Method for manufacturing a sheet of aerosol generating substrate for aerosol generating articles.

Abstract

A method for producing a sheet of aerosol-generating substrate for an aerosol-generating article. The method comprises mixing a recipe with water to form a mixture, kneading the mixture in a kneader to form a paste, flattening the paste to form a sheet, and drying the flattened sheet to obtain a sheet of aerosol-generating substrate for an aerosol-generating article. The recipe comprises, as components, plant particles and / or alkaloid particles, a binder, and an aerosol-forming agent. The amount of binder in the recipe is 1.0 percent to 7.0 percent on a dry weight basis, and the liquid content of the paste is 25 percent to 35 percent on a wet weight basis.

Description

Technical Field

[0001] The present disclosure relates to a method for manufacturing a sheet of an aerosol generating substrate for aerosol generating articles. The present disclosure also relates to an apparatus for manufacturing a sheet of an aerosol generating substrate for aerosol generating articles, a dough for manufacturing a sheet of an aerosol generating substrate for aerosol generating articles, a process for manufacturing an aerosol generating article component, and an aerosol generating article.

Background Art

[0002] Aerosol generating articles or heat-not-burn tobacco in which an 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 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 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, aerosol-generating articles are made from cast leaves obtained through a casting process from components such as tobacco powder or other nicotine-containing materials, water, and fibers, e.g., cellulose, glycerin, guar. The first step is to produce a tobacco slurry by mixing the above components. The slurry is an aqueous mixture of insoluble substances with a water content of 70-80 percent. In the second step, the tobacco slurry is placed inside a casting box and cast by a casting knife on a moving conveyor steel belt to create a continuous sheet of tobacco cast leaves. In the third step, once the tobacco is cast onto the belt, the belt moves to a heater / dryer unit several hundred meters long, where the temperature is controlled to progressively heat and dry the tobacco cast leaves so that the moisture level in the tobacco cast leaves is finally less than 20%. At the outlet of the dryer, as a fourth step, there is a cooler where the temperature of the cast web is reduced before winding the cast web onto a bobbin. In the fifth step, the cast sheet is unwound, slits are cut into it to form a smaller bobbin, and it is crimped between crimping rollers and wound into the final consumable.

[0004] International Publication 2020 / 058814A1 discloses a method for producing reconstituted tobacco, wherein the solid components of tobacco are ground to particle size, and the resulting ground product is mixed with water, at least one binder and at least one material to form an aerosol until a mixture having a liquid content of about 35–40 percent is obtained. The mixture is subjected to a first lamination and a series of further rolling passages to obtain flaks of substantially constant thickness, and the flaks are then dried to reduce their liquid content to about 8–15 percent.

[0005] U.S. Patent Application Publication 2022 / 369690A1 discloses a method for producing an aerosol-generating substrate for an aerosol-generating article. The method comprises forming a mixture comprising ginger particles, water, an aerosol-forming agent, a binder, and tobacco particles; casting or extruding the slurry in the form of a sheet; and drying the sheet. The mixture may be a paste having at least 60 percent dry mass.

[0006] U.S. Patent Application Publication 2022 / 0346433A1 discloses a method for producing tobacco paste and tobacco-containing films for creating aerosol-forming substrates for heat-non-combustible products. The method comprises preparing a tobacco powder material, preparing a binder gel, mixing the tobacco powder material and the binder to obtain a tobacco paste, smoothing the tobacco paste to obtain a flat web material, and drying the flat web material.

[0007] International Publication No. 2022 / 096860A1 discloses an aerosol generating material and a method for producing an article containing the aerosol generating material. The method comprises forming a first composition comprising a binder and an aerosol forming body; forming a second composition comprising a tobacco material, a filler and a second binder; and mixing and extruding the compositions. The mixture of the first and second compositions may be in the form of a “paste” that is extruded through a die.

[0008] It is desirable to have a method for producing an aerosol-generating substrate sheet that has good mechanical properties and reduces water and energy consumption compared to conventional methods using slurries. [Overview of the project]

[0009] This disclosure relates to a method for producing a sheet of aerosol-generating substrate for aerosol-generating articles. The method comprises mixing a recipe with water to form a mixture. The recipe may contain plant particles and / or alkaloid particles, a binder, and an aerosol-forming agent as components. The mixture may be kneaded to form a paste. The mixture may be kneaded in a kneader to form a paste. The paste may be flattened to form a sheet. The flattened sheet may be dried. The amount of binder in the recipe may be 1.0 percent to 7.0 percent on a dry weight basis. The liquid content of the paste may be 25 percent to 35 percent on a wet weight basis.

[0010] The inventors found that sheets of aerosol-generating substrate for aerosol-generating articles manufactured through this method possess good mechanical properties, including tensile strength and elongation to break.

[0011] The inventors found that the method enables a desired good range of tensile strength and elongation to break of a sheet of aerosol-generating substrate obtained from a paste, both in the longitudinal and transverse directions.

[0012] The inventors found that the binder in the claims results in high mechanical properties, including longitudinal and transverse tensile strength, as well as higher elongation to break. The more binder in the recipe, the longer the elongation to break.

[0013] The inventors found that this method allows for a reduction in energy and water consumption for sheets produced from cast slurries. In fact, the water content, which almost exclusively determines the liquid content of the paste mixture, is much lower than the water content of slurries in typical manufacturing processes.

[0014] One or more of the following disclosed features and embodiments may also be combined with the above methods for filing a divisional or continuation application.

[0015] The amount of binder in the recipe may be 1.5 percent to 6.5 percent by dry weight. The amount of plant particles and / or alkaloid particles in the recipe may be 50 percent to 80 percent by dry weight, or optionally 70 percent to 80 percent by dry weight. The amount of aerosol-forming agent in the recipe may be 16 percent to 20 percent by dry weight. The amount of aerosol-forming agent in the recipe may be 17.5 percent to 20 percent by dry weight.

[0016] In some embodiments, the plant particles and / or alkaloid particles include tobacco particles. In some embodiments, the aerosol-generating substrate sheet is a reconstituted tobacco sheet.

[0017] In some embodiments, the plant particles and / or alkaloid particles may include tobacco and / or nicotine and / or plant components and / or cellulose powder. The plant components may include cellulose fibers such as sheet fibers or powder fibers. The plant components may include one or more of clove, star anise, lavender, rosemary, peppermint, sage, and chamomile. The tobacco may include a tobacco blend.

[0018] In some embodiments, tobacco is 0 to 80 percent by dry weight, optionally 50 to 80 percent by dry weight, and plant components are 1 to 20 percent by dry weight. In some other embodiments, plant components and / or cellulose powder are 50 to 80 percent by dry weight.

[0019] In some embodiments, the binder is a derivative of cellulose. The binder may be methylcellulose, ethylcellulose, ethylhydroxymethyl, or carboxymethylcellulose. In some embodiments, the binder may include natural pectin, optionally fruit, citrus, or tobacco pectin, or guar gum, optionally hydroxyethyl guar or hydroxypropyl guar, or locust bean gum, optionally hydroxyethyl and hydroxypropyl locust bean gum, or alginate, or starch, optionally modified or derivatized starch, or tamarind gum, or dextran, or pralon, or konjac powder, or xanthan gum, or a mixture of the above.

[0020] In some embodiments, the aerosol-forming agent is a polyhydric alcohol. The polyhydric alcohol may be triethylene glycol, 1,3-butanediol, or glycerin or propylene glycol. In some embodiments, the aerosol-forming agent may include a monohydric alcohol, optionally menthol, or an ester of a polyhydric alcohol, optionally glycerol monoacetate, diacetate, or triacetate, or an aliphatic ester of a monocarboxylic acid, dicarboxylic acid, or polycarboxylic acid, optionally dimethyl dodecanediate, dimethyl tetradecanediate, or triethyl citrate.

[0021] In some embodiments, the recipe further includes fibers. The amount of fibers in the recipe may be 0.1 percent to 2.5 percent on a dry weight basis, and optionally 5.0 percent on a dry weight basis. The fibers may be cellulose fibers. The fibers may be soft wood fibers, hard wood fibers, jute fibers, flax fibers, or tobacco fibers. The length of the fibers may be 5 μm to 2500 μm, optionally 155 μm to 1500 μm, optionally 750 μm to 2500 μm, and optionally 710 μm to 1600 μm. The ratio of binder to fibers may be 0.48 to 1.82. The inventors have found that the ratio of binder to fibers is a good parameter for maximizing the elongation and tensile strength to break of the sheet in the longitudinal (long axis direction) and transverse directions. The disclosed ratio of binder to fibers optimizes the elongation and tensile strength to break while maintaining good processability of the paste.

[0022] In some embodiments, the recipe includes additional plant components. The amount of plant components in the recipe may range from 1.0 percent to 20.0 percent on a dry weight basis.

[0023] The viscosity of the binder may be 800 cp to 10000 cp (0.8 to 10 Pa·s). The viscosity of the binder may be greater than 3900 cp (3.9 Pa·s). The viscosity of the binder may be 1950 cp to 6000 cp (1.95 to 6 Pa·s), and optionally 4000 cp to 5000 cp (4 to 5 Pa·s). The viscosity of the binder may be 7200 cp to 7600 cp (7.2 to 7.6 Pa·s). The inventors have found that the viscosity of the binder affects the elongation to fracture and tensile strength. When the viscosity is highest, the elongation to fracture is longest, and when the viscosity is lowest, the tensile strength is highest. The disclosed viscosity range provides a good balance between elongation to fracture and tensile strength.

[0024] In some embodiments, 90 percent of the plant particles and / or alkaloid particles have a size smaller than 600 μm, optionally smaller than 450 μm, optionally smaller than 300 μm, optionally smaller than 200 μm, optionally smaller than 150 μm.

[0025] In some embodiments, mixing the recipe with water includes premixing at least one component of the recipe before kneading the mixture in a kneader. The water may be premixed with at least one component, such as a fiber (i.e., the fiber is hydrated), and / or added to the kneader. In other embodiments, there is no premixing and all components are preferably mixed together in the kneader.

[0026] In some embodiments, the fiber is hydrated, i.e., premixed with water, or the fiber and aerosol former are hydrated, i.e., premixed with water, and then other components are added.

[0027] In some embodiments, mixing the recipe with water includes premixing only at least one component of the recipe or a portion of at least one of the aforementioned components to form a first premix, premixing one or more of the remaining components of the recipe or one or more of the remaining portions of one or more of the components of the recipe to form a second premix, and combining the first premix and the second premix in a kneader. The water may be premixed in the first premix and / or the second premix and / or added in the kneader.

[0028] In some embodiments, mixing the recipe with water includes first mixing the binder with water and then contacting the binder with the aerosol former. The inventors have found that this order provides proper hydration of the binder by water.

[0029] In other embodiments, mixing the recipe with water involves first mixing the binder with the aerosol-forming agent and then contacting the binder with water. The inventors have found that this order enables prevention of agglomerate formation.

[0030] In one embodiment, mixing the recipe with water includes mixing the plant particles and / or alkaloid particles with the aerosol-forming agent to produce a first premix, mixing water and the binder to produce a second premix, and combining the first premix and the second premix in a kneader. In this embodiment, mixing the plant particles and / or alkaloid particles with the aerosol-forming agent can include first mixing the plant particles and / or alkaloid particles with the fibers and then adding the aerosol-forming agent to produce the first premix.

[0031] In one embodiment, mixing the recipe with water includes mixing the plant particles and / or alkaloid particles with the binder to produce a first premix and combining the first premix, the aerosol-forming agent, and water in a kneader by adding first water, then the first premix, and then the aerosol-forming agent. In this embodiment, the fibers may also be mixed with the plant particles and / or alkaloid particles and the binder to produce the first premix.

[0032] In one embodiment, mixing the recipe with water includes mixing the binder to produce a first premix, mixing water, the plant particles and / or alkaloid particles, and the first premix to produce a second premix, and combining the second premix and the aerosol-forming agent in a kneader. In this embodiment, the fibers may also be mixed with the binder to produce the first premix.

[0033] In one embodiment, mixing the recipe with water includes mixing a binder to prepare a first premix and combining plant particles and / or alkaloid particles, the first premix, water, and an aerosol-forming agent in a kneader. In this embodiment, fibers may also be mixed with a binder to prepare a first premix.

[0034] In one embodiment, mixing the recipe with water includes mixing plant particles and / or alkaloid particles to produce a first premix, mixing an aerosol-forming agent and a binder, then adding water to produce a second premix, and combining the first premix and the second premix in a kneader. In this embodiment, the fibers may be mixed with plant particles and / or alkaloid particles to produce the first premix.

[0035] In one embodiment, mixing the recipe with water includes: mixing plant particles and / or alkaloid particles with a binder to prepare a first premix; mixing an aerosol-forming agent with water to prepare a second premix; and combining the first premix and the second premix in a kneader. In this embodiment, the fibers may be mixed with plant particles and / or alkaloid particles and a binder to prepare the first premix.

[0036] In one embodiment, mixing the recipe with water includes mixing plant particles and / or alkaloid particles with a binder to prepare a first premix, and combining the first premix, aerosol-forming agent, and water in a kneader by first adding the aerosol-forming agent and the first premix, and then water. In this embodiment, the fibers may be mixed with plant particles and / or alkaloid particles and a binder to prepare the first premix.

[0037] In one embodiment, mixing the recipe with water includes: mixing plant particles and / or alkaloid particles, a portion of the aerosol-forming agent, and a portion of the water to make a first premix; mixing the remaining portion of the aerosol-forming agent, the remaining portion of the water, and then the binder to make a second premix; and combining the first premix and the second premix in a kneader. In this embodiment, the fibers may be mixed with plant particles and / or alkaloid particles, a portion of the aerosol-forming agent, and a portion of the water to make a first premix. In this embodiment, the portion of the aerosol-forming agent may be half of the total amount of aerosol-forming agent. In this embodiment, the portion of the water may be one-quarter of the total amount of water.

[0038] In one embodiment, mixing the recipe with water includes mixing plant particles and / or alkaloid particles, an aerosol-forming agent, and water to prepare a first premix, mixing the first premix in a kneader, and then adding a binder. In this embodiment, the fibers may be mixed with plant particles and / or alkaloid particles, an aerosol-forming agent, and water to prepare a first premix.

[0039] In one embodiment, mixing the recipe with water involves mixing the plant particles and / or alkaloid particles, aerosol-forming agent, binder, and water together in a kneader. In this embodiment, the fibers may also be mixed with the plant particles and / or alkaloid particles, aerosol-forming agent, binder, and water in a kneader.

[0040] In one embodiment, mixing the recipe with water includes mixing plant particles and / or alkaloid particles and a binder to produce a first premix, mixing fibers with water to produce a second premix, and combining the first premix with the second premix in a kneader.

[0041] In one embodiment, mixing the recipe with water includes: mixing plant particles and / or alkaloid particles and a binder to prepare a first premix; mixing fibers with a portion of water and then with an aerosol-forming agent to prepare a second premix; and combining the first premix with the second premix in a kneader and adding the remaining portion of water.

[0042] In some embodiments, the water temperature is 5°C to 120°C. For example, the water temperature is 20°C to 80°C, preferably 20°C to 50°C, and optionally 50°C to 80°C. For example, the water temperature is 15°C to 25°C. The inventors have found that these temperatures prevent deterioration of the paste during processing, which would affect the mechanical properties of the sheet.

[0043] In some embodiments, the temperature of the paste at the end of preparation before planarization is 20°C to 50°C, preferably 20°C to 35°C. For example, the temperature of the paste before planarization is 35°C to 45°C. The inventors have found that higher temperature pastes provide weaker mechanical properties while providing sheets that are easier to process.

[0044] In some embodiments, flattening is performed through rollers. The roller temperature may be 5°C to 50°C. For example, the roller temperature may be 8°C to 40°C. For example, the roller temperature may be 10°C to 30°C. The inventors have found that these roller temperatures prevent deterioration of the paste and reduce the mechanical properties of the sheet.

[0045] The planarization step may include calendering the mixture to pre-form a thick sheet. The thick sheet may have a thickness of 2 mm to 20 mm. The planarization step may also further include planarizing the thick sheet to form a thin sheet. The thickness of the thin sheet may be 0.15 mm to 0.35 mm. For example, the thickness of the thin sheet may be 0.15 mm to 0.30 mm. Preferably, the thickness of the thin sheet may be 0.172 mm to 0.285 mm. The thick sheet may be transformed into a thin sheet of a adjusted thickness through several rolling steps. The thin sheet may have a moisture content of 25 to 35 percent.

[0046] In some embodiments, the drying process dries the flattened sheets to a liquid content of 5.8–11.2 percent by wet weight. In the drying process, the flattened sheets may be dried to a liquid content of 8.5 percent by wet weight. Drying may be carried out by transporting the flattened sheets through a dryer on a belt conveyor, the conveyor belt being optionally a mesh belt. The drying technique may be a combination of infrared radiation and hot air, microwaves and hot air, or via conduction and convection with hot air through a steam heating belt.

[0047] In some embodiments, plant particles and / or alkaloid particles are produced by grinding plant fragments and / or alkaloid fragments in a grinder.

[0048] This disclosure also relates to a paste for producing a sheet of aerosol-generating substrate for aerosol-generating articles. The paste may comprise water and a recipe. The recipe may comprise plant particles and / or alkaloid particles, a binder, and an aerosol-forming agent as components. The amount of binder in the recipe may be between 1.0 percent and 7.0 percent on a dry weight basis. The liquid content of the paste may be between 25 percent and 35 percent on a wet weight basis.

[0049] The inventors have found that the compound disclosed above makes it possible to manufacture a sheet of aerosol-generating substrate for aerosol-generating articles having good mechanical properties, including tensile strength and elongation to fracture.

[0050] The inventors have found that the compound disclosed above enables the sheet of aerosol generating substrate to achieve a desirable range of tensile strength and elongation to break in both the longitudinal and transverse directions.

[0051] In fact, the inventors found that the binder in the claims resulted in high mechanical properties, including longitudinal and transverse tensile strength, as well as higher elongation to break. The more binder in the recipe, the longer the elongation to break.

[0052] One or more of the discretionary features and embodiments disclosed below may be combined with the above-mentioned material for the purpose of filing a divisional or continuation application.

[0053] The amount of binder in the recipe may be 1.5 percent to 6.5 percent by dry weight. The amount of plant particles and / or alkaloid particles in the recipe may be 50 percent to 80 percent by dry weight, or optionally 70 percent to 80 percent by dry weight. The amount of aerosol-forming agent in the recipe may be 16 percent to 20 percent by dry weight. The amount of aerosol-forming agent in the recipe may be 17.5 percent to 20 percent by dry weight.

[0054] In some embodiments, the plant particles and / or alkaloid particles include tobacco particles. In some embodiments, the aerosol-generating substrate sheet is a reconstituted tobacco sheet.

[0055] In some embodiments, the plant particles and / or alkaloid particles may include tobacco and / or nicotine and / or plant components and / or cellulose powder. The plant components may include cellulose fibers such as sheet fibers or powder fibers. The plant components may include one or more of clove, star anise, lavender, rosemary, peppermint, sage, and chamomile. The tobacco may include a tobacco blend.

[0056] In some embodiments, tobacco is 0 to 80 percent by dry weight, optionally 50 to 80 percent by dry weight, and plant components are 1 to 20 percent by dry weight. In some other embodiments, plant components and / or cellulose powder are 50 to 80 percent by dry weight.

[0057] In some embodiments, the binder is a derivative of cellulose. The binder may be methylcellulose, ethylcellulose, ethylhydroxymethyl, or carboxymethylcellulose. In some embodiments, the binder may include natural pectin, optionally fruit, citrus, or tobacco pectin, or guar gum, optionally hydroxyethyl guar or hydroxypropyl guar, or locust bean gum, optionally hydroxyethyl and hydroxypropyl locust bean gum, or alginate, or starch, optionally modified or derivatized starch, or tamarind gum, or dextran, or pralon, or konjac powder, or xanthan gum, or a mixture of the above.

[0058] In some embodiments, the aerosol-forming agent is a polyhydric alcohol. The polyhydric alcohol may be triethylene glycol, 1,3-butanediol, or glycerin or propylene glycol. In some embodiments, the aerosol-forming agent may include a monohydric alcohol, optionally menthol, or an ester of a polyhydric alcohol, optionally glycerol monoacetate, diacetate, or triacetate, or an aliphatic ester of a monocarboxylic acid, dicarboxylic acid, or polycarboxylic acid, optionally dimethyl dodecanediate, dimethyl tetradecanediate, or triethyl citrate.

[0059] In some embodiments, the recipe further includes fibers. The amount of fibers in the recipe may be 0.1 percent to 2.5 percent on a dry weight basis, and optionally 5.0 percent on a dry weight basis. The fibers may be cellulose fibers. The fibers may be soft wood fibers, hard wood fibers, jute fibers, flax fibers, or tobacco fibers. The length of the fibers may be 5 μm to 2500 μm, optionally 155 μm to 1500 μm, optionally 750 μm to 2500 μm, and optionally 710 μm to 1600 μm. The ratio of binder to fibers may be 0.48 to 1.82. The inventors have found that the ratio of binder to fibers is a good parameter for maximizing the elongation and tensile strength to break of the sheet in the longitudinal (long axis direction) and transverse directions. The disclosed ratio of binder to fibers optimizes the elongation and tensile strength to break while maintaining good processability of the paste.

[0060] In some embodiments, the recipe includes additional plant components. The amount of plant components in the recipe may range from 1.0 percent to 20.0 percent on a dry weight basis.

[0061] The viscosity of the binder may be 800 cp to 10000 cp (0.8 to 10 Pa·s). The viscosity of the binder may be greater than 3900 cp (3.9 Pa·s). The viscosity of the binder may be 1950 cp to 6000 cp (1.95 to 6 Pa·s), and optionally 4000 cp to 5000 cp (4 to 5 Pa·s). The viscosity of the binder may be 7200 cp to 7600 cp (7.2 to 7.6 Pa·s). The inventors have found that the viscosity of the binder affects the elongation to fracture and tensile strength. When the viscosity is highest, the elongation to fracture is longest, and when the viscosity is lowest, the tensile strength is highest. The disclosed viscosity range provides a good balance between elongation to fracture and tensile strength.

[0062] In some embodiments, 90 percent of the plant particles and / or alkaloid particles have a size smaller than 600 μm, optionally smaller than 450 μm, optionally smaller than 300 μm, optionally smaller than 200 μm, and optionally smaller than 150 μm.

[0063] This disclosure also relates to a process for manufacturing components of aerosol-generating articles.

[0064] The process may include producing a sheet of aerosol-generating substrate for an aerosol-generating article through a method for producing a sheet of aerosol-generating substrate for an aerosol-generating article. The method may be the method disclosed on the previous page. The method may include mixing the recipe with water to form a mixture. The recipe may contain plant particles and / or alkaloid particles, a binder and an aerosol-forming agent as components. The mixture may be kneaded to form a paste. The mixture may be kneaded in a kneader to form a paste. The paste may be flattened to form a sheet. The flattened sheet may be dried. The amount of binder in the recipe may be 1.0 percent to 7.0 percent on a dry weight basis. The liquid content of the paste may be 25 percent to 35 percent on a wet weight basis.

[0065] One or more of the following disclosed features and embodiments may also be combined with the above process for filing a divisional or continuation application.

[0066] The process may involve using a paste to produce a sheet of aerosol-generating substrate for an aerosol-generating article. The paste may be one of those disclosed on the previous page. The paste may contain water and a recipe. The recipe may contain plant particles and / or alkaloid particles, a binder, and an aerosol-forming agent as components. The amount of binder in the recipe may be between 1.0 percent and 7.0 percent on a dry weight basis. The liquid content of the paste may be between 25 percent and 35 percent on a wet weight basis.

[0067] According to some embodiments, a sheet of aerosol generating substrate is divided along its longitudinal axis into multiple tapes of aerosol generating substrate, and then each tape of aerosol generating substrate is assembled and wound to form a continuous rod.

[0068] Dividing a sheet of aerosol generating substrate into multiple tapes of aerosol generating substrate along its longitudinal axis may include winding the sheet of aerosol generating substrate onto a core to form a master bobbin.

[0069] Dividing a sheet of aerosol generating substrate into multiple tapes of aerosol generating substrate along its longitudinal axis may involve cutting a master bobbin into smaller bobbins, with each smaller bobbin carrying one of the tapes of aerosol generating substrate wound on its respective portion of the core.

[0070] Alternatively, dividing a sheet of aerosol generating substrate into multiple tapes of aerosol generating substrate along its longitudinal axis may involve cutting the sheet of aerosol generating substrate into multiple tapes and then winding each tape onto its own small bobbin.

[0071] The process may include collecting sheets of aerosol-generating substrate. The process may also include winding the aggregate of sheets of aerosol-generating substrate into a wrapper to form a continuous rod.

[0072] The process may include cutting a continuous rod into a plurality of aerosol-generating article components, each having a rod shape. Each aerosol-generating article component may include an assembly of sheets formed from cut portions of a sheet of aerosol-generating substrate.

[0073] The inventors found that the disclosed process makes it possible to obtain high-quality aerosol-generating article components, which result in reduced manufacturing costs and reduced energy consumption.

[0074] This disclosure also relates to an apparatus for producing a sheet of aerosol-generating substrate for aerosol-generating articles. The apparatus may be configured to carry out the method disclosed on the previous page. The method may include mixing a recipe with water to form a mixture. The recipe may include plant particles and / or alkaloid particles, a binder and an aerosol-forming agent as components. The mixture may be kneaded to form a paste. The mixture may be kneaded in a kneader to form a paste. The paste may be flattened to form a sheet. The flattened sheet may be dried. The amount of binder in the recipe may be 1.0 percent to 7.0 percent on a dry weight basis. The liquid content of the paste may be 25 percent to 35 percent on a wet weight basis.

[0075] The apparatus may include a kneader configured to mix a mixture with a recipe and water to form a paste. The kneader may be a batch mixer or a continuous mixer. The apparatus may include a flattening roller operably positioned downstream of the kneader and configured to flatten the paste to form a sheet. The apparatus may include a dryer operably positioned downstream of the flattening roller and configured to dry the flattened sheet to obtain a sheet of aerosol-generating substrate for an aerosol-generating article. The apparatus may include a rewinder operably positioned downstream of the dryer and configured to wind the sheet onto a bobbin. Alternatively, the apparatus may include an in-line slitter operably positioned downstream of the dryer and configured to divide the sheet of aerosol-generating substrate into several tapes. The apparatus may also include several small rewinders for winding each tape onto its own small bobbin.

[0076] The inventors have found that, for example, the dryer of this apparatus is shorter than the 100-meter-long heater / dryer used in the prior art to dry slurries, thus the disclosed apparatus has a reduced footprint. This contributes to a reduction in capital expenditures, i.e., the amount an organization or legal entity spends on purchasing, maintaining, or improving fixed assets such as buildings, vehicles, equipment, or land.

[0077] One or more of the optional features and embodiments disclosed below may also be combined with the above apparatus for filing a divisional or continuation application.

[0078] According to some embodiments, the grinder is operably positioned upstream of the kneader and is configured to grind the plant and / or alkaloid into particles.

[0079] According to some embodiments, one or more premixers are operably positioned upstream of the kneader and are configured to premix at least one, some, or all of the ingredients of the recipe.

[0080] According to some embodiments, the paste sheeter is configured to calender the paste to pre-form a thick sheet. The paste sheeter may be part of the kneader, or it may be operably positioned immediately downstream of the kneader.

[0081] This disclosure also relates to an aerosol generating article comprising at least one aerosol generating article component. The aerosol generating article component may be manufactured according to the processes for manufacturing aerosol generating article components disclosed on the previous page.

[0082] The process may include producing a sheet of aerosol-generating substrate for an aerosol-generating article through a method for producing a sheet of aerosol-generating substrate for an aerosol-generating article. The method may be the method disclosed on the previous page. The method may include mixing the recipe with water to form a mixture. The recipe may include plant particles and / or alkaloid particles, a binder and an aerosol-forming agent as components. The mixture may be kneaded to form a paste. The mixture may be kneaded in a kneader to form a paste. The kneader may operate in a batch or continuous process. The paste may be flattened to form a sheet. The flattened sheet may be dried. The amount of binder in the recipe may be 1.0 percent to 7.0 percent on a dry weight basis. The liquid content of the paste may be 25 percent to 35 percent on a wet weight basis.

[0083] As used herein, the term “recipe” means a group of ingredients with no restrictions on the order and timing of their combination with each other and / or with water.

[0084] As used herein, the term “mixture” means a mixture that is stiff enough to be kneaded or rolled, as opposed to “slurry,” which is a watery mixture of insoluble substances with a very high water content (e.g., 70 to 80 percent) that cannot be kneaded or rolled.

[0085] As used herein, the terms “upstream” and “downstream” are used to describe the relative position of a component or part of a component of an apparatus with respect to the direction in which one or more materials pass through the apparatus along a given path. [Examples]

[0086] The present invention is defined in the claims. However, a non-exclusive list of non-limiting embodiments is provided below. One or more features of these embodiments may be combined with one or more features of any of the features described above, for example, one or more features of other embodiments, forms, or aspects described herein.

[0087] Example 1. A method for producing a sheet of aerosol-generating substrate for an aerosol-generating article, comprising: mixing a recipe with water to form a mixture, wherein the recipe comprises, as components, plant particles and / or alkaloid particles, a binder and an aerosol-forming agent; kneading the mixture in a kneader to form a paste; flattening the paste to form a sheet; and drying the flattened sheet to obtain a sheet of aerosol-generating substrate for an aerosol-generating article, wherein the amount of binder in the recipe is 1.0 percent to 7.0 percent on a dry weight basis, the liquid content of the paste is 25 percent to 35 percent on a wet weight basis, and optionally the kneader operates in a batch or continuous process. Example 2. A paste for manufacturing a sheet of aerosol-generating substrate for an aerosol-generating article, comprising water and a recipe, wherein the recipe comprises, as components, plant particles and / or alkaloid particles, a binder, and an aerosol-forming agent, the amount of the binder in the recipe being 1.0 percent to 7.0 percent on a dry weight basis, and the liquid content of the paste being 25 percent to 35 percent on a wet weight basis. Example 3. A process for manufacturing components of an aerosol-generating article, - To manufacture a sheet of aerosol generating substrate for an aerosol generating article by means of the method of Example 1 or by using the paste of Example 2, - Collecting sheets of aerosol generating substrate, winding the aggregate of aerosol generating substrate sheets inside a wrapper to form a continuous rod, - A process comprising cutting a continuous rod into a plurality of aerosol-generating article components, each having a rod shape, wherein each aerosol-generating article component includes an assembly of sheets formed from the cut portions of a sheet of an aerosol-generating substrate. Example 4. An apparatus for producing a sheet of aerosol generating substrate for an aerosol generating article, wherein the apparatus is configured to carry out the method according to Example 1, and the apparatus comprises: a kneader configured to knead a mixture with a recipe and water to form a paste; a flattening roller operably positioned downstream of the kneader and configured to flatten the paste to form a sheet; a dryer operably positioned downstream of the flattening roller and configured to dry the flattened sheet to obtain a sheet of aerosol generating substrate for an aerosol generating article; and a winder operably positioned downstream of the dryer and configured to wind the sheet onto bobbins, or alternatively, an apparatus comprising an inline slitter operably positioned downstream of the dryer and configured to divide the sheet of aerosol generating substrate into a plurality of tapes, and a plurality of small winders for winding each tape onto a respective small bobbin. Example 5. An aerosol-generating article comprising at least one aerosol-generating article component prepared according to the process of Example 3 or using the paste of Example 2. Example 6. A paste made according to the method in Example 1 or the method in Example 2, wherein the amount of binder in the recipe is 1.5 percent to 6.5 percent on a dry weight basis. Example 7. The paste according to Example 1 or Example 2, or the paste according to Example 6, wherein the amount of plant particles and / or alkaloid particles in the recipe is 50 to 80 percent by dry weight, optionally 70 to 80 percent by dry weight. Example 8. The amount of aerosol-forming agent in the recipe is 16 percent to 20 percent by dry weight, as described in Example 1 or Example 2, or as described in Example 6 or Example 7. Example 9. The method or paste according to Example 8, wherein the amount of aerosol-forming agent in the recipe is 17.5 percent to 20 percent on a dry weight basis. Example 10. A paste according to Example 1 or Example 2, or a paste according to any of Examples 6 to 9, wherein the plant particles and / or alkaloid particles include tobacco particles, the aerosol generating substrate sheet is a reconstituted tobacco sheet, or the plant particles and / or alkaloid particles include tobacco and / or nicotine and / or plant components and / or cellulose powder, optionally the plant components include cellulose fibers such as sheet fibers or powder fibers, optionally the plant components include one or more of clove, star anise, lavender, rosemary, peppermint, sage, and chamomile, optionally the tobacco includes a tobacco blend, optionally the tobacco is 0 to 80 percent by dry weight, optionally the tobacco is 50 to 80 percent by dry weight, the plant components are 1 to 20 percent by dry weight, and optionally the plant components and / or cellulose powder are 50 to 80 percent by dry weight. Example 11. The recipe is a paste made according to the method in Example 1 or the method in Example 2, or a paste made according to any of Examples 6 to 10, further containing fiber. Example 12. The method or paste according to Example 11, wherein the amount of fiber in the recipe is 0.1 percent to 2.5 percent on a dry weight basis, and optionally 5.0 percent on a dry weight basis. Example 13. The recipe is a paste made according to the method in Example 1 or the method in Example 2, or a paste made according to any of Examples 6 to 12, further containing plant-based ingredients. Example 14. The method or paste according to Example 13, wherein the amount of additional plant ingredients in the recipe is between 1.0 percent and 20.0 percent by dry weight. Example 15. The method described in Example 1 or Example 2, or the method described in any of Examples 6 to 14, wherein the binder is a derivative of cellulose. Example 16. The method or paste according to Example 15, wherein the cellulose derivative is methylcellulose, ethylcellulose, ethylhydroxymethylcellulose, or carboxymethylcellulose. Example 17. A paste according to Example 1 or Example 2, or a paste according to any of Examples 6 to 14, wherein the binder contains natural pectin and optionally fruit and citrus or tobacco pectin, or guar gum, optionally hydroxyethyl guar or hydroxypropyl guar, or locust bean gum, optionally hydroxyethyl and hydroxypropyl locust bean gum, or alginate, or starch, optionally modified or derivatized starch, or tamarind gum, or dextran, or pralon, or konjac powder, or xanthan gum, or a mixture of the above. Example 18. The aerosol-forming agent is a polyhydric alcohol, the paste described in Example 1 or Example 2, or the paste described in any of Examples 6 to 17. Example 19. The method or paste according to Example 18, wherein the polyhydric alcohol is triethylene glycol, 1,3-butanediol, or glycerin or propylene glycol. Example 20. The method according to Example 1, or the paste described in Example 2, or the method according to any of Examples 6 to 17, wherein the aerosol-forming agent comprises a monohydric alcohol, optionally menthol, or an ester of a polyhydric alcohol, optionally glycerol monoacetate, diacetate, or triacetate, or an aliphatic ester of a monocarboxylic acid, dicarboxylic acid, or polycarboxylic acid, optionally dimethyl dodecanediate, dimethyl tetradecanediate, or triethyl citrate. Example 21. The method or paste according to Example 11 or Example 12, wherein the fibers are cellulose fibers. Example 22. The method or paste according to Example 21, wherein the cellulose fiber is coniferous tree fiber, hardwood fiber, jute fiber, flax fiber, or tobacco fiber. Example 23. The method or paste according to Example 11, Example 12, Example 21, or Example 22, wherein the fiber length is 5 μm to 2500 μm, optionally 155 μm to 1500 μm, optionally 710 μm to 1600 μm, or optionally 750 μm to 2500 μm (long fiber). Example 24. The ratio of binder to fiber is 0.48 to 1.82, according to any of the methods or pastes described in Examples 11, 12, 21, 22, or 23. Example 25. A paste according to the method described in Example 1 or Example 2, or a paste according to any of Examples 6 to 24, wherein the viscosity of the binder is 800 cp to 10000 cp (0.8 to 10 Pa·s). Example 26. The method or paste according to Example 25, wherein the viscosity of the binder is greater than 3900 cp (3.9 Pa·s), optionally, the viscosity of the binder is 1950 cp to 6000 cp (1.95 to 6 Pa·s), optionally, 4000 cp to 5000 cp (4 to 5 Pa·s), and optionally, the viscosity of the binder is 7200 cp to 7600 cp (7.2 to 7.6 Pa·s). Example 27. A paste according to Example 1 or Example 2, or a paste according to any of Examples 6 to 26, wherein 90 percent of the plant particles and / or alkaloid particles have a size of less than 600 μm, optionally less than 450 μm, or optionally less than 300 μm. Example 28. The method or paste according to Example 27, wherein 90 percent of the plant particles and / or alkaloid particles have a size of less than 200 μm, and optionally less than 150 μm. Example 29. The plant particles and / or alkaloid particles are the pastes described in Example 1 or Example 2, or the pastes described in any of Examples 6 to 28, having a size of less than 325 μm. Example 30. The method according to either Example 1 or Example 6 to Example 29, wherein mixing the recipe with water includes premixing at least one component of the recipe before kneading the mixture in a kneader, and the water is premixed with at least one component, for example, fiber, and / or added to the kneader, otherwise there is no premixing, all components are preferably mixed together in the kneader, optionally, the fiber is hydrated, i.e., premixed with water, or the fiber and aerosol-forming agent are hydrated, i.e., premixed with water, and then the other components are added. Example 31. The method according to Example 1 or any of Examples 6 to 30, wherein mixing the recipe with water comprises premixing at least one component of the recipe or a portion of at least one of the aforementioned components to form a first premix, premixing one or more remaining components of one or more components of the recipe or one or more remaining portions of one or more components of the recipe to form a second premix, and combining the first premix and the second premix in a kneader, wherein water is premixed in the first premix and / or the second premix and / or added to the kneader. Example 32. The method according to either Example 1 or Examples 6 to 31, wherein mixing the recipe with water involves first mixing the binder with water and then contacting the binder with the aerosol-forming agent. Example 33. The method according to either Example 1 or Examples 6 to 31, wherein mixing the recipe with water involves first mixing the binder with the aerosol-forming agent and then bringing the binder into contact with water. Example 34. The method according to Example 32, comprising: mixing the recipe with water; mixing plant particles and / or alkaloid particles with an aerosol-forming agent to prepare a first premix; mixing water with a binder to prepare a second premix; and combining the first premix and the second premix in a kneader. Example 35. The method of Example 34, if Example 32 is described in Example 11, Example 12, or any of Examples 21 to 24, comprising first mixing plant particles and / or alkaloid particles with fibers, and then adding the aerosol-forming agent to prepare a first premix. Example 36. The method according to Example 32, comprising: mixing the recipe with water; mixing plant particles and / or alkaloid particles with a binder to make a first premix; and combining the first premix, aerosol-forming agent, and water in a kneader by first adding water, then the first premix, then the aerosol-forming agent. Example 37. The method of Example 36, if Example 32 is described in Example 11, Example 12, or any of Examples 21 to 24, wherein the fibers are also mixed with plant particles and / or alkaloid particles and a binder to prepare a first premix. Example 38. The method according to Example 32, comprising: mixing the recipe with water; mixing a binder to prepare a first premix; mixing water, plant particles and / or alkaloid particles, and the first premix to prepare a second premix; and combining the second premix and an aerosol-forming agent in a kneader. Example 39. The method according to Example 32, comprising mixing the recipe with water, mixing a binder to prepare a first premix, and combining plant particles and / or alkaloid particles, the first premix, water, and an aerosol-forming agent in a kneader. Example 40. The method according to Example 38 or Example 39, wherein the fibers are also mixed with a binder to prepare a first premix. Example 41. The method according to either Example 1 or Example 6 to Example 31, comprising mixing the recipe with water, mixing plant particles and / or alkaloid particles to make a first premix, mixing an aerosol-forming agent and a binder, then adding water to make a second premix, and combining the first premix and the second premix in a kneader. Example 42. The method according to Example 41, as described in Example 11, Example 12, or any of Examples 21 to 24, wherein the fibers are mixed with plant particles and / or alkaloid particles to prepare a first premix. Example 43. The method according to either Example 1 or Example 6 to Example 31, comprising: mixing the recipe with water; mixing plant particles and / or alkaloid particles with a binder to prepare a first premix; mixing an aerosol-forming agent with water to prepare a second premix; and combining the first premix and the second premix in a kneader. Example 44. The method according to either Example 1 or Example 6 to Example 31, comprising: mixing the recipe with water; mixing plant particles and / or alkaloid particles with a binder to prepare a first premix; and combining the first premix, aerosol-forming agent, and water in a kneader by first adding the aerosol-forming agent and the first premix, then water. Example 45. The method according to Example 43 or Example 44, in the case of Example 11, Example 12, or any of Examples 21 to 24, wherein the fibers are mixed with plant particles and / or alkaloid particles and a binder to prepare a first premix. Example 46. The method according to either Example 1 or Example 6 to Example 31, comprising: mixing the recipe with water; mixing plant particles and / or alkaloid particles, a portion of the aerosol-forming agent, and a portion of the water to make a first premix; mixing the remaining portion of the aerosol-forming agent, the remaining portion of the water, and then the binder to make a second premix; and combining the first premix and the second premix in a kneader. Example 47. The method according to Example 46, as described in Example 11, Example 12, or any of Examples 21 to 24, wherein the fibers are mixed with plant particles and / or alkaloid particles, part of an aerosol-forming agent, and part of water to prepare a first premix. Example 48. The method according to Example 46 or Example 47, wherein a portion of the aerosol-forming agent is half the total amount of the aerosol-forming agent, and a portion of the water is one-quarter of the total amount of water. Example 49. The method according to either Example 1 or Example 6 to Example 31, comprising: mixing the recipe with water; mixing plant particles and / or alkaloid particles, an aerosol-forming agent, and water to prepare a first premix; mixing the first premix in a kneader; and then adding a binder. Example 50. The method according to Example 49, as described in Example 11, Example 12, or any of Examples 21 to 24, wherein the fibers are mixed with plant particles and / or alkaloid particles, an aerosol-forming agent, and water to prepare a first premix. Example 51. The method according to either Example 1 or Example 6 to Example 31, wherein the recipe is mixed with water, and the plant particles and / or alkaloid particles, aerosol-forming agent, binder, and water are all mixed together in a kneader. Example 52. The fibers are also mixed in a kneader with plant particles and / or alkaloid particles, an aerosol-forming agent, a binder, and water, as described in Example 11, Example 12, or any of Examples 21 to 24, or as described in Example 51. Example 53. The method according to Example 1 or any of Examples 6 to 52, wherein the water temperature is 5°C to 120°C. Example 54. The method according to Example 53, wherein the water temperature is 20°C to 80°C. Example 55. The method according to Example 54, wherein the water temperature is 20°C to 50°C. Example 56. The method according to Example 1 or any of Examples 6 to 55, wherein the temperature of the paste before flattening is 20°C to 50°C, preferably 20°C to 35°C. Example 57. The method according to Example 56, wherein the temperature of the paste before flattening is 35°C to 45°C. Example 58. The method according to Example 1 or any of Examples 6 to 57, wherein the planarization is performed through a planarization roller, and the temperature of the planarization roller is 5°C to 50°C. Example 59. The method according to Example 58, wherein the temperature of the flattening roller is 8°C to 40°C. Example 60. The method according to Example 59, wherein the roller temperature is 10°C to 30°C. Example 61. The planarization step is the method according to Example 1 or any of Examples 6 to 60, which includes calendering the paste to pre-form a thick sheet having a thickness of 2 mm to 20 mm. Example 62. The method according to Example 61, further comprising a planarization step of planarizing a thick sheet to form a thin sheet having a thickness of 0.15 mm to 0.35 mm. Example 63. The thin sheet has a thickness of 0.15 mm to 0.30 mm, as described in Example 62. Example 64. The thin sheet has a thickness of 0.172 mm to 0.285 mm, as described in Example 63. Example 65. In the drying process, the flattened sheet is dried to a liquid content of 5.8 to 11.2 percent by wet weight, according to the method of Example 1 or any of Examples 6 to 64. Example 66. The method according to Example 65, wherein in the drying process, the flattened sheet is dried to a liquid content of 8.5 percent by wet weight. Example 67. Plant particles and / or alkaloid particles are prepared by grinding plant fragments and / or alkaloid fragments in a grinder, according to the method of Example 1 or any of Examples 6 to 66. Example 68. The method according to either Example 1 or Example 6 to Example 67, wherein drying is carried out by transporting the flattened sheet through a dryer on a belt conveyor, and optionally the conveyor belt is a mesh belt. Example 69. The process according to Example 3, wherein a sheet of aerosol generating substrate is divided along its longitudinal axis into multiple tapes of aerosol generating substrate, and then each tape of aerosol generating substrate is collected and wound to form a continuous rod. Example 70. The process according to Example 69, wherein dividing a sheet of aerosol generating substrate into multiple tapes of aerosol generating substrate along the longitudinal axis includes winding the sheet of aerosol generating substrate onto a core to form a master bobbin, and cutting the master bobbin into smaller bobbins, each of which carries one of the tapes of aerosol generating substrate wound on each portion of the core, or dividing a sheet of aerosol generating substrate into multiple tapes along the longitudinal axis includes cutting the sheet of aerosol generating substrate into multiple tapes, and then winding each tape onto its respective smaller bobbin. Example 71. The apparatus according to Example 4, further comprising a grinder operably positioned upstream of the kneader and configured to grind plants and / or alkaloids into particles, wherein the kneader is optionally a batch mixer or a continuous mixer. Example 72. The apparatus according to Example 4 or Example 71, further comprising at least one premixer operably positioned upstream of the kneader and configured to premix at least one, some, or all of the ingredients of the recipe. Example 73. The apparatus according to Example 4, Example 71, or Example 72, further comprising a paste sheeter, the paste sheeter being part of the kneader or operably positioned immediately downstream of the kneader, for calendering the paste to pre-form a thick sheet. Example 74. A recipe for producing a sheet of aerosol-generating substrate for an aerosol-generating article, comprising plant particles and / or alkaloid particles, a binder, and an aerosol-forming agent as components, wherein the amount of binder in the recipe is 1.0 percent to 7.0 percent on a dry weight basis. Example 75. The recipe described in Example 74, wherein the amount of binder in the recipe is 1.5 percent to 6.5 percent on a dry weight basis. Example 76. The recipe according to Example 74 or Example 75, wherein the amount of plant particles and / or alkaloid particles in the recipe is 50 to 80 percent by dry weight, and optionally 70 to 80 percent by dry weight. Example 77. A recipe according to any of Examples 74 to 76, wherein the amount of aerosol-forming agent in the recipe is 16 percent to 20 percent on a dry weight basis. Example 78. The recipe described in Example 77, wherein the amount of aerosol-forming agent in the recipe is 17.5 percent to 20 percent on a dry weight basis. Example 79. A recipe according to any of Examples 73 to 78, wherein the plant particles and / or alkaloid particles include tobacco particles, the aerosol generating substrate sheet is a reconstituted tobacco sheet, or the plant particles and / or alkaloid particles include tobacco and / or nicotine and / or plant components and / or cellulose powder, optionally the plant components include cellulose fibers such as sheet fibers or powder fibers, optionally the plant components include one or more of clove, star anise, lavender, rosemary, peppermint, sage, and chamomile, optionally the tobacco includes a tobacco blend, optionally the tobacco is 0 to 80 percent by dry weight, optionally the tobacco is 50 to 80 percent by dry weight, optionally the plant components are 1 to 20 percent by dry weight, and optionally the plant components and / or cellulose powder are 50 to 80 percent by dry weight. Example 80. A recipe that further includes fiber, as described in any of Examples 73 to 78. Example 81. The recipe described in Example 80, wherein the amount of fiber in the recipe is 0.1 percent to 2.5% on a dry weight basis, and optionally 5.0% on a dry weight basis. Example 82. A recipe according to any of Examples 73 to 81, further containing plant-based ingredients. Example 83. The recipe described in Example 82, wherein the amount of additional plant ingredients in the recipe is between 1.0 percent and 20.0 percent by dry weight. Example 84. A recipe according to any of Examples 73 to 83, wherein the binder is a derivative of cellulose. Example 85. The recipe according to Example 84, wherein the cellulose derivative is methylcellulose, ethylcellulose, ethylhydroxymethylcellulose, or carboxymethylcellulose. Example 86. The recipe according to any of Examples 73 to 85, wherein the binder comprises natural pectin, optionally fruit, citrus, or tobacco pectin, or guar gum, optionally hydroxyethyl guar or hydroxypropyl guar, or locust bean gum, optionally hydroxyethyl and hydroxypropyl locust bean gum, or alginate, or starch, optionally modified or derivatized starch, or tamarind gum, or dextran, or pralon, or konjac powder, or xanthan gum, or a mixture of the above. Example 87. A recipe according to any of Examples 73 to 86, wherein the aerosol-forming agent is a polyhydric alcohol. Example 88. The recipe according to Example 87, wherein the polyhydric alcohol is triethylene glycol, 1,3-butanediol, or glycerin or propylene glycol. Example 89. The aerosol-forming agent is a recipe according to any of Examples 73 to 88, comprising a monohydric alcohol, optionally menthol, or an ester of a polyhydric alcohol, optionally glycerol monoacetate, diacetate, or triacetate, or an aliphatic ester of a monocarboxylic acid, dicarboxylic acid, or polycarboxylic acid, optionally dimethyl dodecanediate, dimethyl tetradecanediate, or triethyl citrate. Example 90. The recipe described in Example 80 or Example 81, wherein the fibers are cellulose fibers. Example 91. The recipe according to Example 90, wherein the cellulose fiber is coniferous fiber, hardwood fiber, jute fiber, flax fiber, or tobacco fiber. Example 92. The recipe described in Example 80, Example 81, Example 90, or Example 91, wherein the fiber length is 5 μm to 2500 μm, optionally 155 μm to 1500 μm, optionally 710 μm to 1600 μm, or optionally 750 μm to 2500 μm (long fiber). Example 93. The ratio of binder to fiber is 0.48 to 1.82, according to any of the recipes in Examples 80, 89, 90, 91, or 92. Example 94. A recipe according to any of Examples 73 to 93, wherein the viscosity of the binder is 800 cp to 10000 cp (0.8 to 10 Pa·s). Example 95. The recipe described in Example 94, wherein the viscosity of the binder is greater than 3900 cp (3.9 Pa·s), optionally the viscosity of the binder may be 1950 cp to 6000 cp (1.95 to 6 Pa·s), optionally the viscosity of the binder may be 4000 cp to 5000 cp (4 to 5 Pa·s), and optionally the viscosity of the binder may be 7200 cp to 7600 cp (7.2 to 7.6 Pa·s). Example 96. A recipe according to any of Examples 73 to 95, wherein 90 percent of the plant particles and / or alkaloid particles have a size of less than 600 μm, optionally less than 450 μm, and optionally less than 300 μm. Example 97. The recipe according to Example 96, wherein 90 percent of the plant particles and / or alkaloid particles have a size of less than 200 μm, and optionally less than 150 μm. Example 98. The plant particles and / or alkaloid particles are recipes from any of Examples 73 to 97, having a size of less than 325 μm. Example 99. A sheet of aerosol-generating substrate for an aerosol-generating article, comprising a recipe described in any of Examples 73 to 98, or passing through the paste of Example 2, or the paste described in any of Examples 7 to 29. Example 100. An aerosol generating article comprising a sheet of the aerosol generating substrate described in Example 99, and optionally a filter. Example 101. The method of Example 51, as described in any of Examples 11, 12, or 21 to 24, comprising: mixing the recipe with water; mixing plant particles and / or alkaloid particles and a binder to make a first premix; mixing the fibers with water to make a second premix; and combining the first premix with the second premix in a kneader. Example 102. The method of Example 51, as described in any of Examples 11, 12, or 21 to 24, comprising: mixing the recipe with water; mixing plant particles and / or alkaloid particles and a binder to make a first premix; mixing the fibers with a portion of the water and then with an aerosol-forming agent to make a second premix; and combining the first premix with the second premix in a kneader and adding the remaining portion of the water.

[0088] Here, we will further describe the examples with reference to the figures. [Brief explanation of the drawing]

[0089] [Figure 1] Figure 1 schematically shows an apparatus for manufacturing a sheet of aerosol generating substrate for a heated aerosol generating article according to the present invention. [Figure 2] Figure 2 shows a flowchart of a part of a method for manufacturing a sheet of aerosol generating substrate for an aerosol generating article according to an embodiment of the present invention. [Figure 3] Figure 3 shows a flowchart of a part of a method for manufacturing a sheet of aerosol generating substrate for an aerosol generating article according to an embodiment of the present invention. [Figure 4] Figure 4 shows a flowchart of a part of a method for manufacturing a sheet of aerosol generating substrate for an aerosol generating article according to an embodiment of the present invention. [Figure 5] Figure 5 shows a flowchart of a part of a method for manufacturing a sheet of aerosol generating substrate for an aerosol generating article according to an embodiment of the present invention. [Figure 6] Figure 6 shows a flowchart of a part of a method for manufacturing a sheet of aerosol generating substrate for an aerosol generating article according to an embodiment of the present invention. [Figure 7] Figure 7 shows a flowchart of a part of a method for manufacturing a sheet of aerosol generating substrate for an aerosol generating article according to an embodiment of the present invention. [Figure 8] Figure 8 shows a flowchart of a part of a method for manufacturing a sheet of aerosol generating substrate for an aerosol generating article according to an embodiment of the present invention. [Figure 9] Figure 9 shows a flowchart of a part of a method for manufacturing a sheet of aerosol generating substrate for an aerosol generating article according to an embodiment of the present invention. [Figure 10] Figure 10 shows a flowchart of a part of a method for manufacturing a sheet of aerosol generating substrate for an aerosol generating article according to an embodiment of the present invention. [Figure 11] Figure 11 shows a flowchart of a part of a method for manufacturing a sheet of aerosol generating substrate for an aerosol generating article according to an embodiment of the present invention. [Figure 12] Figures 12A and 12B show one step in the process for manufacturing components of an aerosol generating article. [Figure 13] Figure 13 shows an apparatus for manufacturing components of an aerosol generating article. [Figure 14] Figure 14 shows the longitudinal section and cross-section of the aerosol-generating article components. [Figure 15] Figure 15 shows the longitudinal section and cross-section of the aerosol-generating article components. [Modes for carrying out the invention]

[0090] The apparatus 1 shown in Figure 1 is a schematic example of an apparatus configured to carry out a method for manufacturing a sheet of aerosol generating substrate for an aerosol generating article according to the present invention.

[0091] Apparatus 1 comprises a grinder 2 configured to grind plants and / or alkaloids into particles "T". For example, if the plants and / or alkaloids are tobacco flakes, the grinder 2 is a tobacco mill adapted to coarsely grind the tobacco flakes into tobacco particles, 90% of which have a size of less than 275 μm. A buffer silo, not shown in the accompanying drawings, for uniform mass flow control may be located after the grinder 2.

[0092] From the pulverizer 2, the plant particles and / or alkaloid particles "T" are transported, for example, by pneumatic transport to the powder mixing silo 3 schematically shown in Figure 1. In the powder mixing silo 3, other powders such as cellulose fibers "F" can be introduced and mixed to form the first premix "PM1".

[0093] Apparatus 1 further comprises a container 4, in which a moist mixture is loaded with an aerosol-forming agent "A" such as glycerin, a binder "B" such as carboxymethylcellulose (CMC), and then water "W," and mixed to form a second premix "PM2."

[0094] The first premix "PM1" and the second premix "PM2" are supplied to a kneader 5, which is operationally located downstream of the powder mixing silo 3 and container 4. The powder mixing silo 3 and container 4 define their respective premixers, which are operationally located upstream of the kneader 5 and configured to premix one or more components of the recipe. The kneader 5 may operate in batches or in a continuous process.

[0095] In the kneader 5, the first premix "PM1" and the second premix "PM2" form a mixture that is kneaded through the kneading element 6 to form the paste "D".

[0096] Therefore, paste "D" is prepared by mixing the recipe and water in a kneader 5, the recipe comprising plant particles and / or alkaloid particles "T", aerosol-forming agent "A", fiber "F", and binder "B".

[0097] Next, the paste "D" is calendered through a paste sheeter or calender roller 7, which may be part of the kneading machine 5, to form a paste "D" like a thick sheet 8. For example, the thickness of the thick sheet is 2 mm to 20 mm.

[0098] Downstream of the kneader 5, the apparatus 1 includes flattening rollers 9 configured to flatten a thick sheet 8 to form a flattened thin sheet 10. A non-limiting embodiment in Figure 3 shows two pairs of flattening rollers 9 arranged sequentially. The flattening rollers 9 are provided with heating or cooling devices (not shown) configured to heat or cool the peripheral surfaces of the flattening rollers 9 and the thick sheet 8 passing between them to maintain a kneading temperature of about 20-24°C. The thickness of the thin sheet 10 may be 0.15mm to 0.35mm, optionally 0.15mm to 0.30mm, for example 0.172mm to 0.285mm.

[0099] The dryer 11 is operably positioned downstream of the flattening rollers 9 and is configured to dry the flattened thin sheets 10 to obtain a sheet 12 of aerosol-generating substrate for aerosol-generating articles. The dryer 11 may comprise a casing defining a chamber 13 and a belt conveyor 14, such as a mesh belt that moves through the chamber 13 while supporting the thin sheets 10. A heating device, not shown, is configured to heat and dry the thin sheets 10 as they move through the chamber 13. The heating / drying technique may be a combination of infrared radiation and hot air, microwaves and hot air, or via conduction and convection with hot air through a steam heating belt.

[0100] The flattened sheet 10 is dried to a liquid content of 5.8 to 11.2 percent on a wet weight basis, for example, to 8.5 percent on a wet weight basis.

[0101] Downstream of the dryer 11, the longitudinal ends of the sheet 12 are trimmed through a trimming device 15. A winding machine, operably positioned downstream of the dryer 11 and the trimming device 15, is configured to wind the aerosol-generating substrate sheet 12 onto a core 16 to form a master bobbin 17.

[0102] A cooling station, not shown in the figure, may be placed between the dryer 11 and the winding machine so that the aerosol generating substrate sheet 12 is cooled before it is wound up.

[0103] In a different embodiment not shown in the drawings, the apparatus 1 includes an in-line slitter operably positioned downstream of the dryer 11 and configured to divide the aerosol-generating substrate sheet 12 into multiple tapes. Multiple small winders are used to wind each tape onto their respective small bobbins.

[0104] The apparatus 1 described above enables the execution of the method of the present invention. The proportions and supply order of the ingredients of the recipe and the water "W" can be varied from those disclosed above.

[0105] Tables 1A and 1B below contain Recipe Examples 1-10.

[0106] [Table 1]

[0107] [Table 2]

[0108] Table 1C below contains further examples of recipes containing graphite. [Table 3]

[0109] Tables 1D, 1E, and 1F below contain further examples of recipes with plant-based ingredients.

[0110] [Table 4]

[0111] [Table 5]

[0112] [Table 6]

[0113] Table 2 below contains some of the characteristics of the components. [Table 7]

[0114] In the above embodiment, the plant particles and / or alkaloid particles "T" are tobacco particles, and therefore the aerosol-generating substrate sheet is a reconstituted tobacco sheet. In other embodiments, the plant particles and / or alkaloid particles "T" may be plant components.

[0115] In the above example, the amount of tobacco particles "T" in the recipe is 76.1 percent by dry weight. In any case, the amount of plant particles and / or alkaloid particles, such as tobacco particles, may be 70 to 80 percent by dry weight, and optionally 70 to 80 percent by dry weight.

[0116] In the above examples, 90 percent of the tobacco particles are smaller than 175 μm or 275 μm, and there are no particles larger than 450 μm. If particles larger than 500 μm are present, the visual quality of the product may be affected, but its functionality may not be.

[0117] In the above example, the amount of cellulose fiber in recipe "F" is 0.0 percent (no fiber) to 4.2 percent. In any case, the amount of fiber, such as cellulose fiber, in the recipe may be 0.0 percent (no fiber) to 5.0 percent on a dry weight basis.

[0118] In the above embodiments, the binder "B" is carboxymethylcellulose (CMC). In other embodiments, the binder "B" may include methylcellulose, ethylcellulose, ethylhydroxymethyl or carboxymethylcellulose, or natural pectin, optionally fruit and citrus or tobacco pectin, or guar gum, optionally hydroxyethyl guar or hydroxypropyl guar, or locust bean gum, optionally hydroxyethyl and hydroxypropyl locust bean gum, or alginate, or starch, optionally modified or derivatized starch, or tamarind gum, or dextran, or pralon, or konjac powder, or xanthan gum, or a mixture of the above.

[0119] In the above examples, the viscosity of CMC is 1950 cp to 6000 cp (1.95 to 6 Pa·s), for example, 3900 cp (3.9 Pa·s). The viscosity of Guar is 7200 cp (7.2 Pa·s). In any case, the viscosity of the binder may be 800 cp to 10000 cp (0.8 to 10 Pa·s).

[0120] In the above embodiments, the ratio of binder to fiber is greater than 0.28. In some embodiments, the ratio of binder to fiber is between 0.48 and 1.82.

[0121] In the above examples, the amount of carboxymethylcellulose (CMC) in the recipe is 1.2 percent to 6.2 percent by dry weight. In any case, the amount of binders such as CMC in the recipe may be 1.0 percent to 7.0 percent by dry weight.

[0122] In the above embodiment, the aerosol-forming agent "A" is glycerin. In other embodiments, the polyhydric alcohol may be triethylene glycol or 1,3-butanediol. In some other embodiments, the aerosol-forming agent "A" may contain a monohydric alcohol, optionally menthol, or an ester of a polyhydric alcohol, optionally glycerol monoacetate, diacetate, or triacetate, or an aliphatic ester of a monocarboxylic acid, dicarboxylic acid, or polycarboxylic acid, optionally dimethyl dodecanediate, dimethyl tetradecanediate, or triethyl citrate.

[0123] In the above examples, the amount of glycerin in the recipe is 17.7 percent to 19.7 percent on a dry weight basis. In any case, the amount of aerosol-forming agent "A", for example glycerin, in the recipe may be 16 percent to 20 percent on a dry weight basis.

[0124] In other embodiments, the recipe may also further include additional botanical ingredients such as cloves, star anise, rosemary, sage, peppermint, chamomile, lavender, eucalyptus, lemon peel FD, passionberry, and geranium. The amount of additional botanical ingredients may range from 1.0 percent to 20.0 percent on a dry weight basis.

[0125] Tables 3A, 3B, 3C and accompanying Figures 2-11 below provide examples of supply sequences F1-F14 of components and water "W" (F11 and F12 are not shown in the drawings). As disclosed in Tables 3A and 3B, some components may be pre-mixed with water "W" in the powder mixing silo 3 and / or container 4 before mixing and kneading in the kneader 5, or they may be pre-mixed without water "W". Some other embodiments may include the same supply sequences as F1-F14, but without the use of fiber "F". F8 indicates that pre-mixing may be optional.

[0126] [Table 8]

[0127] [Table 9]

[0128] [Table 10]

[0129] Table 4 below provides exemplary parameters and / or methods for the apparatus 1 of the present invention.

[0130] [Table 11]

[0131] In the above examples, the temperature of the water "W" mixed with the recipe is between 20°C and 50°C. In any case, the tested temperature of the water "W" may be up to 80°C.

[0132] In the above example, the temperature of the paste before flattening is 35°C to 45°C. In any case, the temperature of the paste before flattening may be 20°C to 50°C.

[0133] In the above embodiment, the temperature of the flattening roller 9 is 10°C to 30°C. In any case, the temperature of the flattening roller 9 may be 5°C to 50°C, or optionally 8°C to 40°C.

[0134] The aerosol-generating substrate sheet 12 on the master bobbin 17 is used to manufacture the aerosol-generating article components 18 and the aerosol-generating article. The master bobbin 17 is cut into several smaller bobbins 19, so that each smaller bobbin 19 has a tape 20 of the aerosol-generating substrate wound on a portion of the core 16 (Figures 12A and 12B). Alternatively, no master bobbin is formed, and the aerosol-generating substrate sheet is divided into several tapes along the long axis using an in-line slitter, and then each tape is wound onto its respective smaller bobbin.

[0135] Each tape 20 of the aerosol generating substrate may be collected and wound through an apparatus 22 for manufacturing aerosol generating article components to form a continuous rod 21, for example, as shown in Figures 13, 14, and 15.

[0136] The apparatus 22 for manufacturing aerosol-generating article components includes a reel holder 23 for carrying smaller bobbins 19 formed by aerosol-generating substrate tape 20 for aerosol-generating article components. The previously manufactured aerosol-generating substrate tape 20 is unwound from the bobbins 19 and supplied along the supply path in the supply direction "F".

[0137] Downstream of the reel holder 23, the apparatus 1 includes two rotating cylindrical rollers 24 against which the tape 20 is pressed. These rollers 24 have a processed ridged pattern that conforms to the outer surface and crimp the tape 20 by stretching the substrate fibers laterally. This crimping process helps to fold and collect the tape 20 of the aerosol-generating substrate to form a rod piece that fits into an aerosol-generating article. In practice, the term “crimped tape” means the tape 20 having a number of substantially parallel ridges or folds substantially parallel to the cylindrical axis of the rod piece. This facilitates folding and collecting the crimped tape 20 of the aerosol-generating substrate to form an aerosol-generating article component.

[0138] Figure 13 schematically shows a folding device 25 positioned downstream of two rotating cylindrical rollers 24, configured to move the tape 20 from a flat configuration (upstream of the folding device 24) to a collected rod-shaped configuration (downstream of the folding device 25), and to wrap a wrapper 26 around the collected tape 20 to obtain a continuous rod 21. The folding device 24 may be shaped like a tapered funnel. The continuous rod 21 is then cut into a plurality of aerosol-generating article components 27. Each aerosol-generating article component 27 has a rod shape and contains collected tape formed from the cut portion of the tape 20 of the aerosol-generating substrate (Figures 14 and 15).

[0139] Table 5 below compares the mechanical properties of aerosol-generating substrate sheets obtained using parts of the recipes in Tables 1 and 2, and through the same supply sequence (F3), with the mechanical properties of tobacco cast leaves produced from the slurry. TS-LD tensile strength in the longitudinal direction, SB-LD Elongation to fracture in the longitudinal direction, TS-CD lateral tensile strength, SB-CD refers to the elongation until fracture in the lateral direction.

[0140] [Table 12]

[0141] Table 6 below compares the supply sequence and some of the parameters from Tables 3 and 4, along with the mechanical properties of aerosol-generating substrate sheets obtained through the same recipe (Recipe 1 in Table 1A), with the mechanical properties of tobacco cast leaves produced from the slurry.

[0142] [Table 13]

[0143] The tensile strength in the longitudinal direction (TS-LD) and elongation to fracture in the longitudinal direction (SB-LD) of the aerosol generating substrate sheet according to the present invention may be better than the values ​​obtained from tobacco cast leaves obtained from slurry. The tensile strength in the transverse direction (TS-CD) of the aerosol generating substrate sheet according to the present invention is close to the value obtained from tobacco cast leaves obtained from slurry. The elongation to fracture in the transverse direction (SB-CD) of the aerosol generating substrate sheet according to the present invention is far better than the value obtained from tobacco cast leaves obtained from slurry.

[0144] Furthermore, the water content, which almost exclusively determines the liquid content of the paste mixture, is far lower than the water content of a typical manufacturing process slurry.

[0145] Table 7 below shows the mechanical properties of aerosol-generating substrate sheets obtained with supply sequence n.11 and longer fibers.

[0146] [Table 14]

[0147] For the purposes of this specification and the appended claims, unless otherwise indicated, all numerical values ​​representing quantities, amounts, percentages, etc., should be understood in all instances as being modified by the term “approximately.” Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges therewith, which may or may not be specifically listed herein. Thus, in this context, number A is understood as A ± 5 percent of A. In this context, number A may be considered to include numerical values ​​that fall within the general standard error to the measured value of the characteristic modified by number A. Number A may deviate by the percentages listed above, provided that in some instances, such as those used in the appended claims, the amount by which A deviates does not substantially affect the fundamental and novel characteristics of the claimed invention. Furthermore, all ranges include the disclosed maximum and minimum points and any intermediate ranges therewith, which may or may not be specifically listed herein.

Claims

1. A method for manufacturing a sheet of aerosol generating substrate for an aerosol generating article, The process involves mixing a recipe with water to form a mixture, wherein the recipe comprises plant particles and / or alkaloid particles, a binder, and an aerosol-forming agent as components. The mixture is kneaded in a kneader to form a paste, The aforementioned paste is flattened to form a sheet, The process includes drying the flattened sheet to obtain a sheet of aerosol generating substrate for an aerosol generating article, The amount of the binder in the above recipe is 1.0 percent to 7.0 percent on a dry weight basis. The liquid content of the aforementioned paste is 25 percent to 35 percent on a wet weight basis. A method in which flattening is performed by passing the roller through a roller, wherein the temperature of the roller is between 5°C and 50°C.

2. The method according to claim 1, wherein the amount of the binder in the recipe is 1.5 percent to 6.5 percent on a dry weight basis, the amount of the plant particles and / or alkaloid particles in the recipe is 50 percent to 80 percent on a dry weight basis, optionally 70 percent to 80 percent on a dry weight basis, and the amount of the aerosol-forming agent in the recipe is 16 percent to 20 percent on a dry weight basis.

3. The method according to claim 1 or 2, wherein mixing the recipe with water comprises premixing at least one component of the recipe before kneading the mixture in a kneader, the water being premixed with the at least one component and / or added to the kneader.

4. The method according to any one of claims 1 to 3, wherein mixing the recipe with water comprises premixing at least one component of the recipe or a portion of at least one component to form a first premix; premixing one or more remaining components of the one or more components of the recipe, or one or more remaining portions of the one or more components of the recipe to form a second premix; and combining the first premix and the second premix in a kneader, wherein the water is premixed in the first premix and / or the second premix and / or added to the kneader.

5. The method according to any one of claims 1 to 4, wherein mixing the recipe with the water comprises first mixing the binder with the water, and then contacting the binder with the aerosol-forming agent.

6. The method according to any one of claims 1 to 5, wherein the temperature of the water is 20°C to 80°C.

7. The method according to any one of claims 1 to 6, wherein the temperature of the paste before flattening is 20°C to 50°C.

8. The method according to any one of claims 1 to 7, wherein the temperature of the roller is 8°C to 40°C.

9. The method according to any one of claims 1 to 8, wherein the viscosity of the binder is 0.8 Pa·s to 10 Pa·s.

10. The method according to any one of claims 1 to 9, wherein 90 percent of the plant particles and / or alkaloid particles have a size smaller than 600 μm.

11. The method according to any one of claims 1 to 10, wherein the plant particles and / or alkaloid particles comprise tobacco and / or nicotine and / or plant components and / or cellulose powder.

12. The method according to any one of claims 1 to 11, wherein the binder is a derivative of cellulose, and the derivative of cellulose is methylcellulose, ethylcellulose, ethylhydroxymethyl, or carboxymethylcellulose.

13. The method according to any one of claims 1 to 12, wherein the aerosol-forming agent is a polyhydric alcohol, and the polyhydric alcohol is triethylene glycol, 1,3-butanediol, glycerin, or propylene glycol.

14. The method according to any one of claims 1 to 13, wherein the recipe further contains fiber, and the amount of fiber in the recipe is 0.1 percent to 2.5 percent on a dry weight basis.

15. The method according to claim 14, wherein the length of the fiber is 5 μm to 2500 μm.

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