating article is shown to terminate downstream of the aerosol-forming substrate 120, it will be apparent to the skilled person that this arrangement is purely exemplary and other arrangements are possible, for example, this description will also include the outer tubular element 130 terminating at the aerosol-forming substrate 120.

Fig. 3 shows an outer packaging sheet 200 of the present invention. Since the illustrated outer wrapping sheet 200 is used to simultaneously wrap a pair of inner tubular members 105', 105 "in a back-to-back manner, the outer wrapping sheet is symmetrical about the centerline 155. For the sake of brevity, only the left side of the mirror image sheet will be described. Such a single outer wrapping sheet may be used to wrap the single inner tubular member 105'. As shown, the outer packaging sheet 200 has a proximal edge 205 and a distal edge 210 that extend substantially perpendicular to the longitudinal axis 150, with a first edge 215 and a second edge 220 extending therebetween parallel to the longitudinal axis 150. The width of the sheet 200 between the first edge 215 and the second opposing edge 220 is at least equal to twice the circumference of the first inner tubular element 105'. An intermediate line 225 extends between the first edge 215 and the second edge 220 and defines a first region 230 and a second region 240. The medial line 225 is spaced a first distance from the proximal edge 205. The first distance may be in the range 1mm to 60mm, preferably in the range 5mm to 15 mm. In this embodiment, the point at which the intermediate line 225 joins the first edge 215 divides the first edge 215 into a first proximal edge portion 215a and a first distal edge portion 215 b. The intermediate line 225 may be spaced from the distal edge 210 by a distance in the range of 6mm to 140mm, preferably in the range of 9mm to 50 mm. However, in some embodiments, the beginning of the first distal edge portion 215b may not coincide with the intermediate line 228. The first distal edge portion 215b is shown forming an acute angle a with the longitudinal axis 150. The angle α between the first distal edge portion 215b and the longitudinal axis 150 may be in the range of 1 ° to 40 °, preferably in the range of 7 ° to 31 °. When the intermediate line 225 joins the second edge 220, the second edge 220 may be divided into a second proximal edge portion 220a and a second distal edge portion 220 b. The first area 230 is substantially covered by adhesive of a first glue pattern adapted to bond the outer packaging sheet 200 to the strip 105 during the first circumferential wrapping and for the second wrapping to bond the proximal end of the outer packaging sheet corresponding to the first area to itself.

Additionally, a boundary line 235 is shown extending between the distal edge 210 and the intermediate line 225. The boundary line 235 may be spaced from the first edge distal portion 215b by a second distance that is at least equal to the circumference of the inner tubular member. The second distance may be in the range 10mm to 40mm, preferably in the range 10mm to 25 mm. The boundary line may be spaced from the second edge distal portion 220b by a distance in the range of 5mm to 20mm, preferably in the range of 7mm to 15 mm. The boundary line 235 serves to divide the second region 240 into a first region 240a and a second region 240 b. The second area 240b is substantially covered by the adhesive of the second glue pattern and may be considered as a glue area. The adhesive is suitable for bonding the outer packaging sheet 200 to itself during the second circumferential wrapping. The adhesive applied to the first region 230 may be similar to or different from the adhesive applied to the second region 240 b. The first region 240a is free of adhesive and may be considered a non-glued region.

Although the first proximal edge portion 215a is shown in fig. 3 as being parallel to the longitudinal axis 150, this is not required for the present invention. While the second distal edge portion 220b preferably forms an acute angle with the longitudinal axis 150, this is not essential to the invention. While the second proximal edge portion 220a is shown parallel to the longitudinal axis 150, this is not required for the present invention. While the first distal edge portion 215b is preferably parallel to the second distal edge portion 220b, this is not required for the present invention. The point at which the boundary line 235 extends from the intermediate line 225 may be spaced from the second edge proximal portion 220a by a distance in the range of 6mm to 30mm, preferably in the range of 10mm to 21 mm. The point at which the boundary line 235 extends from the intermediate line 225 may be spaced from the first edge proximal portion 215a by a distance in the range of 9mm to 35mm, preferably in the range of 13mm to 26 mm. While the distance between the first edge 215 and the second edge 220 is preferably substantially constant, this is not essential to the invention. Although the boundary line 235 is shown as being parallel to the first distal edge portion 215b, this is not necessary to the present invention.

As shown in fig. 3 and 4, the outer packaging sheet 200 may be used to manufacture aerosol-generating articles in a back-to-back configuration by providing a symmetrical outer packaging sheet 200 integrally attached at its respective proximal end 205. This allows for simultaneous overwrapping of the rod 106 comprising the first inner tubular element 105' and the second inner tubular element 105 "and the mouthpiece filter element 129. The first inner tubular element 105 ' and the second inner tubular element 105 "are shown to have respective mouthpiece filter ends 107 ', 107" and respective distal ends 104 ', 104 ". The first inner tubular element 105 'and the second inner tubular element 105 "are shown mounted to the mouthpiece filter element 129 at respective mouthpiece filter ends 107', 107". It is also shown that the first inner tubular member 105 'and the second inner tubular member 105 "include respective first and second void spaces 125' and 125". When the aerosol-generating article is manufactured in a back-to-back configuration, a mouthpiece filter element 129 comprising a combined first and second mouthpiece filter 127', 127 "may be used. As shown in fig. 3, the second distal edge 220b can form an acute angle with respect to the second proximal edge 220 a. As shown in fig. 3, the second distal edge 220b can be parallel to the first distal edge 215 b. In other embodiments, the shape of the second edge may match the shape of the first edge. This can avoid cutting losses. The size of the outer wrapper sheet may be selected such that the second edge is proximate to the first edge when wrapped on the aerosol-generating article. This may ensure that the outer wrapper sheet has a single consistent diameter along its length on the finished aerosol-generating article 100. However, while this arrangement is preferred, it will be apparent to the skilled person that this arrangement is not essential to the invention.

For the first circumferential wrapping, when the outer wrapper sheet 200 is wrapped over the first inner tubular element 105 ' and the mouthpiece filter 127 ' (see also fig. 5), the first inner tubular element 105 ' is initially attached to the outer wrapper sheet 200 at the first proximal edge portion 215a by adhesive. The mouthpiece filter 127', if included, may also be attached to the outer wrapper sheet 200. When the outer package sheet 200 is wrapped over the first inner tubular member 105 ', the adhesive applied to the first region 230 adheres the outer package sheet 200 to a portion of the first inner tubular member 105' at the first proximal edge portion 215 a. The adhesive applied to the first region 230, if present, may also adhere the outer wrapper sheet 200 to the mouthpiece filter 127'. When the outer wrap sheet 200 is wrapped over the first inner tubular member 105 ', the first distal edge 215b is also brought into contact with the first inner tubular member 105 ' and the first unglued region 240a is wrapped over another portion of the first inner tubular member 105 '. The unglued area 240a of the outer package sheet 200 is not adhered to the first inner tubular member 105'. When the adhesive is applied over the entire length of the first proximal edge portion 215a, any tension created along the first edge 215 as a result of the temporary attachment of the outer wrapper sheet 200 to the rotating roller 320 pulls the first distal edge 215b towards the first inner tubular member 105 ', thereby enhancing contact between the unglued region 240a and the first inner tubular member 105'. The acute angle between the first distal edge portion 215b and the first proximal edge 215a further enhances contact between the unglued region 240a and the first inner tubular member 105'. This is in contrast to the prior art, where tension on the first edge 21 may cause the unglued region of the outer wrapper sheet 200 to separate from the first inner tubular member 105' during the overwrapping process. The present invention allows the unglued region 240a to be tightly wrapped around the first inner tubular member 105', thereby reducing the cone effect found in the prior art.

While the manufacturing process has been described using a mouthpiece filter 127', it will be apparent to the skilled person that this is not essential to the invention. Although the manufacturing process has been described in the context of a single aerosol-generating article 100, it will be apparent to the skilled person that this description will apply, mutatis mutandis, to the manufacture of aerosol-generating articles manufactured in a back-to-back configuration, which may be preferred for process efficiency, so as to be able to produce two articles simultaneously in a single production line.

For the second circumferential wrap, when the outer wrapper sheet 200 is wrapped over the mouthpiece filter 127 'and the first inner tubular element 105', the remaining adhesive applied to the first region 230 and the adhesive applied to the second region 240b enable the outer wrapper sheet 200 to adhere to itself along substantially its own length, thereby forming an outer tubular element. When manufactured in a back-to-back configuration, a combined first outer tubular member and second outer tubular member are formed.

Fig. 5 shows a side view of an overwrap station for wrapping overwrap sheet 200 over strip 106. The overwrap station generally includes a first rotating roller 320, a channel or nip 310 defined by the first rotating roller 320 and a stationary guide 330, and a second rotating roller 340. The outer packaging sheet 200 with the depicted glue pattern is typically temporarily attached to the surface of the first rotating drum 320. Such temporary attachment may be created by vacuum holding the outer wrap sheet 200 to the surface of the first rotating drum 320. This may be accomplished, as is known in the art, by including a series of holes in the outer surface of the first rotating drum 320 through which air may be drawn to create the vacuum. The strip 106 is also shown attached to the first proximal edge portion 215a of the outer wrapper sheet 200. As the first rotating drum 320 rotates, the strip 106 and the outer wrap sheet 200 are brought to the channel or nip 310 defined by the first rotating drum 320 and the stationary guide plate 330. As the strip 106 passes through the press section 310, rotation of the first rotating drum 320 rolls the strip 106 on the fixed plate 330, which causes the overwrap sheet 200 to wrap around the rod 106. Although the described overwrap station includes a press 310 to wrap the overwrap sheet 200 over the rod 106, it will be apparent to the skilled artisan that this is not essential to the invention and that other overwrapping methods known in the art may be used.

Once the outer packaging sheet 200 is wrapped over the rod 106, the aerosol-generating article 100 is formed and may be removed from the press 310 by the second rotating drum 340. If manufactured in a back-to-back configuration, a bonded outer tubular element will be formed around the strip 106 and may be removed from the extrusion 310 by a second rotating roller 340. In such a case, the bonded outer tubular element may be severed along the centerline 155 through the bonded outer tubular element and the bonded mouthpiece filter element 129 to form the first and second aerosol-generating articles 100. This arrangement is preferred because the aerosol-generating article 100 can be manufactured using existing processes and at existing line speeds. Although the overwrapping process has been described in the context of manufacturing aerosol-generating articles in a back-to-back configuration, it will be apparent to the skilled person that this description is equally applicable to individually manufacturing aerosol-generating articles, and that it is not essential to the invention that aerosol-generating articles are manufactured in a back-to-back configuration. The cutting of the combined outer tubular element and the combined mouthpiece filter element 129 may be performed in the overwrap station or at a separate cutting station.

The aerosol-generating article 100 may have a length and diameter similar to a conventional cigarette. The second article length L2 may be about 90% of the first article length or less than the first article length. The second article length may be about 80% of the first article length or less than the first article length. The second article length may be about 70% of the first article length or less than the first article length.

Although the mouthpiece filter 127 and the mouthpiece filter element 129 are included in this description for clarity, they are not essential to the invention. Similarly, although the removable cap 110 has been described as a way of holding the aerosol-forming substrate, the removable cap 110 is not essential to the invention. Similarly, although transfer member 117 has been described, it is not essential to the invention. While adhesive has been described as one method of securing the outer wrap sheet 200 to the inner tubular member 105 and itself, this is not essential to the present invention and other securing methods, including mechanical securing methods such as perforations or surface features, are included in the present description. Although the outer wrapper sheet 200 is described as being adhered to itself along substantially the entire length of the outer wrapper sheet 200, this is not essential to the invention. Adhesion along less than the entire length of the outer wrap sheet 200 may still provide the benefits of the present invention.

Features, integers, characteristics or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless incompatible therewith. All of the features disclosed in this specification (including any accompanying claims, abstract and drawings), and/or all of the steps of any method or process so disclosed, may be combined in any combination, except combinations where at least some of such features and/or steps are mutually exclusive. The invention is not restricted to the details of any of the foregoing embodiments. The invention extends to any novel one, or any novel combination, of the features disclosed in this specification (including any accompanying claims, abstract and drawings), or to any novel one, or any novel combination, of the steps of any method or process so disclosed.

Examples of the invention

1. A packaging sheet which, when rolled about a longitudinal axis, forms a tubular element of an aerosol-generating article, the packaging sheet comprising:

a first edge comprising a proximal portion and a distal portion, wherein the proximal portion comprises a glued segment, and wherein the distal portion extends from the proximal portion at an acute angle relative to the longitudinal axis.

2. The packaging sheet of example 1, wherein a proximal portion of the first edge is substantially parallel to the longitudinal axis.

3. The packaging sheet of example 1 or example 2, further comprising a second edge opposite the first edge and comprising a second edge proximal portion and a second edge distal portion, wherein the first edge and the second edge define a width of the sheet.

4. The packaging sheet of example 3 wherein the second edge proximal portion is substantially parallel and substantially the same length as the proximal portion of the first edge.

5. The packaging sheet of example 3 or example 4, wherein the second edge distal portion is substantially parallel and substantially the same length as the first edge distal portion.

6. The packaging sheet of any one of examples 3-5, further comprising proximal and distal edges extending between the first and second edges at respective proximal and distal ends thereof.

7. The packaging sheet according to any one of examples 3 to 6, wherein a first area is defined by the area of the sheet between the first edge proximal portion and the second edge proximal portion, and wherein a first glue pattern comprising the gluing section is applied to the first area.

8. The packaging sheet of example 7 wherein the first glue pattern is applied over the entire extent of the first area.

9. The packaging sheet according to any one of examples 3 to 8, wherein a second area is defined by the area of the sheet between the first edge distal portion and the second edge distal portion, and wherein the second area is divided into a first region adjacent the first edge and a second region adjacent the second edge by a boundary line extending from the distal edge to the first area, and wherein a second glue pattern is applied to the second region.

10. The packaging sheet of example 9 wherein the second glue pattern is applied over the entire extent of the second zone.

11. The packaging sheet of example 9 or example 10, wherein the boundary line is substantially parallel to the first edge distal portion.

12. A method of making an aerosol-generating article, the method comprising:

-providing a packaging sheet according to any of the preceding examples;

-providing an inner tubular element;

-overwrapping at least a portion of said inner tubular element with said packaging sheet, starting from a first edge of said packaging sheet, by:

-wrapping said packaging sheet on said inner tubular element by rolling.

13. The method of example 12, wherein overwrapping comprises applying the wrapping sheet using a rotating cylinder.

14. The method of example 13, wherein the overwrapping comprises rolling the inner tubular member through a press between a rotating roller to which the wrapping sheet is temporarily attached and a stationary guide plate, the sheet wrapping over the inner tubular member during passage of the inner tubular member through the press.

15. The method of any one of examples 12-14, comprising back-to-back manufacturing a pair of aerosol-generating articles, comprising providing a single mouthpiece filter element having first and second ends corresponding to the first and second mouthpiece filters initially joined, wherein providing an inner tubular element comprises providing first and second inner tubular elements mounted to the respective first and second ends of the single mouthpiece filter element, wherein the first and second inner tubular elements are simultaneously overwrapped using a single sheet of wrapping that is symmetric about the center of the mouthpiece filter element to form first and second outer tubular elements that are initially joined, the method comprising severing the outer tubular element and the mouthpiece filter element, to separate the combined article into a first aerosol-generating article and a second aerosol-generating article.

Claims

1. An aerosol-generating article having a proximal end and a distal end, the aerosol-generating article comprising:

2. An aerosol-generating article according to claim 1, wherein a proximal portion of the first edge is substantially parallel to the longitudinal axis.

3. An aerosol-generating article according to claim 1 or claim 2, wherein the outer packaging sheet further comprises a second edge opposite the first edge and comprising a second edge proximal portion and a second edge distal portion, wherein the first edge and the second edge define a width of the sheet.

4. An aerosol-generating article according to claim 3, wherein the second edge proximal portion is substantially parallel to and substantially the same length as the proximal portion of the first edge.

5. An aerosol-generating article according to claim 3 or claim 4, wherein the second edge distal portion is substantially parallel to and substantially the same length as the distal portion of the first edge.

6. An aerosol-generating article according to any one of claims 3 to 5, wherein the outer packaging sheet further comprises proximal and distal edges extending between the first and second edges at respective proximal and distal ends thereof.

7. An aerosol-generating article according to any one of claims 3 to 6, wherein a first region is defined by the area of the sheet between the first edge proximal portion and the second edge proximal portion, and wherein a first glue pattern comprising the glued section is applied to the first region.

8. An aerosol-generating article according to claim 7, wherein the first glue pattern is applied over the entire extent of the first region.

9. An aerosol-generating article according to any one of claims 3 to 8, wherein a second region is defined by the area of the sheet between a first edge distal portion and the second edge distal portion, and wherein the second region is divided into a first region adjacent the first edge and a second region adjacent the second edge by a boundary line extending from the distal edge to the first region, and wherein a second glue pattern is applied to the second region.

10. An aerosol-generating article according to claim 9, wherein the second glue pattern is applied over the entire extent of the second zone.

11. An aerosol-generating article according to claim 9 or claim 10, wherein the boundary line is substantially parallel to the first edge distal portion.

12. An aerosol-generating article according to any preceding claim, wherein the outer tubular element extends from a proximal end of the aerosol-generating article towards a distal end thereof.

13. An aerosol-generating article according to any preceding claim, wherein the outer wrapper sheet overwraps at least a portion of the inner tubular element.

14. An aerosol-generating article according to any preceding claim, wherein the glued section of the first edge proximal portion is adhesively joined to the proximal end of the inner tubular element.

15. An aerosol-generating article according to any preceding claim, wherein the aerosol-generating article further comprises a void space.

16. An aerosol-generating article according to claim 15, wherein the inner wrapper comprises a foldable portion surrounding at least the void space.

17. A method of manufacturing an aerosol-generating article, wherein the aerosol-generating article has a proximal end and a distal end, the method of manufacturing an aerosol-generating article comprising the steps of:

-wrapping the outer wrapping sheet on the inner tubular element by rolling.

18. The method of any one of claims 17, wherein overwrapping comprises applying the overwrap sheet using a rotating drum.

19. The method according to claim 18, wherein the over-wrapping comprises rolling the inner tubular member through an extrusion between a rotating drum to which the over-wrapped sheet is temporarily attached and a stationary guide plate, the over-wrapped sheet being wrapped over the inner tubular member during passage of the inner tubular member through the extrusion.

20. A method according to any one of claims 17 to 19, comprising back-to-back manufacturing a pair of aerosol-generating articles, comprising providing a single mouthpiece filter element having first and second ends corresponding to the first and second mouthpiece filters initially joined, wherein providing an inner tubular element comprises providing first and second inner tubular elements mounted to the respective first and second ends of the single mouthpiece filter element, wherein the first and second inner tubular elements are simultaneously overwrapped using a single overwrap sheet that is symmetrical about the centre of the mouthpiece filter element to form first and second outer tubular elements that are initially joined, the method comprising severing the joined outer tubular elements and the mouthpiece filter element, to separate the combined article into a first aerosol-generating article and a second aerosol-generating article.