Manufacturing method and manufacturing device of aerosol generating substrate

Abstract

The embodiment of the invention provides a manufacturing method and a manufacturing device of an aerosol generating substrate. The manufacturing method comprises the following steps: extruding a mixed material at a low temperature to form an extruded substrate; and freeze-drying the extruded matrix. According to the manufacturing method provided by the embodiment of the invention, low-temperature extrusion molding and freeze drying are matched for use, so that endogenous substances in the extrusion matrix are further reserved, the form of the extrusion matrix is kept, and the loss of effective substances such as plant alkaloid, a smoke agent and aroma components in the extrusion matrix is reduced. And in the freeze drying process, the extrusion matrix can form a microporous structure, the void ratio of the extrusion matrix is improved, the machinability of the aerosol-generating matrix is high, continuous production of the aerosol-generating matrix can be achieved, the production efficiency is high, and the manufacturing cost is low.

Description

Technical Field

[0001] The present application relates to the technical field of smoking products, and in particular to a method and device for manufacturing an aerosol generating substrate. Background Art

[0002] Smoking articles include smoking articles that form aerosols by ignition and smoking articles that form aerosols by heating without burning. In a typical smoking article that heats without burning, it contains an aerosol-generating substrate that can volatilize when heated to produce an aerosol. The aerosol-generating substrate is heated by an external heat source so that it is heated just to a degree sufficient to emit a fragrance. The aerosol-generating substrate does not burn, but instead loads an atomizer and releases the atomizer through high-temperature heating to form smoke when used.

[0003] The core of the existing manufacturing system is mainly cast film, coating, and roller pressing. It needs to use hot air drying to control the moisture and shape of the matrix, and needs to use gathering or filling equipment to prepare a cylindrical aerosol-generating matrix. The related methods and manufacturing systems have the problems of long processes, many intermediate products from raw materials to finished products, large investment in the manufacturing system, and easy loss of effective substances during the manufacturing process. Summary of the invention

[0004] In view of this, the embodiments of the present application hope to provide a method and a device for manufacturing an aerosol generating substrate with a short process and high production efficiency.

[0005] To achieve the above object, the present application provides a method for manufacturing an aerosol generating substrate, the manufacturing method comprising:

[0006] The mixed material is extruded at low temperature to form an extrusion matrix;

[0007] The extruded matrix was freeze-dried.

[0008] In some embodiments, the manufacturing method further comprises:

[0009] The extruded matrix is ​​cut into media segments of predetermined lengths.

[0010] In some embodiments, the step of cutting the extruded matrix into media segments of predetermined lengths comprises:

[0011] Before freeze-drying the extruded matrix, cutting the extruded matrix into medium segments of predetermined lengths; or,

[0012] Before freeze-drying the extruded matrix, the extruded matrix is ​​pre-cut, and after freeze-drying the extruded matrix, the pre-cut extruded matrix is ​​cut into medium segments of a preset length.

[0013] In some embodiments, before freeze-drying the extruded matrix, the manufacturing method further comprises:

[0014] The extruded matrix is ​​hardened.

[0015] In some embodiments, the hardening treatment method is cooling hardening.

[0016] In some embodiments, the extrusion temperature of the low-temperature extrusion is greater than or equal to -50°C and less than 10°C.

[0017] In some embodiments, the extrusion pressure of the low-temperature extrusion is 0.5 bar to 300 bar.

[0018] In some embodiments, the extrusion temperature of the low-temperature extrusion is -35°C to 5°C.

[0019] In some embodiments, the extrusion pressure of the low-temperature extrusion is 30 bar to 150 bar.

[0020] In some embodiments, the extrusion direction of the low-temperature extrusion is horizontal; or,

[0021] The extrusion direction of the low-temperature extrusion is a vertical direction; or,

[0022] The extrusion direction of the low-temperature extrusion is an inclined direction.

[0023] In some embodiments, the mixed material is formed by mixing a solid material and a liquid material. Before the mixed material is subjected to low-temperature extrusion to form an extruded matrix, the manufacturing method further comprises:

[0024] The solid material and the liquid material are fed separately.

[0025] In some embodiments, the solid material and the liquid material are fed separately, comprising:

[0026] adding the solid material;

[0027] When the solid material moves along the material conveying direction to the adding position of the liquid material, the liquid material is added.

[0028] In some embodiments, freeze-drying the extruded matrix comprises:

[0029] Freezing stage: freezing the extruded matrix in a freeze-drying environment so that the water in the extruded matrix freezes into ice crystals;

[0030] Sublimation drying stage: the extruded matrix is ​​heated to sublime the ice crystals in the extruded matrix.

[0031] In some embodiments, the temperature of the extruded matrix during the freezing stage is between -100°C and -30°C.

[0032] In some embodiments, the temperature of the extruded substrate in the sublimation drying stage is -100°C to -30°C, and the temperature of the extruded substrate in the sublimation drying stage is higher than the temperature in the freezing stage.

[0033] In some embodiments, the temperature of the extruded matrix during the freezing stage is between -80°C and -40°C; and / or the temperature of the extruded matrix during the sublimation drying stage is between -80°C and -40°C.

[0034] In some embodiments, the absolute vacuum degree of the freeze-drying environment during the sublimation drying stage is 1 Pa to 40 Pa; and / or, during the sublimation drying stage, the temperature of the freeze-drying environment is 10° C. to 60° C. higher than the temperature of the extruded matrix.

[0035] In some embodiments, the absolute vacuum degree of the freeze-drying environment during the sublimation drying stage is 5Pa to 30Pa; and / or, during the sublimation drying stage, the temperature of the freeze-drying environment is 20°C to 40°C higher than the temperature of the extruded matrix.

[0036] In some embodiments, the temperature of the freeze-drying environment is -70°C to 50°C.

[0037] In some embodiments, before the freezing stage, the manufacturing method further comprises:

[0038] Pre-freezing stage: placing the extruded matrix in the freeze-drying environment, and pre-freezing the extruded matrix, so that the temperature of the extruded matrix after pre-freezing is -30°C to 0°C.

[0039] In some embodiments, after the sublimation drying stage, the manufacturing method further comprises:

[0040] Desorption drying stage: the extruded matrix is ​​heated to evaporate the bound water in the extruded matrix.

[0041] In some embodiments, the absolute vacuum degree of the freeze-drying environment during the desorption drying stage is 1 Pa to 40 Pa; and / or the temperature of the extruded matrix during the desorption drying stage is 0° C. to 50° C.

[0042] In some embodiments, the absolute vacuum degree of the freeze-drying environment during the desorption drying stage is 5 Pa to 30 Pa; and / or the temperature of the extruded matrix during the desorption drying stage is 20° C. to 35° C.

[0043] In some embodiments, during the desorption drying stage, the temperature of the freeze-drying environment is consistent with the temperature of the extruded matrix.

[0044] In some embodiments, the moisture content of the extruded matrix after drying is 3% to 20% of the total weight of the extruded matrix.

[0045] In some embodiments, in 100 parts by weight of the mixed material, the plant raw materials are 30 to 90 parts, the auxiliary raw materials are 1 to 15 parts, the smoke agent raw materials are 5 to 30 parts, the adhesive raw materials are 1 to 10 parts, and the fragrance raw materials are 1 to 15 parts.

[0046] The present application also provides an aerosol-generating substrate manufacturing device, including:

[0047] An extruder, wherein the extruder is used to perform low-temperature extrusion molding on the mixed material at an extrusion temperature below 10°C;

[0048] A freeze drying device is used to freeze dry the extruded matrix.

[0049] In some embodiments, the extrusion die of the extruder is a single-die single-mouth die having a bottom die, and a mouth die at the discharge end of the bottom die.

[0050] In some embodiments, the extrusion die of the extruder is a single-die multi-die having a bottom die, and a discharge end of the bottom die having a plurality of die openings.

[0051] In some embodiments, the extrusion die of the extruder is a multi-die multi-port die having a plurality of bottom dies, and the discharge end of each of the bottom dies has a plurality of port dies.

[0052] The manufacturing method of the aerosol generating matrix of the embodiment of the present application is mainly to form an extruded matrix by extruding the mixed material at low temperature, wherein the mixed material is a component of the aerosol generating matrix, and then freeze-drying the extruded matrix. During low-temperature extrusion molding, the viscosity of the mixed material increases, the mixed slurry presents viscoelastic and plastic state, and the extruded matrix is ​​more likely to adhere tightly, and is not prone to loosening and cracking. At the same time, temperature will affect the parameters such as the retention rate of volatile aroma substances and the viscosity of the mixed material of the extruded matrix, and low-temperature extrusion molding can offset the heat generated by the pressure and mutual friction during the extrusion of the mixed material. Low-temperature extrusion molding and freeze-drying are used in combination, which is further conducive to retaining the endogenous substances in the extruded matrix, maintaining the extruded matrix morphology, and reducing the loss of effective substances such as alkaloids, smoke-generating agents, and aroma components in the extruded matrix. And in the freeze-drying process, the water in the extruded matrix is ​​first frozen to form ice crystals. When the ice crystals sublimate and escape, micropores generated by the volume expansion caused by the freezing of liquid water will be formed in the extruded matrix. Thus, freeze-drying is conducive to the formation of microporous structure in the extruded matrix and improves the porosity of the extruded matrix. In addition, the freeze-drying process and equipment are mature and can be processed in batches to reduce intra-batch errors. The aerosol-generating matrix has high processability and can also achieve continuous production of the aerosol-generating matrix, with a short process, high production efficiency and low manufacturing cost. BRIEF DESCRIPTION OF THE DRAWINGS

[0053] Figure 1 A schematic diagram of a method for manufacturing an aerosol generating substrate according to an embodiment of the present application;

[0054] Figure 2 A schematic diagram of a freeze-drying curve according to an embodiment of the present application;

[0055] Figure 3 This is a schematic structural diagram of a manufacturing device for an aerosol-generating substrate according to an embodiment of the present application, in which a mixed material and an extruded substrate are shown at the same time;

[0056] Figure 4 for Figure 3 A cross-sectional view of

[0057] Figure 5 This is a schematic structural diagram of a manufacturing device for an aerosol-generating substrate according to another embodiment of the present application, in which a mixed material and an extruded substrate are shown at the same time;

[0058] Figure 6 for Figure 5 A cross-sectional view of

[0059] Figure 7 This is a schematic structural diagram of a vacuum drying device according to an embodiment of the present application, and also shows an extruded matrix;

[0060] Figure 8This is a schematic structural diagram of a hardening device according to an embodiment of the present application, in which an extrusion die and an extrusion matrix are shown at the same time;

[0061] Fig. 9 for Figure 8 A cross-sectional view of the hardening device shown;

[0062] Fig.10 It is a schematic structural diagram of another hardening device according to an embodiment of the present application, and the extruded matrix is ​​also shown in the figure;

[0063] Fig.11 This is a schematic structural diagram of the first extrusion die of an embodiment of the present application;

[0064] Fig.12 for Fig.11 The structural schematic diagram of the die shown in the figure also shows the extruded matrix;

[0065] Fig.13 This is a schematic diagram of the structure of a second extrusion die according to an embodiment of the present application, and the extruded matrix is ​​also shown in the figure;

[0066] Fig.14 This is a schematic structural diagram of a third extrusion die according to an embodiment of the present application, in which an extrusion matrix and a connector are shown at the same time;

[0067] Fig.15 This is a schematic diagram of the structure of the first extruded matrix of an embodiment of the present application;

[0068] Fig.16 A cross-sectional view of a second extruded matrix according to an embodiment of the present application;

[0069] Fig.17 This is a schematic diagram of the structure of the third extruded matrix according to an embodiment of the present application.

[0070] Description of Reference Numerals

[0071] 10. Extruder; 11. Barrel; 12. Screw; 13. Extrusion die; 131. Bottom die; 132. Mouth die; 14. Solid material feeding port; 15. Liquid material feeding port; 16. Connector; 20. Freeze drying device; 21. Box; 22. Vacuum pump; 23. Partition; 24. Accommodation plate; 30. Hardening device; 31. Container; 31a. Accommodation cavity; 31b. Liquid inlet tank; 31c. Transfer channel; 32. Cooling pipe; 32a. Liquid storage cavity; 321. Inner tube; 321a. Heat exchange channel; 322. Outer tube; 40. First conveying device; 40a. Guide groove; 50. Cutting device; 60. Second conveying device; 70. Third conveying device; 100. Manufacturing device; 200. Extrusion matrix; 200a. Airway; 200′. Mixed material. DETAILED DESCRIPTION

[0072] In this application, the temperature unit "°C" is Celsius and the pressure unit "bar" is bar.

[0073] An embodiment of the present application provides a method for manufacturing an aerosol-generating substrate. The aerosol-generating substrate is used in conjunction with an electronic atomization device having a heating component. Specifically, the heating component heats and atomizes the aerosol-generating substrate to generate an aerosol for users to inhale or for use in medicine, beauty, etc.

[0074] See also Figures 1 to 6 The method for manufacturing the aerosol generating substrate comprises the following steps:

[0075] Step S101: the mixed material is extruded at low temperature to form an extruded matrix, wherein the mixed material is a component of the aerosol generating matrix;

[0076] The materials are added into the extruder 10 , and the materials are mixed uniformly in the extruder 10 to form a mixed material 200 ′.

[0077] The materials of the embodiments of the present application may include plant raw materials, auxiliary raw materials, smoke-generating agent raw materials, adhesive raw materials and flavor raw materials.

[0078] Plant raw materials are used to generate aerosols when heated. Auxiliary raw materials are used to provide skeleton support for plant raw materials. Smoke-generating agent raw materials are used to generate smoke when heated. Adhesive raw materials are used to bond various raw material components. Flavor raw materials are used to provide characteristic aromas. In this way, plant raw materials and smoke-generating agent raw materials can ensure the amount of aerosol generated, while flavor raw materials can increase the release of aroma during the inhalation process and enhance user experience. Auxiliary raw materials can not only improve the fluidity of the mixed materials, but also make the aerosol generation matrix porous to facilitate the extraction and flow of aerosols. Adhesive raw materials ensure that plant raw materials and auxiliary raw materials constitute a stable mixture to avoid loose structure.

[0079] Exemplarily, the plant raw material can be one or more combinations of powders formed after crushing tobacco raw materials, tobacco leaf fragments, tobacco stems, tobacco dust, and flavor plants. Plant raw materials are the core source of flavor. Endogenous substances in plant raw materials can produce physiological satisfaction for users. Endogenous substances such as alkaloids enter the human blood and promote the pituitary gland to produce dopamine, thereby obtaining physiological satisfaction.

[0080] Exemplarily, the auxiliary raw material can be one or more combinations of inorganic fillers, lubricants, and emulsifiers. Among them, the inorganic filler includes one or more combinations of heavy calcium carbonate, light calcium carbonate, zeolite, attapulgite, talc, and diatomaceous earth. The inorganic filler can provide a skeleton support for the plant raw material, and the inorganic filler also has micropores, which can increase the porosity of the aerosol generation matrix, thereby increasing the aerosol release rate. The lubricant includes one or more combinations of candelilla wax, carnauba wax, shellac, sunflower wax, rice bran, beeswax, stearic acid, and palmitic acid. The lubricant can increase the fluidity of the plant raw material powder, reduce the friction between the plant raw material powders, make the overall density of the plant raw material powder distribution more uniform, and can also reduce the pressure required for the extrusion molding process, and reduce the wear of the die 132. The emulsifier includes one or more combinations of polyglycerol fatty acid esters, Tween-80, and polyvinyl alcohol. The emulsifier can slow down the loss of flavor substances during storage to a certain extent, increase the stability of flavor substances, and improve the sensory quality of the product.

[0081] Exemplarily, the smoke-generating agent raw material may include: a monohydric alcohol (such as menthol); a polyhydric alcohol (such as propylene glycol, glycerol, triethylene glycol, 1,3-butylene glycol and tetraethylene glycol); an ester of a polyhydric alcohol (such as triacetin, triethyl citrate, a mixture of diacetin esters, triethyl citrate, benzyl benzoate, glyceryl tributyrate); a monocarboxylic acid; a dicarboxylic acid; a polycarboxylic acid (such as lauric acid, myristic acid) or an aliphatic ester of a polycarboxylic acid (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, erythritol, 1,3-butylene glycol, tetraethylene glycol, triethyl citrate, propylene carbonate, ethyl laurate, Triactin, meso-erythritol, a mixture of diacetin esters, diethyl suberate, triethyl citrate, benzyl benzoate, benzyl phenylacetate, ethyl vanillate, glyceryl tributyrate, lauryl acetate) in one or more combinations.

[0082] Exemplarily, the adhesive raw material is in close contact with the component raw material interface by wetting, generating intermolecular attraction, thereby playing the role of bonding the component raw materials, such as powders, liquids, etc. The adhesive raw material can be a natural plant extract, a non-ionized modified viscous polysaccharide, including one or more combinations of tamarind polysaccharides, guar gum, and modified cellulose (such as carboxymethyl cellulose). The adhesive is used to bond the particles together, which is not easy to loosen. In addition, it improves the water resistance of the aerosol generating matrix and is harmless to the human body.

[0083] Exemplarily, the flavor raw material is used to provide a characteristic aroma, such as a solid or liquid substance of hay aroma, roasted sweet aroma, and nicotine. The flavor raw material may include one or more combinations of tobacco or other plants, flavor plant extracts, extracts, essential oils, and absolute oils; the flavor raw material may include one or more combinations of monomer flavor substances, such as megastigmatriene, neophytadiene, geraniol, nerol, and the like.

[0084] For example, in 100 parts by weight of the mixture 200', the plant raw material may be 30 to 90 parts, the auxiliary raw material may be 1 to 15 parts, the smoke agent raw material may be 5 to 30 parts, the adhesive raw material may be 1 to 10 parts, and the flavor raw material may be 1 to 15 parts.

[0085] Specifically, see Figures 2 to 4 Extrusion molding refers to a processing method in which materials are added to an extruder 10, and the materials are evenly mixed in the extruder 10 to form a mixed material 200'. The mixed material 200' is pushed forward by the screw 12 through the action between the barrel 11 and the screw 12 of the extruder 10, and continuously passes through the mold at the outlet of the extruder 10 to form various cross-section products or semi-finished products.

[0086] In the field of extrusion technology, the extrusion temperature (i.e., the temperature inside the barrel of the extruder) below 10°C is defined as low temperature, that is, the extrusion temperature of low-temperature extrusion is lower than 10°C.

[0087] The mixed material 200' is a mixture of solid material and liquid material, that is, the mixed material 200' contains a certain amount of water.

[0088] Temperature affects the retention rate of volatile aroma substances of the extruded matrix 200, the viscosity of the mixed material 200' and other parameters. Low-temperature extrusion can offset the heat generated by the pressure and mutual friction of the mixed material 200' during the extrusion process. Thus, the loss of volatile aroma substances during the extrusion molding process is reduced. The corresponding relationship between temperature and volatile aroma retention rate is shown in Table 1.

[0089] Table 1 Effect of temperature on the retention rate of volatile aroma substances in materials

[0090]

[0091]

[0092] According to Table 1, the higher the temperature, the lower the retention rate of volatile aroma substances in the material; the lower the temperature, the higher the retention rate of volatile aroma substances in the material. Among them, when the extrusion temperature is -10°C, the retention rate of volatile aroma substances in the material is as high as 95%, when the extrusion temperature is 10°C, the retention rate of volatile aroma substances in the material is 85%, and when the extrusion temperature is 60°C, the retention rate of volatile aroma substances in the material is only 50%. It can be seen that when the extrusion temperature of low-temperature extrusion is -10°C to 10°C, the retention rate of volatile aroma substances in the material is relatively high, which can meet the needs and ensure the quality of the extruded matrix 200.

[0093] The temperature has a great influence on the viscosity of the mixed material 200', and the viscosity of the mixed material 200' also has an influence on the extrusion pressure. The corresponding relationship between temperature and the rheological properties of the slurry is shown in Table 2.

[0094] Table 2 Corresponding relationship between temperature and rheological properties of slurry

[0095]

[0096] According to Table 2, as the temperature increases, the viscosity of the mixed material 200' decreases. When the extrusion temperature is higher than or equal to 10°C, the bonding force between the mixed materials is small, and the extruded matrix 200 is easily loose or cracked, resulting in a decrease in the yield rate.

[0097] When the extrusion temperature is lower than 10° C., the viscoelasticity of the mixed slurry 200 ′ increases, and the extruded matrix 200 is more likely to be tightly bonded and less likely to become loose or cracked.

[0098] Exemplarily, the extrusion temperature of the low-temperature extrusion is greater than or equal to -50°C and less than 10°C.

[0099] More preferably, the extrusion temperature of the low-temperature extrusion may be -35°C to 5°C (including -35°C and 5°C).

[0100] When the extrusion temperature is -35°C to 5°C, the extrusion pressure can be at an equilibrium point, and the extruded matrix 200 has a uniform shape and a stable structure.

[0101] Exemplarily, the extrusion pressure of low temperature extrusion is 0.5 bar to 300 bar.

[0102] The extrusion pressure described in the embodiments of the present application refers to the extrusion pressure of the extrusion die located at the outlet of the extruder.

[0103] The extrusion pressure will affect the molding shape, surface smoothness, yield rate, and production rate of the aerosol-generating matrix. In the low-temperature extrusion process, when the extrusion pressure is lower than 0.5 bar, the molding rate of the aerosol-generating matrix is ​​low, and the product defect rate increases, which in turn leads to a slow production rate and an increase in production costs. When the extrusion pressure is higher than 300 bar, the transmission structure load of the extruder 10 is high (the torque required to be provided is high), which leads to a reduction in the service life of the extruder 10. Therefore, controlling the extrusion pressure within the range of 0.5 bar to 300 bar can not only improve the molding rate of the aerosol-generating matrix, but also extend the service life of the extruder 10.

[0104] More preferably, the extrusion pressure of low-temperature extrusion is 30 bar to 150 bar (including 30 bar and 150 bar).

[0105] Step S102: freeze-drying the extruded matrix.

[0106] The purpose of freeze drying is to sublime the water in the extruded matrix 200 , thereby reducing the water content in the extruded matrix 200 .

[0107] It should be noted that step S102 may be the last step of the manufacturing method, that is, the dried extruded matrix 200 is the finished product of the aerosol generating matrix. Step S102 may not be the last step of the manufacturing method, which is equivalent to the dried extruded matrix 200 being only a semi-finished product of the aerosol generating matrix. After step S102, other processing may be performed, including but not limited to slitting, packaging, etc.

[0108] Freeze drying is a drying technology that utilizes the principle of sublimation. The extruded matrix 200 is quickly frozen at low temperature, and then in a proper vacuum environment, the frozen water molecules are directly sublimated into water vapor and escape, so that the water in the extruded matrix 200 is sublimated, thereby reducing the water content in the extruded matrix 200.

[0109] Another embodiment of the present application also provides a manufacturing device for an aerosol generating substrate, see Figures 3 to 6 The manufacturing device 100 mainly includes an extruder 10 and a freeze-drying device 20.

[0110] The extruder 10 is used to perform low-temperature extrusion molding on the mixed material 200 ′ so that the mixed material 200 ′ forms an extruded matrix 200 .

[0111] The extruder 10 can be a single-screw extruder or a twin-screw extruder. A twin-screw extruder is preferably used because, compared with a single-screw extruder, a twin-screw extruder can further homogenize the mixed material 200′ during the conveying process of the mixed material 200′, thereby improving product stability, and the extrusion efficiency of a twin-screw extruder is higher than that of a single-screw extruder.

[0112] The freeze drying device 20 is used to freeze dry the extruded matrix 200 .

[0113] For example, see Figures 1 to 7 The freeze-drying device 20 may include a housing 21, a vacuum pump 22, a heating system (not shown) and an electrical instrument control system (not shown), wherein at least one partition 23 is provided in the housing 21, and a receiving plate 24 may be placed on the partition 23. When the extruded matrix 200 needs to be freeze-dried, the receiving plate 24 may be taken out, the extruded matrix 200 may be placed in the receiving plate 24, and then the receiving plate 24 may be placed on the partition 23 in the housing 21. The vacuum pump 22 is used to form a vacuum in the housing 21, and the partition 23 is heated by the heating system to provide heat for the extruded matrix 200.

[0114] The manufacturing method of the aerosol-generating extrusion matrix of the embodiment of the present application is mainly to perform low-temperature extrusion molding on the mixed slurry 200' so that the mixed slurry 200' forms an extrusion matrix 200, and then freeze-dry the extrusion matrix 200. During low-temperature extrusion molding, the viscosity of the mixed slurry 200' increases, the mixed slurry 200' presents a viscoelastic and plastic state, and the extrusion matrix 200 is more likely to be tightly bonded and not prone to loosening and cracking. At the same time, temperature will affect the parameters such as the retention rate of volatile substances and the viscosity of the mixed slurry 200 of the extrusion matrix 200, and low-temperature extrusion molding can offset the heat generated by the pressure and mutual friction during the extrusion of the mixed slurry 200'. The use of low-temperature extrusion molding and freeze-drying is further conducive to retaining the endogenous substances in the extrusion matrix 200, maintaining the morphology of the extrusion matrix 200, and reducing the loss of effective substances in the extrusion matrix 200, such as alkaloids, smoke-generating agents, and aroma components. In the freeze-drying process, the water in the extruded matrix 200 first freezes to form ice crystals. When the ice crystals sublimate and escape, micropores generated by the volume expansion of liquid water when it freezes will be formed in the extruded matrix 200. Therefore, freeze drying is conducive to the formation of a microporous structure in the extruded matrix 200, and the porosity of the extruded matrix 200 is improved. In addition, the process and equipment of freeze drying are mature, and batch processing can be carried out in batches to reduce the intra-batch error. The aerosol-generated extruded matrix has high processability, and the continuous production of the aerosol-generated extruded matrix can also be realized, with high production efficiency and low manufacturing cost.

[0115] Depending on the different structural forms of the die disposed at the outlet of the extruder 10, the extruded matrix 200 of different structural forms can be extruded, for example, Figures 15 to 17 , an extruded matrix 200 having air channels 200a may be extruded.

[0116] The number of air passages 200a may be one or more. The air passage 200a may be a straight air passage 200a, a spiral air passage 200a, or a combination of a straight air passage 200a and a spiral air passage 200a. The straight air passage 200a is an air passage 200a extending in a straight line, or in other words, the extending direction of the straight air passage 200a is a straight line.

[0117] The spiral airway 200a is an airway 200a in which at least a portion of the area along the extension direction is in a curved shape with a curvature not equal to zero. For example, along the extension direction of the spiral airway 200a, the spiral airway 200a may have a structural form of both a curved segment with a curvature not equal to zero and a straight segment with a curvature of zero, or may have a structural form of only a curved segment with a curvature not equal to zero and no straight segment with a curvature of zero. In other words, from the starting point to the end point of the spiral airway 200a along the extension direction, the spiral airway 200a only needs to not extend along a straight line.

[0118] The airway 200a may be Fig.15 As shown, it is located inside the extruded matrix 200, and can also be as shown. Fig.15 As shown, the air channels 200 a are located on the outer side wall of the extruded matrix 200 . When there are multiple air channels 200 a , some of the air channels 200 a may be located inside the extruded matrix 200 , and other air channels 200 a may be located on the outer side wall of the extruded matrix 200 .

[0119] The shape of the cross section of the air channel 200a located inside the extruded matrix 200 is not limited. For example, the shape of the cross section can be circular, polygonal (including but not limited to triangle, square, prism, etc.), elliptical, racetrack-shaped or irregular, etc., wherein irregular refers to other symmetrical or asymmetrical shapes other than the shapes listed above.

[0120] The cross-sectional shape of the air channel 200a located on the outer side wall of the extruded matrix 200 can be semicircular, semi-elliptical, polygonal or irregular, wherein irregular refers to other symmetrical or asymmetrical shapes other than the shapes listed above.

[0121] The air channel 200a is used to increase the surface area of ​​the aerosol generating substrate (the side wall of the air channel 200a is equivalent to a part of the surface of the aerosol generating substrate), so that the heat acting on the aerosol generating substrate can enter the interior of the aerosol generating substrate from the surface of the aerosol generating substrate to improve the heating efficiency.

[0122] It should be noted that the airway 200a described in the present application is a hole or groove in a macroscopic sense, and the airway 200a is mainly formed by processing. Therefore, the cross-sectional area, length and other dimensions of the airway 200a can be changed according to design requirements.

[0123] In one embodiment, the extrusion direction of the low-temperature extrusion molding is a horizontal direction.

[0124] See also Figure 3 and Figure 4 The extrusion direction of low-temperature extrusion molding is horizontal, that is, the die at the outlet of the extruder 10 is horizontally arranged, and the extruded matrix 200 is extruded in the horizontal direction, or in other words, the extrusion direction of the extruded matrix 200 is parallel to the horizontal plane.

[0125] For the extruded matrix forming the spiral air channel, when the extruded matrix passes through the extrusion die at the exit of the extruder, the die of the extrusion die rotates while the extruded matrix does not rotate, and the extruded matrix extruded by the rotating die directly enters the conveying device (such as Figure 3 and Figure 4 The first conveying device 40 in the embodiment of the present invention, since the rotation of the die will cause a certain stress in the extruded matrix, and horizontal extrusion can reduce the direct release of the stress of the extruded matrix (the generated stress can be eliminated by heating), therefore, horizontal extrusion can improve the yield rate of the aerosol-generating matrix with a spiral airway.

[0126] In one embodiment, the extrusion direction of low-temperature extrusion molding may also be a vertical direction.

[0127] See also Figure 5 and Figure 6 The extrusion direction of low-temperature extrusion molding is vertical, that is, the mold at the outlet of the extruder 10 is set downward, and the extruded matrix 200 is extruded along the direction of gravity, or in other words, the extrusion direction of the extruded matrix 200 is perpendicular to the horizontal plane.

[0128] For the extruded matrix 200 forming the straight air channel 200 a , the extrusion direction of the low-temperature extrusion molding is the vertical direction, which can improve the yield rate and reduce the investment cost of the extruder 10 , and can also reduce the floor space of the extruder 10 .

[0129] In one embodiment, the extrusion direction of the low-temperature extrusion molding may also be an inclined direction.

[0130] The extrusion direction of low temperature extrusion molding is an inclined direction, which means that the die at the outlet of the extruder 10 is inclined, and the angle between the extrusion direction of the extruded matrix 200 and the horizontal plane is greater than 0° and less than 90°.

[0131] The extrusion direction of the low-temperature extrusion molding is an inclined direction, which can not only reduce the extrusion pressure of the mixed material 200 ′, but also facilitate the space design of other equipment.

[0132] In one embodiment, please refer to Fig.11 and Fig.12 The extrusion die 13 can be a single-mode single-port die, that is, a bottom die 131 ( Fig.11 and Fig.12 The bottom mold 131 is not shown in FIG. Fig.13 The bottom mold 131 is a bottom mold 131, and the discharge end of the bottom mold 131 has a mouth mold 132. After the mixed material 200' passes through the mouth mold 132, a medium structure with an air channel 200a can be formed.

[0133] In one embodiment, please refer to Fig.13 The extrusion die 13 may also be a single-mode multi-port die, that is, the bottom die 131 at the outlet of the extruder 10 is one, and the discharge end of the bottom die 131 has multiple port dies 132. After the mixed material 200' passes through the multiple port dies 132, multiple extruded matrices 200 are formed at the same time. When the screw 12 of the extruder 10 is relatively large in size, a single-mode multi-port die can be selected, which can improve production efficiency and is more suitable for mass production.

[0134] In one embodiment, please refer to Fig.14 The extrusion die 13 can also be a multi-mode multi-port die, that is, the connector 16 at the outlet of the extruder 10 is connected to multiple bottom dies 131, and each bottom die 131 has multiple port dies 132 at the discharge end. After the mixed material 200 ′ passes through the port dies 132 on each bottom die 131, multiple medium structures are formed at the same time. When the size of the screw 12 of the extruder 10 is relatively large, a multi-mode multi-port die can also be selected, which can improve production efficiency and is more suitable for mass production.

[0135] In one embodiment, the mixed material 200 ′ is formed by mixing a solid material and a liquid material. Before the mixed material 200 ′ is subjected to low-temperature extrusion to form an extruded matrix, the manufacturing method further includes: feeding the solid material and the liquid material separately.

[0136] Solid material refers to solid material in the mixed material 200 ′, and liquid material refers to liquid material in the mixed material 200 ′.

[0137] For example, taking plant raw materials, auxiliary raw materials and adhesive raw materials as solid materials and smoke-generating agent raw materials and flavor raw materials as liquid materials as an example, the solid materials such as plant raw materials, auxiliary raw materials and adhesive raw materials and the liquid materials such as smoke-generating agent raw materials and flavor raw materials can be added into the barrel 11 of the extruder 10 respectively, so that the solid materials and the liquid materials are mixed in the barrel 11 of the extruder 10 to form a mixed material 200′.

[0138] The advantage of feeding solid and liquid materials separately is that it can reduce the cost of material pre-treatment, ensure the continuity of the production process, and improve the consistency and uniformity of the product while improving production efficiency.

[0139] Furthermore, feeding the solid material and the liquid material separately may include the following steps: adding the solid material; when the solid material moves along the material conveying direction to the adding position of the liquid material, adding the liquid material.

[0140] That is to say, solid material is first added to the extruder 10. After the solid material enters the barrel 11 of the extruder 10, it will move along the material conveying direction toward the direction where the extrusion die 13 is located. When the solid material moves along the material conveying direction to the liquid material adding position, liquid material is added to the extruder 10 to mix the liquid material and the solid material in the barrel 11 of the extruder 10.

[0141] In addition, the feeding amount and feeding speed can also be determined according to the production speed of the extruder 10 and the ratio of each raw material in the mixed material 200'.

[0142] For example, see Figures 3 to 6 A solid material feeding port 14 and a liquid material feeding port 15 connected to the barrel 11 of the extruder 10 may be provided on the extruder 10 , and the liquid material feeding port 15 is located downstream of the solid material feeding port 14 along the material conveying direction.

[0143] The number of the solid material feeding ports 14 may be one or more. When a plurality of solid material feeding ports 14 are provided, each solid material feeding port 14 may be used to add the same solid material or different solid materials.

[0144] Similarly, the number of the liquid material feeding ports 15 can be one or more. When multiple liquid material feeding ports 15 are provided, each liquid material feeding port 15 can be used to add the same liquid material or different liquid materials.

[0145] In addition, whether it is a plurality of solid material feeding ports 14 or a plurality of liquid material feeding ports 15, they can be arranged into a detachable structure so as to facilitate the assembly of the solid material feeding ports 14 and the liquid material feeding ports 15 according to the required number.

[0146] Since the extruder 10 mainly relies on the rotation of the screw 12 to convey the mixed material 200', and the screw 12 and the inner wall of the barrel 11 of the extruder 10 are not completely sealed, that is, there is a gap between the screw 12 and the inner wall of the barrel 11 of the extruder 10. If the liquid material is added first, the liquid material is likely to leak from the gap. Therefore, adding the solid material first and then adding the liquid material when the solid material moves to the liquid material adding position along the material conveying direction can better avoid liquid leakage.

[0147] In some embodiments, the mixed material 200' may not be fed separately as a solid material and a liquid material. For example, a plurality of materials may be mixed to form a mixed material 200' and then fed. That is, the solid material and the liquid material may be mixed to form a material mixture (referred to as mixed slurry feeding) first, and then the material mixture is added to the barrel 11 of the extruder 10 for further mixing to form the mixed material 200'.

[0148] The benefit of mixed slurry feeding is that the mixed material 200' has better consistency, which can ensure the uniformity and stability of the product.

[0149] Also, see Figure 4 and Figure 6 For mixed slurry feeding, the feed port (when mixed slurry feeding is used, Figure 4 and Figure 6 A screw 12 may also be provided at the solid material feeding port 14 (equivalent to the feeding port) to further homogenize the mixed slurry.

[0150] In one embodiment, freeze drying the extruded matrix 200 comprises:

[0151] Freezing stage: freezing the extruded matrix 200 in a freeze-drying environment so that the water in the extruded matrix 200 is frozen into ice crystals;

[0152] Sublimation drying stage: the extruded matrix 200 is heated to sublime the ice crystals in the extruded matrix 200 .

[0153] The freezing stage mainly refers to freezing the extruded matrix 200 in a freeze-drying environment so that the water in the extruded matrix 200 is frozen into ice crystals and reaches a sublimable state.

[0154] The sublimation drying stage mainly refers to the stage of sublimation of ice crystals in the extruded matrix 200. The purpose of the sublimation drying stage is to quickly sublimate the water frozen into ice crystals in the extruded matrix 200. The freeze-drying environment is in a low vacuum environment during the sublimation drying stage, which is conducive to the sublimation of ice crystals.

[0155] In one embodiment, before the freezing stage, the manufacturing method further comprises:

[0156] Pre-freezing stage: the extruded matrix 200 is placed in a freeze-drying environment and pre-frozen so that the temperature of the extruded matrix 200 after pre-freezing is -30°C to 0°C (including -30°C and 0°C).

[0157] The pre-freezing stage mainly refers to the stage in which the extruded matrix 200 reaches a preset freezing temperature from room temperature or other temperatures. Its purpose is to make the extruded matrix 200 reach the preset freezing temperature to facilitate freeze drying and improve freeze drying efficiency.

[0158] The freezing stage mainly refers to that the extruded matrix 200 is kept at a preset freezing temperature for a period of time, so that the water in the extruded matrix 200 is frozen into ice crystals and reaches a sublimable state.

[0159] The extruded matrix 200 may be pre-frozen by means of a low-temperature refrigerator or similar equipment, liquid nitrogen, liquid air or dry ice treatment, so that the temperature of the extruded matrix 200 after pre-freezing is -30°C to 0°C, thereby improving the processing efficiency of the freeze-drying device 20.

[0160] In one embodiment, after the sublimation drying stage, the manufacturing method further comprises:

[0161] Desorption and drying stage: the extruded matrix 200 is heated to evaporate the bound water in the extruded matrix 200 .

[0162] The analytical drying stage mainly refers to the stage of evaporating the bound water in the extruded matrix 200. After the sublimation drying stage, there is still some unfrozen bound water in the extruded matrix 200. In this stage, the temperature of the freeze-drying environment and the extruded matrix 200 can be increased, and the freeze-drying environment is in a relatively low vacuum environment to promote the evaporation of water. The purpose of the analytical drying stage is to remove some of the bound water in the extruded matrix 200 so that the moisture in the extruded matrix 200 reaches the target value.

[0163] Freeze drying requires continuous control of the temperature of the extruded matrix 200 in the box 21, the absolute vacuum degree, and the temperature of the partition 23. The temperature of the extruded matrix 200 is the temperature (surface temperature) of the extruded matrix 200 in the box 21, and the temperature of the freeze drying environment is the temperature of the partition 23 of the freeze drying device 20. Figure 2 As shown, freeze drying includes a pre-freezing stage (a), a freezing stage (b), a sublimation drying stage (c), and an analytical drying stage (d). The temperature of the extruded matrix 200, the absolute vacuum degree, and the temperature of the freeze drying environment will vary to a certain extent in each stage.

[0164] The separator 23 may be of a heater type or an intermediate fluid type to achieve temperature control, and the temperature of the extruded matrix 200 is controlled by the separator 23 through heat conduction and / or heat radiation.

[0165] In one embodiment, the temperature of the freeze drying environment is -70°C to 50°C. For example, -70°C, -65°C, -60°C, -55°C, -50°C, -45°C, -40°C, -35°C, -30°C, -25°C, -20°C, -15°C, -10°C, -5°C, 0°C, 5°C, 10°C, 15°C, 20°C, 25°C, 30°C, 35°C, 40°C, 45°C or 50°C, etc. When freeze drying is carried out at the above temperature, the water in the extruded matrix 200 can be frozen and sublimated at an appropriate speed, and while effectively reducing the water in the extruded matrix 200, the aroma components and effective substances (such as alkaloids and smoke generating agents) in the extruded matrix 200 can be retained as much as possible, thereby ensuring product quality and reducing production costs.

[0166] In one embodiment, the temperature of the extruded matrix 200 in the freezing stage (b) and the sublimation drying stage (c) is -100°C to -30°C, for example, -100°C, -95°C, -90°C, -85°C, -80°C, -75°C, -70°C, -65°C, -60°C, -55°C, -50°C, -45°C, -40°C, -35°C or -30°C, etc.

[0167] When the temperature of the extruded matrix 200 in the freezing stage (b) and the sublimation drying stage (c) is higher than -30°C, it takes a long time for the water in the extruded matrix 200 to sublimate, resulting in low production efficiency and high production cost.

[0168] When the temperature of the extruded matrix 200 in the freezing stage (b) and the sublimation drying stage (c) is lower than -100°C, the alcohol smoke generating agent in the extruded matrix 200 may also freeze and sublime, thereby causing loss of effective substances. In addition, it is difficult for the refrigeration system to reach a temperature below -100°C, and the cost investment is high.

[0169] When the temperature of the extruded matrix 200 in the freezing stage (b) and the sublimation drying stage (c) is -100°C to -30°C, the moisture in the extruded matrix 200 can be frozen and sublimated at an appropriate speed, which can effectively reduce the moisture in the extruded matrix 200 while retaining the aroma components and effective substances (such as alkaloids, smoke-generating agents) in the mixed material 200′ as much as possible, thereby ensuring product quality and reducing production costs.

[0170] Preferably, the temperature of the extruded matrix 200 during the freezing stage and the sublimation drying stage may be -80°C to -40°C.

[0171] In one embodiment, the temperature of the extruded matrix 200 during the sublimation drying stage is higher than the temperature during the freezing stage, so as to facilitate the sublimation of ice crystals in the extruded matrix 200 .

[0172] In one embodiment, the temperature of the extruded matrix 200 during the drying stage (d) is 0°C to 50°C, such as 0°C, 5°C, 10°C, 15°C, 20°C, 25°C, 30°C, 35°C, 40°C, 45°C or 50°C.

[0173] When the temperature of the extruded matrix 200 during the desorption drying stage is less than 0° C., the extruded matrix 200 can obtain less energy, which is not conducive to the evaporation of bound water in the extruded matrix 200 .

[0174] When the temperature of the extruded matrix 200 during the desorption and drying stage is greater than 50° C., the effective substances (such as smoke generating agents, etc.) in the extruded matrix 200 may be lost, thereby affecting the quality of the extruded matrix 200 .

[0175] When the temperature of the extruded matrix 200 in the analytical drying stage is 0°C to 50°C, the bound water in the extruded matrix 200 can sublime at an appropriate speed, which can effectively reduce the moisture in the extruded matrix 200 while retaining the aroma components and effective substances (such as alkaloids, smoke-generating agents) in the mixed material 200' as much as possible to ensure product quality.

[0176] Preferably, the temperature of the extruded matrix 200 during the desorption and drying stage is 20°C to 35°C.

[0177] In one embodiment, in the pre-freezing stage, the temperature of the freeze-drying environment can be consistent with the temperature of the extruded matrix 200. In this stage, the extruded matrix 200 releases heat and lowers the temperature so that the water in the extruded matrix 200 forms ice crystals, thereby, the temperature of the freeze-drying environment can be consistent with the temperature of the extruded matrix 200.

[0178] In one embodiment, during the freezing stage, the temperature of the freeze-drying environment can be consistent with the temperature of the extruded matrix 200. In this stage, the extruded matrix 200 releases heat and lowers the temperature so that the water in the extruded matrix 200 forms ice crystals, thereby, the temperature of the freeze-drying environment can be consistent with the temperature of the extruded matrix 200.

[0179] In one embodiment, during the sublimation drying stage, the temperature of the freeze drying environment is 10°C to 60°C higher than the temperature of the extruded matrix 200, for example, 10°C, 15°C, 20°C, 25°C, 30°C, 35°C, 40°C, 45°C, 50°C, 55°C or 60°C, etc.

[0180] The temperature of the freeze-drying environment is, for example, the temperature of the partition 23 .

[0181] During the sublimation drying stage, the temperature of the freeze-drying environment is 10°C to 60°C higher than the temperature of the extruded matrix 200. That is, during the sublimation drying stage, the temperature of the partition 23 is 10-60°C higher than the temperature of the extruded matrix 200. The temperature of the partition 23 is higher than the temperature of the extruded matrix 200, which can provide the extruded matrix 200 with the energy required for ice crystal sublimation. If the temperature difference is less than 10°C, the energy that the freeze-drying environment can provide is less, and the ice crystals sublime more slowly. If the temperature difference is greater than 60°C, the ice crystals sublime rapidly, which may cause the extruded matrix 200 to collapse, thereby reducing product quality.

[0182] When the temperature of the freeze-drying environment is 10°C to 60°C higher than the temperature of the extruded matrix 200, the freeze-drying environment can provide sufficient energy for the sublimation of ice crystals, and the ice crystals in the extruded matrix 200 can sublime at an appropriate speed, which can avoid causing the extruded matrix 200 to collapse to a certain extent and ensure product quality.

[0183] Preferably, during the sublimation drying stage, the temperature of the freeze-drying environment is 20° C. to 40° C. higher than the temperature of the extruded matrix 200 .

[0184] In one embodiment, during the desorption drying stage, the temperature of the freeze drying environment is consistent with the temperature of the extruded matrix 200. The temperature during the desorption drying stage is higher than that during the sublimation drying stage, the extruded matrix 200 can obtain heat, and this stage is still in a low vacuum environment, and water is easily evaporated.

[0185] In one embodiment, the absolute vacuum degree of the freeze-drying environment in the sublimation drying stage and the analytical drying stage is 1Pa to 40Pa. For example, the absolute vacuum degree of the freeze-drying environment in the sublimation drying stage and the analytical drying stage is 1Pa, 2Pa, 3Pa, 10Pa, 15Pa, 16Pa, 17Pa, 18Pa, 19Pa, 20Pa, 21Pa, 22Pa, 23Pa, 24Pa, 25Pa, 26Pa, 27Pa, 28Pa, 29Pa, 30Pa, 31Pa, 33Pa, 35Pa, 36Pa, 37Pa, 38Pa, 39Pa or 40Pa, etc.

[0186] A low absolute vacuum is conducive to the sublimation of ice crystals, but when the absolute vacuum is less than 1Pa, it is difficult for the equipment to reach and maintain this vacuum for a long time, and the extruded matrix 200 may be deformed due to a large negative pressure, such as collapse; when the absolute vacuum is greater than 40Pa, the water in the extruded matrix 200 sublimates and evaporates at a slower rate, reducing production efficiency and consuming time and energy.

[0187] There is a positive correlation between absolute vacuum and the boiling point of water, that is, the lower the absolute vacuum, the lower the boiling point of water. Therefore, by controlling the absolute vacuum, the boiling point of water in the extruded matrix 200 can be controlled, which is beneficial to the evaporation of bound water in the extruded matrix 200.

[0188] In addition, low temperature is conducive to retaining endogenous substances in the extruded matrix 200. Therefore, setting the absolute vacuum degree of the vacuum environment within the range of 1Pa to 40Pa is conducive to the evaporation of bound water in the extruded matrix 200 under low temperature conditions. This can not only effectively reduce the moisture in the extruded matrix 200, but also retain the aroma components and effective substances (such as alkaloids, smoke-generating agents, etc.) in the raw materials as much as possible, thereby ensuring product quality.

[0189] When the absolute vacuum degree of the freeze-drying environment in the sublimation drying stage and the analytical drying stage is 1Pa to 40Pa, the boiling point of water is low, which is conducive to the sublimation of ice crystals and the evaporation of bound water, thereby improving production efficiency and reducing energy consumption.

[0190] Preferably, the absolute vacuum degree of the freeze-drying environment in the sublimation drying stage and the analytical drying stage is 5Pa to 30Pa.

[0191] In one embodiment, the moisture content of the dried extruded matrix 200 may be 3% to 20% of the total weight of the extruded matrix 200. Exemplarily, the moisture content of the dried extruded matrix 200 may be 3%, 4%, 5%, 10%, 11%, 15%, 16%, 18% or 20%, etc.

[0192] When the water content in the extruded matrix 200 is lower than 3%, during the user's suction process, the impurities generated by the aerosol-generating matrix are relatively high, which reduces the user's suction experience. In addition, if the dried extruded matrix 200 is subsequently processed by other methods (i.e., step S20 is not the last step of the manufacturing method), the dried extruded matrix 200 is fragile in the subsequent processing process, which will also lead to a high defect rate in subsequent production and increase production costs. When the water content in the extruded matrix 200 is higher than 20%, the smoke water content of the aerosol-generating matrix during the heating and suction process is high, and the smoke temperature is not easy to reduce, which easily causes the user to have a "hot mouth" phenomenon during the suction process, reducing the user's suction experience. Therefore, controlling the water content in the dried extruded matrix 200 within the range of 3% to 20% of the total weight of the extruded matrix 200 can effectively improve the user's suction experience. In addition, for the extruded matrix 200 that is processed by other methods after drying, the defect rate in subsequent production can also be reduced.

[0193] More preferably, the moisture content of the extruded matrix 200 after drying may be 4% to 13% (including 4% and 13%) of the total weight of the extruded matrix 200 .

[0194] In one embodiment, the manufacturing method may further include: cutting the extruded matrix 200 into medium segments of a preset length.

[0195] The length of the extruded matrix 200 extruded by extrusion molding is usually relatively long, so the extruded matrix 200 can be cut into required lengths according to different usage scenarios.

[0196] See also Figures 3 to 6 The manufacturing device 100 is provided with a slitting device 50 having a slitting tool (not shown), and the extruded matrix 200 is slid by the slitting tool.

[0197] There are many ways of slitting. For example, in one embodiment, physical contact slitting in which a slitting tool contacts the extruded matrix 200 can be used. That is, the slitting tool directly contacts the extruded matrix 200. Physical contact slitting includes but is not limited to rotary hob cutting, cutting disc cutting, wire cutting, roller cutting, extrusion and the like.

[0198] In another embodiment, non-physical contact slitting may be used in which the slitting tool is spaced from the extruded matrix 200. That is, the slitting tool itself has no physical contact with the extruded matrix 200. Non-physical contact slitting includes but is not limited to laser cutting, plasma cutting, air knife, water knife, and the like.

[0199] Exemplarily, the extruded matrix 200 is cut into medium segments of a predetermined length before freeze drying the extruded matrix 200. That is, the extruded matrix 200 is first cut into predetermined lengths, and then the cut extruded matrix 200 is freeze dried.

[0200] Illustratively, before freeze-drying the extruded matrix 200, the extruded matrix 200 is pre-cut, and after freeze-drying the extruded matrix 200, the pre-cut extruded matrix 200 is cut into medium segments of a predetermined length.

[0201] Pre-cutting is equivalent to performing the initial cutting on the extruded matrix 200 , and the length of the extruded matrix 200 after the pre-cutting is longer than the preset length.

[0202] Exemplarily, the extruded matrix segments cut initially are circumferentially shaped using a jig, and the shaped matrix 200 is freeze-dried.

[0203] Illustratively, after freeze drying, the matrix 200 is extruded, and before slitting, a jig is used to calibrate the circumference and straightness of the extruded matrix segments.

[0204] See also Figure 3 and Figure 4 For a manufacturing device 100 that needs to perform pre-slitting, two slitting devices 50 may be provided.

[0205] To facilitate cutting of the extruded matrix 200 after freeze drying, see Figure 3 and Figure 4 The manufacturing device 100 may also be provided with a second conveying device 60 between the freeze-drying device 20 and the second cutting device 50, and the extruded matrix 200 that has been freeze-dried in the freeze-drying device 20 is conveyed to the second cutting device 50 by the second conveying device 60 for cutting.

[0206] The texture of the extruded matrix 200 extruded by extrusion molding is usually relatively soft. Therefore, before the extruded matrix 200 is freeze-dried, the pre-cutting of the extruded matrix 200 is equivalent to cutting the soft body of the extruded matrix 200.

[0207] After the pre-cut extruded matrix 200 is freeze-dried, the moisture in the extruded matrix 200 is removed and the extruded matrix 200 hardens. Therefore, after freeze-drying, the cutting of the pre-cut extruded matrix 200 is equivalent to cutting the extruded matrix 200 with a relatively hard texture.

[0208] During the freeze-drying process of the extruded matrix 200, the volume of the extruded matrix 200 will shrink. Therefore, the pre-cutting-freeze-drying-cutting method can improve the consistency of the longitudinal dimension (i.e., the dimension along the extrusion direction) of the extruded matrix 200 after cutting, thereby improving the cutting yield.

[0209] It should be noted that in some embodiments, there may be no slitting step, that is, the extruded matrix 200 of a preset length can be directly extruded by extrusion molding. For example, after the extruded matrix 200 is extruded by vertical extrusion, the extruded matrix 200 can naturally detach under the action of its own gravity when it reaches or approaches the preset length, thereby reducing the subsequent slitting steps and further reducing the production cost.

[0210] In one embodiment, before freeze-drying the extruded matrix 200 , the manufacturing method further comprises: hardening the extruded matrix 200 .

[0211] Since the texture of the extruded matrix 200 extruded by extrusion molding is usually relatively soft, in order to facilitate subsequent processing, the extruded matrix 200 may be hardened before freeze-drying to increase the hardness of the extruded matrix 200 .

[0212] Exemplarily, the hardening method is, for example, cooling hardening.

[0213] After the hardening treatment, the hardness of the extruded matrix 200 increases, and the temperature of the extruded matrix 200 also decreases. In this way, it is more conducive to freeze-drying the extruded matrix 200, thereby improving production efficiency.

[0214] Exemplarily, the hardness of the extruded matrix 200 before cooling and hardening can be 0HB~100HB (including 0HB and 100HB), after cooling and hardening, the hardness of the extruded matrix 200 can be 1HB~200HB (including 1HB and 200HB), and after freeze-drying, the hardness of the extruded matrix can be 40HB~300HB (including 40HB and 300HB).

[0215] Preferably, the hardness of the extruded matrix 200 before cooling and hardening can be 1HB~60HB (including 1HB and 60HB), after cooling and hardening, the hardness of the extruded matrix can be 40HB~120HB (including 40HB and 120HB), and after freeze-drying, the hardness of the extruded matrix can be 80HB~250HB (including 80HB and 250HB).

[0216] For example, the temperature of the extruded matrix 200 before cooling and hardening may be 0°C to 40°C, and after cooling and hardening, the temperature of the extruded matrix 200 may be -50°C to 5°C.

[0217] For the manufacturing method having the slitting step, the extruded matrix 200 may be slit into predetermined lengths after the extruded matrix 200 is cooled and hardened.

[0218] Since the hardness of the extruded matrix 200 increases after being cooled and hardened, the extruded matrix 200 is easier to cut after being cooled and hardened, and the extruded matrix 200 after cutting will not be deformed, and the cut surface is more neat and complete.

[0219] In one embodiment, the cooling and hardening may be placing the extruded matrix 200 in a low-temperature environment for freezing and hardening, wherein the temperature of the low-temperature environment is lower than the hardening temperature of the extruded matrix 200 .

[0220] That is, the extruded matrix 200 may be transferred to a low-temperature environment with a relatively low temperature for freezing. In order to meet the hardening requirement, the temperature in the low-temperature environment needs to be lower than the hardening temperature of the extruded matrix 200 .

[0221] Exemplarily, when the extruded matrix 200 is low-temperature extrusion molded, on the premise that the temperature in the low-temperature environment is lower than the hardening temperature of the extruded matrix, if the hardening temperature of the extruded matrix is ​​-100°C to 10°C (including -100°C and 10°C), the temperature of the low-temperature environment can be -270°C to 10°C (including -270°C and 10°C).

[0222] More preferably, if the hardening temperature of the extruded matrix is ​​-30°C to 5°C (including -30°C and 5°C), the temperature of the low-temperature environment may be -50°C to 5°C (including -50°C and 5°C).

[0223] In one embodiment, the cooling and hardening may also be performed by using a refrigerant to cool the extruded matrix 200. The refrigerant may be in the form of a liquid, such as liquid nitrogen or liquefied air, or a gas or a solid.

[0224] For example, the extruded matrix 200 may be directly heat exchanged with a refrigerant.

[0225] Direct heat exchange refers to heat exchange between heat exchange media through direct contact. In other words, the extruded matrix 200 is in direct contact with the refrigerant. For example, see Figure 8 and Fig. 9 The hardening device 30 may be provided with a refrigerant supplier (not shown) and a container 31 having a receiving chamber 31a. The receiving chamber 31a has a transmission channel 31c penetrating opposite sides of the container 31 and a liquid inlet groove 31b connected to the receiving chamber 31a. The extruded matrix 200 extruded from the extruder 10 enters the receiving chamber 31a through the transmission channel 31c. The refrigerant supplier injects liquid refrigerant into the liquid inlet groove 31b. The refrigerant enters the receiving chamber 31a through the liquid inlet groove 31b and contacts the extruded matrix 200 in the receiving chamber 31a for heat exchange.

[0226] Also, see Figure 8 and Fig. 9 When the extrusion die 13 can extrude multiple extrusion matrices 200 at the same time, since the hardness of the extrusion matrix 200 just extruded is relatively low, in order to prevent the multiple extrusion matrices 200 from sticking together, a first conveying device 40 having multiple guide grooves 40a can be provided outside the die opening of the extrusion die 13. The first conveying device 40 passes through the conveying channel 31c to guide each extrusion matrix 200 through the conveying channel 31c into the accommodating cavity 31a for cooling and hardening.

[0227] The advantage of extruded matrix 200 directly exchanging heat with the refrigerant is that the surface of the hardened heat exchange medium can be cooled more quickly, so that the extruded matrix 200 can maintain the stability of the shape, thereby facilitating continuous production and improving production efficiency. For example, the extruded matrix 200 can also be indirectly exchanged with the refrigerant.

[0228] Indirect heat exchange means that the heat exchange media do not directly contact each other during the heat exchange process. In other words, the extruded matrix 200 and the refrigerant do not directly contact each other, but indirectly exchange heat through the middleware. For example, please refer to Fig.10The hardening device 30 may include a cooling tube 32, and the cooling tube 32 includes an inner tube 321 and an outer tube 322. A liquid storage chamber 32a for storing a refrigerant is formed between the inner tube 321 and the outer tube 322. The inner tube 321 has a penetrating heat exchange channel 321a. The extruded matrix 200 extruded from the extruder 10 enters the heat exchange channel 321a and contacts with the inner tube 321 for heat exchange. The inner tube 321 that absorbs the heat of the extruded matrix 200 then exchanges heat with the refrigerant, which is equivalent to indirect heat exchange between the extruded matrix 200 and the refrigerant through the inner tube 321.

[0229] It should be noted that the inner surface of the inner tube 321 forming the heat exchange channel 321a is generally a smooth surface. For example, the roughness of the inner surface of the inner tube 321 can be Ra1.2μm~Ra0.08μm. The friction between the smooth inner surface and the outer surface of the extruded matrix 200 is small, which will not cause deformation of the extruded matrix 200.

[0230] The advantage of indirect heat exchange between the extruded matrix 200 and the refrigerant is that it can effectively avoid the expansion deformation, cracking and other problems that may occur when the extruded matrix 200 directly contacts the refrigerant.

[0231] In some embodiments, there may be no cooling and hardening step. For example, in a manufacturing method, after the extruded matrix 200 is extruded, before freeze drying, only cutting may be performed without cooling and hardening. For an extruded matrix 200 with a relatively short preset length, the slight deformation caused by cutting has no effect on subsequent production, and therefore, the cooling and hardening step may be omitted.

[0232] In one embodiment, after freeze-drying the extruded matrix 200 , the manufacturing method may further include: wrapping a packaging layer on the outer surface of the extruded matrix 200 .

[0233] The packaging layer includes but is not limited to medium consumables such as cigarette paper, paper tube, and tin foil. The extruded matrix 200 wrapped with the packaging layer is equivalent to the finished product of the aerosol generating matrix.

[0234] In some embodiments, the extruded matrix 200 wrapped with the packaging layer may also be combined with other functional segments, such as a cooling segment, a filtering segment, etc., to form an aerosol generating product.

[0235] In another embodiment, after freeze-drying the extruded matrix 200 , the manufacturing method may further include: sealing and packaging the extruded matrix 200 .

[0236] That is to say, instead of wrapping the outer surface of the extruded matrix 200 with a packaging layer, the extruded matrix 200 may be directly sealed and packaged, for example, the extruded matrix 200 may be packaged in a blister packaging container 31. The sealed and packaged extruded matrix 200 is also equivalent to a finished product of the aerosol generating matrix. The sealed and packaged extruded matrix 200 can be directly used on the electronic atomization device after removing the packaging.

[0237] The following are several feasible manufacturing methods of the present application respectively described by different embodiments. It should be noted that the following embodiments are mainly for illustrating the differences between several feasible manufacturing methods, and the specific method of each step in each embodiment is the same as that in the previous embodiment, which will not be repeated here.

[0238] Embodiment 1

[0239] The manufacturing method of the first embodiment mainly comprises the following steps:

[0240] Step S01a: feeding;

[0241] Step S02a: low temperature extrusion molding;

[0242] Step S03a: cooling and hardening;

[0243] Step S04a: cutting;

[0244] Step S05a: freeze drying;

[0245] Step S06a: Packaging.

[0246] Embodiment 2

[0247] The manufacturing method of the second embodiment mainly comprises the following steps:

[0248] Step S01b: feeding;

[0249] Step S02b: low temperature extrusion molding;

[0250] Step S03b: cutting;

[0251] Step S04b: freeze drying;

[0252] Step S05b: Packaging.

[0253] Compared with the manufacturing method of the first embodiment, the manufacturing method of the second embodiment does not have a cooling and hardening step.

[0254] Embodiment 3

[0255] The manufacturing method of the third embodiment mainly comprises the following steps:

[0256] Step S01c: feeding;

[0257] Step S02c: low temperature extrusion molding;

[0258] Step S03c: pre-cutting;

[0259] Step S04c: freeze drying;

[0260] Step S05c: cutting;

[0261] Step S06c: Packaging.

[0262] Compared with the manufacturing method of Example 1, the manufacturing method of Example 3 does not have a cooling and hardening step, and the cutting of Example 3 includes pre-cutting before freeze-drying and cutting after freeze-drying.

[0263] Embodiment 4

[0264] The manufacturing method of the fourth embodiment mainly comprises the following steps:

[0265] Step S01d: feeding;

[0266] Step S02d: low temperature extrusion molding;

[0267] Step S03a: freeze drying;

[0268] Step S03a: Packaging.

[0269] Compared with the manufacturing method of the first embodiment, the manufacturing method of the fourth embodiment does not have the steps of cooling, hardening and slitting.

[0270] In the description of the present application, the description with reference to the terms "in one embodiment", "in some embodiments", "in other embodiments", "in yet other embodiments", or "exemplary" etc. means that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the embodiments of the present application. In the present application, the schematic representation of the above terms does not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in a suitable manner in any one or more embodiments or examples. In addition, those skilled in the art may combine the different embodiments or examples described in the present application and the features of the different embodiments or examples without contradiction.

[0271] The above description is only a preferred embodiment of the present application and is not intended to limit the present application. For those skilled in the art, the present application may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application are included in the protection scope of the present application.

Claims

1. A method for producing an aerosol-generating substrate, characterized in that: The manufacturing method comprises: The mixed material is extruded at low temperature to form an extrusion matrix; The extruded matrix was freeze-dried.

2. The manufacturing method according to claim 1, characterized in that: The manufacturing method further comprises: The extruded matrix is ​​cut into media segments of predetermined lengths.

3. The manufacturing method according to claim 2, characterized in that: The step of cutting the extruded matrix into medium segments of a preset length comprises: Before freeze-drying the extruded matrix, cutting the extruded matrix into medium segments of predetermined lengths; or, Before freeze-drying the extruded matrix, the extruded matrix is ​​pre-cut, and after freeze-drying the extruded matrix, the pre-cut extruded matrix is ​​cut into medium segments of a preset length.

4. The manufacturing method according to claim 1, characterized in that: Prior to freeze drying the extruded matrix, the manufacturing method further comprises: The extruded matrix is ​​hardened.

5. The manufacturing method according to claim 4, characterized in that: The hardening treatment method is cooling hardening.

6. The manufacturing method according to claim 1, characterized in that: The extrusion temperature of the low-temperature extrusion is greater than or equal to -50°C and less than 10°C; and / or, The extrusion pressure of the low-temperature extrusion is 0.5 bar to 300 bar.

7. The manufacturing method according to claim 6, characterized in that: The extrusion temperature of the low-temperature extrusion is -35°C to 5°C; and / or, The extrusion pressure of the low-temperature extrusion is 30 bar to 150 bar.

8. The manufacturing method according to claim 1, characterized in that: The extrusion direction of the low-temperature extrusion is horizontal; or, The extrusion direction of the low-temperature extrusion is a vertical direction; or, The extrusion direction of the low-temperature extrusion is an inclined direction.

9. The manufacturing method according to claim 1, characterized in that: The mixed material is formed by mixing a solid material and a liquid material. Before the mixed material is subjected to low-temperature extrusion to form an extruded matrix, the manufacturing method further comprises: The solid material and the liquid material are fed separately.

10. The manufacturing method according to claim 9, characterized in that: The step of feeding the solid material and the liquid material separately comprises: adding the solid material; When the solid material moves along the material conveying direction to the adding position of the liquid material, the liquid material is added.

11. The manufacturing method according to claim 1, characterized in that: The freeze-drying of the extruded matrix comprises: Freezing stage: freezing the extruded matrix in a freeze-drying environment so that the water in the extruded matrix freezes into ice crystals; Sublimation drying stage: the extruded matrix is ​​heated to sublime the ice crystals in the extruded matrix.

12. The manufacturing method according to claim 11, characterized in that: The temperature of the extruded matrix during the freezing stage is -100°C to -30°C; and / or, The temperature of the extruded substrate in the sublimation drying stage is -100°C to -30°C, and the temperature of the extruded substrate in the sublimation drying stage is higher than the temperature in the freezing stage.

13. The manufacturing method according to claim 12, characterized in that: The temperature of the extruded matrix in the freezing stage is -80°C to -40°C; and / or the temperature of the extruded matrix in the sublimation drying stage is -80°C to -40°C.

14. The manufacturing method according to claim 11, characterized in that: The absolute vacuum degree of the freeze-drying environment in the sublimation drying stage is 1Pa to 40Pa; and / or, in the sublimation drying stage, the temperature of the freeze-drying environment is 10°C to 60°C higher than the temperature of the extruded matrix.

15. The manufacturing method according to claim 14, characterized in that: The absolute vacuum degree of the freeze-drying environment in the sublimation drying stage is 5Pa to 30Pa; and / or, in the sublimation drying stage, the temperature of the freeze-drying environment is 20°C to 40°C higher than the temperature of the extruded matrix.

16. The manufacturing method according to claim 11, characterized in that: The temperature of the freeze-drying environment is -70°C to 50°C.

17. The manufacturing method according to claim 11, characterized in that: Before the freezing stage, the manufacturing method further comprises: Pre-freezing stage: placing the extruded matrix in the freeze-drying environment, and pre-freezing the extruded matrix, so that the temperature of the extruded matrix after pre-freezing is -30°C to 0°C.

18. The manufacturing method according to claim 11, characterized in that: After the sublimation drying stage, the manufacturing method further comprises: Desorption drying stage: the extruded matrix is ​​heated to evaporate the bound water in the extruded matrix.

19. The manufacturing method according to claim 18, characterized in that: The absolute vacuum degree of the freeze-drying environment during the analytical drying stage is 1 Pa to 40 Pa; and / or the temperature of the extruded matrix during the analytical drying stage is 0° C. to 50° C.

20. The manufacturing method according to claim 19, characterized in that: The absolute vacuum degree of the freeze-drying environment during the analytical drying stage is 5Pa to 30Pa; and / or the temperature of the extruded matrix during the analytical drying stage is 20°C to 35°C.

21. The manufacturing method according to claim 18, characterized in that: During the desorption drying stage, the temperature of the freeze drying environment is consistent with the temperature of the extruded matrix.

22. The manufacturing method according to claim 1, characterized in that: The moisture content of the extruded matrix after drying is 3% to 20% of the total weight of the extruded matrix.

23. The manufacturing method according to claim 1, characterized in that: In 100 parts by weight of the mixed material, the plant raw material is 30 to 90 parts, the auxiliary raw material is 1 to 15 parts, the smoke agent raw material is 5 to 30 parts, the adhesive raw material is 1 to 10 parts, and the fragrance raw material is 1 to 15 parts.

24. An apparatus for manufacturing an aerosol-generating substrate, characterized in that: include: An extruder, wherein the extruder is used to perform low-temperature extrusion molding on the mixed material at an extrusion temperature below 10°C; A freeze drying device is used to freeze dry the extruded matrix.

25. The manufacturing device according to claim 24, characterized in that The extrusion die of the extruder is a single-mode single-mouth die having a bottom die, and a discharge end of the bottom die having a mouth die; or, The extrusion die of the extruder is a single-die multi-die having a bottom die, and a discharge end of the bottom die having a plurality of die openings; or, The extrusion die of the extruder is a multi-die multi-port die having a plurality of bottom dies, and the discharge end of each bottom die has a plurality of port dies.

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