FIELD OF THE INVENTION

The present invention concerns a method of fabrication of a consumable article for an aerosol generating device.

Particularly, the consumable article is configured to operate with an aerosol generating device, also known as a heat-not-burn device or HNB device. Such type of aerosol generating devices is adapted to heat, rather than burn, an aerosol generating substrate comprised in the article.

BACKGROUND OF THE INVENTION

The popularity and use of reduced-risk or modified-risk devices (also known as vaporisers or aerosol generating devices) has grown rapidly in the past few years as an aid to assist habitual smokers wishing to quit smoking traditional tobacco products such as cigarettes, cigars, cigarillos, and rolling tobacco. Various devices and systems are available that heat or warm vaporizable substances as opposed to burning tobacco in conventional tobacco products.

A commonly available reduced-risk or modified-risk device is the heated substrate aerosol generation device or heat-not-burn device, also known as HNB device. Devices of this type generate aerosol or vapour by heating an aerosol generating substrate that typically comprises moist leaf tobacco or other suitable vaporizable material to a temperature typically in the range 150°C to 350°C. Heating an aerosol generating substrate, but not combusting or burning it, releases aerosol that comprises the components sought by the user but not the toxic and carcinogenic by-products of combustion and burning. Furthermore, the aerosol produced by heating the tobacco or other vaporizable material does not typically comprise the burnt or bitter taste resulting from combustion and burning that can be unpleasant for the user and so the substrate does not therefore require the sugars and other additives that are typically added to such materials to make the smoke and/or vapour more palatable for the user. Some HNB devices can be adapted to operate with consumable articles having reduced dimensions. Such articles can have for example a flat shape and form a sensibly cuboid shape of 1 or 2 mm of thickness. Their transversal and longitudinal dimensions can be comprised between 10 and 30 mm. Due to such shape and dimensions, these consumable articles make the heat transfer for vapour generation more efficient compared to a rod-type format.

The development of these new tobacco consumable types requires the development of new fabrication methods to obtain these consumables.

SUMMARY OF THE INVENTION

One of the aims of the invention is to propose a method of fabrication of a consumable article, which may be easily carried out, while being fast and efficient.

For this purpose, the invention relates to a method of fabrication of a consumable article, for example a flat-shaped consumable article, for an aerosol generating device, the consumable article extending along an article axis and comprising:

- a tobacco substrate defining at least a first pair of opposite lateral surfaces extending along the article axis ;

- a support structure comprising an outlet portion arranged successively with the tobacco substrate along the article axis and a substrate portion extending from the outlet portion along the article axis and configured to be engaged with said first pair of opposite lateral surfaces to maintain the tobacco substrate together with the support structure, the outlet portion comprising an airflow passage extending from the tobacco substrate; the method comprising at least the following steps :

- providing a stack of several tobacco substrates arranged one on top of another in a container, the container defining two openings facing each other;

- providing a support structure;

- placing the support structure in front of the first opening;

- pushing via the second opening one of the tobacco substrates out of the container through the first opening to insert said tobacco substrate into said support structure.

Thanks to these features, the method enables to load a plurality of tobacco substrates inside a container to form a stack of tobacco substrates, allowing them to drop down through the container. The openings of the container enable a tobacco substrate to be pushed out of the container through the first opening. Said tobacco substrate is then inserted into a support structure placed in front of it. The rest of the tobacco substrates in the container then drops down without any external action and a new tobacco substrate may be pushed out of the container. This enables a fast and efficient assembling of several tobacco substrates with the associated support structure to obtain a consumable article, for example a flat-shaped consumable article.

In some embodiments, the method comprises a step of pulling out and moving said support structure and said tobacco substrate away from the first opening.

Thanks to these features, the assembled consumable article is moved away from the container enabling the tobacco substrates comprised in the container to drop down and enabling a new support structure to be placed in front of the first opening.

According to some embodiments, the tobacco substrate is pushed out of the container through a pusher tip providing a linear displacement along a pushing axis.

Thanks to these features, the pusher tip is able to push easily through the second opening a tobacco substrate out of the container. The pusher tip is able to repeatedly push a tobacco substrate out of the container and to be withdrawn out of the second opening to enable the stack of tobacco substrates to drop down.

According to some embodiments, the pusher tip presents a length along the pushing axis greater than the length between the two openings of the container along the pushing axis.

Thanks to these features, it is not possible for the stack of tobacco substrates contained in the container to drop behind the pusher tip and to block the withdrawal of it out of the container.

According to some embodiments, the pusher tip comprises two opposite faces, a first face extending along the pushing axis, a second face able to be in contact with the stack of tobacco substrates, the first face and the second face presenting an angle between them, the angle being comprised between 1 ° and 25°, preferably between 5° and 20°, even more preferably between 10° and 15°. Thanks to these features, these slopes enable a smoother drop of the next tobacco substrate in the stack.

According to some embodiments, the support structure is placed in front of the first opening by a holder, the holder being chosen between:

- a pincer/tweezer arrangement,

- a pneumatic/vacuum operated surface mount technology system, a silicone mold holder.

Thanks to these features, the support structure is easily handled by the holder in order to place and then withdraw the support structure efficiently in front of the first opening.

According to some embodiments, the substrate portion comprising a pair of legs, each leg being configured to extend along at least a part of the corresponding lateral surface; wherein the container comprises two curved flaps arranged on both side of the first opening transversally to the pushing axis; wherein during the step of pushing the tobacco substrate out of the first opening, the tobacco substrate pushes the flaps; the flaps deflecting and spreading the support legs of the support structure and allowing the tobacco substrate to be inserted in the support structure.

According to some embodiments, the flaps are made of metal.

According to some embodiments, the flaps are closing again after the tobacco substrate being pushed out of the container through pneumatics, springs, or a compressed compliant material.

Thanks to these features, the flaps allow an easy insertion of the tobacco substrate into the support structure. In particular, the flaps are curved to enter into the support structure. As a consequence, as the tobacco substrate is pushed through the flaps, they deflect spreading the support legs and allowing the tobacco substrate to be inserted without unwanted stress and possible deformation into the associated support structure.

According to some embodiments, each flap is deflected on a maximum deflection of

1 mm. Thanks to these features, the degree of deflection of the flaps is small to prevent damage to support legs.

According to some embodiments, the support structure is provided via a linear or rotary conveyor circulating in front of the container.

Thanks to these features, a rapid fabrication is possible as a plurality of support structures are placed continuously one after the other in front of the first opening to be filled with an associated tobacco substrate.

According to some embodiments, at least one additional container is arranged aside of said container, each additional container comprising a stacks of several tobacco substrates, the conveyor circulating in front of all the containers.

Thanks to these features, multiple parallel filling of tobacco consumables in their associated support structures is possible, enabling to produce several consumable articles at the same time.

According to some embodiments, a stack of support structures is facing the container comprising the stack of tobacco substrates, a gap between the two stacks being slightly larger than the length of the assembled flat-shaped consumable article.

Thanks to these features, once the tobacco substrate has been inserted in the support structure, the assembled article is easily removed while enabling a compact fabrication architecture.

According to some embodiments, the method comprises further the followings steps:

- providing at least a wrapper layer,

- application of at least one line of glue along the article axis on each wrapper layer and/or the tobacco article,

- wrapping the article with the wrapper layer(s) along the article axis without any overlapping of the wrapper layer(s) on the wide lateral faces.

Thanks to these features, overlapping of the wrapper layer(s) is formed on the narrow sides only. This ensures low thermal insulation between the heater of the aerosol generating device and the tobacco substrate. In some embodiments, the consumable article forms a substantially circular or square or ellipsoidal cross-sectional shape. In some embodiments, it can form at least one rounded face.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention and its advantages will be better understood upon reading the following description, which is given solely by way of non-limiting example and which is made with reference to the appended drawings, in which:

Figure 1 is a perspective view of an aerosol generating assembly comprising an aerosol generating device and a flat-shaped consumable article;

Figure 2 is a perspective view of the flat-shaped consumable article of Figure 1 , the consumable article comprising a wrapper;

Figure 3 is a perspective view of a flat-shaped consumable article of Figure 1 according to another embodiment than Figure 2;

Figure 4 is a view similar to the view of Figure 2, the consumable article being without the wrapper;

Figures 5, 6 and 7 are vertical side cross-sectional views of an installation carrying out a method of fabrication according to a first embodiment of the consumable article of Figures 2 to 4;

Figures 8 and 9 are horizontal side cross-sectional views of the installation carrying out the method of fabrication according to a first embodiment;

Figure 10 is a vertical side cross-sectional view of wrapping phase of the method of fabrication according to a first embodiment;

Figures 11 and 12 are vertical side cross-sectional views of an installation carrying out a wrapping phase of the method of fabrication according to a second embodiment; Figure 13 is a vertical side cross-sectional view of an installation carrying out a method of fabrication according to a third embodiment of the consumable article of Figures 2 to 4; and

Figure 14 is a horizontal side cross-sectional view of an installation carrying out a method of fabrication according to a fourth embodiment of the consumable article of Figures 2 to 4.

DETAILED DESCRIPTION OF THE INVENTION

Before describing the invention, it is to be understood that it is not limited to the details of construction set forth in the following description. It will be apparent to those skilled in the art having the benefit of the present disclosure that the invention is capable of other embodiments and of being practiced or being carried out in various ways.

As used herein, the term “aerosol generating device” or “device” may include a vaping device to deliver an aerosol to a user, including an aerosol for vaping, by means of a heater element explained in further detail below. The device may be portable. “Portable” may refer to the device being for use when held by a user. The device may be adapted to generate a variable amount of aerosol, e.g. by activating the heater element for a variable amount of time (as opposed to a metered dose of aerosol), which can be controlled by a trigger. The trigger may be user activated, such as a vaping button and/or inhalation sensor. The inhalation sensor may be sensitive to the strength of inhalation as well as the duration of inhalation to enable a variable amount of vapour to be provided (so as to mimic the effect of smoking a conventional combustible smoking article such as a cigarette, cigar or pipe, etc.). The device may include a temperature regulation control to drive the temperature of the heater and/or the heated aerosol generating substance (aerosol pre-cursor) to a specified target temperature and thereafter to maintain the temperature at the target temperature that enables efficient generation of aerosol.

As used herein, the term “aerosol” may include a suspension of vaporizable material as one or more of: solid particles; liquid droplets; gas. Said suspension may be in a gas including air. Aerosol herein may generally refer to/include a vapour. Aerosol may include one or more components of the vaporizable material. As used herein, the term “vaporizable material” or “precursor” may refer to a smokable material which may for example comprise nicotine or tobacco and an aerosol former. Tobacco may take the form of various materials such as shredded tobacco, granulated tobacco, tobacco leaf and/or reconstituted tobacco. Suitable aerosol formers include: a polyol such as sorbitol, glycerol, and glycols like propylene glycol or triethylene glycol; a non-polyol such as monohydric alcohols, acids such as lactic acid, glycerol derivatives, esters such as triacetin, triethylene glycol diacetate, triethyl citrate, glycerin or vegetable glycerin. In some embodiments, the aerosol generating agent may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. The substrate may also comprise at least one of a gelling agent, a binding agent, a stabilizing agent, and a humectant.

As used herein, the term “wider” applied in relation with two surfaces is used to compare dimensions of these surfaces in a transversal direction, i.e. direction perpendicular to the extension direction of these surfaces. When at least one of the surfaces has a nonplane shape, said dimension is measured according to a plane passing through at least two points limiting the surface according to the transversal direction.

DESCRIPTION OF THE ARTICLE AND THE ASSOCIATED DEVICE

Figure 1 shows an aerosol generating assembly 10 comprising an aerosol generating device 1 1 and a consumable article 12 according to a first embodiment of the invention, called hereinafter consumable article 12. The aerosol generating device 11 is intended to operate with the consumable article 12 which is shown in more detail in Figure 2.

Referring to Figure 1 , the aerosol generating device 1 1 comprises a device body 15 extending along a device axis Y. The device body 15 comprises a mouthpiece 16 and a housing 17 arranged successively along the device axis Y. According to the example of Figure 1 , the mouthpiece 16 and the housing 17 form two different pieces. Particularly, according to this example, the mouthpiece 16 is designed to be fixed on or be received in an insertion opening formed at one of the ends of the housing 17. In this case, the consumable article 12 can be inserted inside the device 11 when the mouthpiece 16 is removed from the housing 17. According to another example (not-shown), the mouthpiece 16 and the housing 17 form one unique piece. In this case, the consumable article 12 can be inserted inside the device 11 through for example a flow outlet. According to both examples, the mouthpiece 16 defines a through hole adapted to receive at least partially the consumable article 12. Particularly, the through hole can be adapted to receive at least an outlet portion of the consumable article 12, explained in further detail below. According to still another embodiment (not-shown), no mouthpiece 16 is provided with the aerosol generating device 11 . In this case, the outlet portion of the consumable article 12 can form a mouth end designed to be in contact with the user’s lips and/or mouth while a vaping session.

The housing 17 delimits an internal space of the device 11 receiving various elements designed to carry out different functionalities of the device 11 . This internal space may for example receive a battery for powering the device 11 , a control module for controlling the operation of the device 11 , etc.

The housing 17 further delimits a receiving cavity configured to receive the consumable article 12. In particular, the receiving cavity presents an opening through which the consumable article 12 may be inserted. The receiving cavity is further designed to heat the consumable article 12 using an appropriate heater. The receiving cavity 20 may be for example arranged in the extension of the through hole of the mouthpiece 16, according to the device axis Y. The receiving cavity 20 is delimited by walls presenting a sensibly parallelepipedic shape, complementary to the shape of the consumable article 12. The walls are advantageously made of ceramic.

In reference to Figure 2, the consumable article 12 is for example a flat-shaped consumable article presenting a flat-shaped cuboid extending along an article axis X between an inlet end 18 and an outlet end 19, and having external dimensions LxWxH. According to other embodiments, the consumable article 12 presents any other suitable shape. It can for example form a substantially circular or square or ellipsoidal cross- sectional shape.

The consumable article 12 is adapted to conduct an airflow from the inlet end 18 to the outlet end 19 as it will be explained in further detail below. In a typical example, the length L of the article 12 according to the article axis X equals substantially to 25-35 mm, for example 33 mm while its width W is comprised between 8 and 15 mm, for example substantially equal to 12 mm and height H is comprised between 0.8 and 2 mm, for example is substantially equal to 1 ,2 mm. According to different examples, the values L, W and H can be selected within a range of +/- 40%, for example. In the example of Figure 2, the consumable article 12 is wrapped by a common wrapper 21 . In other words, in this example, the wrapper 21 is formed from a unique sheet wrapping substantially the whole length of the consumable article 12 around the article axis X. In other examples, the wrapper 21 extends only along a part of the length of the consumable article 12. For example, the wrapper 21 can extend only along the tobacco substrate of the consumable article 12 and advantageously, wrap only the tobacco substrate, as it is shown in an alternative embodiment of Figure 3. According to another example, the wrapper 21 is formed from two different sheets wrapping separately for example the tobacco substrate and the support structure of the consumable article 12. The wrapper 21 can be made of aluminium and/or paper. The paper can be coated with an impermeable coating to prevent liquid absorption like cooking/backing paper. In some embodiments, when the wrapper 21 is made of aluminium, it can wrap only the tobacco substrate to prevent condensation leakage and/or vapour leakage. Additionally, aluminium allows a better heat transfer.

Figure 4 shows the consumable article 12 without the wrapper 21. In some embodiments, the consumable article 12 can be provided and used without the wrapper 21 , as it is shown in Figure 3. In reference to this Figure 4, the consumable article 12 comprises a tobacco substrate 25 for generating aerosol and a support structure 26 for retaining the tobacco substrate 25. The support structure 26 may also serve to collect the aerosol flow from the tobacco substrate 25 and guide it to the user’s mouth.

The tobacco substrate 25 defines the inlet end 18 of the consumable article 12 and contains a vaporizable or smokable material as defined above. The vaporizable material is for example compressed to form a solid structure which is able to release aerosol upon heating. Examples of tobacco substrates and their manufacturing methods are described in WO/2021/094365 and WO/2021/094366. Particularly, the tobacco substrate 25 defines for example a substantially flat-shaped cuboid defining a first pair of opposite lateral surfaces (represented as the right and left sides of the substrate in Figure 4), and a second pair of opposite lateral surfaces (represented as the top and bottom sides of the substrate in Figure 4), each of said pairs of lateral surfaces extending along the article axis X. According to other embodiments, the tobacco substrate 25 can have any other suitable shape. The second pair of opposite lateral surfaces is for example at least 5 times, advantageously 10 times, wider than the first pair of lateral surfaces. The first pair of opposite lateral surfaces is designed to be in contact with the support structure 26. Each lateral surface of the first pair can define a generally flat shape which can define rounded edges in each cross- section. Particularly, in each cross-section, each lateral surface of the first pair can have a convex rounded shape. The second pair of lateral surfaces is designed to be heated by the heating chamber of the device 1 1 by conduction and/or convection. According to another embodiment, the tobacco substrate 25 comprises susceptors and is designed to be heated by induction further to a magnetic interaction of the susceptors with a magnetic coil.

The support structure 26 is able to retain the tobacco substrate 25. In a preferred embodiment of the invention, the support structure 26 is formed from one single piece using for example an injection moulding process. The support structure 26 can be made of or comprise a paper pulp material. In some embodiments, the support structure 26 can comprise milled tobacco or a flavouring agent releasable upon heating. The support structure 26 can also be recyclable. The support structure 26 can also comprise at least one visual characteristic, such a colour, a symbol or an image, defining at a flavour of the tobacco substrate.

The support structure 26 comprises an outlet portion 30 designed to be arranged successively with the tobacco substrate 25 along the article axis X and a substrate portion 32 extending from the outlet portion 30 along the article axis X and configured to be engaged with the first pair of opposite lateral surfaces to maintain the tobacco substrate 25 together with the support structure 26.

The outlet portion 30 defines an airflow passage extending from the tobacco substrate 25 until the outlet end 19 of the consumable article 12 formed by this outlet portion 30. Thus, the outlet portion 30 is intended to extend the flow channels of the tobacco substrate 25 and to conduct an airflow from each of these flow channels until the outlet end 19 of the consumable article 12

The substrate portion 32 comprises a pair of legs 34, extending along the article axis X from the outlet portion 30 toward the inlet end 18 of the consumable article 12. Particularly, each leg 34 is configured to extend along at least a part of the corresponding lateral surface of the first pair of lateral surfaces of the tobacco substrate 25. In the example of Figures 3 and 4, the legs 34 extend according to the whole length of the tobacco substrate 25. According to other examples, the legs 34 extend according to at least ¹ /z, advantageously % of the total length (in direction of axis X) of the tobacco substrate 25. The legs 34 are for example symmetric in respect with a central plane passing in the middle between the two legs 34 according to the article axis X. DESCRIPTION OF A FIRST EMBODIMENT OF THE METHOD OF FABRICATION

A method of fabrication of such a consumable article 12 according to a first embodiment of the invention will now be described, in reference to Figures 5 to 10.

Initially, as visible in Figure 5, a stack of several tobacco substrates 25 is arranged a one on top of another along an elevation axis B. The stack of tobacco substrates 25 is placed into a container 40. Here fourteen tobacco substrates 25 are placed into the container 40, but the skilled person will understand that the container 40 may comprise more tobacco substrates 25, for example fifty tobacco substrates 25 or more.

The container 40 is notably a hollow metal tower presenting a rectangular transversal section. In particular, the container 40 is slightly larger in the transversal section than the tobacco substrates 25. Therefore, the container 40 limits lateral movements of the tobacco substrates 25 but allows them to drop down along the elevation axis B.

The container 40 defines two openings facing each other, and in particular a first opening 42 and a second opening 44. The two openings 42, 44 are advantageously arranged at the base of the container 40. The two openings 42, 44 face each other along a pushing axis A. Each opening 42, 44 presents a slightly larger cross-sectional area than the transversal section of one tobacco substrate 25, for example 13 mm wide by 1 ,5 mm high, to allow a tobacco substrate 25 to pass through each opening 42, 44.

Referring to Figure 8, the container 40 further comprises two curved flaps 46 arranged on both side of the first opening 42 transversally to the pushing axis A. The flaps 46 are advantageously made of metal. Each flap 46 is fixed at one extremity to one side of the first opening 42 and the other extremity is free. As visible on Figure 9, each flap 46 is able to deflect, advantageously on a maximum deflection of 1 mm.

Referring again to Figure 5, a support structure 26 is provided. The support structure 26 is placed in front of the first opening 42. Here, the support structure 26 is placed in front of the first opening 42 by a holder 48. The holder 48 is advantageously chosen between: a pincer/tweezer arrangement, a pneumatic/vacuum operated surface mount technology system or a silicone mold holder. A pusher tip 50 is placed in front of the second opening 44. The pusher tip 50 is in particular a pusher which operates with linear displacement motion along the pushing axis A. The pusher tip 50 is notably driven by pneumatic, solenoid or motor for example. The pusher tip 50 presents a length along the pushing axis A greater than the length between the two openings 42, 44 of the container 40 along the pushing axis A to avoid a tobacco substrate 25 falling down behind the pusher tip 50 when pushing a tobacco substrate 25 out of the container 40.

The pusher tip 50 comprises two opposite faces 52, 54. The first face 52 extends along the pushing axis A and faces the support surface on which rest the container 40. The second face 54 is opposite to the first face 52 along the elevation axis B. The second face 54 is able to be in contact with the stack of tobacco substrates 25. In an advantageous embodiment, the first face 52 and the second face 54 present a non-zero angle a between them. The angle a is notably comprised between 1 ° and 25°, preferably between 5° and 20°, even more preferably between 10° and 15°. This allows for a smoother drop of the next tobacco substrate 25 in the stack.

Referring now to Figure 6, the method then comprises a step of pushing via the second opening 44 one of the tobacco substrates 25 out of the container 40 through the first opening 42 to insert said tobacco substrate 25 into said support structure 26. In particular, the tobacco substrate 25 is pushed out of the container 40 through the pusher tip 50 moving along the pushing axis A and being inserted inside the container 40 through the second opening 44.

As visible on Figures 8 and 9, during the step of pushing the tobacco substrate 25 out of the first opening 42, the tobacco substrate 25 pushes the flaps 46. The flaps 46 deflect and spread the support legs 34 of the support structure 26 in order to allow the tobacco substrate 25 to be inserted in the support structure 26.

Then, as visible on Figure 7, the pusher tip 50 gets back to its initial position by moving out of the container 40. The stack of tobacco substrates 25 in the container 40 then drops down along the elevation axis B. The assembled article 12 comprising the support structure 26 with the inserted tobacco substrate 25 is then pulled out and moved away from the first opening 42. The flaps 46 close again after the tobacco substrate 25 being pushed out of the container 40 through pneumatics, springs, or a compressed compliant material. Then, a wrapping phase may be optionally carried out, which will be described below.

To that end, at least a wrapper layer 21 is provided. In particular, a single wrapper layer 21 may be provided for several articles 12 and then cut before being wrapped around the associated article 12. The wrapper layer 21 may be fed through on a conveyor belt with vacuum suction to ensure the movement. It may then be cut after the application of the glue to the correct dimensions with a normal or ultrasonic blade to ensure minimal sticking. Alternatively, the wrapper layer 21 can be cut before application of the glue.

In a variant, the wrapper layer 21 may be provided in already separated sheets.

At least one line of glue 56 is applied along the article axis X on each wrapper layer 21 . In a variant or in a complement, at least one line of glue 56 is applied along the article axis X directly on the tobacco article 12. Advantageously, two or even three parallel lines of glue 56 are applied. The glue may be applied fully or partially to the support structure 26 while it moves through the conveyor belt.

The article 12 is then wrapped with the wrapper layer(s) 21 along the article axis X without any overlapping of the wrapper layer(s) 21 on the wide lateral faces. An overlap may occur on the short edge side of the article 12, namely on one of the first pair of opposite lateral surfaces. Alternatively, as visible in Figure 10, an overlap may occur on the two lateral faces of the first pair of opposite lateral surfaces. In another alternative, not shown, the wrapper layer may be adhered to the support structure 26 with no overlap.

Referring to Figure 10, a single wrapper layer 21 is used to wrap the entire article 12. The tobacco substrate 25 is then inserted into the support structure 16 and then the entire assembled article is wrapped to obtain a wrapped article 12 as shown on Figure 2.

In a variant, the wrapping is only carried out for the tobacco substrate 25 and the wrapped tobacco substrate 25 is inserted into the support structure 26 to obtain an article 12 as shown on Figure 3.

The wrapping phase may be carried out using known wrapping machines.

DESCRIPTION OF A SECOND EMBODIMENT OF THE METHOD OF FABRICATION A second embodiment of the fabrication method according to the invention will be described below, referring to Figure 1 1 .

The fabrication method according to the second embodiment is similar to the fabrication method according to the first embodiment explained above except the features described below.

The wrapping of the article 12 may be achieved in two steps as illustrated in Figures 11 and 12 with two separated wrapper layers 21 for each article 12. Here two lines of glue 56 are applied on both side of each wrapper layer 21 . The article 12 may for example be grabbed and handled by an internal support inserted in the inlet end 18 and/or the outlet end 19.

As visible in Figure 1 1 , the article 12 is placed on the middle of the first layer 21 and the first layer 21 sticks on a first half of the article 12. Referring to Figure 12, the article 12 is then turn upside down and placed in front of the second wrapper layer 21 . The article 12 is placed on the middle of the second layer 21 and the second layer 21 sticks on the other half of the article 12, with an overlapping of the two layers 21 on the opposite lateral faces. This allows a stronger bond as each wrapper 21 has the full height of the support structure 26 to adhere to.

DESCRIPTION OF A THIRD EMBODIMENT OF THE METHOD OF FABRICATION

A third embodiment of the fabrication method according to the invention will be described below, referring to Figure 13.

The fabrication method according to the third embodiment is similar to the fabrication method according to the first embodiment explained above except the features described below.

As visible on Figure 13, a stack of support structures 26 is facing the container 40 comprising the stack of tobacco substrates 25.

The stack of support structures 26 is contained into a second container 60. The second container 60 is similar to the container 40 with dimensions adapted to the size of the support structures 26. A second pusher tip 62 is arranged next to the second container 60. The second pusher tip 62 is able to push a support structure 26 in the direction of the stack of tobacco substrates 25.

The gap between the two stacks is slightly larger than the length of the assembled consumable article 12, to enable an easy removal of the assembled article 12.

The tobacco substrate 25 and the support structure 26 are pushed out of their respective container 40, 60 at slightly the same moment to obtain an assembled article 12, as visible in Figure 13.

Once the tobacco substrate 25 and the support structure 26 have been inserted to obtain the article 12, a third pusher, not shown, may remove the assembled article 12 by pushing it away in a direction orthogonal to the pushing axis A.

In an advantageous embodiment, a glue dispenser 66 is arranged in the second container 60 or at the exit second container 60 to obtain several assembled articles 12. The glue is then applied as the support structure 26 is pushed out of the second container 60.

DESCRIPTION OF A FOURTH EMBODIMENT OF THE METHOD OF FABRICATION

A fourth embodiment of the fabrication method according to the invention will be described below, referring to Figure 14.

The fabrication method according to the fourth embodiment is similar to the fabrication method according to the first embodiment explained above except the features described below.

Several support structures 26 are here provided via a linear or rotary conveyor 70 circulating in front of the container 40 comprising the stack of tobacco substrates 25.

The support structures 26 may advantageously have glue applied while moving on the conveyor by two glue dispensers 66 on either side of the conveyor 70. Advantageously, at least one additional container 40 is arranged aside of the container 40. Here four containers 40 are arranged side by side. Each additional container 40 is similar to said container 40 and comprises a stack of several tobacco substrates 25.

The containers 40 are arranged side to side and a pusher tip 50 is associated to each container 40.

The conveyor 60 is then circulating in front of all the containers 40 so that a support structure 26 is placed in front of each container.

All the pusher tips 50 push at slightly the same moment the lower tobacco substrate 25 of the associated container in the associated support structure 26. This allows fast and multiple filling of tobacco substrate 25 in parallel.

The assembled articles 12 are then moved away with the conveyor 70.