Apparatus and method for producing a cast sheet for a smoking article

Abstract

An apparatus for producing a cast sheet for a smoking article comprises a continuous mixer (2) configured for mixing a formulation component and water to form a slurry mixture. The continuous mixer (2) defines a mixing path (4) and has a plurality of inlets in communication with the mixing path (4) and configured to feed ingredients and water into the mixing path (4), and an outlet (28) at an end of the mixing path (4) and configured to discharge a slurry mixture from the continuous mixer (2). The continuous mixer (2) is configured to mix the ingredient and water while advancing the ingredient and water in the mixing path (4) towards the outlet (28). A casting box (32) is in fluid communication with the outlet (28) to receive the slurry mixture from the continuous mixer (2), and a surface is located below the casting box (32) and is configured to receive the slurry mixture from the casting box (32) to form a cast sheet (42).

Description

TECHNICAL FIELD

[0001] The present disclosure relates to an apparatus and a method for producing a cast sheet for a smoking article. The present disclosure also relates to a cast sheet manufactured in the apparatus and / or by the method. BACKGROUND

[0002] Cast sheets for smoking articles are known in the art and can be used for manufacturing conventional smoking articles which are lit at one end so as to smolder, and for manufacturing aerosol-generating articles or heat-not-burn cigarettes in which an aerosol-generating substrate is heated rather than combusted. In conventional smoking articles, the cast sheet can be a reconstituted tobacco leaf which can be combined with other tobacco leaves for use in a tobacco blend. For example, the reconstituted tobacco leaf can be shredded and mixed with other leaves to obtain a resulting tobacco blend which is intended to be lit and smoked. In aerosol-generating articles, the cast sheet can be a sheet of the above-mentioned aerosol-generating substrate. For example, the sheet of aerosol-generating substrate is rolled, gathered, wrapped in a rod and cut into aerosol-generating substrate sticks which are intended to release volatile compounds by heat transfer from a heat source of an aerosol-generating system.

[0003] Cast sheets are prepared by casting a slurry having a high water content on a movable support. Currently, slurry preparation is carried out in a batch mode. The current slurry preparation process is performed by mixing the different ingredients inside a slurry preparation tank at a mixing speed to achieve proper homogeneity. After preparation, the slurry is transferred to a slurry storage tank where it is stored for up to four hours before the subsequent casting process.

[0004] For example, WO2016050471 and WO2017089589 disclose methods for preparing tobacco-based slurries and sheets. For example, WO2022248378 and WO2020074494 disclose methods for producing aerosol-forming substrates by preparing and casting a slurry. US4325391 discloses a method and apparatus for combining a liquid base web and dry ground tobacco to produce a uniform mixture. US2023011797 discloses an apparatus for producing sheets of an alkaloid-containing material for use in aerosol-generating articles.

[0005] It is also known to prepare reconstituted tobacco sheets by laminating slurries having a lower water content. For example, WO2020058814A1 and WO2021181327A1 disclose a process for producing reconstituted tobacco, wherein the solid components of the tobacco are comminuted to reach a certain particle size, the comminuted product thus obtained is mixed with water, at least one binder and at least one aerosol forming material until a mixture having a liquid content of about 35-40% is obtained. The mixture is then subjected to a first lamination and to a series of further roll passes to obtain a strip having a substantially constant thickness. The strip is then dried to reach a liquid content of about 8-15%. SUMMARY

[0006] It would be desirable to have an apparatus and a process for producing a cast sheet for smoking articles which allows to improve the quality of the cast sheet, and therefore of the smoking articles comprising said cast sheet.

[0007] It would be desirable to have an apparatus and a process for producing a cast sheet for smoking articles which allows to improve the mechanical properties (e.g. breaking force) of the cast sheet and the uniformity of the mechanical properties in the cast sheet, therefore improving the processability of the cast sheet and the uniformity of the properties of the resulting smoking articles.

[0008] It would also be desirable to increase the productivity of the apparatus and the process for producing a cast sheet for smoking articles.

[0009] It would also be desirable to have an apparatus and a process for producing a cast sheet for smoking articles which allows to reduce waste and water consumption.

[0010] It would also be desirable to limit the complexity and the footprint of the apparatus for producing a cast sheet for smoking articles.

[0011] It would also be desirable to increase the flexibility of the apparatus for producing a cast sheet for smoking articles.

[0012] It would also be desirable to simplify the process for producing a cast sheet for smoking articles.

[0013] The present disclosure relates to an apparatus for producing a cast sheet for a smoking article. The apparatus comprises a continuous mixer configured to mix a recipe ingredient and water to form a slurry mixture. The continuous mixer can define a mixing path. The continuous mixer can have at least one inlet in communication with the mixing path configured to feed the ingredient and water into the mixing path and an outlet at an end of the mixing path configured to discharge the slurry mixture from the continuous mixer. The continuous mixer is configured to mix the ingredient and water while advancing the ingredient and water in the mixing path toward the outlet. The apparatus can comprise a casting box in fluid communication with the outlet to receive the slurry mixture from the continuous mixer. The apparatus can comprise a surface below the casting box and configured to receive the slurry mixture from the casting box and form a cast sheet.

[0014] The present disclosure relates to a method for producing a cast sheet for a smoking article. The method comprises feeding a recipe ingredient and water through at least one inlet and into a mixing path of a continuous mixer; mixing the ingredient and water while advancing the ingredient and water in the mixing path toward an outlet of the continuous mixer to form a slurry mixture, and discharging the slurry mixture from the outlet. The method can further comprise casting the slurry mixture from the outlet on a surface to form a cast sheet.

[0015] The method can be performed by the apparatus, and / or the apparatus can be configured to perform the method.

[0016] The inventors found that the disclosed apparatus and method allow manufacturing a cast sheet having an improved quality compared to a cast sheet obtained from a slurry prepared by a batch mode.

[0017] Indeed, the slurry preparation achieved by the disclosed apparatus and method, by continuously feeding the ingredient, continuously mixing the ingredient and continuously feeding a subsequent casting box, prevents slurry degradation. In particular, the disclosed apparatus and method prevent the enzymatic degradation of the slurry due to its aging during storage associated with the preparation by batch mode.

[0018] The inventors found that the disclosed apparatus and method have an impact on the mechanical properties of the cast sheet. Indeed, the continuous mixing increases the mechanical strength of the cast sheet by reducing the aging time of the cast sheet and improves the uniformity of the mechanical properties of the cast sheet.

[0019] The inventors found that the disclosed apparatus and method allow increasing the productivity with respect to known apparatus and methods, as the storage time of the slurry is eliminated.

[0020] The inventors found that the disclosed apparatus and method allow eliminating at least a storage tank and thus reduce the complexity and the footprint of the apparatus for producing a cast sheet for a smoking article.

[0021] The inventors found that the use of a continuous mixer allows to improve the flexibility of the installation.

[0022] The inventors found that the method for producing a cast sheet for smoking articles is simplified and allows to reduce waste and water consumption.

[0023] In some embodiments, the ingredients and water are added to the continuous mixer at the same time. As the water content of the slurry is high, the order of feeding into the continuous mixer can not play an important role.

[0024] In some embodiments, the outlet of the continuous mixer is directly connected to the casting box. The installation can comprise a transfer pipe connecting the outlet of the continuous mixer to the casting box. No buffer tank is located on the transfer pipe between the outlet of the continuous mixer and the casting box.

[0025] The inventors found that the direct connection of the outlet of the continuous mixer to the casting box allows to reduce the transfer time of the slurry from mixing to casting and to increase the breaking force of the cast sheet.

[0026] In some embodiments, the installation comprises a buffer tank placed between the outlet of the continuous mixer and the casting box. The installation can comprise a first transfer pipe connecting the outlet of the continuous mixer to the buffer tank and a second transfer pipe connecting the buffer tank to the casting box. The method can comprise: buffering the slurry mixture coming out of the outlet of the continuous mixer in the buffer tank before casting the slurry mixture on the surface.

[0027] The inventors found that the buffering allows to compensate for possible flow rate variations at the output of the continuous mixer to keep the flow rate of the slurry mixture entering the casting box stable.

[0028] A pump can be placed between the outlet of the continuous mixer and the casting box for pumping the slurry mixture to the casting box. The pump can operate between the buffer tank and the casting box. The pump can be placed on the second transfer pipe.

[0029] The inventors found that the pump allows to continuously feed the casting box and to control the flow rate of the slurry mixture to the casting box.

[0030] In some embodiments, the feeding, mixing and casting are performed simultaneously at least during steady state operation.

[0031] In some embodiments, the slurry mixture is advanced from the continuous mixer to the surface in a continuous flow at least during steady state operation.

[0032] The residence time of the ingredients and water in the continuous mixer and the residence time of the slurry mixture can be between 1 and 20 minutes, optionally between 5 and 15 minutes, optionally between 8 and 10 minutes.

[0033] The transfer time of the slurry mixture from the outlet of the continuous mixer to the surface can be less than 40 minutes, optionally between 1 minute and 30 minutes, or optionally between 1 minute and 15 minutes.

[0034] The inventors have discovered that the transfer time from the continuous mixer to the casting box is significantly shorter than that of known batch methods (where the slurry mixture is stored for several hours before casting), and this results in stronger cast sheets. In fact, the faster the slurry mixture is transferred from the mixer to the casting box, the higher the mechanical properties of the cast sheet.

[0035] The continuous operating time of the equipment can be several hours, optionally between 30 and 60 hours, or optionally 45 hours.

[0036] The flow rate of the slurry mixture exiting the continuous mixer can be between 80 kg / h and 3000 kg / h, or optionally between 1000 kg / h and 2500 kg / h.

[0037] The inventors have discovered that the continuous operation time is very long and is limited only by cleaning cycle requirements and / or maintenance requirements. Therefore, the productivity of the equipment is increased.

[0038] In some embodiments, a two-way valve is located at the outlet of the continuous mixer. The two-way valve may be connected to a discharge port. The two-way valve may be configured to feed the slurry mixture toward the casting box or to deflect the slurry mixture toward the discharge port.

[0039] The inventors have discovered that a two-way valve allows for the direct disposal of non-conforming portions of the slurry mixture after a continuous mixer, without the risk of contaminating the slurry mixture transfer pipeline with non-conforming products.

[0040] In some embodiments, at least one inlet includes multiple inlets. The at least one inlet may include multiple inlets for components and a water inlet. The multiple inlets may be located at different locations along the continuous mixer, or they may be combined at a single location on the continuous mixer.

[0041] The equipment may include multiple component tanks connected to at least one inlet, and optionally to multiple inlets for components. Feed valves and / or feed pumps and / or feed flow meters may be placed between each component tank and at least one inlet.

[0042] According to some embodiments, the ingredients include: fibers, such as cellulose fibers; binders, such as cellulose derivatives (such as carboxymethyl cellulose (CMC) and hydroxypropyl methyl cellulose (HPMC)); and aerosol forming agents, such as polyols (e.g., triethylene glycol or 1,3-butanediol or glycerol); optionally, the ingredients also include nicotine and / or fumaric acid.

[0043] According to some embodiments, the ingredients include: tobacco powder or other nicotine-containing materials; fibers, such as cellulose fibers; aerosol forming agents, such as glycerin; and binders, such as guar gum.

[0044] Aerosol forming agents and fibers can be stored in component tanks. Fibers can be stored as pulp (i.e., fiber and water) in one of the component tanks.

[0045] A water tank or water source can be operatively connected to at least one inlet, optionally to a water inlet. Water can be stored in the tank or can be sourced from the water source. A water valve and / or a water pump and / or a water flow meter can be placed between the water tank or water source and at least one inlet. The water content in the slurry mixture can be higher than 65%, optionally between 70% and 90%.

[0046] When fed into the continuous mixer, the temperature of the components can be between 15°C and 35°C, optionally 21°C.

[0047] The temperature of the slurry mixture at the outlet of the continuous mixer can be controlled by controlling the temperature of the main body of the continuous mixer, optionally via a built-in jacket and a temperature-controlled water (hot / cold) supply source. The temperature of the slurry mixture at the outlet of the continuous mixer can also be controlled, optionally by increasing the water temperature to up to 50°C via the temperature of the water fed through at least one inlet.

[0048] The temperature increase of the mixed slurry mixture can be between 1°C and 20°C, or optionally between 3°C and 4°C.

[0049] The viscosity of the slurry mixture in the continuous mixer can be between 2000 cP and 4000 cP (measured at 35°C and a shear rate of 100 Hz). Given that the slurry mixture is fresh, as the holding time may not exceed 20 minutes, production can allow for a higher viscosity range for the slurry mixture.

[0050] In some embodiments, the apparatus includes a screw conveyor having an inlet with a hopper and an outlet connected to at least one inlet of a continuous mixer. At least two of a plurality of component tanks may be in communication with the hopper. The screw conveyor may be configured to disperse one component from one of the two tanks into another component from the other of the two tanks before feeding it into the continuous mixer. The screw conveyor may include at least one screw and a motor connected to the screw to rotate the screw.

[0051] In some embodiments, one component of the composition is dispersed onto another component of the composition before being fed into a continuous mixer. Dispersion can be carried out using the screw conveyor disclosed above. The one component and the other component can each be stored in one of the two tanks disclosed above. For example, a binder is dispersed onto tobacco powder or other nicotine-containing materials.

[0052] The inventors discovered that dispersion avoids the formation of agglomerates in the slurry mixture during mixing.

[0053] In some embodiments, the continuous mixer includes at least one mixing tool located in a mixing path and configured to mix the ingredients and water. The at least one mixing tool may also be configured to advance the ingredients and water, as well as the slurry mixture, along the mixing path. Mixing can be performed using at least one mixing tool.

[0054] A continuous mixer may include a main motor connected to at least one mixing tool and configured to rotate the mixing tool. The at least one mixing tool may be configured to rotate about an axis parallel to the mixing path. In some embodiments, the mixing path and axis are horizontal, and the continuous mixer is a horizontal mixer. In some embodiments, the at least one mixing tool includes at least two mixing tools that rotate about a parallel axis.

[0055] In some embodiments, the continuous mixer includes a built-in jacket and a temperature-controlled water (hot / cold) supply source connected to the built-in jacket. Water temperature control ensures that the temperature of the slurry mixture at the mixer outlet matches the desired setpoint.

[0056] In some embodiments, the movable support is located downstream of the casting box, and the surface below the casting box is part of the movable support. The movable support may include a belt conveyor, and the surface may be an upper branch of the belt conveyor.

[0057] The cooling device can be configured to cool the movable support. In some embodiments, the cooling device includes a cooling water source. The cooling device can be positioned and configured to cool the movable support at a location where it does not support the cast sheet.

[0058] The heating device may be configured to heat a surface and a cast sheet supported by the surface to dry the cast sheet. The heating device may include a steam source and / or a hot air source. The cast sheet may optionally be dried by steam and / or hot air, or optionally by the heating device disclosed above.

[0059] In some embodiments, no cooling device is used, and the first roller is hot.

[0060] In some embodiments, the belt conveyor includes a first roller, a second roller, and a belt forming a closed loop around the first roller and the second roller. The first roller may be located near the casting box. A conveyor motor may be connected to at least one of the first roller and the second roller.

[0061] In some embodiments, the heating device is configured to heat the upper branch and / or the first roller. In some embodiments, the cooling device is configured to cool the lower branch and / or the first roller of the belt conveyor.

[0062] The slurry mixture can be cast on the first roller. The temperature of the first roller can be kept constant, optionally between 45°C and 65°C, optionally 55°C. The first roller can be kept hot because the slurry mixture from the continuous mixer is fresh and does not degrade.

[0063] In some embodiments, the casting box includes a casting doctor blade adapted to cast a slurry mixture from the casting box onto a surface.

[0064] In some embodiments, during the inflow time at the start of production, the outlet of the continuous mixer is closed to keep the slurry mixture inside while the components are fed in a defined sequence.

[0065] The inventors discovered that this ensures no loss occurs and that the first portion of the produced slurry mixture already conforms to the formulation.

[0066] In some embodiments, during the inflow time at the start of production, before the slurry mixture begins to flow onto the surface, the outlet of the continuous mixer is opened to fill the buffer tank disclosed above.

[0067] In some embodiments, during the outflow time at the end of production, the feeding of components is stopped in a defined sequence, and the outlet of the continuous mixer is opened while mixing continues to discharge all slurry mixture.

[0068] The inventors discovered that this ensures all good products are discharged without any loss.

[0069] A control unit (optionally an electronic control unit) may be operatively connected to the continuous mixer. The control unit may be configured to monitor and control at least one operating parameter of the continuous mixer. The operating parameters of the continuous mixer may include the power consumption and / or rotational speed and / or temperature and / or torque of at least one mixing tool. The control unit may be configured to optionally control the temperature of the water fed through at least one inlet by increasing the water temperature to up to 50°C, thereby adjusting the temperature of the slurry mixture at the outlet of the continuous mixer. The control unit may be configured to monitor and control at least one operating parameter of a screw conveyor. The control unit may be configured to monitor and control at least one operating parameter of a feed valve and / or feed pump and / or water valve and / or water pump. The control unit may be configured to monitor and control at least one operating parameter of a belt conveyor. The control unit may be configured to monitor and control at least one operating parameter of a heating device. The control unit may be configured to monitor and control at least one operating parameter of a cooling device.

[0070] Sensors can be connected to a control unit, which is configured to manage the operation of the equipment via sensors. For example, sensors may include flow meters and / or pressure sensors and / or temperature sensors and / or weight sensors and / or speed sensors and / or torque sensors and / or viscometers. Non-conforming portions of the slurry mixture can be detected using a viscometer.

[0071] The control unit can be configured to detect whether the mixing process is stable, detect changes in at least one operating parameter of the continuous mixer, and trigger an alarm and / or redirect the slurry mixture toward the discharge port.

[0072] The control unit may be configured to optionally detect changes in component supply and / or slurry mixture output via sensors, and if said changes exceed tolerances, trigger an alarm and / or divert the slurry mixture toward the discharge port. The control unit may also be configured to optionally detect interruptions in component supply and / or output via sensors, and if said interruptions occur, trigger an alarm and / or divert the slurry mixture toward the discharge port.

[0073] This disclosure also relates to a cast sheet manufactured in the apparatus and / or by the methods detailed above. The cast sheet may have a temperature of 100 N / cm in the machine direction or transverse direction. 2 With 500 N / cm 2 The fracture force between them. Cast sheets can be aerosol-generating matrices or reconstituted tobacco leaves.

[0074] This disclosure also relates to a smoking article comprising the cast sheet disclosed above, wherein the smoking article may be a conventional smoking article or an aerosol-generating article.

[0075] This disclosure also relates to a factory for manufacturing smoking articles, including the equipment disclosed herein.

[0076] This disclosure also relates to a process for manufacturing smoking articles, including the methods of this disclosure. According to some embodiments, cast sheets are aggregated, wrapped in strips, and cut into aerosol-generating matrix rods designed to release volatile compounds through heat transfer from a heat source of an aerosol-generating system. According to some embodiments, the cast sheets are shredded and mixed with other tobacco leaves to obtain a resulting tobacco blend intended to be ignited and inhaled.

[0077] As used in this specification, the term "continuous mixer" means a device capable of mixing components while simultaneously delivering said components from one or more inlets to an outlet. Unlike a "batch mixer," which is loaded with a given amount of components and must be stopped after mixing to discharge a given output, a continuous mixer receives a continuous input of components through one or more inlets and provides a continuous output through an outlet.

[0078] As used in this specification, the term "smoking article" means both conventional smoking articles (such as cigars and cigarettes) that are ignited at one end and thus smolder, and aerosol-generating articles or heated non-combustible cigarettes in which the aerosol-generating matrix is ​​heated rather than burned.

[0079] As used in this specification, the term "slurry" refers to an aqueous mixture of insoluble substances with a very high water content (e.g., 65%–90%), which is a mixture that is hard enough to be kneaded or rolled, unlike a "lump" that is a mixture that is hard enough to be kneaded or rolled.

[0080] As used in this specification, "holding time" is the average time that particles of a slurry mixture remain in the mixer during a continuous process.

[0081] As used in this specification, "transfer time" is the time it takes to feed a single particle of the slurry mixture from the mixer outlet to the casting box. It does not include "holding time" within the mixer.

[0082] As used in this specification, the term "formulation" means a group of ingredients, with no restrictions on the order and timing of their combination with each other and / or with water.

[0083] As used in this specification, the terms “upstream” and “downstream” are used to describe the relative position of a component or part of a component of a device with respect to one or more materials along a given path through the device.

[0084] The 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.

[0085] EX1. An apparatus for producing cast sheets for smoking articles, comprising:

[0086] A continuous mixer configured to mix formulation ingredients and water to form a slurry mixture; the continuous mixer defines a mixing path and has at least one inlet communicating with the mixing path and an outlet located at an end of the mixing path, the at least one inlet being configured to feed the ingredients and the water into the mixing path, and the outlet being configured to discharge the slurry mixture from the continuous mixer; the continuous mixer is configured to mix the ingredients and the water while allowing the ingredients and the water to advance toward the outlet in the mixing path;

[0087] A casting box, the casting box being in fluid communication with the outlet to receive the slurry mixture from the continuous mixer;

[0088] A surface located below the casting box and configured to receive the slurry mixture from the casting box and form a cast sheet.

[0089] EX2. According to the device of EX1, the outlet of the continuous mixer is directly connected to the casting box.

[0090] EX3. The apparatus according to EX2 includes a transfer pipe connecting the outlet of the continuous mixer to the casting chamber, wherein no buffer tank is located on the transfer pipe between the outlet of the continuous mixer and the casting chamber.

[0091] EX4. The apparatus according to EX1, wherein the apparatus includes a buffer tank placed between the outlet of the continuous mixer and the casting box.

[0092] EX5. The device according to EX4 includes a first transfer pipe connecting the outlet of the continuous mixer to the buffer tank and a second transfer pipe connecting the buffer tank to the casting box.

[0093] EX6. An apparatus according to any one of EX1 to EX5, comprising a pump placed between the outlet of the continuous mixer and the casting box for pumping the slurry mixture into the casting box.

[0094] EX7. When EX6 is based on EX4 or EX5, the device according to EX6, wherein the pump operates between the buffer tank and the casting box.

[0095] EX8. The device according to EX7 when EX6 is based on EX5, wherein the pump is placed on the second transfer pipe.

[0096] EX9. An apparatus according to any one of EX1 to EX8, comprising a two-way valve located at the outlet of the continuous mixer; optionally wherein the two-way valve is connected to a discharge port.

[0097] EX10. According to the device of EX9, wherein the two-way valve is configured to feed the slurry mixture toward the casting box or to divert the slurry mixture toward the discharge port.

[0098] EX11. The apparatus according to any one of EX1 to EX10, wherein the at least one inlet comprises a plurality of inlets, optionally a plurality of inlets for the component, and a water inlet.

[0099] EX12. According to the device of EX11, the plurality of inlets are located at different locations along the continuous mixer, or combined at a single location on the continuous mixer.

[0100] EX13. An apparatus according to any one of EX1 to EX12, comprising a plurality of ingredient containers connected to the at least one inlet and optionally connected to a plurality of inlets for the ingredients.

[0101] EX14. The device according to any one of EX13, wherein a feed valve and / or feed pump and / or feed flow meter is placed between each component tank and said at least one inlet.

[0102] EX15. An apparatus according to any one of EX1 to EX14, comprising a water tank or water source operatively connected to the at least one inlet, optionally connected to a water inlet.

[0103] EX16. The device according to EX15, wherein a water valve and / or a water pump and / or a water flow meter are placed between the water tank or the water source and the at least one inlet.

[0104] EX17. An apparatus according to any one of EX1 to EX16, comprising a screw conveyor having an inlet provided with a hopper and an outlet connected to at least one inlet of the continuous mixer.

[0105] EX18. The device according to EX17 when EX17 is based on EX13, wherein at least two of the plurality of component tanks are in communication with the hopper.

[0106] EX19. The apparatus according to EX18, wherein the screw conveyor is configured to disperse one component from one of the two tanks into another component from the other of the two tanks before feeding it into the continuous mixer.

[0107] EX20. An apparatus according to any one of EX17 to EX19, wherein the screw conveyor comprises at least one screw body and a motor connected to the screw body to rotate the screw body.

[0108] EX21. An apparatus according to any one of EX1 to EX20, wherein the continuous mixer includes at least one mixing tool located in the mixing path and configured to mix the ingredients and the water, and to advance the ingredients and the water and the slurry mixture along the mixing path; optionally, the continuous mixer includes a built-in jacket and a temperature-controlled water (hot / cold) supply source connected to the built-in jacket.

[0109] EX22. The device according to EX21, wherein the continuous mixer includes a main motor connected to the at least one mixing tool and configured to rotate the mixing tool.

[0110] EX23. The device according to EX21 or EX22, wherein the at least one mixing tool is configured to rotate about an axis parallel to the mixing path; optionally, wherein the mixing path and the axis are horizontal, and the continuous mixer is a horizontal mixer.

[0111] EX24. The device according to any one of EX21 to EX23, wherein the at least one mixing tool comprises at least two mixing tools rotating about a parallel axis.

[0112] EX25. An apparatus according to any one of EX1 to EX24, comprising a movable support located downstream of the casting box; wherein the surface located below the casting box is part of the movable support.

[0113] EX26. The device according to EX25, wherein the movable support comprises a belt conveyor, and the surface is an upper branch of the belt conveyor.

[0114] EX27. The device according to EX25 or EX26 includes a cooling device configured to cool a movable support; optionally, the cooling device includes a cooling water source.

[0115] EX28. The apparatus according to EX27, wherein the cooling device is placed and configured to cool the movable support at a location where the movable support does not support the cast sheet.

[0116] EX29. An apparatus according to any one of EX1 to EX28, comprising a heating device configured to heat the surface and the cast sheet supported by the surface to dry the cast sheet; optionally, the heating device includes a steam source and / or a hot air source.

[0117] EX30. The apparatus according to EX26, EX27 and EX29, wherein the belt conveyor includes a first roller, a second roller and a belt forming a closed loop around the first roller and the second roller; wherein the first roller is adjacent to the casting box; wherein the conveyor motor is connected to at least one of the first roller and the second roller.

[0118] EX31. The device according to EX30, wherein the heating device is configured to heat the upper branch and / or the first roller.

[0119] EX32. The device according to EX30 or EX31, wherein the cooling device is configured to cool the lower branch of the belt conveyor and / or the first roller.

[0120] EX33. An apparatus according to any one of EX1 to EX32, wherein the casting box includes a casting doctor blade adapted to cast the slurry mixture from the casting box onto the surface.

[0121] EX34. An apparatus according to any one of EX1 to EX33, including a control unit operatively connected to the continuous mixer, and optionally an electronic control unit.

[0122] EX35. The device according to EX34, wherein the control unit is configured to monitor and control at least one operating parameter of the continuous mixer; optionally, the control unit is configured to control the temperature of the water fed through the at least one inlet by increasing the temperature of the water to up to 50°C, in order to adjust the temperature of the slurry mixture at the outlet of the continuous mixer.

[0123] EX36. The device according to EX35 when EX34 is according to any one of EX21 to EX24, wherein the operating parameters of the continuous mixer include the power consumption and / or rotational speed and / or temperature and / or torque of the at least one mixing tool.

[0124] EX37. An apparatus according to EX35 when EX34 is according to any one of EX17 to EX20, wherein the control unit is configured to monitor and control at least one operating parameter of the screw conveyor.

[0125] EX38. An apparatus according to EX35 when EX34 is according to EX14 and / or EX16, wherein the control unit is configured to monitor and control at least one operating parameter of the feed valve and / or the feed pump and / or the water valve and / or the water pump.

[0126] EX39. An apparatus according to EX35 when EX34 is according to any one of EX30 to EX32, wherein the control unit is configured to monitor and control at least one operating parameter of the belt conveyor and / or at least one operating parameter of the heating device and / or at least one operating parameter of the cooling device.

[0127] EX40. An apparatus according to any one of EX35 to EX39, comprising a sensor connected to the control unit, wherein the control unit is configured to manage the operation of the apparatus via the sensor; optionally, wherein the sensor comprises a flow meter and / or a pressure sensor and / or a temperature sensor and / or a weight sensor and / or a speed sensor and / or a torque sensor and / or a viscometer.

[0128] EX41. An apparatus according to any one of EX35 to EX40, wherein the control unit is configured to detect a change in at least one operating parameter of the continuous mixer and trigger an alarm and / or divert the slurry mixture toward the discharge port of EX9 or EX10; optionally, the control unit is configured to:

[0129] Optionally, changes in component supply and / or slurry output are detected by sensors on the EX40, and if the changes exceed tolerances, an alarm is triggered and / or the slurry mixture is diverted toward the discharge port; or

[0130] Optionally, an interruption in the component supply and / or output can be detected by the EX40's sensors, and if the interruption occurs, an alarm can be triggered and / or the slurry mixture can be diverted toward the discharge port.

[0131] EX42. A method for producing cast sheets for smoking articles, comprising:

[0132] The formulation ingredients and water are fed through at least one inlet into the mixing path of a continuous mixer; optionally, the ingredients and water are added to the continuous mixer at the same time.

[0133] The ingredients and water are mixed while the ingredients and water are advanced in the mixing path toward the outlet of the continuous mixer to form a slurry mixture, and the slurry mixture is discharged from the outlet;

[0134] The slurry mixture from the outlet is cast onto the surface to form a cast sheet.

[0135] EX43. The method according to EX42, wherein the method is performed by a device according to any one of EX1 to EX41.

[0136] EX44. According to the method of EX42 or EX43, feeding, mixing and casting are performed simultaneously, at least during steady-state operation.

[0137] EX45. The method according to any one of EX42 to EX44, wherein, at least during steady-state operation, the slurry mixture advances in a continuous flow from the continuous mixer to the surface.

[0138] EX46. The method according to any one of EX42 to EX45, wherein the holding time of said component, said water, and said slurry mixture in said continuous mixer is between 1 minute and 20 minutes, optionally between 5 minutes and 15 minutes, optionally between 8 minutes and 10 minutes.

[0139] EX47. The method according to any one of EX42 to EX46, wherein the flow rate of the slurry mixture exiting the outlet of the continuous mixer is between 80 kg / h and 3000 kg / h, optionally between 1000 kg / h and 2500 kg / h.

[0140] EX48. The method according to any one of EX42 to EX47, wherein mixing is performed by at least one mixing tool according to any one of EX21 to EX24.

[0141] EX49. The method according to any one of EX42 to EX48, wherein the continuous operating time of said device is a number of hours, optionally between 30 hours and 60 hours, optionally 45 hours.

[0142] EX50. The method according to any one of EX42 to EX49, wherein the transfer time of the slurry mixture from the outlet of the continuous mixer to the surface is less than 40 minutes, optionally between 1 minute and 30 minutes, optionally between 1 minute and 15 minutes.

[0143] EX51. The method according to any one of EX42 to EX50 further includes: buffering the slurry mixture in a buffer tank, optionally in a buffer tank according to EX4, EX5 or EX7, before casting the slurry mixture exiting the outlet of the continuous mixer onto the surface.

[0144] EX52. The method according to any one of EX42 to EX51 further includes: optionally drying the cast sheet by steam and / or hot air, optionally by a heating device according to EX29 or EX31.

[0145] EX53. The method according to any one of EX42 to EX52 further includes: dispersing one of the components onto another component of the components before feeding it into the continuous mixer; optionally by means of a screw conveyor according to EX17, EX19, EX20 or EX37; optionally wherein the one component of the components and the other component of the components are each stored in one of the two tanks of EX18.

[0146] EX54. The method according to any one of EX42 to EX53, wherein the water is stored in the water tank or from a water source according to EX15 or EX16.

[0147] EX55. The method according to any one of EX42 to EX54, wherein the water content in the slurry mixture is higher than 65%, optionally between 70% and 90%.

[0148] EX56. The method according to any one of EX42 to EX55, wherein said component comprises: fiber, such as cellulose fiber; binder, such as cellulose derivatives (such as carboxymethyl cellulose (CMC) and hydroxypropyl methyl cellulose (HPMC)); and aerosol forming agent, such as polyol (e.g., triethylene glycol or 1,3-butanediol or glycerol); optionally said component also includes nicotine and / or fumaric acid.

[0149] EX57. The method according to any one of EX42 to EX55, wherein said component comprises: tobacco powder or other nicotine-containing material; fiber, such as cellulose fiber; aerosol forming agent, such as glycerin; and binder, such as guar gum.

[0150] EX58. According to the method of EX57, wherein the binder is dispersed on the tobacco powder or other nicotine-containing material according to EX53.

[0151] EX59. According to the method of EX56 or EX58, wherein the aerosol forming agent and the fiber are stored in a component container according to EX13 or EX14.

[0152] EX60. According to the method of EX59, the fiber is stored as pulp (i.e., fiber and water) in one of the component tanks.

[0153] EX61. The method according to any one of EX42 to EX60, wherein the temperature of the component when fed to the continuous mixer is between 15°C and 35°C, optionally 21°C.

[0154] EX62. The method according to any one of EX42 to EX61, wherein the temperature of the slurry mixture at the outlet of the continuous mixer is controlled by controlling the temperature of the body of the continuous mixer, optionally by a built-in jacket and a temperature-controlled water (hot / cold) supply source, or optionally by controlling the temperature of the water fed through the at least one inlet by increasing the temperature of the water to up to 50°C.

[0155] EX63. The method according to any one of EX62, wherein the temperature of the slurry mixture increases after mixing between 1°C and 20°C, optionally between 3°C and 4°C.

[0156] EX64. The method according to any one of EX42 to EX63, wherein the slurry mixture is cast on a first roller of EX30, wherein the temperature of the first roller is kept constant, optionally between 45°C and 65°C, optionally 55°C.

[0157] EX65. The method according to any one of EX42 to EX64, wherein during the inflow time at the start of production, the outlet of the continuous mixer is closed to retain the slurry mixture inside while the components are fed in a defined sequence.

[0158] EX66. According to the method of EX65, wherein during the inflow time at the start of production, before the slurry mixture is started to flow onto the surface, the outlet of the continuous mixer is opened to fill the buffer tank of any one of EX4, EX5, and EX6.

[0159] EX67. The method according to any one of EX42 to EX66, wherein during the outflow time at the end of production, the feeding of the components is stopped in a defined sequence, and the outlet of the continuous mixer is opened while mixing continues to discharge all of the slurry mixture.

[0160] EX68. The method according to any one of EX42 to EX67, wherein the viscosity of the slurry mixture in the continuous mixer is between 2000 cP and 4000 cP (measured at 35°C and 100 Hz shear rate).

[0161] EX69. Devices according to EX1 to EX41, configured to perform any of the methods according to EX42 to EX68.

[0162] EX70. A cast sheet manufactured in an apparatus according to any one of EX1 to EX41 and / or by a method according to any one of EX42 to EX68.

[0163] EX71. A cast sheet according to EX70, wherein the cast sheet has a temperature of 100 N / cm in the machine direction or transverse direction. 2 With 500 N / cm 2 The breaking force between them.

[0164] EX72. The cast sheet according to EX70, wherein the cast sheet is an aerosol generating matrix.

[0165] EX73. Cast sheet according to EX70 or EX71, wherein the cast sheet is reconstituted tobacco leaf.

[0166] EX74. A smoking article comprising a cast sheet according to any one of EX70 to EX73, wherein the smoking article is a conventional smoking article or an aerosol-generating article.

[0167] EX75. A factory for manufacturing smoking articles, comprising equipment of any one of EX1 to EX41.

[0168] EX76. A process for manufacturing smoking articles, comprising any one of the methods of EX42 to EX68.

[0169] EX77. According to the process of EX76, wherein the cast sheet is aggregated, wrapped in a strip and cut into aerosol generating matrix rods, the aerosol generating matrix rods being designed to release volatile compounds through heat transfer from a heat source of the aerosol generating system.

[0170] EX78. According to the process of EX76, the cast sheet is shredded and mixed with other tobacco leaves to obtain a resulting tobacco blend intended to be lit and smoked. Attached Figure Description

[0171] The examples will now be described further with reference to the accompanying drawings, in which:

[0172] Figure 1 The diagram schematically illustrates equipment used for producing cast sheets for smoking articles;

[0173] Figure 2 It shows Figure 1 A variant embodiment of the device;

[0174] Figure 3 and 4 It shows the way Figure 1 Mechanical properties of cast sheets manufactured by equipment 2 or 2. Detailed Implementation

[0175] The apparatus 1 includes a continuous mixer 2 configured to mix formulation components and water to form a slurry mixture. The continuous mixer 2 includes a shell 3 shaped like a cylinder and defining a mixing path 4 internally. The mixing path 4 is horizontal, and the continuous mixer 2 is a horizontal mixer. A mixing tool 5 is inserted into and secured within the mixing path 4 and supported by the shell 3, for example, by a bearing not shown. Figure 1 The mixing tool 5 is shaped like a shaft extending along an axis “XX” parallel to the mixing path 4. The shaft of the mixing tool 5 is provided with mixing elements (such as protrusions or blades not shown in detail) and is connected to a main motor 6 configured to rotate the shaft about the corresponding axis “XX”. The mixing tool 5 is configured to mix the ingredients and water, and to advance the ingredients, water, and slurry mixture along the mixing path 4.

[0176] Multiple inlets are machined to pass through shell 3 and communicate with mixing path 4 to feed ingredients and water into mixing path 4. Figure 1 In an exemplary embodiment, device 1 has a first inlet 7, a second inlet 8, a third inlet 9, and a fourth inlet 10. The first inlet 7 is located near the first end of the housing 3 and near the main motor 6. The second inlet 8, the third inlet 9, and the fourth inlet 10 are placed one after another along the axis “XX”.

[0177] The first inlet 7 is connected to the screw conveyor 11. The screw conveyor 11 includes a housing 12 that houses a screw 13 rotated by a corresponding motor 14. The housing 12 has an inlet 15 located at one end of the screw 13 and an outlet 16 located at the opposite end of the screw 13. The outlet 16 of the screw conveyor 11 is connected to the first inlet 7 of the continuous mixer 2 via a pipe. A hopper 17 is positioned at the inlet 15. A first component tank 18 and a second component tank 19, each equipped with a feed pump 20, a feed valve 21, and a feed flow meter (not shown), are located above the hopper 17 and communicate with the inlet 22 of the hopper 17.

[0178] According to this exemplary embodiment, the first component container 18 stores a binder (e.g., guar gum), and the second component container 19 stores tobacco powder or another powder containing nicotine. The manufacture of the tobacco powder may fall into known categories, such as: selection of tobacco type and grade, inspection of tobacco integrity, shredding of tobacco leaves, coarse grinding of tobacco leaves, blending of different tobacco types, and fine grinding.

[0179] Guar gum and tobacco powder are fed into hopper 17 and then into inlet 15 of screw conveyor 11. Thus, guar gum is metered onto the tobacco powder being conveyed by the screw conveyor. Screw conveyor 11 disperses the guar gum on the tobacco powder while moving these components toward outlet 16 of screw conveyor 11 and toward the first inlet 7 of continuous mixer 2.

[0180] The second inlet 8 of the continuous mixer 2 is connected via a corresponding feed pump 20, feed valve 21, and feed flow meter (not shown) to a third component tank 23 storing an aerosol forming agent (e.g., glycerol). The third inlet 9 of the continuous mixer 2 is connected via a corresponding feed pump 20, feed valve 21, and feed flow meter (not shown) to a fourth component tank 24 storing pulp (i.e., a premix of cellulose fibers and water). Cellulose pulp can be prepared by known steps. For example, cellulose fibers and water are mixed in a concentrated form (the total amount of cellulose fibers in the pulp is between about 3% and 5% of the total pulp weight before dilution). If pulp storage is performed, the storage time of the concentrated pulp may vary between 0.1 days and 7 days. The concentrated pulp is then diluted; water is added to the concentrated pulp in an amount less than about 1% of the total pulp weight of cellulose fibers. Additional mixing steps may also be performed. An optional step of fibrillation of fibers may be performed after pulp preparation step 107.

[0181] The fifth inlet 10 of the continuous mixer 2 is connected to a fifth water tank 25 for storing water via a water pump 26, a water valve 27, and a water flow meter (not shown), or it may be connected to a water source (e.g., a water supply network). The ingredients can be metered relative to the tobacco powder that is the main material stream.

[0182] The outlet 28 of the mixing path 4 is located at the second end of the housing 3 (i.e., at the end of the mixing path 4 and the distal end of the mixing tool 5). The outlet 28 is connected to a two-way valve 29. The two-way valve 29 is configured to discharge the slurry mixture through the outlet 28 or to divert the slurry mixture toward an auxiliary outlet 30 connected to the discharge port 31.

[0183] The continuous mixer 2 is configured to mix the ingredients and water, while simultaneously moving the mixed ingredients and water in the mixing path 4 and toward the outlet 28, thus forming a slurry mixture.

[0184] The casting box 32 is in fluid communication with the outlet 28 to receive the slurry mixture from the continuous mixer 2, and a belt conveyor 33 is located below the casting box 32. The belt conveyor includes a first roller 34, a second roller 35, and a belt 36 forming a closed loop around the first roller 34 and the second roller 35. A conveyor motor 37 is connected to the first roller 34 to move the upper branch 38 of the belt 36 in the conveying direction "F".

[0185] The casting box 32 has a top opening 39 and a bottom opening 40. The bottom opening 40 is close to and faces a portion of the upper branch 38 of the belt 36 located at the first roller 34. The casting box 32 includes a casting doctor blade 41, which, together with the upper branch 38 of the belt 36, defines a slit. The casting doctor blade 41 is an element having an edge designed to contact the slurry mixture. The edge may have a sharp, knife-like shape, or a rectangular or rounded shape. The belt 36 is a movable support, and the upper branch of the belt 36 is a movable surface located below the casting box 32, which moves along the conveying direction "F" and is configured to receive the slurry mixture from the casting box 32 and form a cast sheet 42.

[0186] The slurry mixture is transferred from outlet 28 of the continuous mixer 2 to casting box 32 via a first transfer pipe 43 connecting outlet 28 to buffer tank 44 and a second transfer pipe 45 connecting buffer tank 44 to casting box 32. The end opening 46 of the second transfer pipe 45, equipped with an end-opening valve 46a, is located directly above the top opening 39 of the casting box 32. A pump 47 operates on the second transfer pipe 45 to pump the slurry mixture into the casting box 32.

[0187] The device 1 also includes a heating device configured to heat the upper branch 38 of the heating band 36 and the cast sheet 42 supported by the upper branch 38, and to dry the cast sheet 42. Figure 1 In an exemplary embodiment, the heating device includes a steam source 48 positioned below the upper branch 38 and configured to increase or maintain the temperature of the tape 36. The heating device also includes another steam source 49 positioned above the upper branch 38 and above the cast sheet 42 to dry the cast sheet 42. A further steam source 50 is connected to the first roller 34 to increase or maintain the temperature of the first roller 34.

[0188] exist Figure 1 The device 1 shown also includes a cooling device (e.g., a cooling water source 51) that operates on the first roller 34 and on the lower branch of the belt 36 to cool the components. Figure 1 In the depicted embodiment, cooling water source 51 is connected to a portion of the lower branch of belt 36. Another steam source 49, yet another steam source 50, and cooling water source 51 can be controlled to adjust the temperature of the first roller 34 and the temperature of belt 36. For example, the temperature of the first roller 34 is kept constant, optionally between 45°C and 65°C, optionally at 55°C.

[0189] The housing 3 of the continuous mixer 2 is also provided with a built-in jacket 52 connected to a temperature-controlled water (hot / cold) supply source 53.

[0190] Electronic control unit 54 (in) Figure 1(Schematally shown) The device 1 is configured to operate, monitor and control it. The electronic control unit 54 is operatively connected to: the main motor 6, the motor 14, the conveyor motor 37, the feed pump 20, the feed valve 21, the water pump 26, the water valve 27, the two-way valve 29, the pump 47, the steam source 48, another steam source 49, yet another steam source 50, the cooling water source 51, and the temperature control water supply source 53.

[0191] exist Figure 1 Sensors, not shown, are also connected to control unit 54, and control unit 54 is configured to manage the operation of device 1 and additionally control the operating parameters of device 1 via signals received from the sensors. Sensors include the feed flow meter and / or pressure sensor and / or temperature sensor and / or weight sensor and / or speed sensor and / or torque sensor and / or viscometer mentioned above.

[0192] Electronic control unit 54 is configured to monitor and control the operating parameters of feed valve 21 and feed pump 20, as well as the operating parameters of water valve 27 and water pump 26. Electronic control unit 54 is configured to monitor and control the flow of binder from first component tank 18 and the flow of tobacco powder from second component tank 19. Control unit 54 is configured to monitor and control the rotational speed of screw conveyor 11's screw 13. Control unit 54 is configured to monitor and control the flow of aerosol forming agent from third component tank 23, the flow of pulp from fourth component tank 24, and the flow of water from fifth water tank 25. When fed to continuous mixer 2, the temperature of the components is controlled between 15°C and 35°C, optionally 21°C. Water flow is controlled such that the water content in the pulp mixture is above 65%, optionally between 70% and 90%.

[0193] The electronic control unit 54 is configured to monitor and control the rotational speed, torque, power consumption, and temperature of the mixing tool 5, as well as the flow and / or temperature of the water supply source 53. The temperature increase of the mixed slurry mixture is between 1°C and 20°C, optionally between 3°C and 4°C. The viscosity of the slurry mixture in the continuous mixer is between 2000 cP and 4000 cP (measured at 35°C and a shear rate of 100 Hz).

[0194] The electronic control unit 54 is configured to monitor and control the two-way valve 29 and the pump 47.

[0195] Electronic control unit 54 is configured to monitor and control the speed of conveyor motor 37. Control unit 54 is configured to monitor and control the flow and / or temperature of steam from steam source 48, another steam source 49, and another steam source 50. Control unit 54 is configured to monitor and control the flow and / or temperature of cooling water from cooling water source 51.

[0196] The electronic control unit 54 is also configured to detect changes or interruptions in the component supply and / or slurry mixture output, and to trigger an alarm and / or divert the slurry mixture toward the discharge port 31 if the changes exceed tolerances or if the interruption occurs.

[0197] According to the method for producing cast sheets for smoking articles executed by equipment 1, binder, tobacco powder, aerosol forming agent, pulp (formulation components), and water (via electronic control unit 54) are fed in a controlled manner to continuous mixer 2. These components and water are mixed by mixing tool 5 and move toward outlet 28, while the temperature of the pulp mixture can be controlled by temperature control water in built-in jacket 52 or by controlling the temperature of water fed through water inlet (e.g., by increasing the temperature of water fed through water inlet to up to 50°C).

[0198] During the inflow period at the start of production, the ingredients and water are fed in a defined sequence, while the outlet 28 of the continuous mixer 2 is closed to keep the slurry mixture inside.

[0199] The non-conforming portion of the slurry mixture is detected by a viscometer, and the two-way valve 29 is controlled to divert the non-conforming portion to the discharge port 31.

[0200] Then, during the inflow time, outlet 28 opens to fill buffer tank 44, while end-opening valve 46a closes. The slurry mixture is sent to buffer tank 44, where it accumulates before the conveyor motor 37 is started and a heating device configured to dry the slurry mixture is installed. This can help allow for filling of casting box 32 in a short time, for example, by operating pump 47 in overspeed mode to achieve a defined fill level and stable hydraulic conditions in casting box 32.

[0201] Then open the end opening valve 46a and begin continuous casting.

[0202] During steady-state operation, feeding, mixing, and casting occur simultaneously, adding components and water to the continuous mixer 2 at the same time, and the slurry mixture progresses in a continuous flow from the continuous mixer 2 to the belt 36 of the belt conveyor 33. The buffer tank 44 allows for compensation for possible flow rate variations at the output 28 of the continuous mixer 2 to maintain a stable flow rate of the slurry mixture entering the casting box 32.

[0203] During steady-state operation, the mixture of components, water, and slurry travels within the mixing path 4 from the first inlet 7, the second inlet 8, the third inlet 9, and the fourth inlet 10 to the outlet 28 for a duration between 1 minute and 20 minutes, optionally between 5 minutes and 15 minutes, and optionally between 8 minutes and 10 minutes.

[0204] During steady-state operation and once out of outlet 28, the transfer time of the slurry mixture from outlet 28 to belt 36 of belt conveyor 33 (flowing through first transfer pipe 43, buffer tank 44, and second transfer pipe 45) is less than 40 minutes, optionally between 1 minute and 30 minutes, optionally between 1 minute and 15 minutes. Pump 47 allows continuous feeding to casting box 32 and controls the flow rate of the slurry mixture to casting box 32.

[0205] During steady-state operation, the continuous operation time of equipment 1 is several hours, optionally between 30 hours and 60 hours, optionally 45 hours, and the flow rate of the slurry mixture exiting from outlet 28 of continuous mixer 2 is between 80 kg / h and 3000 kg / h, optionally between 1000 kg / h and 2500 kg / h.

[0206] During the outflow time, at the end of the continuous operation time, the feeding of components is stopped in a defined sequence, and the outlet 28 of the continuous mixer 2 remains open while mixing continues to discharge all slurry mixture.

[0207] Figure 2 A variant embodiment of device 1 is illustrated schematically. Figure 1 and 2 In the figures, the same reference numerals indicate the same elements. Belt conveyor 33 is shown in part.

[0208] Unlike Figure 1 Equipment 1, Figure 2 The equipment consists of only four component tanks (the second component tank 19 for tobacco powder is absent), and lacks the screw conveyor 11 and buffer tank 44. The feed pump 20 and feed valve 21, water pump 26 and water valve 27 are not shown.

[0209] The first component tank 18 stores binders (e.g., carboxymethyl cellulose (CMC) and hydroxypropyl methyl cellulose (HPMC)), the third component tank 23 stores aerosol forming agents (such as polyols), the fourth component tank 24 stores pulp (i.e., a premix of cellulose fibers and water, for example), and the fifth water tank 25 stores water. Multiple inlets are combined into a single inlet 55 on the continuous mixer 2.

[0210] There is no buffer tank located on the transfer pipe 43 between the outlet 28 of the continuous mixer 2 and the casting box 32.

[0211] Continuous mixer 2 and Figure 1 The continuous mixer 2 is the same as that shown. In other embodiments not shown, the continuous mixer 2 may include two or more mixing tools 5 that rotate about a parallel axis.

[0212] exist Figure 2The heating and cooling devices not shown can be used with... Figure 1 The apparatus is the same as that disclosed. In other embodiments not shown, the heating device includes a source of hot air (instead of steam).

[0213] Cast sheets can have a strength of 100 N / cm in the machine direction or transverse direction. 2 With 500 N / cm 2 The breaking force between them.

[0214] Then, at the end of the drying step (downstream of the heating device), the cast sheet 42 obtained is wound into a roll and then slit into smaller rolls, or first slit into strips and then each strip is wound into a corresponding smaller roll.

[0215] The cast sheet 42 manufactured by apparatus 1 and by the method of this disclosure can be an aerosol generating matrix for manufacturing aerosol-generating articles, or it can be reconstituted tobacco leaves for manufacturing conventional smoking articles or also for manufacturing aerosol-generating articles. For example, the cast sheet 42 is rolled, aggregated, wrapped in a strip, and cut into aerosol-generating matrix bars designed to release volatile compounds through heat transfer from a heat source of the aerosol generating system. For example, the cast sheet 42 is shredded and mixed with other tobacco leaves to obtain a resulting tobacco blend intended to be lit and inhaled in conventional smoking articles.

[0216] Figure 3 and 4 The results show a comparison between cast sheets obtained by apparatus 1 and by the method of this disclosure (continuous mixing) and cast sheets obtained by conventional batch mixing. Figure 3 and Figure 4 The mechanical properties of the cast sheet 42, which vary with its position along the length of the roll of the cast sheet 42, are shown. Figure 3 The fracture strain is shown in the machine direction (i.e., the direction in which the sheet moves through the machine). Figure 4 The fracture force in the transverse direction is shown. "L1 0" refers to the first section of the roll being cast at the beginning of the process, while "L1 9" is the final section. The total size of each roll is 200 m, and each sampling point is set approximately every 20 m.

[0217] Figure 3 The fracture strain (elongation at break) at different points on the drum in the machine direction is shown. Lines C, D, E, F, and G relate to operation in the continuous mixing mode of this disclosure, while lines A and B relate to the batch mixing mode. The fracture strain of the slurry mixture obtained by the continuous mixing mode is higher than that of the slurry mixture obtained by the batch mode (Table 1 below).

[0218] Table 1

[0219]

[0220] Figure 4 The fracture forces in the transverse direction at different points on the drum are shown. Lines C, D, E, and F relate to operation in the continuous mixing mode of this disclosure, while lines A and B relate to the batch mixing mode. The fracture forces of the slurry mixture obtained by the continuous mixing mode are higher than those obtained by the batch mixing mode (Table 2 below).

[0221] Table 2

[0222]

[0223] For batch operation (lines C, D, E, F, G), a significant decrease in mechanical properties occurs as we approach the end of the drum. This is consistent with the fact that in batch operation, the slurry mixture has already partially degraded (aged) by the end of the process. On the other hand, for continuous operation (lines A and B), the mechanical properties are quite stable.

[0224] Furthermore, the cast sheet 42 manufactured by continuous mixing according to this disclosure appears more uniform visually compared to the cast sheet obtained by batch processing.

[0225] For the purposes of this specification and the appended claims, unless otherwise indicated, all figures representing quantities, quantities, percentages, etc., shall be understood to be modified by the term "about" in all cases. Furthermore, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges that may be specifically listed or not listed herein. Thus, in this context, the number A is understood to be A ± 5% of A. In this context, the number A can be considered to include a value within the general standard error for the measurement of the property 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 deviation from A does not materially affect the essential and novel features of the claimed invention. Moreover, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges that may be specifically listed or not listed herein.

Claims

1. Equipment for producing cast sheets for smoking articles, comprising: Continuous mixer (2), the continuous mixer being configured to mix formulation components and water to form a slurry mixture; The continuous mixer (2) defines a mixing path (4) and has at least one inlet communicating with the mixing path (4) and an outlet (28) located at the end of the mixing path (4), the at least one inlet being configured to feed the components and the water into the mixing path (4), and the outlet (28) being configured to discharge the slurry mixture from the continuous mixer (2); the continuous mixer (2) is configured to mix the components and the water while allowing the components and water to advance toward the outlet (28) in the mixing path (4); wherein the continuous mixer (2) The mixer (2) includes at least one mixing tool (5) located in the mixing path (4) and configured to mix the ingredients and the water, and to advance the ingredients, the water, and the slurry mixture along the mixing path (4); wherein the at least one mixing tool (5) is configured to rotate about an axis (XX) parallel to the mixing path (4); wherein the at least one inlet includes a plurality of inlets for the ingredients and a water inlet; wherein the mixing path (4) and the axis (XX) are horizontal, and the continuous mixer (2) is a horizontal mixer; Casting box (32), which is in fluid communication with the outlet (28) to receive the slurry mixture from the continuous mixer (2); The surface is located below the casting box (32) and configured to receive the slurry mixture from the casting box (32) and form a cast sheet (42).

2. The device according to claim 1, wherein the outlet (28) of the continuous mixer (2) is directly connected to the casting box (32), or the device (1) includes a buffer tank (44) placed between the outlet (28) of the continuous mixer (2) and the casting box (32).

3. The apparatus according to claim 2, comprising a pump (47) positioned between the outlet (28) of the continuous mixer (2) and the casting box (32) for pumping the slurry mixture to the casting box (32), optionally wherein the pump (47) operates between the buffer tank (44) and the casting box (32).

4. The device according to any one of claims 1 to 3, comprising a plurality of component tanks connected to the plurality of inlets for the components and a water tank (25) or water source operatively connected to the water inlets.

5. The device according to any one of claims 1 to 4, wherein the at least one mixing tool (5) comprises at least two mixing tools that rotate about a parallel axis.

6. The device according to any one of claims 1 to 5, wherein the plurality of inlets are located at different locations along the continuous mixer (2), or combined at a single location on the continuous mixer (2).

7. The apparatus according to any one of claims 1 to 6, comprising a two-way valve (30) located at the outlet (28) of the continuous mixer (2); the two-way valve (30) being configured to feed the slurry mixture toward the casting box (32) or to deflect the slurry mixture toward the discharge port (31).

8. The apparatus according to any one of claims 1 to 7, comprising a screw conveyor (11) having an inlet (15) provided with a hopper (17) and an outlet (16) connected to at least one inlet of the continuous mixer (2); wherein at least two of the plurality of component tanks are in communication with the hopper (17).

9. The device according to any one of claims 1 to 8, comprising a control unit (54) operatively connected to the continuous mixer (2), wherein the control unit (54) is configured to monitor and control at least one operating parameter of the continuous mixer (2), optionally the power consumption and / or rotational speed and / or temperature and / or torque of the at least one mixing tool (5).

10. A method for producing cast sheets for smoking articles, performed by the apparatus according to any one of claims 1 to 9, the method comprising: The formulation ingredients and water are fed through at least one inlet into the mixing path (4) of the continuous mixer (2); The ingredients and water are mixed while the ingredients and water are moved in the mixing path (4) toward the outlet (28) of the continuous mixer (2) to form a slurry mixture, and the slurry mixture is discharged from the outlet (28); The slurry mixture from the outlet (28) is cast onto the surface to form a cast sheet (42). The duration of the components, the water, and the slurry mixture in the continuous mixer (2) is between 1 minute and 20 minutes.

11. The method of claim 10, wherein feeding, mixing, and casting are performed simultaneously, at least during steady-state operation.

12. The method according to claim 10 or 11, wherein at least during steady-state operation, the slurry mixture advances in a continuous flow from the continuous mixer (2) to the surface.

13. The method according to any one of claims 10 to 12, wherein the holding time is between 5 minutes and 15 minutes, optionally between 8 minutes and 10 minutes.

14. The method according to any one of claims 10 to 13, wherein the flow rate of the slurry mixture exiting from the outlet (28) of the continuous mixer (2) is between 80 kg / h and 3000 kg / h, optionally between 1000 kg / h and 2500 kg / h.

15. The method according to any one of claims 10 to 14, wherein the continuous operating time of the device (1) is several hours, optionally between 30 hours and 60 hours, optionally 45 hours.

Images