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

Abstract

An apparatus (1) for weakening a sheet (2) of aerosol-generating substrate for an aerosol-generating article component (3) comprises a first roller (12) including a first radially outer surface having a plurality of first circumferential ridges (15) and a plurality of first circumferential grooves (16), the first circumferential ridges (15) having a circumferential recess (17) forming a first interruption band (19) on the first radially outer surface, and a second roller (13) including a second radially outer surface having a plurality of second circumferential ridges (20) and a plurality of second circumferential grooves (21), the second circumferential ridges (20) having a circumferential recess (17) forming a second interruption band (22) on the second radially outer surface. In the connection zone of the first roller (12) and the second roller (13), the first circumferential ridge (15) is partially inserted into the second circumferential groove (21), and the second circumferential ridge (20) is partially inserted into the first circumferential groove (16). The first interrupted band (19) and the second interrupted band (22) cross each other when facing each other in the connection zone.

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, such as heat-and-burn products in which the aerosol-generating substrate is heated rather than burned, are known in the art. The aerosol-generating substrate is, for example, a tobacco-free herbaceous or plant-based cast sheet, 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] Document EP3609352B1 discloses an apparatus for crimping a sheet of tobacco material. The apparatus comprises first and second opposing crimping rollers defining a first axis of rotation and a second axis of rotation, respectively. The first roller includes a first plurality of circumferential ridges, each of which is interrupted along its circumferential extension, such that at a given angle of interruption, the amplitude of the ridge differs from the amplitude of the ridges in the remaining circumferential extension. The plurality of interruption gaps form interrupted bands defining an extension direction, which is angled at an angle between about 2° and about 25° relative to the direction defined by the first axis of rotation. The plurality of interruption gaps allows for reduced occurrence of fractures in the tobacco sheet and for achieving good tensile strength. Summary of the Invention [Problem to be solved by the invention]

[0008] 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 further improves the quality of the sheet of aerosol-generating substrate and the final aerosol-generating article.

[0009] It would be desirable to have an apparatus and method for weakening sheets of aerosol-generating substrates for aerosol-generating articles that allows for enhanced machine production rates and reliability.

[0010] It would be desirable to have an apparatus and method for weakening sheets of aerosol-generating substrate for aerosol-generating article components that can act on sheets of aerosol-generating substrate made from materials other than tobacco or reconstituted tobacco. [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 1 shows a schematic side view of a portion of an apparatus for manufacturing an aerosol-generating article component comprising an apparatus for weakening a sheet of aerosol-generating substrate for the aerosol-generating article component according to the present invention. [Figure 2] FIG. 2 shows a top view of a portion of FIG. [Figure 3] FIG. 3 shows a longitudinal section of an aerosol-generating article component produced through the apparatus of FIGS. [Figure 4] FIG. 4 shows a cross section of the aerosol-generating article component of FIG. [Figure 5] FIG. 5 is a front view of the roller of the apparatus of FIGS. 1 and 2. FIG. [Figure 6] FIG. 6 is a side view of the roller of FIG. [Figure 7] FIG. 7 is an enlarged side view of one of the rollers of FIG. [Figure 8] FIG. 8 shows the cylindrical radially outer surface of one of the rollers flattened onto a plane. [Figure 9] FIG. 9 is an enlarged front view of a portion of one of the rollers of FIG. [Figure 10] FIG. 10 is a cross-sectional view taken along plane IX-IX of FIG. [Figure 11] FIG. 11 shows a cross-sectional view of FIG. 10 according to an alternative embodiment. [Figure 12] 12 is an enlarged cross-sectional front view of the coupling zone of the roller of FIG. 5. FIG. [Figure 13] FIG. 13 is a sheet of aerosol-generating substrate that has been processed through the apparatus of the preceding figure. DETAILED DESCRIPTION OF THE INVENTION

[0012] 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 and a plurality of first circumferential ridges provided on a first radially outer surface of the first roller. The first circumferential ridges may define respective first circumferential grooves on the first radially outer surface. Each first circumferential ridge may have at least one circumferential recess, and the circumferential recesses of the plurality of first circumferential ridges may form at least one first interrupted band on the first radially outer surface. The apparatus may include a second roller having a second axis of rotation and a plurality of second circumferential ridges provided on a second radially outer surface of the second roller. The second circumferential ridges may define respective second circumferential grooves on the second radially outer surface. Each second circumferential ridge may have at least one circumferential recess, and the circumferential recesses of the plurality of second circumferential ridges may form at least one second interruption band on the second radially outer surface. The first roller and the second roller may be configured to rotate in opposite directions about their respective first and second rotation axes. At a coupling zone between the first roller and the second roller, the first circumferential ridge may be partially inserted into the second circumferential groove, and the second circumferential ridge may be partially inserted into the first circumferential groove. The at least one first interruption band and the at least one second interruption band may cross each other when facing each other at the coupling zone. Optionally, a motor is operably connected to at least one of the first roller and the second roller. The motor may be configured to rotate the first roller and the second roller in opposite directions.

[0013] The inventors have found that the disclosed apparatus avoids or reduces the tendency of the material of the sheet of aerosol-generating substrate to stick and settle on rollers used to weaken the sheet, for example rollers configured to crimp the sheet.

[0014] The inventors have found that the disclosed apparatus allows for a reduction in machine downtime for roller cleaning operations and / or the time required for each cleaning operation.

[0015] The inventors have found that the disclosed apparatus improves the quality of the final product, i.e., the aerosol-generating article, in terms of a homogeneous aerosol-generating substrate.

[0016] The inventors have found that the disclosed apparatus avoids increasing the tension in the sheet and / or reducing the roller speed, which may partially solve the stickiness problem, but cancels the weakening effect, e.g., crimping effect, provided by the roller, potentially creating voids in the substrate.

[0017] The inventors have found that the disclosed apparatus avoids reducing the roller speed, which may potentially solve the stickiness problem, but may reduce productivity, and therefore the disclosed apparatus may operate at its design speed.

[0018] The inventors have found that the disclosed device allows the design weakening depth, e.g., crimp depth, to be maintained, which may possibly partially solve the sticking problem, but may reduce the weakening effect, e.g., crimping effect, provided by the roller.

[0019] A ratio of an area of ​​the at least one first interruption band on the first radially outer surface to an area of ​​the first radially outer surface provided with the plurality of first circumferential ridges and the plurality of first circumferential grooves may be between 0.03 and 0.30, optionally between 0.05 and 0.25, optionally 0.20.

[0020] For example, the area of ​​the at least one first interruption band on the first radially outer surface is 2000 mm 2 ~50,000mm 2 , optionally, 2000mm 2 ~10,000mm 2 , optionally, 40000mm2 ~50,000mm 2 For example, the area of ​​the first radially outer surface provided with the plurality of first circumferential ridges and the plurality of first circumferential grooves is 170,000 mm 2 ~180,000mm 2 is.

[0021] A ratio of an area of ​​the at least one second interruption band on the second radially outer surface to an area of ​​the second radially outer surface provided with the plurality of second circumferential ridges and the plurality of second circumferential grooves may be between 0.03 and 0.30, optionally between 0.05 and 0.25, optionally 0.20.

[0022] For example, the area of ​​the at least one second interruption band on the second radially outer surface is 2000 mm 2 ~50,000mm 2 , optionally, 2000mm 2 ~10,000mm 2 , optionally, 40000mm 2 ~50,000mm 2 For example, the area of ​​the second radially outer surface provided with the plurality of second circumferential ridges and the plurality of second circumferential grooves is 170,000 mm 2 ~180,000mm 2 is.

[0023] The inventors have found that the disclosed areas and ratios provide a good balance between weakening and anti-sticking effects.

[0024] According to some embodiments, the at least one first interruption band is skewed relative to the first axis of rotation, for example, at least one circumferential recess of one first circumferential ridge is circumferentially offset relative to at least one circumferential recess of two first circumferential ridges adjacent to the one first circumferential ridge to form a skewed first interruption band.

[0025] Considering the first radially outer surface flattened onto a plane, the at least one first interrupted band may define an angle (α) with the first axis of rotation that may be between 2° and 25°.

[0026] According to some embodiments, at least one second interruption band is skewed relative to the second axis of rotation, for example, at least one circumferential recess of one second circumferential ridge is circumferentially offset relative to at least one circumferential recess of two second circumferential ridges adjacent to the one second circumferential ridge to form a skewed second interruption band.

[0027] Considering the second radially outer surface flattened onto a plane, the at least one second interrupted band may define an angle (α') with the second axis of rotation that may be between 2° and 25°.

[0028] According to some embodiments, the at least one first interruption band may be parallel to the first axis of rotation, and according to other embodiments, the at least one second interruption band may be parallel to the second axis of rotation.

[0029] According to some embodiments, the at least one first interrupted band and the at least one second interrupted band are distorted congruently, i.e., in the same direction, optionally at the same angle (α=α′) or at different angles (α≠α′).

[0030] According to some other embodiments, the at least one first interrupted band and the at least one second interrupted band are distorted non-coincidentally, ie, in opposite directions and at different angles (α≠α′).

[0031] A plurality of first interruption bands may be provided on the first radially outer surface. For example, each first circumferential ridge may have a plurality of circumferential recesses, and the circumferential recesses of the plurality of first circumferential ridges form a plurality of first interruption bands on the first radially outer surface. The number of first interruption bands may be between 20 and 80.

[0032] According to some embodiments, the first interruption bands are evenly spaced circumferentially on the first radially outer surface.

[0033] A plurality of second interruption bands may be provided on the second radially outer surface. For example, each second circumferential ridge may have a plurality of circumferential recesses, and the circumferential recesses of the plurality of second circumferential ridges form a plurality of second interruption bands on the second radially outer surface. The number of second interruption bands may be between 20 and 80.

[0034] According to some embodiments, the second interruption bands are evenly spaced circumferentially on the second radially outer surface.

[0035] At the connection zone between the first roller and the second roller, each first interruption band may intersect with multiple second interruption bands, and / or each second interruption band may intersect with multiple first interruption bands.

[0036] According to some embodiments, the first roller and the second roller are identical, and the identical first roller and second roller may be axially shifted to allow the first circumferential ridge to be partially inserted into the second circumferential groove, and the second circumferential ridge to be partially inserted into the first circumferential groove.

[0037] For example, the shape and size of the first circumferential ridge and first circumferential groove may be the same as the shape and size of the second circumferential ridge and second circumferential groove.

[0038] For example, the shape and size of the at least one first interruption band may be the same as the shape and size of the at least one second interruption band, and the shape, size, and number of the first interruption bands may be the same as the shape, size, and number of the second interruption bands.

[0039] The inventors have found that identical rollers can help reduce the cost of the equipment.

[0040] According to some embodiments, in a cross section containing the first axis of rotation, the first circumferential ridge and the first circumferential groove may have a wavy, rounded profile.

[0041] According to some embodiments, in a cross section containing the second axis of rotation, the second circumferential ridge and the second circumferential groove may have a wavy, rounded profile.

[0042] Optionally, in a cross section including the first axis of rotation and the second axis of rotation, the first circumferential ridge may have a shape complementary to a shape of the second circumferential groove, and the second circumferential ridge may have a shape complementary to a shape of the first circumferential groove.

[0043] The ratio of the axial pitch (ap) of the first circumferential ridges to the thickness (t) of the aerosol-generating substrate sheet and / or the ratio of the axial pitch (ap) of the second circumferential ridges to the thickness (t) of the aerosol-generating substrate sheet may be 2.0 to 20.0. The ratio of the axial pitch (ap) of the first circumferential ridges to the maximum diameter (D) of the first circumferential ridges and / or the ratio of the axial pitch (ap) of the second circumferential ridges to the maximum diameter (D) of the second circumferential ridges may be 0.0017 to 0.05. The axial pitch (ap) of the first circumferential ridges and / or the axial pitch (ap) of the second circumferential ridges may be 0.5 mm to 2.0 mm. The ratio of the height (h) of the first circumferential ridges to the thickness (t) of the aerosol-generating substrate sheet and / or the ratio of the height (h) of the second circumferential ridges to the thickness (t) of the aerosol-generating substrate sheet may be 2.0 to 13.0. The ratio of the height (h) of the first circumferential ridge to the maximum diameter (D) of the first circumferential ridge and / or the ratio of the height (h) of the second circumferential ridge to the maximum diameter (D) of the second circumferential ridge may be 0.0017 to 0.05. The height (h) of the first circumferential ridge and / or the height (h) of the second circumferential ridge may be 0.5 mm to 2.0 mm. The ratio of the width (w) of the at least one first interrupting band to the thickness (t) of the aerosol-generating substrate sheet and / or the ratio of the width (w) of the at least one second interrupting band to the thickness (t) of the aerosol-generating substrate sheet may be 8.0 to 70.0. The ratio of the width (w) of the at least one first interrupting band to the maximum diameter (D) of the first circumferential ridge and / or the ratio of the width (w) of the at least one second interrupting band to the maximum diameter (D) of the second circumferential ridge may be 0.0067 to 0.25. The width (w) of the at least one first interrupting band and / or the width (w) of the at least one second interrupting band may be from 2.0 mm to 10.0 mm, optionally from 2.0 mm to 20.0 mm. The ratio of the circumferential pitch (cp) of the first interrupting bands to the thickness (t) of the sheet of aerosol-generating substrate and / or the ratio of the circumferential pitch (cp) of the second interrupting bands to the thickness (t) of the sheet of aerosol-generating substrate may be from 40 to 335.The ratio of the circumferential pitch (cp) of the first interrupting bands to the maximum diameter (D) of the first circumferential ridges and / or the ratio of the circumferential pitch (cp) of the second interrupting bands to the maximum diameter (D) of the second circumferential ridges may be 0.033 to 1.25. The circumferential pitch (cp) of at least one first interrupting band and / or the circumferential pitch (cp) of at least one second interrupting band may be 10.0 mm to 50.0 mm. The ratio of the radius of curvature (r) of the first circumferential ridges to the thickness (t) of the aerosol-generating substrate sheet and / or the ratio of the radius of curvature (r) of the second circumferential ridges to the thickness (t) of the aerosol-generating substrate sheet may be 0.4 to 3.33. The ratio of the radius of curvature (r) of the first circumferential ridge to the maximum diameter (D) of the first circumferential ridge and / or the ratio of the radius of curvature (r) of the second circumferential ridge to the maximum diameter (D) of the second circumferential ridge may be 0.0003 to 0.0125. The radius of curvature (r) of the first circumferential ridge and / or the radius of curvature (r) of the second circumferential ridge may be 0.1 mm to 0.5 mm. The ratio of the width (A) of the aerosol-generating substrate sheet to the axial length (L) of the first roller and / or the ratio of the width (A) of the aerosol-generating substrate sheet to the axial length (L) of the second roller may be 0.25 to 0.95. The axial length (L) of the first roller and / or the axial length (L) of the second roller may be 80 mm to 400 mm. The maximum diameter (D) of the first circumferential ridge and / or the maximum diameter (D) of the second circumferential ridge may be 40 mm to 300 mm. The taper angle (β) of each first circumferential ridge and / or the taper angle (β) of each second circumferential ridge may be 15° to 65°. The width (A) of the sheet of aerosol-generating substrate may be 80 mm to 250 mm. The thickness (t) of the sheet of aerosol-generating substrate may be 0.15 mm to 0.25 mm.

[0044] The present disclosure also relates to a method for weakening a sheet of aerosol-generating substrate for an aerosol-generating article component.

[0045] The method includes feeding a sheet of aerosol-generating substrate between a first roller and a second roller of an apparatus to weaken the sheet of aerosol-generating substrate for an aerosol-generating article component while the first roller and the second roller rotate in opposite directions.

[0046] The device may be a device disclosed above or may have one or more of the features of the devices disclosed above.

[0047] The apparatus may include a first roller having a first axis of rotation and a plurality of first circumferential ridges provided on a first radially outer surface of the first roller. The first circumferential ridges may define respective first circumferential grooves on the first radially outer surface. Each first circumferential ridge may have at least one circumferential recess, and the circumferential recesses of the plurality of first circumferential ridges may form at least one first interruption band on the first radially outer surface. The apparatus may include a second roller having a second axis of rotation and a plurality of second circumferential ridges provided on a second radially outer surface of the second roller. The second circumferential ridges may define respective second circumferential grooves on the second radially outer surface. Each second circumferential ridge may have at least one circumferential recess, and the circumferential recesses of the plurality of second circumferential ridges may form at least one second interruption band on the second radially outer surface. The first roller and the second roller may be configured to rotate in opposite directions about their respective first and second rotation axes. At a coupling zone between the first roller and the second roller, the first circumferential ridge may be partially inserted into the second circumferential groove, and the second circumferential ridge may be partially inserted into the first circumferential groove. The at least one first interruption band and the at least one second interruption band may cross each other when facing each other at the coupling zone. Optionally, a motor is operably connected to at least one of the first roller and the second roller. The motor may be configured to rotate the first roller and the second roller in opposite directions.

[0048] The inventors have found that, as described above for the apparatus, the disclosed method positively impacts the quality of the aerosol-generating substrate sheets and the final aerosol-generating article, as well as the productivity and reliability of the equipment for manufacturing the aerosol-generating article components and articles.

[0049] In some embodiments, the aerosol-generating substrate sheet is a fiber-based substrate. For example, the aerosol-generating substrate sheet may be made from a cellulose mixture, which may include fibers, a binder, and an aerosol-forming agent. The fibers may be cellulose fibers. The binder may include derivatives of cellulose, such as carboxymethylcellulose and hydroxypropylmethylcellulose. The aerosol-forming agent may be a polyhydric alcohol, such as triethylene glycol, 1,3-butanediol, or glycerin.

[0050] The amount of fiber in the mixture may be 15.0 percent to 20.0 percent on a dry weight basis. The amount of binder in the mixture may be 28.0 percent to 30.0 percent on a dry weight basis. The amount of aerosol-forming agent in the mixture may be 45.0 percent to 55.0 percent on a dry weight basis. For example, the amount of carboxymethylcellulose in the mixture may be 5.0 percent to 6.0 percent on a dry weight basis. For example, the amount of hydroxypropylmethylcellulose in the mixture may be 21.0 percent to 24.0 percent on a dry weight basis. The mixture may also include nicotine and fumaric acid. The amount of nicotine in the mixture may be 1.0 percent to 2.0 percent on a dry weight basis. The amount of fumaric acid in the mixture may be 1.5 percent to 2.0 percent on a dry weight basis.

[0051] According to some embodiments, the sheet of aerosol-generating substrate has an elongation at break in the longitudinal direction of 5.0 mm to 7.5 mm, optionally 5.5 mm to 7.0 mm. The sheet of aerosol-generating substrate may have an elongation at break in the transverse direction of 9.5 mm to 12.5 mm, optionally 10.0 mm to 12.0 mm.

[0052] The aerosol-generating substrate sheet may have a Young's modulus in the transverse direction of 0.8 N / mm to 1.2 N / mm, optionally 0.9 N / mm to 1.1 N / mm, and in the longitudinal direction of 5 N / mm to 7 N / mm, optionally 5.5 N / mm to 6.5 N / mm.

[0053] The sheet of aerosol-generating substrate may have a thickness (t) of 0.15 mm to 0.25 mm. The sheet of aerosol-generating substrate may have a density of 100 g / m 2 ~160g / m 2 The aerosol-generating substrate sheet may have a basis weight of 1000 g / cm². The aerosol-generating substrate sheet may have a humidity of 5 to 10 percent. The aerosol-generating substrate sheet may have a viscosity of 0.0150 N to 0.0165 N. The aerosol-generating substrate sheet may have a width (A) of 80 to 250 mm.

[0054] The inventors have found that the above-disclosed apparatus and method are particularly effective when used in combination with a sheet of aerosol-generating substrate provided with one or more of the above-disclosed properties. In fact, the elastic behavior of this type of sheet is such that, when it becomes sticky, a high force is required to remove it from the roller so that the sheet does not immediately break. This results in the roller not operating optimally for long periods when this type of sheet is processed.

[0055] Furthermore, since this type of sheet is found to be less susceptible to crimping due to its elasticity, it was found that viscosity has a significant effect on this type of sheet due to the high pressure applied during the crimping process, resulting in a high viscosity effect during the crimping process.

[0056] In another embodiment, the sheet of aerosol-generating substrate is a cast leaf, such as a tobacco cast leaf. Cast leaf can be obtained through a casting process from ingredients such as tobacco powder or other nicotine-containing material, water, and fibers, such as cellulose, glycerin, and guar. The first step can be to produce a tobacco slurry by mixing the ingredients. The slurry is an aqueous mixture of insoluble materials with a high water content, e.g., 70 to 80 percent. In the second step, the slurry can be placed inside a casting box and cast by a casting knife on a moving conveyor to produce a continuous sheet.

[0057] The present disclosure also relates to a frangible sheet of aerosol-generating substrate.

[0058] According to some embodiments, the frangible sheet of aerosol-generating substrate is weakened through the apparatus disclosed above and / or through the method disclosed above.

[0059] The frangible sheet of the aerosol-generating substrate may have weakened portions and non-weakened bands, the non-weakened bands intersecting each other.

[0060] The non-weak band may be created by at least one first interrupted band and by at least one second interrupted band of the device.

[0061] The weakened portion may be created by an area of ​​the first radially outer surface provided with a plurality of first circumferential ridges and a plurality of first circumferential grooves, and by an area of ​​the second radially outer surface provided with a plurality of second circumferential ridges and a plurality of second circumferential grooves.

[0062] According to some embodiments, the weakened portions are crimped portions and the non-weakened bands are uncrimped portions.

[0063] The present disclosure also relates to a process for manufacturing an aerosol-generating article component, the process comprising the method disclosed above.

[0064] The process is as follows: - manufacturing a sheet of aerosol-generating substrate; - weakening the sheet of aerosol-generating substrate by the method disclosed above; - 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.

[0065] In some embodiments, the frangible sheet of the aerosol-generating substrate is a fiber-based substrate. For example, the frangible sheet of the aerosol-generating substrate may be made from a cellulose mixture, which may include fibers, a binder, and an aerosol-forming agent. The fibers may be cellulose fibers. The binder may include derivatives of cellulose, such as carboxymethylcellulose and hydroxypropylmethylcellulose. The aerosol-forming agent may be a polyhydric alcohol, such as triethylene glycol, 1,3-butanediol, or glycerin. The substrate may be made from a tobacco-free cellulose mixture.

[0066] The amount of fiber in the mixture may be 15.0 percent to 20.0 percent on a dry weight basis. The amount of binder in the mixture may be 28.0 percent to 30.0 percent on a dry weight basis. The amount of aerosol-forming agent in the mixture may be 45.0 percent to 55.0 percent on a dry weight basis. For example, the amount of carboxymethylcellulose in the mixture may be 5.0 percent to 6.0 percent on a dry weight basis. For example, the amount of hydroxypropylmethylcellulose in the mixture may be 21.0 percent to 24.0 percent on a dry weight basis. The mixture may also include nicotine and fumaric acid. The amount of nicotine in the mixture may be 1.0 percent to 2.0 percent on a dry weight basis. The amount of fumaric acid in the mixture may be 1.5 percent to 2.0 percent on a dry weight basis.

[0067] According to some embodiments, the sheet of aerosol-generating substrate has an elongation at break in the longitudinal direction, prior to weakening, of 5.0 mm to 7.5 mm, optionally 5.5 mm to 7.0 mm. The sheet of aerosol-generating substrate may have an elongation at break in the transverse direction, prior to weakening, of 9.5 mm to 12.5 mm, optionally 10.0 mm to 12.0 mm.

[0068] The sheet of aerosol-generating substrate may have a Young's modulus in the transverse direction of 0.8 N / mm to 1.2 N / mm, optionally 0.9 N / mm to 1.1 N / mm, before weakening.The sheet of aerosol-generating substrate may have a Young's modulus in the longitudinal direction of 5 N / mm to 7 N / mm, optionally 5.5 N / mm to 6.5 N / mm, before weakening.

[0069] The sheet of aerosol-generating substrate may have a thickness (t) of 0.15 mm to 0.25 mm before weakening. The sheet of aerosol-generating substrate may have a density of 100 g / m 2 ~160g / m 2The aerosol-generating substrate sheet may have a basis weight of 1000 g / cm². Before being weakened, the aerosol-generating substrate sheet may have a humidity of 5 to 10 percent. Before being weakened, the aerosol-generating substrate sheet may have a viscosity of 0.0150 N to 0.0165 N. Before being weakened, the aerosol-generating substrate sheet may have a width (A) of 80 to 250 mm.

[0070] In another embodiment, the sheet of aerosol-generating substrate is a cast leaf, such as a tobacco cast leaf. Cast leaf can be obtained through a casting process from ingredients such as tobacco powder or other nicotine-containing material, water, and fibers, such as cellulose, glycerin, and guar. The first step can be to produce a tobacco slurry by mixing the ingredients. The slurry is an aqueous mixture of insoluble materials with a high water content, e.g., 70 to 80 percent. In the second step, the slurry can be placed inside a casting box and cast by a casting knife on a moving conveyor to produce a continuous sheet.

[0071] 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 an aerosol-generating article component as disclosed above.

[0072] The present disclosure also relates to an aerosol-generating article comprising at least one aerosol-generating article component made according to the process for manufacturing an aerosol-generating article component disclosed above.

[0073] As used herein, an interlocking zone of a first roller and a second roller is a portion of the intermeshing first roller and second roller where a first circumferential ridge of the first roller is at least partially inserted into a second circumferential groove of the second roller and a second circumferential ridge of the second roller is at least partially inserted into a first circumferential groove of the first roller.

[0074] As used in this description, axial length or distance is the distance measured parallel to the first and second axes of rotation.

[0075] As used in this description, radial height or distance is the distance measured perpendicular to the first and second axes of rotation.

[0076] As used herein, the term circumference refers to a circumference about a first axis of rotation or a second axis of rotation.

[0077] 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.

[0078] 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 closest to the first or second axis of rotation, respectively.

[0079] As used herein, a circumferential recess in a first or second circumferential ridge is a portion of the first or second circumferential ridge that has a radial height less than the radial height of its respective upper portion (less corrugated). The circumferential recess may also be flush with the bottom of the first or second circumferential groove (non-corrugated).

[0080] 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.

[0081] 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 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, each first circumferential ridge having at least one circumferential recess, the circumferential recesses of the plurality of first circumferential ridges forming at least one first interrupted band 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 the second roller, the second circumferential ridges defining a respective plurality of second circumferential grooves on the second radially outer surface, each second circumferential ridge having at least one circumferential recess, the circumferential recesses of the plurality of second circumferential ridges including at least one second interrupted band on the second radially outer surface; the first roller and the second roller are configured to rotate in opposite directions about respective first and second axes of rotation; At a coupling zone between the first roller and the second roller, the first circumferential ridge is partially inserted into the second circumferential groove, and the second circumferential ridge is partially inserted into the first circumferential groove; the at least one first interrupted band and the at least one second interrupted band cross each other when facing each other in the connection zone; Optionally, the apparatus, wherein a motor is operably connected to at least one of the first roller and the second roller and configured to rotate the first roller and the second roller in opposite directions. Example 2. A method for weakening a sheet of aerosol-generating substrate for an aerosol-generating article component, the method comprising: feeding 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. 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. An apparatus for manufacturing an aerosol-generating article component, the apparatus comprising the apparatus described in Example 1. Example 6 2. The device of example 1, wherein a ratio of an area of ​​the at least one first interruption band on the first radially outer surface to an area of ​​the first radially outer surface provided with the plurality of first circumferential ridges and the plurality of first circumferential grooves is between 0.03 and 0.30, optionally between 0.05 and 0.25, optionally 0.20. Example 7 The area of ​​the at least one first interruption band on the first radially outer surface is 2000 mm 2 ~50,000mm 2 , optionally 2000mm 2 ~10,000mm 2 , optionally 40000mm 2 ~50,000mm 2 The device described in Examples 1 to 6, Example 8 8. The device of example 1, or 6, or 7, wherein a ratio of an area of ​​the at least one second interruption band on the second radially outer surface to an area of ​​the second radially outer surface provided with the plurality of second circumferential ridges and the plurality of second circumferential grooves is between 0.03 and 0.30, optionally between 0.05 and 0.25, optionally 0.20. Example 9. The area of ​​the at least one second interruption band on the second radially outer surface is 2000 mm 2 ~50,000mm 2 , optionally 2000mm 2 ~10,000mm 2 , optionally 40000mm 2 ~50,000mm 2 The device according to any one of Example 1 or Examples 6 to 8, Example 10. The apparatus of any one of example 1 or examples 6-9, wherein the at least one first interruption band is skewed relative to the first axis of rotation. Example 11 The device of any one of example 1 or examples 6-10, wherein at least one circumferential recess of one first circumferential ridge is circumferentially offset relative to at least one circumferential recess of two first circumferential ridges adjacent to the one first circumferential ridge to form a distorted first interrupted band. Example 12 The apparatus of any of Examples 1 or 6-11, wherein, considering the first radially outer surface flattened onto a plane, the at least one first interrupted band defines an angle (α) with the first axis of rotation of between 2° and 25°. Example 13 The apparatus of any one of example 1 or examples 6-12, wherein the at least one second interruption band is skewed relative to the second axis of rotation. Example 14. The device of any one of example 1 or examples 6-13, wherein at least one circumferential recess of one second circumferential ridge is circumferentially offset relative to at least one circumferential recess of two second circumferential ridges adjacent to the one second circumferential ridge to form a distorted second interrupted band. Example 15. The apparatus of any of Examples 1 or 6-14, wherein, considering the second radially outer surface flattened onto a plane, the at least one second interrupted band defines an angle (α') with the second axis of rotation of 2° to 25°. Example 16. The device of example 1 or any of examples 6-15, wherein each first circumferential ridge has a plurality of circumferential recesses, and the circumferential recesses of the plurality of first circumferential ridges form a plurality of first interrupted bands on the first radially outer surface. Example 17. 17. The device of example 16, wherein the first interrupted bands are evenly spaced circumferentially on the first radially outer surface. Example 18. 18. The device of Example 16 or 17, wherein the number of first interrupted bands is 20 to 80. Example 19. The device of example 1 or any of examples 6-18, wherein each second circumferential ridge has a plurality of circumferential recesses, and the circumferential recesses of the plurality of second circumferential ridges form a plurality of second interrupted bands on the second radially outer surface. Example 20. 20. The device of example 19, wherein the second interrupted bands are evenly spaced circumferentially on the second radially outer surface. Example 21. 21. The device of Example 19 or 20, wherein the number of second interrupted bands is 20 to 80. Example 22. 22. The apparatus of any one of claims 16 to 21, wherein each first interrupted band intersects with a plurality of second interrupted bands in the connection zone of the first roller and the second roller. Example 23. 23. The apparatus of any one of Examples 16 to 22, wherein each second interrupted band intersects with a plurality of first interrupted bands in the connection zone of the first roller and the second roller. Example 24. The apparatus of any one of example 1 or examples 6-23, wherein the at least one first interruption band is parallel to the first axis of rotation. Example 25. The apparatus of any one of example 1 or examples 6-23, wherein the at least one second interruption band is parallel to the second axis of rotation. Example 26. The apparatus of example 1 or any of examples 6-25, wherein the first roller and the second roller are coaxially and axially shifted to allow the first circumferential ridge to be partially inserted into the second circumferential groove and the second circumferential ridge to be partially inserted into the first circumferential groove. Example 27. The device of any one of Example 1 or Examples 6-26, wherein the shape and size of the first circumferential ridge and the first circumferential groove are identical to the shape and size of the second circumferential ridge and the second circumferential groove. Example 28. The device of example 1 or any of examples 6-27, wherein the shape and size of the at least one first interrupting band is the same as the shape and size of the at least one second interrupting band. Example 29. 24. The device of any one of Examples 16-23, wherein the shape, size, and number of the first interrupting bands are identical to the shape, size, and number of the second interrupting bands. Example 30. The device of example 1 or any of examples 6-29, wherein in a cross section containing the first axis of rotation, the first circumferential ridge and the first circumferential groove have a wavy, rounded profile. Example 31. The device of example 1 or any of examples 6-30, wherein in a cross section containing the second axis of rotation, the second circumferential ridge and the second circumferential groove have a wavy, rounded profile. Example 32. The device of any one of Example 1 or Examples 6 to 31, wherein in a cross section including the first rotation axis and the second rotation axis, the first circumferential ridge has a shape complementary to the shape of the second circumferential groove, and the second circumferential ridge has a shape complementary to the shape of the first circumferential groove. Example 33. An apparatus as described in any of Examples 1 or 6-32, wherein the ratio of the axial pitch (ap) of the first circumferential ridges to the thickness (t) of the sheet of aerosol-generating substrate is 2.0 to 20.0. Example 34. An apparatus as described in any of Examples 1 or 6 to 33, wherein the ratio of the axial pitch (ap) of the second circumferential ridges to the thickness (t) of the sheet of aerosol-generating substrate is 2.0 to 20.0. Example 35. The device of any of Examples 1 or 6-34, wherein the ratio of the axial pitch (ap) of the first circumferential ridges to the maximum diameter (D) of the first circumferential ridges is 0.0017 to 0.05. Example 36. The device of any of Examples 1 or 6-35, wherein the ratio of the axial pitch (ap) of the second circumferential ridges to the maximum diameter (D) of the second circumferential ridges is 0.0017 to 0.05. Example 37. The device of any one of Example 1 or Examples 6-36, wherein the axial pitch (ap) of the first circumferential ridges is 0.5 mm to 3.0 mm. Example 38. The device of any of Example 1 or Examples 6-37, wherein the axial pitch (ap) of the second circumferential ridges is 0.5 mm to 3.0 mm. Example 39. The device of any of Examples 1 or 6-38, wherein the ratio of the height (h) of the first circumferential ridge to the thickness (t) of the sheet of aerosol-generating substrate is 2.0 to 13.0. Example 40. An apparatus as described in Example 1 or any of Examples 6 to 39, wherein the ratio of the height (h) of the second circumferential ridge to the thickness (t) of the sheet of aerosol-generating substrate is 2.0 to 13.0. Example 41. The device of any of Examples 1 or 6-40, wherein the ratio of the height (h) of the first circumferential ridge to the maximum diameter (D) of the first circumferential ridge is 0.0017 to 0.05. Example 42. The device of any of Examples 1 or 6-41, wherein the ratio of the height (h) of the second circumferential ridge to the maximum diameter (D) of the second circumferential ridge is 0.0017 to 0.05. Example 43. The device of any of Examples 1 or 6-42, wherein the height (h) of the first circumferential ridge is between 0.5 mm and 2.0 mm. Example 44. The device of any of Examples 1 or 6-43, wherein the height (h) of the second circumferential ridge is 0.5 mm to 2.0 mm. Example 45. An apparatus according to any one of Examples 1 and 6 to 44, wherein the ratio of the width (w) of the at least one first interrupting band to the thickness (t) of the sheet of aerosol-generating substrate is between 8.0 and 70.0. Example 46. An apparatus as described in any of Examples 1 or 6 to 45, wherein the ratio of the width (w) of the at least one second interrupting band to the thickness (t) of the sheet of aerosol-generating substrate is 8.0 to 70.0. Example 47. The device of any of Examples 1 or 6-46, wherein the ratio of the width (w) of the at least one first interruption band to the maximum diameter (D) of the first circumferential ridge is 0.0067 to 0.25. Example 48. The device of any of Examples 1 or 6-47, wherein the ratio of the width (w) of the at least one second interruption band to the maximum diameter (D) of the second circumferential ridge is 0.0067 to 0.25. Example 49. The apparatus of example 1 or any of examples 6-48, wherein the width (w) of the at least one first interruption band is between 2.0 mm and 10.0 mm, optionally between 2.0 mm and 20.0 mm. Example 50. The device of Example 1 or any of Examples 6-49, wherein the width (w) of the at least one second interruption band is between 2.0 mm and 10.0 mm, optionally between 2.0 mm and 20.0 mm. Example 51. An apparatus according to any one of Examples 1 and 6 to 50, wherein the ratio of the circumferential pitch (cp) of the first interrupted band to the thickness (t) of the sheet of aerosol-generating substrate is 40 to 335. Example 52. An apparatus according to any one of Examples 1 and 6 to 51, wherein the ratio of the circumferential pitch (cp) of the second interrupted band to the thickness (t) of the sheet of aerosol-generating substrate is 40 to 335. Example 53. The device of any of Examples 1 or 6-52, wherein the ratio of the circumferential pitch (cp) of the first interrupted band to the maximum diameter (D) of the first circumferential ridge is 0.033 to 1.25. Example 54. The device of any of Examples 1 or 6-53, wherein the ratio of the circumferential pitch (cp) of the second interrupted band to the maximum diameter (D) of the second circumferential ridge is 0.033 to 1.25. Example 55. The apparatus of any one of Example 1 or Examples 6-54, wherein the circumferential pitch (cp) of the at least one first interrupted band is 10.0 mm to 50.0 mm. Example 56. The apparatus of any one of Example 1 or Examples 6-55, wherein the circumferential pitch (cp) of the at least one second interrupted band is 10.0 mm to 50.0 mm. Example 57. The device of any of Examples 1 or 6-56, wherein the ratio of the radius of curvature (r) of the first circumferential ridge to the thickness (t) of the sheet of aerosol-generating substrate is 0.4 to 3.33. Example 58. The article of any of Examples 1 or 6-57, wherein the ratio of the radius of curvature (r) of the second circumferential ridge to the thickness (t) of the sheet of aerosol-generating substrate is 0.4 to 3.33. Example 59. The device of any of Examples 1 or 6-58, wherein the ratio of the radius of curvature (r) of the first circumferential ridge to the maximum diameter (D) of the first circumferential ridge is 0.0003 to 0.0125. Example 60. The device of any of Examples 1 or 6-59, wherein the ratio of the radius of curvature (r) of the second circumferential ridge to the maximum diameter (D) of the second circumferential ridge is 0.0003 to 0.0125. Example 61. The device of any of Examples 1 or 6-60, wherein the radius of curvature (r) of the first circumferential ridge is between 0.1 mm and 0.5 mm. Example 62. The device of any of Examples 1 or 6-61, wherein the radius of curvature (r) of the second circumferential ridge is between 0.1 mm and 0.5 mm. Example 63. The apparatus according to any one of Example 1 or Examples 6 to 62, wherein the ratio of the width (A) of the sheet of aerosol-generating substrate to the axial length (L) of the first roller is 0.2 to 0.95. Example 64. The apparatus according to any one of Example 1 or Examples 6 to 63, wherein the ratio of the width (A) of the sheet of aerosol-generating substrate to the axial length (L) of the second roller is 0.25 to 0.95. Example 65. The apparatus according to any one of Example 1 or Examples 6 to 64, wherein the width (A) of the sheet of aerosol-generating substrate is 80 mm to 250 mm. Example 66. The apparatus according to any one of Example 1 or Examples 6 to 65, wherein the axial length (L) of the first roller is 80 mm to 400 mm. Example 67. The apparatus of any one of Example 1 or Examples 6 to 66, wherein the axial length (L) of the second roller is 80 mm to 400 mm. Example 68. The device according to any one of Example 1 or Examples 6 to 67, wherein the thickness (t) of the sheet of the aerosol-generating substrate is 0.15 mm to 0.25 mm. Example 69. The device of any of Examples 1 or 6-68, wherein the maximum diameter (D) of the first circumferential ridge is between 40 mm and 300 mm. Example 70. The device of any of Examples 1 or 6-69, wherein the maximum diameter (D) of the second circumferential ridge is between 40 mm and 300 mm. Example 71. The device of example 1 or any of examples 6-70, wherein the taper angle (β) of each first circumferential ridge is between 15° and 65°. Example 72. The device of any of Examples 1 or 6-71, wherein the taper angle (β) of each second circumferential ridge is between 15° and 65°. Example 73. The apparatus according to any one of Example 1 or Examples 6 to 72, or the method according to Example 2, wherein the aerosol-generating substrate sheet is a fibrous substrate. Example 74. An apparatus according to any one of Examples 1 or 6 to 73, or a method according to Examples 2 to 72, wherein the sheet of aerosol-generating substrate is made from a cellulose mixture. Example 75. The apparatus of Example 1 or any of Examples 6-74, or the method of Example 2, 72, or 73, wherein the sheet of aerosol-generating substrate is made from a mixture comprising fibers, a binder, and an aerosol-forming agent. Example 76. Example 76. The device or method of Example 75, wherein the fibers are cellulose fibers, the binder comprises a derivative of cellulose, and the aerosol forming agent is a polyhydric alcohol. Example 77. 77. The apparatus or method of example 75 or 76, wherein the amount of fiber in the mixture is 15.0 percent to 20.0 percent on a dry weight basis. Example 78. 78. The apparatus or method of any of Examples 75-77, wherein the amount of binder in the mixture is 28.0 percent to 30.0 percent on a dry weight basis. Example 79. The apparatus or method of any of Examples 75-78, wherein the amount of aerosol forming agent in the mixture is 45.0 percent to 55.0 percent on a dry weight basis. Example 80. The apparatus or method of Example 76 or any of Examples 77-79 when according to Example 76, wherein the cellulose derivatives include carboxymethylcellulose and hydroxypropylmethylcellulose. Example 81. 81. The apparatus or method of example 80, wherein the amount of carboxymethyl cellulose in the mixture is 5.0 percent to 6.0 percent on a dry weight basis. Example 82. The apparatus or method of example 80 or 81, wherein the amount of hydroxypropyl methylcellulose in the mixture is 21.0 percent to 24.0 percent on a dry weight basis. Example 83. The apparatus or method described in Example 76 or any of Examples 77 to 79 when according to Example 76, wherein the polyhydric alcohol is triethylene glycol, 1,3-butanediol, or glycerin. Example 84. The device or method of any of Examples 75-83, wherein the mixture further comprises nicotine and fumaric acid. Example 85. The device or method of example 84, wherein the amount of nicotine in the mixture is 1.0 percent to 2.0 percent on a dry weight basis. Example 86. The apparatus or method of example 84 or 85, wherein the amount of fumaric acid in the mixture is 1.5 percent to 2.0 percent on a dry weight basis. Example 87. The device according to any one of Examples 1 or 6 to 86, or the method according to Example 2, or the device or method according to any one of Examples 73 to 86, wherein the sheet of aerosol-generating substrate has an elongation at break of 5.0 mm to 7.5 mm in the longitudinal direction. Example 88. An apparatus or method according to Example 87, wherein the sheet of aerosol-generating substrate has an elongation at break along its longitudinal axis of 5.5 mm to 7.0 mm. Example 89. An apparatus as described in any one of Examples 1 or 6 to 88, or a method as described in Example 2 or any one of Examples 73 to 88, wherein the sheet of aerosol-generating substrate has an elongation at break in the cross direction of 9.5 mm to 12.5 mm. Example 90. An apparatus or method according to example 89, wherein the sheet of aerosol-generating substrate has an elongation at break in the cross direction of 10.0 mm to 12.0 mm. Example 91. An apparatus as described in any one of Examples 1 or 6 to 90, or a method as described in Example 2 or any one of Examples 73 to 90, wherein the sheet of aerosol-generating substrate has a Young's modulus in the lateral direction of 0.8 N / mm to 1.2 N / mm. Example 92. 92. An apparatus or method according to example 91, wherein the sheet of aerosol-generating substrate has a Young's modulus in the transverse direction of 0.9 N / mm to 1.1 N / mm. Example 93. An apparatus as described in any one of Examples 1 or 6 to 92, or a method as described in Example 2 or any one of Examples 73 to 92, wherein the aerosol-generating substrate sheet has a Young's modulus in the longitudinal direction of 5 N / mm to 7 N / mm. Example 94. An apparatus or method according to Example 93, wherein the sheet of aerosol-generating substrate has a Young's modulus in the longitudinal direction of 5.5 N / mm to 6.5 N / mm. Example 95. An apparatus as described in any one of Examples 1 or 6 to 94, or a method as described in Example 2 or any one of Examples 73 to 94, wherein the sheet of aerosol-generating substrate has a thickness (t) of 0.15 mm to 0.25 mm. Example 96. An apparatus as described in any one of Example 1 or Examples 6 to 95, or a method as described in Example 2 or Examples 73 to 95, wherein the sheet of aerosol-generating substrate has a width (A) of 80 mm to 250 mm. Example 97. The aerosol-generating substrate sheet is 100 g / m 2 ~160g / m 2The apparatus of any one of Example 1 or Examples 6 to 96, or the method of Example 2 or Examples 73 to 96, having a basis weight of Example 98. The apparatus of any one of Examples 1 or 6 to 97, or the method of Example 2 or any one of Examples 73 to 97, wherein the sheet of aerosol-generating substrate has a humidity of 5 percent to 10 percent. Example 99. The device according to any one of Example 1 or Examples 6 to 98, or the method according to Example 2 or Examples 73 to 98, wherein the aerosol-generating substrate sheet has a viscosity of 0.0150 N to 0.0165 N. Example 100. The apparatus according to any one of Examples 1 and 6 to 72, or the method according to Example 2, wherein the aerosol-generating substrate sheet is a tobacco cast leaf. Example 101. 101. The apparatus or method of example 100, wherein the tobacco cast leaves are obtained by mixing tobacco powder, water, fibers, and an aerosol former, such as glycerin, to obtain a tobacco slurry. Example 102. 102. The apparatus or method of example 101, wherein the slurry is placed inside a casting box and cast by a casting knife on a moving conveyor to produce a continuous sheet. Example 103. A frangible sheet of aerosol-generating substrate, wherein the sheet is weakened through the apparatus of any of Example 1 or Examples 6-102, or through the method of Example 2 or any of Examples 73-102. Example 104. A frangible sheet of an aerosol-generating substrate as described in Example 103, having weakened portions and non-weakened bands, the non-weakened bands intersecting one another. Example 105. 105. The frangible sheet of an aerosol-generating substrate of claim 104, wherein the non-frangible band is created by at least one first interrupted band and by at least one second interrupted band of the device. Example 106. A frangible sheet of an aerosol-generating substrate as described in Example 104 or 105, wherein the frangible portion is created by an area of ​​the first radially outer surface provided with a plurality of first circumferential ridges and a plurality of first circumferential grooves, and by an area of ​​the second radially outer surface provided with a plurality of second circumferential ridges and a plurality of second circumferential grooves. Example 107. The fragile sheet of an aerosol-generating substrate according to any one of Examples 104 to 106, wherein the fragile portions are crimped portions. Example 108. A frangible sheet of an aerosol-generating substrate according to any one of Examples 104 to 107, wherein the non-frangible bands are uncrimped portions. Example 109. The device of Examples 10-15, wherein the at least one first interrupted band and the at least one second interrupted band are congruently distorted, i.e., in the same direction, optionally at the same angle (α=α') or at different angles (α≠α'). Example 110. 16. The device of Examples 10-15, wherein the at least one first interrupted band and the at least one second interrupted band are non-coincident, i.e., distorted in opposite directions and at different angles (α≠α').

[0082] The embodiments will now be further described with reference to the figures.

[0083] 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.

[0084] The aerosol-generating article typically comprises an aerosol-generating article component 3 comprising an aerosol-generating substrate and a filter having a mouthpiece end.

[0085] 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.

[0086] 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.

[0087] 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.

[0088] Downstream of the reel holder 4, relative to the feed direction "F," the apparatus includes an upper lamination roller 6 and a lower lamination roller 7, which 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 one another, 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.

[0089] Downstream of the upper lamination roller 6 and the lower lamination roller 7 relative to the feed direction F, the apparatus includes a device 1 for weakening the sheet of aerosol-generating substrate 2. The device 1 is a crimping device configured to create a plurality of longitudinal pleats or creases 8 in the sheet of aerosol-generating substrate 2 to define longitudinal folds that facilitate folding and collection of the sheet of aerosol-generating substrate 2 to form a rod 9 (Figures 1 and 2). 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).

[0090] 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 10 around the collection of sheets 2. The folding device 11 may be shaped like a tapered funnel.

[0091] 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 ) to enable rotation about the first axis of rotation "XX" and the second axis of rotation "YY", respectively, and are operatively connected to motors (not shown) to rotate about said first and second axes of rotation "XX", "YY".

[0092] 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 ) to enable rotation about their respective first and second axes of rotation "XX" and "YY", and are operatively connected to motors (not shown) configured to rotate about the first and second axes of rotation "XX", "YY", and in opposite directions.

[0093] 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.

[0094] The first roller 12 includes a plurality of first circumferential ridges 15 provided on a first radially outer surface of the first roller 12 and defining a respective plurality of first circumferential grooves 16 on the first radially outer surface (FIGS. 5, 7-11).

[0095] 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.

[0096] 7 and 9, each first circumferential ridge 15 includes a plurality of circumferential recesses 17 spaced circumferentially along the first circumferential ridge 15, with a plurality of raised portions 18 defined between the circumferential recesses 17. Each circumferential recess 17 is spaced apart from another circumferential recess 17 by one raised portion 18. The upper portion 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 diameter "D" and a center about the first axis of rotation "XX."

[0097] The circumferential recess 17 of one first circumferential ridge 15 may be circumferentially offset relative to the circumferential recesses 17 of the two first circumferential ridges 15 adjacent to the one first circumferential ridge 15. While moving in one direction along the first axis of rotation "XX" (e.g., from left to right in Figures 5 and 8), the circumferential recess 17 of each first circumferential ridge 15 is always circumferentially offset in the same direction (clockwise or counterclockwise) relative to the preceding first circumferential ridge 15 by an offset distance "Od".

[0098] The circumferential recesses 17 of the plurality of first circumferential ridges 15 form a plurality of first interruption bands 19 on the first radially outer surface of the first roller 12. For example, 20 circumferential recesses 17 are formed on each first circumferential ridge 15, and 20 first interruption bands 19 are formed on the first radially outer surface of the first roller 12.

[0099] In the depicted embodiment, the first interrupted bands 19 are skewed relative to the first axis of rotation "XX" and are evenly spaced circumferentially on the first radially outer surface. When considering the first radially outer surface flattened onto a plane (i.e., the cylindrical first radially outer surface is substantially unrolled until it lies flat on an unfolded surface, as in FIG. 8), the interrupted bands 19 define an angle (α) of 20° with the first axis of rotation "XX."

[0100] In the embodiment shown in Figures 7, 8, 9 and 10, each first interruption band 19 is non-corrugated and smooth, i.e., no circumferential ridges or grooves are provided and it is flush with the bottom of the first circumferential groove 16.

[0101] In the modified embodiment of Figure 11, each first interruption band 19 is provided with a circumferential ridge and a circumferential groove, but the ridge of each first interruption band 19 has a radial height that is less than the radial height of the first circumferential ridge 15 (is less corrugated).

[0102] Thus, the first radially outer surface of the first roller 12 includes an area that is the sum of the area provided with the plurality of first circumferential ridges 15 and the plurality of first circumferential grooves 16 and the area of ​​the first interruption band 19. The area of ​​the first interruption band 19 may be, for example, 40,000 mm 2 The area having the plurality of first circumferential ridges and the plurality of first circumferential grooves is, for example, 180,000 mm 2 The ratio of the area of ​​the first interruption band 19 to the area having the plurality of first circumferential ridges and the plurality of first circumferential grooves is, for example, 0.22.

[0103] The second roller 13 in the illustrated embodiment is identical to the first roller 12, meaning that the shape and size of the first circumferential ridge 15 and first circumferential groove 16 are identical to the shape and size of the second circumferential ridge 20 and second circumferential groove 21 of the second roller 13. The shape, size, and number of the first interrupting bands 19 are identical to the shape and size of the second interrupting bands 22 of the second roller 13. In a cross section containing the first rotation axis "XX" and the second rotation axis "YY" of the second roller 13, the first circumferential ridge 15 has a shape complementary to the shape of the second circumferential groove 21, and the second circumferential ridge 20 has a shape complementary to the shape of the first circumferential groove 16. Both the first circumferential ridge 15 and the second circumferential ridge 20 have wavy, rounded profiles.

[0104] 9, 10, and 11 show the contours of the first circumferential ridge 15 and the first circumferential groove 16. FIG. 12 shows the coupling zone of the first roller 12 and the second roller 13, showing that the first roller 12 and the second roller 13 are identical and are axially shifted to allow the first circumferential ridge 15 to be partially inserted into the second circumferential groove 21, and the second circumferential ridge 20 to be partially inserted into the first circumferential groove 16.

[0105] Table 1 below provides ranges of geometric values ​​for the first roller 12 and second roller 13 of the aerosol-generating substrate, and the sheet 2. [Table 1]

[0106] Table 2 below provides the ratio ranges for the values ​​in Table 1. [Table 2]

[0107] In other embodiments not shown in the accompanying drawings, first roller 12 may be different from second roller 13. For example, the shape and / or size of first circumferential ridge 15 and first circumferential groove 16 may be different from the shape and / or size of second circumferential ridge 20 and second circumferential groove 21. For example, the shape and / or size and / or number of first interrupting bands 19 may be different from the shape and / or size and / or number of second interrupting bands 22.

[0108] The first roller 12 and the second roller 13 are mounted on a frame 14 such that a first axis "XX" of the first roller 12 and a second axis "YY" of the second roller 13 are parallel to each other and the first roller 12 and the second roller 13 intermesh at an interlocking zone. A motor rotates the first roller 12 and the second roller 13 in opposite directions about their respective first and second axes of rotation "XX" and "YY".

[0109] Furthermore, the first roller 12 and the second roller 13 are mounted on the frame 14 such that the first interrupting bands 19 and the second interrupting bands 22 intersect with each other when facing each other in the connection zone. In particular, each first interrupting band 19 intersects with a plurality of second interrupting bands 22, and each second interrupting band 22 intersects with a plurality of first interrupting bands 19.

[0110] In the illustrated embodiment, where the first roller 12 and the second roller 13 are identical, this can be achieved when the first interrupting band 19 and the second interrupting band 22 are distorted in the same way on the first roller 12 and the second roller 13, as shown in FIG.

[0111] In other embodiments not shown in the accompanying drawings, the angle (α) of the first interrupting band 19 may be different from the angle (α') of the second interrupting band 22; in either case, the first interrupting band 19 and the second interrupting band 22 intersect with each other when facing each other at the coupling zone. For example, the first interrupting band 19 is parallel to the first axis of rotation "XX" (i.e., α=0), and the second interrupting band 22 is skewed with respect to the second axis of rotation "YY" (i.e., α'≠0). For example, the second interrupting band 22 is parallel to the second axis of rotation "XX" (i.e., α'=0), and the first interrupting band 19 is skewed with respect to the first axis of rotation "YY" (i.e., α≠0). According to some other embodiments, the first interruption band 19 and the second interruption band 22 are distorted non-coincidentally, i.e., in opposite directions and at different angles (α≠α'), so that the first interruption band 19 and the second interruption band 22 still intersect with each other when facing each other in the connection zone.

[0112] According to the method for weakening a sheet of aerosol-generating substrate 2 for an aerosol-generating article component 3 disclosed herein, the sheet of aerosol-generating substrate 2 is fed between a first roller 12 and a second roller 13 of an apparatus 1 while the first roller 12 and the second roller 13 are rotated in opposite directions as shown in Figures 1 and 2.

[0113] Tables 3, 4, and 5 below provide characteristics of an example of aerosol-generating substrate, Sheet 2, made with cellulose fiber, carboxymethyl cellulose, and hydroxypropyl methyl cellulose as binders and glycerin as the aerosol-forming agent. [Table 3] [Table 4] [Table 5]

[0114] Test information for data in Table 5: 25-50 mm rectangular specimens are tested at 50 mm / min, i.e., a strain rate of 1 / min (0.0167 / sec). Testing begins when 0.5 N is measured. Young's modulus slopes from 0.001 to 0.002 strain. The viscous test measures the friction between two sheet layers, i.e., the force required to separate the two sheet layers.

[0115] According to other embodiments, glycerin may be replaced by another polyhydric alcohol, such as triethylene glycol or 1,3-butanediol.

[0116] 13 shows the sheet 2 of the aerosol-generating substrate after passing between the first roller 12 and the second roller 13 of the apparatus 1. The frangible sheet 2 of the aerosol-generating substrate has weakened portions 23 and non-weakened bands 24. The non-weakened bands 24 cross each other (following a fishbone pattern), and the weakened portions 23 have a diamond shape defined by the non-weakened bands 24. In the weakened portions 23, the sheet 2 is crimped to provide parallel ridges or corrugations created by a region of the first radially outer surface provided with a plurality of first circumferential ridges 15 and a plurality of first circumferential grooves 16, and a region of the second radially outer surface provided with a plurality of second circumferential ridges 20 and a plurality of second circumferential grooves 21. In the non-weakened bands 24, the sheet 2 is uncrimped, i.e., flat, and the non-weakened bands 24 are created by the first interrupted bands 19 and the second interrupted bands 22.

[0117] The inventors have verified through testing that the disclosed apparatus and method for weakening the sheet 2 of the aerosol-generating substrate disclosed above avoids or reduces the tendency of material from the sheet 2 to stick and settle on the rollers 12, 13, making it possible to reduce machine stoppages due to the cleaning operations of the rollers 12, 13 and / or the time required for each cleaning operation.

[0118] Table 6 below provides the test parameters and results. The rollers of the standard device include one roller provided with an interrupted band and one roller without an interrupted band, as disclosed, for example, in document EP 3609352 B1. [Table 6]

[0119] As shown in the above test, to process a sheet of the aerosol-generating substrate disclosed above (Test 1) using standard equipment with a conventional crimping roller configuration (i.e., as in EP3609352B1), high tension (12-14 N) is required on the sheet to limit its stickiness on the rollers. High tension can cause quality problems in the final product. In fact, after this high tension, the sheet attempts to recover its original length (the material exhibits elastic behavior), and the cut rod tends to shrink, leaving less material at both ends. In addition, high tension can also adversely affect the crimping effect on the sheet. Furthermore, with standard equipment, the speed must be reduced (120 m / min), and the machine must be stopped frequently (1-2 minutes) for cleaning operations, remaining stopped for long periods (10-15 minutes). This subsequently reduces productivity.

[0120] Conversely, by using the apparatus disclosed herein (Test 2), the machine running speed is higher (200 m / min) than in Test 1, and the tension required is much lower than in Test 1. The machine can run for much longer without stopping, with each stop time being limited (1-2 minutes).

[0121] Another example of the aerosol-generating substrate sheet 2 processed through the apparatus 1 may be a cast leaf, such as tobacco cast leaf. Cast leaf is obtained through a casting process from ingredients such as tobacco powder or other nicotine-containing material, water, and fibers such as cellulose, glycerin, and guar. The first step is to produce a tobacco slurry by mixing the above ingredients. The slurry is an aqueous mixture of insoluble materials with a water content of 70 to 80 percent. In the second step, the slurry is placed inside a casting box and cast by a casting knife on a moving conveyor steel belt to produce a continuous sheet.

[0122] The inventors have found that processing the cast leaf through apparatus 1 allows the sheet to be crimped without fracturing the material, which creates the so-called "spaghetti effect." This is because the fishbone pattern on sheet 2 created by first interrupting band 19 and second interrupting band 22 avoids breaking the material after crimping.

[0123] For purposes of this specification and the appended claims, unless otherwise indicated, all numbers expressing amounts, quantities, percentages, and the like are understood to be modified in all instances 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 values ​​that are within the typical standard error for measurement of the property that it modifies. In some cases, 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. 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, each first circumferential ridge having at least one circumferential recess, the circumferential recesses of the plurality of first circumferential ridges forming at least one first interrupted band 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 the second roller, the second circumferential ridges defining a respective plurality of second circumferential grooves on the second radially outer surface, each second circumferential ridge having at least one circumferential recess, the circumferential recess of the plurality of second circumferential ridges including at least one second interrupted band on the second radially outer surface; the first roller and the second roller are configured to rotate in opposite directions about the respective first and second axes of rotation; In a coupling zone between the first roller and the second roller, the first circumferential ridge is partially inserted into the second circumferential groove, and the second circumferential ridge is partially inserted into the first circumferential groove; The device, wherein the at least one first interruption band and the at least one second interruption band cross each other when facing each other at the connection zone.

2. 2. The device of claim 1, wherein a ratio of an area of ​​the at least one first interruption band on the first radially outer surface to an area of ​​the first radially outer surface provided with the plurality of first circumferential ridges and the plurality of first circumferential grooves is between 0.03 and 0.30, and a ratio of an area of ​​the at least one second interruption band on the second radially outer surface to an area of ​​the second radially outer surface provided with the plurality of second circumferential ridges and the plurality of second circumferential grooves is between 0.03 and 0.

30.

3. 3. The apparatus of claim 1, wherein each first circumferential ridge has a plurality of circumferential recesses, the circumferential recesses of the plurality of first circumferential ridges forming a plurality of first interruption bands on the first radially outer surface, each second circumferential ridge has a plurality of circumferential recesses, the circumferential recesses of the plurality of second circumferential ridges forming a plurality of second interruption bands on the second radially outer surface, and wherein each first interruption band intersects with a plurality of second interruption bands and each second interruption band intersects with a plurality of first interruption bands in the connection zone between the first roller and the second roller.

4. 4. The device according to claim 1, wherein the at least one first interruption band is parallel to the first axis of rotation or the at least one second interruption band is parallel to the second axis of rotation.

5. 5. An apparatus as described in any one of claims 1 to 4, wherein the ratio of the width (w) of the at least one first interruption band to the thickness (t) of the sheet of aerosol-generating substrate is from 8.0 to 70.0, and the ratio of the width (w) of the at least one second interruption band to the thickness (t) of the sheet of aerosol-generating substrate is from 8.0 to 70.

0.

6. 6. The device according to claim 1, wherein the shape and size of the first circumferential ridge (15) and the first circumferential groove (16) are identical to the shape and size of the second circumferential ridge (20) and the second circumferential groove (21).

7. The device according to any one of claims 1 to 6, wherein the shape and size of said at least one first interruption band (19) is identical to the shape and size of said at least one second interruption band (22).

8. 8. The apparatus according to claim 1, wherein the first roller (12) and the second roller (13) are identical and are axially shifted to allow the first circumferential ridge (15) to be partially inserted into the second circumferential groove (21) and the second circumferential ridge (20) to be partially inserted into the first circumferential groove (16).

9. 9. A method for weakening a sheet of aerosol-generating substrate for an aerosol-generating article component, the method comprising feeding the sheet of aerosol-generating substrate between the first roller and the second roller of an apparatus according to any one of claims 1 to 8 while the first roller and the second roller rotate in opposite directions.

10. 10. The method of claim 9, wherein the sheet of aerosol-generating substrate is a fibrous substrate having an elongation at break in the longitudinal direction of 5.0 mm to 7.5 mm and an elongation at break in the transverse direction of 9.5 mm to 12.5 mm.

11. 11. A method according to claim 9 or 10, wherein the sheet of aerosol-generating substrate has a Young's modulus in the longitudinal direction of 5 N / mm to 7 N / mm and a Young's modulus in the transverse direction of 0.8 N / mm to 1.2 N / mm.

12. 12. The method of claim 9, wherein the aerosol-generating substrate sheet is made from a mixture comprising cellulose fibers, a binder, and an aerosol-forming agent, wherein the fibers are cellulose fibers, the binder comprises a derivative of cellulose, and the aerosol-forming agent is a polyhydric alcohol, the amount of the fibers in the mixture is 15.0 to 20.0 percent by dry weight, the amount of the binder in the mixture is 28.0 to 30.0 percent by dry weight, and the amount of the aerosol-forming agent in the mixture is 45.0 to 55.0 percent by dry weight.

13. 13. The method of claim 12, wherein the cellulose derivatives comprise carboxymethyl cellulose and hydroxypropyl methyl cellulose, and the amount of the carboxymethyl cellulose in the mixture is from 5.0 percent to 6.0 percent on a dry weight basis, and the amount of the hydroxypropyl methyl cellulose in the mixture is from 21.0 percent to 24.0 percent on a dry weight basis.

14. 15. A sheet of aerosol-generating substrate weakened by means of an apparatus according to any one of claims 1 to 8 or by means of a method according to any one of claims 9 to 14, wherein the sheet of aerosol-generating substrate has weakened portions and non-weakened bands, the non-weakened bands crossing each other.

15. 1. A process for manufacturing an aerosol-generating article component, said process comprising: - producing a sheet of aerosol-generating substrate; - weakening the sheet of aerosol-generating substrate by a method according to any one of claims 9 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 the frangible sheet of aerosol-generating substrate.

Images