Apparatus and method for producing extrudates of aerosol-generating material having cross-sectional shapes - Patents.com

Abstract

The present invention relates to an apparatus for producing an extrudate 9 comprising an aerosol-generating material 23, the apparatus comprising an extruder 1, the extruder 1 having an inlet 2 and an outlet 5, the inlet 2 adapted to receive a mixture 3, the outlet 5 adapted to extrude the mixture 3 to form the extrudate 9, the outlet 5 having a die component 10 adapted to form the extrudate 9 comprising the aerosol-generating material 23, the die component 10 adapted to form a cross-sectional shape in the extrudate 9. The present invention also relates to a method for producing an extrudate 9 comprising an aerosol-generating material 23, the method comprising the steps of feeding a mixture 3 into the extruder 1 through an inlet 2 of the extruder 1, moving the mixture 3 along an extrusion direction 100, and extruding the mixture 3 from the extruder 1 through an outlet 5, where the mixture 3 is extruded through a die element 10 at the outlet 5 of the extruder 1 to form an extrudate 9 comprising the aerosol-generating material 23 having a cross-sectional shape. The present invention further relates to the use of the extruder 1 to extrude the extrudate 9 comprising the aerosol-generating material 23 so as to form a cross-sectional shape in the extrudate 9. The present invention also relates to aerosol-generating material 23, aerosol-generating articles, and systems comprising an apparatus and mixture for forming the extrudate 9 comprising the aerosol-generating material 23.

Description

[Technical Field]

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

[0002] Aerosol-generating articles refer not only to filter cigarettes and other smoking articles in which materials are burned to form smoke, but also to articles that generate an aerosol from an aerosol-generating material without requiring combustion of the aerosol-generating material. Such articles are often referred to as "heat-and-burn" aerosol-generating articles because the aerosol-generating material is heated to a relatively low temperature to induce aerosol formation but prevents combustion of materials contained within the aerosol-generating material. Typically, the aerosol composition generated by such "heat-and-burn" aerosol-generating articles is substantially based on homogenized tobacco material, which typically constitutes the majority of the tobacco content of the aerosol-generating material. For this reason, the composition and quality of the homogenized tobacco material play an important role in the overall quality and user experience of the aerosol-generating article.

[0003] Generally, homogenized tobacco material can be formed as cast leaf or reconstituted tobacco sheet. In the former case, ground tobacco, binders, and other ingredients may be mixed to form a slurry, which is then subjected to thermomechanical processing and cast onto a moving metal belt to produce cast leaf. Alternatively, reconstituted tobacco sheet can be produced using a process similar to papermaking, using a slurry with a lower viscosity and higher moisture content than that used in the cast leaf process. The cast leaf or reconstituted tobacco sheet is then wound onto a bobbin for storage and shipping, and unwound for further processing.

[0004] Such other processing of the homogenized tobacco material may include crimping the cast leaf or reconstituted tobacco sheet to obtain a corrugated shape, and the corrugated cast leaf or reconstituted tobacco sheet may then be compressed, folded, and / or rolled into a cylindrical shape and then separated into individual segments that may be inserted into a corresponding aerosol-generating article as an aerosol-generating material.

[0005] As briefly mentioned, the manufacturing steps required to produce aerosol-generating materials for use in aerosol-generating articles are numerous. Furthermore, each manufacturing step requires, for example, complex and precise machinery and a relatively large manufacturing area within a manufacturing hall. For this reason, each stage of manufacturing is typically performed as a batch process, with each step occurring relatively independently of previous and / or subsequent manufacturing steps. This can result in unnecessary downtime between individual manufacturing steps, and manufacturing processes must be precisely calculated and scheduled to minimize such downtime and optimize the overall manufacturing line. Failure to do so can result in lost manufacturing capacity and associated capital.

[0006] The present invention therefore aims to provide an alternative to the above manufacturing process, in particular by compressing some manufacturing steps and allowing a continuous manufacturing process between at least some individual manufacturing steps. Summary of the Invention

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

[0008] The extruder may be implemented to produce an extrudate in the form of an object of a predetermined shape by extrusion. Specifically, during extrusion, compressive and shear forces are applied to the mixture to produce the extrudate. Specifically, the extrudate is a continuous product having a length substantially greater than the dimensions defining its cross-sectional shape.

[0009] Specifically, the inlet of the extruder is in fluid communication with the outlet of the extruder to allow movement of the mixture from the inlet to the outlet. Specifically, the path of movement of the mixture from the inlet to the outlet defines an extrusion direction of the extruder. Specifically, the inlet is located upstream of the outlet, and the outlet is located downstream of the inlet.

[0010] The extruder may include a hopper adapted to feed the mixture into an inlet of the extruder.

[0011] The extruder outlet is adapted to extrude the mixture to form an extrudate. The extrudate exits the extruder at a downstream end of the outlet. Specifically, the mixture may be considered an extrudate when it enters the outlet. The outlet, which may comprise multiple components and parts, comprises at least one die component. The die component is adapted to shape the extrudate and to provide a cross-sectional shape thereto. The extrudate may be formed by providing the extrudate with a defined geometric contour that includes the defined cross-sectional shape. The die component may be adapted to change the cross-sectional shape of the extrudate before it reaches its final cross-sectional shape.

[0012] The die element may comprise a plurality of elements, specifically at least one die plate having at least one opening. The opening in the die plate may be adapted to form the cross-sectional shape of the extrudate and thus to define the outer profile of the extrudate. The geometry of the opening may be rounded, may exhibit a circular or elliptical shape. The geometry of the opening may be at least partially or completely helical. A sidewall of the die element may define the opening. The sidewall may exhibit a corrugated shape.

[0013] The die plate may exhibit a plurality of openings, which may be adapted to collectively form the extrudate and define a cross-sectional shape therein. A die plate having a plurality of openings in the form of openings may be selected to define the cross-sectional shape of the extrudate as the profile of the hollow chamber. The openings may comprise at least one or more of circular openings, elliptical openings, and at least partially or completely spiral-shaped openings. The openings may be shaped like an inverse wagon wheel or at least two rings connected by at least one spoke.

[0014] An extrudate having a hollow chamber profile may have a cross-sectional shape with at least one region that does not contain extrudate, which may be considered a void, cavity, or hollow chamber, which extends along the length of the extrudate, and a component may be present in the region.

[0015] The die plate may exhibit multiple, i.e., at least two, groups of openings to allow for the simultaneous production of multiple extrudates. The groups of openings may have the same geometric shape. The groups of openings may have different shapes. The die plate may exhibit at least one opening and at least one group of openings to allow for the simultaneous production of multiple extrudates.

[0016] The die components may include at least one mandrel having at least one protrusion. The die plate and mandrel may be positioned and adapted to one another to form the cross-sectional shape of the hollow chamber profile in the extrudate. The die plate and mandrel may be integrally formed, or they may be at least two separate components adapted to be secured directly or relative to one another. Such securing may be achieved, for example, by another component of the outlet.

[0017] The geometric contour of the die plate, particularly the opening, may be adapted to accommodate the geometric contour of the mandrel, particularly the protrusion. In this manner, the protrusion of the mandrel may be arranged to be at least partially inside the opening of the die plate. The protrusion may extend through the opening so that the downstream end face of the protrusion is flush with the downstream end face of the die plate. The downstream end face of the protrusion may extend beyond the downstream end face of the die plate.

[0018] Specifically, the mandrel projections correspond to and are adapted to the die plate openings, with the die plate openings adapted to form the outer profile of the cross-sectional shape of the extrudate, and the mandrel projections adapted to form the inner profile of the cross-sectional shape of the extrudate. The geometry of the projections, particularly their downstream end surfaces, may be shaped in the shape of a circle or, if not completely, at least partially, in the shape of a spiral. The projections may exhibit corrugations and thus be adapted to form the inner profile of the cross-sectional shape of the corrugated hollow body profile of the extrudate.

[0019] The protrusions may correspond to and fit over at least one of the openings or over the entire openings.

[0020] In an embodiment where a die component exhibits multiple openings and / or opening groups for co-extrusion of multiple extrudates, the corresponding mandrel may exhibit multiple protrusions. The number of protrusions may equal the number of openings and / or opening groups, although not every opening or opening group may be associated with a protrusion.

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

[0022] The extruder may comprise at least one screw adapted to convey the mixture from the inlet to the outlet of the extruder along the extrusion direction. In such cases, the extruder may be referred to as a screw extruder, or, if the extruder comprises two screws, a twin-screw extruder. Specifically, the diameter of the screw increases along the extrusion direction, i.e., the screw exhibits an increased diameter downstream in the extrusion direction.

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

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

[0025] In particular, the outlet may comprise a cooling unit adapted to cool at least a portion, if not all, of the die components to a temperature of between 10 degrees Celsius and 50 degrees Celsius, particularly between 20 degrees Celsius and 40 degrees Celsius, and especially between 25 degrees Celsius and 35 degrees Celsius.

[0026] In particular, the apparatus may comprise a susceptor material supply device adapted to insert susceptor material into the extrudate. The susceptor material supply device may be adapted to insert susceptor material into the extrudate downstream of the die component, particularly downstream of the outlet. The susceptor material supply device may be adapted to insert susceptor material into the extrudate at the outlet, particularly within the die component, during extrusion.

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

[0028] Specifically, the susceptor material is in the form of a continuous strip or rod and is provided on a bobbin. A strip may be considered a layered element whose length is substantially greater than its width and thickness, while a rod may be considered a cylindrical element whose length is substantially greater than its diameter. The width of the susceptor material strip may be 1 mm to 10 mm, while the thickness of the susceptor material strip may be 1 mm to 10 mm. The width and thickness of the susceptor material strip may be equal so that the cross-sectional shape of the susceptor material strip is square. The diameter of the susceptor material rod may be 1 mm to 10 mm. The rod may exhibit an elliptical cross-sectional shape.

[0029] In particular, the susceptor material supply apparatus may include at least one guide element, such as a set of guide rollers, to facilitate transport of the susceptor material from the bobbin to the extruder.

[0030] The apparatus may include a rotation device adapted to rotate the susceptor material, thereby allowing the extrudate to encase the susceptor material. The rotated susceptor material may have a wrapped shape within the extrudate, which may improve heat distribution within the extrudate when the susceptor material is heated. Rotation of the susceptor material may improve adhesion of the susceptor material to the extrudate, particularly at the exit of the extruder.

[0031] The apparatus may comprise at least one dryer adapted to dry the extrudate so as to substantially maintain its cross-sectional shape. The dryer is adapted to achieve a drying temperature of 70°C to 110°C, in particular 80°C to 100°C, and especially 85°C to 95°C. Such a dryer may be constructed as a continuous dryer, for example a tunnel dryer. Such a continuous dryer may exhibit at least two chambers or zones adapted to achieve different drying temperatures.

[0032] The apparatus may include at least one cutting device adapted to separate the extrudate into individual segments. The cutting device may be located immediately downstream of the outlet. If the apparatus also includes a dryer, for example, the cutting device may be located downstream thereof.

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

[0034] The mixture may include plant-derived materials, water, and additional aerosol formers. Weight percentage values ​​and ranges of components of the mixtures described herein are based on the total weight of the mixture, in accordance with the art-known definition of "weight percent," unless otherwise specified.

[0035] The mixture may be a slurry, which may be a mixture of at least one denser solid suspended in at least one liquid.

[0036] Specifically, plant-derived materials are materials that contain alkaloids.

[0037] The amount of alkaloid- or plant-derived material in the mixture is between 30 and 80 weight percent, especially between 40 and 70 weight percent.

[0038] Alkaloid-containing materials may be defined as materials that contain at least one alkaloid, which may include, for example, nicotine, which is present in tobacco.

[0039] Instead of or in addition to tobacco, other plant-derived materials may be part of the mixture. The herbal materials may be free of alkaloids.

[0040] Alkaloids are a group of naturally occurring 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 oxygen, sulfur, and more rarely other elements such as chlorine, bromine, and phosphorus.

[0041] 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.

[0042] The alkaloid-containing material may be tobacco leaf.

[0043] 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 usually produced from parts of the tobacco plant that are not well suited for the production of cut filler, such as tobacco stems, tobacco mesophyll, or tobacco dust. Tobacco dust is typically produced as a by-product during the handling of tobacco leaves during production. The homogenized tobacco material may contain small amounts of one or more of tobacco dust, tobacco fines, and other particulate tobacco by-products formed during tobacco processing, handling, and transport. The starting material for the production of the homogenized tobacco material may be primarily tobacco leaves having 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 a majority, or substantially the total amount, of the tobacco present in the aerosol-generating material.

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

[0045] 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. Starch 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 polymeric molecules: linear and helical amylose and branched amylopectin, which are arranged in semicrystalline granules within the plant.

[0046] Specifically, the particles of the alkaloid-containing material have an average particle size of 0.02 to 0.3 millimeters. An average particle size of about 0.02 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 particle size can be advantageous for obtaining a smooth and uniform extrudate during downstream processing of the alkaloid-containing material.

[0047] Specifically, the water content of the mixture is 5 to 70 weight percent or more, particularly 10 to 18 weight percent, or 25 to 60 weight percent, especially 11 to 14 weight percent, or 35 to 50 weight percent.

[0048] Specifically, the amount of aerosol former in the mixture is between 1 and 10 weight percent, particularly between 1 and 5 weight percent. In particular, the aerosol former is an additional component in the mixture that is believed to be separated from the alkaloid-containing material, particularly from tobacco.

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

[0050] Examples of preferred aerosol formers are glycerin and propylene glycol.

[0051] The alkaloid-containing material may have an aerosol former content of greater than 3 weight percent of the total amount of alkaloid-containing material. Alternatively, the alkaloid-containing material may have an aerosol former content of 3 to 30 weight percent. The alkaloid-containing material may contain 7 to 25 weight percent aerosol former. The alkaloid-containing material may particularly contain 10 to 25 weight percent aerosol former. Specifically, the aerosol former content of the alkaloid-containing material is an inherent component of the alkaloid-containing material, and therefore, its amount is not related to the amount of aerosol former that may be included in the mixture, as described above.

[0052] In particular, the mixture may include a binder, and the amount of binder in the mixture may be up to 1 weight percent, but may include 1 weight percent to 15 weight percent, particularly 1 weight percent to 12 weight percent, and more particularly 1 weight percent to 5 weight percent.

[0053] The binder in the mixture may be any of the gums or pectins described herein. The binder may ensure that the particles of the alkaloid-containing material remain substantially dispersed throughout the mixture and extrudate. For a descriptive review 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 (2nd ed. 1973), and Lawrence, Natural Gums for Edible Purposes, Noyes Data Corp. (1976).

[0054] While any binder may be employed, preferred binders are natural pectins (such as fruit pectins, citrus pectins, or tobacco pectins), guar gums (such as hydroxyethyl guar and hydroxypropyl guar), locust bean gums (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, carboxymethylcellulose), tamarind gum, dextran, puralon, konjac flour, xanthan gum, and the like. A particularly preferred binder for use in the present invention is guar.

[0055] In particular, the mixture may contain reducing sugars in an amount of from 2 to 30 percent by weight, particularly from 5 to 25 percent by weight, more particularly from 10 to 15 percent by weight, and especially from 11 to 14 percent by weight.

[0056] 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.

[0057] The presence of reducing sugars in a mixture can modify the alkaloid-containing material when mechanical energy is applied to the mixture. A reaction between the reducing sugar and the alkaloid-containing material can occur, particularly when the latter contains ammonia- or ammonium-containing compounds. This reaction can modify the composition of the alkaloid-containing material, such that the resulting mixture and aerosol-generating material have a lower amount of ammonia- or ammonium-containing compounds compared to an aerosol-generating material formed from a mixture that does not contain reducing sugars. This can affect the properties and characteristics of the aerosol-generating material, for example, in terms of flavor.

[0058] Specifically, the mixture may contain cellulose fibers. Cellulose fibers are known to generally increase the tensile strength of the mixture and the resulting aerosol-generating material, thereby functioning as a strengthening agent. Cellulose fibers for mixtures containing alkaloid-containing materials, such as homogenized tobacco materials, are known in the art and include, but are not limited to, softwood fibers, hardwood fibers, jute fibers, flax fibers, tobacco fibers, and combinations thereof. Specifically, cellulose fibers, such as wood fibers, contain low lignin content. Alternatively, fibers, such as plant fibers, may be used in combination with any of the above fibers or hemp and bamboo fibers. Cellulose fibers may include tobacco stem material, petioles, or other tobacco plant materials.

[0059] The amount of cellulose fiber added to the mixture can be from 1 to 10 weight percent, particularly from 1 to 7 weight percent, and especially from 1 to 5 weight percent. 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 mixture.

[0060] The cellulose fibers advantageously have a length of about 0.2 millimeters to about 4 millimeters. Specifically, the average length by weight of the cellulose fibers is 1 millimeter to 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.

[0061] The mixture may be formed and fed to the inlet of the extruder by any known means, specifically, the mixture is fed to a hopper that is in fluid communication with the inlet of the extruder.

[0062] The mixture is moved along an extrusion direction from an inlet of the extruder to an outlet of the extruder, specifically, this transport is facilitated by the rotation of at least one screw within the extruder.

[0063] The incorporation of at least one screw into an extruder can facilitate the movement of the mixture along the extrusion direction. The screw can modify the properties of the mixture along the extrusion direction. The rotation of the screw during extrusion imparts shear forces, i.e., mechanical work, to the mixture, increasing the mixing of the mixture and inducing chemical reactions between the individual components of the mixture. The mechanical work can result in the generation of heat, which can affect the chemical and physical structure of the mixture and its individual components. Some chemical reactions between the mixture and its individual components can be induced. The implementation of a screw can promote a gradual increase in density along the extrusion direction. That is, the mixture can exhibit a higher density downstream in the extrusion direction and a lower density upstream in the extrusion direction. The rotation of the screw can have a dewatering effect on the mixture, especially along the extrusion direction. That is, the moisture content of the mixture can decrease along the extrusion direction as it travels.

[0064] Specifically, the screw rotates at a rotational speed of 20 to 40 revolutions per minute, 40 to 80 revolutions per minute, or 60 to 120 revolutions per minute.

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

[0066] The mixture is forced through an exit die element to form an extrudate comprising the aerosol-generating material having a cross-sectional shape.

[0067] An aerosol-generating material refers to a material capable of releasing an aerosol containing a volatile compound, such as nicotine, as a result of a heating process. The aerosol-generating material primarily corresponds to the mixture fed to the inlet of the extruder, but specifically exhibits at least a different composition, chemical properties, or physical properties than the mixture. For example, the aerosol-generating material may be denser than the fed mixture, more viscous than the fed mixture, have a lower water content than the fed mixture, contain more glycerin, guar, or cellulose fiber than the fed mixture, or contain less ammonia or ammonium-containing compounds than the fed mixture. The aerosol-generating material may exhibit any combination of the above properties. These differences may be the result of the movement of the mixture through the extruder along the extrusion direction. Furthermore, applying mechanical work to the mixture, for example, by rotating the screw, or changing its temperature by heating or cooling certain sections of the extruder, may result in changes in at least the composition, chemical properties, or physical properties of the aerosol-generating material compared to the fed mixture.

[0068] Specifically, the cross-sectional shape of the extrudate is round, particularly circular or elliptical, and the diameter of the cross-sectional shape of the extrudate may be 5 mm to 10 mm.

[0069] By extruding the mixture through a die element at the exit of the extruder to form an extrudate containing the aerosol-generating material having a cross-sectional shape, the aerosol-generating material can be produced in a single manufacturing process, thereby eliminating the need to produce a sheet or cast leaf, wind it onto a bobbin, transport the bobbin, unwind the sheet for further processing, and produce a cylindrical aerosol-generating material. This reduces the manufacturing effort and corresponding manufacturing time, as well as the costs associated with such a manufacturing line.

[0070] Specifically, the cross-sectional shape of the extrudate is the profile of a hollow chamber, and at least one region of the cross-sectional shape of the extrudate is free of aerosol-generating material. Such a region may be considered, for example, a cavity, void, or hollow chamber. Specifically, the region free of aerosol-generating material, i.e., the hollow chamber, extends along the length of the extrudate, particularly along the entire length of the extrudate. Such extensions may form flow channels within the extrudate. If the hollow chamber profile exhibits multiple hollow chambers, each hollow chamber may form a flow channel within the extrudate, resulting in the extrudate exhibiting multiple flow channels.

[0071] The flow paths within the extrudate are directly related to the airflow characteristics of the aerosol-generating material during its use in the aerosol-generating article. The flow paths may be adapted to enhance the release of a substance from the aerosol-generating material. The flow paths may also be adapted to adjust the "resistance to draw" (RTD) characteristics of the aerosol-generating material. A lower resistance to draw may reduce the perceived temperature of the generated aerosol to a level that a user finds acceptable.

[0072] Furthermore, by creating at least one channel during extrusion of the extrudate, additional processing steps, such as crimping, can be avoided, which reduces the complexity of the production line in terms of the required machinery and shortens production time. The negative effects of crimping, such as damage to the homogenized tobacco sheet or cast leaf and increased shredding and tearing, can be prevented.

[0073] The hollow chamber profile can exhibit various geometric shapes and contours. The hollow chamber profile can have at least one hollow chamber that is rounded, specifically circular or elliptical. The hollow chamber profile can have three or more hollow chambers. If the hollow chamber profile exhibits multiple hollow chambers, the geometric shape of each hollow chamber can be identical. If the hollow chamber profile exhibits multiple hollow chambers, the geometric shape of each hollow chamber can exhibit a different contour. The hollow chamber profile can be at least partially in the shape of at least one spiral. The hollow chamber profile can be at least partially in the shape of at least two rings connected by at least one spoke. The hollow chamber profile can be in the shape of a wagon wheel. The hollow chamber profile can be any combination of any of the above shapes. At least one of the surfaces defining the hollow chamber profile can exhibit a corrugation.

[0074] Specifically, the extrusion has a length of 2 meters to 10 meters.

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

[0076] Combining the insertion step of the susceptor material with the extrusion of the extrudate containing the aerosol-generating material may eliminate individual manufacturing steps and minimize the associated time and costs.

[0077] In particular, the method may include inserting a susceptor material into the cross-sectional shape of the extrudate containing the aerosol-generating material after extruding the extrudate containing the aerosol-generating material.

[0078] Combining the insertion of susceptor material with the extrusion of an extrudate containing the aerosol-generating material may allow for a continuous manufacturing process without the need for the separate steps associated with batch processing.

[0079] Specifically, the susceptor material is inserted into the center of the cross-sectional shape of the extrudate. Specifically, the susceptor material is inserted into a hollow chamber of the cross-sectional shape of the extrudate. Specifically, the susceptor material is inserted into a hollow chamber located at the center of the cross-sectional shape. The susceptor material may fill the corresponding hollow chamber into which it is inserted.

[0080] Specifically, the susceptor material is inserted into the extrudate containing the aerosol-generating material at a pressure of between 2 bar and 6 bar of insertion force.

[0081] Specifically, the susceptor material is rotated during insertion into the cross-sectional shape of the extrudate. The susceptor material may be rotated at 20 revolutions per minute to 150 revolutions per minute.

[0082] Rotation of the susceptor material during insertion into the extrudate may prevent adhesion to the aerosol-generating material and reduce the required insertion force. This rotation of the susceptor may result in a helical susceptor shape, which may improve heat distribution within the extrudate when the susceptor material is heated. Rotation of the susceptor material may improve adhesion of the susceptor material to the extrudate, particularly at the exit of the extruder. Rotation of the susceptor material may be achieved by a tube or groove adapted to convey material around the susceptor material to enable rotation of the susceptor material.

[0083] In particular, the method may include maintaining the extruder outlet, particularly the die components, at a temperature of from 10 degrees Celsius to 50 degrees Celsius, particularly from 20 degrees Celsius to 40 degrees Celsius, and especially from 25 degrees Celsius to 35 degrees Celsius.

[0084] Maintaining the outlet temperature within the above ranges can further stabilize the structural properties of the cross-sectional shape of the extrudate and ensure that the structural properties are maintained after extrusion, i.e., after leaving the outlet, which may be due, for example, to a further reduction in the moisture content of the extrudate.

[0085] Specifically, the outlet applies vibration to the extrudate during extrusion. Applying vibration to the die components, particularly during extrusion, can affect the forming force required and reduce sticking of the extrudate to the inner walls of the die components.

[0086] Specifically, the method may include drying the extrudate to substantially maintain its cross-sectional shape, the dryer being adapted to a drying temperature of between 70°C and 110°C, particularly between 80°C and 100°C, and more particularly between 85°C and 95°C.

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

[0088] A substantially maintained cross-sectional shape is one that reflects the cross-sectional shape of the extrudate immediately after extrusion, i.e., after exiting the extruder. When the cross-sectional shape of the extrudate is the profile of a hollow chamber, a substantially maintained cross-sectional shape is one in which at least one hollow chamber is not completely collapsed. The hollow chamber may exhibit slight deviations from the contour associated with the hollow chamber immediately after exiting the extruder.

[0089] Specifically, the method may include cutting an extrudate containing an aerosol-generating material into segments having lengths between 3 millimeters and 10 millimeters. Specifically, the apparatus may include at least one cutting device adapted to separate the extrudate into individual sections.

[0090] According to a third aspect of the present invention there is provided the use of an extruder for extruding an extrudate comprising an aerosol-generating material so as to form a cross-sectional shape in the extrudate.

[0091] According to a fourth aspect of the present invention, there is provided a method for producing aerosol-generating material surrounding a susceptor material, the method comprising the steps of: providing a length of aerosol-generating material having a helical cross-sectional shape; feeding the susceptor material to the center of the helical cross-sectional shape of the aerosol-generating material by a susceptor material feeding device; rotating the susceptor material by a rotation device; forcing the susceptor material into the center of the cross-sectional shape of the aerosol-generating material; and unwinding the aerosol-generating material around the susceptor material.

[0092] A length of aerosol-generating material having a helical cross-sectional shape may be provided by extrusion, in particular by extruding an extrudate comprising the aerosol-generating material, the cross-sectional shape of the extrudate being the profile of a hollow chamber having a helical shape. A length of aerosol-generating material having a helical cross-sectional shape may also be provided by rolling a sheet of aerosol-generating material.

[0093] The susceptor material is rotated and forced into the center of the helical cross-sectional shape of the aerosol-generating material. The rotational movement of the susceptor material, in addition to the forward movement associated with the pushing action of the susceptor material, causes the aerosol-generating material to unwind from its helical cross-sectional shape and wrap around the susceptor material, i.e., the aerosol-generating material unwinds and wraps around the susceptor material, layer by layer.

[0094] Specifically, the length of the aerosol-generating material having a spiral cross-sectional shape is between 80 mm and 150 mm.

[0095] Specifically, the diameter of the spiral cross section is 5 to 8 millimeters.

[0096] Specifically, the susceptor material is forced into the center of the aerosol-generating material at a pressure of 2 to 6 bars.

[0097] Specifically, the susceptor material is rotated during insertion into the cross-sectional shape of the extrudate, specifically at a speed of 20 to 150 revolutions per minute.

[0098] Both the rotation speed of the susceptor material and its pushing force can affect how much the aerosol-generating material overlaps as it unwinds around the susceptor material, which can ultimately affect the total thickness of the final product, i.e., the aerosol-generating material surrounding the susceptor material. Specifically, such thickness is between 0.20 millimeters and 0.75 millimeters.

[0099] The wrap angle of the aerosol-generating material may be between 2 degrees and 15 degrees, particularly between 4 degrees and 8 degrees, and in one embodiment, 6 degrees 17 minutes (6 degrees 17'). Specifically, the wrap angle is the angle formed by the aerosol-generating material with respect to the periphery of the susceptor material. That is, a wrap angle of 0 degrees indicates that the aerosol-generating material is unwound along the defined periphery of the susceptor material. In such a case, the aerosol-generating material is wrapped around the susceptor at that point without covering the entire length of the susceptor material. The wrap angle allows the aerosol-generating material to cover the entire length of the susceptor material during wrapping. The wrap angle can affect the thickness or coverage of the susceptor material by the aerosol-generating material. Such a wrap angle may improve tension in the aerosol-generating material during unwinding and prevent breakage or uneven wrapping.

[0100] The apparatus of the first aspect may be operated in accordance with the method of the second or fourth aspect, or may be used in accordance with the third aspect. The method of the second or fourth aspect may comprise the apparatus of the first aspect. [Example]

[0101] The present invention is defined in the claims. However, below is provided 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 features of any other example, embodiment, or aspect described herein.

[0102] Example 1: 1. An apparatus for producing an extrudate comprising an aerosol-generating material, the apparatus comprising: An extrusion molding machine is provided, the extruder having an inlet and an outlet; an inlet adapted to receive the mixture; an outlet adapted to extrude the mixture to form an extrudate; the outlet comprises a die element; die components adapted to form an extrudate including the aerosol-generating material; An apparatus in which die components are adapted to form a cross-sectional shape in an extrudate. Example 2: the die components comprising a die plate and a mandrel; the die plate exhibits at least one opening; the mandrel exhibits at least one protrusion; 2. The device of example 1, wherein the protrusion is disposed at least partially inside the opening. Example 3: The apparatus of Example 2, wherein the die plate and mandrel are adapted to form an extrudate such that the cross-sectional shape of the extrudate is the profile of the hollow chamber. Example 4: 4. The apparatus of example 2 or 3, wherein the downstream end surface of the protrusion is at least partially shaped in the shape of a spiral. Example 5: The apparatus of any one of Examples 2 to 4, wherein the mandrel and the die plate are integrally formed. Example 6: 5. The apparatus of any of Examples 2-4, wherein the mandrel and the die plate are two separate parts that are fixed to each other or adapted to be fixed relative to each other. Example 7: The apparatus of any one of Examples 2 to 6, wherein the protrusion extends through the opening to the downstream end face of the die plate. Example 8: The device according to any one of Examples 2 to 7, wherein the downstream end surface of the protrusion is formed in a circular shape. Example 9: The device of any one of Examples 2 to 8, wherein the protrusions have a corrugated shape. Example 10: 10. The apparatus of any of Examples 1-9, wherein the extruder comprises a screw adapted to move the mixture along an extrusion direction from an inlet to an outlet of the extruder. Example 11: 11. An apparatus according to any one of the preceding examples, wherein the extruder is provided with a screw exhibiting an increasing diameter downstream in the direction of extrusion. Example 12: 12. The apparatus of any one of Examples 1-11, wherein the outlet comprises a vibrating component. Example 13: 13. The apparatus of any of Examples 1-12, wherein the extruder further comprises a heating zone upstream in the direction of extrusion and adapted to heat the mixture to a temperature of from 90 degrees Celsius to 190 degrees Celsius, preferably from 140 degrees Celsius to 190 degrees Celsius, most preferably from 175 degrees Celsius to 185 degrees Celsius. Example 14: 14. The apparatus of any of Examples 1-13, wherein the extruder further comprises a cooling zone downstream in the direction of extrusion and adapted to cool the mixture to a temperature of between 30 degrees Celsius and 70 degrees Celsius, preferably between 35 degrees Celsius and 50 degrees Celsius, most preferably between 25 degrees Celsius and 35 degrees Celsius. Example 15: The device, Further comprising a susceptor material supply device; The apparatus of any of Examples 1-14, wherein the susceptor material supply device is adapted to insert susceptor material into the extrudate. Example 16: The apparatus of example 15, wherein the susceptor material feeder is adapted to insert susceptor material into the extrudate downstream of the die component. Example 17: The apparatus of example 15, wherein the susceptor material feeder is adapted to insert susceptor material into the extrudate during extrusion at the outlet. Example 18: The apparatus of any of Examples 1-17, wherein the apparatus further comprises a rotation device adapted to rotate the susceptor material. Example 19: 19. The apparatus of any of Examples 1-18, wherein the apparatus further comprises a dryer adapted to dry the extrudate comprising the aerosol-generating material to substantially maintain its cross-sectional shape. Example 20: The apparatus of any one of Examples 1 to 19, wherein the mixture is a slurry. Example 21: The apparatus of any one of Examples 1 to 20, wherein the extrudate is a cast tobacco leaf. Example 22: 1. A method for producing an extrudate comprising an aerosol-generating material, the method comprising the steps of: feeding the mixture into an extruder via an extruder inlet; moving the mixture along an extrusion direction; and extruding the mixture through an outlet from the extruder; The method wherein the mixture is extruded through a die element at the exit of the extruder to form an extrudate comprising the aerosol-generating material having a cross-sectional shape. Example 23: The method of example 22, wherein the density of the mixture increases while moving along the extrusion direction. Example 24: 24. The method of claim 22 or 23, wherein the moisture content of the mixture decreases during movement along the extrusion direction. Example 25: 25. The method of any of Examples 22-24, wherein the extrudate comprising the aerosol-generating material has a circular cross-section with a diameter of 5 millimeters to 10 millimeters. Example 26: The method of any of Examples 22 to 25, wherein the cross-sectional shape of the extrudate is the profile of a hollow chamber. Example 27: The method of example 26, wherein the hollow chamber profile forms a channel within the extrudate. Example 28: 28. The method of any one of Examples 26 to 27, wherein the profile of the hollow chamber is circular, with at least one hollow chamber. Example 29: 28. The method of example 26 or 27, wherein the profile of the hollow chamber is at least partially in the shape of at least one spiral. Example 30: 28. The method of embodiment 26 or 27, wherein the profile of the hollow chamber is at least partially in the shape of at least two rings connected by at least one spoke. Example 31: The method according to any of embodiments 26 to 30, wherein at least one surface of the profile of the hollow chamber exhibits a corrugation. Example 32: 32. The method of any of Examples 22 to 31, wherein the extrudate has a length of 2 meters to 10 meters. Example 33: 33. The method of any of Examples 22-32, further comprising inserting a susceptor material into the cross-sectional shape of the extrudate comprising the aerosol-generating material during extrusion of the extrudate comprising the aerosol-generating material from the die components. Example 34: The method of any of Examples 22 to 32, further comprising inserting a susceptor material into the cross-sectional shape of the extrudate comprising the aerosol-generating material after extrusion of the extrudate comprising the aerosol-generating material. Example 35: The method of any of Examples 22-34, wherein the die components are maintained at a temperature of 20 degrees Celsius to 40 degrees Celsius. Example 36: The method of any of Examples 22-35, wherein the extrudate is dried at a temperature of 80 degrees Celsius to 100 degrees Celsius. Example 37: 37. The method of any one of Examples 22-36, further comprising dividing the extrudate of aerosol-generating material into segments having lengths of 3 millimeters to 10 millimeters. Example 38: The method of any of Examples 22 to 37, wherein the mixture is a slurry. Example 39: The method of any one of Examples 22 to 38, wherein the extrudate is a tobacco cast leaf. Example 40: Use of an extruder to extrude an extrudate containing an aerosol-generating material to form a cross-sectional shape in the extrudate. Example 41: 1. A method for producing an aerosol-generating material surrounding a susceptor material, the method comprising the steps of: forming a helical cross-sectional shape on a length of aerosol-generating material; supplying a susceptor material to the center of the spiral cross-sectional shape of the aerosol-generating material by a susceptor material supply device; rotating the susceptor material with a rotating device; forcing the susceptor material into the center of the cross-sectional shape of the aerosol-generating material; and unwinding the aerosol-generating material around the susceptor material. Example 42: 42. The method of claim 41, wherein the length of aerosol-generating material having a helical cross-sectional shape is obtained by extrusion. Example 43: 42. The method of claim 41, wherein the length of aerosol-generating material having a helical cross-sectional shape is obtained by rolling a sheet of aerosol-generating material. Example 44: 44. The method of any of Examples 41-43, wherein the susceptor material is forced into the center of the aerosol-generating material at a pressure of 2 bar to 6 bar. Example 45: 45. The method of any of Examples 41-44, wherein the susceptor material rotates between 20 revolutions per minute and 150 revolutions per minute. Example 46: An aerosol-generating material produced according to the method described in any one of Examples 22 to 39. Example 47: An aerosol-generating article comprising an aerosol-generating material produced according to any one of Examples 22 to 39. Example 48: A system comprising the apparatus of any one of Examples 1-21 and a mixture for forming an extrudate comprising an aerosol-generating material.

[0103] Examples of embodiments of the present invention will now be further described with reference to the following figures: [Brief explanation of the drawings]

[0104] [Figure 1] FIG. 1 shows a cross-sectional view of an extruder. [Figure 2] FIG. 2 shows a perspective view of the die components. [Figure 3] FIG. 3 shows a cross section of the extrudate, showing the hollow chamber profile, where the extrudate has multiple circular hollow chambers. [Figure 4] FIG. 4 shows a cross section of the extrudate, showing the profile of a hollow chamber with multiple rings and connecting spokes. [Figure 5]FIG. 5 shows a cross section of the extrudate, which exhibits a hollow chamber profile shaped like a wagon wheel, with the spokes of the wagon wheel exhibiting corrugations. [Figure 6] FIG. 6 shows a cross section of the extrudate, which shows a hollow chamber shaped like a spiral. [Figure 7] FIG. 7 shows a cross section of the extrudate, showing the profile of the hollow chamber, which is shaped like a double helix. [Figure 8] FIG. 8 shows a perspective view of the extrudate leaving the extruder outlet, showing the hollow chamber profile of the extrudate in a spiral-like shape. [Figure 9] FIG. 9 shows a cross-sectional view of the extruder where the susceptor material is inserted into the extrudate during its extrusion. [Figure 10] FIG. 10 shows a cross-sectional view of an extruder where the susceptor material is inserted into the extrudate after it is extruded. [Figure 11] FIG. 11 shows a cross-sectional view of an extruder with a dryer and cutting device. [Figure 12] FIG. 12 shows a perspective view of a method for unwinding the aerosol-generating material around the susceptor material. DETAILED DESCRIPTION OF THE INVENTION

[0105] The extruder 1, as shown in FIG. 1, exhibits an inlet 2 adapted to receive a mixture 3 provided from a hopper 4. The inlet 2 is in fluid communication with an outlet 5 of the extruder 1, allowing the mixture 3 to be conveyed from the inlet 2 to the outlet 5 along an extrusion direction 100. The extrusion direction 100 is further indicated by an arrow in FIG. 1. The extruder 1 further comprises a screw 7 disposed within a barrel 8 of the extruder 1. Rotation of the screw 7 facilitates movement of the mixture 3 toward the outlet 5. The outlet 5 of the extruder 1 is adapted to extrude the mixture 3 to form an extrudate 9 having a cross-sectional shape by implementing a die component 10.

[0106] 2, die components 10 include a die plate 11 having openings 12 and a mandrel 13 having protrusions 14. Die plate 11 and mandrel 13 are positioned and adapted relative to one another to form a cross-sectional shape of a circular hollow chamber profile 15 in extrudate 9. Furthermore, the geometric contour of opening 12 is adapted to accommodate the geometric contour of protrusions 14 so that, when assembled into outlet 5, protrusions 14 are positioned within opening 12 and downstream end faces 16 of protrusions 14 are flush with downstream end faces 17 of die plate 11.

[0107] At the outlet 5 there is shown a cooling unit 21 adapted to cool the die element 10 as well as a vibration element 18 for applying vibration to the die element 10 during extrusion of the extrudate 9 .

[0108] The extruder 1 also includes a heating zone 19 and a cooling zone 20 .

[0109] As illustrated in Figures 3-7, the hollow chamber profile 15 of the extrudate 9 can exhibit significant differences in geometric design. For example, the hollow chamber profile 15 may exhibit multiple hollow chambers 22 surrounded by aerosol-generating material 23, as shown in Figure 3, or multiple concentric rings 25 connected by multiple spokes 26, both of which contain aerosol-generating material 23, as shown in Figure 4. The hollow chamber profile 15 may also be formed in the shape of a wagon wheel with spokes 26 exhibiting corrugated surfaces 24, in a spiral shape, or in a double spiral shape, as shown in Figures 5, 6, and 7, respectively. Figure 8 shows a perspective view of an extrudate 9 having a spiral hollow chamber profile 15 extruded from an outlet 5.

[0110] 9 and 10 show an apparatus for producing an extrudate 9 containing an aerosol-generating material 23, the apparatus comprising a susceptor material feeder 27 adapted to insert susceptor material 28 into the extrudate 9. According to the embodiment shown in FIG. 9, the susceptor material 28 is fed along the extrusion direction 100 by the screw 7 of the extruder 1 so that the susceptor material 28 can be inserted into the extrudate 9 during extrusion at the outlet 5. In another embodiment shown in FIG. 10, the susceptor material 28 is guided from the susceptor material feeder 27 to the extrudate 9 so that the susceptor material 28 is inserted into the extrudate 9 after it has been extruded from the outlet 5. In both embodiments, the susceptor material 28 is guided into the extrudate 9 with the aid of specially arranged guide rollers 29.

[0111] The apparatus shown in FIG. 9 further comprises a rotation device 30 adapted to rotate the susceptor material 28 .

[0112] FIG. 11 shows an apparatus for producing an extrudate 9 containing an aerosol-generating material 23, the apparatus comprising a dryer 31 adapted to dry the extrudate 9, followed by a cutting device 32 adapted to separate the extrudate 9 into individual segments 33.

[0113] 12 shows the susceptor material 28 being supplied from the susceptor material supply device 27 to the center 34 of the aerosol-generating material 23. The susceptor material 28 is rotated by the rotation device 30 and forced into the center 34 of the aerosol-generating material 23, causing the aerosol-generating material 23 to unwind and wrap around the susceptor material 28, forming aerosol-generating material 23 surrounding the susceptor material 28.

[0114] As shown in FIG. 1 , mixture 3 is fed into inlet 2 of extruder 1 by hopper 4, after which mixture 3 enters barrel 8 of extruder 1. Mixture 3 is then conveyed along extrusion direction 100 of extruder 1 by rotation of screw 7 until it reaches outlet 5 of extruder 1. As mixture 3 is conveyed along extrusion direction 100, mixture 3 is conveyed through heating zone 19 followed by cooling zone 20, where mixture 3 is heated and cooled, respectively.

[0115] At the exit 5 of the extruder 1, the mixture 3 is forced through a die element 10 to form an extrudate 9 including an aerosol-generating material 23 having a cross-sectional shape.

[0116] The mandrel 13 and die plate 11 elements of the die component 10 shown in Figure 2 direct the flow of the mixture 3 during extrusion so that the cross-sectional shape of the resulting extrudate 9 is circular and exhibits a hollow chamber profile. Examples of such cross-sectional shapes are shown in Figures 3-8.

[0117] The susceptor material 28 can be inserted into the cross-sectional shape of the extrudate 9. As illustrated in Figure 9, this can be accomplished by feeding the susceptor material 28 into the extruder 1 by a susceptor material feeding device 27. The susceptor material 28 then enters an opening in the extruder 1 and travels along a channel in the screw 7 until it reaches the die component 10 at the exit 5 of the extruder 1, where the susceptor material 28 is inserted into the cross-sectional shape of the extrudate 9 during its extrusion. During the insertion of the susceptor material 28 into the cross-sectional shape of the extrudate 9, the susceptor material 28 is rotated by a rotating device 30.

[0118] Alternatively, as shown in FIG. 10, the susceptor material 28 may also be of interest to the cross-sectional shape of the extrudate 9 after extrusion thereof.

[0119] During extrusion of the extrudate 9, the die element 10 is maintained at a temperature of 10 to 50 degrees Celsius by a cooling unit 21 and is vibrated by a vibrating element 18, as shown in FIG.

[0120] After exiting the extruder 1, the extrudate 9 is dried in a dryer 31 so as to substantially maintain its cross-sectional shape before being cut into segments 33 by a cutting device 32. The above process steps are shown in Figure 11.

[0121] For purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like should be understood in all instances to be modified by the term "about." Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein. Thus, in this context, the number A is understood as A ± 10% of A. Within this context, the number A can be considered to include values ​​that are within the typical standard error for measurement of the property that the number A modifies. In some instances, as used in the appended claims, the number A may deviate by the percentages recited above, provided that the amount by which A deviates does not materially affect the basic and novel characteristics of the claimed invention. Also, all ranges include the disclosed maximum and minimum points, and include any intermediate ranges therein, which may or may not be specifically recited herein.

Claims

1. An extrusion molding machine (1), The extruder (1) has an inlet (2) and an outlet (5), said inlet (2) being adapted to receive a mixture (3); the outlet (5) is adapted to extrude the mixture (3) to form an extrudate (9); said outlet (5) comprising a die element (10); the die component (10) is adapted to form an extrudate (9) comprising an aerosol-generating material; The die components (10) are adapted to form a cross-sectional shape in the extrudate (9).

1. An apparatus for producing an extrudate comprising an aerosol-generating material (23), comprising: The die components (10) comprise a die plate (11) and a mandrel (13); said die plate (11) presents at least one opening (12); said mandrel (13) exhibits at least one protrusion (14); and the protrusion (14) is at least partially disposed inside the opening (12); the downstream end surface of said projection (14) is at least partially spirally shaped; or the die plate (11) and the mandrel (13) are adapted to form the extrudate (9) so that it presents a hollow chamber profile (15) having a plurality of circular hollow chambers (22), or a hollow chamber profile (15) in the form of at least two rings (25) connected at least partially by at least one spoke (26), or a hollow chamber profile (15) in the form of a double helix, The device is characterized by:

2. A susceptor material supply device (27) adapted to insert a susceptor material (28) into the extrusion (9); a rotating device (30) adapted to rotate the susceptor material (28); The apparatus of claim 1 further comprising:

3. An apparatus as described in claim 2, wherein the susceptor material supply device (27) is adapted to insert susceptor material (28) into the extrusion molding downstream of the die component (10).

4. The apparatus of claim 1, further comprising a dryer (31) adapted to dry the extrusion (9) containing the aerosol-generating material (23) and substantially maintain its cross-sectional shape.

5. The following steps: feeding the mixture into the extruder (1) through the inlet (2) of the extruder (1); moving the mixture along an extrusion direction; and extruding the mixture from the extruder (1) through an outlet (5), the mixture is extruded through a die element (10) at the outlet (5) of the extruder (1) to form an extrudate (9) having a cross-sectional shape and including an aerosol-generating material (23); the cross-sectional shape of the extrusion (9) is the profile (15) of a hollow chamber; A method for producing an extrudate (9) comprising an aerosol-generating material (23), comprising: the extrudate exhibits a hollow chamber profile (15) with a plurality of circular hollow chambers (22) or a hollow chamber profile (15) in the form of at least two rings (25) connected at least partially by at least one spoke (26), A method characterized by:

6. 6. The method of claim 5, further comprising inserting a susceptor material (28) into the cross-sectional shape of the extrudate (9) containing the aerosol-generating material (23) during extrusion of the extrudate (9) containing the aerosol-generating material (23) from the die component (10).

7. 6. The method of claim 5, further comprising inserting a susceptor material (28) into the cross-sectional shape of the extrudate (9) containing aerosol-generating material (23) after the extrusion of the extrudate (9) containing aerosol-generating material (23).

8. 1. Use of an extruder (1) for extruding an extrudate (9) containing an aerosol-generating material (23) such that a cross-sectional shape is formed in the extrudate (9), the cross-sectional shape of the extrudate (9) being the profile (15) of a hollow chamber, comprising: the profile (15) of said hollow chamber is at least partially in the shape of at least one spiral, or the extrudate exhibits a hollow chamber profile (15) with a plurality of circular hollow chambers (22), or a hollow chamber profile (15) in the form of at least two rings (25) connected at least partially by at least one spoke (26), or a hollow chamber profile (15) in the form of a double helix, Use characterized by:

9. An extrudate (9) produced according to the method of any one of claims 5 to 7.

10. An extrusion (9) exhibiting a hollow chamber profile (15), the hollow chamber profile (15) exhibiting a plurality of concentric rings (25) connected by a plurality of spokes (26) each containing an aerosol-generating material (23).

11. An aerosol-generating article comprising an extrudate (9) manufactured according to any one of claims 5 to 7.

12. A system comprising an apparatus according to any one of claims 1 to 4 and a mixture for forming an extrudate (9) comprising an aerosol-generating material (23).

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