Apparatus and method for producing cross-section shaped aerosol-generating material extrudate

Abstract

The invention relates to a device for producing an extrudate 9 comprising an aerosol-generating material 23, the device comprising an extruder 1 wherein the extruder 1 comprises an inlet 2 and an outlet 5 wherein the inlet 2 is adapted to receive a mixture 3 wherein the outlet 5 is adapted to extrude the mixture 3 to form the extrudate 9 wherein the outlet 5 comprises a die part 10, wherein the mold part 10 is adapted to form an extrudate 9 comprising an aerosol-generating material 23, and wherein the mold part 10 is adapted to provide a cross-sectional shape for the extrudate 9. The invention also relates to a method for producing an extrudate 9 comprising an aerosol-generating material 23, comprising the steps of providing a mixture 3 to an extruder 1 via an inlet 2 of the extruder 1, moving the mixture 3 in an extrusion direction 100, extruding the mixture 3 from the extruder 1 via an outlet 5, wherein the mixture 3 is extruded through a die part 10 of an outlet 5 of the extruder 1 to form an extrudate 9 having a cross-sectional shape comprising the aerosol-generating material 23. Furthermore, the invention relates to the use of an extruder 1 for extruding an extrudate 9 comprising an aerosol-generating material 23 such that the extrudate 9 is provided with a cross-sectional shape. The invention also relates to an aerosol-generating material 23, an aerosol-generating article, and a system comprising a device and a mixture for forming an extrudate 9 comprising an aerosol-generating material 23.

Description

Technical Field

[0001] The present disclosure relates to an apparatus for producing an extrudate comprising an aerosol - forming material, a method for extruding an aerosol - forming material, and the use of an extruder for extruding an aerosol - forming material. Background Art

[0002] Aerosol - generating articles refer not only to filter cigarettes and other smoking articles in which materials are burned to form smoke, but also to those articles that generate an aerosol from an aerosol - forming material without its combustion. Since the aerosol - forming material is heated to a relatively low temperature to cause the formation of an aerosol, but combustion of the materials contained within the aerosol - forming material is prevented, such articles are typically designated as "heat - not - burn" aerosol - generating articles. Generally, the aerosol composition generated by such "heat - not - burn" aerosol - generating articles is substantially based on a homogenized tobacco material, which typically constitutes the majority of the tobacco content of the aerosol - forming material. Thus, the composition and quality of the homogenized tobacco material play a key role in the overall quality and user experience of the aerosol - generating article.

[0003] Generally, the homogenized tobacco material can be formed into a cast leaf or a reconstituted tobacco sheet. For the former, ground tobacco, a binder, and other ingredients are mixed to form a slurry, which can be subjected to thermo - mechanical treatment before being cast onto a moving metal belt to produce a cast leaf. Alternatively, a slurry with lower viscosity and higher water content (such as that used in the cast - leaf process) can be used to form a reconstituted tobacco sheet according to a process similar to papermaking. After that, the cast leaf or reconstituted tobacco sheet is wound onto a bobbin for storage and transportation purposes, and then unwound for further processing.

[0004] This further processing of the homogenized tobacco material can include curling of the cast leaf or reconstituted tobacco sheet, which thus results in its corrugated form. The corrugated cast leaf or reconstituted tobacco sheet can then be compressed, folded, and / or rolled into a cylindrical form, which is subsequently divided into individual segments that can be inserted into corresponding aerosol - generating articles as the aerosol - forming material.

[0005] As briefly pointed out, the production steps for manufacturing an aerosol - forming material for insertion into and for use in an aerosol - generating article are cumbersome. In addition, for example, each manufacturing step requires complex and precise machinery and a relatively large production area within the production workshop. Thus, each stage of manufacturing is typically implemented as batch processing, where each step undergone is relatively independent of the previous and / or subsequent manufacturing steps. This can lead to undesirable downtime between individual production steps, and precise calculation and scheduling of the production process are required to minimize such downtime and optimize the entire production line. If not done so, production capacity and the associated capital may be lost. Summary of the Invention

[0006] Accordingly, it is an object of the present invention to provide an alternative to the above production process, in particular by compressing certain production steps to achieve a continuous production process at least between certain individual manufacturing steps.

[0007] According to a first aspect of the present invention, there is provided an apparatus for producing an extrudate comprising an aerosol-forming material. The apparatus comprises an extruder. The extruder comprises an inlet and an outlet, wherein the inlet is adapted to receive a mixture and the outlet is adapted to extrude the mixture to form an extrudate. The outlet comprises a die member. The die member is adapted to form an extrudate comprising an aerosol-forming material. The die member is further adapted to provide a cross-sectional shape to the extrudate.

[0008] The extruder may be implemented to produce an extrudate in the form of an object having a predetermined shape via extrusion. In particular, during extrusion, a compressive force and a shear force are applied to the mixture in order to produce the extrudate. In particular, the extrudate is a continuous product whose length is substantially greater than the dimension defining its cross-sectional shape.

[0009] In particular, the inlet of the extruder is in fluid connection with the outlet of the extruder so as to enable the mixture to move from the inlet to the outlet. In particular, the path of movement of the mixture from the inlet to the outlet defines the extrusion direction of the extruder. In particular, the inlet is located upstream of the outlet and the outlet is located downstream of the inlet.

[0010] The extruder may comprise a hopper adapted to supply the mixture to the inlet of the extruder.

[0011] The outlet of the extruder is adapted to extrude the mixture to form an extrudate. The extrudate exits the extruder at the downstream end of the outlet. In particular, once the mixture has entered the outlet, it can be regarded as an extrudate. The outlet, which may comprise a plurality of components and parts, comprises at least one die member. The die member is adapted to form the extrudate and provide it with a cross-sectional shape. The extrudate may be formed by providing the extrudate with a defined geometric profile defining the cross-sectional shape. The die member may be adapted to provide a gradient of the cross-sectional shape to the extrudate before the final cross-sectional shape is achieved.

[0012] The die member may comprise a plurality of components, and in particular at least one die plate having at least one orifice. The orifice of the die plate may be adapted to provide the cross-sectional shape of the extrudate and may thus be adapted to define the outer contour of the extrudate. The geometric form of the orifice may be circular and may appear circular or oval. The geometric form of the orifice may be at least partially or completely in a spiral form. The side walls of the die member may define the orifice. The side walls may exhibit corrugations.

[0013] The die plate can exhibit a plurality of orifices and is adapted to cause the plurality of orifices to jointly form an extrudate and to provide a cross-sectional shape to the extrudate. A die plate having a plurality of orifices in the form of orifice groups can be selected to form the cross-sectional shape of the extrudate into a hollow chamber profile. The orifice groups can include at least one or several of circular orifices, oval orifices, and at least partially or fully spiral orifices. The shape of the orifice groups can resemble the inverted form of a wagon wheel or the inverted form of at least two rings connected by at least one spoke.

[0014] An extrudate having a hollow chamber profile can have a cross-sectional shape in which at least one region is free of extrudate. The region can be regarded as a void, cavity, or hollow chamber. The hollow chamber extends along the length of the extrudate. Components can be present in the region.

[0015] The die plate can exhibit a plurality, i.e., at least two, orifice groups to enable the simultaneous production of a plurality of extrudates. The orifice groups can have the same geometric configuration. The orifice groups can have different configurations. The die plate can exhibit at least one orifice and at least one orifice group to enable the simultaneous manufacture of a number of extrudates.

[0016] The die component can include at least one mandrel having at least one protrusion. The die plate and the mandrel can be arranged and adapted to each other such that the extrudate is provided with a cross-sectional shape of a hollow chamber profile. The die plate and the mandrel can be integrally formed, or they can be at least two separate parts adapted to be directly fixed to each other or fixed relative to each other. For example, such fixation can be achieved by another component of the outlet.

[0017] The geometric profile of the die plate, in particular the orifices, can be adapted to accommodate the geometric profile of the mandrel, in particular the protrusion. Thus, the protrusion of the mandrel can be arranged at least partially inside the orifices of the die plate. The protrusion can extend through the orifices such that the downstream end surface of the protrusion is flush with the downstream end surface of the die plate. The downstream end surface of the protrusion can extend beyond the downstream end surface of the die plate.

[0018] In particular, the protrusion of the mandrel corresponds to and is adapted to the orifices of the die plate. In this case, the orifices of the die plate are adapted to provide the outer profile of the cross-sectional shape of the extrudate, while the protrusion of the mandrel is adapted to provide the inner profile for the cross-sectional shape of the extrudate. The geometric form of the protrusion, in particular the downstream end surface of the protrusion, can be shaped in a circular form or can be at least partially (if not fully) shaped in a spiral form. The protrusion can exhibit corrugations and can thus be adapted to provide corrugations for the inner profile of the cross-sectional shape of the hollow body profile of the extrudate.

[0019] The protrusion can correspond to and be adapted to at least one orifice or the entire orifice group in the orifice group.

[0020] In embodiments where the die component exhibits multiple orifices and / or orifice groups for simultaneously extruding multiple extrudates, the corresponding mandrel may exhibit multiple protrusions. The amount of protrusions may be equal to the amount of orifices and / or orifice groups; however, not every orifice or orifice group must be associated with a protrusion.

[0021] In particular, the outlet may include a vibrating component. The vibrating component may be adapted to apply vibrations to the die component during extrusion. Such vibrations may be ultrasonic in nature. The vibrations may improve the flow of the extrudate through the outlet. In particular, adhesion of the extrudate to the outlet may be reduced. A more precise cross-sectional shape may be obtained. Vibrating the die component may accelerate the movement of the mixture. Vibrating the die component may prevent separation of the mixture during extrusion. The vibrations may increase extrusion efficiency and reduce waste and maintenance of the extruder.

[0022] The extruder may include at least one screw adapted to convey the mixture from the inlet of the extruder to the outlet along the extrusion direction. In this case, the extruder may be referred to as a single-screw extruder, or as a twin-screw extruder if the extruder includes two screws. In particular, the diameter of the screw increases along the extrusion direction. That is, the screw exhibits an increasing diameter downstream in the extrusion direction.

[0023] The extruder may include a heating zone located upstream in the extrusion direction and adapted to heat the mixture to a temperature between 90 °C and 190 °C, especially between 140 °C and 190 °C, and most especially between 175 °C and 185 °C.

[0024] The extruder may include a cooling zone located downstream in the extrusion direction and adapted to cool the mixture to a temperature between 30 °C and 70 °C, especially between 35 °C and 50 °C, and most especially between 25 °C and 35 °C.

[0025] In particular, the outlet may include a cooling unit adapted to cool at least a portion (if not the whole) of the die component to a temperature between 10 °C and 50 °C, especially between 20 °C and 40 °C, and most especially between 25 °C and 35 °C.

[0026] In particular, the apparatus may include a sensor material feeding device adapted to insert sensor material into the extrudate. The sensor material feeding device may be adapted to insert the sensor material downstream of the die component, especially downstream of the outlet. The sensor material feeding device may be adapted to insert the sensor material into the extrudate during extrusion in the outlet, especially in the die component.

[0027] The susceptor material is a material that can be inductively heated, including but not limited to any material that can be inductively heated to a temperature sufficient to generate an aerosol from the aerosol-forming material. The susceptor material may comprise at least one metal, such as technically or industrially pure iron or aluminum, but may comprise metal alloys, such as ferromagnetic alloys, ferritic iron, ferromagnetic steel, ferromagnetic stainless steel, stainless steel or aluminum alloy. The susceptor material may be carbon-based, such as graphite. The susceptor material may be heated to a temperature exceeding 250 degrees Celsius.

[0028] In particular, the susceptor material is in the form of a continuous strip or bar and is disposed on a bobbin. The strip can be considered a layered element whose length is substantially greater than its width and thickness, while the bar can be considered a cylindrical element whose length is substantially greater than its diameter. The width of the susceptor material strip can be between 1 mm and 10 mm, while the thickness of the susceptor material strip can be between 1 mm and 10 mm. The width and thickness of the susceptor material strip can be equal, such that the cross-sectional shape of the susceptor material strip is square. The diameter of the susceptor material bar can be between 1 mm and 10 mm. The bar can exhibit an oval cross-sectional shape.

[0029] In particular, the susceptor material feeding device may comprise at least one guiding member, such as a pair of guiding rollers, to enable the susceptor material to be transferred from the bobbin to the extruder.

[0030] The device may comprise a rotating device adapted to rotate the susceptor material. This can enable the extrudate to wrap around the susceptor material. The rotating susceptor material may have a wound shape in the extrudate. This can improve the heat distribution in the extrudate when heating the susceptor material. The rotation of the susceptor material can improve the adhesion between the susceptor material and the extrudate, especially at the outlet of the extruder.

[0031] The device may comprise at least one dryer adapted to dry the extrudate to substantially maintain its cross-sectional shape. The dryer is adapted to provide a drying temperature between 70 degrees Celsius and 110 degrees Celsius, especially between 80 degrees Celsius and 100 degrees Celsius, and most especially between 85 degrees Celsius and 95 degrees Celsius. Such a dryer can be configured as a continuous dryer, such as a tunnel dryer. Such a continuous dryer may exhibit at least two chambers or zones adapted to provide different drying temperatures.

[0032] The device may comprise at least one cutting device adapted to separate the extrudate into individual segments. The cutting device may be located directly downstream of the outlet. For example, if the device also comprises a dryer, the cutting device may be located downstream thereof.

[0033] According to a second aspect of the present invention, there is provided a method for producing an extrudate comprising an aerosol - forming material, the method comprising the steps of: providing a mixture to an extruder via an inlet of the extruder, moving the mixture along an extrusion direction, and extruding the mixture from the extruder via an outlet, wherein the mixture is extruded through a die member at the outlet of the extruder to form the extrudate comprising the aerosol - forming material having a cross - sectional shape.

[0034] The mixture may comprise a plant - based material, water, and additional aerosol - forming agents. Unless otherwise specified, the weight - percentage values and ranges of the components of the mixture provided herein are based on the total weight of the mixture, according to the technically known "weight percentage" definition.

[0035] The mixture can be a slurry. A slurry can be a mixture of at least one denser solid suspended in at least one liquid.

[0036] In particular, the plant - based material is an alkaloid - containing material.

[0037] The amount of the alkaloid - containing material or plant - based material in the mixture is between 30% and 80% by weight, more particularly between 40% and 70% by weight.

[0038] An alkaloid - containing material can be defined as a material containing at least one alkaloid, which may comprise nicotine, such as nicotine present in tobacco.

[0039] Instead of or as a supplement to tobacco, other plant - based materials can be part of the mixture. The herbaceous materials can be alkaloid - free.

[0040] Alkaloids are a group of naturally occurring compounds that mainly contain basic nitrogen atoms. This group also includes some related compounds with neutral or even weakly acidic properties. Some synthetic compounds with similar structures are also called alkaloids. In addition to carbon, hydrogen, and nitrogen, alkaloids may also contain oxygen, sulfur, and less commonly other elements such as chlorine, bromine, and phosphorus.

[0041] Alkaloids are produced by a variety of organisms including bacteria, fungi, plants, and animals. They can be purified from the crude extracts of these organisms by acid - base extraction. Caffeine, nicotine, theobromine, atropine, tubocurarine are examples of alkaloids.

[0042] The alkaloid - containing material can be tobacco leaves.

[0043] In particular, the alkaloid-containing material is a homogenized tobacco material formed by agglomerating particulate tobacco containing at least the alkaloid nicotine. Such homogenized tobacco materials are typically made from parts of the tobacco plant that are less suitable for producing cut filler, such as tobacco stems, tobacco laminae, or tobacco dust. Usually, tobacco dust is produced as a by-product during the processing of tobacco leaves during manufacturing. The homogenized tobacco material may contain one or more of a small amount of tobacco dust, tobacco fines, and other particulate tobacco by-products formed during the handling, transportation, and storage of tobacco. The starting material for producing the homogenized tobacco material may mainly be tobacco leaves having the same size and physical properties as the tobacco used for blending cut filler. The tobacco present in the homogenized tobacco material may constitute the majority of the tobacco, or even substantially the total amount of tobacco present in the aerosol-forming material.

[0044] The alkaloid-containing material may contain starch. However, the starch may be included as a separate component in the mixture.

[0045] Starch is a polymeric carbohydrate composed of a large number of glucose units linked by glycosidic bonds. Starch is produced by most green plants as an energy store. It is the most common carbohydrate in the human diet and is contained in plants such as potatoes, wheat, maize (corn), rice, and tobacco. It consists of two types of polymer molecules: linear and helical amylose and branched amylopectin, which are arranged in semi-crystalline granules in the plant itself.

[0046] In particular, the particles of the alkaloid-containing material have an average particle size between 0.02 mm and 0.3 mm. An average particle size between about 0.02 mm and about 0.3 mm represents the particle size at which the tobacco cells are at least partially disrupted. Using an alkaloid-containing material having such an average size can advantageously produce a smooth and uniform extrudate in downstream processing steps of the alkaloid-containing material.

[0047] In particular, the water content of the mixture is between 5 wt% and 70 wt% or greater, especially between 10 wt% and 18 wt% or between 25 wt% and 60 wt%, most especially between 11 wt% and 14 wt% or between 35 wt% and 50 wt%.

[0048] In particular, the amount of aerosol former in the mixture is between 1 wt% and 10 wt%, especially between 1 wt% and 5 wt%. In particular, the aerosol former is an additional component in the mixture and should be considered separately from the alkaloid-containing material, especially from the tobacco.

[0049] Suitable aerosol - forming agents for the mixture are known in the art and include, but are not limited to: monohydric alcohols, such as menthol; polyhydric alcohols, such as triethylene glycol, 1,3 - butanediol, and glycerol; esters of polyhydric alcohols, such as glyceryl monoacetate, glyceryl diacetate, or glyceryl triacetate; and aliphatic esters of mono -, di - or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0050] Examples of preferred aerosol - forming agents are glycerol and propylene glycol.

[0051] The alkaloid - containing material can have an aerosol - forming agent content greater than 3% by weight of the total amount of the alkaloid - containing material. Alternatively, the alkaloid - containing material can have an aerosol - forming agent content between 3% and 30% by weight. In particular, the aerosol - forming agent comprises the alkaloid - containing material between 7% and 25% by weight. The aerosol - forming agent especially comprises the alkaloid - containing material between 10% and 25% by weight. In particular, the aerosol - forming agent content of the alkaloid - containing material is an inherent component of the alkaloid - containing material and thus the amount thereof is independent of the amount of aerosol - forming agent that may be included in the mixture as described above.

[0052] In particular, the mixture can contain a binder. In particular, the amount of binder in the mixture is at most 1% by weight. However, it is possible to include from 1% to 15% by weight, especially from 1% to 12% by weight, and most especially from 1% to 5% by weight.

[0053] The binder in the mixture can be any type of gum or pectin described herein. The binder can ensure that the alkaloid - containing material particles remain substantially dispersed throughout the mixture and the extrudate. For a descriptive review of gums that can be used as binders, see Gums And Stabilizers For The Food Industry, IR.L Press (G.O.Phillip et al. eds. 1988); Whistler, Industrial Gums: Polysaccharides And Their Derivatives, Academic Press (2nd ed., 1973); and Lawrence, Natural Gums For Edible Purposes, Noyes Data Corp. (1976).

[0054] Although any binder can be used, preferred binders are natural pectins such as fruit, citrus or tobacco pectin, guar gums such as hydroxyethyl guar gum and hydroxypropyl guar gum, locust bean gums such as hydroxyethyl and hydroxypropyl locust bean gum, alginates, starches such as modified or derivative starches, celluloses such as methyl, ethyl, ethylhydroxymethyl and carboxymethyl cellulose, tamarind gum, dextran, pullulan, konjac flour, xanthan gum and the like. A particularly preferred binder for use in the present invention is guar gum.

[0055] In particular, the mixture may comprise from 2% to 30% by weight, especially from 5% to 25% by weight, even more especially from 10% to 15% by weight, and most especially from 11% to 14% by weight of reducing sugar.

[0056] In particular, the reducing sugar is glucose, fructose, xylose, ribose or galactose, or can be a mixture thereof. In particular, the reducing sugar is glucose, fructose or a mixture of both.

[0057] When mechanical energy is applied to the mixture, the presence of reducing sugar in the mixture can modify the alkaloid-containing material. A reaction may occur between the reducing sugar and the alkaloid-containing material, especially if the alkaloid-containing material contains ammonia or ammonium compounds. This reaction can modify the composition of the alkaloid-containing material such that the resulting mixture and aerosol-generating material have a lower amount of ammonia or ammonium compounds compared to an aerosol-generating material formed from a mixture without reducing sugar. This can affect the properties and characteristics of the aerosol-generating material, such as in terms of flavor.

[0058] In particular, the mixture may comprise cellulose fibers. It is known that cellulose fibers generally increase the tensile strength of the mixture and the resulting aerosol-generating material and thus act as a strengthening agent. Cellulose fibers for use in mixtures containing alkaloid-containing materials such as homogenized tobacco materials are known in the art and include but are not limited to: softwood fibers, hardwood fibers, jute fibers, flax fibers, tobacco fibers and combinations thereof. In particular, cellulose fibers such as wood fibers contain a low lignin content. Alternatively, fibers such as plant fibers can be used together with the above fibers. The cellulose fibers can include tobacco stalk material, stems or other tobacco plant material.

[0059] The amount of cellulose fibers added to the mixture can be between 1% and 10% by weight, especially between 1% and 7% by weight, and more especially between 1% and 5% by weight. These values do not include the amount of cellulose fibers contained in and associated with the alkaloid-containing material but should be considered as a separate component in the mixture.

[0060] The length of the cellulose fibers is advantageously between 0.2 mm and 4 mm. In particular, the average length per unit weight of the cellulose fibers is between 1 mm and 3 mm. In addition to pulping, the incorporated cellulose fibers may be subjected to suitable processes such as refining, mechanical pulping, chemical pulping, bleaching, sulfate pulping, and combinations thereof.

[0061] The mixture can be formed by any known means and provided to the inlet of the extruder. In particular, the mixture is provided to a hopper that is fluidly connected to the inlet of the extruder.

[0062] The mixture moves from the inlet of the extruder to the outlet of the extruder along the extrusion direction. In particular, such conveyance is facilitated by the rotation of at least one screw within the extruder.

[0063] Including at least one screw in the extruder can facilitate the movement of the mixture along the extrusion direction. However, the screw can change the properties of the mixture along the extrusion direction. The rotation of the screw during extrusion imparts shear force, i.e., mechanical work, on the mixture, which can increase its mixing and can cause chemical reactions between the individual components of the mixture. The mechanical work can result in the generation of heat, which can affect the chemical and physical structures of the mixture and its individual components. Certain chemical reactions between the mixture and its individual components can be caused. The implementation of the screw can cause an increasing density increase along the extrusion direction. That is to say, the mixture can exhibit a higher density downstream in the extrusion direction and a lower density upstream in the extrusion direction. The rotation of the screw can especially have a dewatering effect on the mixture along the extrusion direction. That is to say, the water content of the mixture can be reduced during movement along the extrusion direction.

[0064] In particular, the screw is rotated at a rotational speed between 20 revolutions per minute and 40 revolutions per minute, between 40 revolutions per minute and 80 revolutions per minute, or between 60 revolutions per minute and 120 revolutions per minute.

[0065] The amount of mechanical energy of the mixture provided to the extruder is specifically at least 20 watt-hours per kilogram of the mixture.

[0066] The mixture is extruded from the die member at the outlet to form an extrudate including the aerosol-generating material having a cross-sectional shape.

[0067] An aerosol - forming material refers to a material that can release volatile compounds (such as nicotine) containing aerosol due to a heating process. The aerosol - forming material mainly corresponds to the mixture provided at the inlet of an extruder, but particularly exhibits at least different composition, different chemical properties, or different physical properties from this mixture. For example, the aerosol - forming material may be denser than the provided mixture, may have a higher viscosity than the provided mixture, may have a lower water content than the provided mixture, may have a higher content of glycerol, guar gum, or cellulose fibers than the provided mixture, or may have a lower content of ammonia or ammonium - containing compounds than the provided mixture. The aerosol - forming material can exhibit a combination of any of the above - mentioned properties. These differences may be the result of the mixture passing through the extruder and moving along the extrusion direction. Additionally, for example, providing mechanical work to the mixture via a rotating screw or changing its temperature by heating or cooling certain sections of the extruder may cause changes in at least the composition, chemical properties, or physical properties of the aerosol - forming material compared to the provided mixture.

[0068] In particular, the cross - sectional shape of the extrudate is circular, especially round or oval. The diameter of the cross - sectional shape of the extrudate can be between 5 mm and 10 mm.

[0069] By extruding the mixture through a die member at the outlet of the extruder to form an extrudate comprising an aerosol - forming material having a cross - sectional shape, the aerosol - forming material can be produced in a single manufacturing step. This eliminates the need to produce sheets or cast leaves, wind them on bobbins, transport the bobbins, and unwind the sheets for further processing to produce cylindrical aerosol - forming materials. In addition to the costs associated with such production lines, this can also reduce the production workload and the corresponding production time.

[0070] In particular, the cross - sectional shape of the extrudate is a hollow - chamber profile, where at least one region of the cross - sectional shape of the extrudate does not contain the aerosol - forming material. For example, such a region can be regarded as a cavity, void, or hollow chamber. In particular, the region without the aerosol - forming material (i.e., the hollow chamber) extends along the length of the extrudate, especially along the entire length of the extrudate. This extension can form flow channels in the extrudate. If the hollow - chamber profile exhibits multiple hollow chambers, each hollow chamber can form a flow channel in the extrudate, such that the extrudate exhibits multiple flow channels.

[0071] During the use of the aerosol - forming material in an aerosol - generating article, the flow channels within the extrudate are directly related to the airflow characteristics of the aerosol - forming material. The flow channels can be adapted to enhance the release of substances from the aerosol - forming material. The flow channels can be adapted to adjust the "resistance to draw" (RTD) characteristics of the aerosol - forming material. A low resistance to draw can reduce the perceived temperature of the generated aerosol to a level acceptable to the user.

[0072] In addition, by creating at least one flow channel during the extrusion of the extrudate, additional processing steps such as curling can be avoided. This can reduce the complexity of the production line in terms of required machinery and reduce the production time. The negative aspects of curling can be prevented, such as damage to the homogenized tobacco sheet or cast leaf and increased shredding and tearing thereof.

[0073] The hollow chamber profile can exhibit different geometries and contours. The hollow chamber profile can have at least one hollow chamber that is circular, particularly circular or oval. The hollow chamber profile can have more than two hollow chambers. If the hollow chamber profile exhibits multiple hollow chambers, the geometry of each hollow chamber can be the same. If the hollow chamber profile exhibits multiple hollow chambers, the geometry of each hollow chamber can exhibit different contours. The hollow chamber profile can be at least partially in the form of at least one helix. The hollow chamber profile can be at least partially in the form of at least two rings connected by at least one spoke. The hollow chamber profile can be in the form of a wagon wheel. The hollow chamber profile can be any combination of any of the above forms. At least one of the surfaces defining the hollow chamber profile can exhibit corrugations.

[0074] In particular, the extrudate has a length between 2 meters and 10 meters.

[0075] In particular, the method can include the step of inserting a susceptor material into the cross-sectional shape of an extrudate comprising an aerosol-generating material during the extrusion of the extrudate comprising the aerosol-generating material. The susceptor material can be inserted through an outlet, in particular through a die component.

[0076] By combining the step of inserting the susceptor material with the extrusion of the extrudate comprising the aerosol-generating material, separate production steps can be reduced and the associated time and costs can be minimized.

[0077] In particular, the method can include the step of inserting a susceptor material into the cross-sectional shape of an extrudate comprising an aerosol-generating material after the extrusion of the extrudate comprising the aerosol-generating material.

[0078] Combining the insertion of the susceptor material with the extrusion of the extrudate comprising the aerosol-generating material can enable a continuous production process without the individualized steps associated with batch processing.

[0079] In particular, the susceptor material is inserted into the center of the cross-sectional shape of the extrudate. In particular, the susceptor material is inserted into a hollow chamber of the cross-sectional shape of the extrudate. In particular, the susceptor material is inserted into a hollow chamber located in the center of the cross-sectional shape. The susceptor material can fill the corresponding hollow chamber into which it is inserted.

[0080] In particular, the susceptor material is inserted into the extrudate comprising the aerosol-forming material at a pressure (i.e., insertion force) between 2 bar and 6 bar.

[0081] In particular, the susceptor material is rotated during insertion into the cross-sectional shape of the extrudate. The susceptor material can be rotated between 20 revolutions per minute and 150 revolutions per minute.

[0082] Rotation of the susceptor material during insertion into the extrudate can prevent adhesion to the aerosol-forming material, thereby reducing the required insertion force. This rotation of the susceptor can result in a wound susceptor shape. This can improve the thermal distribution in the extrudate when heating the susceptor material. Rotation of the susceptor material can improve the adhesion of the susceptor material to the extrudate, especially at the exit of the extruder. Rotation of the susceptor material can be achieved by a tube or groove adapted to convey material around the susceptor material to allow the susceptor material to rotate.

[0083] In particular, the method can include the step of maintaining the exit of the extruder, especially the die member, at a temperature between 10 degrees Celsius and 50 degrees Celsius, especially between 20 degrees Celsius and 40 degrees Celsius, and most especially between 25 degrees Celsius and 35 degrees Celsius.

[0084] Maintaining the exit temperature within the above range can further stabilize the structural properties of the cross-sectional shape of the extrudate to ensure that the structural properties can be maintained after extrusion, i.e., after leaving the exit. For example, this may be due to a further reduction in the water content of the extrudate.

[0085] In particular, the exit applies vibrations to the extrudate during extrusion. Applying vibrations especially to the die member during extrusion can affect the required forming force and reduce the adhesion of the extrudate to the inner wall of the die member.

[0086] In particular, the method can include drying the extrudate to substantially maintain its cross-sectional shape. The dryer is adapted to provide a drying temperature between 70 degrees Celsius and 110 degrees Celsius, especially between 80 degrees Celsius and 100 degrees Celsius, and most especially between 85 degrees Celsius and 95 degrees Celsius.

[0087] Drying the extrudate can further reduce the water content of the extrudate, thereby stabilizing the structural integrity of its cross-sectional shape. If the cross-sectional shape of the extrudate exhibits a hollow chamber profile, this reduction in water content can prevent the hollow chamber from partially or completely collapsing, thereby maintaining the established flow channels in the extrudate.

[0088] The substantially retained cross-sectional shape is the shape that directly reflects the cross-sectional shape of the extrudate after extrusion, i.e., after leaving the extruder. If the cross-sectional shape of the extrudate is a hollow chamber profile, the substantially retained cross-sectional shape is a cross-sectional shape in which at least one of the hollow chambers does not completely collapse. After leaving the extruder, the hollow chambers may directly exhibit a slight deviation from the profile associated with the hollow chambers.

[0089] In particular, the method may include cutting an extrudate comprising an aerosol-forming material into segments having a length between 3 millimeters and 10 millimeters. In particular, the apparatus may include at least one cutting device adapted to separate the extrudate into individual sections.

[0090] According to a third aspect of the present invention, there is provided a use of an extruder for extruding an extrudate comprising an aerosol-forming material such that the extrudate is provided with a cross-sectional shape.

[0091] According to a fourth aspect of the present invention, there is provided a method for producing an aerosol-forming material comprising a susceptor material, the method comprising the steps of: providing a length of aerosol-forming material having a helical cross-sectional shape, providing the susceptor material to the center of the helical cross-sectional shape of the aerosol-forming material via a susceptor material feed device, rotating the susceptor material via a rotating device, pressing the susceptor material into the center of the cross-sectional shape of the aerosol-forming material, and unwrapping the aerosol-forming material around the susceptor material.

[0092] A length of aerosol-forming material having a helical cross-sectional shape can be provided via extrusion, in particular via extrusion of an extrudate comprising an aerosol-forming material, wherein the cross-sectional shape of the extrudate is a hollow chamber profile similar in shape to a helix. A length of aerosol-forming material having a helical cross-sectional shape can be provided by rolling up a sheet of aerosol-forming material.

[0093] The susceptor material is rotated and pressed into the center of the helical cross-sectional shape of the aerosol-forming material. Due to the rotational movement of the susceptor material, in addition to the forward movement associated with the pressing movement of the susceptor material, the aerosol-forming material unwraps from its helical cross-sectional shape to wrap around the susceptor material. That is, the aerosol-forming material unwraps layer by layer and wraps around the susceptor material.

[0094] In particular, the length of the aerosol-forming material having a helical cross-sectional shape is between 80 millimeters and 150 millimeters.

[0095] In particular, the diameter of the helical cross-sectional shape is between 5 millimeters and 8 millimeters.

[0096] In particular, the susceptor material is pressed into the center of the aerosol - forming material at a pressure between 2 bar and 6 bar.

[0097] In particular, the susceptor material is rotated during its insertion into the cross - sectional shape of the extrudate. In particular, the susceptor material is rotated between 20 revolutions per minute and 150 revolutions per minute.

[0098] Both the rotational speed of the susceptor material and its pressing force can affect how much the aerosol - forming material overlaps with itself during its deployment around the susceptor material. This can ultimately affect the overall thickness of the final product, i.e., the aerosol - forming material containing the susceptor material. In particular, this thickness is between 0.20 mm and 0.75 mm.

[0099] The winding angle of the aerosol - forming material can be between 2 degrees and 15 degrees, especially between 4 degrees and 8 degrees, and in one embodiment is 6 degrees 17 minutes (6°17’). In particular, the winding angle is the angle formed by the aerosol - forming material relative to the circumference of the susceptor material. That is, a winding angle of 0 degrees means the aerosol - forming material unfolds along the defined circumference of the susceptor material. In this case, the aerosol - forming material will wind at the said point of the susceptor without covering that certain length of the susceptor material. The winding angle enables a certain length of the susceptor material to be covered by the aerosol - forming material during winding. The winding angle can affect the thickness or the coverage of the susceptor material by the aerosol - forming material. Such a winding angle can improve the tension of the aerosol - forming material during deployment to prevent its breakage or uneven overlap.

[0100] The device of the first aspect can be operated according to the method of the second aspect or the fourth aspect or used according to the third aspect. The method of the second aspect or the fourth aspect can relate to the device of the first aspect.

[0101] The present invention is defined in the claims. However, a non - exhaustive list of non - limiting examples is provided below. Any one or more features of these examples can be combined with any one or more features of another example, embodiment, or aspect described herein.

[0102] Example Ex1: A device for producing an extrudate comprising an aerosol - forming material, the device comprising

[0103] an extruder,

[0104] wherein the extruder comprises an inlet and an outlet,

[0105] wherein the inlet is adapted to receive a mixture,

[0106] wherein the outlet is adapted to extrude the mixture to form the extrudate,

[0107] wherein the outlet includes a die member,

[0108] wherein the die member is adapted to form an extrudate comprising an aerosol - forming material, and

[0109] wherein the die member is adapted to provide a cross - sectional shape to the extrudate.

[0110] Example Ex2: The apparatus according to Ex1, wherein the die member includes a die plate and a mandrel,

[0111] wherein the die plate exhibits at least one orifice,

[0112] wherein the mandrel exhibits at least one protrusion, and

[0113] wherein the protrusion is at least partially disposed inside the orifice.

[0114] Example Ex3: The apparatus according to Ex2, wherein the die plate and the mandrel are adapted to form the extrudate such that the cross - sectional shape of the extrudate is a hollow - chamber profile.

[0115] Example Ex4: The apparatus according to Ex2 or Ex3, wherein the downstream end surface of the protrusion is at least partially formed in a helical form.

[0116] Example Ex5: The apparatus according to any one of Ex2 to Ex4, wherein the mandrel and the die plate are integrally formed.

[0117] Example Ex6: The apparatus according to any one of Ex2 to Ex4, wherein the mandrel and the die plate are two separate parts adapted to be fixed to each other or relative to each other.

[0118] Example Ex7: The apparatus according to any one of Ex2 to Ex6, wherein the protrusion extends through the orifice to the downstream end surface of the die plate.

[0119] Example Ex8: The apparatus according to any one of Ex2 to Ex7, wherein the downstream end surface of the protrusion is formed in a circular form.

[0120] Example Ex9: The apparatus according to any one of Ex2 to Ex8, wherein the protrusion has corrugations.

[0121] Example Ex10: The apparatus according to any one of Ex1 to Ex9, wherein the extruder includes a screw adapted to move the mixture along the extrusion direction from the inlet of the extruder to the outlet.

[0122] Example Ex11: The apparatus according to any one of Ex1 to Ex10, wherein the extruder includes a screw that exhibits an increasing diameter downstream in the extrusion direction.

[0123] Example Ex12: The apparatus according to any one of Ex1 to Ex11, wherein the outlet comprises a vibrating member.

[0124] Example Ex13: The apparatus according to any one of Ex1 to Ex12, wherein the extruder further comprises a heating zone upstream in the extrusion direction, the heating zone being adapted to heat the mixture to a temperature between 90 degrees Celsius and 190 degrees Celsius, preferably between 140 degrees Celsius and 190 degrees Celsius, and most preferably between 175 degrees Celsius and 185 degrees Celsius.

[0125] Example Ex14: The apparatus according to any one of Ex1 to Ex13, wherein the extruder further comprises a cooling zone downstream in the extrusion direction, the cooling zone being adapted to cool the mixture to a temperature between 30 degrees Celsius and 70 degrees Celsius, preferably between 35 degrees Celsius and 50 degrees Celsius, and most preferably between 25 degrees Celsius and 35 degrees Celsius.

[0126] Example Ex15: The apparatus according to any one of Ex1 to Ex14, wherein the apparatus further comprises a sensor material feeding device,

[0127] wherein the sensor material feeding device is adapted to insert the sensor material into the extrudate.

[0128] Example Ex16: The apparatus according to Ex15, wherein the sensor material feeding device is adapted to insert the sensor material into the extrudate downstream of the die member.

[0129] Example Ex17: The apparatus according to Ex15, wherein the sensor material feeding device is adapted to insert the sensor material into the extrudate during extrusion in the outlet.

[0130] Example Ex18: The apparatus according to any one of Ex1 to Ex17, wherein the apparatus further comprises a rotating device adapted to rotate the sensor material.

[0131] Example Ex19: The apparatus according to any one of Ex1 to Ex18, wherein the apparatus further comprises a dryer adapted to dry the extrudate comprising the aerosol-generating material to substantially maintain its cross-sectional shape.

[0132] Example Ex20: The apparatus according to any one of Ex1 to Ex19, wherein the mixture is a slurry.

[0133] Example Ex21: The apparatus according to any one of Ex1 to Ex20, wherein the extrudate is a tobacco cast leaf.

[0134] Example Ex22: A method for producing an extrudate comprising an aerosol - generating material, the method comprising the steps of:

[0135] Providing a mixture to an extruder via an inlet of the extruder,

[0136] Moving the mixture along an extrusion direction,

[0137] Extruding the mixture from the extruder via an outlet,

[0138] wherein the mixture is extruded through a die member at the outlet of the extruder to form the extrudate comprising the aerosol - generating material having a cross - sectional shape.

[0139] Example Ex23: The method according to Ex22, wherein the density of the mixture increases while the mixture moves along the extrusion direction.

[0140] Example Ex24: The method according to Ex22 or Ex23, wherein the water content of the mixture decreases during movement along the extrusion direction.

[0141] Example Ex25: The method according to any one of Ex22 to Ex24, wherein the extrudate comprising the aerosol - generating material has a circular cross - section with a diameter between 5 millimeters and 10 millimeters.

[0142] Example Ex26: The method according to any one of Ex22 to Ex25, wherein the cross - sectional shape of the extrudate is a hollow - chamber profile.

[0143] Example Ex27: The method according to Ex26, wherein the hollow - chamber profile forms a flow channel in the extrudate.

[0144] Example Ex28: The method according to Ex26 or Ex27, wherein the hollow - chamber profile has at least one hollow chamber that is circular.

[0145] Example Ex29: The method according to Ex26 or Ex27, wherein the hollow - chamber profile is at least partially in the form of at least one helix.

[0146] Example Ex30: The method according to Ex26 or Ex27, wherein the hollow - chamber profile is at least partially in the form of at least two rings connected by at least one spoke.

[0147] Example Ex31: The method according to any one of Ex26 to Ex30, wherein at least one surface of the hollow - chamber profile exhibits corrugations.

[0148] Example Ex32: The method according to any one of Ex22 to Ex31, wherein the extrudate has a length between 2 meters and 10 meters.

[0149] Example Ex33: The method according to any one of Ex22 to Ex32 further comprises the step of inserting a sensor material into the cross-sectional shape of the extrudate comprising the aerosol-generating material during extrusion of the extrudate comprising the aerosol-generating material from the die member.

[0150] Example Ex34: The method according to any one of Ex22 to Ex32 further comprises the step of inserting a sensor material into the cross-sectional shape of the extrudate comprising the aerosol-generating material after extrusion of the extrudate comprising the aerosol-generating material.

[0151] Example Ex35: The method according to any one of Ex22 to Ex34, wherein the die member is maintained at a temperature between 20 degrees Celsius and 40 degrees Celsius.

[0152] Example Ex36: The method according to any one of Ex22 to Ex35, wherein the extrudate is dried at a temperature between 80 degrees Celsius and 100 degrees Celsius.

[0153] Example Ex37: The method according to any one of Ex22 to Ex36 further comprises the step of separating the aerosol-generating material extrudate into segments having a length between 3 millimeters and 10 millimeters.

[0154] Example Ex38: The method according to any one of Ex22 to Ex37, wherein the mixture is a slurry.

[0155] Example Ex39: The method according to any one of Ex22 to Ex38, wherein the extrudate is a tobacco cast leaf.

[0156] Example Ex40: Use of an extruder for extruding an extrudate comprising an aerosol-generating material such that the extrudate is provided with a cross-sectional shape.

[0157] Example Ex41: A method for producing an aerosol-generating material comprising a sensor material, the method comprising the steps of:

[0158] Providing a length of aerosol-generating material having a helical cross-sectional shape,

[0159] Providing the sensor material to the center of the helical cross-sectional shape of the aerosol-generating material via a sensor material feeding device,

[0160] Rotating the sensor material via a rotating device,

[0161] Pressing the sensor material into the center of the cross-sectional shape of the aerosol-generating material, and

[0162] The aerosol - forming material is deployed around the susceptor material.

[0163] Example Ex42: The method according to Ex41, wherein a length of aerosol - forming material having a helical cross - sectional shape is provided by extrusion.

[0164] Example Ex43: The method according to Ex41, wherein a length of aerosol - forming material having a helical cross - sectional shape is provided by rolling up a sheet of aerosol - forming material.

[0165] Example Ex44: The method according to any one of Ex41 to Ex43, wherein the susceptor material is pressed into the center of the aerosol - forming material at a pressure between 2 bar and 6 bar.

[0166] Example Ex45: The method according to any one of Ex41 to Ex44, wherein the susceptor material is rotated between 20 revolutions per minute and 150 revolutions per minute.

[0167] Example Ex46: An aerosol - forming material produced by the method according to any one of Ex22 to Ex39.

[0168] Example Ex47: An aerosol - forming article comprising an aerosol - forming material produced by the method according to any one of Ex22 to Ex39.

[0169] Example Ex48: A system comprising an apparatus according to any one of Ex1 to Ex21 and a mixture for forming an extrudate comprising an aerosol - forming material. BRIEF DESCRIPTION OF THE DRAWINGS

[0170] Embodiments of the invention will now be further described with reference to the accompanying drawings, in which:

[0171] Figure 1 A cross - sectional view of an extruder is shown;

[0172] Figure 2 A perspective view of a die component is shown;

[0173] Figure 3 A cross - sectional view of an extrudate is shown, wherein the extrudate exhibits a hollow - chamber profile having a plurality of circular hollow chambers;

[0174] Figure 4 A cross - sectional view of an extrudate is shown, wherein the extrudate exhibits a hollow - chamber profile having a plurality of rings and connecting spokes;

[0175] Figure 5 A cross - sectional view of an extrudate is shown, wherein the extrudate exhibits a hollow - chamber profile similar to a wagon wheel, wherein the spokes of the wagon wheel exhibit corrugations;

[0176] Figure 6 A cross-sectional view of an extrudate is shown, wherein the extrudate exhibits a hollow chamber having a shape similar to a helix;

[0177] Figure 7 A cross-sectional view of an extrudate is shown, wherein the extrudate exhibits a hollow chamber profile having a shape similar to a double helix;

[0178] Figure 8 A perspective view of an extrudate exiting the outlet of an extruder is shown, wherein the extrudate exhibits a hollow chamber profile having a shape similar to a helix;

[0179] Figure 9 A cross-sectional view of an extruder is shown, wherein sensing material is inserted into the extrudate during the extrusion of the extrudate;

[0180] Figure 10 A cross-sectional view of an extruder is shown, wherein sensing material is inserted into the extrudate after the extrusion of the extrudate;

[0181] Figure 11 A cross-sectional view of an extruder having a dryer and a cutting device is shown;

[0182] Figure 12 A perspective view of a method for deploying aerosol-generating material around sensing material is shown. Detailed Description

[0183] As Figure 1 depicted in, the extruder 1 exhibits an inlet 2 that is adapted to receive a mixture 3 provided from a hopper 4. The inlet 2 is in fluid communication with an outlet 5 of the extruder 1 so that the mixture 3 can be conveyed from the inlet 2 to the outlet 5 along an extrusion direction 100. The extrusion direction 100 is also indicated by an arrow in Figure 1 . The extruder 1 further includes a screw 7 located within a barrel 8 of the extruder 1. Rotation of the screw 7 facilitates movement of the mixture 3 towards the outlet 5. The outlet 5 of the extruder 1 is adapted to extrude the mixture 3 to form an extrudate 9 having a cross-sectional shape via the implementation of a die member 10.

[0184] As Figure 2 further shown in, the die member 10 includes a die plate 11 having an orifice 12 and a mandrel 13 having a protrusion 14. The die plate 11 and the mandrel 13 are arranged and adapted to each other such that the extrudate 9 is provided with a cross-sectional shape of a circular hollow chamber profile 15. Additionally, the geometric profile of the orifice 12 is adapted to accommodate the geometric profile of the protrusion 14 such that when assembled in the outlet 5, the protrusion 14 is disposed within the orifice 12 and the downstream end surface 16 of the protrusion 14 is flush with the downstream end surface 17 of the die plate 11.

[0185] In addition to the cooling unit 21 adapted to cool the die member 10, the outlet 5 also exhibits a vibration member 18 for applying vibration to the die member 10 during the extrusion of the extrudate 9.

[0186] The extruder 1 also includes a heating zone 19 and a cooling zone 20.

[0187] As Figures 3 to 7 illustrated, the hollow chamber profile 15 of the extrudate 9 can exhibit great variations in its geometric design. For example, the hollow chamber profile 15 can exhibit a plurality of hollow chambers 22 surrounded by an aerosol-forming material 23, such as Figure 3 shown, or can exhibit a plurality of concentric rings 25 connected by a plurality of spokes 26, both the spokes and the concentric rings including the aerosol-forming material 23, as Figure 4 shown. As shown respectively in Figure 5 , 6 and 7, the hollow chamber profile 15 can also have the form of a wagon wheel with spokes 26 exhibiting a corrugated surface 24, shaped in a spiral shape, or even in a double helix shape. Figure 8 A perspective view of the extrudate 9 is provided, in which the helical hollow chamber profile 15 is extruded from the outlet 5.

[0188] Figure 9 and 10 depict an apparatus for producing an extrudate 9 comprising an aerosol-forming material 23, the apparatus including a susceptor material feeding device 27 adapted to insert a susceptor material 28 into the extrudate 9. According to Figure 9 the embodiment shown, the susceptor material 28 is fed through the screw 7 of the extruder 1 along the extrusion direction 100 such that the susceptor material 28 can be inserted into the extrudate 9 during extrusion at the outlet 5. In Figure 10 another embodiment shown, the susceptor material 28 is guided from the susceptor material feeding device 27 to the extrudate 9 such that the susceptor material 28 is inserted into the extrudate 9 after the extrudate is extruded from the outlet 5. In both embodiments, the susceptor material 28 is guided to the extrudate 9 with the aid of specifically placed guide rollers 29.

[0189] Figure 9 The apparatus shown in

[0190] Figure 11 also includes a rotating device 30 adapted to rotate the susceptor material 28.

[0190] Figure 11 depict an apparatus for producing an extrudate 9 comprising an aerosol-forming material 23, the apparatus including a dryer 31 adapted to dry the extrudate 9, followed by a cutting device 32 adapted to separate the extrudate 9 into individual segments 33.

[0191] Figure 12The perspective view shows that the susceptor material 28 is fed from the susceptor material feeding device 27 into the center 34 of the aerosol - generating material 23. Since the susceptor material 28 is rotated by the rotating device 30 and pressed into the center 34 of the aerosol - generating material 23, the aerosol - generating material 23 is forced to expand and wrap around the susceptor material 28, thereby forming the aerosol - generating material 23 containing the susceptor material 28.

[0192] As Figure 1 depicted in, the mixture 3 is provided to the inlet 2 of the extruder 1 via the hopper 4, where the mixture 3 then continues into the barrel 8 of the extruder 1. Due to the rotation of the screw 7, the mixture 3 is subsequently conveyed along the extrusion direction 100 of the extruder 1 until it reaches the outlet 5 of the extruder 1. During the conveyance of the mixture 3 along the extrusion direction 100, the mixture 3 is passed through the heating zone 19 and the subsequent cooling zone 20, in which the mixture 3 is heated and cooled respectively.

[0193] At the outlet 5 of the extruder 1, the mixture 3 is extruded through the die member 10 to form an extrudate 9 including the aerosol - generating material 23 having a cross - sectional shape.

[0194] Figure 2 The mandrel 13 and the die plate 11 elements of the die member 10 shown in guide the flow of the mixture 3 during extrusion such that the resulting cross - sectional shape of the extrudate 9 is circular and exhibits a hollow - chamber profile. Examples of such cross - sectional shapes are shown in Figures 3 to 8

[0195] The susceptor material 28 can be inserted into the cross - sectional shape of the extrudate 9. As Figure 9 shown in, this can be achieved by providing the susceptor material 28 to the extruder 1 via the susceptor material feeding device 27. Then, the susceptor material 28 enters the opening inside the extruder 1 and extends along the channel inside the screw 7 until it reaches the die member 10 at the outlet 5 of the extruder 1, where the susceptor material 28 is subsequently inserted into the cross - sectional shape of the extrudate 9 during the extrusion of the extrudate. During the insertion of the susceptor material 28 into the cross - sectional shape of the extrudate 9, the susceptor material 28 is rotated via the rotating device 30.

[0196] Alternatively, as Figure 10 depicted in, the susceptor material 28 can also be inserted into the cross - sectional shape of the extrudate 9 after the extrusion of the extrudate.

[0197] As Figure 1 shown in, during the extrusion of the extrudate 9, the die member 10 is maintained at a temperature between 10 degrees Celsius and 50 degrees Celsius via the cooling unit 21 and is also vibrated via the vibration member 18.​

[0198] After being extruded from the extruder 1, the extrudate 9 is dried by a dryer 31 to substantially maintain its cross-sectional shape before being cut into segments 33 by a cutting device 32. Figure 11 The process steps are depicted therein.

[0199] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing quantities, amounts, percentages, etc. should be understood to be modified in all instances by the term "about". Additionally, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therebetween, whether or not specifically enumerated herein. Thus, in this context, the number A is understood to be A ± 10% A. In this context, the number A can be considered to include values within the normal standard error for the measurement of the property modified by the number A. In certain cases used in the appended claims, the number A may deviate from the percentage listed above, provided that the amount by which A deviates does not substantially affect the basic and novel characteristics of the claimed invention. Additionally, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therebetween, whether or not specifically enumerated herein.

Claims

1. An apparatus for producing an extrudate comprising an aerosol - forming material, the apparatus comprising an extruder, wherein the extruder comprises an inlet and an outlet, wherein the inlet is adapted to receive a mixture, wherein the outlet is adapted to extrude the mixture to form the extrudate, wherein the outlet comprises a die member, wherein the die member is adapted to form an extrudate comprising an aerosol - forming material, and wherein the die member is adapted to provide a cross - sectional shape to the extrudate.

2. The apparatus according to claim 1, wherein the die member comprises a die plate and a mandrel, wherein the die plate exhibits at least one orifice, wherein the mandrel exhibits at least one protrusion, and wherein the protrusion is at least partially disposed inside the orifice.

3. The apparatus according to claim 2, wherein the die plate and the mandrel are adapted to form the extrudate such that the cross - sectional shape of the extrudate is a hollow - chamber profile.

4. The apparatus according to claim 2 or 3, wherein the downstream end surface of the protrusion is at least partially shaped in a helical form.

5. The apparatus according to any one of claims 1 to 4, wherein the apparatus further comprises a rotating device adapted to rotate a susceptor material.

6. The apparatus according to any one of claims 1 to 5, wherein the apparatus further comprises a dryer adapted to dry the extrudate comprising the aerosol - forming material so as to substantially maintain its cross - sectional shape.

7. A method for producing an extrudate comprising an aerosol - forming material, the method comprising the steps of: providing a mixture to the extruder via an inlet of the extruder, moving the mixture along an extrusion direction, extruding the mixture from the extruder via an outlet, wherein the mixture is extruded through a die member of the outlet of the extruder to form the extrudate comprising the aerosol - forming material having a cross - sectional shape.

8. The method according to claim 7, wherein the cross - sectional shape of the extrudate is a hollow - chamber profile.

9. The method according to claim 8, wherein the hollow - chamber profile is at least partially in the form of at least one helix.

10. The method according to any one of claims 7 to 9, further comprising the step of inserting a susceptor material into the cross - sectional shape of the extrudate comprising the aerosol - forming material during extrusion of the extrudate comprising the aerosol - forming material from the die member.

11. The method according to any one of claims 7 to 9, further comprising the step of inserting a susceptor material into the cross - sectional shape of the extrudate comprising the aerosol - forming material after extrusion of the extrudate comprising the aerosol - forming material.

12. Use of an extruder for extruding an extrudate comprising an aerosol - forming material such that the extrudate is provided with a cross - sectional shape.

13. An aerosol - forming material produced according to the method as claimed in any one of claims 8 to 12.

14. An aerosol - generating article comprising an aerosol - forming material produced according to any one of claims 8 to 12.

15. A system, the system comprising the apparatus according to any one of claims 1 to 6 and a mixture for forming an extrudate comprising an aerosol-forming material.

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