Formation of aerosol-generating substrates between conveyor surfaces

Abstract

Formation of an aerosol-generating substrate between conveyor surfaces. The present invention relates to an aerosol-generating substrate manufacturing system (1) comprising a first conveyor (14) having at least a first conveyor surface (19) and a second conveyor (21) having at least a second conveyor surface (27), wherein the first conveyor surface (19) provides support for an aerosol-generating material (3), the first conveyor surface (19) extending along a conveyance path (100), and the second conveyor surface (27) extending at least locally along the conveyance path (100), whereby the aerosol-generating material (3) is formed into an aerosol-generating substrate (4) between the first conveyor surface (19) and the second conveyor surface (27). The present invention further relates to a method of manufacturing an aerosol-generating substrate (4) and to the use of the first corrugated conveyor belt (17) to form the aerosol-generating material (3).

Description

[Technical Field]

[0001] The present disclosure relates to an aerosol-generating substrate manufacturing apparatus, a method for manufacturing an aerosol-generating substrate, and the use of a first corrugated conveyor belt. The aerosol-generating substrate may be a homogenized sheet of tobacco or non-tobacco for the manufacture of aerosol-generating articles, such as heat-and-non-combustion aerosol-generating articles. [Background technology]

[0002] In the manufacture of an aerosol-generating article, at least one component may include an aerosol-generating material that is subjected to a crimping process. The crimped component is then converged and cut into segments. These aerosol-generating segments are components of the aerosol-generating article.

[0003] A crimping installation comprising a first crimping roller and a second crimping roller between which a sheet of aerosol-generating material is processed is known from WO 2018 / 189325 A1. WO 2020 / 002652 A1 discloses a casting installation having a casting blade including a corrugated portion.

[0004] The crimping process serves to converge the sheet of aerosol-generating material to form a segment for an aerosol-generating article, but the crimping process also affects the amount of air contact, resistance to draw (RTD), among other things.

[0005] Applying the proper crimping pressure is a critical aspect of the crimping process, which has an impact on the RTD and, consequently, the user experience.

[0006] There is a need for new methods and equipment to provide an alternative to known crimping processes. Summary of the Invention

[0007] According to a first aspect of the present invention, there is provided an aerosol-generating substrate manufacturing apparatus. The aerosol-generating substrate manufacturing apparatus comprises a first conveyor having at least a first conveyor surface. The aerosol-generating substrate manufacturing apparatus comprises a second conveyor having at least a second conveyor surface. The first conveyor surface provides support for the aerosol-generating material. The first conveyor surface extends along a transport path. The second conveyor surface extends at least locally along the transport path. The aerosol-generating material is formed into an aerosol-generating substrate between the first conveyor surface and the second conveyor surface.

[0008] The aerosol-generating material may be a viscous slurry. The aerosol-generating substrate may have increased dimensional stability compared to the aerosol-generating material.

[0009] The aerosol-generating substrate may have a top surface and a bottom surface. The aerosol-generating material may be an intermediate product. Specifically, the aerosol-generating material may be a semi-finished product manufactured or prepared within an aerosol-generating substrate manufacturing facility. The aerosol-generating material may be received at a first end of the aerosol-generating substrate manufacturing facility. The aerosol-generating material received at the first end of the aerosol-generating substrate manufacturing facility may be processed along a conveying path. The aerosol-generating material may be a tobacco slurry. The processed and potentially dried aerosol-generating material may be an aerosol-generating substrate. The aerosol-generating substrate may be a formed tobacco leaf sheet. The aerosol-generating substrate may be a final product of the aerosol-generating substrate manufacturing facility. Specifically, the aerosol-generating substrate may be manufactured or prepared within the aerosol-generating substrate manufacturing facility ready for use in further processes in the manufacture of an aerosol-generating article. The types of chemical components may be the same in the intermediate product and the final product. The amount of water may differ between the intermediate product and the final product. The viscosity of the intermediate product and the final product may differ from each other. The stiffness of the intermediate product and the final product may differ from each other. The aerosol-generating substrate may have a lower moisture content than the aerosol-generating material. The aerosol-generating substrate may be a sheet or foil of aerosol-generating material, particularly a cast aerosol-generating material, processed in an aerosol-generating substrate manufacturing facility. The aerosol-generating substrate may be a tobacco web.

[0010] Specifically, the aerosol-generating material is transported along a transport path. The transport path may extend along at least a section of the aerosol-generating substrate manufacturing facility. Preferably, the transport path extends straight in the transport direction. Alternatively, the transport path may be a curved path. The transport path may be an undulating transport path. The transport path may have a longitudinal length of about 10 meters to about 150 meters, specifically about 20 meters to about 100 meters, and preferably about 30 meters to about 75 meters.

[0011] The second conveyor surface may extend at least along a partition of the conveying path. The partition may have a longitudinal length of about 5 meters to about 125 meters, specifically about 10 meters to about 95 meters, and preferably about 20 meters to about 50 meters. The first conveyor surface or the second conveyor surface, or the first conveyor surface and the second conveyor surface, may extend perpendicularly along the conveying path for a distance of 0.5 meters to 4 meters, specifically 1.5 meters to 2.5 meters, and more preferably 2 meters.

[0012] The aerosol-generating substrate manufacturing facility may be part, section, or unit of an aerosol-generating article production line, preferably for "heat-and-no-combustion" aerosol-generating articles. During the formation of the aerosol-generating material into the aerosol-generating substrate, the aerosol-generating material may be shaped into a desired shape.

[0013] The second conveyor may be disposed above the first conveyor. The second conveyor surface may be adapted to contact a top surface of the aerosol-generating material. The first conveyor surface may be adapted to contact a bottom surface of the aerosol-generating material. The first conveyor surface and the second conveyor surface may be adapted to move in the same direction. The first conveyor surface and the second conveyor surface may be adapted to move synchronously, particularly at least locally, along the transport path.

[0014] The present invention may enable forming the aerosol-generating material into an aerosol-generating substrate, particularly between two elongated surfaces along a transport path. The present invention may enable forming a desired shape on the aerosol-generating material, particularly between two elongated surfaces along a transport path. The present invention may enable applying pressure while forming the aerosol-generating material into an aerosol-generating substrate. The present invention may enable applying pressure while forming a desired shape on the aerosol-generating material. The amount of pressure applied may be sufficient to maintain the shape of the aerosol-generating substrate, particularly after fabrication, and at the same time minimize structural defects in the aerosol-generating substrate, such as cracks, tears, and ruptures. The present invention may enable applying pressure to the aerosol-generating material along the transport path, particularly for at least about 1 meter along the transport path, and more preferably for at least about 10 meters along the transport path. The present invention may enable applying pressure to sections of the aerosol-generating material for at least 1 minute, preferably at least 5 minutes, more preferably at least 20 minutes, and preferably less than 60 minutes. The present invention may enable reducing the average pressure required to form the aerosol-generating material into an aerosol-generating substrate, particularly without reducing production speed. The present invention may allow the overall manufacturing process to be carried out at high speeds, which may allow reduced pressures to be applied to the aerosol-generating material.

[0015] The first conveyor surface may be adapted to move or translate along the transport path, which may advantageously increase the contact time during which the first conveyor surface contacts the aerosol-generating material to form the aerosol-generating material into the aerosol-generating substrate.

[0016] The second conveyor surface may be adapted to move or translate at least locally along the transport path, which may advantageously increase contact time with the aerosol-generating material, wherein the second conveyor surface contacts the aerosol-generating material while applying pressure to the aerosol-generating material to form it into the aerosol-generating substrate, particularly between the first and second conveyor surfaces.

[0017] The first conveyor surface or the second conveyor surface, or the first and second conveyor surfaces, may be adapted to move at least locally in a straight line along the transport path, which may make it possible to reduce or avoid shear forces within the aerosol-generating substrate between the first and second conveyor surfaces.

[0018] The first conveyor may include at least two rollers. The at least two rollers may be adapted to rotate. At least one of the rollers may be a drive roller. The drive roller may be adapted to drive the first conveyor surface along the transport path.

[0019] The second conveyor may comprise at least two rollers, in particular three rollers. At least two rollers may be adapted to rotate. At least one of the rollers may be a drive roller. The drive roller may be adapted to at least locally move the second conveyor surface along the transport path. The drive rollers of the first conveyor and the second conveyor may be synchronized.

[0020] The first conveyor surface or the second conveyor surface, or the first conveyor surface and the second conveyor surface, may have a structured surface adapted to be embossed onto the surface of the aerosol-generating material.

[0021] The first conveyor surface or the second conveyor surface, or the first and second conveyor surfaces, may have corrugations on at least a portion thereof. This may advantageously allow the aerosol-generating material to be corrugated or to be formed on the aerosol-generating material. The formed corrugations may act as channels, specifically air channels, within the aerosol-generating article including the aerosol-generating substrate. The corrugations or channels may improve the release of material from the aerosol-generating article, specifically into the air flowing through the segments formed by the aerosol-generating substrate. The corrugations or channels may provide an advantageous RTD value for the aerosol-generating article including the aerosol-generating substrate. Advantageous RTD values ​​may be between 20 millimeters of water column and 70 millimeters of water column, specifically between about 22 millimeters of water column and about 68 millimeters of water column, or specifically between about 25 millimeters of water column and about 65 millimeters of water column, specifically between about 28 millimeters of water column and about 55 millimeters of water column, and specifically between about 35 millimeters of water column and about 52 millimeters of water column. Advantageous RTD values ​​may be 37 mm of water column, 40 mm of water column, 48 mm of water column, 50 mm of water column.

[0022] The first conveyor surface or the second conveyor surface may have corrugations in at least a portion thereof, while the other of the first conveyor surface and the second conveyor surface is at least substantially flat in the area facing the corrugated portion. The substantially flat conveyor surface may provide a substantially flat surface on the aerosol-generating material and may also increase the mechanical resilience of the aerosol-generating substrate, particularly the tensile strength of the aerosol-generating substrate.

[0023] The corrugated portions on the first conveyor surface and the corrugated portions on the second conveyor surface may be symmetrical or complementary with respect to each other. This may advantageously result in an aerosol-generating substrate having a symmetrical pattern of channels on the top and bottom surfaces of the aerosol-generating substrate. This arrangement may advantageously hinder the propagation of mechanical defects, particularly in a direction perpendicular to the transport path.

[0024] The corrugated portions on the first conveyor surface and the corrugated portions on the second conveyor surface may be asymmetric with respect to each other. This may advantageously result in an aerosol-generating substrate having a first pattern of channels on the top surface of the aerosol-generating substrate and a second pattern of channels on the bottom surface of the aerosol-generating substrate. This arrangement may advantageously hinder the propagation of mechanical defect cracks, particularly in a direction perpendicular to the conveying direction.

[0025] The corrugations may extend at least partially along the transport path of the aerosol-generating material.

[0026] The corrugations may be formed by alternating ridges and depressions. The ridges may be multiple protrusions extending outward in a direction perpendicular to the surface from which the ridges protrude. A depression may be formed between at least two consecutive ridges. The corrugations may have at least one shape from the following group: sinusoidal, sawtooth, zipper polygon, or polygon with rounded edges. The polygon may be triangular or rectangular. The corrugations on the first conveyor surface, or the corrugations on the second first conveyor surface, or the corrugations on the first conveyor surface and the corrugations on the second first conveyor surface, may be symmetrical. The corrugations on the first conveyor surface, or the corrugations on the second first conveyor surface, or the corrugations on the first conveyor surface and the corrugations on the second first conveyor surface may be asymmetrical.

[0027] At least some of the protuberances or recesses may have a height of about 0.01 mm to about 10 mm, specifically about 0.1 mm to about 3 mm, and preferably about 0.5 mm to about 2 mm. The heights of two consecutive protuberances may be different from each other.

[0028] At least a portion of the protrusions or recesses may have a width of about 0.01 mm to about 20 mm, specifically about 0.1 mm to about 10 mm, and preferably about 1 mm to about 5 mm. The widths of two consecutive protrusions may be different from each other.

[0029] The first conveyor surface or the second conveyor surface, or the first and second conveyor surfaces, may have at least interrupted gaps without corrugations. The interrupted gaps may extend perpendicular to the conveying direction. The interrupted gaps may be aligned at an angle relative to an axis perpendicular to the conveying direction. The angle may be between 1 and 45 degrees, specifically between 2 and 25 degrees, and more preferably between 3 and 15 degrees. The first conveyor surface or the second conveyor surface, or the first and second conveyor surfaces, may have a first corrugation pattern within the interrupted gaps that is different from the second corrugation pattern disposed on the first and / or second conveyor surfaces. The ridges or depressions, or the ridges and depressions, may have a lower height in the first corrugation pattern than in the second corrugation pattern. The interrupted gaps may advantageously increase the tensile strength of the aerosol-generating substrate.

[0030] The recesses on the first conveyor surface may not have protrusions on the second conveyor surface. This may ensure a separation distance between the first and second conveyor surfaces of the aerosol-generating substrate manufacturing equipment. The separation distance may extend perpendicular to the conveying direction. This arrangement between the first and second conveyor surfaces may allow for the application of appropriate pressure to form corrugations on the aerosol-generating material. This may reduce compression or deformation of the aerosol-generating material during the formation of corrugations on the aerosol-generating material.

[0031] The first conveyor may include a first conveyor belt forming a first conveyor surface.

[0032] The second conveyor may include a second conveyor belt forming a second conveyor surface.

[0033] The first conveyor belt and / or the second conveyor belt may be a metal conveyor belt. The width of the first conveyor belt, or the width of the second conveyor, or the width of the first conveyor belt and the second conveyor, may be 0.5 meters to 2 meters. The width of the first conveyor belt and / or the second conveyor may be approximately the same as the width of the bobbin on which the aerosol-generating substrate is wound. The width of the bobbin may be 1 meter to 1.5 meters, more preferably 1.3 meters.

[0034] The first conveyor belt or the second conveyor, or the first conveyor belt and the second conveyor belt, may be an endless conveyor belt.

[0035] The first conveyor belt or the second conveyor belt, or the first conveyor belt and the second conveyor belt, may be flexible.

[0036] The first movable support and / or the second movable support may be heatable. The first movable support and / or the second movable support may be heatable to a temperature of about 5 degrees Celsius to about 100 degrees Celsius, specifically about 10 degrees Celsius to about 80 degrees Celsius, and preferably about 15 degrees Celsius to about 50 degrees Celsius.

[0037] The first conveyor surface may be arranged at least locally parallel to the second conveyor surface, in particular along the transport path.

[0038] The aerosol-generating substrate manufacturing facility may include a casting device for casting the aerosol-generating material onto the first conveyor surface.

[0039] The casting device may be adapted to cast the aerosol-generating material onto the first conveyor surface. The aerosol-generating material cast onto the first conveyor surface may have a moisture content of about 90 weight percent to about 40 weight percent, specifically about 85 weight percent to about 50 weight percent, and preferably about 80 weight percent to about 60 weight percent. Specifically, the weight percentages are based on the total weight of the aerosol-generating material.

[0040] The casting apparatus may include a casting box adapted to contain a slurry of aerosol-generating material. The casting box may also include a density control device for controlling the density of the cast web. The casting box may have an opening on the bottom of the casting box. The slurry may be cast through the opening onto the first conveyor surface. The opening may extend perpendicular to the conveying direction.

[0041] The slurry may include one or more of the following components: an alkaloid-containing material, preferably a plant-derived material, more preferably tobacco; a binder, preferably guar or carboxymethylcellulose; cellulose fibers; an aerosol former; and water. The cellulose fibers advantageously have a length of about 0.3 millimeters to about 3 millimeters, specifically about 1 millimeter to about 2 millimeters.

[0042] The casting box may have any geometric shape, and may be, for example, a prism. The slurry of aerosol-generating material may be transported to the aerosol-generating substrate manufacturing facility through a slurry transport system of the aerosol-generating article production line. The slurry transport system or casting apparatus may include a pump, preferably with flow control.

[0043] The casting box may include a heating device. The temperature of the casting box may vary between 10°C and 50°C, specifically between 15°C and 35°C, and more preferably between 20°C and 28°C. The temperature of the aerosol-generating material slurry in the casting box may vary between 10°C and 50°C, specifically between 15°C and 35°C, and more preferably between 20°C and 28°C. This may advantageously allow the slurry to be maintained at a predetermined temperature, specifically by using a first temperature control means.

[0044] The apparatus may be adapted such that at least one roller of the first conveyor, particularly the roller disposed closer to the casting box, has a temperature between 0°C and 70°C, particularly between 5°C and 60°C, more preferably between 10°C and 30°C. At least one roller of the first conveyor may be heated. The roller may be heated by hot water provided inside the roller. This may advantageously allow the slurry, particularly on the first movable surface, to be maintained at a predetermined temperature. At least one roller of the first conveyor may be cooled. The roller may be cooled by cold water provided inside the roller.

[0045] The roller may be maintained at a temperature such that the temperature difference between the temperature of the first movable surface at the location of slurry deposition and the temperature of the slurry in the casting box is comprised between about 0 degrees Celsius and about 30 degrees Celsius, specifically between 0 degrees Celsius and about 15 degrees Celsius, and more preferably between 0 degrees Celsius and about 7 degrees Celsius. The temperature of the roller may be controlled by a second temperature control means.

[0046] The casting apparatus may include a casting blade adapted to cast the aerosol-generating material contained in the casting box onto the first conveyor surface. The casting blade, preferably in conjunction with a casting box level control system, may be used to control the thickness of the aerosol-generating material cast onto the first conveyor surface. A gap may exist between the casting blade and the first conveyor surface. The dimensions of the gap may determine the thickness of the aerosol-generating material. The gap may be larger than the average distance between the first and second conveyor surfaces in a direction perpendicular to these surfaces. This may allow for further spreading of the aerosol-generating material when processed between the first and second conveyor surfaces.

[0047] The second conveyor surface may be applied onto the aerosol-generating material immediately after it is cast onto the first conveyor surface. The distance between the first end of the second conveyor and the casting device may be between 50 millimeters and 10 meters, particularly between 100 millimeters and 5 meters, and more preferably between 200 millimeters and 1 meter.

[0048] The first conveyor surface may be at least partially disposed within at least the first drying unit. The rollers of the first conveyor may be disposed outside the first drying unit. The first drying unit may advantageously allow for the formation of a shape on the aerosol-generating material to be fixed. In the first drying unit, hot steam or hot air may be applied to the top and / or bottom surfaces of the aerosol-generating material. The drying unit may extend over at least about one-tenth, specifically at least about one-fifth, and preferably at least about one-third of the length of the conveying path. The temperature in the first drying unit may be between about 50°C and about 200°C, specifically between about 80°C and about 170°C, and preferably between about 100°C and about 140°C. The temperature in the first drying unit may be about 60°C. The drying unit may include subunits, specifically subunits of different lengths. The subunits may be set to different temperatures. The temperatures of the subunits may be sequentially decreased in the conveying direction, or the temperatures of the subunits may be sequentially increased in the conveying direction.

[0049] The second conveyor surface may be disposed at least partially within at least the first drying unit. The rollers of the second conveyor may be disposed outside the first drying unit. The rollers of the second conveyor may be disposed inside the first drying unit.

[0050] The first drying unit may be adapted to reduce the moisture content of the aerosol-generating material by about 90 weight percent to about 10 weight percent, specifically about 85 weight percent to about 15 weight percent, and preferably about 75 weight percent to about 20 weight percent, where the weight percentages are based on the total weight of the aerosol-generating material.

[0051] The first drying unit may comprise a heater, a steam dryer, or an air dryer.

[0052] The steam dryer may be operated using a pressure between 30 kilograms per hour and 500 kilograms per hour, specifically between 80 kilograms per hour and 300 kilograms per hour, and more preferably between 100 kilograms per hour and 200 kilograms per hour.

[0053] The first conveyor surface carrying the aerosol-generating material may be adapted to move or translate through the first drying unit.

[0054] At least a second drying unit may be disposed upstream or downstream from the second conveyor along the transport path, and the aerosol-generating substrate manufacturing equipment may be adapted to apply a second conveyor surface onto the aerosol-generating material before the first conveyor surface carrying the aerosol-generating material enters the second drying unit.

[0055] The second drying unit may include a heater, a steam dryer, or an air dryer. In the second drying unit, hot steam or hot air may be applied to the top and / or bottom of the aerosol-generating material. The temperature in the second drying unit may be lower than the temperature in the first drying unit. The temperature in the second drying unit may be higher than the temperature in the first drying unit. The second drying unit may include an air dryer. The drying air temperature in the second drying unit may be about 70°C to about 140°C, specifically about 75°C to about 105°C. The temperature in the second drying unit may be about 70°C to about 140°C, specifically about 75°C to about 105°C. The temperature in the second drying unit may be about 50°C to about 200°C, specifically about 80°C to about 170°C, preferably about 100°C to about 140°C. The temperature in the first drying unit may be about 60° C. The aerosol-generating substrate manufactured in the aerosol-generating substrate manufacturing facility may have corrugations in the form of ridges and / or depressions. At least one outer wall portion of the ridge or depression may be inclined at an angle of 2 to 45 degrees, more preferably 5 to 15 degrees, relative to an axis perpendicular to the base of the aerosol-generating substrate.

[0056] The aerosol-generating substrates produced in the aerosol-generating substrate-producing facility may be conveyed to a cooling section and then to a bobbin-forming unit or a slicing unit. The aerosol-generating substrates, particularly slices of the aerosol-generating substrates, may be conveyed to a rod-forming unit, where the slices of the aerosol-generating substrate are formed into rods.

[0057] According to a second aspect of the present invention, there is provided a method of manufacturing an aerosol-generating substrate, the method may include forming an aerosol-generating material between a first conveying surface of a first conveyor and a second conveying surface of a second conveyor, and drying the aerosol-generating material during formation.

[0058] The first conveying surface or the second conveying surface may comprise at least a portion of a corrugation.

[0059] The first conveyor surface may be the surface of a first conveyor belt.

[0060] The second conveyor surface may be the surface of a second conveyor belt.

[0061] The method may include translating the second conveyor surface along the transport path.

[0062] The method may include casting the aerosol-generating material onto the first conveyor, particularly onto the surface of the first conveyor.

[0063] The aerosol-generating material cast onto the first conveyor surface may have a moisture content of about 90 weight percent to about 40 weight percent, specifically about 85 weight percent to about 50 weight percent, and preferably about 80 weight percent to about 60 weight percent, where the weight percentages are based on the total weight of the aerosol-generating material.

[0064] The method may include drying the aerosol-generating material by applying heat to the aerosol-generating material, particularly by conveying the aerosol-generating material through hot air provided in a drying unit.

[0065] The aerosol-generating material dried in the drying unit may have a moisture content of about 10 percent to about 20 percent by weight, where the weight percentage is based on the total weight of the aerosol-generating material.

[0066] The aerosol-generating material may comprise a slurry containing alkaloid-containing material, preferably plant-derived material, more preferably tobacco.

[0067] The aerosol-generating substrate may be a sheet or foil or web or extrusion comprising alkaloid-containing material, preferably plant-derived material, more preferably tobacco.

[0068] According to a third aspect of the present invention, there is provided a use of a first corrugated conveyor belt for forming an aerosol-generating material. This may enable the aerosol-generating material to be formed into an aerosol-generating substrate, specifically by using only a single elongated surface along the aerosol-generating material's transport path. The present invention may enable the formation of a desired shape on the aerosol-generating material, specifically by using only a single elongated surface along the aerosol-generating material's transport path. The present invention may enable the formation of a desired shape on the aerosol-generating material, specifically without using mechanical force. This allows the formation of corrugations on the aerosol-generating material using only a single corrugated conveyor belt. This allows the aerosol-generating material to be shaped, while the aerosol-generating material is a viscous slurry. The shape formed on the aerosol-generating material may be fixed by drying the aerosol-generating material with hot steam and / or hot air, specifically in a drying unit. The first corrugated conveyor belt may be conveyed through the drying unit.

[0069] The use may include a second corrugated conveyor belt facing the first corrugated conveyor belt to form the aerosol-generating material between the first and second corrugated conveyor belts, which allows for shaping of the aerosol-generating material, particularly using mechanical force.

[0070] The water content of the aerosol-generating material may be between 90 percent and 40 percent by weight.

[0071] According to a fourth aspect of the present invention, there is provided an aerosol-generating substrate comprising an aerosol-generating substrate manufactured as described above, or an aerosol-generating substrate manufactured in an aerosol-generating substrate manufacturing facility as described above.

[0072] The aerosol-generating substrate may comprise a fibrous material, preferably a plastic fibrous material, more preferably a biodegradable fibrous material, more preferably cotton, more preferably cellulose.

[0073] According to a fifth aspect of the present invention, there is provided an aerosol-generating article comprising an aerosol-generating substrate or an aerosol-generating extrudate as described above. The aerosol-generating article may be a cigarette or a heatable smoking article adapted to generate an aerosol when heated to a temperature below its combustion temperature. The aerosol-generating article may comprise the aerosol-generating substrate in the form of a rod and at least a filter. At least wrapping paper may be wrapped around at least the filter and around the rod. According to a sixth aspect of the present invention, a system comprises an aerosol-generating substrate manufacturing facility as described above, an aerosol-generating material as described above, and an aerosol-generating substrate as described above.

[0074] The moisture content of the aerosol-generating material, particularly before the drying process, may be between 90 weight percent and 40 weight percent, specifically between 85 weight percent and 50 weight percent, and preferably between 80 weight percent and 60 weight percent. Specifically, the weight percentages are based on the total weight of the aerosol-generating material. After the drying process, the aerosol-generating material may have a moisture content of between about 10 weight percent and about 20 weight percent. Specifically, the weight percentages are based on the total weight of the aerosol-generating material. The dried aerosol-generating material may be an aerosol-generating substrate.

[0075] The aerosol-generating material may include plant-derived material, water, and additional aerosol formers. Weight percentage values ​​and ranges for components of the aerosol-generating material as provided herein are based on the total weight of the aerosol-generating material, in accordance with the art-known definition of "weight percent," unless otherwise specified.

[0076] Specifically, plant-derived materials are materials that contain alkaloids.

[0077] The amount of alkaloid- or plant-derived material in the aerosol-generating material is between 30 and 80 weight percent, more particularly between 40 and 70 weight percent, specifically based on the total weight of the aerosol-generating material.

[0078] Alkaloid-containing materials may be defined as materials that contain at least one alkaloid, which may include, for example, nicotine as found in tobacco.

[0079] Instead of or in addition to tobacco, other plant-derived materials may be part of the aerosol-generating material. The herbal material may be free of alkaloids.

[0080] Alkaloids are a group of naturally occurring chemical compounds that contain primarily basic nitrogen atoms. This group also includes some related compounds with neutral properties, and even some related compounds with weakly acidic properties. Some synthetic compounds of similar structure are also called alkaloids. In addition to carbon, hydrogen, and nitrogen, alkaloids may contain other elements such as oxygen, sulfur, and more rarely, chlorine, bromine, and phosphorus.

[0081] Alkaloids are produced by a wide variety of organisms, including bacteria, fungi, plants, and animals. They can be purified from crude extracts of these organisms by acid-base extraction. Caffeine, nicotine, theobromine, atropine, and tubocurarine are examples of alkaloids.

[0082] The alkaloid-containing material may be tobacco leaf.

[0083] Specifically, the alkaloid-containing material is a homogenized tobacco material, which is formed by agglomerating particulate tobacco containing at least the alkaloid nicotine. This homogenized tobacco material is typically produced from parts of the tobacco plant that are less suitable for the production of cut filler (e.g., tobacco stems, tobacco blades, or tobacco dust). Tobacco dust is typically produced as a by-product during the handling of tobacco leaves during manufacturing. The homogenized tobacco material may contain one or more small amounts of tobacco dust, tobacco fines, and other particulate tobacco by-products formed during tobacco processing, handling, and transportation. The starting material for the production of the homogenized tobacco material may be tobacco leaves having a majority of the same size and physical characteristics as the tobacco used to blend the cut filler. The tobacco present in the homogenized tobacco material may constitute the majority of the tobacco, or even substantially the total amount of tobacco present in the aerosol-generating material.

[0084] The alkaloid-containing material may also contain starch, however, the starch may also be included in the aerosol-generating material as a separate component.

[0085] Starch is a polymeric carbohydrate consisting of many glucose units joined by glycosidic bonds. It is produced by most green plants as an energy reserve. It is the most common carbohydrate in the human diet and is found in plants such as potato, wheat, maize (corn), rice, and tobacco. It consists of two types of polymers: linear and helical amylose, and branched amylopectin, which arrange themselves as semicrystalline granules within the plant.

[0086] Specifically, the particles of the alkaloid-containing material have an average particle size of 0.02 millimeters to 0.3 millimeters. An average particle size of about 0.02 millimeters to about 0.3 millimeters represents a particle size at which tobacco cells are at least partially destroyed. The use of alkaloid-containing material having such an average size advantageously leads to a smooth and uniform extrudate during downstream processing of the alkaloid-containing material.

[0087] Specifically, the water content of the aerosol-generating material is 5 to 70 weight percent or more, and particularly 10 to 18 weight percent, or 25 to 60 weight percent, and most particularly 11 to 14 weight percent, or 35 to 50 weight percent, where the weight percentages are based on the total weight of the aerosol-generating material.

[0088] Specifically, the amount of aerosol former in the aerosol-generating material is between 1 and 10 weight percent, particularly between 1 and 5 weight percent. Specifically, the weight percentage is based on the total weight of the aerosol-generating material. Specifically, the aerosol former is an additional component within the aerosol-generating material, considered separately from the alkaloid-containing material, particularly separately from tobacco.

[0089] Suitable aerosol formers for aerosol-generating materials are known in the art and include, but are not limited to, monohydric alcohols such as menthol, polyhydric alcohols (such as triethylene glycol, 1,3-butanediol, glycerin), esters of polyhydric alcohols (such as glycerol monoacetate, diacetate, or triacetate), and aliphatic esters of mono-, di-, or polycarboxylic acids (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, etc.).

[0090] Examples of preferred aerosol formers are glycerin and propylene glycol.

[0091] The alkaloid-containing material may have an aerosol former content of more than 3 weight percent of the total amount of alkaloid-containing material. Specifically, the weight percentage is based on the total weight of the alkaloid-containing material. Alternatively, the alkaloid-containing material may have an aerosol former content of between 3 weight percent and 30 weight percent. Specifically, the aerosol former consists of between 7 weight percent and 25 weight percent alkaloid-containing material. Specifically, the weight percentage is based on the total weight of the alkaloid-containing material. The aerosol former is especially comprised of between 10 weight percent and 25 weight percent alkaloid-containing material. Specifically, the weight percentage is based on the total weight of the alkaloid-containing material. Specifically, the aerosol former content of the alkaloid-containing material is an inherent component of the alkaloid-containing material, and therefore, the amount is not related to the amount of aerosol former that may be included in the aerosol-generating material, as described above.

[0092] Specifically, the aerosol-generating material may include a binder. Specifically, the amount of binder in the aerosol-generating material is at most 1 weight percent, but can include 1 to 15 weight percent, particularly 1 to 12 weight percent, and most particularly 1 to 5 weight percent. Specifically, the weight percentages are based on the total weight of the aerosol-generating material.

[0093] The binder in the aerosol-generating material may be any type of gum or pectin described herein. The binder may ensure that the particles of the alkaloid-containing material remain substantially dispersed throughout the aerosol-generating material and extrudate. For descriptive reviews of gums that can be used as binders, see Gums and Stabilizers for the Food Industry, IR.L Press (GO Phillip et al. eds. 1988); Whistler, Industrial Gums: Polysaccharides and Their Derivatives, Academic Press (2d ed. 1973); and Lawrence, Natural Gums for Edible Purposes, Noyes Data Corp. (1976).

[0094] While any binder may be employed, preferred binders are natural pectins (such as fruit pectin, citrus pectin, or tobacco pectin), guar gum (such as hydroxyethyl guar and hydroxypropyl guar), locust bean gum (such as hydroxyethyl locust bean gum and hydroxypropyl locust bean gum), alginates, starches (such as modified or derivatized starches), celluloses (such as methylcellulose, ethylcellulose, ethylhydroxymethylcellulose, and carboxymethylcellulose), tamarind gum, dextran, puralon, konjac flour, xanthan gum, and the like. A particularly preferred binder for use in the present invention is guar.

[0095] Specifically, the aerosol-generating material may contain reducing sugars in an amount of from 2 to 30 weight percent, particularly from 5 to 25 weight percent, even more particularly from 10 to 15 weight percent, and most particularly from 11 to 14 weight percent, wherein the weight percentages are based on the total weight of the aerosol-generating material.

[0096] Specifically, the reducing sugar may be glucose, fructose, xylose, ribose, or galactose, or a mixture thereof. Specifically, the reducing sugar is glucose, fructose, or a mixture of the two.

[0097] The presence of reducing sugars in the aerosol-generating material may modify the alkaloid-containing material when mechanical energy is applied to the aerosol-generating material. A reaction between the reducing sugar and the alkaloid-containing material may occur, particularly when the latter contains an ammonia- or ammonium-containing compound. This reaction may modify the composition of the alkaloid-containing material, such that the resulting mixture and aerosol-generating material have a lower amount of ammonia- or ammonium-containing compounds compared to an aerosol-generating material formed from a mixture that does not contain a reducing sugar. This may affect the properties and characteristics of the aerosol-generating material, for example, in terms of flavor.

[0098] Specifically, the aerosol-generating material may include cellulose fibers. Cellulose fibers are known to generally increase the tensile strength of the aerosol-generating substrate, thereby acting as a reinforcing agent. Cellulose fibers for aerosol-generating materials containing alkaloid-containing materials, such as homogenized tobacco material, are known in the art and include, but are not limited to, softwood fibers, hardwood fibers, jute fibers, flax fibers, tobacco fibers, and combinations thereof. Specifically, cellulose fibers, such as wood fibers, contain low lignin content. Alternatively, fibers such as plant fibers may be used either in combination with the above fibers or with hemp and bamboo fibers. Cellulose fibers may include tobacco stem material, petioles, or other tobacco plant materials.

[0099] The amount of cellulose fiber added to the aerosol-generating material can be 1 to 10 weight percent, particularly 1 to 7 weight percent, and more particularly 1 to 5 weight percent. Specifically, the weight percentages are based on the total weight of the aerosol-generating material. These values ​​do not include the amount of cellulose fiber contained in and associated with the alkaloid-containing material, which should be considered a separate component in the aerosol-generating material.

[0100] The length of the cellulose fibers is advantageously between 0.2 and 4 millimeters. Specifically, the average length per weight of the cellulose fibers is between 1 and 3 millimeters. In addition to pulping, the incorporated cellulose fibers may be subjected to suitable processes such as refining, mechanical pulping, chemical pulping, bleaching, sulfate pulping, and combinations thereof.

[0101] The binder and the cellulose fibers are preferably contained in a weight ratio comprised between about 1:7 and about 5:1, and more preferably in a weight ratio comprised between about 1:1 and about 3:1.

[0102] The binder and aerosol former are preferably present in a weight ratio of about 1:30 to about 1:1. More preferably, the binder and aerosol former are present in a weight ratio of about 1:20 to about 1:4.

[0103] The binder and tobacco particles are preferably present in a weight ratio of about 1:100 to about 1:10, more preferably about 1:50 to about 1:15, and even more preferably about 1:30 to 1:20.

[0104] The aerosol formers and tobacco particles are preferably present in a weight ratio of about 1:20 to about 1:1. More preferably, the aerosol formers and tobacco particles are present in a weight ratio of about 1:6 to about 1:2.

[0105] The aerosol formers and tobacco particles are preferably present in a weight ratio of about 1:20 to about 1:1. More preferably, the aerosol formers and tobacco particles are present in a weight ratio of about 1:6 to about 1:2.

[0106] The aerosol former and the cellulose fibers are preferably present in a weight ratio of about 1:1 to about 30:1. More preferably, the aerosol former and the cellulose fibers are present in a weight ratio of about 5:1 to about 15:1.

[0107] The cellulose fibers and tobacco particles are preferably contained in a weight ratio of about 1:100 to about 1:10, and more preferably in a weight ratio of about 1:50 to about 1:20.

[0108] The aerosol-generating material may be in the form of a slurry containing about 25 weight percent to about 95 weight percent, specifically about 45 weight percent to about 93 weight percent, of the alkaloid-containing material. Specifically, the weight percentages are based on the total weight of the first slurry. The first slurry composition may contain up to about 3 weight percent, specifically up to about 5 weight percent, of a binder. Specifically, the weight percentages are based on the total weight of the first slurry composition. The first slurry composition may contain about 0.5 weight percent to about 15 weight percent, specifically about 1 weight percent to about 7 weight percent, of cellulose fiber. Specifically, the weight percentages are based on the total weight of the first slurry composition. The first slurry composition may contain about 5 weight percent to about 45 weight percent, or about 15 weight percent to about 25 weight percent, of an aerosol former. The first slurry composition may contain about 20 weight percent to about 80 weight percent, or about 30 weight percent to about 70 weight percent water. Specifically, the weight percentages are based on the total weight of the first slurry composition.

[0109] The aerosol-generating material may be in the form of a slurry containing about 4.0 weight percent to about 5.0 weight percent, specifically about 4.46 weight percent, preferably about 4.5 weight percent, and more preferably about 4.55 weight percent, of the aerosol former. Specifically, the weight percentages are based on the total weight of the slurry. The second slurry composition may contain about 0.3 weight percent to about 1.5 weight percent, specifically about 0.57 weight percent, preferably about 0.58 weight percent, and more preferably about 0.59 weight percent, of the binder. Specifically, the weight percentages are based on the total weight of the second slurry composition. The second slurry composition may contain about 50 weight percent to about 80 weight percent, specifically about 73.18 weight percent, preferably about 73.92 weight percent, and more preferably about 74.66 weight percent, of water and cellulose fiber. Specifically, the weight percentages are based on the total weight of the second slurry composition. The second slurry composition may comprise 10 to 30 weight percent, specifically 20.79 weight percent, preferably 21.00 weight percent, and more preferably 21.21 weight percent, of the tobacco blend. Specifically, the weight percentages are based on the total weight of the second slurry composition. The tobacco blend may comprise tobacco particles from one type of tobacco or from different types of tobacco.

[0110] All features of the aerosol-generating substrate manufacturing equipment according to the first aspect may be used individually or in any combination in the method of manufacturing an aerosol-generating substrate according to the second aspect and in the use of the first corrugated conveyor belt according to the third aspect to form an aerosol-generating material. All features of the method of manufacturing an aerosol-generating substrate according to the second aspect may be implemented individually or in any combination in the aerosol-generating substrate manufacturing equipment and in the use of the first corrugated conveyor belt according to the third aspect to form an aerosol-generating material. All features of the use of the first corrugated conveyor belt according to the third aspect to form an aerosol-generating material may be applied or implemented individually or in any combination in the aerosol-generating substrate manufacturing equipment according to the first aspect or in the method of manufacturing an aerosol-generating substrate according to the second aspect.

[0111] The aerosol-generating substrate may be a sheet, foil, or web. The aerosol-generating substrate may be a layered element having a width and length substantially greater than its thickness. The sheet, foil, or web may be a layered element having a width and length substantially greater than its thickness. The aerosol-generating substrate may be crimped, and may specifically have a plurality of corrugations. The corrugations may comprise ridges or protrusions. The corrugations may include valleys or depressions. The corrugations are formed by ridges and depressions, or by ridges or depressions. The width of a ridge may be defined as a first distance between two peaks of consecutive depressions. The width of a depression may be defined as a first distance between two peaks of consecutive ridges. The distance between the peak of a ridge and the peak of a depression may define the height of the ridge or depression.

[0112] As used herein, the term "forming" means giving a shape.

[0113] The apparatus, methods, and uses according to aspects of the present invention may not include a crimping roller. Specifically, a crimping roller is a roller having ridges and recesses on its outer surface. The apparatus, methods, and uses according to aspects of the present invention may be adapted to provide a surface structure similar to a crimp profile to an aerosol-generating material or aerosol-generating substrate without the use of a crimping roller. The invention is defined in the claims. However, a non-exhaustive list of non-limiting examples is provided below. Any one or more of the features of these examples may be combined with any one or more features described above, for example, with any one or more features of other examples, embodiments, or aspects described herein.

[0114] Example Ex1: An aerosol-generating substrate manufacturing facility, a first conveyor having at least a first conveyor surface; a second conveyor having at least a second conveyor surface; a first conveyor surface providing support for the aerosol-generating material; a first conveyor surface extending along the conveying path; a second conveyor surface extending at least locally along the conveying path; This allows the aerosol-generating material to be formed into an aerosol-generating substrate between the first conveyor surface and the second conveyor surface, in an aerosol-generating substrate manufacturing facility.

[0115] Example Ex2: An aerosol-generating substrate manufacturing installation according to example Ex1, in which the second conveyor surface is adapted to translate along the transport path at least locally, in particular without rotating, along the transport path.

[0116] Example Ex3: An aerosol-generating substrate manufacturing installation according to Example Ex1 or Ex2, wherein the second conveyor comprises at least two rollers.

[0117] Example Ex4: An aerosol-generating substrate manufacturing installation according to one or more of the preceding examples Ex1 to Ex3, wherein the first conveyor surface or the second conveyor surface, or the first conveyor surface and the second conveyor surface, are at least partially provided with corrugations.

[0118] Example Ex5: An aerosol-generating substrate manufacturing installation according to one or more of the preceding Examples Ex1 to Ex4, wherein one of the first conveyor surface or the second conveyor surface has corrugations in at least a portion thereof, while the other of the first conveyor surface and the second conveyor surface is substantially flat at least in the area facing the portion having the corrugations.

[0119] Example Ex6: An aerosol-generating substrate manufacturing installation according to Example Ex4, in which the corrugated portion on the first conveyor surface and the corrugated portion on the second conveyor surface are symmetrical or complementary with respect to each other.

[0120] Example Ex7: An aerosol-generating substrate manufacturing installation according to Example Ex4, in which the corrugated portion on the first conveyor surface and the corrugated portion on the second conveyor surface are asymmetric with respect to each other.

[0121] Example Ex8: An aerosol-generating substrate manufacturing installation according to one or more of the preceding examples Ex4 to Ex7, wherein the corrugations extend at least partially along the conveyance path of the aerosol-generating material.

[0122] Example Ex9: Apparatus for manufacturing an aerosol-generating substrate according to one or more of the preceding examples Ex4 to Ex8, wherein the corrugations are formed by ridges and / or recesses.

[0123] Example Ex10: Apparatus for manufacturing an aerosol-generating substrate according to one or more of the preceding examples Ex4 to Ex9, wherein the corrugations are formed by ridges and recesses, and the recesses in the first conveyor surface do not include the ridges in the second conveyor surface.

[0124] Example Ex11: Apparatus for manufacturing an aerosol-generating substrate according to one or more of the preceding examples Ex4 to Ex9, wherein the corrugations are formed by ridges and recesses, and the recesses in the first conveyor surface do not include the ridges in the second conveyor surface.

[0125] Example Ex12: An aerosol-generating substrate manufacturing apparatus according to one or more of the preceding Examples Ex9 to Ex11, wherein at least some of the protuberances have a height of from about 0.01 millimeters to about 10 millimeters, particularly from about 0.1 millimeters to about 3 millimeters, and preferably from about 0.5 millimeters to about 2 millimeters.

[0126] Example Ex13: An aerosol-generating substrate manufacturing apparatus according to one or more of the preceding Examples Ex9 to Ex12, wherein at least some of the protuberances have a width of from about 0.01 millimeters to about 20 millimeters, particularly from about 0.1 millimeters to about 10 millimeters, and preferably from about 1 millimeter to about 5 millimeters.

[0127] Example Ex14: An aerosol-generating substrate manufacturing installation according to one or more of the preceding examples Ex1 to Ex13, wherein the first conveyor comprises a first conveyor belt forming the first conveyor surface.

[0128] Example Ex15: An aerosol-generating substrate manufacturing installation according to one or more of the preceding Examples Ex1 to Ex14, wherein the second conveyor comprises a second conveyor belt forming the second conveyor surface.

[0129] Example Ex16: An aerosol-generating substrate manufacturing installation according to one or more of the preceding examples Ex1 to Ex15, wherein the first conveyor surface is arranged locally parallel to the second conveyor surface, specifically along the transport path of the aerosol-generating material.

[0130] Example Ex17: An aerosol-generating substrate manufacturing installation according to one or more of the preceding Examples Ex1 to Ex16, further comprising a casting apparatus for casting aerosol-generating material onto the first conveyor surface.

[0131] Example Ex18: An aerosol-generating substrate manufacturing system according to Example Ex17, wherein the casting apparatus is adapted to cast the aerosol-generating material onto the first conveyor surface at a moisture content of from about 90 weight percent to about 40 weight percent, specifically from about 85 weight percent to about 50 weight percent, and preferably from about 80 weight percent to about 60 weight percent, wherein the weight percentage is based on the total weight of the aerosol-generating material.

[0132] Example Ex19: An aerosol-generating substrate manufacturing installation according to one or more of the preceding Examples Ex17-Ex18, wherein the casting apparatus comprises a casting box adapted to contain a slurry of aerosol-generating material.

[0133] Example Ex20: An aerosol-generating substrate manufacturing installation according to one or more of the preceding Examples Ex17 to Ex19, wherein the casting apparatus comprises a casting blade adapted to cast aerosol-generating material contained in a casting box onto the first conveyor surface.

[0134] Example Ex21: An aerosol-generating substrate manufacturing installation according to one or more of the preceding Examples Ex1 to Ex20, wherein the first conveyor surface is disposed at least partially within the first drying unit.

[0135] Example Ex22: An aerosol-generating substrate manufacturing installation according to Example Ex21, wherein the first drying unit is adapted to reduce the moisture content of the aerosol-generating material from about 90 weight percent to about 10 weight percent, specifically from about 85 weight percent to about 15 weight percent, and preferably from about 75 weight percent to about 20 weight percent, wherein the weight percentages are based on the total weight of the aerosol-generating material.

[0136] Example Ex23: An aerosol-generating substrate manufacturing installation according to Example Ex21 or Ex22, wherein the first drying unit comprises a heater, a steam dryer, or an air dryer.

[0137] Example Ex24: An aerosol-generating substrate manufacturing installation according to one or more of the preceding Examples Ex21 to Ex23, wherein the temperature in the first drying unit is between about 50 degrees Celsius and about 200 degrees Celsius, particularly between about 80 degrees Celsius and about 170 degrees Celsius, preferably between about 100 degrees Celsius and about 140 degrees Celsius.

[0138] Example Ex25: An aerosol-generating substrate manufacturing installation according to one or more of the preceding Examples Ex21 to Ex23, wherein at least a second drying unit is disposed upstream or downstream relative to the second conveyor along the transport path.

[0139] Example Ex26: A method for producing an aerosol-generating substrate, comprising: The method includes forming an aerosol-generating material between a first conveying surface of a first conveyor and a second conveying surface of a second conveyor, and drying the aerosol-generating material during formation.

[0140] Example Ex27: A method of producing an aerosol-generating substrate according to Example Ex26, wherein the first conveyor surface is the surface of a first conveyor belt.

[0141] Example Ex28: A method of producing an aerosol-generating substrate according to Example Ex26 or Ex27, wherein the second conveyor surface is the surface of a second conveyor belt.

[0142] Example Ex29: A method of producing an aerosol-generating substrate according to one or more of the preceding Examples Ex26 to Ex28, further comprising translating the second conveyor surface along the transport path.

[0143] Example Ex30: A method of producing an aerosol-generating substrate according to one or more of the preceding Examples Ex26 to Ex29, further comprising the step of casting an aerosol-generating material onto the first conveyor, particularly onto the surface of the first conveyor.

[0144] Example Ex31: A method of producing an aerosol-generating substrate according to Example Ex30, further comprising: the aerosol-generating material cast onto the first conveyor surface having a moisture content of between 90 and 40 weight percent, specifically between 85 and 50 weight percent, and preferably between 80 and 60 weight percent, wherein the weight percentages are based on the total weight of the aerosol-generating material.

[0145] Example Ex32: A method of producing an aerosol-generating substrate according to one or more of the preceding Examples Ex26 to Ex31, wherein the aerosol-generating material cast onto the first conveyor surface has a moisture content of between 90 and 40 weight percent, particularly between 85 and 50 weight percent, and preferably between 80 and 60 weight percent. Specifically, the weight percentages are based on the total weight of the aerosol-generating material. Example Ex33: A method of producing an aerosol-generating substrate according to one or more of the preceding Examples Ex26 to Ex32, further comprising drying the aerosol-generating material by applying heat to the aerosol-generating material, particularly by conveying the aerosol-generating material through hot air provided in a drying unit.

[0146] Example Ex34: A method of producing an aerosol-generating substrate according to one or more of the preceding Examples Ex26 to Ex33, wherein the aerosol-generating material is a slurry comprising an alkaloid-containing material, preferably a plant-derived material, more preferably tobacco.

[0147] Example Ex35: A method of producing an aerosol-generating substrate according to one or more of the preceding Examples Ex26 to Ex34, wherein the aerosol-generating substrate is a sheet or foil or web or extrusion comprising alkaloid-containing material, preferably plant-derived material, more preferably tobacco.

[0148] Example Ex36: An aerosol-generating substrate comprising an aerosol-generating substrate produced according to the method described in any one of Examples Ex26 to Ex35 or produced in an aerosol-generating substrate production facility according to any one of Examples Ex1 to Ex23.

[0149] Example Ex37: An aerosol-generating substrate according to Ex36, comprising a fibre-based material, preferably a plastic fibre-based material, more preferably a biodegradable fibre-based material, more preferably cotton, more preferably cellulose.

[0150] Example Ex38: An aerosol-generating article comprising an aerosol-generating substrate according to Ex37.

[0151] Example Ex39: A system comprising an aerosol-generating substrate manufacturing installation according to any one of Examples Ex1 to Ex23, an aerosol-generating material, and an aerosol-generating substrate according to any one of Examples Ex36 or Ex37.

[0152] Example Ex40: Use of a first corrugated conveyor belt to form an aerosol-generating material.

[0153] Example Ex41: Use according to example Ex40, further comprising using a second corrugated conveyor belt facing the first corrugated conveyor belt to form an aerosol-generating material between the first corrugated conveyor belt and the second corrugated conveyor belt.

[0154] Example Ex42: Use according to Example Ex40 or Ex41, wherein the water content of the aerosol-generating material is between 90 and 40 weight percent, particularly between 85 and 50 weight percent, preferably between 80 and 60 weight percent, wherein the weight percentages are based on the total weight of the aerosol-generating material.

[0155] The embodiments will now be further described with reference to the figures. [Brief explanation of the drawings]

[0156] [Figure 1] FIG. 1 is a schematic side view of an aerosol-generating substrate manufacturing facility according to an embodiment of the present invention. [Figure 2] FIG. 2 is a schematic side view of an aerosol-generating substrate manufacturing facility according to an embodiment of the present invention. [Figure 3] FIG. 3 is a schematic side view of a first conveyor surface and a second conveyor surface of an aerosol-generating substrate manufacturing facility according to one embodiment. [Figure 4] FIG. 4 is a schematic side view of a first conveyor surface and a second conveyor surface of an aerosol-generating substrate manufacturing facility according to one embodiment. [Figure 5] FIG. 5 is a schematic side view of a first conveyor surface and a second conveyor surface of an aerosol-generating substrate manufacturing facility according to one embodiment. [Figure 6] FIG. 6 is a schematic side view of a first conveyor surface and a second conveyor surface of an aerosol-generating substrate manufacturing facility according to one embodiment. [Figure 7] FIG. 7 is a schematic side view of a first conveyor surface or a second conveyor surface of an aerosol-generating substrate manufacturing facility according to one embodiment. [Figure 8] FIG. 8 is a schematic side view of a first conveyor surface or a second conveyor surface of an aerosol-generating substrate manufacturing facility according to one embodiment. [Figure 9] FIG. 9 is a schematic side view of a first conveyor surface or a second conveyor surface of an aerosol-generating substrate manufacturing facility according to one embodiment. [Figure 10] FIG. 10 is a schematic side view of a first conveyor surface or a second conveyor surface of an aerosol-generating substrate manufacturing facility according to one embodiment. [Figure 11] FIG. 11 is a schematic side view of a first conveyor surface or a second conveyor surface of an aerosol-generating substrate manufacturing facility according to one embodiment. [Figure 12] FIG. 12 is a schematic side view of a first conveyor surface or a second conveyor surface of an aerosol-generating substrate manufacturing facility according to one embodiment. [Figure 13]FIG. 13 is a schematic side view of a first conveyor surface or a second conveyor surface of an aerosol-generating substrate manufacturing facility according to one embodiment. DETAILED DESCRIPTION OF THE INVENTION

[0157] 1 illustrates one embodiment of an aerosol-generating substrate manufacturing facility 1. The aerosol-generating substrate manufacturing facility 1 is a unit of an aerosol-generating article production line 2. The aerosol-generating substrate manufacturing facility 1 is adapted to cast an aerosol-generating material 3 and form the aerosol-generating material 3 into an aerosol-generating substrate 4.

[0158] The aerosol-generating substrate manufacturing facility 1 comprises a casting apparatus 5. The casting apparatus 5 is equipped with a casting box 6 and a casting blade 7. The temperature of the casting box 6 can be varied to modify the temperature of the slurry 8 of aerosol-generating material 3. This can be done by a casting box control means 12.

[0159] The slurry 8 of aerosol-generating material 3 may be transferred to the aerosol-generating substrate manufacturing facility 1 through a slurry transfer system 9 of the aerosol-generating article production line 2. The slurry transfer system 9 may preferably include a pump 10 having flow control 11.

[0160] The casting blade 7 , preferably in conjunction with a control means 12 on the casting box 6 , is used to control the thickness 13 of the slurry 8 of aerosol-generating material 3 cast onto a first conveyor 14 .

[0161] First conveyor 14 includes first roller 15, second roller 16, and first conveyor belt 17. First roller 15 and second roller 16 rotate as indicated by first arrow 18, driving first conveyor belt 17. First conveyor belt 17 has a first conveyor surface 19. Aerosol-generating material 3 is cast onto first conveyor belt 17, more specifically, onto first conveyor surface 19. First conveyor surface 19 of first conveyor belt 17 supports aerosol-generating material 3 along a transport path 20. Casting device 5 is disposed above first roller 15. A gap is provided between casting blade 6 and first conveyor surface 19. The dimensions of the gap determine, at least initially, the thickness 13 of aerosol-generating material 3.

[0162] A second conveyor 21 is provided above the first conveyor 14. The second conveyor 21 includes a first roller 22, a second roller 23, a third roller 24, and a second conveyor belt 25. The first roller 22, the second roller 23, and the third roller 24 rotate as indicated by a second arrow 26 and move the second conveyor belt 25 at least locally along the transport path 20. The second conveyor belt 25 has a second conveyor surface 27.

[0163] The aerosol-generating substrate manufacturing facility 1 according to the embodiment illustrated in FIG. 1 includes a first drying unit 28. A steam dryer 29 for providing steam and / or an air dryer 30 for providing heated air may be provided within the aerosol-generating substrate manufacturing facility 1. The first drying unit 28 may include the steam dryer 29 and / or the air dryer 30. Preferably, drying using steam is performed on a first side 31 of the aerosol-generating material 3 that contacts the first conveyor surface 19. Preferably, drying using heated air or steam is performed on a second side 32 of the aerosol-generating material 3.

[0164] Before the first conveyor belt 17, more specifically, the first conveyor surface 19 and the aerosol-generating material 3 conveyed by the first conveyor belt 17, enters the first drying unit 28, the second conveyor surface 27 is applied to the second side 32 of the aerosol-generating material 3 while it moves along at least a first portion 33 of the conveying path 20. The second conveyor surface 27 contacts the aerosol-generating material 3 while it moves along at least the first portion 33. This applies pressure to the aerosol-generating material 3. The aerosol-generating material 3 is sandwiched between the first conveyor surface 19 and the second conveyor surface 27 while it is conveyed through the first drying unit 28. Thus, the aerosol-generating material 3 is formed and simultaneously dried while it is conveyed in the conveying direction 200 along at least the first portion 33 of the conveying path 100. During drying, the moisture content of the aerosol-generating material 3 is reduced. The resulting product is the aerosol-generating substrate 4. The aerosol-generating substrate 4 has a desired shape on at least the first side 31 or the second side 32. The aerosol-generating substrate 4 has a lower water content than the aerosol-generating material 3. The aerosol-generating substrate 4 may be dimensionally stable.

[0165] The aerosol-generating substrate 4 may be moved to another unit in the aerosol-generating article production line 2 for further processing. A cooling station, a winding station, or a slicing station may be provided at the end of the transport path 20, which are not shown in Figure 1.

[0166] 2 illustrates a second embodiment of the aerosol-generating substrate manufacturing installation 1. The difference between the second embodiment and the first embodiment is that in the second embodiment, in addition to the first drying unit 28, a second drying unit 35 is provided in the aerosol-generating substrate manufacturing installation 1. The second drying unit 35 is positioned downstream of the first drying unit 28 in the conveying direction 200.

[0167] The first conveyor belt 17, more specifically the first conveyor surface 19, and the aerosol-generating material 3 transported by the first conveyor belt 17 enter a first drying unit 28. The first drying unit 28 comprises a steam dryer 29. Preferably, drying using steam is performed on a first side 31 and a second side 32 of the aerosol-generating material 3.

[0168] Prior to entering the second drying unit 35, the second conveyor surface 27 is applied onto the second side 32 of the aerosol-generating material 3 at least while the second conveyor surface 27 moves along the second portion 36 of the conveying path 20. The second conveyor surface 27 contacts the aerosol-generating material 3 at least while the second conveyor surface 27 moves along the second portion 36. In this manner, pressure is applied to the aerosol-generating material 3. The aerosol-generating material 3 is sandwiched between the first conveyor surface 19 and the second conveyor surface 27 within the second drying unit 28. In this manner, the aerosol-generating material 3 is formed and simultaneously dried while being conveyed along at least a portion 33 of the conveying path 100.

[0169] The second drying unit 35 comprises an air dryer 30. Preferably, drying with air is carried out on the first side 31 and the second side 32 of the aerosol-generating material 3.

[0170] The aerosol-generating substrate 4 may be moved for further processing to another unit in the aerosol-generating article production line 2. A winding station or a slicing station may be provided at the end of the transport path 100, which is not shown in Figure 1.

[0171] 3 illustrates the first conveyor surface 19 and the second conveyor surface 27 of the aerosol-generating substrate manufacturing facility 1. The first conveyor surface 19 has corrugations 39 on at least a first surface portion 38. The second conveyor surface 27 has corrugations 39 on at least a second surface portion 40. The corrugations 39 of the first conveyor surface 19 are complementary with respect to the corrugations 39 of the second conveyor surface 27. The corrugations 39 of the first conveyor surface 19 may also be symmetrical with the corrugations 39 of the second conveyor surface 27. The corrugations 39 extend in the conveying direction 200. The corrugations 39 shown in FIG. 3 have a sinusoidal profile 41.

[0172] The corrugations 39 are formed by ridges 42 and depressions 43. In this embodiment, the ridges 42 and depressions 43 have substantially the same shape. A width 46 of the ridges 42 is defined as a first distance 48 between two peaks 49 of consecutive depressions 43. A width 47 of the depressions 43 is defined as a second distance 50 between two peaks 51 of consecutive ridges 42.

[0173] Figure 4 illustrates another embodiment of the first conveyor surface 19 and second conveyor surface 27 of the aerosol-generating substrate manufacturing facility 1. The difference in the embodiment shown in Figure 4 compared to the embodiment shown in Figure 3 is that the corrugations 39 have a square-shaped profile 52, where the heights 53 and widths 54 of the ridges 42 and recesses 44 in the square shape 52 are substantially the same.

[0174] Figure 5 illustrates another embodiment of the first conveyor surface 19 and second conveyor surface 27 of the aerosol-generating substrate manufacturing facility 1. The difference of the embodiment shown in Figure 5 compared to the embodiment shown in Figure 3 is that the first conveyor surface 19 is substantially flat, at least in the region 55 facing the second surface portion 40 of the second conveyor surface 27 having the corrugations 39.

[0175] Figure 6 illustrates another embodiment of the first conveyor surface 19 and second conveyor surface 27 of the aerosol-generating substrate manufacturing facility 1. The difference of the embodiment shown in Figure 6 compared to the embodiment shown in Figure 3 is that the second conveyor surface 27 is substantially flat, at least in the region 56 facing the first surface portion 38 of the first conveyor surface 19 having the corrugations 39.

[0176] 7-13 illustrate various embodiments showing different geometric configurations that the first conveyor surface 19 and / or the second conveyor surface 27 may have.

[0177] FIG. 7 shows a corrugation 39 having a uniform rectangular shape profile 57, in which the heights 58 of the ridges 42 and depressions 44 are substantially the same, and the widths 59 of the ridges 42 and depressions 44 are substantially the same, and the widths 59 of the ridges 42 and depressions 44 are greater than the heights 58 of the ridges 42 and depressions 44.

[0178] 8 shows a corrugation 39 having a uniform rectangular shape profile 57, where the heights 60 of the ridges 42 and depressions 44 are substantially the same, and the widths 61 ... greater than the heights 60 of the ridges 42 and depressions 44. The heights 60 of the ridges 42 and depressions 44 shown in FIG. 8 are greater than the heights 58 of the ridges 42 and depressions 44 shown in FIG. 7.

[0179] FIG. 9 shows a corrugation 39 having a non-uniform rectangular shape profile 62 in which at least two consecutive ridges 42 have different heights, a first height 63 and a second height 64 .

[0180] Figure 10 shows a corrugation 39 having a uniform rectangular shape profile 57, where the heights 65 of the ridges 42 and depressions 44 are substantially the same, and the widths 66 of the ridges 42 and depressions 44 are substantially the same, and the heights 65 of the ridges 42 and depressions 44 are greater than the widths 66 of the ridges 42 and depressions 44. The heights 65 of the ridges 42 and depressions 44 shown in Figure 10 are greater than the heights 58 of the ridges 42 and depressions 44 shown in Figure 7a. The widths 66 of the ridges 42 and depressions 44 shown in Figure 10 are less than the widths 59 of the ridges 42 and depressions 44 shown in Figure 7.

[0181] FIG. 11 shows a corrugation 39 having a uniform rectangular shape profile 57, where the heights 67 of the ridges 42 and recesses 44 are substantially the same, and the widths 68 of the ridges 42 and recesses 44 are substantially the same, and the heights 67 of the ridges 42 and recesses 44 are less than the heights 65 of the ridges 42 and recesses 44 shown in FIG. 10.

[0182] 12 shows a corrugation 39 having a non-uniform rectangular shape profile 62, where the ridges 42 have a first width 69 and the recesses 44 have a second width 70. The second width 70 is greater than the first width 69.

[0183] 13 shows a corrugation 39 having a non-uniform rectangular shape profile 62, where the ridges 42 have a first height 71 and a second height 72. The second height 72 is greater than the first height 71.

[0184] The embodiments shown in Figures 7-13 having different geometric configurations may also be implemented with sinusoidal, triangular, half-triangular, and half-rectangular shaped waveforms.

[0185] One embodiment of a method for manufacturing an aerosol-generating substrate 4 includes forming an aerosol-generating material 3 between a first conveying surface 19 of a first conveyor 14 and a second conveying surface 27 of a second conveyor 21, as shown in Figure 1, and drying the aerosol-generating material 3 during formation. The first conveyor surface 19 and the second conveyor surface 27 may be designed as shown in Figures 3-6. The first conveyor surface 19 and / or the second conveyor surface 27 may have different geometric configurations, as illustrated in Figures 7-13.

[0186] Prior to forming the aerosol-generating material 3 between the first conveying surface 19 and the second conveying surface 27, the aerosol-generating material 3 is cast onto the first conveyor 14, specifically onto the first conveyor surface 19. The aerosol-generating material 3 cast onto the first conveyor surface 19 preferably has a moisture content of 90 to 40 weight percent, specifically 85 to 50 weight percent, and preferably 80 to 60 weight percent. Specifically, the weight percentages are based on the total weight of the aerosol-generating material.

[0187] After casting the aerosol-generating material 3, the aerosol-generating material 3 is dried by applying heat to the aerosol-generating material 3. The aerosol-generating material 3 is conveyed through hot air provided in a drying unit 28. Prior to conveying the aerosol-generating material 3 through the drying unit 28, a second conveyor surface 27 is applied onto the aerosol-generating material 3. After the drying step, the aerosol-generating material may have a moisture content of about 10 weight percent to about 20 weight percent. Specifically, the weight percentage is based on the total weight of the aerosol-generating material.

[0188] Another embodiment of a method for producing an aerosol-generating substrate 4 includes forming the aerosol-generating material 3 between a first conveying surface 19 of a first conveyor 14 and a second conveying surface 27 of a second conveyor 21, as shown in Figure 2. The first conveyor surface 19 and the second conveyor surface 27 may be designed as shown in Figures 3-6. The first conveyor surface 19 and / or the second conveyor surface 27 may have different geometric configurations, as illustrated in Figures 7-13.

[0189] Prior to forming the aerosol-generating material 3 between the first conveying surface 19 and the second conveying surface 27, the aerosol-generating material 3 is cast onto the first conveyor 14, specifically onto the first conveyor surface 19. The aerosol-generating material 3 cast onto the first conveyor surface 19 preferably has a moisture content of 90 to 40 weight percent, specifically 85 to 50 weight percent, and preferably 80 to 60 weight percent. Specifically, the weight percentages are based on the total weight of the aerosol-generating material 3.

[0190] After the aerosol-generating material 3 is cast onto the first conveyor surface 19, the aerosol-generating material 3 is conveyed through a first drying unit 28 and a second drying unit 35. Before the aerosol-generating material 3 is conveyed through the second drying unit 35, a second conveyor surface 27 is applied onto the aerosol-generating material 3. After the drying step, the aerosol-generating material may have a moisture content of about 10 weight percent to about 20 weight percent. Specifically, the weight percentage is based on the total weight of the aerosol-generating material 3.

Claims

1. An aerosol-generating substrate manufacturing facility, a first conveyor having at least a first conveyor surface; a second conveyor having at least a second conveyor surface; the first conveyor surface provides support for the aerosol-generating material; the first conveyor surface extends along a conveying path; the second conveyor surface extends at least locally along the transport path; whereby the aerosol-generating material is formed into an aerosol-generating substrate between the first conveyor surface and the second conveyor surface; the first conveyor surface is adapted for translation along the transport path; the second conveyor surface is adapted for at least local translation along the transport path; The aerosol-generating substrate manufacturing facility, wherein the first conveyor surface or the second conveyor surface has corrugations at least in part.

2. 2. The aerosol-generating substrate manufacturing facility according to claim 1, wherein both the first conveyor surface and the second conveyor surface are corrugated at least in part.

3. 3. The aerosol-generating substrate manufacturing facility of claim 2, wherein the corrugations are formed by ridges and recesses, and the recesses of the first conveyor surface do not include the ridges of the second conveyor surface.

4. 4. The aerosol-generating substrate manufacturing facility according to claim 1, wherein the first conveyor comprises a first conveyor belt that forms the first conveyor surface.

5. 5. The aerosol-generating substrate manufacturing facility according to claim 1, wherein the second conveyor comprises a second conveyor belt that forms the second conveyor surface.

6. 6. The aerosol-generating substrate manufacturing equipment according to claim 1, wherein the first conveyor surface is arranged locally parallel to the second conveyor surface, specifically along the conveying direction, preferably along the conveying direction of the aerosol-generating material.

7. 7. The aerosol-generating substrate manufacturing facility according to claim 1, further comprising a casting device for casting the aerosol-generating material onto the first conveyor surface.

8. 8. The aerosol-generating substrate manufacturing facility according to claim 1, wherein the first conveyor surface is at least partially disposed within at least a first drying unit.

9. 9. The aerosol-generating substrate manufacturing facility according to claim 8, wherein the second conveyor surface is at least partially disposed within at least the first drying unit.

10. 10. The aerosol-generating substrate manufacturing facility according to claim 1, wherein at least a second drying unit is disposed upstream or downstream of the second conveyor along the transport path.

11. 1. A method for producing an aerosol-generating substrate, comprising: forming an aerosol-generating material between a first conveying surface of the first conveyor and a second conveying surface of the second conveyor; drying the aerosol-generating material during formation; The method, wherein the first conveying surface or the second conveying surface comprises corrugations on at least a portion thereof.

12. 12. The method of claim 11, further comprising casting the aerosol-generating material onto the first conveyor, specifically onto the surface of the first conveyor.

13. 13. The method of claim 12, wherein the aerosol-generating material cast onto the first conveyor surface has a moisture content of from 90 to 40 percent by weight, specifically from 85 to 50 percent by weight, and preferably from 80 to 60 percent by weight.

14. 14. The method of claim 11, further comprising drying the aerosol-generating material by applying heat to the aerosol-generating material, in particular by conveying the aerosol-generating material through hot air provided in a drying unit.

15. A method according to any one of claims 11 to 14, wherein the aerosol-generating material is an alkaloid-containing material, preferably a plant-derived material, more preferably a slurry comprising tobacco.

16. 16. A method according to any one of claims 11 to 15, wherein the aerosol-generating substrate is a sheet or foil or web or extrudate comprising the alkaloid-containing material, preferably a plant-derived material, more preferably tobacco.

17. An aerosol-generating substrate, comprising an aerosol-generating substrate produced according to the method described in any one of claims 11 to 16, or produced in the aerosol-generating substrate production facility described in any one of claims 1 to 10.

18. 18. An aerosol-generating substrate according to claim 17, comprising a fibre-based material, preferably a plastic fibre-based material, more preferably a biodegradable fibre-based material, more preferably cotton, more preferably cellulose.

19. 19. An aerosol-generating article comprising the aerosol-generating substrate of claim 18.

20. A system comprising the aerosol-generating substrate manufacturing equipment according to any one of claims 1 to 10, an aerosol-generating material, and the aerosol-generating substrate according to claim 17 or 18.

21. Use of a first corrugated conveyor belt to form an aerosol-generating material, wherein the moisture content of the aerosol-generating material is between 90 percent and 40 percent by weight.

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