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

Abstract

An apparatus for weakening a sheet of aerosol-generating substrate for an aerosol-generating article component, the apparatus comprising: a first roller (12) having a plurality of first circumferential ridges (15) defining a respective plurality of first circumferential grooves (16) on its first radially outer surface; and a second roller (13) having a plurality of second circumferential ridges (23) defining a respective plurality of second circumferential grooves (24) on its second radially outer surface. Each first circumferential ridge (15) has a plurality of relief recesses (17) circumferentially spaced apart from one another along said first circumferential ridge (15), and a plurality of raised portions (18) defined between the relief recesses (17). At the joining zone between the first roller (12) and the second roller (13), the raised portions (18) of the first circumferential ridges (15) are inserted into the second circumferential grooves (24). In cross section, each first circumferential ridge (15) and each second circumferential ridge (23) has a rectangular outline with sharp edges (21, 27) configured to create cuts (8) in the sheet (2) of aerosol-generating substrate passing between the first roller (12) and the second roller (13).

Description

[Technical Field]

[0001] The present disclosure relates to an apparatus and method for weakening a sheet of aerosol-generating substrate for an aerosol-generating article component. [Background technology]

[0002] Aerosol-generating articles in which the aerosol-generating substrate is heated rather than burned, or non-combustion heated tobacco products, are known in the art. The aerosol-generating substrate is, for example, a tobacco-free herbaceous or plant-based cast sheet, or a plastic fiber-based material, or a biodegradable fiber-based material. Typically, in such heated aerosol-generating articles, the aerosol is generated by transferring heat from a heat source to a physically separated aerosol-generating substrate or material, which may be located in contact with, within, around, or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are entrained in the air drawn through the aerosol-generating article. As the released compounds cool, they condense to form an aerosol.

[0003] In a typical manufacturing process for an aerosol-generating article, an aerosol-generating substrate in sheet or foil form undergoes a crimping process. The crimped material is then collected into rods and cut into pieces. These cut rods are the components of the aerosol-generating article.

[0004] The crimping process generally uses two rotating cylindrical rollers between which a sheet of material is compressed, the rollers having matching engineered patterns of indentations on their outer surfaces that stretch the substrate fibers transversely, thereby crimping the sheet.

[0005] The crimping process serves to fold and collect the sheet of aerosol-generating substrate into a rod that fits into the aerosol-generating article. Indeed, the term "crimped sheet" refers to a sheet having a plurality of substantially parallel ridges or pleats that are substantially parallel to the cylindrical axis of the rod. This facilitates folding and collecting the crimped sheet of aerosol-generating substrate to form a rod.

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

[0007] For example, EP 3041375 discloses a method and apparatus for producing a variable crimp web material, in which the web material is crimped using a pair of rollers, each roller having corrugations across at least a portion of its width and corrugations along its periphery, the rollers being configured such that the corrugations across the width of the rollers are interleaved with one another to crimp the web material, and such that the valleys of the corrugations along the periphery crimp the web material to a first crimp value and the peaks of the corrugations along the periphery crimp the web material to a second crimp value.

[0008] EP 3542648 A1 discloses an apparatus for producing strands of web material, which includes a separating device configured to separate a flat web of reconstituted tobacco material into multiple strips. The apparatus includes a first roller and a second roller, the sides of which have alternating axially closed circumferential grooves and raised portions. The raised portions of the first roller engage with the grooves of the second roller, and the raised portions of the second roller engage with the grooves of the first roller. The flat web is not cut along a dividing line by the interaction of the two blades, but is torn in a defined manner by overstretching.

[0009] EP 3469922 A1 discloses a machine for producing rod-shaped smoking articles comprising unwinding means for unwinding a web of tobacco industry material, first cutting means configured to receive and cut the web to produce a plurality of longitudinal strips, and collecting and conveying means configured to collect and convey the longitudinal strips to produce a continuous stream.

[0010] That is, it would be desirable to have an apparatus and method for weakening a sheet of aerosol-generating substrate for an aerosol-generating article component that provides an alternative method of forming the sheet to facilitate folding and collecting the sheet of aerosol-generating substrate to form a rod, with a crimping effect. Summary of the Invention

[0011] The present disclosure relates to an apparatus for weakening a sheet of aerosol-generating substrate for an aerosol-generating article component. The apparatus may include a first roller having a first axis of rotation. The first roller may include a plurality of first circumferential ridges provided on a first radially outer surface of the first roller, the first circumferential ridges defining a respective plurality of first circumferential grooves on the first radially outer surface. The apparatus may include a second roller having a second axis of rotation. The second roller may include a plurality of second circumferential ridges provided on a second radially outer surface of the second roller, the second circumferential ridges defining a respective plurality of second circumferential grooves on the second radially outer surface. Each first circumferential ridge may include a plurality of relief recesses circumferentially spaced apart from one another along the first circumferential ridge. A plurality of raised portions may be defined between the relief recesses. At a joining zone between the first roller and the second roller, the raised portions of the first circumferential ridges may be inserted into the second circumferential grooves. In a cross section containing the first axis of rotation, each first circumferential ridge may have a rectangular outline. In a cross section containing the second axis of rotation, each second circumferential ridge may have a rectangular outline. The rectangular outlines of the first and second circumferential ridges may have sharp edges configured to cut a slit in a sheet of aerosol-generating substrate passing between the first and second rollers, said slit creating a frangible fold that facilitates folding and collecting said sheet of aerosol-generating substrate to form a rod.

[0012] The inventors have discovered that the scissors-type cutting of the present invention is an alternative to crimping that avoids stretching the aerosol-generating substrate sheet laterally against the crimping rollers, preventing or at least reducing the shredding effect and dust generation, especially at high speeds. Indeed, sheet compression in traditional crimping is a significant issue. While too low a crimping pressure can reduce the positive effects of crimping, too high a pressure can damage the material sheet or reduce its tensile strength, which can increase the occurrence of tearing and even cause shredding.

[0013] The inventors have discovered that cutting instead of crimping prevents stretching of the fibers in the sheet and prevents or at least reduces the generation and accumulation of dust due to fiber defibration.

[0014] The inventors have found that the apparatus according to the invention makes it possible to increase the speed at which sheets of aerosol-generating substrates are weakened and the productivity of the overall manufacturing process, since the speed of the sheets according to the method of the invention is no longer limited by the crimping pressure applied to said sheets. Indeed, in conventional crimping methods, to increase the speed and shorten the crimping time, more pressure must be applied to the sheet to ensure proper crimping, which increases the risk of damaging the sheet, including accidental shredding, during the crimping process.

[0015] The inventors have discovered that the sharp edges of the first and second circumferential ridges can create a precisely defined cut.

[0016] The inventors have discovered that first and second circumferential ridges having a rectangular profile with sharp edges are strong, durable, easy to manufacture, easy to maintain (the edges may be sharpened from time to time), and capable of producing the desired cut.

[0017] The weakening apparatus may also be suitable for weakening sheets of material other than the aerosol-generating substrate, for example, used in the field of aerosol-generating article manufacturing, to make filters or other components of the aerosol-generating article.

[0018] Each of the sharp edges may have an angle (α) of 90 degrees. Each of the sharp edges may have a radius (r1) of 0.05 mm or less. Each of the sharp edges may have a radius (r1) of 0.03 mm or more. The inventors have found that these values ​​for the radius of the sharp edges are capable of producing a precisely defined cut in the sheet of aerosol-generating substrate.

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

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

[0021] The pitch (a) of the relief recesses may be 0.2 mm to 20 mm, optionally 5.0 mm to 20.0 mm, optionally 6 mm to 16 mm. The axial width (b) of each first circumferential ridge may be 1 mm to 15 mm, optionally 2 mm to 4 mm. The axial width (f) of each first circumferential groove may be 1 mm to 15 mm, optionally 2 mm to 4 mm. The axial distance (g) between the centerlines of adjacent first circumferential ridges may be 2 mm to 6 mm. The circumferential amplitude (c) of the raised portion, i.e., the distance between two ends of the raised portion along the circumference, may be 0.1 to 8 mm, optionally 4 to 8 mm, optionally 2 to 4 mm, optionally 0.1 to 2.0 mm. The circumferential amplitude (e) of the recesses, i.e., the distance between the two edges of the recesses along the circumference, may be 0.1 to 8 mm, optionally 2 to 6 mm, optionally 2 to 4 mm, optionally 0.1 to 2.0 mm. The inventors have found that these values ​​of pitch (a), width (b), and amplitude (c) allow for the production of cuts having characteristics that allow for proper and easy folding of the sheet of aerosol-generating substrate.

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

[0023] Each concave surface and each of the two adjacent raised portions may define two auxiliary edges parallel to the first axis of rotation. Each of the auxiliary edges may be rounded. The inventors have found that the rounded auxiliary edges prevent cutting and damage to the sheet along a line transverse to the cut where the sheet contacts said auxiliary edges.

[0024] According to one embodiment of the present disclosure, the relief recesses of one first circumferential ridge may be circumferentially offset relative to the relief recesses of another first circumferential ridge to create an offset break. The relief recesses of one first circumferential ridge may be circumferentially offset relative to the relief recesses of two first circumferential ridges adjacent to the one first circumferential ridge. By moving in one direction along the first rotation axis, the relief recesses of each first circumferential ridge may always be circumferentially offset relative to the preceding first circumferential ridge in the same direction (clockwise or counterclockwise). The offset distance (Od) between the relief recesses of two adjacent first circumferential ridges may be 0 mm to 20 mm. The offset distance (Od) may be 20% to 40% of the circumferential amplitude (c) of the raised portion. The angular offset (β) between the relief recesses of two adjacent first circumferential ridges may be 0 degrees to 30 degrees. The offset of the relief recesses creates offset cuts in the sheet of aerosol-generating substrate, improving the uniformity of the cut distribution.

[0025] According to one embodiment of the present disclosure, the relief recesses of the first circumferential ridge may be aligned with one another along a direction parallel to the first axis of rotation to produce a group of cuts aligned along a direction transverse to the feed direction of the sheet of aerosol-generating substrate. The top of each second circumferential ridge may be continuous or may lack a relief recess. The inventors have discovered that if only the first roller is provided with a relief recess, no phase cooperation between the first roller and the second roller is required. Indeed, the angular position of the first roller relative to the second roller about the respective first and second axes of rotation does not need to be set at the start of the weakening method and does not require adjustment (re-phasing) during operation of the apparatus. This results in easier manufacture of the roller assembly and faster setup.

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

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

[0028] The cut may be a through cut, which goes completely through the thickness of the sheet of aerosol-generating substrate, thus creating a weak segment in the sheet.

[0029] The aerosol-generating substrate sheet may be a herbaceous or plant-based cast sheet. The aerosol-generating substrate sheet may comprise fibers, plant and / or alkaloid particles, a binder, and an aerosol-forming agent. The plant and / or alkaloid particles may comprise tobacco and / or nicotine and / or plant and / or cellulose powder. The aerosol-generating substrate sheet may be tobacco-free or tobacco-containing. The aerosol-generating substrate sheet may be a fibrous material. The fibrous material may be a plastic fibrous material or a biodegradable fibrous material. The biodegradable fibrous material may be cotton. The biodegradable fibrous material may be cellulose. The aerosol-generating substrate sheet may have a thickness comprised between 0.15 and 0.35 mm. The aerosol-generating substrate sheet may comprise an alkaloid. The aerosol-generating substrate sheet may comprise nicotine.

[0030] The present disclosure also relates to a method for weakening a sheet of aerosol-generating substrate for an aerosol-generating article component. The method may include making a cut in the sheet of aerosol-generating substrate. The cut in the sheet may be made by passing the sheet of aerosol-generating substrate between a first roller and a second roller of an apparatus for weakening the sheet of aerosol-generating substrate for an aerosol-generating article component while the first roller and the second roller rotate in opposite directions. The cut creates a weakened fold that facilitates folding and collecting the sheet of aerosol-generating substrate to form a rod. The apparatus may include a first roller having a first axis of rotation. The first roller may include a plurality of first circumferential ridges provided on a first radially outer surface of the first roller, the first circumferential ridges defining respective first circumferential grooves on the first radially outer surface. The apparatus may include a second roller having a second axis of rotation. The second roller may include a plurality of second circumferential ridges provided on the second radially outer surface of the second roller, the second circumferential ridges defining a respective plurality of second circumferential grooves on the second radially outer surface. Each first circumferential ridge may include a plurality of relief recesses circumferentially spaced apart from one another along the first circumferential ridge. A plurality of raised portions may be defined between the relief recesses. In a joining zone between the first roller and the second roller, the raised portions of the first circumferential ridges may be inserted into the second circumferential grooves. In a cross section including the first axis of rotation, each first circumferential ridge may have a rectangular outline. In a cross section including the second axis of rotation, each second circumferential ridge may have a rectangular outline. The rectangular contours of the first and second circumferential ridges may have sharp edges configured to cut a cut in a sheet of aerosol-generating substrate passing between the first and second rollers, said cut creating a frangible fold that facilitates folding and collection of said sheet of aerosol-generating substrate to form a rod.

[0031] The inventors have found that the method according to the present invention is not subject to roller position adjustment. In fact, in conventional crimping methods, the pressure exerted between the rollers tends to move said rollers away from each other, so the distance between the ridges and grooves of the two rollers should be adjusted at scheduled time intervals by moving the rollers closer together. In the setting according to the present invention, the distance can be standard, and no adjustment of the distance between the rollers is required to compensate for variations in the elongation of the substrate fiber.

[0032] The cut may be a through cut.

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

[0034] The sheet of aerosol-generating substrate may move between the first and second rollers at a linear velocity of 60 m / s to 500 m / s. The first roller may rotate at a peripheral velocity of 60 m / s to 500 m / s. The second roller may rotate at a peripheral velocity of 60 m / s to 500 m / s. The inventors have found that the present invention makes it possible to increase the speed of the sheet between the rollers to the disclosed values, and therefore improve the productivity of the overall manufacturing process.

[0035] The present disclosure also relates to a sheet of aerosol-generating substrate for an aerosol-generating article component. The sheet may be obtained through a method for manufacturing an aerosol-generating article component. The method includes making cuts in the sheet of aerosol-generating substrate for the aerosol-generating article component by passing the sheet of aerosol-generating substrate between first and second rollers of an apparatus while the first and second rollers rotate in opposite directions to weaken the sheet of aerosol-generating substrate, the cuts creating weakened folds that facilitate folding and collecting the sheet of aerosol-generating substrate to form a rod.

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

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

[0038] In some embodiments, the cuts are arranged in pairs, each pair comprising two parallel cuts. The transverse distance (b') between two parallel cuts may be 2 to 4 mm. The axial distance (g') between the centerlines of adjacent cut pairs may be 2 to 6 mm. The transverse distance (f') between adjacent cut pairs may be 2 to 4 mm. The offset longitudinal distance (O'd) between adjacent cut pairs may be 0 to 20 mm. The offset longitudinal distance (O'd) may be 20% to 40% of the cut length (c'). When each cut is a zigzag or wavy line, the transverse size (h') of said cuts may be 0.5 to 1.5 mm.

[0039] The present disclosure also relates to a process for manufacturing an aerosol-generating article component. The process may include manufacturing a sheet of aerosol-generating substrate. The process may include weakening the sheet of aerosol-generating substrate for the aerosol-generating article component through a method for weakening the sheet of aerosol-generating substrate for the aerosol-generating article component. The process may include collecting the sheet of aerosol-generating substrate to form a continuous rod. The process may include cutting the continuous rod into a plurality of aerosol-generating article components, each having a rod shape. Each aerosol-generating article component may comprise an assembly of frangible sheets formed from cut portions of the frangible aerosol-generating substrate sheet. The method for weakening the sheet of aerosol-generating substrate for the aerosol-generating article component may include making a cut in the sheet of aerosol-generating substrate. The cut in the sheet may be made by passing the sheet of aerosol-generating substrate between a first roller and a second roller of an apparatus while the first roller and the second roller rotate in opposite directions to weaken the sheet of aerosol-generating substrate for the aerosol-generating article component. The cuts create weakened folds that facilitate folding and collecting the sheet of aerosol-generating substrate to form a rod.

[0040] The inventors have found that the discontinuous longitudinal cuts in the sheet of aerosol-generating substrate made during the manufacturing process through the apparatus of the present invention make it possible to create weak folds that facilitate folding and collecting said sheet of aerosol-generating substrate to form a rod.

[0041] According to one embodiment of the present disclosure, producing a sheet of aerosol-generating substrate may include preparing a slurry using a powder and a binder, and casting the slurry onto a surface to produce a sheet of aerosol-generating substrate.

[0042] The present disclosure also relates to an aerosol-generating article comprising at least one aerosol-generating article component made according to a process for manufacturing an aerosol-generating article component. The process may include a method for weakening a sheet of aerosol-generating substrate for the aerosol-generating article component. The method for weakening a sheet of aerosol-generating substrate for the aerosol-generating article component may include making a cut in the sheet of aerosol-generating substrate. The cut in the sheet may be made by passing the sheet of aerosol-generating substrate between a first roller and a second roller of an apparatus while the first roller and the second roller rotate in opposite directions to weaken the sheet of aerosol-generating substrate for the aerosol-generating article component. The cut creates a weakened fold that facilitates folding and collecting the sheet of aerosol-generating substrate to form a rod.

[0043] The aerosol-generating article may be a non-combustible heated tobacco product. The aerosol-generating article may comprise an aerosol-generating article component and a filter having a mouthpiece end.

[0044] The present disclosure also relates to an apparatus for manufacturing an aerosol-generating article component, the apparatus comprising: a device for weakening a sheet of aerosol-generating substrate for the aerosol-generating article component. The device may comprise a first roller having a first axis of rotation. The first roller may comprise a plurality of first circumferential ridges provided on a first radially outer surface of the first roller, the first circumferential ridges defining a respective plurality of first circumferential grooves on the first radially outer surface. The apparatus may comprise a second roller having a second axis of rotation. The second roller may comprise a plurality of second circumferential ridges provided on a second radially outer surface of the second roller, the second circumferential ridges defining a respective plurality of second circumferential grooves on the second radially outer surface. Each first circumferential ridge may comprise a plurality of relief recesses circumferentially spaced from one another along the first circumferential ridge. A plurality of raised portions are defined between the relief recesses. At the joining zone between the first roller and the second roller, the raised portion of the first circumferential ridge may be inserted into the second circumferential groove. In a cross section containing the first axis of rotation, each first circumferential ridge may have a rectangular outline. In a cross section containing the second axis of rotation, each second circumferential ridge may have a rectangular outline. The rectangular outlines of the first circumferential ridge and the second circumferential ridge may have sharp edges configured to create cuts in the sheet of aerosol-generating substrate passing between the first roller and the second roller. The cuts create weakened folds that facilitate folding and collecting the sheet of aerosol-generating substrate to form a rod.

[0045] The apparatus may comprise upper and lower lamination rollers located upstream or downstream of the apparatus to weaken the sheet of aerosol-generating substrate. Upper and lower lamination rollers may also be located upstream and downstream of the apparatus to weaken the sheet of aerosol-generating substrate.

[0046] The upper and lower lamination rollers may be configured to maintain a constant thickness of the sheet of aerosol-generating substrate. The sheet of aerosol-generating substrate may be calendered before, during, or after the weakening / cutting step to ensure that the thickness of the sheet remains symmetrical after processing and before the collecting and folding steps to make it consumable.

[0047] The equipment may include a reel holder for carrying the sheet of aerosol-generating substrate. An apparatus for weakening the sheet of aerosol-generating substrate for the aerosol-generating article component is located downstream of the reel holder. The equipment may also include a folding device located downstream of the device for weakening the sheet of aerosol-generating substrate and configured to move the sheet from a flat configuration (upstream of the folding device) to a collected rod-like configuration (downstream of the folding device). The folding device may also be configured to wrap a wrapper around the collection of sheets. The folding device may be shaped like a tapered funnel.

[0048] As used herein, the coupling zone of a first roller and a second roller is the portion of the intermeshing first roller and rollers where the first circumferential ridge of the first roller is inserted into the second circumferential groove of the second roller and the second circumferential ridge of the second roller is inserted into the first circumferential groove of the first roller.

[0049] As used herein, "weakening" a sheet means that after weakening, the sheet still retains its integrity such that the sheet can be collected by folding along its longitudinal folds and does not break into pieces and / or strips. In other words, cuts made in the sheet do not cut said sheet into pieces and / or strips, and a frangible sheet, when collected in an aerosol-generating article component, is a folded sheet that does not break into pieces and / or strips.

[0050] As used herein, the top of the first circumferential ridge and the top of the second circumferential ridge are the radially outermost surfaces of said circumferential ridges, i.e., the surfaces of said circumferential ridges that are farthest from the first or second axis of rotation, respectively.

[0051] As used herein, the bottom of a relief recess of a first circumferential ridge is the radially innermost surface of said first circumferential ridge, i.e., the surface of said relief recess that is closest to the first axis of rotation.

[0052] As used herein, the bottom of the first circumferential groove and the bottom of the second circumferential groove are the radially innermost surfaces of said circumferential grooves, i.e., the surfaces of said circumferential grooves that are closest to the first or second axis of rotation, respectively.

[0053] As used herein, a rectangular profile of the cross section of the first and second circumferential ridges means that said cross section has parallel sides and an upper portion that defines two right angles with the parallel sides.

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

[0055] As used in this description, radial distance is the distance measured perpendicular to the first and second axes of rotation.

[0056] As used herein, the term circumference refers to a circumference about a first axis of rotation or a second axis of rotation.

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

[0058] As used herein, circumferential amplitude means the distance between two points along the circumference. [Brief explanation of the drawings]

[0059] [Figure 1]1 shows a schematic side view of a portion of an apparatus for manufacturing an aerosol-generating article component comprising a device for weakening a sheet of aerosol-generating substrate for the aerosol-generating article component according to the present invention; [Figure 2] 2 shows a top view of a portion of FIG. 1. [Figure 3] 3 shows a longitudinal section of an aerosol-generating article component produced through the apparatus of FIGS. 1 and 2. [Figure 4] 4 shows a cross-sectional view of the aerosol-generating article component of FIG. 3. [Figure 5] FIG. 3 is a front view of elements of the device of FIGS. 1 and 2. [Figure 6] FIG. 6 is a side view of the element of FIG. 5. [Figure 7] FIG. 6 is another side view of the element of FIG. 5. [Figure 8] 7 shows a detail of one of the elements of FIG. 6. [Figure 9] FIG. 2 shows a sheet of aerosol-generating substrate treated by the apparatus of the preceding figure, in accordance with a method for weakening the sheet of aerosol-generating substrate. [Figure 10] This shows one of the elements in Figure 5. [Figure 11] Another element of FIG. 5 is shown. [Figure 12] 12 shows an alternative embodiment of the element of FIG. 11. [Figure 13] 12 is a magnified portion of the element of FIG. 11. [Figure 14] Details of FIG. 13 are shown. [Figure 15] 10 shows another sheet of aerosol-generating substrate treated by an apparatus and through a method according to the present invention. [Figure 16] 10 shows another sheet of aerosol-generating substrate treated by an apparatus and through a method according to the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0060] The embodiments will now be further described with reference to the figures.

[0061] Apparatus 1 shown in Figures 1 and 2 is configured to weaken a sheet 2 of aerosol-generating substrate for an aerosol-generating article component 3. Apparatus 1 is part of an apparatus for manufacturing aerosol-generating article components 3, the apparatus being partially depicted in Figures 1 and 2.

[0062] The aerosol-generating article typically comprises an aerosol-generating article component 3 comprising an aerosol-generating substrate and a filter having a mouthpiece end.

[0063] In an aerosol-generating article, the aerosol is generated by transferring heat from a heat source to a physically separate aerosol-generating substrate, which may be located in contact with, within, around, or downstream of the heat source. During use of the aerosol-generating article, volatile compounds are released from the aerosol-generating substrate by heat transfer from the heat source and are entrained in air drawn through the aerosol-generating article.

[0064] The aerosol-generating article component 3 is realized by manufacturing a sheet of aerosol-generating substrate 2, weakening the sheet of aerosol-generating substrate 2 as further described, collecting the sheet of aerosol-generating substrate 2 to form a continuous rod, and cutting the continuous rod into a plurality of aerosol-generating article components 3, each having a rod shape. The weakening process is useful for folding and collecting the sheet of aerosol-generating substrate 2 into a rod that fits into the aerosol-generating article. Thus, the aerosol-generating article component 3 comprises an assembly of frangible sheets formed from cut portions of the sheet of frangible aerosol-generating substrate 2.

[0065] The aerosol-generating substrate sheet 2 may be realized by preparing a slurry using a powder and a binder, along with possible other ingredients, and casting the slurry onto a surface, such as a moving metal belt, to produce the aerosol-generating substrate sheet 2. The aerosol-generating substrate sheet 2 may include fibers, plant and / or alkaloid particles, a binder, and an aerosol-forming agent. The plant and / or alkaloid particles may include tobacco and / or nicotine and / or plant and / or cellulose powder. The aerosol-generating substrate sheet 2 may be a tobacco-containing substrate, or, for example, a tobacco-free herbaceous or plant-based cast sheet, or a plastic fiber-based material or a biodegradable fiber-based material, such as cotton or cellulose. The aerosol-generating substrate sheet 2 may contain an alkaloid such as nicotine.

[0066] For example, examples of aerosol-generating substrates include tobacco, glycerin, cellulose fibers, carboxymethylcellulose (CMC), and graphite. Other examples include plant components, cellulose powder, cellulose fibers, carboxymethylcellulose (CMC), and glycerin.

[0067] The apparatus for manufacturing the aerosol-generating article component 3 comprises a reel holder 4 carrying a sheet 2 of aerosol-generating substrate for the aerosol-generating article component. A previously manufactured sheet 2 of aerosol-generating substrate is wound onto a bobbin 5 attached to the reel holder 4. The sheet 2 of aerosol-generating substrate unwound from the bobbin 5 is fed in a feed direction "F" along a feed path.

[0068] Downstream of the reel holder 4, relative to the feed direction "F," the apparatus comprises an upper lamination roller 6 and a lower lamination roller 7. The upper lamination roller 6 and the lower lamination roller 7 rotate about two respective parallel axes. The peripheral surfaces of the upper lamination roller 6 and the lower lamination roller 7 are disposed adjacent to each other, defining a gap. As the aerosol-generating substrate sheet 2 unwound from the bobbin 5 passes through the gap, the upper lamination roller 6 and the lower lamination roller 7 are configured to compress the sheet 2, reducing its thickness and smoothing the surface of the sheet 2 to ensure that its thickness remains symmetrical during and after the following steps. The upper lamination roller 6 and the lower lamination roller 7 perform the lamination step.

[0069] Upstream of the upper lamination roller 6 and the lower lamination roller 7, the sheet 2 of aerosol-generating substrate may have an average thickness "t" of 0.15 mm to 0.35 mm. As a result of the lamination process, the average thickness "t" of the sheet 2 may be reduced to about 0.18 mm to 0.26 mm.

[0070] Downstream of the upper lamination roller 6 and the lower lamination roller 7 relative to the feed direction F, the apparatus comprises an apparatus 1 for weakening the sheet of aerosol-generating substrate 2. The apparatus 1 is configured to make a plurality of longitudinal through-scores 8 in the sheet of aerosol-generating substrate 2 to define longitudinal folds that facilitate folding and collecting the sheet of aerosol-generating substrate 2 to form a rod 9 (Figures 1 and 2). The characteristics of the through-scores 8 will be discussed later in this specification. The rod 9 may be wrapped in a wrapper 10 and cut into a plurality of aerosol-generating article components 3 (Figures 3 and 4).

[0071] 1 and 2 show diagrammatically a folding device 11 arranged downstream of the device 1 for weakening a sheet 2 of an aerosol-generating substrate and configured to move the sheet 2 from a flat configuration (upstream of the folding device 11) to a collected rod-like configuration (downstream of the folding device 11) and to wrap a wrapper around the collection of sheets 2. The folding device 11 may be shaped like a tapered funnel.

[0072] The apparatus 1 for weakening a sheet 2 of an aerosol-generating substrate comprises a first roller 12 configured to rotate about a first axis of rotation "XX" and a second roller 13 configured to rotate about a second axis of rotation "YY". The first roller 12 and the second roller 13 are mounted on a frame 14 (schematically represented in FIG. 1 ) so as to be rotatable about the first axis of rotation "XX" and the second axis of rotation "YY", respectively, and are operatively connected to motors (not shown) so as to rotate about said first and second axes of rotation "XX", "YY".

[0073] As depicted by the dashed lines in Figures 1 and 2, the upper lamination roller 6 and the lower lamination roller 7 may be positioned immediately upstream and / or downstream of the first roller 12 and the second roller 13 of the apparatus 1 and may be mounted on the same frame 14.

[0074] The first roller 12 is provided on a first radially outer surface of the first roller 12 and includes a plurality of first circumferential ridges 15 that define a plurality of first circumferential grooves 16 on the first radially outer surface, respectively (FIGS. 5, 11, 12, 13).

[0075] The radially outer surface of the first roller 12 has a cylindrical shape, and each of the first circumferential ridges 15 is in the shape of a circular ring surrounding the radially outer surface and projecting radially from said radially outer surface. Each first circumferential groove 16 is annular and defined between two first circumferential ridges 15. A first rotation axis "XX" passes through the center of each first circumferential ridge 15 and each first circumferential groove 16.

[0076] Each first circumferential ridge 15 includes a plurality of relief recesses 17 spaced circumferentially from one another along said first circumferential ridge, with a plurality of raised portions 18 defined between the relief recesses 17. As better shown in FIGS. 6 and 7, each relief recess 17 is separated from another relief recess 17 by a raised portion 18. The upper portion 19 of each raised portion 18 defines a portion of the radially outermost surface of the first roller 12 and is shaped like a circumferential arch having a maximum radius "Rmax" and a center at the first axis of rotation "XX". Each relief recess 17 is defined by an arch-shaped concave surface having a radius "r3". For example, the arch-shaped concave surface is a semicircle.

[0077] The plurality of raised portions 18 and relief recesses 17 of each first circumferential ridge 15 are arranged around the first axis of rotation "XX" according to a pitch "a", which is the circumferential distance between two consecutive relief recesses 17 or two consecutive raised portions 18. Each raised portion 18 has a circumferential amplitude "c" and each relief recess 17 has a circumferential amplitude "e". Each first circumferential ridge 15 has an axial width "b" and each first circumferential groove 16 has an axial width "f" (FIG. 11).

[0078] In a cross section containing the first axis of rotation "XX" (see FIGS. 13 and 14), each first circumferential ridge 15 has a rectangular outline. The cross section of each first circumferential ridge 15 is defined by the aforementioned top portion 19 and two opposing side surfaces 20. The side surfaces 20 protrude from a respective first circumferential groove 16, and the top portion 20 connects with the distal end of the side surfaces 20. The side surfaces 20 are parallel to one another. Each side surface 20 and the top portion 19 define a 90-degree angle "α" and define a sharpened edge 21. The sharpness of the sharpened edge 21 is determined by the edge radius "r1" of the sharpened edge 21 at its apex.

[0079] As better shown in Figures 6, 7, and 8, the arch-shaped concave surface and the two adjacent raised portions 18 define two auxiliary ends 22 parallel to the first axis of rotation "XX." Unlike the sharp ends 21, each auxiliary end 22 is rounded or blunt. The bluntness of the auxiliary ends 22 is determined by the end radius "r2" of the aforementioned auxiliary ends 22 at their apexes.

[0080] The second roller 13 comprises a plurality of second circumferential ridges 23 provided on a second radially outer surface of said second roller 13 and defining a respective plurality of second circumferential grooves 24 on the second radially outer surface (FIGS. 5, 10, 13).

[0081] The radially outer surface of the second roller 13 has a cylindrical shape, and each of the second circumferential ridges 23 is in the shape of a circular ring surrounding the radially outer surface and projecting radially from said radially outer surface. Each second circumferential groove 24 is annular and defined between two second circumferential ridges 23. A second rotation axis "YY" passes through the center of each second circumferential ridge 23 and each second circumferential groove 24.

[0082] Unlike the first circumferential ridge 15 of the first roller 12, the upper portion 25 of each second circumferential ridge 23 of the second roller 13 is continuous and lacks a relief recess. As better shown in Figures 5, 6, 7 and 10, the upper portion 25 of each second circumferential ridge 23 defines a portion of the radially outermost surface of the second roller 12 and is shaped like a circumference having its center on the second axis of rotation "YY." The maximum radius of the upper portion 25 of the second circumferential ridge 23 may be equal to the maximum radius "Rmax" of the upper portion 19 of the raised portion 18 described above.

[0083] In a cross section containing the second axis of rotation "YY" (see FIGS. 10, 13, and 14), each second circumferential ridge 23 has a rectangular outline. The cross section of each second circumferential ridge 23 is defined by the aforementioned upper portion 25 and two opposing side surfaces 26. The side surfaces 26 protrude from the respective second circumferential grooves 24, and the upper portion 25 connects to the distal ends of the side surfaces 26. The side surfaces 26 are parallel to one another. Each side surface 26 and the upper portion 25 define a 90-degree angle "α" and define a sharpened edge 27. The sharpness of the sharpened edge 27 is determined by the edge radius "r1" of the sharpened edge 27 at its apex.

[0084] 5 and 13, the first axis of rotation "XX" and the second axis of rotation "YY" are parallel to one another, and the first roller 12 and the second roller 13 intermesh at a bonding zone, i.e., the raised portion 18 of the first circumferential ridge 15 of the first roller 12 is inserted into the second circumferential groove 24 of the second roller 13, and the second circumferential ridge 23 of the second roller 13 is inserted into the first circumferential groove 16 of the first roller 12. The bonding zone is a zone that straddles or lies in a plane that includes both the first axis of rotation "XX" and the second axis of rotation "YY".

[0085] The relative positions and dimensions of the first roller 12 and the second roller 13 are set so that when one raised portion 18 of the first circumferential ridge 15 is located in the bonding zone, said raised portion 18 is partially located within the respective second circumferential groove 24, as shown in Figures 6 and 13. In this position, the upper portion 19 of the raised portion 18 and the upper portion 25 of the second circumferential ridge 23 are spaced apart by a maximum radial distance "dmax" measured in a plane containing both the first axis of rotation "XX" and the second axis of rotation "YY" (Figures 6 and 13). Furthermore, said raised portion 18 of the first circumferential ridge 15 is axially spaced apart by a minimum axial distance "daxial" from two adjacent second circumferential ridges 23 of the second roller 13, i.e., the first circumferential ridge 15 and the second circumferential ridges 23 do not contact each other.

[0086] The relative positions and dimensions of the first roller 12 and the second roller 13 are set so that when one relief recess 17 of the first circumferential ridge 15 is located in the bonding zone, said relief recess 17 is radially spaced apart from the respective second circumferential groove 24, and the first circumferential ridge 15 is outside said second circumferential groove 24 as in Figure 7. In this position, the bottom of the relief recess 17 of the first roller 12 and the top 25 of the second circumferential ridge 23 of the second roller 13 are spaced apart by a minimum radial distance "dmin" measured in a plane containing both the first axis of rotation "XX" and the second axis of rotation "YY" (Figures 7 and 13).

[0087] The relative positions and dimensions of the first roller 12 and the second roller 13 are set so that at the joining zone of the first roller 12 and the second roller 13, the raised portion of the first circumferential ridge 15 is spaced a further radial distance "d" from the bottom of the second circumferential groove 24 (Figure 13).

[0088] In the illustrated non-limiting example, the relief recesses 17 of one first circumferential ridge 15 are circumferentially offset with respect to the relief recesses 17 of the two first circumferential ridges 15 adjacent to the one first circumferential ridge 15. Moving in one direction along the first axis of rotation "XX" (e.g., from left to right in Figures 5, 11, or 12), the relief recesses 17 of each first circumferential ridge 15 are always circumferentially offset in the same direction (clockwise or counterclockwise) with respect to the preceding first circumferential ridge 15 by an offset distance "Od" corresponding to the angular offset "β" (Figure 7).

[0089] In the alternative embodiment of Figure 12, the relief recesses 17 and raised portions 18 of the first circumferential ridge 15 are all axially aligned, i.e., the offset distance "Od" and angular offset "β" are zero.

[0090] The first roller 12 has a first axial length "L1" measured parallel to the first axis of rotation "XX" and between two first circumferential ridges 15 located at opposite ends of the first roller 12 (FIG. 11). The second roller 13 has a second axial length "L2" measured parallel to the second axis of rotation "YY" and between two second circumferential grooves 24 located at opposite ends of the second roller 13 (FIG. 11).

[0091] The first axial length "L1" and the second axial length "L2" may be designed as a function of the width "w" of the sheet 2 of the aerosol-generating substrate. The first axial length "L1" and the second axial length "L2" may be smaller than the width "w" to avoid cutting the longitudinal edges of the sheet 2. For example, the first axial length "L1" is equal to the second axial length "L2", which is equal to 80 to 90 percent of the width "w" of the sheet 2.

[0092] The first roller 12 may be manufactured by creating and then assembling a plurality of first discs and a plurality of second discs, the first discs and second discs being stacked and arranged alternately, the first discs including a first circumferential ridge 15 and the second discs defining the bottom of a first circumferential groove 16.

[0093] The second roller 13 may be manufactured by creating and then assembling a plurality of third discs and a plurality of fourth discs, where the third discs and the fourth discs are alternately stacked and arranged, the third discs including the second circumferential ridge and the fourth disc defining the bottom of the second circumferential groove.

[0094] Other manufacturing processes may also be employed, for example, the first and second rollers 12, 13 may each be manufactured by machining them from a respective solid body.

[0095] The sheet of aerosol-generating substrate 2 is weakened by passing said sheet of aerosol-generating substrate 2 between a first roller 12 and a second roller 13 while the first roller 12 and the second roller 13 rotate in opposite directions.

[0096] The sharp edge 21 of the raised portion 18 of the first circumferential ridge 15 and the sharp edge 27 of the second circumferential ridge 23 create a through cut 8 in the sheet 2 of the aerosol-generating substrate only when the raised portion 18 of the first circumferential ridge 15 is located in the bonding zone. The rounded auxiliary edge 22 does not cut the sheet 2 along a line intersecting the cut where the sheet 2 contacts said auxiliary edge 22.

[0097] When the relief recess 17 of the first circumferential ridge 15 is located in the bonding zone, the sharp edge 21 of the raised portion 18 of the first circumferential ridge 15 and the sharp edge 27 of the second circumferential ridge 23 do not cut the sheet 2 .

[0098] The offset through cuts 8 made by the first and second rollers 12, 13 of FIG. 5 are shown in FIG.

[0099] The modified embodiment of Figure 12 makes it possible to produce groups of cuts 8 aligned along a direction transverse to the feed direction "F" of the sheet 2 of aerosol-generating substrate.

[0100] In all embodiments, the through cuts 8 act as weakened segments or folds in the sheet 2 of the aerosol-generating substrate, which assist in bending the sheet 2 at said segments or folds during the following folding and collection process by the folding device 11.

[0101] All of the sizes provided above allow for the creation of through cuts 8 without compressing and damaging the sheet 2 and may be designed as a function of the thickness "t" and / or width "w" of the sheet 2 of the aerosol-generating substrate.

[0102] Furthermore, the first roller 12 and the second roller 13 may be rotated at a peripheral speed of 60 m / s to 500 m / s in order to move the aerosol-generating substrate sheet 2 between the first roller 12 and the second roller 13 at a linear speed of 60 m / s to 500 m / s.

[0103] Tables 1 and 2 below show possible dimensions of the first roller 12 and the second roller 13, which are graphically represented in FIGS. 6, 7, 8, 11, 13 and 14.

[0104] [Table 1]

[0105] [Table 2]

[0106] Table 3 below shows further possible dimensions for the first roller 12.

[0107] [Table 3]

[0108] Table 4 below shows possible dimensions of the cut 8 (shown in FIG. 9) in the sheet 2 made through the first roller 12 provided with the characteristics of Table 3.

[0109] The cuts 8 are arranged in pairs, each pair including two parallel cuts 8. Each cut 8 is a straight line parallel to the feed direction of the aerosol-generating substrate sheet 2. The cut pairs 8 are aligned along longitudinal paths, with the pair of cuts 8 in one path being offset relative to the pair of cuts 8 in an adjacent path.

[0110] [Table 4]

[0111] Figure 15 shows a further example of a sheet of aerosol-generating substrate treated by an apparatus and through a method according to the invention. The cuts 8 are single linear cuts aligned along each path and offset relative to the cuts 8 of adjacent paths. Examples of measurements for these single linear cuts are shown in Table 5 below.

[0112] [Table 5]

[0113] Figure 16 shows another example of a sheet of aerosol-generating substrate treated by an apparatus and through a method according to the invention. The cuts 8 are single zigzag cuts aligned along each path and offset relative to the cuts 8 of adjacent paths. Examples of measurements for these single zigzag cuts are shown in Table 6 below.

[0114] [Table 6]

[0115] For purposes of this specification and the appended claims, unless otherwise indicated, all numerical values ​​expressing amounts, quantities, percentages, and the like are to be understood as being modified in all examples 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 ± 5 percent of A. Within this context, the number A may be considered to include numerical values ​​that are within the common standard error of measurement for the property that it modifies. In some cases, such as when 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. [Example]

[0116] 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.

[0117] Example 1 1. An apparatus for weakening a sheet of aerosol-generating substrate for an aerosol-generating article component, the apparatus comprising: a first roller having a first axis of rotation and comprising a plurality of first circumferential ridges provided on a first radially outer surface of said first roller, the first circumferential ridges defining a respective plurality of first circumferential grooves on said first radially outer surface; and a second roller having a second axis of rotation and comprising a plurality of first circumferential ridges provided on a second radially outer surface of said second roller, the second circumferential ridges defining a respective plurality of second circumferential grooves on said second radially outer surface, each first circumferential ridge being circumferentially spaced apart from one another along said first circumferential ridge. a plurality of relief recesses and a plurality of raised portions defined between the relief recesses, wherein at a joining zone between the first roller and the second roller, the raised portions of the first circumferential ridges are inserted into the second circumferential grooves, each first circumferential ridge has a rectangular outline in a cross section containing the first axis of rotation, and each second circumferential ridge has a rectangular outline in a cross section containing the second axis of rotation, the rectangular outlines of the first circumferential ridges and the second circumferential ridges having sharp edges configured to create cuts in a sheet of aerosol-generating substrate passing between the first roller and the second roller, said cuts creating frangible folds that facilitate folding and collection of said sheet of aerosol-generating substrate to form a rod. Example 2. A method for weakening a sheet of aerosol-generating substrate for an aerosol-generating article component, the method comprising: making a cut in the sheet of aerosol-generating substrate by passing the sheet of aerosol-generating substrate between a first roller and a second roller of the apparatus described in Example 1 while the first roller and the second roller rotate in opposite directions, the cut creating a weakened fold that facilitates folding and collection of the sheet of aerosol-generating substrate to form a rod. Example 3 1. A process for manufacturing an aerosol-generating article component, the process comprising: - manufacturing a sheet of aerosol-generating substrate; weakening the sheet of aerosol-generating substrate by the method of Example 2; - collecting the sheet of aerosol-generating substrate to form a continuous rod; - cutting the continuous rod into a plurality of aerosol-generating article components, each having a rod shape, each aerosol-generating article component comprising an assembly of frangible sheets formed from cut portions of the sheet of frangible aerosol-generating substrate. Example 4. An aerosol-generating article comprising at least one aerosol-generating article component made according to the process of Example 3. Example 5. 1. An apparatus for manufacturing an aerosol-generating article component comprising the device of Example 1. Example 6 10. The device of example 1, wherein each of the sharp edges has an angle (α) of 90 degrees. Example 7 The device of example 1 or example 6, wherein each of the sharp edges has a radius (r1) of 0.05 mm or less. Example 8 The device of Example 7, wherein the radius (r1) of each of the sharp edges is 0.03 mm or greater. Example 9. The apparatus of any one of Example 1 or Examples 6-8, wherein the minimum radial distance (dmin) between the bottom of the relief recess of the first roller and the top of the second circumferential ridge of the second roller is 0.5 mm or more. Example 10. 10. The device of example 9, wherein the minimum radial distance (dmin) is 2 mm or less. Example 11 An apparatus as described in any one of Example 1 or Examples 6 to 10, wherein the ratio (dmin / Rmax) of the minimum radial distance (dmin) between the bottom of the relief recess of the first roller and the top of the second circumferential protuberance of the second roller to the maximum radius of the raised portion (Rmax) is 0.005 or more. Example 12 The device of Example 11, wherein the ratio (dmin / Rmax) of the minimum radial distance (dmin) to the maximum radius (Rmax) is 0.03 or less. Example 13 The device of any of Example 1 or Example 6 to Example 11, wherein the maximum radius (Rmax) is between 40 mm and 300 mm, optionally between 90 mm and 120 mm. Example 14. An apparatus as described in any of Examples 1 or 6 to 13, wherein the ratio (dmin / t) of the minimum radial distance (dmin) between the bottom of the relief recess of the first roller and the top of the second circumferential ridge of the second roller to the thickness (t) of the sheet of aerosol-generating substrate is 1.5 or more. Example 15. The device of Example 14, wherein the ratio of minimum radial distance (dmin) to thickness (t) (dmin / t) is 3.5 or less. Example 16. An apparatus according to any one of Example 1 or Examples 6 to 15, wherein in the joining zone between the first roller and the second roller, the raised portion of the first circumferential ridge is spaced apart from the bottom of the second circumferential groove. Example 17. The apparatus of any one of Example 1 or Example 6 to Example 16, wherein the minimum axial distance (daxial) between the first circumferential ridge of the first roller and the second circumferential ridge of the adjacent second roller is 0.02 mm to 0.06 mm. Example 18. The device according to Example 17, wherein the minimum axial distance (daxial) is 0.03 mm to 0.04 mm. Example 19. An apparatus described in any one of Example 1 or Example 6 to Example 18, wherein the ratio (daxial / Rmax) of the minimum axial distance (daxial) between the first circumferential ridge of the first roller and the second circumferential ridge of the adjacent second roller to the maximum radius (Rmax) of the raised portion is 0.0002 to 0.0005. Example 20. An apparatus described in any of Example 1 or Examples 6 to 19, wherein the ratio (daxial / t) of the minimum axial distance (daxial) between the first circumferential ridge of the first roller and the second circumferential ridge of the adjacent second roller to the thickness (t) of the sheet of aerosol-generating substrate is 0.2 to 0.3. Example 21. The device according to any one of Example 1 or Example 6 to Example 20, wherein the thickness (t) of the sheet of the aerosol-generating substrate is 0.15 mm to 0.35 mm. Example 22. The apparatus according to any one of Example 1 or Example 6 to Example 21, wherein the width (w) of the sheet of aerosol-generating substrate is 80 mm to 180 mm. Example 23. The device of any of Example 1 or Example 6 to Example 22, wherein the pitch (a) of the relief recesses is 0.2 mm to 20 mm, optionally 5.0 mm to 20.0 mm, optionally 6 mm to 16 mm. Example 24. The device of any of Example 1 or Examples 6 to 23, wherein the axial width (b) of each first circumferential ridge is between 1 mm and 15 mm, optionally between 2 mm and 4 mm, and / or the axial width (f) of each first circumferential groove is between 1 mm and 15 mm, optionally between 2 mm and 4 mm, and / or the axial distance (g) between centerlines of adjacent first circumferential ridges is between 2 mm and 6 mm. Example 25. The device of any of Example 1 or Examples 6-24, wherein the circumferential amplitude (c) of the raised portion, i.e., the distance between the two ends of the raised portion along the circumference, is 0.1 to 8 mm, optionally 4 to 8 mm, optionally 2 to 4 mm, optionally 0.1 to 2.0 mm, and / or the circumferential amplitude (e) of the recessed portion, i.e., the distance between the two ends of the recessed portion along the circumference, is 0.1 to 8 mm, optionally 2 to 6 mm, optionally 2 to 4 mm, optionally 0.1 to 2.0 mm. Example 26. The device of any one of example 1 or examples 6 to 25, wherein each relief recess is defined by a concave surface. Example 27. 27. The device of example embodiment 26, wherein the concave surface is arch-shaped. Example 28. The device according to Example 27, wherein the radius (r3) of the concave surface is 5 mm to 15 mm. Example 29. The device of any one of Example 1 or Examples 6 to 28, wherein each concave surface and each of the two adjacent raised portions define two auxiliary ends parallel to the first axis of rotation, each of the auxiliary ends being rounded. Example 30. The apparatus of any one of Example 1 or Examples 6 to 29, wherein the relief recess of one first circumferential ridge is circumferentially offset relative to the relief recess of another first circumferential ridge to create an offset cut. Example 31. 31. The device of example 30, wherein the relief recess of one first circumferential ridge is circumferentially offset relative to the relief recesses of two first circumferential ridges adjacent to the one first circumferential ridge. Example 32. 32. The device of claim 31, wherein the device moves in one direction along the first axis of rotation, and the relief recess of each first circumferential ridge is circumferentially offset relative to the preceding first circumferential ridge, always in the same direction (clockwise or counterclockwise). Example 33. An apparatus according to any one of Examples 30 to 32, wherein the offset distance (Od) between the relief recesses of two adjacent first circumferential protuberances is 0 mm to 20 mm, and / or the offset distance (Od) is 20% to 40% of the circumferential amplitude (c) of the raised portion. Example 34. The device of any of Example 1 or Examples 6-33, wherein the angular offset (β) between the relief recesses of two adjacent first circumferential ridges is between 0 degrees and 30 degrees. Example 35. An apparatus as described in any of Examples 1 or 6 to 29, wherein the relief recesses of the first circumferential ridge are aligned with each other along a direction parallel to the first axis of rotation to produce a group of cuts aligned along a direction transverse to the feed direction of the sheet of aerosol-generating substrate. Example 36. The device of any one of Example 1 or Examples 6-35, wherein the top of each second circumferential ridge is continuous and lacks a relief recess. Example 37. An apparatus as described in any of Examples 1 or 6 to 36, wherein the first roller has a first axial length (L1) measured parallel to the first axis of rotation (XX) and between two first circumferential ridges located at opposite ends of the first roller, and the first axial length (L1) is 80 to 90 percent of the width (w) of the sheet of aerosol-generating substrate. Example 38. An apparatus as described in any of Examples 1 or 6 to 37, wherein the second roller has a second axial length (L2) measured parallel to the second axis of rotation (YY) and between two second circumferential ridges located at opposite ends of the second roller, and the second axial length (L2) is 80 to 90 percent of the width (w) of the sheet of aerosol-generating substrate. Example 39. The apparatus of any one of Example 1 or Examples 6 to 38, wherein the first roller includes a plurality of first discs and a plurality of second discs, the first discs and the second discs are stacked and arranged alternately, the first disc includes a first circumferential ridge, and the second disc defines a bottom of a first circumferential groove. Example 40. An apparatus described in any of Example 1 or Examples 6 to 39, wherein the second roller includes a plurality of third discs and a plurality of fourth discs, the third discs and the fourth discs are stacked and arranged alternately, the third disc includes a second circumferential ridge, and the fourth disc defines a bottom of a second circumferential groove. Example 41. 6. The apparatus of claim 5, further comprising an upper lamination roller and a lower lamination roller positioned upstream or downstream of the apparatus to weaken the sheet of aerosol-generating substrate, optionally the upper lamination roller and the lower lamination roller positioned upstream and downstream of the apparatus to weaken the sheet of aerosol-generating substrate. Example 42. The device according to any one of Example 1 or Examples 6 to 40, or the method according to Example 2, wherein the cut is a through cut. The cuts extend completely through the thickness of the sheet of aerosol-generating substrate, thus creating a weak segment within the sheet. Example 43. The device of any of Examples 1 or 6 to 40, or the method of Example 2 or Example 42, wherein the sheet of aerosol-generating substrate may comprise fibers, plant and / or alkaloid particles, a binder, and an aerosol-forming agent, and optionally the sheet of aerosol-generating substrate is a cast sheet of herbaceous or plant-based material, and optionally the plant and / or alkaloid particles comprise tobacco and / or nicotine and / or plant and / or cellulose powder. Example 44. 44. The device of Example 43, wherein the sheet of aerosol-generating substrate is a tobacco-free or tobacco-containing substrate. Example 45. The device according to any one of Example 1 or Examples 6 to 40, or the method according to Example 2 or Examples 42 to 44, wherein the aerosol-generating substrate sheet is made of a fibrous material. Example 46. 46. ​​The device or method of example 45, wherein the fiber-based material is a plastic fiber-based material or a biodegradable fiber-based material. Example 47. The device of Example 46, wherein the biodegradable fiber-based material is cotton. Example 48. The device according to any one of Example 1 or Examples 6 to 40, or the method according to any one of Example 2 or Examples 42 to 47, wherein the biodegradable fiber material is cellulose. Example 49. The apparatus according to any one of Example 1 or Examples 6 to 40, or the method according to Example 2 or Examples 42 to 48, wherein the sheet of aerosol-generating substrate has a thickness of 0.15 to 0.35. Example 50. The device according to any one of Example 1 or Examples 6 to 40, or the method according to Example 2 or Examples 42 to 49, wherein the aerosol-generating substrate sheet contains an alkaloid. Example 51. The device according to any one of Example 1 or Examples 6 to 40, or the method according to Example 2 or Examples 42 to 50, wherein the aerosol-generating substrate sheet contains nicotine. Example 52. The process described in Example 3, wherein producing a sheet of aerosol-generating substrate comprises preparing a slurry using a powder and a binder, and casting the slurry onto a surface to produce a sheet of aerosol-generating substrate. Example 53. The method of example 2, wherein the sheet of aerosol-generating substrate moves between the first roller and the second roller at a linear velocity of between 60 m / s and 500 m / s. Example 54. The method of example 2, wherein the first roller rotates at a peripheral speed of between 60 m / s and 500 m / s. Example 55. The method of example 2, wherein the second roller rotates at a peripheral speed of between 60 m / s and 500 m / s. Example 56. The article of Example 4, wherein the aerosol-generating article is a non-combustible heated tobacco product. Example 57. The article of example 4 or example 56, wherein the aerosol-generating article comprises an aerosol-generating article component and a filter having a mouthpiece end. Example 58. A sheet of aerosol-generating substrate for use as a component of an aerosol-generating article, obtained through the method of any of Example 2, Examples 42 to 51, or Examples 53 to 55, wherein the cuts are longitudinal cuts parallel to the feed direction of the sheet of aerosol-generating substrate, and optionally each cut is a straight line, a zigzag line, or a wavy line. Example 59. The sheet of Example 58, wherein each cut has a length (c') of 0.1 to 8 mm, optionally 4 to 8 mm, optionally 2 to 4 mm, optionally 0.1 to 2.0 mm. Example 60. The sheet of Example 58 or Example 59, wherein the longitudinal distance (e') between the continuously aligned cuts is 0.1 to 8 mm, optionally 2 to 6 mm, optionally 2 to 4 mm, optionally 0.1 to 2.0 mm. Example 61. The sheet according to any one of Examples 58 to 60, wherein the transverse distance (b') between adjacent cuts is 1 mm to 15 mm, optionally 2 mm to 4 mm. Example 62. The sheet according to any one of Examples 58 to 61, wherein the pitch (a') of the continuously aligned cuts is 0.2 mm to 20 mm, optionally 5.0 mm to 20.0 mm, and optionally 6 mm to 16 mm. Example 63. A sheet described in any of Examples 58 to 62, wherein the offset longitudinal distance (O'd) between adjacent cuts is 0 mm to 20 mm, and / or the offset longitudinal distance (O'd) is 20% to 40% of the cut length (c'). Example 64. The sheet of any one of Examples 58 to 63, wherein the cuts are arranged in pairs, each pair including two parallel cuts. Example 65. The sheet of Example 64, wherein the transverse distance (b') between two parallel cuts is 2 to 4 mm. Example 66. The sheet described in Example 64 or Example 65, wherein the axial distance (g') between the center lines of adjacent pairs of cuts is 2 mm to 6 mm. Example 67. The sheet according to any one of Examples 64 to 66, wherein the transverse distance (f') between adjacent pairs of cuts is 2 mm to 4 mm. Example 68. A sheet described in any of Examples 64 to 67, wherein the offset longitudinal distance (O'd) between adjacent pairs of cuts is 0 mm to 20 mm, and / or the offset longitudinal distance (O'd) is 20% to 40% of the cut length (c'). Example 69. The sheet according to any one of Examples 64 to 67, wherein when each cut is a zigzag line or a wavy line, the cross-sectional size (h') of the cut is 0.5 mm to 1.5 mm.

Claims

1. 1. An apparatus for weakening a sheet of aerosol-generating substrate for an aerosol-generating article component, said apparatus comprising: a first roller having a first axis of rotation and including a plurality of first circumferential ridges provided on a first radially outer surface of the first roller, the first circumferential ridges defining a respective plurality of first circumferential grooves on the first radially outer surface; a second roller having a second axis of rotation and including a plurality of second circumferential ridges provided on a second radially outer surface of said second roller, said second circumferential ridges defining a respective plurality of second circumferential grooves on said second radially outer surface; each first circumferential ridge comprising a plurality of relief recesses spaced circumferentially from one another along said first circumferential ridge and a plurality of raised portions defined between said relief recesses; In a joining zone between the first roller and the second roller, the raised portion of the first circumferential ridge is inserted into the second circumferential groove; In a cross section containing the first axis of rotation, each first circumferential ridge has a rectangular outline, and in a cross section containing the second axis of rotation, each second circumferential ridge has a rectangular outline; the rectangular contours of the first circumferential ridge and the second circumferential ridge have sharp edges configured to create cuts in a sheet of aerosol-generating substrate passing between the first roller and the second roller, the cuts creating frangible folds that facilitate folding and collecting the sheet of aerosol-generating substrate to form a rod.

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

3. 3. The device of claim 1, wherein each of the sharp edges has a radius (r1) of 0.05 mm or less.

4. 4. An apparatus according to claim 1, wherein the ratio (dmin / t) of the minimum radial distance (dmin) between the bottom of the relief recess of the first roller and the top of the second circumferential ridge of the second roller to the thickness (t) of the sheet of aerosol-generating substrate is 1.5 or greater.

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

3.

6. An apparatus according to any preceding claim, wherein each relief recess is defined by a concave surface.

7. 7. The apparatus of claim 6, wherein each concave surface and each of two adjacent raised portions defines two auxiliary ends parallel to said first axis of rotation, each of said auxiliary ends being rounded.

8. 8. Apparatus according to any preceding claim, wherein the relief recess of one first circumferential ridge is circumferentially offset relative to the relief recess of another first circumferential ridge to create an offset break.

9. 9. The device of any preceding claim, wherein the upper portion of each second circumferential ridge is continuous and devoid of a relief recess.

10. 10. A method for weakening a sheet of aerosol-generating substrate for an aerosol-generating article component, the method comprising: making a cut in the sheet of aerosol-generating substrate by passing the sheet of aerosol-generating substrate between the first roller and the second roller of an apparatus as defined in any one of claims 1 to 9 while the first roller and the second roller rotate in opposite directions, the cut creating a weakened fold that facilitates folding and collection of the sheet of aerosol-generating substrate to form a rod.

11. The method of claim 10, wherein the cut is a through cut.

12. 12. The method of claim 10 or 11, wherein the sheet of aerosol-generating substrate is a herbaceous or plant-based cast sheet, or the sheet of aerosol-generating substrate is a fibrous material.

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

35.

14. 1. A process for manufacturing an aerosol-generating article component, said process comprising: producing a sheet of an aerosol-generating substrate; weakening the sheet of aerosol-generating substrate by a method according to any one of claims 1 to 13; collecting the sheet of aerosol-generating substrate to form a continuous rod; cutting the continuous rod into a plurality of aerosol-generating article components, each having a rod shape, each aerosol-generating article component comprising an assembly of frangible sheets formed from cut portions of a sheet of frangible aerosol-generating substrate.

15. producing a sheet of the aerosol-generating substrate, preparing a slurry using a powder and a binder; and casting the slurry onto a surface to produce a sheet of the aerosol-generating substrate.

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