Method for producing an aerosol-generating substrate sheet for an aerosol-generating article

Description

1 / 52 METHOD FOR PRODUCING AN AEROSOL-GENERATING SUBSTRATE SHEET FOR AN AEROSOL-GENERATING ARTICLE

[001] The present invention also relates to a method for producing an aerosol-generating substrate sheet for an aerosol-generating article. The present invention also relates to an apparatus for producing an aerosol-generating substrate sheet for an aerosol-generating article, to a mass for producing an aerosol-generating substrate sheet for an aerosol-generating article, to a process for manufacturing a component of the aerosol-generating article and to an aerosol-generating article.

[002] Aerosol-generating articles or non-combustion heating cigarettes, in which an aerosol-generating substrate is heated instead of undergoing combustion, are known in the art. The aerosol-generating substrate is, for example, a molded herbaceous or plant-based sheet without tobacco, or a plastic fiber-based material, or a biodegradable fiber-based material. Typically, in such heated aerosol-generating articles, an aerosol is generated by heat transfer from a heat source to a physically separate aerosol-generating material or substrate, which may be located in contact with, within, around, or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are carried along with the inhaled air through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol.

[003] In a typical manufacturing process, aerosol-generating articles are made from a molded sheet that is obtained through a molding process of ingredients such as tobacco powder or other nicotine-containing materials, water, fibers, for example, cellulose, glycerin, guar. A first step is the manufacture of a fluid paste of Petition 870250090281, dated 03 / 10 / 2025, page 15 / 83 2 / 52 Tobacco mixing the above ingredients. The fluid paste is an aqueous mixture of insoluble matter with a water content of 70 percent - 80 percent. In a second step, the tobacco fluid paste is placed inside a molding box to be shaped by a molding blade on a moving steel conveyor belt to create a continuous sheet of molded tobacco leaf. In a third step, once the tobacco is molded onto the belt, the belt moves hundreds of meters in length through heating / drying units, where the temperature is controlled to progressively heat and dry the reconstituted molded tobacco leaf so that, in the end, the water level in the reconstituted tobacco is below 20%. At the dryer outlet there is a cooler where the temperature of the molded weft is reduced before winding the molded weft into coils, as a fourth step.In a fifth step, the molded sheet is unrolled and cut to form smaller coils, crimped between crimping rollers, and wrapped into a final consumable.

[004] Document W02020058814A1 describes a method for producing reconstituted tobacco in which the solid components of tobacco are fragmented to bring them to a particle size, the fragmented product thus obtained is mixed with water, at least one binding agent and at least one material to form an aerosol until a mixture with a liquid content of about 35-40 percent is obtained. The mixture is subjected to a first lamination and a series of additional rolling passes to obtain a strip with a substantially constant thickness and then the strip is dried to bring its liquid content to about 8-15 percent.

[005] US2022 / 369690A1 describes a method for producing an aerosol-generating substrate for an aerosol-generating article. This method comprises: forming a mixture comprising particles of Petition 870250090281, dated 03 / 10 / 2025, page 16 / 83 3 / 52 Ginger, water, aerosol former, binder, and tobacco particles; mold or extrude the fluid paste into the shape of a sheet; dry the sheet. The mixture can be a mass with a dry weight of at least 60 percent.

[006] US2022 / 0346433A1 describes a method for producing a tobacco paste and tobacco-containing film for making an aerosol-forming substrate for non-burning heating products. This method comprises: making a powdered tobacco material, making a binder gel, mixing the powdered tobacco material and the binder to obtain a tobacco paste, flattening the tobacco paste to obtain a flat weave material, and drying the flat weave material.

[007] W02022096860A1 describes a method for manufacturing an aerosol-generating material and articles comprising aerosol-generating material. This method comprises: forming a first composition comprising a binder and an aerosol former and forming a second composition comprising tobacco material, filler and a second binder; mixing and extruding the compositions. The mixture of the first composition and the second composition may be in the form of a mass that is extruded through a die.

[008] It would be desirable to have a method for manufacturing an aerosol-generating substrate sheet, wherein the resulting aerosol-generating substrate sheet has good mechanical properties and wherein the method allows for reduced water and energy consumption compared to traditional methods employing fluid paste.

[009] The present invention also relates to a method for producing an aerosol-generating substrate sheet for an aerosol-generating article. The method comprises: mixing a recipe with water to form a mixture. The recipe may comprise as ingredients: vegetable particles and / or alkaloids, a binder and an aerosol-forming agent. The mixture may be kneaded to form Petition 870250090281, dated 03 / 10 / 2025, page 17 / 83 4 / 52 a dough. The mixture can be kneaded in a dough mixer to form the dough. The dough can be flattened to form a sheet. The flattened sheet can be dried. The amount of binder in the recipe can be from 1.0 percent to 7.0 percent based on dry weight. The liquid content of the dough can be from 25 percent to 35 percent based on wet weight.

[0010] The aerosol-generating substrate sheet for an aerosol-generating article produced by this method has been found to have good mechanical properties, including tensile strength and elongation at break.

[0011] The method has been found to allow achieving good desired ranges of tensile strength and elongation at break in the aerosol-generating substrate sheet obtained from the mass, both in the longitudinal and transverse directions.

[0012] The claimed binder range has been found to lead to high mechanical properties, including tensile strength in the machine and transverse directions, as well as greater elongation at break. The more binder in the recipe, the greater the elongation at break.

[0013] The method has been found to reduce energy and water consumption compared to sheets made from molded fluid paste. In fact, the water content, which almost exclusively determines the liquid content of the paste mixture, is much lower than the water content of fluid paste from typical manufacturing processes.

[0014] One or more of the following optional features and modalities described may be combined with the above method, also for split or continuation order deposits.

[0015] The amount of binder in the recipe may be from 1.5 percent to 6.5 percent based on dry weight. The amount of vegetable particles and / or alkaloids in the recipe may be 50 percent. Petition 870250090281, dated 03 / 10 / 2025, p. 18 / 83 5 / 52 to 80 percent based on dry weight, optionally 70 percent to 80 percent based on dry weight. The amount of aerosol-forming agent in the recipe may be 16 percent to 20 percent based on dry weight. The amount of aerosol-forming agent in the recipe may be 17.5 percent to 20 percent based on dry weight.

[0016] In some embodiments, the plant particles and / or alkaloids comprise tobacco particles. In some embodiments, the aerosol-generating substrate leaf is a reconstituted tobacco leaf.

[0017] In some embodiments, the plant particles and / or alkaloids may comprise tobacco and / or nicotine and / or botanical products and / or cellulose powder. The botanical products may comprise cellulose fibers, such as leaf fibers or powdered fibers. The botanical products may comprise one or more of the following: clove, star anise, lavender, rosemary, peppermint, sage, chamomile. The tobacco may comprise tobacco mixtures.

[0018] In some embodiments, tobacco is from 0 percent to 80 percent on a dry weight basis, optionally from 50 percent to 80 percent on a dry weight basis, and botanical products are from 1 percent to 20 percent on a dry weight basis. In some other embodiments, botanical products and / or cellulose powder are from 50 percent to 80 percent on a dry weight basis.

[0019] In some embodiments, the binder is a cellulose derivative. The binder may be methylcellulose, ethylcellulose, ethylhydroxymethyl or carboxymethylcellulose. In some embodiments, the binder may comprise natural pectins, optionally fruit, citrus or tobacco pectins; or guar gums, optionally hydroxyethyl guar or hydroxypropyl guar; or locust bean gums, optionally hydroxyethyl and hydroxypropyl locust bean gum; or alginate; or starches, starches Petition 870250090281, dated 03 / 10 / 2025, page 19 / 83 6 / 52 optionally modified or derived; or tamarind gum; or dextran; or pullalon; or konjac flour; or xanthan gum; or a mixture of the above.

[0020] In some embodiments, the aerosol-forming agent is a polyhydric alcohol. The polyhydric alcohol may be triethylene glycol, 1,3-butanediol, or glycerin or propylene glycol. In some embodiments, the aerosol-forming agent may comprise monohydric alcohols, optionally menthol; or esters of polyhydric alcohols, optionally mono-, di-, or triacetate of glycerol; or aliphatic esters of mono-, di-, or polycarboxylic acids, optionally dimethyl dodecanedioate, dimethyl tetradecanedioate, or triethyl citrate.

[0021] In some embodiments, the recipe additionally comprises fibers. The amount of fibers in the recipe may be from 0.1 percent to 2.5 percent on a dry weight basis, optionally to 5.0 percent on a dry weight basis. The fibers may be cellulose fibers. The fibers may be softwood fibers, hardwood fibers, jute fibers, flax fibers, or tobacco fibers. The length of the fibers may be between 5 µm and 2500 µm, optionally between 155 µm and 1500 µm, optionally between 750 µm and 2500 µm, optionally between 710 µm and 1600 µm. The binder-to-fiber ratio may be between 0.48 and 1.82. The binder-to-fiber ratio has been found to be a good parameter for maximizing elongation at break and tensile strength of the sheet in the machine (longitudinal) and transverse directions.The described ratios between the binder and the fibers optimize elongation at break and tensile strength, while maintaining good dough processability.

[0022] In some embodiments, the recipe includes additional botanical products. The amount of botanical products in the recipe may be from 1.0 percent to 20.0 percent based on dry weight. Petition 870250090281, dated 03 / 10 / 2025, p. 20 / 83 7 / 52

[0023] The viscosity of the binder can be between 800 cp and 10000 cp (0.8 - 10 Pa s). The binder viscosity can be greater than 3900 cp (3.9 Pa s). The binder viscosity can be between 1950 cp and 6000 cp (1.95 - 6 Pa s), optionally between 4000 cp and 5000 cp (4 - 5 Pa s). The binder viscosity can be between 7200 cp and 7600 cp (7.2 - 7.6 Pa s). The binder viscosity has been found to influence elongation at break and tensile strength: the higher the viscosity, the longer the elongation at break; the lower the viscosity, the greater the tensile strength. The described viscosity range provides a good balance between elongation at break and tensile strength.

[0024] In some embodiments, 90 percent of the plant particles and / or alkaloids have a size smaller than 600 pm, optionally smaller than 450 pm, optionally smaller than 300 pm, optionally smaller than 200 pm, optionally smaller than 150 pm.

[0025] In some embodiments, mixing the recipe with water comprises: pre-mixing at least one ingredient of the recipe before kneading the mixture in a dough mixer. The water may be pre-mixed with at least one ingredient, for example, fiber (i.e., the fiber is hydrated) and / or added in the dough mixer. In other embodiments, there is no pre-mixing and all ingredients are mixed, preferably in the dough mixer.

[0026] In some embodiments, the fibers are hydrated, that is, premixed with water, or the fibers and the aerosol-forming agent are hydrated, that is, premixed with water and then other ingredients are added.

[0027] In some embodiments, mixing the recipe with water comprises: pre-mixing at least one ingredient or only a portion of said at least one ingredient of the recipe to form a Petition 870250090281, dated 03 / 10 / 2025, p. 21 / 83 8 / 52 first premix; premix the remaining ingredient(s) or the remaining portion(s) of the ingredient(s) of the recipe to form a second premix; combine the first premix and the second premix in the dough mixer. Water may be premixed into the first premix and / or the second premix and / or added in the dough mixer.

[0028] In some embodiments, mixing the recipe with water comprises: first mixing the binder with water and then bringing the binder into contact with the aerosol-forming agent. This sequence has been found to provide proper hydration of the binder by water.

[0029] In other methods, mixing the recipe with water involves: first mixing the binder with the aerosol-forming agent and then bringing the binder into contact with the water. This sequence has been found to prevent the formation of lumps.

[0030] In one embodiment, mixing the recipe with water comprises: mixing the vegetable particles and / or alkaloids and the aerosol-forming agent to make a first premix; mixing the water and the binder to make a second premix; combining the first premix and the second premix in the dough mixer. In this embodiment, mixing the vegetable particles and / or alkaloids and the aerosol-forming agent may comprise: first mixing the vegetable particles and / or alkaloids and the fibers and then adding the aerosol-forming agent to make the first premix.

[0031] In one embodiment, mixing the recipe with water comprises: mixing the vegetable particles and / or alkaloids and the binder to make a first premix; combining the first premix, the aerosol-forming agent and the water in the dough mixer by adding the water first, then the first premix, and then the aerosol-forming agent. In this embodiment, fibers may also be Petition 870250090281, dated 03 / 10 / 2025, p. 22 / 83 9 / 52 mixed with the vegetable particles and / or alkaloids and the binder to make the first premix.

[0032] In one embodiment, mixing the recipe with water comprises: mixing the binder to make a first premix; mixing water, vegetable particles and / or alkaloids and the first premix to make a second premix; combining the second premix and the aerosol-forming agent in the mass mixer. In this embodiment, fibers can also be mixed with the binder to make the first premix.

[0033] In one embodiment, mixing the recipe with water comprises: mixing the binder to make a first premix; combining the vegetable particles and / or alkaloids, the first premix, the water and the aerosol-forming agent in the dough mixer. In this embodiment, the fibers can also be mixed with the binder to make the first premix.

[0034] In one embodiment, mixing the recipe with water comprises: mixing the vegetable particles and / or alkaloids to make a first premix; mixing the aerosol-forming agent and the binder and then adding water to make a second premix; combining the first premix and the second premix in the dough mixer. In this embodiment, the fibers can be mixed with the vegetable particles and / or alkaloids to make the first premix.

[0035] In one embodiment, mixing the recipe with water comprises: mixing the vegetable particles and / or alkaloids and the binder to make a first premix; mixing the aerosol-forming agent and water to make a second premix; combining the first premix and the second premix in the dough mixer. In this embodiment, the fibers can be mixed with the vegetable particles and / or alkaloids and the binder to make the first premix. Petition 870250090281, dated 03 / 10 / 2025, page 23 / 83 10 / 52

[0036] In one embodiment, mixing the recipe with water comprises: mixing the vegetable particles and / or alkaloids and the binder to make a first premix; combining the first premix, the aerosol-forming agent and the water in the dough mixer by first adding the aerosol-forming agent and the first premix and then the water. In this embodiment, the fibers can be mixed with the vegetable particles and / or alkaloids and the binder to make the first premix.

[0037] In one embodiment, mixing the recipe with water comprises: mixing the vegetable particles and / or alkaloids, a portion of the aerosol-forming agent and a portion of water to make a first premix; mixing a remaining portion of the aerosol-forming agent, a remaining portion of water and then the binder to make a second premix; combining the first premix and the second premix in the dough mixer. In this embodiment, the fibers can be mixed with the vegetable particles and / or alkaloids, the portion of the aerosol-forming agent and the portion of water to make the first premix. In this embodiment, the portion of the aerosol-forming agent can be half of a total quantity of the aerosol-forming agent. In this embodiment, the portion of water can be a quarter of a total quantity of water.

[0038] In one embodiment, mixing the recipe with water comprises: mixing the vegetable particles and / or alkaloids, the aerosol-forming agent and water to make a first premix; mixing the first premix in the dough mixer and then adding the binder. In this embodiment, the fibers can be mixed with the vegetable particles and / or alkaloids, the aerosol-forming agent and water to make the first premix.

[0039] In one embodiment, mixing the recipe with water comprises: mixing the plant particles and / or alkaloids, the forming agent Petition 870250090281, dated 03 / 10 / 2025, page 24 / 83 11 / 52 of aerosol, the binder and water all together in the mass mixer. In this embodiment, the fibers can also be mixed with the vegetable particles and / or alkaloids, the aerosol-forming agent, the binder and water in the mass mixer.

[0040] In one embodiment, mixing the recipe with water comprises: mixing the vegetable particles and / or alkaloids and the binder to make a first premix; mixing the fibers with water to make a second premix; combining the first premix with the second premix in the dough mixer.

[0041] In one embodiment, mixing the recipe with water comprises: mixing the vegetable particles and / or alkaloids and the binder to make a first premix; mixing the fibers with a portion of water and then with the aerosol-forming agent to make a second premix; combining the first premix with the second premix in the dough mixer and adding a remaining portion of water.

[0042] In some embodiments, a water temperature is between 5 °C and 120 °C. For example, the water temperature is between 20 °C and 80 °C, preferably between 20 °C and 50 °C, optionally between 50 °C and 80 °C. For example, the water temperature is between 15 °C and 25 °C. These temperatures have been found to prevent a degradation of the mass during processing that would affect the mechanical properties of the sheet.

[0043] In some embodiments, the dough temperature at the end of preparation, before flattening, is between 20 °C and 50 °C, preferably between 20 °C and 35 °C. For example, the dough temperature before flattening is between 35 °C and 45 °C. Higher dough temperatures have been found to provide weaker mechanical properties, but an easily processable sheet. Petition 870250090281, dated 03 / 10 / 2025, p. 25 / 83 12 / 52

[0044] In some embodiments, flattening is performed by means of rollers. The temperature of the rollers can be between 5 °C and 50 °C. For example, the temperature of the rollers is between 8 °C and 40 °C. For example, the temperature of the rollers is between 10 °C and 30 °C. These roller temperatures have been found to prevent a degradation of the mass, which would reduce the mechanical properties of the sheet.

[0045] The flattening stage may comprise: rolling the mass to pre-form a thick sheet. The thick sheet may have a thickness between 2 mm and 20 mm. The flattening stage may also further comprise: flattening the thick sheet to form a thin sheet. The thickness of the thin sheet may be between 0.15 mm and 0.35 mm. For example, the thickness of the thin sheet may be between 0.15 mm and 0.30 mm. Preferably, the thickness of the thin sheet may be between 0.172 mm and 0.285 mm. The thick sheet may be transformed into the thin sheet, of calibrated thickness, with several rolling stages. The thin sheet may have a moisture content between 25 and 35 percent.

[0046] In some embodiments, in the drying stage, the flat sheet is dried to a liquid content of 5.8–11.2 percent on a wet weight basis. In the drying stage, the flat sheet may be dried to a liquid content of 8.5 percent on a wet weight basis. Drying may be carried out by conveying the flat sheet through a dryer on a belt conveyor, optionally the conveyor belt being a mesh belt. The drying technology may be a combination of infrared and hot air, microwave and hot air, or by means of conduction through a steam-heated belt and convection with hot air.

[0047] In some embodiments, plant particles and / or alkaloids are made by grinding plant fragments and / or alkaloids in a grinder. Petition 870250090281, dated 03 / 10 / 2025, p. 26 / 83 13 / 52

[0048] The present invention also relates to a mass for producing an aerosol-generating substrate sheet for an aerosol-generating article. The mass may comprise: water and a recipe. The recipe may comprise as ingredients: vegetable particles and / or alkaloids, a binder and an aerosol-forming agent. The amount of binder in the recipe may be from 1.0 percent to 7.0 percent on a dry weight basis. The liquid content of the mass may be from 25 percent to 35 percent on a wet weight basis.

[0049] The mass described above has been found to allow the production of an aerosol-generating substrate sheet for an aerosol-generating article with good mechanical properties, including tensile strength and elongation at break.

[0050] It has been found that the mass described above allows achieving good desired ranges of tensile strength and elongation at break of the aerosol-generating substrate sheet, both in the longitudinal and transverse directions.

[0051] In fact, it has been found that the claimed range of binder leads to high mechanical properties, including tensile strength in the machine and transverse directions, as well as greater elongation at break. The more binder in the recipe, the greater the elongation at break.

[0052] One or more of the following optional features and modalities described may be combined with the above mass, also for the deposit of split or continuation orders.

[0053] The amount of binder in the recipe may be from 1.5 percent to 6.5 percent based on dry weight. The amount of vegetable particles and / or alkaloids in the recipe may be from 50 percent to 80 percent based on dry weight, optionally 70 percent to 80 percent based on dry weight. The amount of aerosol-forming agent in the recipe may be from 16 percent to 20 percent. Petition 870250090281, dated 03 / 10 / 2025, p. 27 / 83 14 / 52 based on dry weight. The amount of aerosol-forming agent in the recipe may be from 17.5 percent to 20 percent based on dry weight.

[0054] In some embodiments, the plant particles and / or alkaloids comprise tobacco particles. In some embodiments, the aerosol-generating substrate leaf is a reconstituted tobacco leaf.

[0055] In some embodiments, the plant particles and / or alkaloids may comprise tobacco and / or nicotine and / or botanical products and / or cellulose powder. The botanical products may comprise cellulose fibers, such as leaf fibers or powdered fibers. The botanical products may comprise one or more of the following: clove, star anise, lavender, rosemary, peppermint, sage, chamomile. The tobacco may comprise tobacco mixtures.

[0056] In some embodiments, tobacco is from 0 percent to 80 percent on a dry weight basis, optionally from 50 percent to 80 percent on a dry weight basis, and botanical products are from 1 percent to 20 percent on a dry weight basis. In some other embodiments, botanical products and / or cellulose powder are from 50 percent to 80 percent on a dry weight basis.

[0057] In some embodiments, the binder is a cellulose derivative. The binder may be methylcellulose, ethylcellulose, ethylhydroxymethyl or carboxymethylcellulose. In some embodiments, the binder may comprise natural pectins, optionally fruit, citrus or tobacco pectins; or guar gums, optionally hydroxyethyl guar or hydroxypropyl guar; or locust bean gums, optionally hydroxyethyl and hydroxypropyl locust bean gum; or alginate; or starches, optionally modified starches or derivatives; or tamarind gum; or dextran; or pullalon; or konjac flour; or xanthan gum; or a mixture of the above items. Petition 870250090281, dated 03 / 10 / 2025, page 28 / 83 15 / 52

[0058] In some embodiments, the aerosol-forming agent is a polyhydric alcohol. The polyhydric alcohol may be triethylene glycol, 1,3-butanediol, or glycerin or propylene glycol. In some embodiments, the aerosol-forming agent may comprise monohydric alcohols, optionally menthol; or esters of polyhydric alcohols, optionally mono-, di-, or triacetate of glycerol; or aliphatic esters of mono-, di-, or polycarboxylic acids, optionally dimethyl dodecanodioate, dimethyl tetradecanodioate, or triethyl citrate.

[0059] In some embodiments, the recipe additionally comprises fibers. The amount of fibers in the recipe may be from 0.1 percent to 2.5 percent on a dry weight basis, optionally to 5.0 percent on a dry weight basis. The fibers may be cellulose fibers. The fibers may be softwood fibers, hardwood fibers, jute fibers, flax fibers, or tobacco fibers. The length of the fibers may be between 5 µm and 2500 µm, optionally between 155 µm and 1500 µm, optionally between 750 µm and 2500 µm, optionally between 710 µm and 1600 µm. The binder-to-fiber ratio may be between 0.48 and 1.82. The binder-to-fiber ratio has been found to be a good parameter for maximizing elongation at break and tensile strength of the sheet in the machine (longitudinal) and transverse directions.The described ratios between the binder and the fibers optimize elongation at break and tensile strength, while maintaining good dough processability.

[0060] In some embodiments, the recipe includes additional botanical products. The amount of botanical products in the recipe may be from 1.0 percent to 20.0 percent based on dry weight.

[0061] The viscosity of the binder may be between 800 cp and 10000 cp (0.8 - 10 Pa s). The viscosity of the binder may be greater than 3,900 cp (3.9 Pa s). The viscosity of the binder may be between Petition 870250090281, dated 03 / 10 / 2025, p. 29 / 83 16 / 52 The viscosity of the binder can be between 1950 cp and 6000 cp (1.95 - 6 Pa s), optionally between 4000 cp and 5000 cp (4 - 5 Pa s). The viscosity of the binder can be between 7200 cp and 7600 cp (7.2 - 7.6 Pa s). The viscosity of the binder has been found to influence elongation at break and tensile strength: the higher the viscosity, the longer the elongation at break; the lower the viscosity, the greater the tensile strength. The described viscosity range provides a good balance between elongation at break and tensile strength.

[0062] In some embodiments, 90 percent of the plant particles and / or alkaloids have a size smaller than 600 pm, optionally smaller than 450 pm, optionally smaller than 300 pm, optionally smaller than 200 pm, optionally smaller than 150 pm.

[0063] The present invention also relates to a process for manufacturing a component of the aerosol generating article.

[0064] The process may comprise manufacturing an aerosol-generating substrate sheet for an aerosol-generating article by means of a method for producing an aerosol-generating substrate sheet for an aerosol-generating article. The method may be as described on the preceding pages. The method may comprise: mixing a recipe with water to form a mixture. The recipe may comprise as ingredients: vegetable particles and / or alkaloids, a binder, and an aerosol-forming agent. The mixture may be kneaded to form a dough. The mixture may be kneaded in a dough mixer to form the dough. The dough may be flattened to form a sheet. The flattened sheet may be dried. The amount of binder in the recipe may be from 1.0 percent to 7.0 percent on a dry weight basis. The liquid content of the dough may be from 25 percent to 35 percent on a wet weight basis.

[0065] One or more of the following characteristics and modalities Petition 870250090281, dated 03 / 10 / 2025, page 30 / 83 The 17 / 52 options described can be combined with the above process, also for the deposit of split or continuation orders.

[0066] The process may comprise using a mass to produce an aerosol-generating substrate sheet for an aerosol-generating article. The mass may be as described on the preceding pages. The mass may comprise: water and a recipe. The recipe may comprise as ingredients: vegetable particles and / or alkaloids, a binder, and an aerosol-forming agent. The amount of binder in the recipe may be from 1.0 percent to 7.0 percent on a dry weight basis. The liquid content of the mass may be from 25 percent to 35 percent on a wet weight basis.

[0067] According to some embodiments, the aerosol-generating substrate sheet is longitudinally divided into a plurality of aerosol-generating substrate strips and each aerosol-generating substrate strip is then bundled and wrapped to form a respective continuous column.

[0068] Dividing the aerosol-generating substrate sheet longitudinally into a plurality of aerosol-generating substrate strips may comprise: winding the aerosol-generating substrate sheet onto a core to form a master coil.

[0069] Dividing the aerosol-generating substrate sheet longitudinally into a plurality of aerosol-generating substrate strips may comprise: cutting the main coil into smaller coils, each smaller coil carrying one of the aerosol-generating substrate strips wound onto a respective portion of the core.

[0070] Alternatively, dividing the aerosol-generating substrate sheet longitudinally into a plurality of aerosol-generating substrate strips may comprise: cutting the aerosol-generating substrate sheet into a plurality of strips and then winding each strip onto a respective small coil. Petition 870250090281, dated 03 / 10 / 2025, page 31 / 83 18 / 52

[0071] The process may comprise: assembling the aerosol-generating substrate sheet. The process may comprise: enclosing the assembled aerosol-generating substrate sheet in an envelope to form a continuous column.

[0072] The process may comprise: cutting the continuous column into a plurality of aerosol-generating article components, each having a column shape. Each aerosol-generating article component may comprise a bundled sheet formed from a cut portion of the aerosol-generating substrate sheet.

[0073] The process described has been found to make it possible to obtain high-quality aerosol generating articles with reduced production costs and reduced energy consumption.

[0074] The present invention also relates to an apparatus for producing an aerosol-generating substrate sheet for an aerosol-generating article. The apparatus can be configured to perform the method described in the preceding pages. The method may comprise: mixing a recipe with water to form a mixture. The recipe may comprise as ingredients: vegetable particles and / or alkaloids, a binder, and an aerosol-forming agent. The mixture may be kneaded to form a dough. The mixture may be kneaded in a dough mixer to form the dough. The dough may be flattened to form a sheet. The flattened sheet may be dried. The amount of binder in the recipe may be from 1.0 percent to 7.0 percent on a dry weight basis. The liquid content of the dough may be from 25 percent to 35 percent on a wet weight basis.

[0075] The apparatus may comprise a dough mixer configured to knead the mixture with the recipe and water to form the dough. The dough mixer may be a batch mixer or a continuous mixer. The apparatus may comprise flattening rollers operationally placed downstream of the dough mixer. Petition 870250090281, dated 03 / 10 / 2025, page 32 / 83 19 / 52 and configured to flatten the mass to form the sheet. The apparatus may comprise a dryer operatively placed downstream of the flattening rollers and configured to dry the flattened sheet and thus obtain an aerosol-generating substrate sheet for an aerosol-generating article. The apparatus may comprise a winder operatively placed downstream of the dryer and configured to wind the sheet onto a reel. Alternatively, the apparatus may comprise an in-line cutter operatively placed downstream of the dryer and configured to divide the aerosol-generating substrate sheet into a plurality of ribbons. The apparatus may also comprise a plurality of small winders for winding each ribbon onto a respective small reel.

[0076] The described apparatus has been found to have a reduced footprint, since, for example, the dryer in this apparatus is shorter than the hundred-meter-long heaters / dryers used to dry the fluid paste of the prior art. This contributes to reducing capital expenditure, that is, the money that an organization or corporate entity spends to purchase, maintain, or improve its fixed assets, such as buildings, vehicles, equipment, or land.

[0077] One or more of the following optional features and modes described may be combined with the device above, also for split or continuation order deposit.

[0078] According to some embodiments, a grinder is operationally placed upstream of the dough mixer and is configured to grind the vegetable and / or alkali into particles.

[0079] According to some embodiments, one or more premixers are operationally placed upstream of the dough mixer and are configured to premix at least one ingredient or some ingredients or all of the ingredients of the recipe.

[0080] According to some models, a laminator of Petition 870250090281, dated 03 / 10 / 2025, p. 33 / 83 The 20 / 52 dough sheeter is configured to calender the dough to pre-form a thick sheet. The dough sheeter can be part of the dough mixer or can be operationally placed downstream of the dough mixer.

[0081] The present invention also relates to an aerosol generating article comprising at least one aerosol generating article component. The aerosol generating article component can be made according to the process for manufacturing an aerosol generating article component described on the preceding pages.

[0082] The process may comprise manufacturing an aerosol-generating substrate sheet for an aerosol-generating article by means of a method for producing an aerosol-generating substrate sheet for an aerosol-generating article. The method may be as described on the preceding pages. The method may comprise: mixing a recipe with water to form a mixture. The recipe may comprise as ingredients: vegetable particles and / or alkaloids, a binder, and an aerosol-forming agent. The mixture may be kneaded to form a dough. The mixture may be kneaded in a dough mixer to form the dough. The dough mixer may operate in batches or in a continuous process. The dough may be flattened to form a sheet. The flattened sheet may be dried. The amount of binder in the recipe may be from 1.0 percent to 7.0 percent on a dry weight basis. The liquid content of the dough may be from 25 percent to 35 percent on a wet weight basis.

[0083] As used in this descriptive report, the term recipe means a group of ingredients without any limitation as to the order and timing in which they are combined with each other and / or with water.

[0084] As used in this descriptive report, the term Petition 870250090281, dated 03 / 10 / 2025, page 34 / 83 21 / 52 dough means a mixture that is stiff enough to be kneaded or rolled, as opposed to a runny paste, which is an aqueous mixture of insoluble matter with such a high water content (e.g., 70 percent - 80 percent) that it cannot be kneaded or rolled.

[0085] As used in this descriptive report, the terms upstream and downstream are used to describe the relative positions of the components, or portions of the components, of the apparatus in relation to the direction in which a material or materials pass through the apparatus along a given path.

[0086] The invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. 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 in this document.

[0086] EX1. A method for producing an aerosol-generating substrate sheet for an aerosol-generating article, the method comprising: mixing a recipe with water to form a mixture, the recipe comprising as ingredients: vegetable particles and / or alkaloids, a binder and an aerosol-forming agent; kneading the mixture in a dough mixer to form a dough; flattening the dough to form a sheet; drying the flattened sheet to obtain an aerosol-generating substrate sheet for an aerosol-generating article; wherein an amount of the binder in the recipe is from 1.0 percent to 7.0 percent on a dry weight basis; wherein a liquid content of the dough is from 25 percent to 35 percent on a wet weight basis; optionally, the dough mixer operates in batches or with a continuous process.

[0087] EX2. A mass for producing an aerosol-generating substrate sheet for an aerosol-generating article, the mass comprises Petition 870250090281, dated 03 / 10 / 2025, page 35 / 83 22 / 52 understanding: water and a recipe, the recipe comprising as ingredients: vegetable particles and / or alkaloids, a binder and an aerosol-forming agent; wherein the amount of the binder in the recipe is from 1.0 percent to 7.0 percent based on dry weight; wherein the liquid content of the mass is from 25 percent to 35 percent based on wet weight.

[0088] EX3. A manufacturing process for a component of an aerosol-generating article, comprising: - to manufacture an aerosol-generating substrate sheet for an aerosol-generating article using the EX1 method or using the mass of EX2; - To group the aerosol-generating substrate sheet and wrap the grouped aerosol-generating substrate sheet in an envelope to form a continuous column; - cutting the continuous column into a plurality of aerosol-generating article components, each having a column shape, each aerosol-generating article component comprising a bundled sheet formed from a cut portion of the aerosol-generating substrate sheet.

[0089] EX4. An apparatus for producing a sheet of aerosol-generating substrate for an aerosol-generating article, the apparatus being configured to perform the method according to EX1, the apparatus comprising: a dough mixer configured to knead the mixture with the recipe and water to form the dough; flattening rollers operatively placed downstream of the dough mixer and configured to flatten the dough to form the sheet; a dryer operatively placed downstream of the flattening rollers and configured to dry the flattened sheet and obtain a sheet of aerosol-generating substrate for an aerosol-generating article; a winder operatively placed downstream of the dryer and configured to wind the Petition 870250090281, dated 03 / 10 / 2025, page 36 / 83 23 / 52 sheet on a reel; alternatively, the apparatus comprises an in-line cutter operationally placed downstream of the dryer and configured to divide the aerosol-generating substrate sheet into a plurality of tapes, and a plurality of small winders for winding each tape onto a respective small reel.

[0090] EX5. An aerosol-generating article comprising at least one component of the aerosol-generating article made in accordance with the process of EX3 or using the mass of EX2.

[0091] EX6. The method according to EX1, or the mass according to EX2, wherein the amount of binder in the recipe is from 1.5 percent to 6.5 percent based on dry weight.

[0092] EX7. The method according to EX1, or the mass according to EX2, or the method or mass according to EX6, wherein an amount of the vegetable particles and / or alkaloids in the recipe is 50 percent to 80 percent on a dry weight basis, optionally 70 percent to 80 percent on a dry weight basis.

[0093] EX8. The method according to EX1, or the mass according to EX2, or the method or mass according to EX6 or EX7, wherein an amount of the aerosol-forming agent in the recipe is 16 percent to 20 percent based on dry weight.

[0094] EX9. The method or mass according to EX8, wherein the amount of aerosol-forming agent in the recipe is 17.5 percent to 20 percent based on dry weight.

[0095] EX10. The method according to EX1 or the mass according to EX2 or the method or mass according to any of EX6 to EX9, wherein the vegetable particles and / or alkaloids comprise tobacco particles and the aerosol-generating substrate sheet is a reconstituted tobacco leaf; or the vegetable particles and / or alkaloids comprise tobacco and / or nicotine and / or botanical products and / or cellulose powder; optionally, the botanical products comprise fibers of Petition 870250090281, dated 03 / 10 / 2025, page 37 / 83 24 / 52 Cellulose, as leaf fibers or powdered fibers; optionally, the botanical products comprise one or more of: clove, star anise, lavender, rosemary, peppermint, sage, chamomile; optionally, the tobacco comprises tobacco mixtures; optionally, the tobacco is from 0 percent to 80 percent on a dry weight basis, optionally 50 percent to 80 percent on a dry weight basis, and the botanical products are from 1 percent to 20 percent on a dry weight basis; optionally, the botanical products and / or cellulose powder are from 50 percent to 80 percent on a dry weight basis.

[0096] EX11. The method according to EX1, or the dough according to EX2, or the method or dough according to any one of EX6 to EX10, wherein the recipe additionally includes fiber.

[0097] EX12. The method or mass according to EX11, wherein an amount of fiber in the recipe is from 0.1 percent to 2.5 percent on a dry weight basis, optionally to 5.0 percent on a dry weight basis.

[0098] EX13. The method according to EX1, or the dough according to EX2, or the method or dough according to any one of EX6 to EX12, wherein the recipe includes additional botanical products.

[0099] EX14. The method or mass according to EX13, wherein an amount of the additional botanicals in the recipe is from 1.0 percent to 20.0 percent based on dry weight.

[00100] EX15. The method according to EX1, or the mass according to EX2, or the method or mass according to any one of EX6 to EX14, wherein the binder is a cellulose derivative.

[00101] EX16. The method or mass according to EX15, wherein the cellulose derivative is methylcellulose, ethylcellulose, ethylhydroxymethyl or carboxymethylcellulose.

[00102] EX17. The method according to EX1 or the mass according to Petition 870250090281, dated 03 / 10 / 2025, p. 38 / 83 25 / 52 with EX2 or the method or mass according to any one of EX6 to EX14, wherein the binder comprises natural pectins, optionally fruit, citrus or tobacco pectins; or guar gums, optionally hydroxyethyl guar or hydroxypropyl guar; or locust bean gums, optionally hydroxyethyl and hydroxypropyl locust bean gum; or alginate; or starches, optionally modified starches or derivatives; or tamarind gum; or dextran; or pullalon; or konjac flour; or xanthan gum; or a mixture of the above items.

[00103] EX18. The method according to EX1, or the mass according to EX2, or the method or mass according to any one of EX6 to EX17, wherein the aerosol-forming agent is a polyhydric alcohol.

[00104] EX19. The method or mass according to EX18, wherein the polyhydric alcohol is triethylene glycol, 1,3-butanediol or glycerin or propylene glycol.

[00105] EX20. The method according to EX1, or the mass according to EX2, or the method or mass according to any one of EX6 to EX17, wherein the aerosol-forming agent comprises monohydric alcohols, optionally menthol; or esters of polyhydric alcohols, optionally mono-, di- or triacetate glycerol; or aliphatic esters of mono-, di- or polycarboxylic acids, optionally dimethyl dodecanodioate, dimethyl tetradecanodioate or triethyl citrate.

[00106] EX21. The method or mass according to EX11 or EX12, wherein the fibers are cellulose fibers.

[00107] EX22. The method or mass according to EX21, wherein the cellulose fibers are: softwood fibers, hardwood fibers, jute fibers, flax fibers or tobacco fibers.

[00108] EX23. The method or mass according to EX11 or EX12 or EX21 or EX22, wherein a fiber length is between 5 pm Petition 870250090281, dated 03 / 10 / 2025, page 39 / 83 26 / 52 and 2500 pm, optionally between 155 pm and 1500 pm, optionally between 710 pm and 1600 pm, optionally between 750 pm and 2500 pm (long fibers).

[00109] EX24. The method or mass according to any one of EX11, EX12, EX21, EX22, EX23, wherein the ratio of binder to fiber is between 0.48 and 1.82.

[00110] EX25. The method according to EX1, or the mass according to EX2, or the method or mass according to any one of EX6 to EX24, wherein the viscosity of the binder is between 800 cp and 10000 cp (0.8-10 Pa s).

[00111] EX26. The method or mass according to EX25, wherein the viscosity of the binder is greater than 3900 cp (3.9 Pa s); optionally, the viscosity of the binder is between 1950 cp and 6000 cp (1.95 - 6 Pa s); optionally, between 4000 cp and 5000 cp (4 - 5 Pa s); optionally, the viscosity of the binder is between 7200 cp and 7600 cp (7.2 - 7.6 Pa s).

[00112] EX27. The method according to EX1, or the mass according to EX2, or the method or mass according to any one of EX6 to EX26, wherein 90 percent of the plant particles and / or alkaloids have a size smaller than 600 µm, optionally smaller than 450 µm, optionally smaller than 300 µm.

[00113] EX28. The method or mass according to EX27, wherein 90 percent of the plant and / or alkaloid particles have a size smaller than 200 µm, optionally smaller than 150 µm.

[00114] EX29. The method according to EX1, or the mass according to EX2, or the method or mass according to any one of EX6 to EX28, wherein the vegetable particles and / or alkaloids have a size less than 325 pm.

[00115] EX30. The method according to EX1 or any of the above EX6 to EX29, where mixing the recipe with water includes: pre Petition 870250090281, dated 03 / 10 / 2025, page 40 / 83 27 / 52 mix at least one ingredient of the recipe before kneading the mixture in a dough mixer, where the water is premixed with at least one ingredient, for example, fiber, and / or added to the dough mixer; otherwise, there is no premixing and all ingredients are mixed, preferably in the dough mixer; optionally, the fiber is hydrated, i.e., premixed with water, or the fiber and the aerosol-forming agent are hydrated, i.e., premixed with water, and then other ingredients are added.

[00116] EX31. The method according to EX1 or any one of EX6 to EX30, wherein mixing the recipe with water comprises: premixing at least one ingredient or only a part of said at least one ingredient of the recipe to form a first premix; premixing the remaining ingredient or ingredients or the remaining part or parts of the ingredient or ingredients of the recipe to form a second premix; combining the first premix and the second premix in the dough mixer; wherein water is premixed into the first premix and / or the second premix and / or added to the dough mixer.

[00117] EX32. The method according to EX1 or any one of EX6 to EX31, in which mixing the recipe with water comprises: first mixing the binder with the water and then bringing the binder into contact with the aerosol-forming agent.

[00118] EX33. The method according to EX1 or any one of EX6 to EX31, in which mixing the recipe with water comprises: first mixing the binder with the aerosol-forming agent and then bringing the binder into contact with the water.

[00119] EX34. The method according to EX32, in which the recipe is mixed with water, comprises: mixing the vegetable particles and / or alkaloids and the aerosol-forming agent to make a first premixture; mixing the water and the binder to make a second premixture. Petition 870250090281, dated 03 / 10 / 2025, p. 41 / 83 28 / 52 Mixture; combine the first premixture and the second premixture in the dough mixer.

[00120] EX35. The method according to EX34, when EX32 is in accordance with any of EX11, EX12 or EX21 to EX24, in which mixing the vegetable particles and / or alkaloids and the aerosol-forming agent comprises: first mixing the vegetable particles and / or alkaloids and the fibers and then adding the aerosol-forming agent to make the first premix.

[00121] EX36. The method according to EX32, in which mixing the recipe with water comprises: mixing the vegetable particles and / or alkaloids and the binder to make a first premix; combining the first premix, the aerosol-forming agent and the water in the dough mixer by adding the water first, then the first premix and then the aerosol-forming agent.

[00122] EX37. The method according to EX36, when EX32 is in accordance with any of EX11, EX12 or EX21 to EX24, wherein the fibers are also mixed with the vegetable particles and / or alkaloids and the binder to make the first premix.

[00123] EX38. The method according to EX32, in which mixing the recipe with water comprises: mixing the binder to make a first premix; mixing the water, vegetable particles and / or alkaloids and the first premix to make a second premix; combining the second premix and the aerosol-forming agent in the dough mixer.

[00124] EX39. The method according to EX32, in which mixing the recipe with water comprises: mixing the binder to make a first premix; combining the vegetable particles and / or alkaloids, the first premix, the water and the aerosol-forming agent in the dough mixer. Petition 870250090281, dated 03 / 10 / 2025, page 42 / 83 29 / 52

[00125] EX40. The method according to EX38 or EX39, in which the fibers are also mixed with the binder to make the first premix.

[00126] EX41. The method according to EX1 or any one of EX6 to EX31, in which mixing the recipe with water comprises: mixing the vegetable particles and / or alkaloids to make a first premix; mixing the aerosol-forming agent and the binder and then adding water to make a second premix; combining the first premix and the second premix in the dough mixer.

[00127] EX42. The method according to EX41, when in accordance with any of EX11, EX12 or EX21 to EX24, wherein the fibers are mixed with vegetable particles and / or alkaloids to make the first premix.

[00128] EX43. The method according to EX1 or any one of EX6 to EX31, in which mixing the recipe with water comprises: mixing the vegetable particles and / or alkaloids and the binder to make a first premix; mixing the aerosol-forming agent and water to make a second premix; combining the first premix and the second premix in the dough mixer.

[00129] EX44. The method according to EX1 or any of EX6 to EX31, in which mixing the recipe with water comprises: mixing the vegetable particles and / or alkaloids and the binder to make a first premix; combining the first premix, the aerosol-forming agent and the water in the dough mixer by first adding the aerosol-forming agent and the first premix and then the water.

[00130] EX45. The method according to EX43 or EX44, when in accordance with any of EX11, EX12 or EX21 to EX24, wherein the fibers are mixed with the vegetable particles and / or alkaloids and the binder to make the first premix. Petition 870250090281, dated 03 / 10 / 2025, p. 43 / 83 30 / 52

[00131] EX46. The method according to EX1 or any one of EX6 to EX31, in which mixing the recipe with water comprises: mixing the vegetable particles and / or alkaloids, a part of the aerosol-forming agent and a part of the water to make a first premixture; mixing a remaining part of the aerosol-forming agent, a remaining part of the water and then the binder to make a second premixture; combining the first premixture and the second premixture in the dough mixer.

[00132] EX47. The method according to EX46, when in accordance with any of EX11, EX12 or EX21 to EX24, wherein the fibers are mixed with the vegetable particles and / or alkaloids, the aerosol-forming agent part and the water part to make the first premix.

[00133] EX48. The method according to EX46 or EX47, wherein the aerosol-forming agent portion is one half of a total quantity of aerosol-forming agent; wherein the water portion is one quarter of a total quantity of water.

[00134] EX49. The method according to EX1 or any one of EX6 to EX31, in which mixing the recipe with water comprises: mixing the vegetable particles and / or alkaloids, the aerosol-forming agent and the water to make a first premix; mixing the first premix in the dough mixer and then adding the binder.

[00135] EX50. The method according to EX49, when in accordance with any of EX11, EX12 or EX21 to EX24, wherein the fibers are mixed with the vegetable particles and / or alkaloids, the aerosol-forming agent and water to make the first premix.

[00136] EX51. The method according to EX1 or any one of EX6 to EX31, in which mixing the recipe with water comprises: mixing the vegetable particles and / or alkaloids, the forming agent of Petition 870250090281, dated 03 / 10 / 2025, page 44 / 83 31 / 52 aerosol, the binder and the water all together in the mass mixer.

[00137] EX52. The method according to EX51, when according to any of EX11, EX12 or EX21 to EX24, wherein the fibers are also mixed with the vegetable particles and / or alkaloids, the aerosol-forming agent, the binder and the water in the mass mixer.

[00138] EX53. The method according to EX1 or any one of EX6 to EX52, wherein the water temperature is between 5 °C and 120 °C.

[00139] EX54. The method according to EX53, in which the water temperature is between 20 °C and 80 °C.

[00140] EX55. The method according to EX54, in which the water temperature is between 20 °C and 50 °C.

[00141] EX56. The method according to EX1 or any one of EX6 to EX55, wherein the temperature of the mass before flattening is between 20 °C and 50 °C, preferably between 20 °C and 35 °C.

[00142] EX57. The method according to EX56, in which the temperature of the mass before flattening is between 35 °C and 45 °C.

[00143] EX58. The method according to EX1 or any of EX6 to EX57, wherein the flattening is performed by means of flattening rolls and the temperature of the flattening rolls is between 5 °C and 50 °C.

[00144] EX59. The method according to EX58, where the temperature of the flattening rolls is between 8 °C and 40 °C.

[00145] EX60. The method according to EX59, where the temperature of the rollers is between 10 °C and 30 °C.

[00146] EX61. The method according to EX1 or any one of EX6 to EX60, wherein the flattening step comprises: ca Petition 870250090281, dated 03 / 10 / 2025, page 45 / 83 32 / 52 grind the mass to pre-form a thick sheet with a thickness between 2 mm and 20 mm.

[00147] EX62. The method according to EX61, wherein the flattening step further comprises: flattening the thick sheet to form a thin sheet with a thickness between 0.15 mm and 0.35 mm.

[00148] EX63. The method according to EX62, wherein the thin sheet has a thickness between 0.15 mm and 0.30 mm.

[00149] EX64. The method according to EX63, wherein the thin sheet has a thickness between 0.172 mm and 0.285 mm.

[00150] EX65. The method, according to EX1 or any one of EX6 to EX64, in which, in the drying step, the flattened sheet is dried to a liquid content of 5.8 -11.2 percent on a wet weight basis.

[00151] EX66. The method, according to EX65, in which, in the drying step, the flattened sheet is dried to a liquid content of 8.5 percent on a wet weight basis.

[00152] EX67. The method, according to EX1 or any one of EX6 to EX66, in which vegetable particles and / or alkaloids are made by grinding vegetable fragments and / or alkaloids in a grinder.

[00153] EX68. The method, according to EX1 or any one of EX6 to EX67, in which drying is carried out by conveying the flattened sheet through a dryer on a belt conveyor, optionally the conveyor belt being a mesh belt.

[00154] EX69. The process, according to EX3, in which the aerosol-generating substrate sheet is longitudinally divided into a plurality of aerosol-generating substrate strips and each aerosol-generating substrate strip is then bundled and wrapped to form a respective continuous column. Petition 870250090281, dated 03 / 10 / 2025, page 46 / 83 33 / 52

[00155] EX70. The process according to EX69, wherein splitting the aerosol-generating substrate sheet longitudinally into a plurality of aerosol-generating substrate tapes comprises: winding the aerosol-generating substrate sheet onto a core to form a master coil and cutting the master coil into smaller coils, each smaller coil carrying one of the aerosol-generating substrate tapes wound onto a respective portion of the core; or wherein splitting the aerosol-generating substrate sheet longitudinally into a plurality of aerosol-generating substrate tapes comprises: cutting the aerosol-generating substrate sheet into a plurality of tapes and then winding each tape onto a respective small coil.

[00156] EX71. The apparatus according to EX4, further comprising a grinder operationally placed upstream of the dough mixer and configured for grinding the vegetable and / or alkali into particles; optionally wherein the dough mixer is a batch mixer or a continuous mixer.

[00157] EX72. The apparatus according to EX4 or EX71, further comprising at least one premixer operationally placed upstream of the dough mixer and configured to premix at least one ingredient or some ingredients or all of the ingredients of the recipe.

[00158] EX73. The apparatus, according to EX4 or EX71 or EX72, further comprising a dough laminator, the dough laminator being part of the dough mixer or being operatively placed downstream of the dough mixer, for calendering the dough in order to pre-form a thick sheet.

[00159] EX74. A recipe for producing an aerosol-generating substrate sheet for an aerosol-generating article, comprising as ingredients: vegetable particles and / or alkaloids, a binder Petition 870250090281, dated 03 / 10 / 2025, p. 47 / 83 34 / 52 and an aerosol-forming agent; wherein the amount of the binder in the recipe is from 1.0 percent to 7.0 percent on a dry weight basis.

[00160] EX75. The recipe, according to EX74, where the amount of binder in the recipe is from 1.5 percent to 6.5 percent based on dry weight.

[00161] EX76. The recipe, according to EX74 or EX75, wherein an amount of the vegetable particles and / or alkaloids in the recipe is 50 percent to 80 percent on a dry weight basis, optionally 70 percent to 80 percent on a dry weight basis.

[00162] EX77. The recipe, according to any of the EX74 to EX76, where the amount of the aerosol-forming agent in the recipe is 16 percent to 20 percent based on dry weight.

[00163] EX78. The recipe, according to EX77, wherein the amount of aerosol-forming agent in the recipe is 17.5 percent to 20 percent based on dry weight.

[00164] EX79. The recipe, according to any of the EX73 to EX78, wherein the plant particles and / or alkaloids comprise tobacco particles and the aerosol-generating substrate sheet is a reconstituted tobacco leaf; or the plant particles and / or alkaloids comprise tobacco and / or nicotine and / or botanical products and / or cellulose powder; optionally, the botanical products comprise cellulose fibers, such as leaf fibers or powdered fibers; optionally, the botanical products comprise one or more of the following: clove, star anise, lavender, rosemary, peppermint, sage, chamomile; optionally, the tobacco comprises tobacco mixtures; optionally, the tobacco is between 0 percent and 80 percent on a dry weight basis, optionally 50 percent and 80 percent on a dry weight basis, and the botanical products are from 1 percent to 20 percent on a dry weight basis; optionally, the botanical products and / or cellulose powder Petition 870250090281, dated 03 / 10 / 2025, page 48 / 83 35 / 52 is 50 percent to 80 percent based on dry weight.

[00165] EX80. The recipe, according to any of the EX73 to EX78, where the recipe additionally includes fiber.

[00166] EX81. The recipe, according to EX80, wherein an amount of the fiber in the recipe is from 0.1 percent to 2.5 percent on a dry weight basis, optionally to 5.0 percent on a dry weight basis.

[00167] EX82. The recipe, according to any of EX73 to EX81, additionally including botanical products.

[00168] EX83. The recipe, according to EX82, wherein an amount of the additional botanical products in the recipe is from 1.0 percent to 20.0 percent based on dry weight.

[00169] EX84. The recipe, according to any of the EX73 to EX83, where the binder is a cellulose derivative.

[00170] EX85. The recipe, according to EX84, in which the cellulose derivative is methylcellulose, ethylcellulose, ethylhydroxymethyl or carboxymethylcellulose.

[00171] EX86. The recipe, according to any of the EX73 to EX85, wherein the binder comprises natural pectins, optionally fruit, citrus or tobacco pectins; or guar gums, optionally hydroxyethyl guar or hydroxypropyl guar; or locust bean gums, optionally hydroxyethyl and hydroxypropyl locust bean gum; or alginate; or starches, optionally modified starches or derivatives; or tamarind gum; or dextran; or pullalon; or konjac flour; or xanthan gum; or a mixture of the above items.

[00172] EX87. The recipe, according to any of the EX73 to EX86, in which the aerosol-forming agent is a polyhydric alcohol.

[00173] EX88. The recipe, according to EX87, wherein the polyhydric alcohol is triethylene glycol, 1,3-butanediol or glycerin or propylene glycol.

[00174] EX89. The recipe, according to any of the EX73 to EX88, wherein the aerosol-forming agent comprises alcohols Petition 870250090281, dated 03 / 10 / 2025, page 49 / 83 36 / 52 monohydric, optionally menthol; or esters of polyhydric alcohols, optionally mono-, di- or triacetate of glycerol; or aliphatic esters of mono-, di- or polycarboxylic acids, optionally dimethyl dodecanedioate, dimethyl tetradecanedioate or triethyl citrate.

[00175] EX90. The recipe, according to EX80 or EX81, wherein the fibers are cellulose fibers.

[00176] EX91. The recipe, according to EX90, wherein the cellulose fibers are: softwood fibers, hardwood fibers, jute fibers, flax fibers or tobacco fibers.

[00177] EX92. The recipe, according to EX80 or EX81 or EX90 or EX91, where fiber length is between 5 pm and 2500 pm, optionally between 155 pm and 1500 pm, optionally between 710 pm and 1600 pm, optionally between 750 pm and 2500 pm (long fibers).

[00178] EX93. The recipe, according to any of the EX80, EX89, EX90, EX91, EX92, where the ratio between the binder and the fibers is between 0.48 and 1.82.

[00179] EX94. The recipe, according to any of the EX73 to EX93, where the viscosity of the binder is between 800 cp and 10000 cp (0.8-10 Pa s).

[00180] EX95. The recipe, according to EX94, wherein the viscosity of the binder is greater than 3900 cp (3.9 Pa s); optionally, the viscosity of the binder may be between 1950 cp and 6000 cp (1.95 - 6 Pa s); optionally, between 4000 cp and 5000 cp (4 - 5 Pa s); optionally, the viscosity of the binder may be between 7200 cp and 7600 cp (7.2 - 7.6 Pa s).

[00181] EX96. The recipe, according to any of the EX73 to EX95, wherein 90 percent of the plant and / or alkaloid particles have a size smaller than 600 µm, optionally smaller than 450 µm, optionally smaller than 300 µm.

[00182] EX97. The recipe, according to EX96, where the 90 per Petition 870250090281, dated 03 / 10 / 2025, p. 50 / 83 37 / 52 percent of the plant particles and / or alkaloids have a size smaller than 200 µm, optionally smaller than 150 µm.

[00183] EX98. The recipe, according to any of the EX73 to EX97, in which the plant particles and / or alkaloids are smaller than 325 pm.

[00184] EX99. An aerosol-generating substrate sheet for an aerosol-generating article, comprising the recipe of any one of EX73 to EX98 or through the mass of EX2 or any one of EX7 to EX29.

[00185] EX100. An aerosol-generating article comprising an aerosol-generating substrate sheet according to EX99 and, optionally, a filter.

[00186] EX101. The method, according to EX51, when in accordance with any one of EX11, EX12 or EX21 to EX24, in which mixing the recipe with water comprises: mixing the vegetable particles and / or alkaloids and the binder to make a first premix; mixing the fibers with water to make a second premix; combining the first premix with the second premix in the dough mixer.

[00187] EX102. The method, according to EX51, when in accordance with any one of EX11, EX12 or EX21 to EX24, in which mixing the recipe with water comprises: mixing the vegetable particles and / or alkaloids and the binder to make a first premix; mixing the fibers with a portion of water and then with the aerosol-forming agent to make a second premix; combining the first premix with the second premix in the dough mixer and adding a remaining portion of water.

[00188] The examples will now be described further with reference to the figures, in which:

[00189] Figure 1 schematically shows an apparatus for producing an aerosol-generating substrate sheet for a generating article. Petition 870250090281, dated 03 / 10 / 2025, p. 51 / 83 38 / 52 aerosol according to the invention;

[00190] Figures 2 to 11 show flowcharts of part of a method for producing an aerosol-generating substrate sheet for an aerosol-generating article according to embodiments of the invention;

[00191] Figures 12A and 12B show a step in a process for manufacturing the aerosol-generating article component;

[00192] Figure 13 is an apparatus for producing a component of the aerosol generating article;

[00193] Figures 14 and 15 show a longitudinal section and a cross-section of a component of the aerosol-generating article.

[00194] Apparatus 1 shown in Figure 1 is a schematic example of an apparatus configured to perform a method for producing an aerosol-generating substrate sheet for an aerosol-generating article according to the invention.

[00195] Apparatus 1 comprises a grinder 2 configured for grinding vegetables and / or alkaloids into particles T. For example, the vegetable and / or alkaloid are tobacco strips and the grinder 2 is a tobacco mill adapted for coarsely grinding the tobacco strips into tobacco particles, 90% of the particles having a size less than 275 µm. A buffer silo, not shown in the accompanying figures, for uniform control of the mass flow may be located after the grinder 2.

[00196] From grinder 2, vegetable particles and / or alkaloids T are transported, for example, by means of a pneumatic conveyor, to a powder mixing silo 3 schematically shown in Figure 1. In the powder mixing silo 3, other powders, such as cellulose fibers F, can be introduced and mixed to form a first premix PM1.

[00197] Apparatus 1 further comprises a container 4, in which a wet mixture is formed by carrying a forming agent. Petition 870250090281, dated 03 / 10 / 2025, pp. 52 / 83 39 / 52 of aerosol A, such as glycerin, a binder B, such as carboxymethylcellulose (CMC), and then water W, to mix them and form a second premix PM2.

[00198] The first premix PM1 and the second premix PM2 are fed to a mass mixer 5 operationally located downstream of the powder mixing silo 3 and the container 4. The powder mixing silo 3 and the container 4 define the respective premixers operationally placed upstream of the mass mixer 5 and configured to premix one or more ingredients of a recipe. The mass mixer 5 can operate in batches or with a continuous process.

[00199] In dough mixer 5, the first premix PM1 and the second premix PM2 form a mixture that is kneaded to form a dough D through kneading elements 6.

[00200] Dough D is therefore made by mixing the recipe and water in dough mixer 5, where the recipe comprises vegetable particles and / or alkaloids T, aerosol forming agent A, fibers F and binder B.

[00201] Dough D is then calendered through a dough sheeter or calendering rollers 7, which may be part of the dough mixer 5, to shape dough D as a thick sheet 8. For example, a thickness of the thick sheet is between 2 mm and 20 mm.

[00202] Downstream of the dough mixer 5, the apparatus 1 comprises flattening rollers 9 which are configured to flatten the thick sheet 8 to form a thin flattened sheet 10. The non-limiting embodiment of Figure 3 shows two pairs of flattening rollers 9 arranged one after the other. The flattening rollers 9 are provided with heating devices or cooling devices, not shown, configured to heat or cool a peripheral surface of the flattening rollers 9 and to heat or cool the thick sheet 8 passing between them in order to maintain a temperature of Petition 870250090281, dated 03 / 10 / 2025, pp. 53 / 83 40 / 52 mass at around 20-24 °C. A thin sheet thickness of 10 can be between 0.15 mm and 0.35 mm, optionally between 0.15 mm and 0.30 mm, for example, between 0.172 mm and 0.285 mm.

[00203] A dryer 11 is operationally placed downstream of the flattening rolls 9 and is configured to dry the flattened thin sheet 10 and obtain the aerosol-generating substrate sheet 12 for an aerosol-generating article. The dryer 11 may comprise a lining that delimits a chamber 13 and a belt conveyor 14, for example, a mesh belt, moving through the chamber 13 while supporting the thin sheet 10. Heating devices, not shown, are configured to heat and dry the thin sheet 10 moving through the chamber 13. The heating / drying technology may be a combination of infrared and hot air, microwave and hot air, or by means of conduction through a steam-heated belt and convection with hot air.

[00204] The flat sheet 10 is dried to a liquid content of 5.8–11.2 percent on a wet weight basis, for example, to 8.5 percent on a wet weight basis.

[00205] Downstream of dryer 11, the longitudinal edges of sheet 12 are trimmed by means of a trimming device 15. A winder operationally placed downstream of dryer 11 and trimming device 15 is configured to wind the sheet 12 of aerosol generating substrate onto a core 16 to form a master coil 17.

[00206] A cooling station, not shown, may be placed between dryer 11 and winder so that the sheet 12 of the aerosol generating substrate is cooled before being wound.

[00207] In a different embodiment, not shown in the drawings, apparatus 1 comprises an in-line cutter operationally placed downstream of dryer 11 and configured to split the subsheet. Petition 870250090281, dated 03 / 10 / 2025, pp. 54 / 83 41 / 52 aerosol generating tract 12 in a plurality of tapes. A plurality of small winders is employed to wind each tape onto a respective small reel.

[00208] Apparatus 1 described above allows the method of the present invention to be carried out. The percentage of ingredients in the recipe and water W and the order of feeding may change from what has been described above.

[00209] Tables 1A and 1B below contain examples 1 to 10 of recipes. Table 1A 1 2 3 4 5 Tobacco 76.1% 76.1% 76.1% 76.1% 76.1% Cellulose fibers 4.2% 2.2% 1.2% 0.0% 2.2% CMC 2.0% 4.0% 4.0% 6.2% 2.0% Glycerin 17.7% 17.7% 18.7% 17.7% 19.7% CMC / cellulose fiber ratio 0.48 1.82 3.33 N / A 0.90 Table 1B 6 7 8 9 10 Tobacco 76.1% 76.1% 76.1% 76.1% 76.1% Cellulose fibers 1.2% 3.2% 3.9% 3.2% 3.9% CMC 1.2% 3.0% 2.3% 1.5% 1.5% Guar / / / 1.5% 0.8% Glycerin 17.7% 17.7% 17.7% 17.7% 17.7% Binder / cellulose fiber ratio 1 0.94 0.59 0.94 0.59

[00210] Table 1C below contains additional examples of recipes using graphite. Petition 870250090281, dated 03 / 10 / 2025, pp. 55 / 83 42 / 52 Table 1C G1 G2 G3 G4 G5 Tobacco D90 200 76.1% 73.1% 73.1% 71.5% 71.5% Glycerin 17.7% 17.7% 17.7% 17.7% 17.7% Fiber / 2.2% 2.2% 2.2% 2.2% CMC 4% 4% 4% 4% 4% Graphite 2.2% 3% / 4.6% / Expanded graphite / / 3% / 4.6%

[00211] Tables 1D, 1E, and 1F below contain additional examples of recipes using botanical products. Table 1D 1 2 3 Tobacco 75.53% 72.48% 61.03% Botanical products 0.76% 3.81% 15.26% Fiber 3.93% 3.93% 3.93% CMC 2.09% 2.09% 2.09% Glycerin 17.69% 17.69% 17.69% Table 1E 1 2 3 Botanical products 76.29% 50.00% 10.00% Cellulose powder 0.00% 0.00% 44.00% Fibers 3.93% 7% 6% CMC 2.09% 5% 5% Glycerin 17.69% 38% 35% Table 1F 1 2 3 Botanical products 74.19% 73.79% 72.79% Fiber 3.93% 3.93% 3.93% CMC 2.09% 2.09% 2.09% Glycerin 17.69% 17.69% 17.69% Nicotine 1% 1% 1.5% Lactic acid / fumaric acid 1.1% 1.5% 2% Petition 870250090281, dated 03 / 10 / 2025, pp. 56 / 83 43 / 52

[00212] Table 2 below contains characteristics of some of the ingredients. Table 2 Tobacco particle size D90 175 µm - 275 µm; no particles > 450 µm. CMC viscosity 1950-6000 cp (1.95-6 Pa s). Cellulose fiber length 50 µm - 2500 µm. Botanical products D90 200 µm - 500 µm. Cellulose powder D90 50 µm - 75 µm.

[00213] In the examples above, the plant particles and / or alkaloids T are tobacco particles and therefore the aerosol-generating substrate sheet is a reconstituted tobacco leaf. In other embodiments, the plant particles and / or alkaloids T may be botanical products.

[00214] In the examples above, the amount of tobacco particles T in the recipe is 76.1 percent on a dry weight basis. In any case, the amount of plant particles and / or alkaloids, as tobacco particles, may be between 70 percent and 80 percent on a dry weight basis, optionally 70 percent and 80 percent on a dry weight basis.

[00215] In the examples above, 90 percent of the tobacco particles are smaller than 175 µm or smaller than 275 µm with no particles larger than 450 µm. When particles larger than 500 µm are also present, the visual quality of the product may be affected, but not its functionality.

[00216] In the examples above, the amount of cellulose fibers in recipe F is between 0.0 percent (no fibers) and 4.2 percent. In any case, the amount of fibers, such as cellulose fibers, in the recipe can be from 0.0 (no fibers) percent to 5.0 percent based on dry weight. Petition 870250090281, dated 03 / 10 / 2025, pp. 57 / 83 44 / 52

[00217] In the examples above, binder B is carboxymethylcellulose (CMC). In other embodiments, binder B may be methylcellulose, ethylcellulose, ethylhydroxymethyl or carboxymethylcellulose; or it may comprise natural pectins, optionally fruit, citrus or tobacco pectins; or guar gums, optionally hydroxyethyl guar or hydroxypropyl guar; or locust bean gums, optionally hydroxyethyl and hydroxypropyl locust bean gum; or alginate; or starches, optionally modified starches or derivatives; or tamarind gum; or dextran; or pullalon; or konjac flour; or xanthan gum; or a mixture of the above items.

[00218] In the examples above, the viscosity of CMC is between 1950 cp and 6000 cp (1.95 - 6 Pa s), for example, 3900 cp (3.9 Pa s). The viscosity of guar is 7200 cp (7.2 Pa s). In any case, the viscosity of the binder can be between 800 cp and 10000 cp (0.8 - 10 Pa s).

[00219] In the examples above, the ratio between the binder and the fibers is greater than 0.28. In some embodiments, the ratio between the binder and the fibers is between 0.48 and 1.82.

[00220] In the examples above, the amount of carboxymethylcellulose (CMC) in the recipe is between 1.2 percent and 6.2 percent based on dry weight. In any case, the amount of the binder, such as CMC, in the recipe can be from 1.0 percent to 7.0 percent based on dry weight.

[00221] In the examples above, aerosol-forming agent A is glycerin. In other embodiments, the polyhydric alcohol may be triethylene glycol, 1,3-butanediol. In some other embodiments, aerosol-forming agent A may comprise monohydric alcohols, optionally menthol; or esters of polyhydric alcohols, optionally mono-, di- or triacetate glycerol; or aliphatic esters of mono-, di- or triacetate acids. Petition 870250090281, dated 03 / 10 / 2025, p. 58 / 83 45 / 52, di- or polycarboxylic acids, optionally dimethyl dodecanedioate, dimethyl tetradecanedioate or triethyl citrate.

[00222] In the examples above, the amount of glycerin in the recipe is between 17.7 percent and 19.7 percent based on dry weight. In any case, the amount of aerosol-forming agent A, for example, glycerin, in the recipe can be from 16 percent to 20 percent based on dry weight.

[00223] In other embodiments, the recipe may also include additional botanicals such as cloves, star anise, rosemary, sage, peppermint, chamomile, lavender, eucalyptus, freeze-dried lemon peel, passion fruit, geranium. The amount of the additional botanicals may be from 1.0 percent to 20.0 percent on a dry weight basis.

[00224] Tables 3A, 3B, 3C below and the attached Figures 2 to 11 provide examples of the feed orders F1 to F14 of the ingredients and water W (F11 and F12 are not shown in the drawings). As described in Tables 3A and 3B, some ingredients may be premixed with or without water W in the powder mixing silo 3 and / or container 4 before mixing and kneading in the dough mixer 5. Some other embodiments may comprise the same feed orders as F1 to F14, wherein fibers F are not employed. F8 shows that premixing may be optional. Petition 870250090281, dated 03 / 10 / 2025, pp. 59 / 83 Table 3A F5 (Figure 6) Tobacco “T” + Fibers “F” + Binder “B” V / N First Water “W” in Premix 1 “PM1”, then glycerin “A” F4 (Figure 5) Tobacco “T” + Fibers “F” + Binder “B” V / N First Glycerin “A” in Premix 1 “PM1”, then water “W”. F3 (Figure 4) Tobacco “T” + Fibers “F” + Binder “B” Glycerin “A” + Water “W” Premix 1 “PM1” into Premix 2 “PM2” F2 (Figure 3) Tobacco “T” + Fibers “F”, then Glycerin “A” Water “W”, then Binder “B” Premix 1 “PM1” into Premix 2 “PM2” F1 (Figure 2) Tobacco “T” + Fibers “F” Glycerin “A” + Binder “B”, then Water “W” Premix 1 “PM1” into Premix 2 “PM2” Feeding order Premix 1 Premix 2 (wet mix) Mass mixer F10 (Figure 11) Gluten-free “B” + Fibers “F” V / N Tobacco “T” + Pre-mixture 1 “PM1” + Water “W” + Glycerin “A” 6 “B” + Fi- Tobacco stura 1 2 “PM2” A” T- 05 φ + E 2 Z5 an 55 'PDC CD c ll = n _ óü Φ Ij_ '-1—» ffi 1 T— ré-m Glic σ> glu ras ” _+ 2 gi |j_ <C -Q < = y- CL + σΓ 2 Z O) dos os ingredites juntos “T”, “A”, “B”, “W” 00 O c Γ. I I z z I— Φ = f- Fibras “F” + Glicerina “A” epois adicionte “B” CO 2 Ê- * e d tina Z5 O) O > or “ 2 CD | | ro ro < JD Z5 ( / ) ro cd 05 1 I |— z S c + = >gua e “B”. E Ll ibras “ 1 / 4 Ág + 34, lutinan PMT ( PM2” u- + - + P OJ 05 ω ro ro 2 I— s C= b Z5 Z5 CÜ 5— CL O) aco erin lice de| ( / ) ( / ) EE CO JD O ro = 0 > 5— H 0 CL CL imentação 2 (mixture and mass ro ro ro φ Z5 Z5 o Ό M—» T5 E φ ( / ) 'e -mis da) turai Ό Έ E ω o CL CL O Petition 870250090281, 03 / 10 / 2025, pág. 60 / 83 Table 3C F14 Fibers “F” + 1 / 2 Water “W” + Glycerin “A” 2 / 3 Tobacco “T” + Binder “B” Premix 1 “PM1” in Premix 2 “PM2” + 1 / 3 Tobacco “T”, then 1 / 2 Water “W” F13 Fibers “F” + Water “W” Binder “B” + Glycerin “A” Premix 1 “PM1” in Premix 2 “PM2” + Tobacco “T” F12 Tobacco “T” + Binder “B” Fibers “F” + portion of Water “W”, then Glycerin “A” Premix 2 “PM2” in Premix 1 “PM1”. Then, residual water “W” F11 Tobacco “T” + Binder “B” Fibers “F” + Water “W” Premix 2 “PM1” Premix 1 “PM2” + Glycerin “A” Feeding order Premix 1 Premix 2 (wet mix) Mass mixer o <05 oc (D > C (D (D (Λ (D I O I 3D and I Petition 870250090281, dated 03 / 10 / 2025, pp. 61 / 83 48 / 52

[00226] In the examples above, the temperature of the water W mixed with the recipe is between 20 °C - 50 °C. In any case, the tested temperature of the water W can be up to 80 °C.

[00227] In the examples above, the temperature of the dough before flattening is between 35 °C and 45 °C. In any case, the temperature of the dough before flattening can be between 20 °C and 50 °C.

[00228] In the examples above, the temperature of the flattening rollers 9 is between 10 °C - 30 °C. In any case, the temperature of the flattening rollers 9 can be between 5 °C and 50 °C, optionally between 8 °C and 40 °C.

[00229] The sheet 12 of the aerosol generating substrate of the main coil 17 is employed in the manufacture of components of the aerosol generating article 18 and of an aerosol generating article. The main coil 17 is cut into a plurality of smaller coils 19 such that each smaller coil 19 comprises a strip 20 of aerosol generating substrate wound onto a respective portion of the core 16 (Figures 12A and 12B). Alternatively, the main coil is not formed and the sheet of aerosol generating substrate is longitudinally divided in line into a plurality of strips by an in-line cutter and then each strip is wound onto a respective small coil.

[00230] Each strip 20 of aerosol generating substrate can, for example, be grouped and wrapped to form a respective continuous column 21 by means of an apparatus 22 for manufacturing aerosol generating article components, as shown in Figures 13, 14 and 15.

[00231] The apparatus 22 for manufacturing aerosol-generating article components comprises a coil holder 23 carrying the smaller coil 19 formed from the aerosol-generating substrate tape 20 for an aerosol-generating article component. The previously manufactured aerosol-generating substrate tape 20 is unwound from the coil 19 and fed along a feed path in one direction. Petition 870250090281, dated 03 / 10 / 2025, pp. 62 / 83 49 / 52 power supply F.

[00232] Downstream of the coil support 23, the apparatus 1 comprises two rotating cylindrical rollers 24 between which the tape 20 is pressed. These rollers 24 have matching patterns of ridges and corresponding textured grooves on their outer surfaces that crimp the tape 20 through transverse stretching of the substrate fibers. The crimping process is useful for folding and bundling the aerosol-generating substrate tape 20 into column pieces that will fit into the aerosol-generating articles. In fact, the term crimped tape denotes a tape 20 with a plurality of substantially parallel ridges or corrugations that are substantially parallel to the cylindrical axis of the column piece. This facilitates the folding and bundling of the crimped aerosol-generating substrate tape 20 to form the aerosol-generating article component.

[00233] Figure 13 schematically shows a folding device 25 placed downstream of the two rotating cylindrical rollers 24 and configured to move the tape 20 from a flat configuration (upstream of the folding device 24) to a bundled column configuration (downstream of the folding device 25) and to wrap the casing 26 around the bundled tape 20 to obtain the continuous column 21. The folding device 24 may be in the form of a conical funnel. The continuous column 21 is then cut into a plurality of aerosol generating article components 27. Each aerosol generating article component 27 has a column shape and comprises a bundled tape formed from a cut portion of the aerosol generating substrate tape 20 (Figures 14 and 15).

[00234] Table 5 below compares the mechanical properties of the aerosol-generating substrate sheet obtained with some of the recipes from Tables 1 and 2 and through the same feed order (F3) Petition 870250090281, dated 03 / 10 / 2025, pp. 63 / 83 50 / 52 with mechanical properties of a molded sheet of reconstituted tobacco manufactured from a fluid paste, wherein: TS - LD tensile strength in the longitudinal direction; SB - LD elongation until rupture in the longitudinal direction; TS - CD tensile strength in the transverse direction; SB - CD elongation until rupture in the transverse direction. Table 5 Recipe TS-LD (N / mm2) SB-LD (mm) TS-CD (N / mm2) SB-CD (mm) 1 2.16 3.77 0.94 3.10 7 2.46 4.77 1.42 4.60 2 2.60 6.70 1.29 6.61 Reconstituted molded sheet 2.45 5.35 1.56 1.73

[00235] Table 6 below compares the mechanical properties of the aerosol-generating substrate sheet obtained with some of the feed orders and parameters from Tables 3 and 4 and using the same recipe (Recipe 1 in Table 1A) with the mechanical properties of a molded sheet of reconstituted tobacco manufactured from a fluid paste. Table 6 Feeding order TS-LD (N / mm2) SB-LD (mm) TS-CD (N / mm2) SB-CD (mm) F1 1.87 6.02 1 5.64 F2 2.66 4.4 1.33 3.76 F3 2.85 4.41 1.46 3.49 F6 2.49 4.43 1.41 4.23 F4 2.36 4.31 1.40 4.19 F5 2.56 4.03 1.51 4.08 F8 2.17 3.89 1.12 3.11 F11 2.33 4.13 1.26 4.28 Reconstituted molded sheet 2.45 5.35 1.56 1.73 Petition 870250090281, dated 03 / 10 / 2025, pp. 64 / 83 51 / 52

[00236] The tensile strength in the longitudinal direction (TS - LD) and the elongation at break in the longitudinal direction (SB - LD) of the aerosol-generating substrate sheet according to the invention can be better than the values ​​of the molded sheet of reconstituted tobacco obtained from a fluid paste. The tensile strength in the transverse direction (TS - CD) of the aerosol-generating substrate sheet according to the invention is close to the values ​​of the molded sheet of reconstituted tobacco obtained from a fluid paste. The elongation at break in the transverse direction (SB - CD) of the aerosol-generating substrate sheet according to the invention is much better than the values ​​of the molded sheet of reconstituted tobacco obtained from a fluid paste.

[00237] Furthermore, the water content, which almost exclusively determines the liquid content of the paste mixture, is much lower than the water content of the fluid paste from typical manufacturing processes.

[00238] Table 7 below shows the mechanical properties of the aerosol-generating substrate sheet obtained with feed order n.11 and longer fibers. Table 7 Feed order TS-LD (N / mm2) SB-LD (mm) TS-CD (N / mm2) SB-CD (mm) F11 3.9 5.02 1.32 4.4 Reconstituted molded sheet 2.45 5.35 1.56 1.73

[00239] For the purposes of this description and the appended claims, except where otherwise indicated, all numbers expressing values, quantities, percentages, and so forth shall be understood as being modified in all cases by the term approximately. Furthermore, all ranges include the maximum and minimum points described and include any intermediate intervals therein, which may or may not be specifically enumerated in this document. In this context, therefore, a number A is understood as A ± 5 Petition 870250090281, dated 03 / 10 / 2025, pages 65 / 83 52 / 52 percent of A. In this context, an A-number can be considered as including numerical values ​​that are within the general standard error for the measurement of the property that the A-number modifies. The A-number, in some cases, as used in the appended claims, may deviate by the percentages enumerated above, provided that the amount by which A deviates does not materially affect the basic and novel features of the claimed invention. Furthermore, all ranges include the maximum and minimum points described and include any intermediate ranges therein, which may or may not be specifically enumerated in this document. Petition 870250090281, dated 03 / 10 / 2025, pp. 66 / 83

Claims

1 / 3 CLAIMS 1. A method for producing an aerosol-generating substrate sheet for an aerosol-generating article, characterized in that it comprises: mixing a recipe with water to form a mixture, the recipe comprising as ingredients vegetable particles and / or alkaloids, a binder and an aerosol-forming agent; kneading the mixture in a dough mixer to form a dough; flattening the dough to form a sheet; drying the flattened sheet to obtain an aerosol-generating substrate sheet for an aerosol-generating article; wherein the amount of the binder in the recipe is from 1.0 percent to 7.0 percent on a dry weight basis; wherein the liquid content of the dough is from 25 percent to 35 percent on a wet weight basis; wherein the flattening is performed using rollers and the temperature of the rollers is between 5 °C and 50 °C.

2. Method according to claim 1, characterized in that the amount of binder in the recipe is from 1.5 percent to 6.5 percent on a dry weight basis; wherein an amount of vegetable particles and / or alkaloids in the recipe is from 50 percent to 80 percent on a dry weight basis, optionally from 70 percent to 80 percent on a dry weight basis; wherein an amount of aerosol-forming agent in the recipe is from 16 percent to 20 percent on a dry weight basis.

3. Method, according to claim 1 or 2, characterized in that mixing the recipe with water comprises: premixing at least one ingredient of the recipe before kneading the mixture in a dough mixer; wherein the water is premixed with at least one ingredient and / or added to the pasta mixer.

4. A method according to any one of claims 1 to 3, characterized in that mixing the recipe with water comprises: premixing at least one ingredient or only a portion of said at least one ingredient of the recipe to form a first premix; premixing the remaining ingredient or ingredients or the remaining portion or portions of the ingredient or ingredients of the recipe to form a second premix; combining the first premix and the second premix in the dough mixer; wherein water is premixed into the first premix and / or the second premix and / or added to the dough mixer.

5. A method according to any one of claims 1 to 4, characterized in that mixing the recipe with water comprises: first mixing the binder with water and then bringing the binder into contact with the aerosol-forming agent.

6. A method according to any one of claims 1 to 5, characterized in that the water temperature is between 20 °C and 80 °C.

7. A method, according to any one of claims 1 to 6, characterized in that the temperature of the mass before flattening is between 20 °C and 50 °C.

8. Method, according to any one of claims 1 to 7, characterized in that the temperature of the rollers is between 8 °C and 40 °C.

9. Method, according to any one of claims 1 to 8, characterized in that the viscosity of the binder is between 0.8 Pa and 10 Pa s.

10. Method, according to any one of claims 1 to 9, characterized in that 90 percent of the plant particles and / or alkaloids have a size smaller than 600 µm. Petition 870250090281, dated 03 / 10 / 2025, p. 68 / 83 3 / 3 11. A method according to any one of claims 1 to 10, characterized in that the plant particles and / or alkaloids comprise tobacco and / or nicotine and / or botanical products and / or cellulose powder.

12. A method according to any one of claims 1 to 11, characterized in that the binder is a cellulose derivative, the cellulose derivative being methylcellulose, ethylcellulose, ethylhydroxymethyl or carboxymethylcellulose.

13. Method, according to any one of claims 1 to 12, characterized in that the aerosol-forming agent is a polyhydric alcohol, the polyhydric alcohol being triethylene glycol, 1,3-butanediol or glycerin or propylene glycol.

14. Method, according to any one of claims 1 to 13, characterized in that the recipe further comprises fiber, the amount of fiber in the recipe being from 0.1 percent to 2.5 percent on a dry weight basis.

15. Method, according to claim 14, characterized in that the fiber length is between 5 µm and 2500 µm. Petition 870250090281, dated 03 / 10 / 2025, pp. 69 / 83

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