FORMING OF AEROSOL GENERATING SUBSTRATE IN BETWEEN CONVEYOR SURFACES

Description

The present disclosure relates to an aerosol generating substrate production apparatus, a method of producing an aerosol generating substrate and a use of a first corrugated conveyor belt. The aerosol generating substrate may be a homogenized sheet of tobacco or non-tobacco, in particular for the manufacture of aerosol generating articles, such as “heat-not-burn” aerosol generating articles.

In the manufacture of aerosol-generating articles, at least one component may comprise an aerosol-generating material that is exposed to a crimping process. This crimped component is then converged and cut into segments. These aerosol-generating segments are components of the aerosol-generating articles.

A crimping apparatus comprising first and second crimping rollers, between which a sheet of aerosol-generating material is treated, is known from WO 2018/189325 A1. WO 2020/002652 A1 discloses a casting apparatus with a casting blade including a corrugated portion.

While the crimping process is helpful for converging a sheet of aerosol-generating material to form segments for aerosol-generating articles, the crimping process also influences, inter alia, the amount of air contact, the Resistance-To-Draw (RTD).

Applying an adequate crimping pressure is an important aspect of the crimping process, which has an impact on the RTD and consequently on the user experience. There is a need for a new method and an apparatus to provide an alternative for the known crimping process.

According to a first aspect of the present invention, an aerosol-generating substrate production apparatus is provided. The aerosol-generating substrate production apparatus comprises a first conveyor having at least a first conveyor surface. The aerosol-generating substrate production apparatus comprises a second conveyor having at least a second conveyor surface. The first conveyor surface provides a support for an aerosol-generating material. The first conveyor surface extends along a transport path. The second conveyor surface extends at least locally along the transport path. The aerosol-generating material is formed to an aerosol-generating substrate in between the first conveyor surface and the second conveyor surface.

The aerosol-generating material may be a viscous slurry. The aerosol-generating substrate may have an increased dimensional stability compared to the aerosol-generating material.

The aerosol-generating substrate may have a top surface and a bottom surface. The aerosol-generating material may be an intermediate product. In particular, the aerosol-generating material may be a semi-finished product produced or prepared in the aerosol-generating substrate production apparatus. The aerosol-generating material may be received at a first end of the aerosol-generating substrate production apparatus. The aerosol-generating material received at the first end of the aerosol-generating substrate production apparatus may be processed along the transport path. The aerosol-generating material may be a tobacco slurry. The processed and potentially dried aerosol-generating material may be the aerosol-generating substrate. The aerosol-generating substrate may be a formed tobacco leaf sheet. The aerosol-generating substrate may be a final product of the aerosol-generating substrate production apparatus. In particular, the aerosol-generating substrate may be produced or prepared in the aerosol-generating substrate production apparatus, which is ready to be used in a further process in the production of an aerosol-generating article. The type of chemical ingredients might be the same in the intermediate product and in the final product. The amount of water might differ in the intermediate product and in the final product. The viscosity of the intermediate product and the final product might differ from each other. The stiffness of the intermediate product and the final product might differ from each other. The aerosol-generating substrate may comprise a lower water content than the aerosol-generating material. The aerosol-generating substrate may be a sheet or a foil of aerosol-generating material, in particular of a processed, cast aerosol-generating material in the aerosol-generating substrate production apparatus. The aerosol-generating substrate may be a tobacco web.

In particular, the aerosol-generating material is transported along the transport path. The transport path may extend at least along a section of the aerosol-generating substrate production apparatus. Preferably, the transport path extends straight in a transport direction. Alternatively, the transport path may be a curved path. The transport path may be an undulating transport path. The transport path may have a longitudinal length between about 10 meters to about 150 meters, in particular between about 20 meters to about 100 meters, preferably between about 30 meters to about 75 meters.

The second conveyor surface may extend at least along a partition of the transport path. The partition may have a longitudinal length between about 5 meters to about 125 meters, in particular between about 10 meters to about 95 meters, preferably between about 20 meters to about 50 meters. The first conveyor surface or the second conveyor surface or, the first conveyor surface and the second conveyor surface may extend orthogonal to the transport path along between 0.5 meter to 4 meters, in particular between 1.5 meters to 2.5 meters, more preferable 2 meters.

The aerosol-generating substrate production apparatus may be a part, a section, or a unit of an aerosol-generating article production line, preferably for a “heat-not-burn” aerosol-generating article. During forming the aerosol-generating material to the aerosol-generating substrate, the aerosol-generating material may be shaped into a desired shape.

The second conveyor may be arranged above the first conveyor. The second conveyor surface may be adapted to contact the top surface of the aerosol-generating material. The first conveyor surface may be adapted to contact the bottom surface of the aerosol-generating material. The first conveyor surface and the second conveyor surface may be adapted to move in the same direction. The first conveyor surface and the second conveyor surface may be adapted to move synchronous, in particular at least locally along the transport path.

The present invention may allow forming the aerosol-generating material to the aerosol-generating substrate, in particular between two elongated surfaces along the transport path. The present invention may allow forming a desired shape on the aerosol-generating material, in particular between two elongated surfaces along the transport path. The present invention may allow applying pressure during forming the aerosol-generating material to the aerosol-generating substrate. The present invention may allow applying pressure during forming a desired shape on the aerosol-generating material. The amount of pressure applied may be sufficient to retain the shape the aerosol-generating substrate, in particular after the production and at the same time to minimize the structural defects in the aerosol-generating substrate, such as cracks, tearing, rupture. The present invention may allow applying a pressure to the aerosol generating material along the transport path, in particular along at least about 1 meter more preferably along at least about 10 meters. The present invention may allow applying a pressure to a section of the aerosol-generating material over at least 1 minute, preferably at least 5 minutes, more preferably at least 20 minutes, and preferably less than 60 minutes, respectively. The present invention may allow reducing a mean pressure required for forming the aerosol-generating material to the aerosol-generating substrate, in particular without decreasing the production speed. The present invention may allow running the overall production process at high speed. A high-speed production process may allow applying reduced pressure on the aerosol-generating material.

The first conveyor surface may be adapted to move or translate along the transport path. This may advantageously increase a contact time, where the first conveyor surface is contacting the aerosol-generating material for forming the aerosol-generating material to the aerosol-generating substrate.

The second conveyor surface may be adapted to move or translate at least locally along the transport path. This may advantageously increase a contact time, where the second conveyor surface is contacting the aerosol-generating material for forming the aerosol-generating material, in particular while applying pressure to the aerosol-generating material for forming it to the aerosol-generating substrate between the first conveyor surface and the second conveyor surface.

The first conveyor surface or the second conveyor surface or the first conveyor surface and the second conveyor surface may be adapted to move straight at least locally along the transport path. This may allow reducing or avoiding shear forces in the aerosol-generating substrate in between the first conveyor surface and the second conveyor surface.

The first conveyor may comprise at least two rollers. The at least two rollers may be adapted rotate. At least one of the rollers may be drive roller. The drive roller may be adapted to drive the first conveyor surface along the transport path.

The second conveyor may comprise at least two rollers, in particular three rollers. The at least two rollers may be adapted to rotate. At least one of the rollers may be drive roller. The drive roller may be adapted to move the second conveyor surface at least locally along the transport path. The drive rollers of the first conveyor and second conveyor may be synchronized.

The first conveyor surface or the second conveyor surface, or the first conveyor surface and the second conveyor surface may have a structured surface, adapted to be imprinted on the surface of the aerosol-generating material.

The first conveyor surface or the second conveyor surface, or the first conveyor surface and the second conveyor surface may comprise at least a portion with corrugations. This may advantageously allow corrugating the aerosol-generating material or forming corrugations on the aerosol-generating material. The corrugations formed may act as channels, in particular air channels in an aerosol-generating article comprising the aerosol-generating substrate. The corrugations or the channels may improve a release of substances from the aerosol-generating article, in particular to air flowing through a segment formed of the aerosol-generating substrate. The corrugations or the channels may provide a favorable RTD value of the aerosol-generating article comprising the aerosol-generating substrate. A favorable RTD value may be between 20 millimeters of water gauge and 70 millimeters of water gauge, in particular between about 22 millimeters of water gauge and about 68 millimeters of water gauge, or in particular about 25 millimeters of water gauge and about 65 millimeters of water gauge, in particular between about 28 millimeters of water gauge and about 55 millimeters of water gauge, in particular between about 35 millimeters of water gauge and about 52 millimeters of water gauge. A favorable RTD value may be 37 millimeters of water gauge, 40 millimeters of water gauge, 48 millimeters of water gauge, 50 millimeters of water gauge.

The first conveyor surface or the second conveyor surface may comprise at least a portion with corrugations, while the other of the first conveyor surface and the second conveyor surface is substantially flat at least in the region facing the portion with corrugations. The substantially flat conveyor surface may form a substantially flat surface on the aerosol-generating material, and increase the mechanical resilience of the aerosol-generating substrate, in particular increasing the tensile strength of the aerosol-generating substrate.

The portion with corrugations on the first conveyor surface and the portion with corrugations on the second conveyor surface may be symmetrical or complementary regarding each other. This may advantageously result in an aerosol-generating substrate having a symmetrical pattern of channels on a top and bottom surfaces of the aerosol-generating substrate. This arrangement may advantageously impede propagation of mechanical defects, in particular in a direction perpendicular to the transport path.

The portion with corrugations on the first conveyor surface and the portion with corrugations on the second conveyor surface may be asymmetrical regarding each other. This may advantageously yield to an aerosol-generating substrate having a first pattern of channels on the top surface of the aerosol-generating substrate and a second pattern of channels on the bottom surface of the aerosol-generating substrate. This arrangement may advantageously impede crack propagation of mechanical defects, in particular in a direction perpendicular to the transport direction.

The corrugations may at least partially extend along the transport path of the aerosol-generating material.

The corrugations may be formed by alternating ridges and recesses. The ridges may be a plurality of protrusions extending outwardly in a direction orthogonal to the surface from which the ridges protrude. Between at least two consecutive ridges a recess may be formed. The corrugations may have a shape of at least one shape from the following group: sinusoid, saw-tooth, zipper polygon, polygon with rounded edges. The polygon may be a triangle or rectangular. The corrugations of on the first conveyor surface or the corrugations of on second first conveyor surface, or the corrugations of on the first conveyor surface and the corrugations of on second first conveyor surface may be symmetrical. The corrugations of on the first conveyor surface or the corrugations of on second first conveyor surface, or the corrugations of on the first conveyor surface and the corrugations of on second first conveyor surface may be asymmetrical.

At least some of the ridges or recesses may have a height of about 0.01 millimeters to about 10 millimeters, in particular about 0.1 millimeters to about 3 millimeters, preferably about 0.5 millimeters to about 2 millimeters. The height of two consecutive ridges may be different from 30 each other.

At least some of the ridges or recesses may have a width of about 0.01 millimeters to about 20 millimeters, in particular about 0.1 millimeters to about 10 millimeters, preferably about 1 millimeters to about 5 millimeters. The width of two consecutive ridges may be different from each other.

The first conveyor surface or the second conveyor surface, or the first conveyor surface and the second conveyor surface may have at least an interruption gap without corrugations. The interruption gap may extend orthogonal to the transport direction. The interruption gap may be aligned with an angle to an axis being orthogonal to the transport direction. The angle may be between 1 degree and 45 degrees, in particular 2 degrees and 25 degrees, more preferably 3 degrees and 15 degrees. The first conveyor surface or the second conveyor surface, or the first conveyor surface and the second conveyor surface may have a first corrugation pattern in the interruption gap differing from a second corrugation pattern arranged on the first conveyor surface and/or the second conveyor surface. The ridges or recesses, or the ridges and the recesses may have a lower height in the first corrugation pattern than in the second corrugation pattern. An interruption gap may advantageously enhance the tensile strength of the aerosol-generating substrate.

The recesses of the first conveyor surface may be free of the ridges of the second conveyor surface. This may ensure a separation distance between the first conveyor surface and the second conveyor surface an aerosol-generating substrate production apparatus. The separation distance may extend orthogonal to the transport direction. This arrangement between the first conveyor surface and the second conveyor surface may allow applying an adequate pressure for forming corrugations on the aerosol-generating material. This may reduce compression or deformation of the aerosol-generating material during forming corrugations on the aerosol-generating material.

The first conveyor may comprise a first conveyor belt forming the first conveyor surface.

The second conveyor may comprise a second conveyor belt forming the second conveyor surface.

The first conveyor belt and/or the second conveyor belt may be a metallic conveyor belt. A width of the first conveyor belt or a width of the second conveyor, or a width of the first conveyor belt and the second conveyor may be between 0.5 meters and 2 meters. A width of the first conveyor belt and/or the second conveyor may be approximately the same of a width of a bobbin, on which the aerosol-generating substrate is wounded. The width of the bobbin may be between 1 meter and 1.5 meters, more preferably 1.3 meters.

The first conveyor belt or the second conveyor, or the first conveyor belt and the second conveyor belt may be an endless conveyor belt.

The first conveyor belt or the second conveyor belt, or the first conveyor belt and the second conveyor belt may be flexible.

The first movable support and/or the second movable support may be heatable. The first movable support and/or the second movable support may be heatable to a temperature between about 5 degrees Celsius and about 100 degrees Celsius, in particular about 10 degrees Celsius and about 80 degrees Celsius, preferably about 15 degrees Celsius and about 50 degrees Celsius.

The first conveyor surface may be arranged at least locally parallel to the second conveyor surface, in particular along the transport path.

The aerosol-generating substrate production apparatus may comprise a casting device for casting the aerosol-generating material onto the first conveyor surface.

The casting device may be adapted to cast the aerosol-generating material onto the first conveyor surface. The aerosol-generating material casted on the first conveyor surface may have a moisture content of about 90 weight percent to about 40 weight percent, in particular from about 85 weight percent to about 50 weight percent, preferably from about 80 weight percent to about 60 weight percent. In particular, the weight percentage is based on the total weight of the aerosol-generating material.

The casting device may comprise a casting box adapted to contain a slurry of the aerosol-generating material. Casting box may also comprise a density control device to control the density of the cast web. The casting box may have an opening on the bottom of the casting box. The slurry may be casted onto the first conveyor surface through the opening. The opening may extend orthogonal to the transport direction.

The slurry may comprise one or more of the following ingredients: an alkaloid containing material being preferably plant based material, more preferably tobacco; a binder being preferably guar or carboxymethyl cellulose; cellulose fibers; an aerosol former; water. The length of cellulose fibers is advantageously between about 0.3 millimeters and about 3 millimeters, in particular about 1 millimeters and about 2 millimeters.

The casting box may have any geometrical shape, in particular a prism. The slurry of the aerosol-generating material may be transferred to the aerosol-generating substrate production apparatus through a slurry transfer system of an aerosol-generating article production line. The slurry transfer system or the casting device may comprise a pump, preferably having a flow control.

The casting box may have a heating device. A temperature of casting box may be varied between 10 degrees Celsius and 50 degrees Celsius, in particular between 15 degrees Celsius and 35 degrees Celsius, more preferably between 20 degrees Celsius and 28 degrees Celsius. A temperature of the slurry of the aerosol-generating material in the casting box may be varied between 10 degrees Celsius and 50 degrees Celsius, in particular between 15 degrees Celsius and 35 degrees Celsius, more preferably between 20 degrees Celsius and 28 degrees Celsius. This may advantageously allow keeping the slurry in a predetermined temperature, in particular by using a first temperature control means.

The apparatus may be adapted such that at least one roller of the first conveyor, in particular the roller arranged closer to the casting box, has a temperature in between 0 degrees Celsius and 70 degrees Celsius, in particular between 5 degrees Celsius and 60 degrees Celsius, more preferably 10 degrees Celsius and 30 degrees Celsius. The at least one roller of the first conveyor may be heated. The roller may be heated by hot water provided inside the roller. This may advantageously allow keeping the slurry at a predetermined temperature, in particular on the first movable surface. The at least one roller of the first conveyor may be cooled. The roller may be cooled by cool water provided inside the roller.

The roller may be kept at a temperature such that a temperature difference between the temperature of the first movable surface at a location of slurry deposition and the temperature of the slurry in the casting box is comprised between about 0 degree Celsius and about 30 degrees Celsius, in particular between 0 degrees Celsius and about 15 degrees Celsius, more preferably between 0 degrees Celsius and about 7 degrees Celsius. The temperature of the roller may be controlled by means of second temperature control means.

The casting device may comprise a casting blade adapted to cast the aerosol-generating material contained in the casting box onto the first conveyor surface. The casting blade, preferably together with a level control system of the casting box may be used to control a thickness of the aerosol-generating material casted on the first conveyor surface. Between the casting blade and the first conveyor surface a gap may be present. The dimension of the gap may determine the thickness of the aerosol-generating material. The gap may be larger than the average distance in between the first conveyor surface and second conveyor surface in the direction normal to these surfaces. This may enable further spreading of the aerosol-generating material when being processed in between the first conveyor surface and second conveyor surface.

The second conveyor surface may be applied on the aerosol-generating material right after the same is casted on the first conveyor surface. A distance between a first end of the second conveyor and the casting device may be 50 millimeters to 10 meters, in particular 100 millimeters to 5 meters, more preferably 200 millimeters to 1 meter.

The first conveyor surface may be at least partially arranged at least in a first drying unit. The rollers of the first conveyor may be arranged outside of the first drying unit. The first drying unit may advantageously allow fixing the shape formed on the aerosol-generating material. In the first drying unit, a hot steam or hot air may be applied to a top and/or bottom surface of the aerosol-generating material. The drying unit may extend at least about one tenth, in particular at least about one fifth, preferably at least about one third of the length of the transport path. A temperature in the first drying unit may be between about 50 degrees Celsius to about 200 degrees Celsius, in particular between about 80 degrees Celsius to about 170 degrees Celsius, preferably between about 100 degrees Celsius to about 140 degrees Celsius. A temperature in the first drying unit may be about 60 degrees Celsius. The drying unit may comprise sub-units, in particular sub-units of different lengths. The sub-units may be set to different temperatures. The temperature of the sub-units may have a descending order in the transport direction. The temperature of the sub-units may have an ascending order in the transport direction.

The second conveyor surface may be at least partially arranged at least in the first drying unit. The rollers of the second conveyor may be arranged outside the first drying unit. The rollers of the second conveyor may be arranged inside the first drying unit.

The first drying unit may be adapted to reduce a moisture content of the aerosol-generating material from about 90 weight percent to about 10 weight percent, in particular from about 85 weight percent to about 15 weight percent, preferably from about 75 weight percent to about 20 weight percent. In particular, the weight percentage is based on the total weight of the aerosol-generating material.

The first drying unit may comprise a heater, a steam dryer, or an air dryer.

The steam dryer may be operated with a pressure between 30 kilograms per hour and 500 kilograms per hour, in particular with a pressure between 80 kilograms per hour and 300 kilograms per hour, more preferably with a pressure between 100 kilograms per hour and 200 kilograms per hour.

The first conveyor surface carrying the aerosol-generating material may be adapted to move or translate through the first drying unit.

At least a second drying unit may be arranged upstream or downstream to the second conveyor along the transport path. The aerosol-generating substrate production apparatus may be adapted to apply the second conveyor surface on the aerosol-generating material before the first conveyor surface carrying the aerosol-generating material enters in the second drying unit.

The second drying unit may comprise a heater, a steam dryer, or an air dryer. In the second drying unit, a hot steam or hot air may be applied to a top and/or bottom surface of the aerosol-generating material. A temperature in the second drying unit may be lower than the temperature of the first drying unit. A temperature in the second drying unit may be higher than the temperature of first drying unit. The second drying unit may comprise an air dryer. A dry air temperature in the second drying unit may be between about 70 degrees Celsius to about 140 degrees Celsius, in particular between about 75 degrees Celsius to about 105 degrees Celsius. A temperature in the second drying unit may be between about 70 degrees Celsius to about 140 degrees Celsius, in particular between about 75 degrees Celsius to about 105 degrees Celsius. A temperature in the second drying unit may be between about 50 degrees Celsius to about 200 degrees Celsius, in particular between about 80 degrees Celsius to about 170 degrees Celsius, preferably between about 100 degrees Celsius to about 140 degrees Celsius. A temperature in the first drying unit may be about 60 degrees Celsius. The aerosol-generating substrate produced in the aerosol-generating substrate production apparatus may comprise corrugations in the shape ridges and/or recesses. At least one outer wall portion of the ridges or recesses may be inclined to an axis orthogonal to the base of the aerosol-generating substrate, in particular with an angle between 2 degrees and 45 degrees, more preferably 5 degrees and 15 degrees.

The aerosol-generating substrate produced in the aerosol-generating substrate production apparatus may be transported to a cooling section, and then to a bobbin formation unit or a slicing unit. The aerosol-generating substrate, in particular a slice of the aerosol-generating substrate may be transported to a rod-forming unit, where it is formed into a rod.

According to second aspect of the invention, a method of producing an aerosol-generating substrate is provided. The method may comprise the steps of forming an aerosol-generating material between a first conveying surface of a first conveyor and a second conveying surface of a second conveyor and drying the aerosol-generating material during forming.

The first conveying surface or the second conveying surface may comprise at least a portion with corrugations.

The first conveyor surface may be a surface of a first conveyor belt.

The second conveyor surface may be a surface of a second conveyor belt.

The method may comprise a step of translating the second conveyor surface along a transport path.

The method may comprise a step of casting the aerosol-generating material onto the first conveyor, in particular on the first conveyor surface.

The aerosol generating material casted onto the first conveyor surface may have a moisture content of about 90 weight percent to about 40 weight percent, in particular from about 85 weight percent to about 50 weight percent, preferably in particular from about 80 weight percent to about 60 weight percent. In particular, the weight percentage is based on the total weight of the aerosol-generating material.

The method may comprise the step of drying the aerosol-generating material by applying heat to the aerosol-generating material, in particular by conveying the aerosol-generating material through hot air provided in a drying unit.

The aerosol-generating material dried in the drying unit may have a moisture content of about 10 weight percent to about 20 weight percent. In particular, the weight percentage is based on the total weight of the aerosol-generating material.

The aerosol-generating material may comprise a slurry comprising an alkaloid containing material being preferably a plant based material, more preferably tobacco.

The aerosol-generating substrate may be a sheet or foil or web or extrudate comprising the alkaloid containing material being preferably a plant based material, more preferably tobacco.

According to a third aspect of the invention, a use of a first corrugated conveyor belt for forming an aerosol-generating material is provided. This may allow forming the aerosol-generating material to the aerosol-generating substrate, in particular by using only one along the transport path of the aerosol-generating material elongated surface. The present invention may allow forming a desired shaped on the aerosol-generating material, in particular by using only one along the transport path of the aerosol-generating material elongated surface. The present invention may allow forming a desired shaped on the aerosol-generating material, in particular without using mechanical force. This allows forming corrugations on the aerosol-generating material using solely one corrugated conveyor belt. This allows shaping the aerosol-generating material, while the aerosol-generating material is a viscous slurry. The shape formed on the aerosol-generating material may be fixed by drying the aerosol-generating material with hot steam and/or hot air, in particular in a drying unit. The first corrugated conveyor belt may be transported through the drying unit.

The use may comprise a second corrugated conveyor belt facing the first corrugated conveyor belt for forming the aerosol-generating material in between the first corrugated conveyor belt and the second corrugated conveyor belt. This allows shaping the aerosol-generating material, in particular using mechanical force.

A moisture content of the aerosol-generating material may be 90 weight percent to 40 weight percent.

According to a fourth aspect of the invention, an aerosol-generating substrate produced as described above or comprising aerosol-generating substrate produced in the aerosol-generating substrate production apparatus as described above is provided.

The aerosol-generating substrate may comprise a fiber-based material, preferably a plastic fiber-based material, more preferably a biodegradable fiber-based material, more preferably cotton, more preferably cellulose.

According to a fifth aspect of the invention, an aerosol-generating article comprising an aerosol generating substrate or an aerosol-generating extrudate as described above is provided. The aerosol-generating article may be a cigarette or a heatable smoking article adapted to generate aerosol when heated to a temperature below combustion temperature. The aerosol-generating article may comprise the aerosol generating substrate in the form of a rod and at least a filter. At least a wrapping paper may be wrapped around the at least filter and around the rod. According to a sixth aspect of the invention, a system comprising the aerosol-generating substrate production apparatus as described above, an aerosol-generating material as described above and an aerosol-generating substrate as described above.

The moisture content of the aerosol-generating material may be 90 weight percent to 40 weight percent, in particular 85 weight percent to 50 weight percent, preferably from 80 weight percent to 60 weight percent, in particular before a drying process. In particular, the weight percentage is based on the total weight of the aerosol-generating material. After the drying process, the aerosol-generating material may have a moisture content of about 10 weight percent to about 20 weight percent. In particular, the weight percentage is based on the total weight of the aerosol-generating material. The dried aerosol-generating material may be an aerosol-generating substrate.

The aerosol-generating material may comprise plant-based material, water, and an additional aerosol-former. The weight percent values and ranges for the constituents of the aerosol-generating material, as provided herein, are based on the total weight of the aerosol-generating material, according to the technically known definition of “weight percent”, unless otherwise specified.

In particular, the plant-based material is a material containing alkaloids.

The amount of material containing alkaloids or plant-based material in the aerosol-generating material is between 30 weight percent and 80 weight percent, more especially between 40 weight percent and 70 weight percent. In particular, the weight percentage is based on the total weight of the aerosol-generating material.

A material containing alkaloids, which may be defined as a material containing at least one alkaloid, which alkaloid may comprise nicotine, such as that found in tobacco, for example.

Instead or in addition to tobacco, other plant-based materials may be part of the aerosol-generating material. The herbaceous materials may be free of alkaloids.

Alkaloids are a group of naturally occurring chemical compounds that mostly contain basic nitrogen atoms. This group also includes some related compounds with neutral and even weakly acidic properties. Some synthetic compounds of similar structure are also termed alkaloids. In addition to carbon, hydrogen and nitrogen, alkaloids may contain oxygen, sulfur and, more rarely, other elements such as chlorine, bromine, and phosphorus.

Alkaloids are produced by a large variety of organisms including bacteria, fungi, plants, and animals. They can be purified from crude extracts of these organisms by acid-base extraction. Caffeine, nicotine, theobromine, atropine, tubocurarine are examples of alkaloids.

The material containing alkaloids may be tobacco leaves.

In particular, the material containing alkaloids is homogenized tobacco material, which is formed by agglomerating particulate tobacco containing at least the alkaloid nicotine. This homogenized tobacco material is typically manufactured from parts of the tobacco plant that are less suited for the production of cut filler, like tobacco stems, tobacco lamina or tobacco dust, for example. Typically, tobacco dust is created as a side product during the handling of the tobacco leaves during manufacture. The homogenized tobacco material may comprise a minor quantity of one or more of tobacco dust, tobacco fines, and other particulate tobacco by-products formed during the treating, handling and shipping of tobacco. The starting material for the production of homogenized tobacco material may be mostly tobacco leaves that have the same size and physical properties as the tobacco used for the blending of cut filler. The tobacco present in the homogenized tobacco material may constitute the majority of the tobacco, or even substantially the total amount of tobacco present in the aerosol-generating material.

The material containing alkaloids may contain starch. However, starch may be included into the aerosol-generating material as a separate component.

Starch is a polymeric carbohydrate consisting of a large number of glucose units joined by glycosidic bonds. Starch is produced by most green plants as energy storage. It is the most common carbohydrate in human diets and is contained in plants like potatoes, wheat, maize (corn), rice, and tobacco. It consists of two types of polymeric molecules: the linear and helical amylose and the branched amylopectin, which arrange themselves in the plant in semi-crystalline granules.

In particular, the particles of the material containing alkaloids have a mean particle size between 0.02 millimeters and 0.3 millimeters. The mean particle size of between about 0.02 millimeters and about 0.3 millimeters represents the particle size at which the tobacco cells are at least in part destroyed. The use of a material containing alkaloids having such a mean size may advantageously lead to a smooth and uniform extrudate, in the downstream processing steps of the material containing alkaloids.

In particular, the water content of the aerosol-generating material is between 5 weight percent and 70 weight percent or more and especially, between 10 weight percent and 18 weight percent or 25 weight percent and 60 weight percent and most especially between 11 weight percent and 14 weight percent or 35 weight percent and 50 weight percent. In particular, the weight percentage is based on the total weight of the aerosol-generating material.

In particular, the amount of aerosol-former in the aerosol-generating material is between 1 weight percent and 10 weight percent, especially between 1 weight percent and 5 weight percent. In particular, the weight percentage is based on the total weight of the aerosol-generating material. In particular, an aerosol-former is an additional component in the aerosol-generating material, to be considered separate from the material containing alkaloids, especially separate from tobacco.

Suitable aerosol-formers for the aerosol-generating material are known in the art and include, but are not limited to: monohydric alcohols like menthol, polyhydric alcohols, such as triethylene glycol, 1,3-butanediol and glycerin; esters of polyhydric alcohols, such as glycerol mono-, di- or triacetate; and aliphatic esters of mono-, di- or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

Examples of preferred aerosol-formers are glycerin and propylene glycol.

The material containing alkaloids may have an aerosol-former content of greater than 3 weight percent of the total amount of material containing alkaloids. In particular, the weight percentage is based on the total weight of the material containing alkaloids. The material containing alkaloids may alternatively have an aerosol former content of between 3 weight percent and 30 weight percent. In particular, the aerosol-former is comprised between 7 weight percent to 25 weight percent of the material containing alkaloids. In particular, the weight percentage is based on the total weight of the material containing alkaloids. The aerosol-former is especially comprised between 10 weight percent to 25 weight percent of the material containing alkaloids.

In particular, the weight percentage is based on the total weight of the material containing alkaloids. In particular, the aerosol-former content of the material containing alkaloids is an inherent constituent of the material containing alkaloids, and therefore, the amount thereof does not relate to the amount of aerosol-former that may be included in the aerosol-generating material, as described above.

In particular, the aerosol-generating material may comprise a binder. In particular, the amount of binder within the aerosol-generating material is maximally 1 weight percent, however, it is possible to include between 1 weight percent and 15 weight percent, especially between 1 weight percent and 12 weight percent and most especially 1 weight percent and 5 weight percent. In particular, the weight percentage is based on the total weight of the aerosol-generating material.

The binder in the aerosol-generating material may be any type of gum or pectin described herein. The binder may ensure that the particles of material containing alkaloids remain substantially dispersed throughout the aerosol-generating material and the extrudate. For a descriptive review of gums which can be used as a binder, see Gums And Stabilizers For The Food Industry, IR.L Press (G. O. Phillip et al. eds. 1988); Whistler, Industrial Gums: Polysaccharides And Their Derivatives, Academic Press (2d ed. 1973); and Lawrence, Natural Gums For Edible Purposes, Noyes Data Corp. (1976).

Although any binder may be employed, preferred binders are natural pectins, such as fruit, citrus or tobacco pectins; guar gums, such as hydroxyethyl guar and hydroxypropyl guar; locust bean gums, such as hydroxyethyl and hydroxypropyl locust bean gum; alginate; starches, such as modified or derivitized starches; celluloses, such as methyl, ethyl, ethylhydroxymethyl and carboxymethyl cellulose; tamarind gum; dextran; pullalon; konjac flour; xanthan gum and the like. The particularly preferred binder for use in the present invention is guar.

In particular, the aerosol-generating material may comprise a reducing sugar in an amount of between 2 weight percent and 30 weight percent, especially between 5 weight percent and 25 weight percent, even more especially between 10 weight percent and 15 weight percent and most especially between 11 weight percent and 14 weight percent. In particular, the weight percentage is based on the total weight of the aerosol-generating material.

In particular, the reducing sugar is glucose, fructose, xylose, ribose, or galactose, or may be a mixture thereof. The reducing sugar is in particular glucose, fructose or a mixture of the two.

The presence of reducing sugar in the aerosol-generating material may modify the material containing alkaloids when mechanical energy is applied to the aerosol-generating material. A reaction between the reducing sugar and the material containing alkaloids, particularly if ammonia or an ammonium containing compounds are contained in the latter, may occur. This reaction may modify the composition of the material containing alkaloids, so that the resulting mixture, and the aerosol-generating material, has a lower quantity of ammonia or ammonium containing compounds compared to aerosol-generating material formed from a mixture not containing reducing sugar. This may influence the properties and characteristics of the aerosol-generating material, in terms of flavor, for example.

In particular, the aerosol-generating material may comprise cellulose fibers. Cellulose fibers are known to generally increase the tensile strength of the aerosol-generating substrate, thereby acting as a strengthening agent. Cellulose fibers for aerosol-generating material containing a material containing alkaloids such as homogenized tobacco material are known in the art and include, but are not limited to: soft-wood fibers, hard wood fibers, jute fibers, flax fibers, tobacco fibers and combination thereof. In particular, cellulose fibers such as wood fibers comprise a low lignin content. Alternatively, fibers, such as vegetable fibers, may be used either with the above fibers or with hemp and bamboo fibers. Cellulose fibers may include tobacco stem materials, stalks or other tobacco plant material.

The amount of cellulose fibers added to the aerosol-generating material can be between 1 weight percent and 10 weight percent, especially between 1 weight percent and 7 weight percent and more especially between 1 weight percent and 5 weight percent. In particular, the weight percentage is based on the total weight of the aerosol-generating material. These values do not include the amount of cellulose fibers contained and associated with the material containing alkaloids, but are to be considered a separate constituent in the aerosol-generating material.

The length of cellulose fibers is advantageously between 0.2 millimeters and 4 millimeters. In particular, the mean length per weight of the cellulose fibers is between 1 millimeter and 3 millimeters. In addition to pulping, the incorporated cellulose fibers may be subjected to suitable processes such as refining, mechanical pulping, chemical pulping, bleaching, sulphate pulping and a combination thereof.

The binder and the cellulose fibers are preferably included in a weight ratio comprised between about 1:7 and about 5:1. More preferably, the binder and the cellulose fibers are included in a weight ratio comprised between about 1:1 and about 3:1.

The binder and the aerosol-former are preferably included in a weight ratio comprised between about 1:30 and about 1:1. More preferably, the binder and the aerosol-former are included in a weight ratio comprised between about 1:20 and about 1:4.

The binder and the tobacco particles are preferably included in a weight ratio comprised between about 1:100 and about 1:10. More preferably, the binder and the tobacco particles are included in a weight ratio comprised between about 1:50 and about 1:15, even more preferably between about 1:30 and 1:20.

The aerosol-former and the tobacco particles are preferably included in a weight ratio comprised between about 1:20 and about 1:1. More preferably, the aerosol-former and the tobacco particles are included in a weight ratio comprised between about 1:6 and about 1:2.

The aerosol-former and the tobacco particles are preferably included in a weight ratio comprised between about 1:20 and about 1:1. More preferably, the aerosol-former and the tobacco particles are included in a weight ratio comprised between about 1:6 and about 1:2.

The aerosol former and the cellulose fibers are preferably included in a weight ratio comprised between about 1:1 and about 30:1. More preferably, the aerosol-former and the cellulose fibers are included in a weight ratio comprised between about 5:1 and about 15:1.

The cellulose fibers and the tobacco particles are preferably included in a weight ratio comprised between about 1:100 and about 1:10. More preferably, the cellulose fibers and the tobacco particles are preferably included in a weight ratio comprised between about 1:50 and about 1:20.

The aerosol-generating material may be in the form of a slurry comprising about 25 weight percent to about 95 weight percent, in particular about 45 weight percent to about 93 of alkaloid containing material. In particular, the weight percentage is based on the total weight of the first slurry. The first slurry composition may comprise up to about 3 weight percent, in particular up to about 5 weight percent of binder. In particular, the weight percentage is based on the total weight of the first slurry composition. The first slurry composition may comprise about 0.5 weight percent to about 15 weight percent, in particular about 1 weight percent to about 7 weight percent of cellulose fibers. In particular, the weight percentage is based on the total weight of the first slurry composition. The first slurry composition may comprise about 5 weight percent to about 45 weight percent, about 15 weight percent to about 25 weight percent of aerosol former. The first slurry composition may comprise about 20 weight percent to about 80 weight percent, about 30 weight percent to about 70 weight percent water. In particular, the weight percentage is based on the total weight of the first slurry composition.

The aerosol-generating material may be in the form of a slurry comprising about 4.0 weight percent to about 5.0 weight percent, in particular about 4.46 weight percent, preferably about 4.5 weight percent, more preferably about 4.55 weight percent of aerosol former. In particular, the weight percentage is based on the total weight of the slurry. The second slurry composition may comprise about 0.3 weight percent to about 1.5 weight percent, in particular about 0.57 weight percent, preferably about 0.58 weight percent, more preferably about 0.59 weight percent of binder. In particular, the weight percentage is based on the total weight of the second slurry composition. The second slurry composition may comprise about 50 weight percent to about 80 weight percent, in particular about 73.18 weight percent, preferably about 73.92 weight percent, more preferably about 74.66 weight percent of water and cellulose fiber. In particular, the weight percentage is based on the total weight of the second slurry composition. The second slurry composition may comprise 10 weight percent to 30 weight percent, in particular 20.79 weight percent, preferably 21.00 weight percent, more preferably 21.21 weight percent of tobacco blend. In particular, the weight percentage is based on the total weight of the second slurry composition. Tobacco blend may comprise tobacco particles from one or different types of tobacco.

All of the features of the aerosol-generating substrate production apparatus according to the first aspect may be used individually or combined in the method according to the second aspect of producing an aerosol-generating substrate and in the use according to the third aspect of a first corrugated conveyor belt for forming an aerosol-generating material. All of the features of the method according to the second aspect of producing an aerosol-generating substrate may be performed individually or combined in the aerosol-generating substrate production apparatus and in the use according to the third aspect of a first corrugated conveyor belt for forming an aerosol-generating material. All of the features of the use according to the third aspect of a first corrugated conveyor belt for forming an aerosol-generating material may be applied or performed individually or combined in the aerosol-generating substrate production apparatus according to the first aspect or in the method according to the second aspect of producing an aerosol-generating substrate.

The aerosol-generating substrate may be a sheet, foil or web. The aerosol-generating substrate may be a laminar element having a width and length substantially greater than the thickness thereof. A sheet or foil or web may be a laminar element having a width and length substantially greater than the thickness thereof. The aerosol-generating substrate may be crimped, and in particular have a plurality of corrugations. Corrugations may comprise ridges or protrusions. Corrugations may comprise troughs or recesses. The corrugations are formed by ridges and recesses or ridges or recesses. A width of the ridges may be defined as a first distance between two peaks of the consecutive recesses. A width of the recesses may be defined as a first distance between two peaks of the consecutive ridges. A distance between a peak of the ridge and a peak of the recesses may define a height of the ridges or recesses.

As used herein, the term “forming” means giving a shape.

The apparatus, method and use according to aspects of the present invention may be free of crimping rollers. In particular, a crimping roller is a roller having ridges and recesses on its outer surface. The apparatus, method and use according to aspects of the present invention may be adapted to provide a surface structure to the aerosol-generating material or aerosol-generating substrate, which is similar to a crimping profile, without using crimping rollers. The invention is defined in the claims. However, below there is provided a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more features of another example, embodiment, or aspect described herein.

Example Ex1: An aerosol-generating substrate production apparatus, comprising:

• • a first conveyor having at least a first conveyor surface,
  • a second conveyor having at least a second conveyor surface,
  • wherein the first conveyor surface provides a support for an aerosol-generating material,
  • wherein the first conveyor surface extends along a transport path,
  • wherein the second conveyor surface extends at least locally along the transport path,
  • such that the aerosol-generating material is formed to an aerosol-generating substrate in between the first conveyor surface and the second conveyor surface.

Example Ex2: The aerosol-generating substrate production apparatus according to example Ex1, wherein the second conveyor surface is adapted to translate along the transport path at least locally along the transport path, in particularly without rotation.

Example Ex3: The aerosol-generating substrate production apparatus according to example Ex1 or Ex2, wherein the second conveyor comprises at least two rollers.

Example Ex4: The aerosol-generating substrate production apparatus according to one or more of the preceding examples Ex1-Ex3, wherein the first conveyor surface or the second conveyor surface, or the first conveyor surface and the second conveyor surface comprises at least a portion with corrugations.

Example Ex5: The aerosol-generating substrate production apparatus according to one or more of the preceding examples Ex1-Ex4, wherein one of the first conveyor surface or the second conveyor surface comprises at least a portion with corrugations, while the other of the first conveyor surface and the second conveyor surface is substantially flat at least in the region facing the portion with corrugations.

Example Ex6: The aerosol-generating substrate production apparatus according to example Ex4, wherein the portion with corrugations on the first conveyor surface and the portion with corrugations on the second conveyor surface are symmetrical or complementary regarding each other.

Example Ex7: The aerosol-generating substrate production apparatus according to example Ex4, wherein the portion with corrugations on the first conveyor surface and the portion with corrugations on the second conveyor surface are asymmetrical regarding each other.

Example Ex8: The aerosol-generating substrate production apparatus according to one or more of the preceding examples Ex4-Ex7, wherein the corrugations at least partially extend along the transport path of the aerosol-generating material.

Example Ex9: The aerosol-generating substrate production apparatus according to one or more of the preceding examples Ex4-Ex8, wherein the corrugations are formed by ridges and/or recesses.

Example Ex10: The aerosol-generating substrate production apparatus according to one or more of the preceding examples Ex4-Ex9, wherein the corrugations are formed by ridges and recesses, wherein the recesses of the first conveyor surface are free of the ridges of the second conveyor surface.

Example Ex11: The aerosol-generating substrate production apparatus according to one or more of the preceding examples Ex4-Ex9, wherein the corrugations are formed by ridges and recesses, wherein the recesses of the first conveyor surface are free of the ridges of the second conveyor surface.

Example Ex12: The aerosol-generating substrate production apparatus according to one or more of the preceding examples Ex9-Ex11, wherein at least some of the ridges have a height of about 0.01 millimeters to about 10 millimeters, in particular about 0.1 millimeters to about 3 millimeters, preferably about 0.5 millimeters to about 2 millimeters.

Example Ex13: The aerosol-generating substrate production apparatus according to one or more of the preceding examples Ex9-Ex12, wherein at least some of the ridges have a width of about 0.01 millimeters to about 20 millimeters, in particular about 0.1 millimeters to about 10 millimeters, preferably about 1 millimeters to about 5 millimeters.

Example Ex14: The aerosol-generating substrate production apparatus according to one or more of the preceding examples Ex1-Ex13, wherein the first conveyor comprises a first conveyor belt forming the first conveyor surface.

Example Ex15: The aerosol-generating substrate production apparatus according to one or more of the preceding examples Ex1-Ex14, wherein the second conveyor comprises a second conveyor belt forming the second conveyor surface.

Example Ex16: The aerosol-generating substrate production apparatus according to one or more of the preceding examples Ex1-Ex15, wherein the first conveyor surface is arranged locally parallel to the second conveyor surface, in particular along a transport path of the aerosol-generating material.

Example Ex17: The aerosol-generating substrate production apparatus according to one or more of the preceding examples Ex1-Ex16 further comprising a casting device for casting the aerosol-generating material onto the first conveyor surface.

Example Ex18: The aerosol-generating substrate production apparatus according to example Ex17, wherein the casting device is adapted to cast the aerosol-generating material onto the first conveyor surface with a moisture content of about 90 weight percent to about 40 weight percent, in particular from about 85 weight percent to about 50 weight percent, preferably from about 80 weight percent to about 60 weight percent. In particular, the weight percentage is based on the total weight of the aerosol-generating material.

Example Ex19: The aerosol-generating substrate production apparatus according to one or more of the preceding examples Ex17-Ex18, wherein the casting device comprises a casting box adapted to contain a slurry of the aerosol-generating material.

Example Ex20: The aerosol-generating substrate production apparatus according to one or more of the preceding examples Ex17-Ex19, wherein the casting device comprises a casting blade adapted to cast the aerosol-generating material contained in the casting box onto the first conveyor surface.

Example Ex21: The aerosol-generating substrate production apparatus according to one or more of the preceding examples Ex1-Ex20, wherein the first conveyor surface is at least partially arranged at least in a first drying unit

Example Ex22: The aerosol-generating substrate production apparatus according to example Ex21, wherein the first drying unit is adapted to reduce a moisture content of the aerosol-generating material from about 90 weight percent to about 10 weight percent, in particular from about 85 weight percent to about 15 weight percent, preferably from about 75 weight percent to about 20 weight percent. In particular, the weight percentage is based on the total weight of the aerosol-generating material.

Example Ex23: The aerosol-generating substrate production apparatus according to example Ex21 or E22, wherein the first drying unit comprises a heater, a steam dryer or an air dryer.

Example Ex24: The aerosol-generating substrate production apparatus according to one or more of the preceding examples Ex21-Ex23, wherein a temperature in the first drying unit is between about 50 degrees Celsius to about 200 degrees Celsius, in particular between about 80 degrees Celsius to about 170 degrees Celsius, preferably between about 100 degrees Celsius to about 140 degrees Celsius.

Example Ex25: The aerosol-generating substrate production apparatus according to one or more of the preceding examples Ex21-Ex23, wherein at least a second drying unit is arranged upstream or downstream to the second conveyor along the transport path.

Example Ex26: Method of producing an aerosol-generating substrate, comprising the steps: forming an aerosol-generating material between a first conveying surface of a first conveyor and a second conveying surface of a second conveyor, drying the aerosol-generating material during forming.

Example Ex27: Method of producing an aerosol-generating substrate according to example Ex26, wherein the first conveyor surface is a surface of a first conveyor belt.

Example Ex28: Method of producing an aerosol-generating substrate according to example Ex26 or Ex27, wherein the second conveyor surface is a surface of a second conveyor belt.

Example Ex29: Method of producing an aerosol-generating substrate according to one or more of the preceding examples Ex26-Ex28 further comprising the step of translating the second conveyor surface along a transport path.

Example Ex30: Method of producing an aerosol-generating substrate according to one or more of the preceding examples Ex26-Ex29 further comprising the step of casting the aerosol-generating material onto the first conveyor, in particular on the first conveyor surface.

Example Ex31: Method of producing an aerosol-generating substrate according to example Ex30 further comprising the aerosol-generating material casted onto the first conveyor surface has a moisture content of 90 weight percent to 40 weight percent, in particular from 85 weight percent to 50 weight percent, preferably in particular from 80 weight percent to 60 weight percent. In particular, the weight percentage is based on the total weight of the aerosol-generating material.

Example Ex32: Method of producing an aerosol-generating substrate according to one or more of the preceding examples Ex26-Ex31, wherein the aerosol-generating material casted onto the first conveyor surface has a moisture content of 90 weight percent to 40 weight percent, in particular from 85 weight percent to 50 weight percent, preferably in particular from 80 weight percent to 60 weight percent. In particular, the weight percentage is based on the total weight of the aerosol-generating material. Example Ex33: Method of producing an aerosol-generating substrate according to one or more of the preceding examples Ex26-Ex32 further comprising the step of drying the aerosol-generating material by applying heat to the aerosol-generating material, in particular by conveying the aerosol-generating material through hot air provided in a drying unit.

Example Ex34: Method of producing an aerosol-generating substrate according to one or more of the preceding examples Ex26-Ex33, wherein the aerosol-generating material is a slurry comprising an alkaloid containing material being preferably a plant based material, more preferably tobacco.

Example Ex35: Method of producing an aerosol-generating substrate according to one or more of the preceding examples Ex26-Ex34, wherein the aerosol-generating substrate is a sheet or foil or web or extrudate comprising the alkaloid containing material being preferably a plant based material, more preferably tobacco.

Example Ex36: An aerosol-generating substrate produced according to the method described in any one of the examples Ex26-Ex35 or comprising aerosol-generating substrate produced in the aerosol-generating substrate production apparatus according to any one of the examples Ex1-Ex23.

Example Ex37: The aerosol-generating substrate according to Ex36 comprising a fiber-based material, preferably a plastic fiber-based material, more preferably a biodegradable fiber-based material, more preferably cotton, more preferably cellulose.

Example Ex38: An aerosol-generating article comprising aerosol generating-substrate according to Ex37.

Example Ex39: A system comprising the aerosol-generating substrate production apparatus according to any one of the examples Ex1-Ex23, an aerosol-generating material and an aerosol-generating substrate according to any one of the examples Ex36 or Ex37. Example Ex40: Use of a first corrugated conveyor belt for forming an aerosol-generating material.

Example Ex41: Use according to example Ex40 further comprising using a second corrugated conveyor belt facing the first corrugated conveyor belt for forming the aerosol-generating material in between the first corrugated conveyor belt and the second corrugated conveyor belt.

Example Ex42: Use according to example Ex40 or Ex41, wherein the moisture content of the aerosol-generating material is 90 weight percent to 40 weight percent, in particular 85 weight percent to 50 weight percent, preferably from 80 weight percent to 60 weight percent. In particular, the weight percentage is based on the total weight of the aerosol-generating material.

Examples will now be further described with reference to the figures in which:

FIG. 1 is a schematic lateral view of the aerosol-generating substrate production apparatus according to an embodiment of the invention;

FIG. 2 is a schematic lateral view of the aerosol-generating substrate production apparatus according to an embodiment of the invention;

FIG. 3 is a schematic lateral view of the first conveyor surface and the second conveyor surface of the aerosol-generating substrate production apparatus according to an embodiment;

FIG. 4 is a schematic lateral view of the first conveyor surface and the second conveyor surface of the aerosol-generating substrate production apparatus according to an embodiment;

FIG. 5 is a schematic lateral view of the first conveyor surface and the second conveyor surface of the aerosol-generating substrate production apparatus according to an embodiment;

FIG. 6 is a schematic lateral view of the first conveyor surface and the second conveyor surface of the aerosol-generating substrate production apparatus according to an embodiment;

FIG. 7 is a schematic lateral view of the first conveyor surface or the second conveyor surface of the aerosol-generating substrate production apparatus according to an embodiment;

FIG. 8 is a schematic lateral view of the first conveyor surface or the second conveyor surface of the aerosol-generating substrate production apparatus according to an embodiment;

FIG. 9 is a schematic lateral view of the first conveyor surface or the second conveyor surface of the aerosol-generating substrate production apparatus according to an embodiment;

FIG. 10 is a schematic lateral view of the first conveyor surface or the second conveyor surface of the aerosol-generating substrate production apparatus according to an embodiment;

FIG. 11 is a schematic lateral view of the first conveyor surface or the second conveyor surface of the aerosol-generating substrate production apparatus according to an embodiment;

FIG. 12 is a schematic lateral view of the first conveyor surface or the second conveyor surface of the aerosol-generating substrate production apparatus according to an embodiment;

FIG. 13 is a schematic lateral view of the first conveyor surface or the second conveyor surface of the aerosol-generating substrate production apparatus according to an embodiment.

FIG. 1 depicts an embodiment of the aerosol-generating substrate production apparatus 1. The aerosol-generating substrate production apparatus 1 is a unit of an aerosol-generating article production line 2. The aerosol-generating substrate production apparatus 1 is adapted for casting an aerosol-generating material 3 and forming the aerosol-generating material 3 to an aerosol-generating substrate 4.

The aerosol-generating substrate production apparatus 1 comprises a casting device 5. The casting device 5 is equipped with a casting box 6 and a casting blade 7. A temperature of the casting box 6 can be varied in order to modify the temperature of a slurry 8 of the aerosol-generating material 3. This can be done by means of a casting box control means 12.

The slurry 8 of the aerosol-generating material 3 may be transferred to the aerosol-generating substrate production apparatus 1 through a slurry transfer system 9 of the aerosol-generating article production line 2. The slurry transfer system 9 may comprise a pump 10, preferably having a flow control 11.

The casting blade 7, preferably together with a control means 12 of the casting box 6, are used to control a thickness 13 of the slurry 8 of the aerosol-generating material 3 casted on a first conveyor 14.

The first conveyor 14 comprises a first roller 15, a second roller 16 and a first conveyor belt 17. The first roller 15 and the second roller 16 rotate as indicated by a first arrow 18 and moves the first conveyor belt 17. The first conveyor belt 17 has a first conveyor surface 19. The aerosol-generating material 3 is casted on the first conveyor belt 17, more specifically on the first conveyor surface 19. The first conveyor surface 19 of the first conveyor belt 17 supports the aerosol-generating material 3 along a transport path 20. The casting device 5 is arranged above the first roller 15. A gap is provided in between the casting blade 6 and the first conveyor surface 19. The dimension of the gap determines the thickness 13 of the aerosol-generating material 3, at least initially.

A second conveyor 21 is provided above the first conveyor 14. The second conveyor 21 comprises a first roller 22, a second roller 23, a third roller 24 and a second conveyor belt 25. The first roller 22, the second roller 23 and the third roller 24 rotate as indicated by a second arrow 26 and moves the second conveyor belt 25, at least locally along the transport path 20. The second conveyor belt 25 has a second conveyor surface 27.

The aerosol-generating substrate production apparatus 1 according to the embodiment depicted in FIG. 1 comprises a first drying unit 28. A steam dryer 29 for providing steam and/or an air dryer 30 for providing heated air may be provided in the aerosol-generating substrate production apparatus 1. The first drying unit 28 may comprise the steam dryer 29 and/or the air dryer 30. Preferably, the drying with steam is performed on a first side 31 of the aerosol-generating material 3 in contact with the first conveyor surface 19. Preferably, the drying with heated air or with steam is performed on a second side 32 of the aerosol-generating material 3.

Before the first conveyor belt 17, more specifically the first conveyor surface 19 and the aerosol-generating material 3 transported by the first conveyor belt 17, enters the first drying unit 28, the second conveyor surface 27 is applied on the second side 32 of the aerosol-generating material 3, at least while it is moved along a first portion 33 the transport path 20. The second conveyor surface 27 contacts on the aerosol-generating material 3 at least while it is moved along the first portion 33. By this way a pressure if applied on the aerosol-generating material 3. The aerosol-generating material 3 is sandwiched between the first conveyor surface 19 and the second conveyor surface 27, while the aerosol-generating material 3 is conveyed in the first drying unit 28. Thus, the aerosol-generating material 3 is formed and dried at the same time, while it is transported at least along the first portion 33 of the transport path 100 in a transport direction 200. During drying, a moisture content of the aerosol-generating material 3 is reduced. The resulting product is the aerosol-generating substrate 4. The aerosol-generating substrate 4 has the desired shape at least on the first side 31 or on the second side 32. The moisture content of the aerosol-generating substrate 4 is lower than the aerosol-generating material 3. The aerosol-generating substrate 4 may be dimensionally stable.

The aerosol-generating substrate 4 may be moved to another unit of an aerosol-generating article production line 2 for further processing. A cooling station, a winding station or a slicing station may be provided at the end of the transport path 20, which are not shown in FIG. 1.

FIG. 2 depicts a second embodiment of the aerosol-generating substrate production apparatus 1. A difference of the second embodiment in comparison to the first embodiment is that in the second embodiment in addition to the first drying unit 28, a second drying unit 35 is provided in the aerosol-generating substrate production apparatus 1. The second drying unit 35 is positioned downstream of the first drying unit 28 in the transport direction 200.

The first conveyor belt 17, more specifically the first conveyor surface 19 and the aerosol-generating material 3 transported by the first conveyor belt 17 enters the first drying unit 28. The first drying unit 28 comprises the steam dryer 29. Preferably, the drying with steam is performed on the first side 31 and the second side 32 of the aerosol-generating material 3.

Before entering the second drying unit 35 the second conveyor surface 27 is applied on the second side 32 of the aerosol-generating material 3, at least while the second conveyor surface 27 is moved along a second portion 36 of the transport path 20. The second conveyor surface 27 contacts on the aerosol-generating material 3, at least while the second conveyor surface 27 is moved along the second portion 36. By this way, a pressure is applied on the aerosol-generating material 3. The aerosol-generating material 3 is sandwiched between the first conveyor surface 19 and the second conveyor surface 27 in the second drying unit 35. By this way, the aerosol-generating material 3 is formed and dried at the same time, while it is transported at least along a portion 33 of the transport path 100.

The second drying unit 35 comprises the air dryer 30. Preferably, the drying with air is performed on the first side 31 and the second side 32 of the aerosol-generating material 3.

The aerosol-generating substrate 4 may be moved to another unit of an aerosol-generating article production line 2 for further processing. A winding station or a slicing station may be provided at the end of the transport path 100, which are not shown in FIG. 1.

FIG. 3 depicts of the first conveyor surface 19 and the second conveyor surface 27 of the aerosol-generating substrate production apparatus 1. The first conveyor surface 19 comprises at least a first surface portion 38 with corrugations 39. The second conveyor surface 27 comprises at least a second surface portion 40 with corrugations 39. The corrugations 39 of the first conveyor surface 19 is complementary regarding the corrugations 39 of the second conveyor surface 27. The corrugations 39 of the first conveyor surface 19 may be also symmetrical with the corrugations 39 of the second conveyor surface 27. The corrugations 39 extend in the transport direction 200. The corrugations 39 shown in FIG. 3 have a sinusoidal wave profile 41.

The corrugations 39 are formed by ridges 42 and recesses 43. In this embodiment, the ridges 42 and recesses 43 have substantially the same shape. The width 46 of the ridges 42 is defined as a first distance 48 between two peaks 49 of the consecutive recesses 43. The width 47 of the recesses 43 is defined as a second distance 50 between two peaks 51 of the consecutive ridges 42.

FIG. 4 depicts another embodiment of the first conveyor surface 19 and the second conveyor surface 27 of the aerosol-generating substrate production apparatus 1. A difference of the embodiment shown in FIG. 4 in comparison to the embodiment shown in FIG. 3 is that the corrugations 39 have a square shape profile 52, where the height 53 and the width 54 of the ridges 42 and the recesses 44 in the square profile 52 are substantially the same.

FIG. 5 depicts another embodiment of the first conveyor surface 19 and the second conveyor surface 27 of the aerosol-generating substrate production apparatus 1. A difference of the embodiment shown in FIG. 5 in comparison to the embodiment shown in FIG. 3 is that the first conveyor surface 19 is substantially flat at least in the region 55 facing the second surface portion 40 of the second conveyor surface 27 with corrugations 39.

FIG. 6 depicts another embodiment of the first conveyor surface 19 and the second conveyor surface 27 of the aerosol-generating substrate production apparatus 1. A difference of the embodiment shown in FIG. 6 in comparison to the embodiment shown in FIG. 3 is that the second conveyor surface 27 is substantially flat at least in the region 56 facing the first surface portion 38 of the first conveyor surface 19 with corrugations 39.

FIG. 7-13 depict various embodiments showing different geometrical configurations that the first conveyor surface 19 and/or the second conveyor surface 27 might have.

FIG. 7 show corrugations 39 having a uniform rectangular shape profile 57, where the height 58 of the ridges 42 and the recesses 44 are substantially the same, and the width 59 of the ridges 42 and the recesses 44 are substantially the same, wherein the width 59 of the ridges 42 and the recesses 44 is larger than the height 58 of the ridges 42 and the recesses 44.

FIG. 8 show corrugations 39 having a uniform rectangular shape profile 57, where the height 60 of the ridges 42 and the recesses 44 are substantially the same, and the width 61 of the ridges 42 and the recesses 44 are substantially the same, wherein the width 61 of the ridges 42 and the recesses 44 is larger than the height 60 of the ridges 42 and the recesses 44. The height 60 of the ridges 42 and the recesses 44 shown in FIG. 8 is larger than the height 58 of the ridges 42 and the recesses 44 shown in FIG. 7.

FIG. 9 shows corrugations 39 having a non-uniform rectangular shape profile 62, where at least two consecutive ridges 42 have different heights, namely a first height 63 and a second height 64.

FIG. 10 shows corrugations 39 having a uniform rectangular shape profile 57, where the height 65 of the ridges 42 and the recesses 44 are substantially the same, and the width 66 of the ridges 42 and the recesses 44 are substantially the same, wherein the height 65 of the ridges 42 and the recesses 44 is larger than the width 66 of the ridges 42 and the recesses 44. The height 65 of the ridges 42 and the recesses 44 shown in FIG. 10 is larger than the height 58 of the ridges 42 and the recesses 44 shown in FIG. 7a. The width 66 of the ridges 42 and the recesses 44 shown in FIG. 10 is smaller than the width 59 of the ridges 42 and the recesses 44 shown in FIG. 7.

FIG. 11 show corrugations 39 having a uniform rectangular shape profile 57, where the height 67 of the ridges 42 and the recesses 44 are substantially the same, and the width 68 of the ridges 42 and the recesses 44 are substantially the same, wherein the height 67 of the ridges 42 and the recesses 44 is smaller than the height 65 of the ridges 42 and the recesses 44 shown in FIG. 10.

FIG. 12 show corrugations 39 having a non-uniform rectangular shape profile 62, where the ridges 42 have a first width 69 and the recesses 44 have a second width 70. The second width 70 is larger than the first width 69.

FIG. 13 show corrugations 39 having a non-uniform rectangular shape profile 62, where the ridges 42 have a first height 71 and a second height 72. The second height 72 is larger than the first height 71.

The embodiments shown in FIGS. 7-13 with different geometrical configurations may be implemented also in the sinusoidal, triangular, semi-triangular, semi-rectangular shapes corrugations.

An embodiment of the method of producing an aerosol-generating substrate 4 comprises the step of forming the aerosol-generating material 3 between the first conveying surface 19 of the first conveyor 14 and the second conveying surface 27 of the second conveyor 21, and drying the aerosol-generating material 3 during forming, as shown in FIG. 1. The first conveyor surface 19 and the second conveyor surface 27 may be designed as shown in FIGS. 3-6. The first conveyor surface 19 and/or the second conveyor surface 27 might have different geometrical configurations as depicted in FIG. 7-13.

Before forming the aerosol-generating material 3 between the first conveying surface 19 and the second conveying surface 27, the aerosol-generating material 3 is casted onto the first conveyor 14, in particular on the first conveyor surface 19. The aerosol-generating material 3 casted onto the first conveyor surface 19 has a moisture content of 90 weight percent to 40 weight percent, in particular from 85 weight percent to 50 weight percent, preferably in particular from 80 weight percent to 60 weight percent. In particular, the weight percentage is based on the total weight of the aerosol-generating material.

After casting the aerosol-generating material 3, the aerosol-generating material 3 is dried by applying heat to the aerosol-generating material 3. The aerosol-generating material 3 is conveyed through hot air provided in the drying unit 28. Before conveying the aerosol-generating material 3 through the drying unit 28, the second conveyor surface 27 is applied on the aerosol-generating material 3. After the drying step, the aerosol-generating material may have a moisture content of about 10 weight percent to about 20 weight percent. In particular, the weight percentage is based on the total weight of the aerosol-generating material.

An another embodiment of the method of producing an aerosol-generating substrate 4 comprises the step of forming the aerosol-generating material 3 between the first conveying surface 19 of the first conveyor 14 and the second conveying surface 27 of the second conveyor 21, as shown in FIG. 2. The first conveyor surface 19 and the second conveyor surface 27 may be designed as shown in FIGS. 3-6. The first conveyor surface 19 and/or the second conveyor surface 27 might have different geometrical configurations as depicted in FIG. 7-13.

Before forming the aerosol-generating material 3 between the first conveying surface 19 and the second conveying surface 27, the aerosol-generating material 3 is casted onto the first conveyor 14, in particular on the first conveyor surface 19. The aerosol-generating material 3 casted onto the first conveyor surface 19 has a moisture content of 90 weight percent to 40 weight percent, in particular from 85 weight percent to 50 weight percent, preferably in particular from 80 weight percent to 60 weight percent. In particular, the weight percentage is based on the total weight of the aerosol-generating material 3.

After casting the aerosol-generating material 3 on the first conveyor surface 19, the aerosol-generating material 3 is conveyed through the first drying unit 28 and the second drying unit 35. Before the aerosol-generating material 3 is conveyed through the second drying unit 35, the second conveyor surface 27 is applied on the aerosol-generating material 3. After the drying step, the aerosol-generating material may have a moisture content of about 10 weight percent to about weight percent. In particular, the weight percentage is based on the total weight of the aerosol-generating material 3.