Apparatus and method for weakening aerosol-generating substrate sheet for aerosol-generating article component

Abstract

An apparatus for weakening an aerosol-generating substrate sheet for an aerosol-generating article component comprises: a first roller (12) comprising a plurality of first circumferential ridges (15) defining a respective plurality of first circumferential grooves (16) on a first radially outer face; a second roller (13) comprising a plurality of second circumferential ridges (23) defining a respective plurality of second circumferential grooves (24) on a second radially outer face. Each first circumferential ridge (15) comprises a plurality of release recesses (17) circumferentially spaced apart from each other along the first circumferential ridge (15) and a plurality of protrusions (18) defined between the release recesses (17). At the coupling area of the first roller (12) and the second roller (13), the projections (18) of the first circumferential ridges (15) are inserted into the second circumferential grooves (24). In cross section, each first circumferential ridge (15) and each second circumferential ridge (23) have a rectangular profile, and the rectangular profile has a sharp cutting edge (21, 27) configured to create a cut-out (8) in the aerosol-generating substrate sheet (2) passing between the first roller (12) and the second roller (13).

Description

Technical Field

[0001] The present disclosure relates to an apparatus and method for weakening an aerosol-generating substrate sheet for use in components of an aerosol-generating article. Background Art

[0002] Aerosol-generating articles or heat-not-burn cigarettes in which an aerosol-generating substrate is heated rather than burned are known in the art. The aerosol-generating substrate is, for example, a tobacco-free herbal or plant-based cast sheet or a plastic fiber-based material or a biodegradable fiber-based material. Typically, in such heated aerosol-generating articles, an aerosol is generated by transferring heat from a heat source to a physically separated aerosol-generating substrate or material, which can be positioned in contact with, inside, around, or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are entrained in the air drawn through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol.

[0003] In a typical manufacturing process for an aerosol-generating article, an aerosol-generating substrate in sheet or foil form undergoes a rolling process. The rolled material is then gathered into strips, which are then cut into several parts. These cut strips are components of the aerosol-generating article.

[0004] The crimping process typically uses two rotating cylindrical rollers between which a sheet of material is squeezed. These rollers have a pattern of matching textured ridges and grooves on their outer surfaces, which crimp the sheet by stretching the fibers of the matrix laterally.

[0005] The curling process facilitates folding and gathering the aerosol-generating substrate sheet into a strip to be incorporated into an aerosol-generating article. In practice, the term "curled sheet" refers to a sheet having a plurality of substantially parallel ridges or corrugations that are substantially parallel to the cylindrical axis of the strip. This facilitates folding and gathering the curled sheet of aerosol-generating substrate to form a strip.

[0006] The curling process also affects, among other things, air contact, resistance to draw (RTD), etc., and is therefore directly felt by the user of the aerosol-generating article.

[0007] For example, document EP3041375B1 discloses a method and apparatus for producing a variable curl web material, wherein the web material is curled using a set of two rollers, each roller forming a corrugation across at least a portion of its width and around its circumference, the rollers being configured such that the corrugations across the width of the rollers are staggered to curl the web material, and such that the troughs of the corrugations around the circumference curl the web material at a first curl value, and the peaks of the corrugations around the circumference curl the web material at a second curl value.

[0008] Document EP3542648A1 discloses an apparatus for producing strands of web material, comprising a separating device configured to separate a flat web of reconstituted tobacco material into a plurality of strips. The apparatus comprises a first roller and a second roller, wherein the lateral surfaces of the rollers alternately have circumferential grooves and protrusions in the axial direction that are closed in the circumferential direction. The protrusions of the first roller engage in the grooves of the second roller, and the protrusions of the second roller engage in the grooves of the first roller. The flat web is not cut along the separating line by the interaction of the two blades, but is torn in a defined manner by overstretching.

[0009] Document EP3469922A1 discloses a machine for manufacturing rod-shaped smoking articles, comprising: an unwinding device for unwinding a web of material for the tobacco industry, a first cutting device configured to receive and cut the web to produce a plurality of longitudinal strips, and a gathering and conveying device configured to gather and convey the longitudinal strips to produce a continuous flow.

[0010] It would be desirable to have an apparatus and method for weakening an aerosol-generating substrate sheet for use in components of an aerosol-generating article that provides an alternative to having a curling effect, ie shaping the sheet to facilitate folding and gathering the aerosol-generating substrate sheet to form a strip. Summary of the Invention

[0011] The present disclosure relates to a device for weakening an aerosol-generating substrate sheet used as a component of an aerosol-generating article. The device may include a first roller having a first rotational axis. The first roller may include a plurality of first circumferential ridges disposed on a first radially outer surface of the first roller, the first circumferential ridges defining a corresponding plurality of first circumferential grooves on the first radially outer surface. The device may include a second roller having a second rotational axis. The second roller may include a plurality of second circumferential ridges disposed on a second radially outer surface of the second roller, the second circumferential ridges defining a corresponding plurality of second circumferential grooves on the second radially outer surface. Each first circumferential ridge may include a plurality of relief recesses circumferentially spaced from one another along the first circumferential ridge. A plurality of projections may be defined between the relief recesses. At a coupling region between the first and second rollers, the projections of the first circumferential ridges may be inserted into the second circumferential grooves. In a cross-section including the first rotational axis, each first circumferential ridge may have a rectangular profile. In a cross-section including the second rotational axis, each second circumferential ridge may have a rectangular profile. The rectangular profile of the first and second circumferential ridges may have sharp edges configured to create cuts in the aerosol-generating substrate sheet passing between the first roller and the second roller, the cuts creating weakened fold lines to facilitate folding and gathering the aerosol-generating substrate sheet to form a strip.

[0012] The inventors have discovered that the scissor-like cutting of the present invention is an alternative to crimping, particularly at high speeds, as it avoids the aerosol-generating substrate sheet being stretched transversely into the crimping rollers and prevents or at least reduces the fragmentation effect and dust generation. Indeed, compressing the sheet is a key issue in traditional crimping. While crimping pressures that are too low may reduce the positive effects of crimping, too high pressures may damage the material sheet or reduce its tensile strength, which in turn may increase the incidence of tearing and may even cause fragmentation.

[0013] The present inventors have found that cutting rather than crimping avoids stretching the fibers of the sheet and prevents or at least reduces dust generation and accumulation due to defibration.

[0014] The inventors have discovered that the device according to the present invention allows for an increase in the speed of the aerosol-generating substrate sheet to be weakened and in the productivity of the entire production process, since the speed of the sheet according to the method of the present invention is no longer limited by the crimping pressure applied to the sheet. In fact, in conventional crimping methods, in order to increase the speed and reduce the crimping time, greater pressure must be applied to the sheet to ensure proper crimping, which increases the risk of damage to the sheet (including accidental breakage) during the crimping process.

[0015] The inventors have found that the sharp edges of the first and second circumferential ridges enable a defined and precise cut to be produced.

[0016] The inventors have found that first and second circumferential ridges having a rectangular profile with sharp cutting edges are strong, durable, easy to manufacture and easy to maintain (the cutting edges can be regularly sharpened) and are capable of producing the desired cuts.

[0017] The device for weakening may also be suitable for weakening sheets of material other than an aerosol-generating substrate employed in the manufacture of aerosol-generating articles (eg, filters or other components used in the manufacture of aerosol-generating articles).

[0018] Each of the sharp edges may have an angle (α) of 90 degrees. Each of the sharp edges may have a radius (r1) equal to or less than 0.05 mm. Each of the sharp edges may have a radius (r1) equal to or greater than 0.03 mm. The inventors have found that these values ​​of the radius of the sharp edges are capable of producing defined and precise cuts in the aerosol-generating substrate sheet.

[0019] The minimum radial distance (dmin) between the bottom portion of the relief recess of the first roller and the top portion of the second circumferential ridge of the second roller may be equal to or greater than 0.5 mm. The minimum radial distance (dmin) between the bottom portion of the relief recess of the first roller and the top portion of the second circumferential ridge of the second roller may be equal to or less than 2 mm. The ratio (dmin / Rmax) of the minimum radial distance (dmin) between the bottom portion of the relief recess of the first roller and the top portion of the second circumferential ridge of the second roller to the maximum radius (Rmax) of the protrusion may be equal to or greater than 0.005. The ratio (dmin / Rmax) of the minimum radial distance (dmin) between the bottom portion of the relief recess of the first roller and the top portion of the second circumferential ridge of the second roller to the maximum radius (Rmax) of the protrusion may be equal to or less than 0.03. The maximum radius (Rmax) may be between 40 mm and 300 mm, optionally between 90 mm and 120 mm. The ratio (dmin / t) of the minimum radial distance (dmin) between the bottom portion of the relief recess of the first roller and the top portion of the second circumferential ridge of the second roller to the thickness (t) of the aerosol-generating matrix sheet may be equal to or greater than 1.5. The ratio (dmin / t) of the minimum radial distance (dmin) between the bottom portion of the relief recess of the first roller and the top portion of the second circumferential ridge of the second roller to the thickness (t) of the aerosol-generating matrix sheet may be equal to or less than 3.5. At the connection area between the first roller and the second roller, the protrusion of the first circumferential ridge may be spaced apart from the bottom of the second circumferential groove. The inventors have found that the minimum radial distance (dmin) and the distance of the protrusion of the first circumferential ridge from the bottom of the second circumferential groove ensure that the aerosol-generating matrix sheet is not compressed and damaged, but is only cut (scissor-cut) at the sharp edges of the rollers.

[0020] The minimum axial distance (daxial) between the first circumferential ridge of the first roller and the adjacent second circumferential ridge of the second roller may be between 0.02 mm and 0.06 mm. The minimum axial distance (daxial) between the first circumferential ridge of the first roller and the adjacent second circumferential ridge of the second roller may be between 0.03 mm and 0.04 mm. The ratio (daxial / Rmax) of the minimum axial distance (daxial) between the first circumferential ridge of the first roller and the adjacent second circumferential ridge of the second roller to the maximum radius (Rmax) of the protrusion may be between 0.0002 and 0.0005. The ratio (daxial / t) of the minimum axial distance (daxial) between the first circumferential ridge of the first roller and the adjacent second circumferential ridge of the second roller to the thickness (t) of the aerosol-generating substrate sheet may be between 0.2 and 0.3. The thickness (t) of the aerosol-generating substrate sheet may be between 0.15 mm and 0.35 mm. The width (w) of the aerosol-generating substrate sheet may be between 80 mm and 180 mm. The inventors have found that these values ​​of the minimum axial distance (daxial) prevent compression of the sheet and stretching of the fibers.

[0021] The spacing (a) of the release recess can be between 0.2mm and 20mm, optionally between 5.0mm and 20.0mm, optionally between 6mm and 16mm. The axial width (b) of each first circumferential ridge can be between 1mm and 15mm, optionally between 2mm and 4mm. The axial width (f) of each first circumferential groove can be between 1mm and 15mm, optionally between 2mm and 4mm. The axial distance (g) between the center lines of adjacent first circumferential ridges can be between 2mm and 6mm. The circumferential amplitude (c) of the protrusion (that is, the distance between the two ends of the protrusion along the circumference) can be between 0.1 and 8mm, optionally between 4 and 8mm, optionally between 2 and 4mm, optionally between 0.1 and 2.0mm. The circumferential extent (e) of the recess (i.e., the distance between the two ends of the recess along the circumference) may be between 0.1 and 8 mm, optionally between 2 and 6 mm, optionally between 2 and 4 mm, optionally between 0.1 and 2.0 mm. The inventors have found that these values ​​of spacing (a), width (b), and extent (c) enable the production of cuts having characteristics that allow for correct and easy folding of the aerosol-generating substrate sheet.

[0022] Each relief recess may be defined by a concave surface. The concave surface may be arched. The radius (r3) of the concave surface may be between 5 mm and 15 mm. The inventors have found that a first circumferential ridge provided with relief recesses having the disclosed shape is easy to manufacture, for example by milling.

[0023] Each concave surface and the two corresponding adjacent protrusions may define two auxiliary edges parallel to the first axis of rotation. Each of the auxiliary edges may be rounded. The inventors have found that rounded auxiliary edges prevent cutting and damaging the sheet along a line transverse to the cut (i.e., where the sheet contacts the auxiliary edges).

[0024] According to an embodiment of the present disclosure, the release recess of one first circumferential ridge can be circumferentially offset relative to the release recess of another first circumferential ridge to generate an offset cut. The release recess of one first circumferential ridge can be circumferentially offset relative to the release recess of two first circumferential ridges adjacent to the first circumferential ridge. By moving in one direction along the first rotation axis, the release recess of each first circumferential ridge can always be circumferentially offset relative to the previous first circumferential ridge in the same direction (clockwise or counterclockwise). The offset distance (Od) between the release recesses of two adjacent first circumferential ridges is between 0 mm and 20 mm. The offset distance (Od) can be between 20% and 40% of the circumferential amplitude (c) of the protrusion. The angular offset (β) between the release recesses of two adjacent first circumferential ridges can be between 0 degrees and 30 degrees. The offset of the release recesses generates offset cuts in the aerosol generating substrate sheet and improves the uniformity of the cut distribution.

[0025] According to an embodiment of the present disclosure, the release recess of the first circumferential ridge can be aligned back and forth along a direction parallel to the first rotation axis to generate a group of incisions aligned in a direction transverse to the feed direction of the aerosol generating matrix sheet. The top portion of each second circumferential ridge can be continuous and does not have a release recess. The inventors have found that if only the first roller is provided with a release recess, the phase coordination between the first roller and the second roller is not required. In fact, the angular position of the first roller relative to the second roller around its corresponding first rotation axis and the second rotation axis does not need to be set when the weakening method starts, and does not need to be adjusted (phase recalibration) during the operation of the device. This will make the manufacture of the roller assembly easier and faster to set.

[0026] The first roller may have a first axial length (L1) measured parallel to the first rotation axis (XX) and between two first circumferential ridges disposed at opposite ends of the first roller. The first axial length (L1) may be between 80% and 90% of the width (w) of the aerosol-generating substrate sheet. The second roller may have a second axial length (L2) measured parallel to the second rotation axis (YY) and between two second circumferential ridges disposed at opposite ends of the second roller. The second axial length (L2) may be between 80% and 90% of the width (w) of the aerosol-generating substrate sheet.

[0027] According to an embodiment of the present disclosure, the first roller may include a plurality of first discs and a plurality of second discs. The first discs and the second discs may be stacked and arranged in an alternating manner. The first discs may include a first circumferential ridge. The second discs may define the bottom of a first circumferential groove. The second roller may include a plurality of third discs and a plurality of fourth discs. The third discs and the fourth discs may be stacked and arranged in an alternating manner. The third disc may include a second circumferential ridge. The fourth disc may define the bottom of a second circumferential groove. The inventors have found that this structure is simple and inexpensive to manufacture.

[0028] The cut may be a through cut. A cut passes completely through the thickness of the aerosol-generating substrate sheet, thereby creating a weakened section in the sheet.

[0029] The aerosol-generating substrate sheet can be an herbaceous or plant-based cast sheet. The aerosol-generating substrate sheet can contain fibers, plant and / or alkaloid particles, a binder, and an aerosol-forming agent. The plant and / or alkaloid particles can contain tobacco and / or nicotine and / or plant-derived materials and / or cellulose powder. The aerosol-generating substrate sheet can be a tobacco-free or tobacco-containing substrate. The aerosol-generating substrate sheet can be a fiber-based material. The fiber-based material can be a plastic fiber-based material or a biodegradable fiber-based material. The biodegradable fiber-based material can be cotton. The biodegradable fiber-based material can be cellulose. The aerosol-generating substrate sheet can have a thickness between 0.15 and 0.35. The aerosol-generating substrate sheet can contain alkaloids. The aerosol-generating substrate sheet can contain nicotine.

[0030] The present disclosure also relates to a method for weakening an aerosol-generating substrate sheet for use as a component of an aerosol-generating article. The method may include creating an incision in the aerosol-generating substrate sheet. The incision in the sheet may be created by passing the aerosol-generating substrate sheet between a first roller and a second roller of an apparatus for weakening an aerosol-generating substrate sheet for use as a component of an aerosol-generating article, while the first and second rollers rotate in opposite directions. The incision creates a weakened fold line to facilitate folding and gathering the aerosol-generating substrate sheet to form a strip. The apparatus may include a first roller having a first axis of rotation. The first roller may include a plurality of first circumferential ridges disposed on a first radially outer surface of the first roller, the first circumferential ridges defining a corresponding plurality of first circumferential grooves on the first radially outer surface. The apparatus may include a second roller having a second axis of rotation. The second roller may include a plurality of second circumferential ridges disposed on a second radially outer surface of the second roller, the second circumferential ridges defining a corresponding plurality of second circumferential grooves on the second radially outer surface. Each first circumferential ridge may include a plurality of relief recesses circumferentially spaced from one another along the first circumferential ridge. A plurality of projections may be defined between the relief recesses. At the junction of the first and second rollers, the protrusions of the first circumferential ridges may be inserted into the second circumferential grooves. In a cross-section including the first axis of rotation, each first circumferential ridge may have a rectangular profile. In a cross-section including the second axis of rotation, each second circumferential ridge may have a rectangular profile. The rectangular profiles of the first and second circumferential ridges may include sharp edges configured to create an incision in the aerosol-generating substrate sheet passing between the first and second rollers, the incision creating a weakened fold line to facilitate folding and gathering the aerosol-generating substrate sheet to form a strip.

[0031] The inventors discovered that the method according to the present invention does not require roller position adjustment. In fact, in conventional crimping methods, because the pressure applied between the rollers tends to move them away from each other, the distance between the ridges and grooves of the two rollers must be adjusted at predetermined intervals by bringing the rollers closer together. In the arrangement according to the present invention, the distance can be standardized, and there is no need to adjust the distance between the rollers to compensate for the variability in the elongation of the matrix fibers.

[0032] The incision may be a through incision.

[0033] The aerosol-generating matrix sheet may comprise fibers, plant and / or alkaloid particles, a binder, and an aerosol-forming agent. The plant and / or alkaloid particles may comprise tobacco and / or nicotine and / or plant-derived materials and / or cellulose powder. The aerosol-generating matrix sheet may be an herbaceous or plant-based cast sheet. The aerosol-generating matrix sheet may be a tobacco-free or tobacco-containing matrix. The aerosol-generating matrix sheet may be a fiber-based material. The fiber-based material may be a plastic fiber-based material or a biodegradable fiber-based material. The biodegradable fiber-based material may be cotton. The biodegradable fiber-based material may be cellulose. The aerosol-generating matrix sheet may have a thickness between 0.15 and 0.35. The aerosol-generating matrix sheet may contain alkaloids. The aerosol-generating matrix sheet may contain nicotine.

[0034] The aerosol-generating substrate sheet can be moved between the first and second rollers at a linear speed between 60 m / s and 500 m / s. The first roller can rotate at a peripheral speed between 60 m / s and 500 m / s. The second roller can rotate at a peripheral speed between 60 m / s and 500 m / s. The inventors have discovered that the present invention allows the speed of the sheet between the rollers to be increased to the disclosed values, thereby improving the productivity of the overall production process.

[0035] The present disclosure also relates to an aerosol-generating substrate sheet for use as a component of an aerosol-generating article. The sheet can be obtained by a method for manufacturing a component of an aerosol-generating article. The method comprises: creating a cut in the aerosol-generating substrate sheet by passing the aerosol-generating substrate sheet between first and second rollers of a device for weakening an aerosol-generating substrate sheet for use as a component of an aerosol-generating article, while the first and second rollers rotate in opposite directions, the cut creating a weakened fold line to facilitate folding and gathering the aerosol-generating substrate sheet to form a strip.

[0036] The cuts in the sheet may be longitudinal cuts parallel to the feed direction of the aerosol-generating substrate sheet.Each cut may be a straight line or a zigzag line or a wavy line.

[0037] Each incision may have a length (c') between 0.1 and 8 mm, for example, between 4 and 8 mm, for example, between 2 and 4 mm, for example, between 0.1 and 2.0 mm. The longitudinal distance (e') between consecutive aligned incisions may be between 0.1 and 8 mm, for example, between 2 and 6 mm, for example, between 2 and 4 mm, for example, between 0.1 and 2.0 mm. The transverse distance (b') between side-by-side incisions may be between 1 mm and 15 mm, for example, between 2 mm and 4 mm. The spacing (a') between consecutive aligned incisions may be between 0.2 mm and 20 mm, optionally between 5.0 mm and 20.0 mm, for example, between 6 mm and 16 mm. The offset longitudinal distance (O'd) between adjacent incisions may be between 0 mm and 20 mm. The offset longitudinal distance (O'd) may be between 20% and 40% of the length (c') of the incision.

[0038] In some embodiments, the incisions are arranged in pairs, and each pair includes two parallel incisions. The lateral distance (b') between the two parallel incisions can be between 2 and 4 mm. The axial distance (g') between the midlines of adjacent paired incisions can be between 2 and 6 mm. The lateral distance (f') between adjacent paired incisions can be between 2 and 4 mm. The offset longitudinal distance (O'd) between adjacent paired incisions can be between 0 and 20 mm. The offset longitudinal distance (O'd) can be between 20% and 40% of the length (c') of the incision. If each incision is a zigzag line or a wavy line, the lateral dimension (h') of the incision can be between 0.5 and 1.5 mm.

[0039] The present disclosure also relates to a process for manufacturing an aerosol-generating article component. The process may include manufacturing an aerosol-generating substrate sheet. The process may include weakening the aerosol-generating substrate sheet using a method for weakening the aerosol-generating substrate sheet for an aerosol-generating article component. The process may include aggregating the aerosol-generating substrate sheet to form a continuous strip. The process may include cutting the continuous strip into a plurality of aerosol-generating article components, each having a strip shape. Each aerosol-generating article component may include an agglomerated weakened sheet formed from cut portions of the weakened aerosol-generating substrate sheet. The method for weakening the aerosol-generating substrate sheet for an aerosol-generating article component may include creating a cut in the aerosol-generating substrate sheet. The cut in the sheet may be created by passing the aerosol-generating substrate sheet between a first roller and a second roller of an apparatus for weakening the aerosol-generating substrate sheet for an aerosol-generating article component, while the first and second rollers rotate in opposite directions. The cuts create weakened fold lines to facilitate folding and gathering of the aerosol-generating substrate sheet to form a strip.

[0040] The inventors have found that discontinuous and longitudinal cuts in a sheet of aerosol-generating substrate produced by the apparatus of the present invention during the manufacturing process allow for the creation of weakened fold lines that facilitate folding and gathering the aerosol-generating substrate sheet to form strips.

[0041] According to an embodiment of the present disclosure, manufacturing an aerosol-generating substrate sheet may include: preparing a slurry from a powder and a binder; and casting the slurry onto a surface to produce the aerosol-generating substrate sheet.

[0042] The present disclosure also relates to an aerosol-generating article comprising at least one aerosol-generating article component produced according to a process for manufacturing an aerosol-generating article component. The process may include a method for weakening an aerosol-generating substrate sheet for an aerosol-generating article component. The method for weakening an aerosol-generating substrate sheet for an aerosol-generating article component may include creating an incision in the aerosol-generating substrate sheet. The incision in the sheet may be created by passing the aerosol-generating substrate sheet between first and second rollers of an apparatus for weakening an aerosol-generating substrate sheet for an aerosol-generating article component, while the first and second rollers rotate in opposite directions. The incision creates a weakened fold line to facilitate folding and gathering the aerosol-generating substrate sheet to form a strip.

[0043] The aerosol-generating article may be a heat-not-burn cigarette.The aerosol-generating article may comprise an aerosol-generating article component and a filter having a mouthend end.

[0044] The present disclosure also relates to an apparatus for manufacturing a component for an aerosol-generating article, comprising a device for weakening an aerosol-generating substrate sheet for use in the component. The apparatus may include a first roller having a first axis of rotation. The first roller may include a plurality of first circumferential ridges disposed on a first radially outer surface of the first roller, the first circumferential ridges defining a corresponding plurality of first circumferential grooves on the first radially outer surface. The apparatus may include a second roller having a second axis of rotation. The second roller may include a plurality of second circumferential ridges disposed on a second radially outer surface of the second roller, the second circumferential ridges defining a corresponding plurality of second circumferential grooves on the second radially outer surface. Each first circumferential ridge may include a plurality of relief recesses circumferentially spaced from one another along the first circumferential ridge. A plurality of projections may be defined between the relief recesses. At a junction between the first and second rollers, the projections of the first circumferential ridges may be inserted into the second circumferential grooves. In a cross-section including the first axis of rotation, each first circumferential ridge may have a rectangular profile. In a cross-section including the second axis of rotation, each second circumferential ridge may have a rectangular profile. The rectangular profiles of the first and second circumferential ridges may have sharp edges configured to create cuts in the aerosol-generating substrate sheet passing between the first and second rollers. The cuts create weakened fold lines to facilitate folding and gathering the aerosol-generating substrate sheet to form a strip.

[0045] The apparatus may comprise an upper laminating roller and a lower laminating roller, the upper laminating roller and the lower laminating roller being positioned upstream or downstream of the device for weakening the aerosol-generating matrix sheet. The upper laminating roller and the lower laminating roller may also be positioned upstream and downstream of the device for weakening the aerosol-generating matrix sheet.

[0046] The upper and lower laminating rollers may be configured to maintain a constant thickness of the aerosol-generating substrate sheet. The aerosol-generating substrate sheet may be calendered before, during or after the weakening / cutting step to ensure that the thickness of the sheet remains uniform after this process and before the steps of gathering and folding into consumable products.

[0047] The apparatus may include a reel holder for carrying the aerosol-generating matrix sheet. A device for weakening the aerosol-generating matrix sheet for the aerosol-generating article component is placed downstream of the reel holder. The apparatus may include a folding device, which is placed downstream of the device for weakening the aerosol-generating matrix sheet and is configured to move the sheet from a flat configuration (upstream of the folding device) to a gathered strip configuration (downstream of the folding device). The folding device may also be configured to wrap packaging around the gathered sheet. The folding device may be shaped like a conical funnel.

[0048] As used in this specification, the connection area of ​​the first roller and the second roller is the portion where the first roller and the second roller engage with each other, wherein the first circumferential ridge of the first roller is inserted into the second circumferential groove of the second roller, and the second circumferential ridge of the second roller is inserted into the first circumferential groove of the first roller.

[0049] As used herein, a "weakened" sheet material means that the sheet material retains its integrity after being weakened, such that it can be gathered by folding along a longitudinal fold line and does not break into pieces and / or strips. In other words, the cuts made in the sheet material do not cut the sheet material into pieces and / or strips, and once gathered in an aerosol-generating article component, the weakened sheet material is a folded sheet material and does not break into pieces and / or strips.

[0050] As used herein, the top portion of the first circumferential ridge and the top portion of the second circumferential ridge are the radially outermost surfaces of the circumferential ridges, ie the surfaces of the circumferential ridges furthest from the respective first or second axis of rotation.

[0051] As used herein, the bottom portion of the relief recess of the first circumferential ridge is the radially innermost surface of the first circumferential ridge, ie, the surface of the relief recess closest to the first rotation axis.

[0052] As used herein, the bottom of the first circumferential groove and the bottom of the second circumferential groove are the radially innermost surfaces of the circumferential groove, ie, the surfaces of the circumferential groove closest to the respective first or second rotation axis.

[0053] As used in this specification, a rectangular profile of the cross-section of the first and second circumferential ridges means that the cross-section has parallel sides and a top portion defining two right angles with the parallel sides.

[0054] As used in this specification, the axial distance is the distance measured parallel to the first and second rotational axes.

[0055] As used in this specification, a radial distance is a distance measured perpendicular to the first and second rotational axes.

[0056] As used in this specification, the term circumferential direction refers to a circumference centered on the first rotation axis or the second rotation axis.

[0057] As used in this specification, the sharpness of an edge is determined by the edge radius of the edge at its apex.

[0058] As used in this specification, circumferential amplitude means the distance between two points along the circumference of a circle.

[0059] 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 may be combined with any one or more features of another example, embodiment or aspect described herein.

[0060] EX1. An apparatus for weakening an aerosol-generating substrate sheet for use as a component of an aerosol-generating article, the apparatus comprising: a first roller having a first rotational axis and comprising a plurality of first circumferential ridges disposed on a first radially outer face of the first roller, the first circumferential ridges defining a corresponding plurality of first circumferential grooves on the first radially outer face; a second roller having a second rotational axis and comprising a plurality of second circumferential ridges disposed on a second radially outer face of the second roller, the second circumferential ridges defining a corresponding plurality of second circumferential grooves on the second radially outer face; wherein each first circumferential ridge comprises a plurality of release recesses circumferentially spaced apart from one another along the first circumferential ridge, a plurality of projections defined between the release recesses; wherein at the connection area between the first roller and the second roller, the projection of the first circumferential ridge is inserted into the second circumferential groove; wherein in a cross section including the first rotation axis, each first circumferential ridge has a rectangular profile; wherein in a cross section including the second rotation axis, each second circumferential ridge has a rectangular profile; wherein the rectangular profiles of the first circumferential ridge and the second circumferential ridge have sharp edges, the sharp edges being configured to generate an incision in the aerosol generating matrix sheet passing between the first roller and the second roller, the incision producing a weakened fold line to facilitate folding and gathering the aerosol generating matrix sheet to form a strip.

[0061] EX2. A method for weakening an aerosol-generating substrate sheet for use as a component of an aerosol-generating article, the method comprising: creating a cut in the aerosol-generating substrate sheet by passing the aerosol-generating substrate sheet between a first roller and a second roller of an apparatus according to EX1 while the first roller and the second roller rotate in opposite directions, the cut creating a weakened fold line to facilitate folding and gathering the aerosol-generating substrate sheet to form a strip.

[0062] EX3. A process for manufacturing a component of an aerosol-generating article, the process comprising the steps of:

[0063] - Manufacturing aerosol-generating substrate sheets;

[0064] - Weakened aerosol-generating substrate sheet by the EX2 method;

[0065] - gathering the aerosol-generating substrate sheet to form a continuous strip;

[0066] - cutting the continuous strip into a plurality of aerosol-generating article components each having the shape of a strip, each aerosol-generating article component comprising a gathered weakened sheet formed from cut portions of a weakened aerosol-generating substrate sheet.

[0067] EX4. An aerosol-generating article comprising at least one aerosol-generating article component manufactured according to the process of EX3.

[0068] EX5. An apparatus for manufacturing a component of an aerosol-generating article, comprising the apparatus of EX1.

[0069] EX6. The device of EX1, wherein each of the sharp edges has an angle (α) of 90 degrees.

[0070] EX7. The apparatus of EX1 or EX6, wherein each of the sharp edges has a radius (r1) equal to or less than 0.05 mm.

[0071] EX8. The apparatus of EX7, wherein the radius (r1) of each of the sharp edges is equal to or greater than 0.03 mm.

[0072] EX9. An apparatus according to any one of EX1 or EX6 to EX8, wherein a minimum radial distance (dmin) between a bottom portion of the release recess of the first roller and a top portion of the second circumferential ridge of the second roller is equal to or greater than 0.5 mm.

[0073] EX10. The device of EX9, wherein the minimum radial distance (dmin) is equal to or less than 2 mm.

[0074] EX11. An apparatus according to any one of EX1 or EX6 to EX10, wherein the ratio (dmin / Rmax) of the minimum radial distance (dmin) between the bottom portion of the release recess of the first roller and the top portion of the second circumferential ridge of the second roller to the maximum radius (Rmax) of the protrusion is equal to or greater than 0.005.

[0075] EX12. The apparatus of EX11, wherein a ratio (dmin / Rmax) of the minimum radial distance (dmin) to the maximum radius (Rmax) is equal to or less than 0.03.

[0076] EX13. The device according to any one of EX1 or EX6 to EX11, wherein the maximum radius (Rmax) is between 40 mm and 300 mm, optionally between 90 mm and 120 mm.

[0077] EX14. An apparatus according to any one of EX1 or EX6 to EX13, wherein the ratio (dmin / t) of the minimum radial distance (dmin) between the bottom portion of the release recess of the first roller and the top portion of the second circumferential ridge of the second roller to the thickness (t) of the aerosol-generating substrate sheet is equal to or greater than 1.5.

[0078] EX15. The apparatus of EX14, wherein a ratio (dmin / t) of the minimum radial distance (dmin) to the thickness (t) is equal to or less than 3.5.

[0079] EX16. The apparatus according to any one of EX1 or EX6 to EX15, wherein at a coupling region of the first roller and the second roller, the protrusion of the first circumferential ridge is spaced apart from the bottom of the second circumferential groove.

[0080] EX17. Apparatus according to any one of EX1 or EX6 to EX16, wherein a minimum axial distance (daxial) between a first circumferential ridge of the first roller and an adjacent second circumferential ridge of the second roller is between 0.02 mm and 0.06 mm. ...

[0081] EX18. The device of EX17, wherein the minimum axial distance (daxial) is between 0.03 mm and 0.04 mm.

[0082] EX19. An apparatus according to any one of EX1 or EX6 to EX18, wherein the ratio (daxial / Rmax) of the minimum axial distance (daxial) between the first circumferential ridge of the first roller and the adjacent second circumferential ridge of the second roller to the maximum radius (Rmax) of the protrusion is between 0.0002 and 0.0005.

[0083] EX20. An apparatus according to any one of EX1 or EX6 to EX19, wherein the ratio (daxial / t) of the minimum axial distance (daxial) between the first circumferential ridge of the first roller and the adjacent second circumferential ridge of the second roller to the thickness (t) of the aerosol-generating substrate sheet is between 0.2 and 0.3.

[0084] EX21. An apparatus according to any one of EX1 or EX6 to EX20, wherein the thickness (t) of the aerosol-generating substrate sheet is between 0.15 mm and 0.35 mm.

[0085] EX22. An apparatus according to any one of EX1 or EX6 to EX21, wherein the width (w) of the aerosol-generating substrate sheet is between 80 mm and 180 mm.

[0086] EX23. A device according to any one of EX1 or EX6 to EX22, wherein the spacing (a) of the relief recesses is between 0.2 mm and 20 mm, optionally between 5.0 mm and 20.0 mm, optionally between 6 mm and 16 mm.

[0087] EX24. A device according to any one of EX1 or EX6 to EX23, wherein the axial width (b) of each first circumferential ridge is between 1 mm and 15 mm, optionally between 2 mm and 4 mm; and / or wherein the axial width (f) of each first circumferential groove is between 1 mm and 15 mm, optionally between 2 mm and 4 mm; and / or wherein the axial distance (g) between the center lines of adjacent first circumferential ridges is between 2 mm and 6 mm.

[0088] EX25. A device according to any one of EX1 or EX6 to EX24, wherein the circumferential amplitude (c) of the protrusion (i.e., the distance between the two ends of the protrusion along the circumference) is between 0.1 and 8 mm, optionally between 4 and 8 mm, optionally between 2 and 4 mm, optionally between 0.1 and 2.0 mm; and / or wherein the circumferential amplitude (e) of the recess (i.e., the distance between the two ends of the recess along the circumference) is between 0.1 and 8 mm, optionally between 2 and 6 mm, optionally between 2 and 4 mm, optionally between 0.1 and 2.0 mm.

[0089] EX26. A device according to any one of EX1 or EX6 to EX25, wherein each relief recess is defined by a concave surface.

[0090] EX27. An apparatus according to EX26, wherein the concave surface is arcuate.

[0091] EX28. An apparatus according to EX27, wherein the radius (r3) of the concave surface is between 5 mm and 15 mm.

[0092] EX29. The device according to any one of EX1 or EX6 to EX28, wherein each concave surface and two corresponding adjacent protrusions define two auxiliary edges parallel to the first rotation axis, wherein each of the auxiliary edges is rounded.

[0093] EX30. The device of any one of EX1 or EX6 to EX29, wherein the relief recess of one first circumferential ridge is circumferentially offset relative to the relief recess of the other first circumferential ridge to create an offset notch.

[0094] EX31. The device of EX30, wherein the relief recess of one of the first circumferential ridges is circumferentially offset relative to the relief recesses of two first circumferential ridges adjacent to the one first circumferential ridge.

[0095] EX32. An apparatus according to EX31, wherein, moving in one direction along the first rotation axis, the release recess of each first circumferential ridge is always circumferentially offset in the same direction (clockwise or counterclockwise) relative to the previous first circumferential ridge.

[0096] EX33. A device according to any one of EX30 to EX32, wherein the offset distance (Od) between the release recesses of two adjacent first circumferential ridges is between 0 mm and 20 mm; and / or wherein the offset distance (Od) is between 20% and 40% of the circumferential amplitude (c) of the protrusion.

[0097] EX34. The device according to any one of EX1 or EX6 to EX33, wherein an angular offset (β) between the relief recesses of two adjacent first circumferential ridges is between 0 degrees and 30 degrees.

[0098] EX35. A device according to any one of EX1 or EX6 to EX29, wherein the release recesses of the first circumferential ridge are reciprocally aligned along a direction parallel to the first rotation axis to generate groups of cuts aligned along a direction transverse to the feed direction of the aerosol-generating matrix sheet.

[0099] EX36. The device according to any one of EX1 or EX6 to EX35, wherein the top portion of each second circumferential ridge is continuous and free of a relief recess.

[0100] EX37. An apparatus according to any one of EX1 or EX6 to EX36, wherein the first roller has a first axial length (L1) parallel to the first rotation axis (XX) and measured between the two first circumferential ridges arranged at opposite ends of the first roller, wherein the first axial length (L1) is between 80% and 90% of the width (w) of the aerosol-generating substrate sheet.

[0101] EX38. An apparatus according to any one of EX1 or EX6 to EX37, wherein the second roller has a second axial length (L2) parallel to the second rotation axis (YY) and measured between the two second circumferential ridges arranged at opposite ends of the second roller, wherein the second axial length (L2) is between 80% and 90% of the width (w) of the aerosol-generating substrate sheet.

[0102] EX39. An apparatus according to any one of EX1 or EX6 to EX38, wherein the first roller comprises a plurality of first discs and a plurality of second discs; the first discs and the second discs are stacked and arranged in an alternating manner; the first disc comprises the first circumferential ridge; and the second disc defines the bottom of the first circumferential groove.

[0103] EX40. An apparatus according to any one of EX1 or EX6 to EX39, wherein the second roller comprises a plurality of third discs and a plurality of fourth discs; the third discs and the fourth discs are stacked and arranged in an alternating manner; the third disc comprises the second circumferential ridge; and the fourth disc defines the bottom of the second circumferential groove.

[0104] EX41. An apparatus according to EX5, comprising an upper laminating roller and a lower laminating roller, wherein the upper laminating roller and the lower laminating roller are placed upstream or downstream of the device for weakening the aerosol-generating matrix sheet; optionally, the upper laminating roller and the lower laminating roller are placed upstream and downstream of the device for weakening the aerosol-generating matrix sheet.

[0105] EX42. The device according to any one of EX1 or EX6 to EX40 or the method according to EX2, wherein the incision is a through-incision.

[0106] The cuts are made completely through the thickness of the aerosol-generating substrate sheet, thereby creating a weakened section in the sheet.

[0107] EX43. An apparatus according to any one of EX1 or EX6 to EX40, or a method according to EX2 or EX42, wherein the aerosol-generating substrate sheet may comprise fibers, plant and / or alkaloid particles, a binder, and an aerosol-forming agent; optionally the aerosol-generating substrate sheet is a herbal or plant-based cast sheet; optionally the plant and / or alkaloid particles comprise tobacco and / or nicotine and / or plant-derived material and / or cellulose powder.

[0108] EX44. The device of EX43, wherein the aerosol-generating substrate sheet is a tobacco-free or tobacco-containing substrate.

[0109] EX45. An apparatus according to any one of EX1 or EX6 to EX40 or a method according to any one of EX2 or EX42 to EX44, wherein the aerosol-generating substrate sheet is a fiber-based material.

[0110] EX46. An apparatus or method according to EX45, wherein the fiber-based material is a plastic fiber-based material or a biodegradable fiber-based material.

[0111] EX47. The device of EX46, wherein the biodegradable fiber-based material is cotton.

[0112] EX48. The apparatus according to any one of EX1 or EX6 to EX40 or the method according to any one of EX2 or EX42 to EX47, wherein the biodegradable fiber-based material is cellulose.

[0113] EX49. An apparatus according to any one of EX1 or EX6 to EX40 or a method according to any one of EX2 or EX42 to EX48, wherein the aerosol-generating substrate sheet has a thickness of between 0.15 and 0.35.

[0114] EX50. An apparatus according to any one of EX1 or EX6 to EX40 or a method according to any one of EX2 or EX42 to EX49, wherein the aerosol-generating substrate sheet contains an alkaloid.

[0115] EX51. The device according to any one of EX1 or EX6 to EX40, or the method according to any one of EX2 or EX42 to EX50, wherein the aerosol-generating substrate sheet contains nicotine.

[0116] EX52. A process according to EX3, wherein manufacturing the aerosol-generating substrate sheet comprises: preparing a slurry from a powder and a binder; and casting the slurry onto a surface to produce the aerosol-generating substrate sheet.

[0117] EX53. A method according to EX2, wherein the aerosol-generating substrate sheet moves between the first roller and the second roller at a linear speed of between 60 m / s and 500 m / s.

[0118] EX54. The method of EX2, wherein the first roller rotates at a peripheral speed between 60 m / s and 500 m / s.

[0119] EX55. The method of EX2, wherein the second roller rotates at a peripheral speed between 60 m / s and 500 m / s.

[0120] EX56. An article according to EX4, wherein the aerosol-generating article is a heat-not-burn cigarette.

[0121] EX57. An article according to EX4 or EX56, wherein the aerosol-generating article comprises the aerosol-generating article component and a filter having a mouthend.

[0122] EX58. An aerosol-generating substrate sheet for use as a component of an aerosol-generating article obtained by the method of any one of EX2 or EX42 to EX51 or EX53 to EX55, wherein the cut is a longitudinal cut parallel to the feed direction of the aerosol-generating substrate sheet; wherein optionally, each cut is a straight line or a zigzag line or a wavy line.

[0123] EX59. The sheet according to EX58, wherein each cut has a length (c') of between 0.1 and 8 mm, optionally between 4 and 8 mm, optionally between 2 and 4 mm, optionally between 0.1 and 2.0 mm.

[0124] EX60. A sheet according to EX58 or EX59, wherein the longitudinal distance (e') between consecutive aligned cuts is between 0.1 and 8 mm, optionally between 2 and 6 mm, optionally between 2 and 4 mm, optionally between 0.1 and 2.0 mm.

[0125] EX61. The sheet according to any one of EX58 to EX60, wherein the transverse distance (b') between side-by-side cuts is between 1 mm and 15 mm, optionally between 2 mm and 4 mm. EX62.

[0126] EX62. The sheet according to any one of EX58 to EX61, wherein the spacing (a') of consecutive aligned cuts is between 0.2 mm and 20 mm, optionally between 5.0 mm and 20.0 mm, optionally between 6 mm and 16 mm. EX63.

[0127] EX63. A sheet according to any one of EX58 to EX62, wherein the offset longitudinal distance (O'd) between adjacent cuts is between 0 mm and 20 mm; and / or wherein the offset longitudinal distance (O'd) is between 20% and 40% of the length (c') of the cuts.

[0128] EX64. The sheet according to any one of EX58 to EX63, wherein the cuts are arranged in pairs, each pair comprising two parallel cuts.

[0129] EX65. The sheet according to EX64, wherein the transverse distance (b') between the two parallel cuts is between 2 and 4 mm.

[0130] EX66. The sheet according to EX64 or EX65, wherein the axial distance (g') between the midlines of adjacent pairs of cuts is between 2 mm and 6 mm.

[0131] EX67. The sheet according to any one of EX64 to EX66, wherein the transverse distance (f') between adjacent pairs of cuts is between 2 mm and 4 mm. EX68.

[0132] EX68. A sheet according to any one of EX64 to EX67, wherein the offset longitudinal distance (O'd) between adjacent pairs of cuts is between 0 mm and 20 mm; and / or wherein the offset longitudinal distance (O'd) is between 20% and 40% of the length (c') of the cuts.

[0133] EX69. The sheet according to any one of EX64 to EX67, wherein if each cut is a zigzag line or a wavy line, the transverse dimension (h') of the cut is between 0.5 mm and 1.5 mm. BRIEF DESCRIPTION OF THE DRAWINGS

[0134] Several examples will now be further described with reference to the accompanying drawings, in which:

[0135] Figure 1 shows a schematic side view of a portion of an apparatus for manufacturing a component of an aerosol-generating article, the apparatus comprising a device according to the present invention for weakening an aerosol-generating substrate sheet for use in a component of an aerosol-generating article;

[0136] Figure 2 Shown Figure 1 Top view of a portion of;

[0137] Figure 3 Shown by Figure 1 and Figure 2 a longitudinal section of a component of an aerosol-generating article manufactured using a device;

[0138] Figure 4 Shown Figure 3 a cross-section of a component of an aerosol-generating article;

[0139] Figure 5 yes Figure 1 and Figure 2 A front view of the components of the device;

[0140] Figure 6 yes Figure 5 A side view of an element;

[0141] Figure 7 yes Figure 5 Another side view of the element;

[0142] Figure 8 Shown Figure 6 a detail of one of the elements of

[0143] Figure 9 shows an aerosol-generating substrate sheet treated by the apparatus of the preceding figures and according to the method for weakening an aerosol-generating substrate sheet;

[0144] Figure 10 Shown Figure 5 An element in an element;

[0145] Figure 11 Shown Figure 5 Another element in the element;

[0146] Figure 12 Shown Figure 11 A variant embodiment of the element;

[0147] Figure 13 yes Figure 11 an enlarged portion of a component; and

[0148] Figure 14 Shown Figure 13 Details;

[0149] Figure 15 and 16 Other sheets of aerosol-generating substrate treated by the device and by the method according to the invention are shown. DETAILED DESCRIPTION

[0150] exist Figure 1 and Figure 2 The apparatus 1 shown in FIG is configured for weakening an aerosol-generating substrate sheet 2 for an aerosol-generating article component 3. The apparatus 1 is part of an apparatus for manufacturing an aerosol-generating article component 3 and the apparatus is Figure 1 and Figure 2 Partially expressed.

[0151] Aerosol-generating articles typically comprise an aerosol-generating article component 3 comprising an aerosol-generating substrate and a filter having a mouthend end.

[0152] In an aerosol-generating article, an aerosol is generated by transferring heat from a heat source to a physically separate aerosol-generating substrate, which can be positioned in contact with, within, around, or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are entrained in air drawn through the aerosol-generating article.

[0153] The aerosol-generating article component 3 is formed by manufacturing an aerosol-generating substrate sheet 2, weakening the aerosol-generating substrate sheet 2 as will be further explained, gathering the aerosol-generating substrate sheet 2 to form a continuous strip, and cutting the continuous strip into a plurality of aerosol-generating article components 3, each having a strip shape. The weakening process facilitates folding and gathering the aerosol-generating substrate sheet 2 into strips to be incorporated into the aerosol-generating article. Thus, the aerosol-generating article component 3 comprises a gathered, weakened sheet formed from cut portions of the weakened aerosol-generating substrate sheet 2.

[0154] The aerosol generating matrix sheet 2 can be prepared by preparing a slurry with powder and binding agent and possible other ingredients, and by casting this slurry onto a surface (e.g., a moving metal belt) to produce an aerosol generating matrix sheet 2. The aerosol generating matrix sheet 2 can comprise fiber, plant and / or alkaloid particles, binding agent, and an aerosol forming agent. The plant and / or alkaloid particles can comprise tobacco and / or nicotine and / or material from a plant and / or cellulose powder. The aerosol generating matrix sheet 2 can be a tobacco-containing matrix or an herb or plant-based casting sheet (e.g., tobacco-free), or a plastic fiber-based material or a biodegradable fiber-based material (e.g., cotton or cellulose). The aerosol generating matrix sheet 2 can contain alkaloids such as nicotine.

[0155] For example, one example of an aerosol-generating substrate comprises tobacco, glycerol, cellulose fibers, carboxymethyl cellulose (CMC), and graphite. Another example comprises plant-derived material, cellulose powder, cellulose fibers, carboxymethyl cellulose (CMC), and glycerol.

[0156] The apparatus for manufacturing an aerosol-generating article component 3 comprises a reel holder 4 carrying an aerosol-generating substrate sheet 2 for use in the aerosol-generating article component. The previously manufactured aerosol-generating substrate sheet 2 is wound into a reel 5 mounted on the reel holder 4. The aerosol-generating substrate sheet 2 unwound from the reel 5 is fed along a feed path in a feed direction "F".

[0157] Downstream of the reel holder 4 relative to the feed direction "F," the apparatus includes an upper laminating roller 6 and a lower laminating roller 7. The upper laminating roller 6 and the lower laminating roller 7 rotate about two parallel axes. The peripheral surfaces of the upper laminating roller 6 and the lower laminating roller 7 are positioned adjacent to each other to define a gap. The aerosol-generating substrate sheet 2 unwound from the reel 5 passes through the gap, with the upper laminating roller 6 and the lower laminating roller 7 being configured to compact the sheet 2 to reduce its thickness and smooth the surface of the sheet 2 to ensure that its thickness remains uniform during and after the following steps. The upper laminating roller 6 and the lower laminating roller 7 perform the laminating step.

[0158] The aerosol-generating substrate sheet 2 may have an average thickness "t" of between 0.15 mm and 0.35 mm upstream of the upper and lower lamination rollers 6, 7. As a result of the lamination step, the average thickness "t" of the sheet 2 may be reduced to about 0.18 mm to 0.26 mm.

[0159] Downstream of the upper laminating roller 6 and the lower laminating roller 7 with respect to the feed direction "F", the apparatus comprises a device 1 for weakening the aerosol-generating substrate sheet 2. The device 1 is configured for producing a plurality of longitudinal through-cuts 8 in the aerosol-generating substrate sheet 2 so as to define longitudinal fold lines for folding and gathering the aerosol-generating substrate sheet 2 to form strips 9 ( Figure 1 and Figure 2 The characteristics of the through cuts 8 will be discussed later in this specification. The strip 9 may be wrapped in a wrapper 10 and cut into a plurality of aerosol-generating article components 3 ( Figure 3 and Figure 4 ).

[0160] Figure 1 and Figure 2 Schematically shown is a folding device 11, which is placed downstream of the device 1 for attenuating the aerosol-generating substrate sheet 2 and is configured to move the sheet 2 from a flat configuration (upstream of the folding device 11) to a gathered strip configuration (downstream of the folding device 11) and to wrap the package around the gathered sheet 2. The folding device 11 may be shaped like a conical funnel.

[0161] The apparatus 1 for weakening an aerosol-generating substrate sheet 2 comprises a first roller 12 configured to rotate about a first axis of rotation "XX" and a second roller 13 configured to rotate about a second axis of rotation "YY". The first roller 12 and the second roller 13 are mounted on a frame 14 (at Figure 1 ), so that they are allowed to rotate about the respective first rotation axis "XX" and second rotation axis "YY", and are operably connected to a motor not shown, which is configured to rotate the first roller and the second roller about the first rotation axis "XX" and the second rotation axis "YY".

[0162] As in Figure 1 and Figure 2 As depicted by the dashed lines in , the upper laminating roller 6 and the lower laminating roller 7 may be placed just upstream and / or downstream of the first roller 12 and the second roller 13 of the device 1 and may be mounted on the same frame 14 .

[0163] The first roller 12 includes a plurality of first circumferential ridges 15 disposed on a first radially outer face of the first roller 12 and defining a corresponding plurality of first circumferential grooves 16 ( Figure 5 、 Figure 11 、 Figure 12 、 Figure 13 ).

[0164] The radially outer surface of the first roller 12 has a cylindrical shape, and each of the first circumferential ridges 15 is shaped like a ring that surrounds the radially outer surface and radially protrudes from the radially outer surface. Each first circumferential groove 16 is annular and is defined between two first circumferential ridges 15. The first rotation axis "XX" passes through the center of each first circumferential ridge 15 and each first circumferential groove 16.

[0165] Each first circumferential ridge 15 includes a plurality of relief recesses 17 circumferentially spaced from one another along the first circumferential ridge and a plurality of protrusions 18 defined between the relief recesses 17. Figure 6 and Figure 7 As best shown in FIG, each relief recess 17 is separated from another relief recess 17 by a protrusion 18. The top portion 19 of each protrusion 18 defines a portion of the radially outermost surface of the first roller 12 and is shaped like a circumferential arch having a maximum radius "Rmax" and centered on the first rotation axis "XX." Each relief recess 17 is defined by an arched concave surface having a radius "r3." For example, the arched concave surface is semicircular.

[0166] The plurality of projections 18 and relief recesses 17 of each first circumferential ridge 15 are arranged around the first rotation axis "XX" according to a spacing "a", which is the circumferential distance between two consecutive relief recesses 17 or two consecutive projections 18. Each projection 18 has a circumferential amplitude "c", and each relief recess 17 has a circumferential amplitude "e". Each first circumferential ridge 15 has an axial width "b", and each first circumferential groove 16 has an axial width "f" ( Figure 11 ).

[0167] In a section including the first axis of rotation "XX" (see Figure 13 and Figure 14 ), each first circumferential ridge 15 has a rectangular profile. The cross-section of each first circumferential ridge 15 is defined by the aforementioned top portion 19 and by two opposing side faces 20. The side faces 20 protrude from the corresponding first circumferential groove 16, and the top portion 20 connects the distal ends of the side faces 20. The side faces 20 are parallel to each other. Each side face 20 and the top portion 19 define a 90-degree angle "α" and define a sharp edge 21. The sharpness of the sharp edge 21 is determined by the edge radius "r1" of the sharp edge 21 at its apex.

[0168] As in Figure 6 、 Figure 7 and Figure 8 As better shown in FIG, the arched concave surface and the two corresponding adjacent protrusions 18 define two auxiliary edges 22 parallel to the first axis of rotation "XX". Unlike the sharp edges 21, each auxiliary edge 22 is rounded or blunt. The bluntness of the auxiliary edge 22 is determined by the edge radius "r2" of the auxiliary edge 22 at its vertex.

[0169] The second roller 13 comprises a plurality of second circumferential ridges 23 provided on a second radially outer face of the second roller 13 and defining a corresponding plurality of second circumferential grooves 24 ( Figure 5 、 Figure 10 、 Figure 13 ).

[0170] The radially outer surface of the second roller 13 has a cylindrical shape, and each of the second circumferential ridges 23 is shaped like a ring that surrounds the radially outer surface and radially protrudes from the radially outer surface. Each second circumferential groove 24 is annular and is defined between two second circumferential ridges 23. The second rotation axis "YY" passes through the center of each second circumferential ridge 23 and each second circumferential groove 24.

[0171] Unlike the first circumferential ridges 15 of the first roller 12, the top portion 25 of each second circumferential ridge 23 of the second roller 13 is continuous and has no relief recesses. Figure 5 、 Figure 6 、 Figure 7 and Figure 10 As better shown in FIG, the top portion 25 of each second circumferential ridge 23 defines a portion of the radially outermost surface of the second roller 12 and is shaped like a circle centered on the second axis of rotation "YY". The maximum radius of the top portion 25 of the second circumferential ridge 23 can be equal to the maximum radius "Rmax" of the top portion 19 of the protrusion 18 cited above.

[0172] In the cross section including the second rotation axis "YY" (see Figure 10 、 Figure 13 and Figure 14 ), each second circumferential ridge 23 has a rectangular profile. The cross-section of each second circumferential ridge 23 is defined by the aforementioned top portion 25 and by two opposing side faces 26. Side faces 26 protrude from the corresponding second circumferential groove 24, and the top portion 25 connects the distal ends of side faces 26. Side faces 26 are parallel to each other. Each side face 26 and top portion 25 define a 90-degree angle "α" and define a sharp edge 27. The sharpness of the sharp edge 27 is determined by the edge radius "r1" of the sharp edge 27 at its apex.

[0173] As in Figure 5 and Figure 13 As better shown in FIG, the first rotation axis "XX" and the second rotation axis "YY" are parallel to each other, and the first roller 12 and the second roller 13 are engaged with each other at the coupling zone (i.e., the protrusion 18 of the first circumferential ridge 15 of the first roller 12 is inserted into the second circumferential groove 24 of the second roller 13, and the second circumferential ridge 23 of the second roller 13 is inserted into the first circumferential groove 16 of the first roller 12). The coupling zone is a zone located across or at a plane containing both the first rotation axis "XX" and the second rotation axis "YY".

[0174] As in Figure 613, the relative position and dimensions of the first roller 12 and the second roller 13 are such that when the protrusion 18 of one of the first circumferential ridges 15 is located at the coupling zone, the protrusion 18 is partially positioned in the corresponding second circumferential groove 24. In this position, the top portion 19 of the protrusion 18 and the top portion 25 of the second circumferential ridge 23 are separated by a maximum radial distance "dmax" ( Figure 6 and Figure 13 Furthermore, said protrusion 18 of the first circumferential ridge 15 is axially spaced apart from two adjacent second circumferential ridges 23 of the second roller 13 by a minimum axial distance “daxial” (ie the first circumferential ridge 15 and the second circumferential ridge 23 do not hit each other).

[0175] The relative positions and dimensions of the first roller 12 and the second roller 13 are such that when the relief recess 17 of one of the first circumferential ridges 15 is located at the coupling zone, the relief recess 17 is radially spaced from the corresponding second circumferential groove 24 and the first circumferential ridge 15 is radially spaced from the corresponding second circumferential groove 24. Figure 7 In this position, the bottom portion of the relief recess 17 of the first roller 12 and the top portion 25 of the second circumferential ridge 23 of the second roller 13 are separated by a minimum radial distance "dmin" ( Figure 7 and Figure 13 ).

[0176] The relative positions and dimensions of the first roller 12 and the second roller 13 are such that at the coupling region of the first roller 12 and the second roller 13, the protrusion of the first circumferential ridge 15 is spaced apart from the bottom of the second circumferential groove 24 by another radial distance "d" ( Figure 13 ).

[0177] In the non-limiting example of the figures, the relief recess 17 of one first circumferential ridge 15 is circumferentially offset relative to the relief recesses 17 of two first circumferential ridges 15 adjacent to the one first circumferential ridge 15. Figure 5 、 Figure 11 or Figure 12 The relief recess 17 of each first circumferential ridge 15 is always circumferentially offset in the same direction (clockwise or counterclockwise) relative to the previous first circumferential ridge 15 by an offset distance "Od" ( Figure 7 ).

[0178] exist Figure 12In a variant embodiment, the relief recesses 17 and protrusions 18 of the first circumferential ridge 15 are all axially aligned (ie, the offset distance "Od" and the angular offset "β" are zero).

[0179] The first roller 12 has a first axial length "L1" ("X") parallel to the first axis of rotation "XX" and measured between two first circumferential ridges 15 provided at opposite ends of the first roller 12. Figure 11 The second roller 13 has a second axial length "L2" parallel to the second rotation axis "YY" and measured between two second circumferential grooves 24 provided at opposite ends of the second roller 13 ( Figure 11 ).

[0180] The first axial length "L1" and the second axial length "L2" can be designed based on the width "w" of the aerosol-generating substrate sheet 2. The first axial length "L1" and the second axial length "L2" can be smaller than the width "w" to avoid cutting the longitudinal edges of the sheet 2. For example, the first axial length "L1" is equal to the second axial length "L2" and is equal to 80%-90% of the width "w" of the sheet 2.

[0181] The first roller 12 can be manufactured by producing and then assembling a plurality of first discs and a plurality of second discs, wherein the first discs and the second discs are stacked and arranged in an alternating manner. The first discs include a first circumferential ridge 15 and the second discs define the bottom of a first circumferential groove 16.

[0182] The second roller 13 can be manufactured by producing and then assembling a plurality of third discs and a plurality of fourth discs, wherein the third discs and the fourth discs are stacked and arranged in an alternating manner. The third disc includes a second circumferential ridge, and the fourth disc defines the bottom of the second circumferential groove.

[0183] Other manufacturing processes may be employed. For example, the first roller 12 and the second roller 13 may each be manufactured by machining from a respective solid body.

[0184] The aerosol-generating substrate sheet 2 is weakened by passing it between the first roller 12 and the second roller 13 while the first roller 12 and the second roller 13 rotate in opposite directions.

[0185] Only when the protrusion 18 of the first circumferential ridge 15 is located at the coupling region do the sharp edges 21 of the protrusion 18 of the first circumferential ridge 15 and the sharp edges 27 of the second circumferential ridge 23 create a through cut 8 in the aerosol-generating substrate sheet 2. The rounded secondary edges 22 do not cut the sheet 2 along a line transverse to the cut (i.e. where the sheet 2 contacts the secondary edges 22).

[0186] When the relief recess 17 of the first circumferential ridge 15 is located at the coupling area, the sharp edges 21 of the protrusion 18 of the first circumferential ridge 15 and the sharp edges 27 of the second circumferential ridge 23 do not cut the sheet 2 .

[0187] exist Figure 9 It is shown in Figure 5 The first roller 12 and the second roller 13 produce an offset through-cut 8 .

[0188] Figure 12 A variant embodiment of allows for the creation of groups of cuts 8 aligned in a direction transverse to the feed direction “F” of the aerosol-generating substrate sheet 2 .

[0189] In all embodiments, the through cuts 8 act as weakened sections or fold lines of the aerosol-generating substrate sheet 2 , which facilitate bending of the sheet 2 at said sections or lines, performed by the folding device 11 in the subsequent folding and gathering steps.

[0190] All dimensions provided above allow for the creation of the through cuts 8 without compressing and damaging the sheet 2 , and may be designed according to the thickness “t” and / or width “w” of the aerosol-generating substrate sheet 2 .

[0191] Furthermore, the first roller 12 and the second roller 13 may rotate at a peripheral speed of between 60 m / s and 500 m / s so as to move the aerosol-generating substrate sheet 2 between the first roller 12 and the second roller 13 at a linear speed of between 60 m / s and 500 m / s.

[0192] Tables 1 and 2 below show possible dimensions of the first roller 12 and the second roller 13. Figure 6 、 Figure 7 、 Figure 8 、 Figure 11 、 Figure 13 and Figure 14 Represented graphically in .

[0193] Table 1

[0194] a Release recess spacing 5.0-20.0mm b Axial width of the first circumferential ridge 1-15mm c Circumferential amplitude of the protrusion 0.1-2.0mm d Another radial distance 0.5-2mm dmin Minimum radial distance 0.5-2mm dmax Maximum radial distance 0.2–1.5mm daxial Minimum axial distance 0.02–0.06mm e Circumferential width of the release recess 5-20mm f Axial width of the first circumferential groove 1-2mm Od Offset distance between relief pockets 0-20mm t Sheet thickness 0.15–0.35mm w Sheet width 80-180mm α Angle of sharp edge 90 degrees β Angular offset between release recesses 0 degrees-30 degrees r1 Radius of sharp edge 0.03-0.05mm r3 Radius of the concave surface 5-15mm Rmax Maximum radius of the bulge 40-300mm L1 First axial length 200-300mm L2 Second axial length 200-300mm

[0195] Table 2

[0196] dmin / Rmax 0.03-0.005 dmin / t 1.5-3.5 daxial / Rmax 0.0002-0.0005 daxial / t 0.2-0.3

[0197] Table 3 below shows other possible dimensions for the first roller 12 .

[0198] Table 3

[0199] Ex.1 Ex.2 a Release recess spacing 0.2-16.0mm 10mm 7mm b Axial width of the first circumferential ridge 1-15mm 3mm 2mm c Circumferential amplitude of the protrusion 0.1-8.0mm 6mm 4mm e Circumferential width of the release recess 0.1-8.0mm 4mm 3mm f Axial width of the first circumferential groove 2-4mm 2mm 2mm g Axial distance between center lines 2-6mm 5mm 4mm Od Offset distance between relief pockets 20％-40％c 1.2mm 0.8mm

[0200] Table 4 below shows possible dimensions of the cuts 8 of the sheet 2 produced by a first roller 12 provided with the characteristics of Table 3 (in Figure 9 shown in ).

[0201] The cuts 8 are arranged in pairs, and each pair comprises two parallel cuts 8. Each cut 8 is a straight line parallel to the feed direction of the aerosol-generating substrate sheet 2. The pairs of cuts 8 are aligned along the longitudinal paths, and the pairs of cuts 8 of one path are offset relative to the pairs of cuts 8 of the adjacent path.

[0202] Table 4

[0203] scope Ex.1 Ex.2 a'-spacing=c'+e' 0.2-16mm 10mm 7mm b'-lateral distance 1-15mm 3mm 2mm c' - length 0.1-8mm 6mm 4mm e'-longitudinal distance 0.1-8mm 4mm 3mm f' - lateral distance between pairs 2–4 mm 2mm 2mm g' - lateral distance between the center lines "M" 2-6mm 5mm 4mm O'd - offset longitudinal distance 20％-40％c’ 1.2mm 0.8mm

[0204] Figure 15 Another example of an aerosol-generating substrate sheet treated by a device and by a method according to the present invention is shown. The cuts 8 are single straight cuts aligned along the respective paths and offset relative to the cuts 8 of the adjacent paths. Exemplary measurements of these single straight cuts are in Table 5 below.

[0205] Table 5

[0206] Examples a'-spacing=c'+e' 6mm b'-lateral distance 5mm c' - length 4mm e'-longitudinal distance 2mm O'd - offset longitudinal distance 0.8mm

[0207] Figure 16 Another example of an aerosol-generating substrate sheet processed by the apparatus and by the method according to the present invention is shown. The cut 8 is a single zigzag cut aligned along the respective path and offset relative to the cut 8 of the adjacent path. Exemplary measurements of these single zigzag cuts are provided in Table 6 below.

[0208] Table 6

[0209] Examples a'-spacing=c'+e' 6mm b'-lateral distance 5mm c' - length 4mm e'-longitudinal distance 2mm h'-lateral dimension 1.5mm O'd - offset longitudinal distance 0.8mm

[0210] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers representing amounts, quantities, percentages, etc. should be understood to be modified by the term "about" in all cases. Moreover, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein that may be specifically listed or may not be listed in this article. Therefore, in this context, the number A is understood to be 5% of A±A. In this context, the number A can be regarded as including the numerical value within the general standard error for the measurement of the attribute modified by the number A. In some cases used in the appended claims, the number A may deviate from the percentages listed above, provided that the amount of A deviation does not substantially affect the basic characteristics and novel features of the invention claimed. Moreover, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein that may be specifically listed or may not be listed in this article.

Claims

1. A device for weakening an aerosol-generating substrate sheet for use as a component of an aerosol-generating article, the device comprising: a first roller having a first axis of rotation and comprising a first plurality of circumferential ridges disposed on a first radially outer face of the first roller, the first circumferential ridges defining a corresponding first plurality of circumferential grooves on the first radially outer face; a second roller having a second axis of rotation and comprising a second plurality of circumferential ridges disposed on a second radially outer face of the second roller, the second circumferential ridges defining a corresponding second plurality of circumferential grooves on the second radially outer face; wherein each first circumferential ridge comprises a plurality of relief recesses circumferentially spaced apart from one another along the first circumferential ridge, and a plurality of protrusions defined between the relief recesses; wherein at a connection area between the first roller and the second roller, the protrusion of the first circumferential ridge is inserted into the second circumferential groove; wherein in a cross section including the first axis of rotation, each first circumferential ridge has a rectangular profile; wherein in a cross section including the second axis of rotation, each second circumferential ridge has a rectangular profile; wherein the rectangular profiles of the first and second circumferential ridges have sharp edges configured to create cuts in the aerosol-generating substrate sheet passing between the first roller and the second roller, the cuts producing weakened fold lines to facilitate folding and gathering the aerosol-generating substrate sheet to form a strip.

2. The device of claim 1, wherein each of the sharp edges has an angle (α) of 90 degrees.

3. The device according to claim 1 or 2, wherein each of the sharp edges has a radius (r1) equal to or smaller than 0.05 mm.

4. The device according to any one of claims 1 to 3, wherein the ratio (dmin / t) of the minimum radial distance (dmin) between the bottom portion of the release recess of the first roller and the top portion of the second circumferential ridge of the second roller to the thickness (t) of the aerosol-generating substrate sheet is equal to or greater than 1.

5.

5. The device according to any one of claims 1 to 4, wherein the ratio (daxial / t) of the minimum axial distance (daxial) between a first circumferential ridge of the first roller and an adjacent second circumferential ridge of the second roller to the thickness (t) of the aerosol-generating substrate sheet is between 0.2 and 0.

3.

6. The device of any one of claims 1 to 5, wherein each relief recess is defined by a concave surface.

7. The device according to claim 6, wherein each concave surface and two corresponding adjoining protrusions define two secondary edges parallel to the first axis of rotation, wherein each of the secondary edges is rounded.

8. The device of any one of claims 1 to 7, wherein the relief recess of one first circumferential ridge is circumferentially offset relative to the relief recess of the other first circumferential ridge to create an offset notch.

9. The device according to any one of claims 1 to 8, wherein the top portion of each second circumferential ridge is continuous and free of relief recesses.

10. A method for weakening an aerosol-generating substrate sheet for use as a component of an aerosol-generating article, the method comprising: A cut is produced in the aerosol-generating substrate sheet by passing the aerosol-generating substrate sheet between a first roller and a second roller of an apparatus according to any one of claims 1 to 9 while the first roller and the second roller rotate in opposite directions, the cut producing a weakened fold line to facilitate folding and gathering the aerosol-generating substrate sheet to form a strip. The method according to claim 10 , wherein the incision is a through incision.

12. A method according to claim 10 or 11, wherein the aerosol-generating substrate sheet is a herb or plant-based cast sheet, or wherein the aerosol-generating substrate sheet is a fibre-based material.

13. A method according to any one of claims 10 to 12, wherein the aerosol-generating substrate sheet has a thickness (t) of between 0.15 and 0.

35.

14. A process for manufacturing a component of an aerosol-generating article, the process comprising the steps of: - Manufacturing aerosol-generating substrate sheets; - weakening the aerosol-generating substrate sheet by a method according to any one of claims 1 to 13; - gathering the aerosol-generating substrate sheet to form a continuous strip; - cutting the continuous strip into a plurality of aerosol-generating article components each having the shape of a strip, each aerosol-generating article component comprising a gathered weakened sheet formed from cut portions of a weakened aerosol-generating substrate sheet.

15. A process according to claim 14, wherein manufacturing the aerosol-generating substrate sheet comprises: - preparing a slurry from powder and binder; - casting the slurry onto a surface to produce the aerosol-generating substrate sheet.

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