Method for operating a continuous blade

Abstract

The present invention relates to a method for operating a continuous blade, the method comprising: - providing a continuous blade; - providing a movable support surface that conveys a sheet of material; - disposing the continuous blade relative to the movable support surface such that a first portion of the continuous blade contacts the movable support surface within a first region of the movable support surface and a second portion of the continuous blade contacts the movable support surface within a second region of the movable support surface; - wherein the first portion of the continuous blade removes the sheet of material from the movable support surface and - the second portion of the continuous blade removes the residue of the sheet of material from the movable support surface.

Description

Technical Field

[0001] The present invention relates to a method of operating a continuous blade. The present invention further relates to an apparatus for the production of a material sheet.

Background Art

[0002] Material sheets, such as sheets of aerosol-forming substrates or sheets of polymer films, are often deposited on a movable support surface (such as a conveyor belt for drying) by a wet process involving a slurry. After drying and evaporation of the solvent, a solid material sheet is formed, which needs to be removed from the movable support surface.

Summary of the Invention

Problems to be Solved by the Invention

[0003] Removing the material sheet from the movable support surface and then cleaning the support surface is often very time-consuming. The process of removing the material sheet may employ different apparatuses compared to cleaning the support surface. The repair and operation of these different apparatuses can be time-consuming. The repair and operation of these apparatuses may require frequent interruption of the material sheet production process.

[0004] Removal and cleaning may involve the use of blades. Operating such blades can pose safety problems. In particular, changing the blades can pose safety problems. Regularly replacing the blades can generate a large amount of waste. This may be due to the fact that the sheet of blades that fits into the blade holder has to be cut from a long coil of blades. This can result in waste such as cut ends.

[0005] It would be desirable to provide a method for operating a blade that reduces safety issues. Further, it would be desirable to provide a method for operating a blade that is less laborious. It would be desirable to provide a method for operating a blade that results in fewer interruptions required in the manufacturing process of the material sheet. Further, it would be desirable to provide a facility for manufacturing a material sheet that reduces safety issues and requires fewer interruptions in the manufacturing process.

Means for Solving the Problems

[0006] According to one embodiment of the present invention, a method for operating a continuous blade is provided. The method may include a method step of providing a continuous blade. The method may further include providing a movable support surface. The support surface may carry a material sheet. The method may further include disposing the continuous blade relative to the movable support surface such that a first portion of the continuous blade contacts the movable support surface within a first region of the movable support surface. The continuous blade may be disposed relative to the movable support surface such that a second portion of the continuous blade contacts the movable support surface within a second region of the movable support surface. The first portion of the continuous blade may remove the material sheet from the movable support surface. The second portion of the continuous blade may remove the residue of the material sheet from the movable support surface.

[0007] According to another embodiment of the present invention, a method for operating a continuous blade is provided. The method includes a method step of providing a continuous blade. Further, the method includes a method step of providing a movable support surface, the support surface carrying a material sheet. The continuous blade is arranged relative to the movable support surface such that a first portion of the continuous blade contacts the movable support surface within a first region of the movable support surface. The continuous blade is also arranged relative to the movable support surface such that a second portion of the continuous blade contacts the movable support surface within a second region of the movable support surface. The first portion of the continuous blade removes the material sheet from the movable support surface. The second portion of the continuous blade removes the residue of the material sheet from the movable support surface.

[0008] The method of the present invention may enable the removal of the material sheet from the movable support surface in a simple manner and the removal of the residue of the material sheet remaining on the movable support surface after the removal of the material sheet. The method may also enable the simultaneous removal of the material sheet and any residue of the material sheet remaining on the movable support surface after the removal of the material sheet. The method may also enable the use of a single continuous blade for both the removal of the material sheet and the removal of the residue of the material sheet from the movable support surface. This may provide an easier way to reduce blade waste and cuttings compared to methods where separate blades are used to remove the material sheet from the movable support surface and to remove the residue of the material sheet. The method of the present invention may also reduce the need to replace the used blade when the blade becomes dull. This may significantly reduce the need to interrupt the wet process of depositing slurry on the movable support surface to replace the blade. This may also provide a less expensive method compared to methods where separate blades are used to remove the material sheet and to remove the residue of the material sheet.

[0009] After the residue of the material sheet has been removed from the movable support surface, the support surface may be reused to deposit another sheet material thereon.

[0010] The terms "first part of the continuous blade" and "second part of the continuous blade" refer to the first and second parts of a single continuous blade.

[0011] The continuous blade may comprise a member of a part of the blade. Preferably, the continuous blade is formed as a monolithic continuous strip of the blade. The continuous blade may be in the form of a coil. The coil of the continuous blade may be configured to be unwound for disposition relative to the movable support surface.

[0012] This may provide an easy way to provide a continuous blade that can be unwound from a coil.

[0013] The movable support surface may comprise a transport direction for carrying the material sheet. The continuous blade may be guided obliquely with respect to the transport direction across a first region of the movable support surface. The continuous blade may be guided obliquely with respect to the transport direction across a second region of the movable support surface.

[0014] This may provide an easy way to dispose and guide the continuous blade across one or both of the first region of the movable support surface and the second region of the movable support surface. This may enable the first part of the continuous blade to continuously remove the material sheet from the movable support surface carrying the material sheet. This may also enable the second part of the continuous blade to continuously remove the residue of the material sheet from the movable support surface while the movable support surface is carrying the material sheet.

[0015] The first part of the continuous blade may be guided perpendicular to the conveying direction over a first region of the movable support surface. The second part of the continuous blade may be further guided perpendicular to the conveying direction over a second region of the movable support surface.

[0016] This may enable the particularly easy removal of either the material sheet or the residue of the material sheet from the movable support surface. This may enable the efficient removal of either the material sheet or the residue of the material sheet. This may enable the safe removal of either the material sheet or the residue of the material sheet.

[0017] The first part of the continuous blade may be arranged upstream of the second part of the continuous blade with respect to the conveying direction of the material sheet via the movable support surface.

[0018] This may enable the first part of the continuous blade to remove the material sheet. This may also enable the second part of the continuous blade to remove any residue remaining on the movable support surface from the support surface after the removal of the material sheet.

[0019] The first part of the continuous blade may be guided in a first guiding direction over a first region of the movable support surface. The second part of the continuous blade may be guided in a second guiding direction over a second region of the movable support surface. The second guiding direction may be opposite to the first guiding direction.

[0020] This may enable different parts of the continuous blade to be guided in different first and second guiding directions over the movable support surface. This may provide a way to save space for adopting different first and second parts of the continuous blade. This may provide an easy way to guide and arrange the first part of the continuous blade with respect to the second part of the continuous blade.

[0021] The continuous blade may comprise a first intermediate portion between the first part and the second part. The guiding direction of the continuous blade in the first intermediate portion may be changed from a first guiding direction to a second guiding direction.

[0022] The continuous blade may be continuously guided across a first region and a second region of the movable support surface while the material sheet is continuously conveyed via the movable support surface.

[0023] This may provide a simple way to continuously guide the continuous blade across the first region and the second region of the movable support surface. This enables the continuous use of most of the continuous blade for both the removal of the material sheet from the movable support surface and the removal of residues of the material sheet. This method may use most or preferably all of the continuous blade. This may provide continuous wear of the continuous blade across its entire area. This may reduce the frequency of replacing the used blade after it has become dull.

[0024] Specifically, the first part of the continuous blade may be guided in a first guiding direction across the first region of the movable support surface. After being guided across the first region of the movable support surface, this part of the continuous blade may become the first intermediate part of the continuous blade. In this first intermediate part, the guiding direction of the continuous blade may reverse from the first guiding direction to the second guiding direction. Thereafter, a part of the continuous blade whose guiding direction has been changed in the first intermediate part may be guided in a second guiding direction as the second part of the continuous blade across the second region of the movable support surface. This may provide a simple way to continuously guide the continuous blade across the movable support surface while the conveying surface conveys the material sheet. This may provide a simple way to employ a complete continuous blade for the removal of the material sheet and the removal of residues of the material sheet.

[0025] The continuous blade may be guided at a constant speed across a first region of the movable support surface and across a second region of the movable support surface.

[0026] This may enable a particularly simple way of continuously transporting the material sheet and removing the material sheet from the transport surface.

[0027] The movable support surface may comprise a drum for moving the transport surface. The movable support surface may be a continuous belt that moves continuously between two opposing drums. The upper part of the movable support surface may be transported in the forward transport direction, and the lower part of the transport surface may be transported in the backward transport direction. This may enable a continuous operation of the continuous belt as the movable support surface.

[0028] The drum may be configured to change the transport direction of the movable support surface. The drum may be configured to change the transport direction from the forward transport direction to the backward transport direction.

[0029] The continuous blade may be disposed relative to the movable support surface such that a first part of the continuous blade contacts the movable support surface within a first region of the movable support surface where a change in the transport direction takes place.

[0030] This may enable the first part of the continuous blade to easily remove the material sheet from the movable support surface. Specifically, when the material sheet is separated from the movable support surface, it may be easily transported to a secondary movable support surface. The material sheet may be further dried and further processed on the secondary movable support surface. The material sheet may be wound onto a bobbin after drying on the secondary support surface. The material sheet may, for example, fall from the movable support surface on a second transport surface where the material sheet is further dried and processed.

[0031] The temperature of the material sheet, specifically the sheet of the aerosol-forming substrate, may be a temperature in the range of 80 to 90 degrees Celsius, preferably 83 to 87 degrees Celsius, when the first part of the continuous blade removes the material sheet from the movable support surface. At this temperature of the material sheet, it may be easily removed from the movable support surface.

[0032] The movable support surface may include a thermally conductive material. The movable support surface may comprise a flexible metal belt. The movable support surface may comprise an endless conveyor belt, preferably an endless stainless steel conveyor belt. This may allow for a uniform distribution of heat after the deposition of the slurry on the steel conveyor belt. This may allow for a uniform drying of the slurry on the movable support surface, thereby forming the material sheet. This may also allow for an easy removal of the material sheet from the stainless steel conveyor belt.

[0033] One or both of the first part of the continuous blade and the second part of the continuous blade may be arranged relative to the movable support surface so as to contact the movable support surface in the area of contact between the drum and the movable support surface.

[0034] This may facilitate the removal of the material sheet from the movable support surface. This may allow for an easy separation of the material sheet from the movable support surface.

[0035] The feed roll may be employed to provide a bobbin of the continuous blade. The feed roll may be configured to unwind the first part of the continuous blade and the second part of the continuous blade.

[0036] This may provide an easy way to provide a longer coil of the continuous blade.

[0037] The feed roll may be employed to lift the first part of the continuous blade and the second part of the continuous blade after both the first part of the continuous blade and the second part of the continuous blade come into contact with a movable support surface.

[0038] This may provide a method for continuously unwinding and lifting the continuous blade while guiding the continuous blade across the movable support surface.

[0039] The continuous blade may be formed as a continuous metal strip having a first sharp edge on one end of a continuous strip, such as a metal strip. The strip of the continuous blade may be located in a plane. The continuous blade may be arranged with respect to the movable support surface such that the contact angle between the plane in which the first part of the continuous strip is located and the plane in which the movable surface extends is 19 to 25 degrees, preferably 21 to 23 degrees. This may increase the efficiency of removing the material sheet from the movable support surface.

[0040] The roll may be employed in the first intermediate portion of the continuous blade to change from a first guiding direction to a second guiding direction.

[0041] The roll may be capable of changing the guiding direction of the continuous blade from a first guiding direction to a second guiding direction while continuously guiding the continuous blade across the movable support surface.

[0042] In a further embodiment of the method of the present invention, one or both of a first blade holder in a first region of the movable support surface and a second blade holder in a second region of the movable support surface may be present. The first blade holder may be configured to guide the first part of the continuous blade in the first region of the movable support surface. The second blade holder may be configured to guide the second part of the continuous blade in the second region of the movable support surface.

[0043] The first blade holder may be configured to dispose the first part of the continuous blade relative to the first region of the movable support surface such that the first part of the continuous blade can contact the first region of the movable support surface. This may enable reliable removal of the material sheet from the movable support surface within the first region.

[0044] The second blade holder may be configured to dispose the second part of the continuous blade relative to the second region of the movable support surface such that the second part of the continuous blade can contact the second region of the movable support surface. This may enable reliable removal of the residue of the material sheet from the second region of the conveying surface.

[0045] One or both of the first blade holder and the second blade holder may be formed as guide rails. The guide rails may be configured to hold the first part of the continuous blade and the second part of the continuous blade in place respectively.

[0046] A wire, specifically a sharp metal wire, may be used as the continuous blade. Preferably, a continuous strip may be used as the continuous blade. The continuous strip may be a continuous metal strip. The continuous blade may be a metal strip having at least one first sharp edge. The at least one first sharp edge may be employed to contact the first region and the second region of the movable support surface for removing the material sheet and the residue of the material sheet. The metal strip may be, for example, one of stainless steel or alloyed carbon steel.

[0047] The continuous strip of the continuous blade may have a length. The length may be from 5 meters to 500 meters, preferably 450 meters or less.

[0048] The method of the present invention may allow the use of the full length of a continuous strip of blades. Specifically, the full length of the continuous strip of blades may be guided across a first region of the movable support surface and across a second region of the movable support surface. This method may be repeated until the full length of the continuous strip of blades becomes dull. For example, the continuous strip of blades may be in the form of a coil, such as a bobbin. The continuous strip of blades may be unwound and guided across the first region and the second region of the movable support surface and then wound up again as a coil. Thereafter, the continuous strip of blades may be repeatedly unwound and guided across the movable support surface until the continuous strip of blades becomes dull and needs to be replaced.

[0049] This may avoid the cut-off ends that may result when any of the waste of the continuous blades, for example, when it is necessary to cut the continuous blades into individual stripes for installation in a conventional doctor blade holder.

[0050] The continuous strip may comprise a first sharp edge and an opposing second sharp edge. The first sharp edge may be employed to contact the movable support surface within the first region of the movable support surface. The first sharp edge may also be employed to contact the movable support surface within the second region of the movable support surface.

[0051] After the first sharp edge of the continuous strip of blades becomes dull, the continuous strip may be rotated so that the second sharp edge contacts the movable support surface. Thereafter, the second sharp edge may be employed for the removal of the material sheet and the residue of the material sheet within the first region and the second region of the movable support surface.

[0052] According to another embodiment of the method of the present invention, a continuous blade having a first sharp edge and an opposing second sharp edge may be rotated between a first region of a movable support surface and a second region of the movable support surface. This may lead to the second sharp edge being employed to contact the second region of the movable support surface. In this embodiment of the method of the present invention, the first sharp edge may contact the first region of the movable support surface.

[0053] Such methods may make it possible to employ both the first and second sharp edges of the continuous blade, stopping the manufacturing process of the material sheet and reducing the need to replace the continuous blade. Such methods may allow for the same level of efficiency when employing the first and second sharp edges of the continuous blade. This may reduce the risk of lower efficiency when removing residues of the material sheet from the second region of the movable support surface.

[0054] The continuous blade may comprise a bobbin of one of a wire or a strip having a sharp edge. Preferably the continuous blade is a metal strip having at least one first sharp edge. The continuous blade may be a metal strip having a second sharp edge opposite the first sharp edge as already described above.

[0055] The material sheet may comprise one of an aerosol-forming substrate, preferably a homogenized aerosol-forming substrate, a thin film from the food industry, such as a soft mass or a polymer thin film.

[0056] Preferably the material sheet is a homogenized tobacco or plant material sheet comprising an aerosol-forming substrate.

[0057] In a further embodiment, the present invention provides a method as described herein that employs a continuous blade. The continuous blade may comprise a first end, a second end, and an intermediate section located between the first end and the second end. The intermediate section may comprise at least one sharp edge. The first end and the second end may not have sharp edges. The first end may comprise a first connecting element configured to be connectable to a second connecting element. The second end may comprise a second connecting element configured to be connectable to the first connecting element.

[0058] Such a continuous blade may enable an operator to handle the blade by one or both of the first end and the second end that do not have sharp edges. This may increase the safety of handling the continuous blade. This may reduce the risk of the operator being injured by at least one sharp edge within the intermediate section. This may enable the operator to easily connect the continuous blade to a replacement continuous blade when the continuous blade needs to be replaced.

[0059] The continuous blade may be guided a plurality of times across a first region of the movable support surface and across a second region of the movable support surface until the continuous blade needs to be replaced. If the continuous blade becomes overly dull to reliably remove the material sheet from the movable support surface, a need for replacement may arise. The first connecting element of the continuous blade that needs to be replaced may be connected to the second connecting element of the replacement continuous blade. The continuous blade that requires replacement may continue to be guided across a first region of the movable support surface and across a second region of the movable support surface, whereby the replacement continuous blade replaces the continuous blade that needs to be replaced.

[0060] This may provide an easy way to replace a continuous blade that needs to be replaced with a replacement continuous blade. This may allow the operator to simply replace the continuous blade without having to handle the blade within the intermediate section with the sharp edge. By connecting to the blade that needs to be replaced with the replacement continuous blade and further guiding the blade that needs to be replaced through the moving device of the continuous blade, a simple way to screw the replacement continuous blade into the equipment may be provided. After the replacement continuous blade is fully screwed into the equipment (specifically the moving device) for the production of the material sheet, the continuous blade that needs to be replaced can be disconnected from the connection with the replacement continuous blade. The continuous blade that requires replacement can then be discarded. The method of the present invention can be continued using the unused replacement continuous blade.

[0061] As used herein, the term "aerosol-forming substrate" relates to a substrate having the ability to release one or more volatile compounds capable of forming an aerosol. Such volatile compounds may be released by heating the aerosol-forming substrate. Advantageously, the aerosol-forming substrate may be part of an aerosol-generating article or a smoking article.

[0062] The aerosol-forming substrate may be a solid aerosol-forming substrate. The aerosol-forming substrate may comprise both solid and liquid components. The aerosol-forming substrate may comprise a tobacco-containing material containing volatile tobacco flavor compounds released from the substrate upon heating. The aerosol-forming substrate may comprise a non-tobacco material. The aerosol-forming substrate may comprise an aerosol-forming agent that facilitates the formation of a high-density stable aerosol. Suitable aerosol-forming agents are well known in the art and include polyhydric alcohols (such as triethylene glycol, 1,3-butanediol, glycerin, etc.), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate, etc.), and aliphatic esters of monocarboxylic acids, dicarboxylic acids, or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.), but are not limited thereto. The aerosol-forming agent may be a polyhydric alcohol or a mixture thereof (such as triethylene glycol, 1,3-butanediol, glycerin, etc.). The aerosol-forming agent may be propylene glycol. The aerosol-forming agent may comprise both glycerin and propylene glycol.

[0063] The aerosol-forming substrate may comprise a plant-derived material. The aerosol-forming substrate may comprise tobacco. The aerosol-forming substrate may comprise a tobacco-containing material containing volatile tobacco flavor compounds released from the aerosol-forming substrate upon heating. Alternatively, the aerosol-forming substrate may comprise a non-tobacco-containing material. The aerosol-forming substrate may comprise a homogenized plant-derived material. The final slurry may contain a small amount of tobacco. Specifically, the final slurry may contain up to 5 weight percent based on the total weight of the aerosol-forming substrate. Preferably, the final slurry contains a tobacco extract. This may result in an aerosol-forming substrate containing a tobacco extract.

[0064] Additionally, the aerosol-forming substrate may contain flavorants. These flavorants may impart flavors such as menthol, apple, mint, grapefruit, or vanilla.

[0065] The slurry or mass for obtaining the material sheet may include all of the above-described components and may also include a solvent such as water that will mostly evaporate when the solid material sheet is formed on a movable support surface.

[0066] The present invention further provides an apparatus for manufacturing a material sheet. The apparatus may include a movable support surface configured to carry the material sheet in a transport direction. The apparatus may also include a moving device having a continuous blade. The moving device may be configured to move the continuous blade across a first region of the movable support surface. The moving device may be configured to move the continuous blade across a second region of the movable support surface. A first portion of the continuous blade within the first region of the movable support surface may be disposed upstream of a second portion of the continuous blade within the second region of the movable support surface with respect to the transport direction of the material sheet. The moving device may be configured to bring the first portion of the continuous blade into contact with the first region of the movable support surface. The moving device may be configured to bring the second portion of the continuous blade into contact with the second region of the movable support surface.

[0067] According to another embodiment of the present invention, an apparatus for manufacturing a material sheet is provided. The apparatus includes a movable support surface configured to carry the material sheet in a transport direction. The apparatus further includes a moving device having a continuous blade, and the moving device is configured to move the continuous blade across a first region of the movable support surface. The moving device is also configured to move the continuous blade across a second region of the movable support surface. A first portion of the continuous blade within the first region of the movable support surface is disposed upstream of a second portion of the continuous blade within the second region of the movable support surface with respect to the transport direction. The moving device is configured to bring the first portion of the continuous blade into contact with the first region of the movable support surface. The moving device is also configured to bring the second portion of the continuous blade into contact with the second region of the movable support surface.

[0068] The moving device may be configured to bring the first part of the continuous blade into contact with a first region of the movable support surface, so that the material sheet located on the movable support surface can be removed from the support surface. The moving device of the equipment may also be configured to bring the second part of the continuous blade into contact with a second region of the movable support surface, so that any residue of the material sheet located on the movable support surface after the removal of the material sheet may be removed by the second part of the continuous blade.

[0069] Such equipment may be configured to remove the material sheet from the movable support surface using the first part of the continuous blade and to clean the movable support surface from any remaining residue of the material sheet using the second part of the continuous blade so that the movable support surface can be reused. The movable support surface may be cleaned, for example, using water and dried before being reused.

[0070] The moving device may be configured to guide the first part of the continuous blade in a first direction across a first region of the movable support surface. The moving device may be configured to guide the second part of the continuous blade in a second direction across a second region of the movable support surface. The second direction may be opposite to the first direction.

[0071] This may enable a space-saving arrangement of the continuous blade within the first and second regions of the movable support surface.

[0072] The moving device may be configured to guide the continuous blade obliquely with respect to the conveying direction of the material sheet across a first region of the movable support surface. Preferably, the moving device may be configured to guide the continuous blade perpendicular to the conveying direction of the material sheet across a first region of the movable support surface.

[0073] The moving device may be further configured to guide a continuous blade obliquely with respect to the conveying direction of the material sheet over a second region of the movable support surface. Preferably, the moving device may be configured to guide a continuous blade perpendicular to the conveying direction of the material sheet over a second region of the movable support surface.

[0074] The moving device may further comprise a feed roll. The feed roll may be configured to provide a bobbin of the continuous blade. Specifically, the feed roll may be configured to unwind a first part of the continuous blade and a second part of the continuous blade.

[0075] The feed roll may also be configured to receive the continuous blade after being guided over a first region and a second region of the movable support surface.

[0076] The moving device may further comprise a roll. The roll may be configured to change a first guiding direction of the continuous blade to a second guiding direction of the continuous blade.

[0077] The moving device may comprise a roll for changing the guiding direction and a feed roll. The moving device may be configured to continuously guide the continuous blade in a first guiding direction and a second guiding direction between the feed roll and the roll.

[0078] This may lead to the full length of the continuous blade used for the removal of the material sheet and residues of the material sheet.

[0079] The moving device of the equipment may be configured to move a continuous band of blades having a first sharp edge and an opposing second sharp edge. The moving device may be further configured to rotate the continuous band about the longitudinal axis of the band between a first region of the movable support surface and a second region of the movable support surface. This may lead to the moving device being configured to contact the first sharp edge with the first region of the movable support surface. This may lead to the moving device being configured to contact the second sharp edge with the second region of the movable support surface.

[0080] The present invention further provides a continuous blade. The continuous blade has a first end. The continuous blade has a second end. The continuous blade has an intermediate section with at least one sharp edge. The intermediate section is located between the first end and the second end. The intermediate section has at least one sharp edge. The first end and the second end have no sharp edges. The first end has a first connecting element configured to be connectable to a second connecting element. The second end of the continuous blade has a second connecting element configured to be connectable to the first connecting element.

[0081] The present invention further provides a continuous blade. The continuous blade may have a first end. The continuous blade may have a second end. The continuous blade may have an intermediate section with at least one sharp edge. The intermediate section may be located between the first end and the second end. The intermediate section may have at least one sharp edge. The first end and the second end may have no sharp edges. The first end may have a first connecting element configured to be connectable to a second connecting element. The second end of the continuous blade may have a second connecting element configured to be connectable to the first connecting element.

[0082] Such continuous blades may be easily handled by an operator via one or both of a first end and a second end without the risk of injuring the operator. The first and second ends of the continuous blade may facilitate handling of the blade without the need to handle the blade within an intermediate section having at least one sharp edge. A first connection element of the first end of the first continuous blade may be easily connected to a second connection element of the second continuous blade. This may enable the second continuous blade to replace the first continuous blade when the first continuous blade needs to be replaced. The second continuous blade may have the same design as the first continuous blade, including a first end and a second end adjacent to an intermediate section having at least one sharp edge. Specifically, the first continuous blade may be continuously guided through equipment (specifically, a moving device) for manufacturing a material sheet when connected to the second continuous blade. This may enable screwing the second continuous blade into the moving device of the equipment for manufacturing the material sheet. This may enable easy replacement of the first continuous blade by the second continuous blade without the need to handle the blade within an intermediate section having at least one sharp edge. After the second continuous blade is fully screwed into the moving device of the equipment, the first continuous blade can be disconnected from the connection with the second continuous blade and discarded.

[0083] The present invention also provides a continuous blade without any sharp edges. The continuous blade may include a central section. The central section may include a first end and a second end. At least one of the first end and the second end may include a first connection element configured to be connectable to a second connection element.

[0084] Such continuous blades without any sharp edges may function as "dummy" blades and may be used when starting up the equipment for manufacturing the material sheet. This "dummy" blade can be easily handled by the operator and can be positioned within the moving device of the equipment without the risk of injuring the operator. A continuous blade including an intermediate section with at least one sharp edge may be connected to the "dummy" blade by connecting a first connecting element of the "dummy" blade to a second connecting element of the continuous blade with a sharp edge. The "dummy" blade will also automatically engage the continuous blade with a sharp edge into the moving device when being guided through the moving device.

[0085] The following provides a non-exhaustive list of non-limiting examples. Any one or more of the features of these examples may be combined with any one or more of the features of another example, embodiment, or aspect described herein.

[0086] Example E1: A method for operating a continuous blade, comprising: - providing a continuous blade; - providing a movable support surface that transports a material sheet; - disposing the continuous blade relative to the movable support surface such that a first portion of the continuous blade contacts the movable support surface within a first region of the movable support surface and a second portion of the continuous blade contacts the movable support surface within a second region of the movable support surface; - the first portion of the continuous blade removing the material sheet from the movable support surface; and - the second portion of the continuous blade removing the residue of the material sheet from the movable support surface. Example E2: The method according to Example E1, wherein the movable support surface includes a conveying direction for conveying the material sheet, and the continuous blade is guided obliquely with respect to the conveying direction over a first region of the movable support surface, and preferably the continuous blade is further guided obliquely with respect to the conveying direction over a second region of the movable support surface. Example E3: The method according to Example E2, wherein the continuous blade is guided perpendicular to the conveying direction over a first region of the movable support surface, and preferably the continuous blade is further guided perpendicular to the conveying direction over a second region of the movable support surface. Example E4: The method according to any one of Examples E1 to E3, wherein the movable support surface includes a conveying direction for conveying the material sheet, and a first part of the continuous blade is disposed upstream of a second part of the continuous blade with respect to the conveying direction. Example E5: The method according to any one of Examples E1 to E4, wherein a first part of the continuous blade is guided in a first guiding direction over a first region of the movable support surface, and a second part of the continuous blade is guided in a second guiding direction over a second region of the movable support surface, and the second guiding direction is opposite to the first guiding direction. Example E6: The method according to Example E5, wherein the continuous blade includes a first intermediate part between the first part and the second part, and the guiding direction of the continuous blade in the first intermediate part is changed from the first guiding direction to the second guiding direction. Example E7: The method according to any one of Examples E1 to E6, wherein the continuous blade is continuously guided over a first region and a second region of the movable support surface, while the material sheet is continuously conveyed through the movable support surface. Example E8: The method according to any one of Examples E1 to E7, wherein the movable support surface includes a drum for moving the conveying surface, and preferably the drum is for changing the conveying direction of the movable support surface. Example E9: The method according to Example E8, wherein one or both of the first part of the continuous blade and the second part of the continuous blade are arranged with respect to the movable support surface so as to contact the movable support surface in the area of contact between the drum and the movable support surface. Example E10: The method according to any one of Examples E1 to E9, wherein a feed roll is employed to provide a bobbin of the continuous blade, preferably the feed roll is for unwinding the first part of the continuous blade and the second part of the continuous blade. Example E11: The method according to Example E10, wherein the feed roll is for winding up the first part of the continuous blade and the second part of the continuous blade after contacting the movable support surface. Example E12: The method according to any one of Examples E1 to E11, which is further subordinate to Example E6, wherein a roll is employed in the first intermediate part for changing from the first guiding direction to the second guiding direction. Example E13: The method according to any one of Examples E1 to E12, wherein one or both of a first blade holder in a first region of the movable support surface and a second blade holder in a second region of the movable support surface are present, the first blade holder being configured to guide the first part of the continuous blade in the first region of the movable support surface, and the second blade holder being configured to guide the second part of the continuous blade in the second region of the movable support surface. Example E14: The method according to any one of Examples E1 to E13, wherein one of a wire or a continuous band is used as the continuous blade, preferably the continuous band is used as the continuous blade. Example E15: The method according to Example E14, wherein the continuous band has a first sharp edge and an opposing second sharp edge, and the first sharp edge is employed to contact the movable support surface in the first region of the movable support surface. Example E16: The method according to Example E15, wherein the first sharp edge is employed to contact the movable support surface in the second region of the movable support surface. Example E17: The method according to Example E15, wherein the continuous blade is rotated between the first region of the movable support surface and the second region of the movable support surface such that the second sharp edge contacts the second region of the movable support surface. Example E18: The method according to any one of Examples E1 to E17, wherein the continuous blade comprises a bobbin of one of a wire or a strip having a sharp edge, preferably the continuous blade is a metal strip having at least one sharp edge. Example E19: The method according to any one of Examples E1 to E18, wherein the movable support surface comprises an endless conveyor belt. Example E20: The material sheet is - an aerosol forming substrate, preferably a homogenized aerosol forming substrate, a film for the food industry, or - a polymer thin film, and the method according to any one of Examples E1 to E19 includes one of them. Example E21. A continuous blade is employed, the continuous blade comprising a first end, a second end, and an intermediate section located between the first end and the second end, the intermediate section comprising at least one sharp edge, the first end and the second end having no sharp edges, the first end comprising a first connecting element configured to be connectable to a second connecting element, and the second end comprising a second connecting element configured to be connectable to the first connecting element, and the method according to any one of Examples E1 to E20. Example E22. The continuous blade is guided a plurality of times across the first region of the movable support surface and across the second region of the movable support surface until the continuous blade needs to be replaced. The first connecting element of the continuous blade that needs to be replaced is connected to the second connecting element of the replacement continuous blade, and the continuous blade that needs to be replaced is continuously guided across the first region of the movable support surface and across the second region of the movable support surface, whereby the replacement continuous blade replaces the continuous blade that needs to be replaced, and the method according to Example E21. Example E23: Equipment for the production of a material sheet, comprising: - A movable support surface configured to carry the material sheet in a transport direction; - A moving device having a continuous blade, the moving device being configured to move the continuous blade over a first region of the movable support surface and the moving device being configured to move the continuous blade over a second region of the movable support surface; - A first part of the continuous blade within the first region of the movable support surface is disposed upstream of a second part of the continuous blade in the second region of the movable support surface with respect to the transport direction; - The moving device is configured to bring the first part of the continuous blade into contact with the first region of the movable support surface; - The moving device is configured to bring the second part of the continuous blade into contact with the second region of the movable support surface. Example E24: The equipment according to Example E23, wherein the moving device is configured to bring the first part of the continuous blade into contact with the first region of the movable support surface, whereby the first part can remove the material sheet from the movable support surface, and the moving device is configured to bring the second part of the continuous blade into contact with the second region of the movable support surface, whereby the second part can remove the residue of the material sheet from the movable support surface. Example E25: The equipment according to either Example E23 or Example E24, wherein the moving device is configured to guide the first part of the continuous blade in a first guiding direction over the first region of the movable support surface and the moving device is configured to guide the second part of the continuous blade in a second guiding direction over the second region of the movable support surface, the second guiding direction being opposite to the first guiding direction. Example E26: The equipment according to any one of Examples E23 - E25, wherein the moving device is configured to guide a continuous blade obliquely with respect to the conveying direction over a first region of the movable support surface, and preferably the moving device is further configured to guide a continuous blade obliquely with respect to the conveying direction over a second region of the movable support surface. Example E27: The equipment according to any one of Examples E23 - E26, wherein the moving device further comprises a feed roll, and the feed roll is configured to provide a bobbin of the continuous blade, and preferably the feed roll is configured to unwind a first part of the continuous blade and a second part of the continuous blade. Example E28: The equipment according to any one of Examples E23 - E27, which is further subordinate to Example E23, wherein the moving device further comprises a roll, and the roll is configured to change from a first guiding direction to a second guiding direction. Example E29: The equipment according to any one of Examples E23 - E28, wherein the moving device is configured to move a continuous band of blades having a first sharp edge and an opposing second sharp edge, and the moving device is further configured to rotate the continuous band about the longitudinal axis of the band between a first region of the movable support surface and a second region of the movable support surface, and preferably the moving device is configured to bring the first sharp edge into contact with the first region of the movable support surface and the second sharp edge into contact with the second region of the movable support surface. Example E30. A continuous blade comprising a first end, a second end, and an intermediate section located between the first end and the second end, the intermediate section having at least one sharp edge, the first end and the second end having no sharp edges, the first end comprising a first connecting element configured to be connectable to a second connecting element, and the second end comprising a second connecting element configured to be connectable to the first connecting element.

[0087] Features described with respect to one embodiment may equally apply to other embodiments of the present invention.

[0088] Although only by way of illustration, the present invention will be further described with reference to the following accompanying drawings.

Brief Description of the Drawings

[0089]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

Modes for Carrying Out the Invention

[0090] In the following, elements having the same functionality are denoted by the same reference numerals throughout all the figures.

[0091] Figure 1 depicts a schematic cross-sectional view of an apparatus 18 for manufacturing a material sheet. The apparatus includes a movable support surface 10 and two separate drums 28 and 30 for moving the support surface 10. Both drums 28 and 30 rotate as indicated by the respective arrows within the drums such that the upper portion of the movable support surface 10 is moved in the forward conveyance direction as indicated by arrow 20 and the lower portion of the movable support surface 10 is moved in the rearward conveyance direction as indicated by arrow 22. Preferably, the movable support surface is an endless conveyor belt. A casting box 26 containing a slurry of the material for the sheet is employed to uniformly distribute the slurry containing the material of the material sheet onto the movable support surface 10. Preferably, the slurry of the material for the sheet preferably contains homogenized tobacco or plant material for manufacturing a homogenized tobacco or plant material sheet. The slurry distributed on the movable support surface 10 is dried by a heating device 16, thereby producing the material sheet 12. In the area of drum 30 where the forward conveyance direction 20 changes to the rearward conveyance direction 22, a continuous blade is positioned. For clarity only, a first portion 14A of the continuous blade and a second portion 14B of the continuous blade are shown in Figure 1. The first portion 14A of the continuous blade contacts the movable support surface within a first region 10A of the support surface, and the second portion 14B of the continuous blade contacts the movable support surface within a second region 10B of the support surface. The first portion 14A of the continuous blade is positioned upstream of the second portion 14B of the continuous blade with respect to the conveyance direction of the movable support surface. The first portion 14A of the continuous blade removes the material sheet 12 from the movable support surface 10, resulting in a removed material sheet 12A. The removed material sheet 12A may be further processed, for example, on a further conveyor belt, or may be dried to further reduce the moisture content of the material. The second portion 14B of the continuous blade is positioned further downstream with respect to the conveyance direction of the movable support surface and can remove the residue of the material sheet still adhering to the movable support surface from the support surface.After this cleaning step, the movable support surface can return to the casting box so that a layer of another material can be deposited on the movable support surface.

[0092] Figure 2 depicts a schematic front view of the facility 18 for manufacturing the material sheet. This Figure 2 shows only a part of the movable support surface, namely the drum 30 that rotates about the axis indicated by "A", and the drum 30 conveys the material sheet 12 located on the movable support surface 10 in the forward conveying direction 20. The facility 18 includes a feed roll 32 with a bobbin of a continuous band of blades, and the continuous band of blades can be unwound in the first guiding direction 36 and can be guided perpendicular to the forward conveying direction 20 of the material sheet across the movable support surface. There is a first blade holder 40, such as a guide rail, which guides the continuous blade 14 across the movable support surface. Specifically, the first blade holder 40 is configured to guide the first part 14A of the continuous blade across the first region of the movable support surface for removing the material sheet. After the continuous blade 14 passes through the movable conveying surface through the first blade holder 40, it is received by a roll 34 configured to change the guiding direction of the continuous blade. After changing the guiding direction, the second part 14B of the continuous blade is guided in the second guiding direction 38 across the second region of the movable support surface by a second blade holder 42. This second part 14B of the continuous blade can remove the residue of the material sheet still adhering to the movable support surface from the support surface. Thereafter, the continuous blade 14 leaves the second region of the movable support surface to be received by the feed roll 32. This method of guiding the continuous blade 14 through the first blade holder 40 onto the roll 34 and further into the second blade holder 42 and back to the feed roll can be repeated multiple times until the continuous blade 14 becomes dull. The right side of Figure 2 shows an enlarged partial view of the first part 14A of the continuous blade received in the first blade holder 40. One side of the continuous blade includes a first sharp edge 14C. This sharp edge is employed for removing the material sheet from the movable support surface in the first part of the continuous blade and for removing the residue of the material sheet in the second part of the continuous blade.

[0093] Figure 3 depicts a different embodiment of the facility 18 for providing a material sheet as compared to Figure 2. This facility 18 is configured to operate using a continuous strip of blades having a second sharp edge 14D opposite the first sharp edge 14C. This facility 18 includes the same elements as the apparatus shown in Figure 3, except that the roll 34 is replaced by an apparatus 44 for rotating the continuous blade. When the continuous blade 14 is unwound from the feed roll 32, the first sharp edge 14C of the continuous blade 14 is employed to remove the material sheet from the movable support surface 10. Thereafter, the apparatus 44 rotates the continuous blade about its longitudinal axis so that the second sharp edge 14D can be brought into contact with the movable support surface. The second sharp edge 14D is then employed to remove any residue of the material sheet from the movable support surface. The enlarged view of the continuous blade 14 in the upper right portion of the figure shows the first portion 14A of the continuous blade, and the continuous blade is guided by the first blade holder 40 by contacting the second sharp edge 14D of the blade. Thus, the first portion 14A of the continuous blade contacts the movable support surface via its first sharp edge 14C. The enlarged view of the continuous blade in the lower right portion of the figure shows the second portion 14B of the continuous blade after passing through the apparatus 44 for rotating the continuous blade. In this case, the first sharp edge 14C of the continuous blade is guided through the second blade holder 42, and the second sharp edge 14D is in contact with the movable support surface to remove the residue of the material sheet. This embodiment of the facility 18 can employ two opposing first sharp edges 14C and second sharp edges 14D of the continuous strip of blades without the need to manually rotate the blades. This significantly reduces the need to replace the continuous blade, which thus has a longer service life. The apparatus 44 for rotating the continuous blade may comprise a twisted guide rail formed in such a way that the continuous blade is rotated about its longitudinal axis so that the second sharp edge 14D can be brought into contact with the movable support surface.The device 44 for rotating a continuous blade may include a housing. The housing may ensure that the operator cannot access the blade while the blade is rotating.

[0094] FIG. 4 shows an enlarged schematic partial view of the area of the movable support surface 10 in contact with the drum 30. The first part 14A of the continuous blade and the second part 14B of the continuous blade are visible. The first part 14A of the continuous blade extends along a plane 46, and the movable support surface within this first area extends along a plane 48. The contact angle 50 located between both planes 46 and 48 can be determined to be between 19 and 25 degrees, preferably between 21 and 23 degrees, as described herein. Similarly, the second part 14B of the continuous blade extends along a plane 52, and each part of the movable support surface within this second area of the support surface extends along a plane 54. The contact angle 56 extending between both planes 52 and 54 can be determined in the same manner as the contact angle 50. These contact angles 50 and 56 each ensure the best operating mode for the first and second parts of the continuous blade. These contact angles may also reduce the risk of damage to the movable support surface. These contact angles may also reduce the risk that any residue remains on the movable support surface.

[0095] FIG. 5 shows a schematic view of one embodiment of a continuous blade 14 including a first end 60 and a second end 62. The first end comprises a first connecting element 60A, such as a clip. The second end 62 comprises a second connecting element 62A, such as an area for attaching a clip of the first connecting element. The first end and the second end are adjacent to an intermediate section 58 including a first sharp edge 14C. Such a continuous blade 14 can be easily handled by one or both of its first and second ends without the risk of injuring the operator.

[0096] Figure 6 shows a schematic view of a blunt "dummy blade" that includes a central section 64 without any sharp edges. Both ends of the central section 64 include first connection elements 60A, such as clips. These first connection elements can be connected to second connection elements of a continuous blade that include an intermediate section with sharp edges in order to position this continuous blade within a moving device of a facility for manufacturing a sheet of material. The "dummy" blade reduces the risk that an operator will be injured when handling the blade. The central section can be easily handled by an operator without the risk of being injured.

Claims

**Claim 1** A method for operating a continuous blade, comprising: - providing a continuous blade; - providing a movable support surface that conveys a material sheet; - disposing the continuous blade relative to the movable support surface such that a first portion of the continuous blade contacts the movable support surface within a first region of the movable support surface and a second portion of the continuous blade contacts the movable support surface within a second region of the movable support surface; - the first portion of the continuous blade removing the material sheet from the movable support surface; and - the second portion of the continuous blade removing a residue of the material sheet from the movable support surface. **Claim 2** The method of claim 1, wherein the movable support surface includes a conveying direction for conveying the material sheet, and the continuous blade is guided obliquely with respect to the conveying direction across the first region of the movable support surface, preferably further guided obliquely with respect to the conveying direction across the second region of the movable support surface. **Claim 3** The method of claim 2, wherein the continuous blade is guided perpendicular to the conveying direction across the first region of the movable support surface, preferably further guided perpendicular to the conveying direction across the second region of the movable support surface. **Claim 4** The method according to any one of claims 1 to 3, wherein the movable support surface includes a conveying direction for conveying the material sheet, and the first portion of the continuous blade is disposed upstream of the second portion of the continuous blade with respect to the conveying direction. **Claim 5** The method according to any one of claims 1 to 4, wherein the first portion of the continuous blade is guided in a first guiding direction across the first region of the movable support surface, and the second portion of the continuous blade is guided in a second guiding direction across the second region of the movable support surface, the second guiding direction being opposite to the first guiding direction. **Claim 6** The method according to any one of claims 1 to 5, wherein the continuous blade is continuously guided across the first region and the second region of the movable support surface, while the material sheet is continuously conveyed via the movable support surface.

7. The method according to any one of claims 1 to 6, wherein a roll is employed to change from the first guiding direction to the second guiding direction.

8. One or both of a first blade holder in the first region of the movable support surface and a second blade holder in the second region of the movable support surface are present, the first blade holder being configured to guide the first part of the continuous blade in the first region of the movable support surface, and the second blade holder being configured to guide the second part of the continuous blade in the second region of the movable support surface. The method according to any one of claims 1 to 7.

9. The method according to any one of claims 1 to 8, wherein one of a wire or a continuous band is used as the continuous blade, preferably the continuous band is used as the continuous blade.

10. The method according to claim 9, wherein the continuous band has a first sharp edge and an opposing second sharp edge, and the first sharp edge is employed to contact the movable support surface in the first region of the movable support surface.

11. The method according to claim 10, wherein the continuous blade is rotated between the first region of the movable support surface and the second region of the movable support surface such that the second sharp edge is employed to contact the second region of the movable support surface.

12. Equipment for the manufacture of a material sheet, comprising: - a movable support surface configured to convey a material sheet in a conveying direction; - a moving device having a continuous blade, the moving device being configured to move the continuous blade across a first region of the movable support surface and the moving device being configured to move the continuous blade across a second region of the movable support surface. - The first part of the continuous blade within the first region of the movable support surface is disposed upstream of the second part of the continuous blade in the second region of the movable support surface with respect to the conveying direction, - The moving device is configured to bring the first part of the continuous blade into contact with the first region of the movable support surface, - The moving device is configured to bring the second part of the continuous blade into contact with the second region of the movable support surface. Equipment.

13. The equipment according to claim 13, wherein the moving device further comprises a roll configured to change from the first guiding direction to the second guiding direction.

14. The moving device is configured to move a continuous band of blades having a first sharp edge and an opposing second sharp edge, and the moving device is further configured to rotate the continuous band about the longitudinal axis of the band between the first region of the movable support surface and the second region of the movable support surface, preferably the moving device is configured to bring the first sharp edge into contact with the first region of the movable support surface and the second sharp edge into contact with the second region of the movable support surface. The equipment according to any one of claim 12 or claim 13.

15. A continuous blade comprising a first end, a second end, and an intermediate section located between the first end and the second end, the intermediate section having at least one sharp edge, the first end and the second end having no sharp edges, the first end comprising a first connecting element configured to be connectable to a second connecting element, and the second end comprising a second connecting element configured to be connectable to the first connecting element. Continuous blade.

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