Method and apparatus for producing aerosol-generating substrates

Abstract

The embodiments of the present application provide a method for producing an aerosol-generating substrate and an apparatus for producing it, wherein the method for producing an aerosol-generating substrate includes performing room-temperature extrusion molding on a mixed material to form an extruded substrate on the mixed material, and performing cooling and curing on the extruded substrate. The production method of the embodiments of the present application can improve production efficiency.

Description

Technical Field

[0001] (Cross - reference to related applications) This application is filed based on a Chinese patent application with the application number 202310686734.9, filed with the Chinese Patent Office on June 9, 2023. This application claims the priority of the Chinese patent application, and all the contents of the Chinese patent application are incorporated herein by reference.

[0002] This application relates to the technical field of smoke - generating products, and particularly to a manufacturing method and manufacturing apparatus for an aerosol - generating substrate.

Background Art

[0003] Smoke - generating products include smoke - generating products that form aerosols by combustion and smoke - generating products that form aerosols by a heat - not - burn method. Here, a typical heat - not - burn type smoke - generating product contains an aerosol - generating substrate that can volatilize upon heating to generate an aerosol. The aerosol - generating substrate is heated using an external heat source and heated to a sufficient extent to just release the flavor. The aerosol - generating substrate does not burn, has a high - volume atomizing agent, and releases the atomizing agent by high - temperature heating during use to form an aerosol.

[0004] The aerosol - generating substrate mainly has three types: particle type, traditional sliced - tobacco type, and sheet type. However, in related technologies, the manufacturing method of the aerosol - generating substrate is complex, requires high equipment investment, has low production efficiency, and causes a large amount of environmental pollution.

Summary of the Invention

[0005] In view of this, an embodiment of this application aims to provide a manufacturing method and manufacturing apparatus for an aerosol - generating substrate with relatively high production efficiency.

[0006] To achieve the above object, an embodiment of this application provides a manufacturing method for an aerosol - generating substrate, and the manufacturing method includes: Performing room - temperature extrusion molding on a mixed material to form an extrusion substrate in the mixed material; This includes performing cool-curing on the extruded substrate.

[0007] In one embodiment, cooling and curing the extruded substrate is performed. This includes cooling the extruded substrate in a low-temperature environment, wherein the temperature of the low-temperature environment is lower than the curing temperature of the extruded substrate.

[0008] In one embodiment, the curing temperature is -100°C to 60°C, and the temperature of the low-temperature environment is -270°C to 60°C.

[0009] In one embodiment, cooling and curing the extruded substrate includes direct heat exchange between the extruded substrate and the refrigerant.

[0010] In one embodiment, cooling and curing the extruded substrate includes indirect heat exchange between the extruded substrate and a coolant.

[0011] In one embodiment, direct heat exchange between the extruded substrate and the refrigerant includes spraying the refrigerant onto the outer surface of the extruded substrate.

[0012] In one embodiment, the hardness of the extruded substrate after cooling and curing is 1 HB to 200 HB.

[0013] In one embodiment, the temperature of the extruded substrate after cooling and curing is -50°C to 5°C.

[0014] In one embodiment, the extrusion temperature for the room-temperature extrusion molding is 35°C to 70°C.

[0015] In one embodiment, the extrusion pressure for the room-temperature extrusion molding is 0.5 bar to 300 bar.

[0016] In one embodiment, the extrusion pressure is 20 bar to 80 bar.

[0017] In one embodiment, the extrusion method for the room-temperature extrusion molding is one of horizontal extrusion, vertical extrusion, and inclined extrusion.

[0018] In one embodiment, after cooling and curing the extruded substrate, the manufacturing method is performed as follows: The process further includes hot-air drying of the extruded substrate.

[0019] In one embodiment, the temperature of the hot air drying is 50°C to 200°C.

[0020] In one embodiment, the manufacturing method further includes auxiliary drying using at least one of microwaves and ultrasound during the hot air drying process.

[0021] In one embodiment, the water content of the extruded substrate after hot air drying is 3% to 20% of the total weight of the extruded substrate.

[0022] In one embodiment, before performing hot air drying on the extruded substrate, the manufacturing method is performed as follows: The process further includes performing fragmentation on the extruded substrate after cooling and curing.

[0023] In one embodiment, 100 parts by weight of the mixed material contains 30 to 90 parts of plant raw materials, 1 to 15 parts of auxiliary raw materials, 5 to 30 parts of smoke generating agent raw materials, 1 to 10 parts of adhesive raw materials, and 1 to 15 parts of fragrance raw materials.

[0024] The embodiments of this application provide an apparatus for producing an aerosol-generating substrate, the apparatus being An extruder configured to perform room-temperature extrusion molding on a mixed material to form an extrusion substrate on the mixed material, The system includes a curing apparatus configured to perform cooling and curing on the extruded substrate.

[0025] In one embodiment, the curing device includes a refrigerant supplier and a container. The container has a containing cavity for accommodating the extruded substrate, and the refrigerant supplier is used to supply refrigerant into the containing cavity.

[0026] In one embodiment, a liquid injection groove communicating with the containing cavity is provided in the container.

[0027] In one embodiment, the manufacturing device includes a first transport device having a first conveyor belt, and a part of the structure of the first conveyor belt is located in the containing cavity.

[0028] In one embodiment, a plurality of medium containing grooves are provided on the first conveyor belt, and each of the medium containing grooves extends along the conveying direction of the first conveyor belt.

[0029] In one embodiment, the curing device includes a refrigerant supplier and a first cooling pipe. The first cooling pipe includes a pipe body having a first cooling channel, and a refrigerant injection port provided on the side wall of the pipe body and communicating with the first cooling channel. The first cooling channel is used to accommodate the extruded substrate, and the refrigerant supplier injects refrigerant into the first cooling channel through the refrigerant injection port.

[0030] In one embodiment, the number of the refrigerant injection ports is plural. Among the plural refrigerant injection ports, some of the refrigerant injection ports are provided at intervals in the circumferential direction of the pipe body, and some of the refrigerant injection ports are provided at intervals in the extending direction of the first cooling channel.

[0031] In one embodiment, the refrigerant injection port has an inlet end and an outlet end communicating with the first cooling channel. The refrigerant injection port is provided obliquely with respect to the extending direction of the first cooling channel, and the outlet end is located on the side where the inlet end is away from the inlet of the first cooling channel.

[0032] In one embodiment, the curing apparatus comprises a refrigerant supply and a second cooling pipe, the second cooling pipe comprising a first inner pipe and a first outer pipe, the first inner pipe having a second cooling channel for containing the extruded substrate, a first refrigerant cavity formed between the first inner pipe and the first outer pipe, a communication channel connecting the first refrigerant cavity and the second cooling channel provided in the side wall of the first inner pipe, and the refrigerant supply communicates with the first refrigerant cavity.

[0033] In one embodiment, there are multiple communication channels, some of which are spaced apart in the circumferential direction of the first inner pipe, and some of which are spaced apart in the extending direction of the second cooling channel.

[0034] In one embodiment, the communication channel has an inlet end communicating with the first refrigerant cavity and an outlet end communicating with the second cooling channel, the communication channel is provided at an inclination with respect to the extending direction of the second cooling channel, and the outlet end is located on the side away from the inlet of the second cooling channel from the inlet end.

[0035] In one embodiment, the curing apparatus comprises a refrigerant supply and a third cooling pipe, the third cooling pipe comprising a second inner pipe and a second outer pipe, the second inner pipe having a heat exchange channel, a second refrigerant cavity for storing refrigerant formed between the second inner pipe and the second outer pipe, the heat exchange channel used to accommodate the extruded substrate, and the refrigerant supply communicates with the second refrigerant cavity.

[0036] The embodiments of this application provide a method and apparatus for manufacturing an aerosol-generating substrate, wherein the method for manufacturing the aerosol-generating substrate mainly involves performing room-temperature extrusion molding on a mixed material to form an extruded substrate, and then performing cool-hardening on the extruded substrate. Room-temperature extrusion molding can ensure the stability of the slurry's flow characteristics and the stability of the endogenous components of the extruded substrate. On the other hand, since the extruded substrate produced by room-temperature extrusion molding has a relatively soft texture, cool-hardening the extruded substrate increases its hardness and facilitates subsequent processing. By combining room-temperature extrusion molding and cool-hardening, it is possible to achieve uniformity and stability of the aerosol-generating substrate, reduce the difficulty of manufacturing, improve production efficiency, and increase the yield rate. [Brief explanation of the drawing]

[0037] [Figure 1] This is a flowchart of the method for producing the aerosol-generating substrate in the embodiment of the present invention. [Figure 2] This is an illustrative structural diagram of the apparatus for producing an aerosol-generating substrate according to an embodiment of the present invention, and the mixed materials are also shown in the figure. [Figure 3] Figure 2 is a cross-sectional view of the manufacturing apparatus, and the extrusion substrate is also shown in the figure. [Figure 4] This is an illustrative structural diagram of a manufacturing apparatus for another aerosol-generating substrate according to an embodiment of the present invention, and the mixed material and extruded substrate are also shown in the figure. [Figure 5] Figure 4 is a cross-sectional view of the manufacturing apparatus shown. [Figure 6] This is an illustrative structural diagram of the die of a first type of extrusion mold according to an embodiment of the present application. [Figure 7] This is an illustrative structural diagram of a second type of extrusion die according to the embodiment of the present application, and the extrusion substrate is also shown in the figure. [Figure 8] This is an illustrative structural diagram of a third type of extrusion die according to the embodiment of the present application, and the extrusion substrate is also shown in the figure. [Figure 9] This is an illustrative structural diagram of a first type curing apparatus according to an embodiment of the present application, and the figure also shows an extrusion die and an extrusion substrate. [Figure 10] Figure 9 is a cross-sectional view of the curing apparatus. [Figure 11] This is a schematic diagram showing the combination relationship between the extrusion die, extrusion substrate, and type 2 curing apparatus of the embodiment of the present application. [Figure 12] Figure 11 is an illustrative structural diagram of the curing apparatus, and the die and extrusion substrate are also shown in the figure. [Figure 13] Figure 12 is a cross-sectional view of the curing apparatus. [Figure 14] This is a cross-sectional view of a third type of curing apparatus according to an embodiment of the present application. [Figure 15] This is a cross-sectional view of a fourth type of curing apparatus according to an embodiment of the present application. [Figure 16] This is an illustrative structural diagram of the first type of extruded substrate according to the embodiments of the present application. [Figure 17] This is an illustrative structural diagram of the second type of extrusion substrate of the embodiment of the present application. [Figure 18] This is an illustrative structural diagram of the third type of extrusion substrate of the embodiment of the present application. [Modes for carrying out the invention]

[0038] One embodiment of the present invention provides a method for producing an aerosol-generating substrate. The aerosol-generating substrate is used in combination with an electron atomizer having a heating assembly, specifically, the heating assembly heats and atomizes the aerosol-generating substrate to produce an aerosol for inhalation by the user or for use in medical, cosmetic, or other applications.

[0039] Referring to Figure 1, the method for producing the aerosol-generating substrate includes the following steps.

[0040] In step S10, room temperature extrusion molding is performed on the mixed material to form an extrusion substrate on the mixed material.

[0041] Specifically, extrusion molding refers to a manufacturing method in which a material is fed into an extruder, and the material is pushed forward by the action between the barrel and screw of the extruder, continuously passing through an extrusion die at the exit of the extruder to produce products or semi-finished products of various cross-sections. The material formed by extrusion molding is rod-shaped. Mixed material is a material used to produce an aerosol-generating substrate, and the mixed material is a mixture of solid and liquid materials, meaning that the mixed material contains a certain amount of moisture.

[0042] In the field of extrusion molding, a temperature between 10°C and 90°C (including 10°C and 90°C) is defined as room temperature, a temperature below 10°C is defined as low temperature, and a temperature above 90°C is defined as high temperature.

[0043] The room-temperature extrusion molding of the mixed material described in the embodiments of this application refers to performing extrusion molding of the mixed material within an extrusion temperature range of 10°C to 90°C.

[0044] Temperature affects the fluidity of the mixed material within the extruder and the smoothness of the outer surface of the extruded substrate. If the extrusion temperature is below 10°C, the fluidity of the mixed material is poor, the extruder's production rate is slow, efficiency is low, and the torque provided by the extruder at this temperature is high, which affects the extruder's service life.

[0045] When the extrusion temperature exceeds 90°C, the flow of the mixed material is rapid, and the pressure of the mixed material at the extruder outlet becomes relatively low, which is unfavorable for molding the mixed material. This results in a decrease in the yield rate, and at such temperatures, the energy consumption of the extruder increases, leading to increased production costs.

[0046] When the extrusion temperature is between 10°C and 90°C, the fluidity of the mixed material is good, which is advantageous for molding the mixed material, ensuring the stability of the flow properties of the mixed material, and the intrinsic components of the extruded substrate are stable. Furthermore, at this temperature, the torque provided by the extruder is low, resulting in low energy consumption of the extruder, which extends the service life of the extruder and reduces production costs.

[0047] More preferably, the extrusion temperature for room temperature extrusion molding can be 35°C to 70°C (including 35°C and 70°C).

[0048] In step S20, the extruded substrate is subjected to cooling and curing.

[0049] After cooling and curing, the hardness of the extruded substrate increases, and consequently, the temperature of the extruded substrate also decreases.

[0050] For example, the hardness of an extruded substrate extruded by room-temperature extrusion molding before cooling and curing can be 0HB to 100HB (including 0HB and 100HB), and the hardness of the extruded substrate after cooling and curing can be 1HB to 200HB (including 1HB and 200HB).

[0051] More preferably, the hardness of the extruded substrate extruded by room temperature extrusion molding before cooling and curing can be 1HB to 60HB (including 1HB and 60HB), and the hardness of the extruded substrate after cooling and curing can be 40HB to 120HB (including 40HB and 120HB).

[0052] For example, the temperature of the extruded substrate before cooling and curing can be 0°C to 40°C (including 0°C and 40°C), and the temperature of the extruded substrate after cooling and curing can be -50°C to 5°C (including -50°C and 5°C).

[0053] Step S20 is not the final step of the manufacturing process; that is, the extruded substrate after cooling and curing is merely a semi-finished product of the aerosol-generating substrate. Further processing such as drying, fragmentation, and packaging can be performed, and some of the possible processing methods will be described in detail later.

[0054] Another embodiment of the present invention further provides an apparatus 100 for producing an aerosol-generating substrate, which, referring to Figures 2 to 5, comprises an extruder 110 and a curing device 120.

[0055] The extruder 110 is configured to perform room-temperature extrusion molding on the mixed material 200' to form an extrusion substrate 200 on the mixed material 200'.

[0056] The extruder 110 may be a single-screw extruder or a twin-screw extruder, but a twin-screw extruder is preferred. This is because, compared to a single-screw extruder, a twin-screw extruder can further homogenize the mixed material 200' during the transport process, thereby improving product stability, and the extrusion efficiency of a twin-screw extruder is higher than that of a single-screw extruder.

[0057] The curing apparatus 120 is configured to perform cooling curing on the extruded substrate 200.

[0058] In other words, the method for producing an aerosol-generating substrate in the embodiment of the present invention mainly involves performing room-temperature extrusion molding on a mixed material to form an extruded substrate, and then performing cool-hardening on the extruded substrate. Room-temperature extrusion molding can ensure the stability of the slurry's flow characteristics and the stability of the endogenous components of the extruded substrate. On the other hand, since the extruded substrate produced by room-temperature extrusion molding has a relatively soft texture, cool-hardening the extruded substrate increases its hardness, making subsequent processing easier. By combining room-temperature extrusion molding and cool-hardening, it is possible to achieve uniformity and stability of the aerosol-generating substrate, reduce the difficulty of manufacturing, improve production efficiency, and increase the yield of good products.

[0059] The mixed material of the embodiment of the present application may include plant-based raw materials, auxiliary raw materials, smoke-generating raw materials, adhesive raw materials, and fragrance raw materials.

[0060] Plant-based raw materials are used to generate aerosols during heating. Auxiliary raw materials are used to provide skeletal support to the plant-based raw materials. Smoke-generating raw materials are used to generate aerosols during heating. Adhesive raw materials are used to bind the various raw material components together. Fragrance raw materials are used to provide a characteristic scent. In this way, plant-based raw materials and smoke-generating raw materials can guarantee the amount of aerosol generated, while fragrance raw materials can improve the release of scent during the inhalation process, enhancing the user experience. Auxiliary raw materials not only improve the fluidity of the mixed materials but also create a porous structure in the aerosol-generating substrate, facilitating aerosol extraction and flow. Adhesive raw materials ensure that the plant-based raw materials and auxiliary raw materials constitute a stable mixture, preventing structural loosening.

[0061] Exemplary examples include plant-based ingredients, which are one or more combinations of powders formed by grinding tobacco leaf material, tobacco leaf fragments, tobacco stems, tobacco powder, and flavoring plants. Plant-based ingredients are the core source of aroma, and endogenous substances in plant-based ingredients can provide users with physiological satisfaction. For example, endogenous substances such as alkaloids enter the bloodstream and promote dopamine production in the pituitary gland, thereby resulting in physiological satisfaction.

[0062] Exemplary examples, the auxiliary raw materials may be one or more combinations of inorganic fillers, lubricants, and emulsifiers. Here, the inorganic fillers include one or more combinations of heavy calcium carbonate, light calcium carbonate, zeolite, attapulgite, talc, and diatomaceous earth. The inorganic fillers can provide a skeletal support to the plant raw materials, and at the same time, the inorganic fillers have pores, increasing the porosity of the aerosol-generating substrate, thereby improving the aerosol release rate. The lubricants include one or more combinations of candelilla wax, carnauba wax, shellac, sunflower wax, rice bran, beeswax, stearic acid, and palmitic acid. The lubricants can increase the fluidity of the plant raw material powder, reduce the frictional force between the plant raw material powders, make the overall density of the plant raw material powder distribution more uniform, and also reduce the pressure required in the extrusion process and reduce die wear. The emulsifiers include one or more combinations of polyglycerin fatty acid esters, Tween-80, and polyvinyl alcohol. Emulsifiers can, to some extent, mitigate the loss of flavor compounds during storage, enhance the stability of flavor compounds, and improve the sensory quality of the product.

[0063] Exemplary examples, the fume generating agent raw materials may include one or more combinations of monohydric alcohols (e.g., menthol), polyhydric alcohols (e.g., propylene glycol, glycerin, triethylene glycol, 1,3-butanediol, and tetraethylene glycol), esters of polyhydric alcohols (e.g., triacetin, triethyl citrate, diacetin mixture, triethyl citrate, benzyl benzoate, glyceryl butyrate), monocarboxylic acids, dicarboxylic acids, polycarboxylic acids (e.g., lauric acid, myristic acid), or aliphatic esters of polycarboxylic acids (e.g., dimethyl dodecanedioate, dimethyl tetradecanedioate, erythritol, 1,3-butanediol, tetraethylene glycol, triethyl citrate, propylene carbonate, ethyl laurate, triactin, mesoerythritol, diacetin mixture, diethyl suberate, triethyl citrate, benzyl benzoate, benzylphenyl acetate, ethyl vanillate, glyceryl butyrate, lauryl acetate).

[0064] Exemplary, adhesive materials play a role in binding component materials such as powders and liquids by wetting the interface with the component materials, thereby creating close contact and generating intermolecular attractive forces. Adhesive materials can be natural plant extracts, nonionic modified viscous polysaccharides, and include one or more combinations of tamarind polysaccharides, guar gum, and modified cellulose (e.g., carboxymethylcellulose). Adhesives are used to make particles adhere to each other and less likely to disperse, and further improve the water resistance of aerosol-generating substrates and are harmless to the human body.

[0065] For example, fragrance ingredients are used to provide characteristic aromas such as hay, roasted sweet, and solid or liquid nicotine. Fragrance ingredients may include one or more combinations of tobacco or other plants, extracts, extracts, essential oils, or absolutes of aromatic plants, and may include one or more combinations of single aromatic substances such as megastigmatrienone, neophytadiene, geraniol, and nerol.

[0066] For example, in 100 parts by weight of the mixed material, the plant raw materials may be 30 to 90 parts, the auxiliary raw materials 1 to 15 parts, the smoke generating agent raw materials 5 to 30 parts, the adhesive raw materials 1 to 10 parts, and the fragrance raw materials 1 to 15 parts.

[0067] Depending on the structural form of the extrusion die installed at the outlet of the extruder, different structural forms of extrusion substrate 200 can be extruded. For example, referring to Figures 16 to 18, an extrusion substrate 200 having an airway 200a can be extruded.

[0068] There may be one or more airways 200a. Airways 200a may be straight airways as shown in Figure 16, spiral airways as shown in Figure 17, or a combination of straight and spiral airways. A straight airway is an airway that extends along a straight line; in other words, the direction of extension of a straight airway is a straight line.

[0069] A spiral airway is an airway in which at least a portion of its region along the direction of extension exhibits a curved shape with curvature that is not zero. For example, along the direction of extension of a spiral airway, the structure may have both a curved portion with curvature that is not zero and a straight portion with curvature that is zero, or it may have only a curved portion with curvature that is not zero and no straight portion with curvature that is zero. In other words, a spiral airway does not need to extend in a straight line from its starting point to its ending point along the direction of extension.

[0070] The airways 200a may be located inside the extruded substrate 200, as shown in Figures 16 and 17, or they may be located on the outer wall of the extruded substrate 200. If there are multiple airways 200a, some airways 200a may be located inside the extruded substrate 200, while other airways 200a may be located on the outer wall of the extruded substrate 200, as shown in Figure 18.

[0071] The cross-sectional shape of the airway 200a located inside the extruded substrate 200 is not limited. For example, the cross-sectional shape can be circular, polygonal (including but not limited to triangles, quadrilaterals, rhombuses, etc.), elliptical, track-shaped, or irregular, where "irregular" refers to any symmetrical or asymmetrical shape other than those mentioned above.

[0072] The cross-sectional shape of the airway 200a located on the outer wall of the extruded substrate 200 can be semicircular, semielliptical, polygonal, or irregular, where irregular refers to any symmetrical or asymmetrical shape other than those described above.

[0073] Airway 200a is used to increase the surface area of ​​the aerosol-generating substrate (the sidewalls of airway 200a correspond to a portion of the surface of the aerosol-generating substrate), thereby allowing the heat acting on the aerosol-generating substrate to penetrate from the surface into the interior of the substrate, improving heating efficiency.

[0074] In related technologies, some aerosol-generating substrates have naturally formed pores inside. For example, in aerosol-generating substrates of particle binders, the gaps between particles constitute pores. However, the airway 200a described in this application is different from pores. The airway 200a described in this application is a pore in a macroscopic sense, while pores are pores in a microscopic sense. The dimensions of the airway 200a, such as its cross-sectional area and length, are much larger than those of pores. Since the airway 200a is mainly formed by processing, its dimensions, such as its cross-sectional area and length, can be changed according to design requirements. However, the dimensions of pores are determined by the gaps between particles, and the dimensions of pores, such as their cross-sectional area and length, are naturally formed by the extrusion process.

[0075] In one embodiment, the extrusion pressure for room-temperature extrusion molding can be 0.5 bar to 300 bar (including 0.5 bar and 300 bar).

[0076] The extrusion pressure described in the embodiments of this application refers to the extrusion pressure of the extrusion die located at the outlet of the extruder.

[0077] Extrusion pressure affects the molded shape, surface smoothness, yield rate, and production speed of the extruded substrate. If the extrusion pressure is less than 0.5 bar, the molding rate of the extruded substrate is low, the product defect rate increases, resulting in a decrease in production speed and an increase in production costs. If the extrusion pressure exceeds 300 bar, the load on the extruder's drive structure increases (requiring higher torque), resulting in a shorter extruder lifespan. Therefore, controlling the extrusion pressure within the range of 0.5 bar to 300 bar improves the molding rate of the extruded substrate and extends the extruder's lifespan.

[0078] More preferably, the extrusion pressure for room-temperature extrusion molding can be 20 bar to 80 bar (including 20 bar and 80 bar).

[0079] In one embodiment, the extrusion method for room-temperature extrusion molding can be horizontal extrusion.

[0080] Horizontal extrusion refers to a process where the extrusion die at the outlet of the extruder is installed horizontally, and the extrusion substrate is extruded in a horizontal direction (for example, the extruder 110 shown in Figures 2 and 3). In other words, the extrusion direction of the extrusion substrate is parallel to the horizontal plane.

[0081] In the case of an extruded substrate that forms a spiral airway, as the extruded substrate passes through the extruder's outlet, the die of the extruder rotates, while the extruded substrate does not rotate. The extruded substrate, pushed by the rotating die, enters directly into a transport device (e.g., the first transport device 140 in Figures 2 and 3). The rotation of the die generates a certain stress on the extruded substrate, but horizontal extrusion can reduce the direct release of stress on the extruded substrate (the generated stress can be removed by heating), and therefore, horizontal extrusion can improve the yield rate of aerosol-generating substrates having a spiral airway.

[0082] In one embodiment, the extrusion method for room-temperature extrusion molding can also be vertical extrusion.

[0083] Vertical extrusion refers to a method where the extrusion die at the outlet of the extruder is positioned facing downwards, and the extrusion substrate is extruded along the direction of gravity (for example, the extruder 110 shown in Figures 4 and 5). In other words, the extrusion direction of the extrusion substrate is perpendicular to the horizontal plane.

[0084] For illustrative purposes, referring to Figures 4 and 5, the manufacturing apparatus 100 can be equipped with a third transport device 170, and the extrusion substrate 200 enters the third transport device 170 directly after being extruded from the extruder 110.

[0085] For extrusion substrates that form straight airways, vertical extrusion can improve yield, reduce the investment cost of the extruder, and further reduce the extruder's footprint.

[0086] In one embodiment, the extrusion method for room-temperature extrusion molding can also be inclined extrusion.

[0087] Inclined extrusion refers to a method where the extrusion die at the outlet of the extruder is installed at an incline, and the angle between the extrusion direction of the extrusion substrate and the horizontal plane is greater than 0° but less than 90°.

[0088] Inclined extrusion not only reduces the extrusion pressure of mixed materials but also facilitates the spatial design of other equipment.

[0089] In one embodiment, referring to Figure 6, the extrusion mold 113 can be a single-mold, single-die mold. That is, there is one base mold 1131 at the outlet of the extruder 110, and there is one die 1132 at the discharge end of the base mold 1131, and after the mixed material 200' passes through the die 1132, an extrusion substrate 200 having an airway 200a can be formed.

[0090] In one embodiment, referring to Figure 7, the extrusion die 113 can be a single-die, multiple-die die, that is, there is one base die 1131 at the outlet of the extruder 110, and there are multiple dies 1132 at the discharge end of the base die 1131, and after the mixed material 200' passes through the multiple dies 1132, multiple extrusion substrates 200 are formed simultaneously. When the size of the screw 112 of the extruder 110 is relatively large, a single-die, multiple-die die can be selected, thereby increasing production efficiency and making it more suitable for mass production.

[0091] In one embodiment, referring to Figure 8, the extrusion mold 113 can be a multi-mold, multi-die mold, that is, multiple base molds 1131 are connected to the adapter 116 at the outlet of the extruder 110, and multiple dies 1132 are provided at the discharge end of each base mold 1131, so that after the mixed material 200' passes through the dies 1132 on each base mold 1131, multiple extrusion substrates 200 are formed simultaneously. Even when the size of the screw 112 of the extruder 110 is relatively large, a multi-mold, multi-die mold can be selected, thereby increasing production efficiency and making it more suitable for mass production.

[0092] In one embodiment, cooling may be performed by cooling the extruded substrate in a low-temperature environment, where the temperature of the low-temperature environment is lower than the curing temperature of the extruded substrate.

[0093] In other words, the extruded substrate can be transported to a low-temperature environment and frozen, and in order to meet the curing requirements, the temperature of the low-temperature environment must be lower than the curing temperature of the extruded substrate.

[0094] For example, assuming the premise that the temperature of the low-temperature environment is lower than the curing temperature of the extruded substrate, if the curing temperature of the extruded substrate is -100°C to 60°C (including -100°C and 60°C), the temperature of the low-temperature environment can be -270°C to 60°C (including -270°C and 60°C).

[0095] More preferably, if the curing temperature of the extruded substrate is -30°C to 40°C (including -30°C and 40°C), the temperature of the low-temperature environment can be -100°C to 40°C (including -100°C and 40°C).

[0096] In one embodiment, cooling and curing may be performed by cooling the extrusion substrate using a refrigerant. The refrigerant may be a liquid such as liquid nitrogen or liquefied air, or it may be a gas or a solid.

[0097] In one embodiment, the extrusion substrate and the refrigerant can be directly subjected to heat exchange. Direct heat exchange refers to heat exchange occurring through direct contact between heat exchange media. In other words, the extruded substrate and the refrigerant are in direct contact.

[0098] The advantage of directly exchanging heat between the extrusion substrate and the refrigerant is that the surface of the heat exchange medium can be cooled and hardened relatively quickly, allowing the extrusion substrate to maintain its shape stability, thereby facilitating continuous production and increasing production efficiency.

[0099] Illustratively, referring to Figures 9 and 10, the curing apparatus 120 may comprise a refrigerant supply (not shown) and a container 121 having a containment cavity 121a, the containment cavity 121a being used to contain the extruded substrate 200, and the refrigerant supply being used to supply refrigerant into the containment cavity 121a. In other words, the extruded substrate 200 extruded from the extruder 110 is placed in the containment cavity 121a and brought into contact with the refrigerant supplied by the refrigerant supply.

[0100] Referring to Figures 9 and 10, in the case of a liquid refrigerant, a liquid injection groove 121b communicating with the containment cavity 121a can be provided on the container 121. The refrigerant supplier injects the liquid refrigerant into the liquid injection groove 121b, and the refrigerant enters the containment cavity 121a via the liquid injection groove 121b, coming into contact with the extruded substrate 200 inside the containment cavity 121a to perform heat exchange.

[0101] Referring to Figures 9 and 10, in order to facilitate the transport of the extruded substrate 200, the manufacturing apparatus 100 may be equipped with a first transport device 140 having a first conveyor belt 141, the first transport device 140 having a portion of the structure of the first conveyor belt 141 located inside the containment cavity 121a, the first transport device 140 can feed the extruded substrate 200 extruded from the extruder 110 into the containment cavity 121a via the first conveyor belt 141, and transport out the extruded substrate 200 that has undergone cooling and hardening from inside the containment cavity 121a.

[0102] Referring to Figures 9 and 10, if the extrusion die 113 can extrude multiple extrusion substrates 200 simultaneously, the hardness of the newly extruded extrusion substrates 200 is low. Therefore, to prevent the multiple extrusion substrates 200 from sticking together, multiple media storage grooves 140a can be provided on the first conveyor belt 141. Each media storage groove 140a extends along the conveying direction of the first conveyor belt 141, and each extrusion substrate 200 extruded from the extruder 110 enters its corresponding media storage groove 140a, thereby separating each extrusion substrate 200 via the media storage grooves 140a.

[0103] For example, a refrigerant can be sprayed onto the outer surface of the extruded substrate.

[0104] Injection refers to the ejection of a refrigerant under a certain pressure.

[0105] For example, referring to Figures 11 to 13, the curing apparatus 120 may also be equipped with a refrigerant supply (not shown) and a first cooling pipe 122 having a first cooling passage 1221a. The first cooling pipe 122 includes a pipe body 1221 having a first cooling passage 1221a and a refrigerant injection port 1222 provided on the side wall of the pipe body 1221 and communicating with the first cooling passage 1221a. The first cooling passage 1221a is used to contain the extrusion substrate 200, and the refrigerant supply injects refrigerant into the first cooling passage 1221a via the refrigerant injection port 1222.

[0106] In other words, the extruded substrate 200 from the extruder 110 enters the first cooling channel 1221a, and the refrigerant supplier injects refrigerant into the first cooling channel 1221a via the refrigerant injection port 1222 to cool the extruded substrate 200 in the first cooling channel 1221a.

[0107] Referring to Figure 11, the number of first cooling tubes 122 corresponds to the number of extrusion substrates 200 extruded from the extruder 110.

[0108] The shape of the cross-section of the first cooling tube 122 is not limited, and exemplary, the cross-section of the first cooling tube 122 can be a closed shape such as a circle, ellipse, or rectangle. In other embodiments, the shape of the cross-section can be an open shape such as an L-shape, U-shape, V-shape, or arc-shaped groove structure.

[0109] Referring to Figures 12 and 13, the refrigerant injection port 1222 has an inlet end and an outlet end that communicates with the first cooling channel 1221a. The refrigerant injection port 1222 is positioned at an angle to the direction of extension of the first cooling channel 1221a, and the outlet end is located on the side away from the inlet of the first cooling channel 1221a (corresponding to the inlet end being closer to the die 1132 in Figure 12). In other words, the refrigerant entering the first cooling channel 1221a from the refrigerant injection port 1222 flows in the direction of the outlet of the first cooling channel 1221a, thereby effectively preventing the refrigerant from hindering the movement of the extrusion substrate 200 within the first cooling channel 1221a.

[0110] Furthermore, since the extruded substrate 200 extruded from the extruder 110 constantly enters the first cooling channel 1221a, the extruded substrate 200 within the first cooling channel 1221a can be continuously pushed toward the outlet of the first cooling channel 1221a.

[0111] Furthermore, referring to Figures 11 to 13, the first cooling pipe 122 can be provided with a plurality of refrigerant injection ports 1222, some of which are spaced apart in the circumferential direction of the pipe body 1221, and some of which are spaced apart in the extending direction of the first cooling channel 1221a. Since the refrigerant is injected onto the outer surface of the extruded substrate 200 through each refrigerant injection port 1222, the refrigerant can envelop the outer surface of the extruded substrate 200, thereby causing the extruded substrate 200 to exhibit a "floating" state within the first cooling channel 1221a, isolated from the inner wall of the first cooling channel 1221a.

[0112] Furthermore, in order to obtain a good "float" effect, more preferably, the injection pressure of the refrigerant injection port 1222 located below the first cooling channel 1221a can be made greater than the injection pressure of the refrigerant injection port 1222 located above the first cooling channel 1221a, thereby counteracting the gravity of the extruded substrate 200.

[0113] The refrigerant surrounds the outer surface of the extrusion substrate 200, and the refrigerant isolates the extrusion substrate 200 from the inner wall of the first cooling channel 1221a. As a result, the extrusion substrate 200 does not come into contact with the inner wall of the first cooling channel 1221a, and therefore, the problem of the extrusion substrate 200 deforming due to friction with the inner wall of the first cooling channel 1221a can be effectively prevented.

[0114] For illustrative purposes, referring to Figure 14, the curing apparatus 120 may also include a refrigerant supply (not shown) and a second cooling pipe 123, the second cooling pipe 123 including a first inner pipe 1231 and a first outer pipe 1232, the first inner pipe 1231 having a second cooling channel 1231a that accommodates the extruded substrate 200, a first refrigerant cavity 123a formed between the first inner pipe 1231 and the first outer pipe 1232, a communication channel 1231b connecting the first refrigerant cavity 123a and the second cooling channel 1231a in the side wall of the first inner pipe 1231, and the refrigerant supply is in communication with the first refrigerant cavity 123a.

[0115] In other words, the extruded substrate 200 from the extruder 110 enters the second cooling channel 1231a, and the refrigerant supplied from the refrigerant supplier enters the first refrigerant cavity 123a, enters the second cooling channel 1231a via the connecting channel 1231b, and comes into direct contact with the extruded substrate 200.

[0116] The number of connecting channels 1231b may be one or multiple.

[0117] Referring to Figure 14, if there are multiple communication channels 1231b, some of the communication channels 1231b can be spaced apart in the circumferential direction of the first inner pipe 1231, and some of the communication channels 1231b can be spaced apart in the extending direction of the second cooling channel 1231a. This allows the refrigerant in the first refrigerant cavity 123a to enter the second cooling channel 1231a from multiple directions and multiple positions, and the refrigerant flowing into the second cooling channel 1231a also envelops the outer surface of the extruded substrate 200, enabling the extruded substrate 200 to exhibit a "floating" state isolated from the inner wall of the second cooling channel 1231a.

[0118] Furthermore, referring to Figure 14, the communication channel 1231b has an inlet end that communicates with the first refrigerant cavity 123a and an outlet end that communicates with the second cooling channel 1231a. The communication channel 1231b is provided at an inclination with respect to the extending direction of the second cooling channel 1231a, and the outlet end is located on the side away from the inlet of the second cooling channel 1231a (corresponding to the inlet end being closer to the die 1132 in Figure 14). In other words, the refrigerant entering the second cooling channel 1231a from the communication channel 1231b flows in the direction of the outlet of the second cooling channel 1231a, thereby effectively preventing the refrigerant from hindering the movement of the extrusion substrate 200 within the second cooling channel 1231a.

[0119] In other embodiments, the extrusion substrate 200 may be in contact with the inner wall of the first cooling channel 1221a, and the inner wall of the first cooling channel 1221a may be set to a smooth surface in order to reduce friction with the extrusion substrate 200.

[0120] In another embodiment, the extrusion substrate and the refrigerant can be subjected to indirect heat exchange.

[0121] Indirect heat exchange refers to a process where the heat exchange media do not come into direct contact with each other during the heat exchange process. In other words, the extruded substrate and the refrigerant do not come into direct contact, but instead exchange heat indirectly through an intermediate component.

[0122] For illustrative purposes, referring to Figure 15, the curing apparatus 120 may include a refrigerant supply (not shown) and a third cooling pipe 124, the third cooling pipe 124 including a second inner pipe 1241 and a second outer pipe 1242, the second inner pipe 1241 having a heat exchange passage 1241a, a second refrigerant cavity 124a for storing refrigerant formed between the second inner pipe 1241 and the second outer pipe 1242, the heat exchange passage 1241a used to accommodate the extrusion substrate 200, and the refrigerant supply is in communication with the second refrigerant cavity 124a. The extruded substrate 200, extruded from the extruder 110, enters the heat exchange channel 1241a, comes into contact with the second inner tube 1241 and performs heat exchange. The second inner tube 1241, having absorbed the heat from the extruded substrate 200, then performs further heat exchange with the refrigerant. This corresponds to indirect heat exchange between the extruded substrate 200 and the refrigerant via the side walls of the second inner tube 1241.

[0123] Furthermore, the inner surface of the heat exchange channel 1241a formed by the second inner tube 1241 is generally a smooth surface. For example, the roughness of the inner surface of the second inner tube 1241 can be Ra1.2μm to Ra0.08μm (including Ra1.2μm and Ra0.08μm), and the frictional force between the smooth inner surface and the outer surface of the extruded substrate 200 is small, which does not cause deformation of the extruded substrate 200.

[0124] The advantage of indirect heat exchange between the extruded substrate and the refrigerant lies in its ability to effectively avoid problems such as expansion deformation and cracking that can occur when the extruded substrate comes into direct contact with the refrigerant.

[0125] In one embodiment, after cooling and curing the extruded substrate, the manufacturing method may further include hot-air drying of the extruded substrate.

[0126] Hot air drying is a process that uses a hot air blower, oven, or dryer to evaporate the moisture from the extruded substrate after cooling and curing. If the extruded substrate contains a large amount of volatile lubricant, hot air drying can also remove the volatile lubricant.

[0127] For example, referring to Figures 2 to 5, a hot air dryer 130 can be installed in the manufacturing apparatus 100. The hot air dryer 130 includes a housing 131, a heating plate 132, and a fan 133. The heating plate 132 is located inside the housing 131, and the fan 133 is in communication with the housing 131. The heating plate 132 is used to heat the air inside the housing 131, and the fan 133 works in cooperation with the heating plate 132 to create a heat circulation inside the housing 131, thereby evaporating moisture and other substances in the extrusion substrate 200.

[0128] Referring to Figures 2 to 5, in order to facilitate the transport of the extrusion substrate 200, the manufacturing apparatus 100 can be equipped with a second transport device 160 having a second conveyor belt 161, a part of the structure of the second conveyor belt 161 located inside the housing 131, and the second transport device 160 can send the extrusion substrate 200 after cooling and hardening into the housing 131 via the second conveyor belt 161, and transport the extrusion substrate 200 that has undergone hot air drying out from inside the housing 131.

[0129] Furthermore, referring to Figures 2 to 5, multiple heating plates 132 can be installed inside the housing 131, some of which can be installed above the second conveyor belt 161, and others below the second conveyor belt 161. This means that the extrusion substrate 200 can be heated by hot air from both above and below, resulting in uniform heating of the extrusion substrate 200. As a result, not only is the stability of the shape of the extrusion substrate 200 improved, but the dewatering efficiency is increased and the load on a single heating plate is reduced.

[0130] The temperature of the hot air drying can be adjusted as needed; for example, the temperature of the hot air drying can be 50°C to 200°C (including 50°C and 200°C).

[0131] If the hot air drying temperature is below 50°C, the drying time is long, production efficiency is low, the required equipment footprint is large, and production costs are high. If the hot air drying temperature is around 100°C, the extruded substrate can be dried slowly at a low temperature, effectively reducing the moisture content in the extruded substrate while retaining as much of the aroma components and active substances (e.g., plant alkaloids, smoke-generating agents) in the raw materials as possible, thus ensuring product quality. If the hot air drying temperature exceeds 200°C, the moisture on the surface of the extruded substrate evaporates rapidly, while the evaporation of moisture from the inside is relatively slow. This causes the surface of the extruded substrate to shrink rapidly, which is detrimental to the uniform stability of the shape and components of the extruded substrate. Furthermore, aroma components and active substances (e.g., plant alkaloids, smoke-generating agents) in the raw materials are easily lost due to heat, resulting in high manufacturing costs, reduced product quality, and a poor user experience. Therefore, a hot air drying temperature between 50°C and 200°C is a more reasonable temperature range.

[0132] Hot-air dried extruded substrates exhibit low shrinkage, short drying times, mature methods and equipment, and ease of achieving continuous production. Combining room-temperature extrusion molding with hot-air drying results in lower equipment investment costs, the ability to conduct continuous production, high production efficiency, low manufacturing costs, and uniform, stable extruded substrates with high processability.

[0133] More preferably, the hot air drying temperature can be 75°C to 125°C (including 75°C and 125°C).

[0134] In one embodiment, auxiliary drying can be performed using at least one of microwaves and ultrasound during the hot air drying process. That is, auxiliary drying may be performed using microwaves, auxiliary drying may be performed using ultrasound, or auxiliary drying may be performed using microwaves and ultrasound simultaneously.

[0135] Microwave-assisted drying refers to a process in which microwaves generated by a microwave generator cause polar molecules inside the extruded substrate to vibrate violently, generating heat and promoting the evaporation of moisture from the extruded substrate. Microwave-assisted drying can shorten drying time and improve the retention rate of aroma components and active substances in the extruded substrate.

[0136] Ultrasonic-assisted drying refers to a method that uses an ultrasonic device to induce a "cavitation" effect on the moisture inside the extruded substrate, thereby lowering the evaporation temperature of the moisture and promoting its evaporation. Ultrasonic-assisted drying can shorten the drying time and improve the retention rate of aroma components and active substances in the extruded substrate.

[0137] For example, referring to Figures 3 and 5, the hot air drying apparatus 130 can have auxiliary devices 134 installed inside the housing 131. The auxiliary devices 134 may be installed above the heating plate 132, below the heating plate 132, or to the side of the conveyor belt. If multiple auxiliary devices 134 are installed inside the housing 131, at least two of the above, below, and to the side of the heating plate 132 can be equipped with auxiliary devices 134.

[0138] The range of microwaves or ultrasonic waves emitted by the auxiliary device 134 located above or below the heating plate 132 can heat the extrusion substrate 200 more uniformly. Microwaves or ultrasonic waves emitted by the auxiliary device 134 located to the side of the conveyor belt can have less energy loss and improve the overall heating rate of the extrusion substrate 200.

[0139] In one embodiment, the moisture content of the extruded substrate after hot air drying can be 3% to 20% (including 3% and 20%) of the total weight of the extruded substrate.

[0140] If the moisture content of the extruded substrate is less than 3%, the off-flavors generated from the aerosol-generating substrate during the user's inhalation process will increase, degrading the user's inhalation experience. Furthermore, if the dried extruded substrate undergoes further processing (i.e., step S20 is not the final step of the manufacturing method), the dried extruded substrate will be more prone to crumbling during subsequent processing, leading to a higher defect rate in subsequent production and increased production costs. If the moisture content of the extruded substrate exceeds 20%, the moisture content of the smoke during the heating and inhalation process of the aerosol-generating substrate will increase, making it difficult for the smoke temperature to decrease, which can easily cause the user to feel that their mouth is hot during inhalation, thus degrading the user's inhalation experience. Therefore, by controlling the moisture content of the dried extruded substrate to within the range of 3% to 20% of the total weight of the extruded substrate, the user's inhalation experience can be effectively improved, and the defect rate in subsequent production can also be reduced for extruded substrates that undergo further processing after drying.

[0141] More preferably, the moisture content of the extruded substrate after negative pressure drying can be 4% to 13% (including 4% and 13%) of the total weight of the extruded substrate.

[0142] Drying of the extruded substrate is not limited to hot air drying; in some other embodiments, the extruded substrate can also be dried using methods such as microwave heating, resistance heating, or infrared heating.

[0143] In one embodiment, the manufacturing method may further include performing a fragmentation of the extruded substrate after cooling and curing, prior to hot-air drying of the extruded substrate.

[0144] Since the length of the extruded substrate produced by room-temperature extrusion molding is usually relatively long, the extruded substrate can be cut to the required length depending on the different application.

[0145] Referring to Figures 2 to 5, the manufacturing apparatus 100 is equipped with a cutting device 150 having a cutting tool (not shown), and the extrusion substrate 200 is cut through the cutting tool.

[0146] There are various methods of separation; for example, in one embodiment, physical contact separation can be employed in which the separation tool comes into contact with the extrusion substrate, that is, the separation tool comes into direct contact with the extrusion substrate. Physical contact separation includes, but is not limited to, rotary cutter cutting, cutting blade cutting, wire cutting, roll cutting, and crimping.

[0147] In another embodiment, a non-physical contact separation method may be employed in which the separation tool and the extrusion substrate are separated, meaning the separation tool itself does not physically contact the extrusion substrate. Non-physical contact separation methods include, but are not limited to, laser cutting, plasma cutting, air knife cutting, and water jet cutting.

[0148] As the extruded substrate hardens through cooling and hardening, it becomes easier to break apart, and the resulting cross-section does not deform, resulting in a more orderly and perfect cut surface.

[0149] Furthermore, the circumference and straightness of the extruded substrate can be corrected using a jig before cutting.

[0150] In some embodiments, the segmentation step can be omitted, meaning that the extrusion substrate can be directly extruded to a set length by room-temperature extrusion. For example, after the extrusion substrate is extruded using a vertical extrusion method, it can naturally detach due to gravity once it reaches or approaches the set length, thereby reducing the subsequent segmentation step and lowering production costs.

[0151] In one embodiment, the components of the mixed material include a solid material and a liquid material, and before performing room-temperature extrusion molding on the mixed material, the manufacturing method may further include supplying the solid material and the liquid material in two separate modules.

[0152] Solid materials refer to materials that are solid, and liquid materials refer to materials that are liquid. In other words, some components of a mixed material are solid, and some components are liquid, and the mixed material is formed after the solid and liquid materials are mixed together.

[0153] Furthermore, a mixed material formed by mixing solid and liquid materials has a uniform form and can no longer be separated into solid and liquid materials.

[0154] For example, in a case where plant raw materials, auxiliary raw materials, and adhesive raw materials are used as solid materials, and smoke generating raw materials and fragrance raw materials are used as liquid materials, the solid materials such as plant raw materials, auxiliary raw materials, and adhesive raw materials, and the liquid materials such as smoke generating raw materials and fragrance raw materials can be added to the barrel of the extruder, respectively, and the solid materials and liquid materials can be mixed in the barrel of the extruder.

[0155] The advantage of supplying solid and liquid materials in two separate modules is that it reduces the cost of pre-processing mixed materials, ensures continuity of the production process, improves production efficiency, and enhances product consistency and uniformity.

[0156] Furthermore, supplying solid and liquid materials in two separate modules may include the following steps: Adding the solid material, and then adding the liquid material to the solid material when the solid material has moved along the material transport direction to the liquid material addition location.

[0157] In other words, first a solid material is added to the extruder, and after the solid material enters the extruder barrel, it moves along the material transport direction toward the extruder die. When the solid material has moved along the material transport direction to the liquid material addition position, the liquid material is added to the extruder again, so that the liquid material and solid material are mixed in the extruder barrel.

[0158] Furthermore, the supply volume and supply speed can be determined according to the extruder's production speed and the ratio of each raw material in the mixture.

[0159] For example, referring to Figures 2 to 5, the extruder 110 can be provided with a solid material supply port 114 and a liquid material supply port 115 that communicate with the barrel 111 of the extruder 110, with the liquid material supply port 115 located downstream of the solid material supply port 114 in the material transport direction.

[0160] The number of solid material supply ports 114 may be one or multiple. If multiple solid material supply ports 114 are provided, each solid material supply port 114 may be supplied with the same solid material or with different solid materials.

[0161] Similarly, the number of liquid material supply ports 115 may be one or multiple. If multiple liquid material supply ports 115 are provided, each liquid material supply port 115 may be supplied with the same liquid material or with different liquid materials.

[0162] Furthermore, whether it is multiple solid material supply ports 114 or multiple liquid material supply ports 115, both can be made into a removable structure, making it easy to assemble the required number of solid material supply ports 114 and liquid material supply ports 115.

[0163] Extruders primarily transport mixed materials by the rotation of a screw, but the space between the screw and the inner wall of the extruder barrel is not completely sealed; in other words, there is a gap between the screw and the inner wall of the extruder barrel. If liquid material is added first, it is likely to leak through this gap. Therefore, by adding solid material first, and then adding liquid material again once the solid material has moved along the material transport direction to the liquid material addition position, leakage of liquid material can be effectively avoided.

[0164] In some embodiments, the mixed material may not be supplied separately as solid and liquid materials. For example, the solid and liquid materials may be mixed first to form a mixed material (abbreviated as mixed slurry supply), and then the mixed material may be added to the barrel of the extruder.

[0165] The advantage of supplying a mixed slurry is that the mixed materials have good consistency, ensuring the uniformity and stability of the product.

[0166] Furthermore, referring to Figures 3 and 5, in the case of mixed slurry supply, another screw 112 can be installed at the supply port (when mixed slurry supply is adopted, the solid material supply port 114 in Figures 3 and 5 corresponds to the supply port) to further homogenize the mixed slurry.

[0167] In some embodiments, referring to Figures 3 and 5, the extruder 110 can be further provided with a vacuum port 117 communicating with the barrel 111, allowing the barrel 111 of the extruder 110 to be vacuumed after feeding, thereby creating negative pressure inside the barrel 111, which allows for degassing of the mixed material and is advantageous for thorough mixing of each raw material in the mixed material.

[0168] In one embodiment, after hot-air drying of the extrusion substrate, the manufacturing method may further include packaging the extrusion substrate.

[0169] For example, referring to Figures 2 to 5, the manufacturing apparatus 100 can be equipped with a packaging apparatus 180 to package the extrusion substrate 200.

[0170] There are various packaging methods; for example, a packaging layer can be wrapped around the outer surface of an extruded substrate.

[0171] The packaging layer includes, but is not limited to, media consumables such as roll paper, paper tubes, and aluminum foil, and the extruded substrate wrapped in the packaging layer corresponds to the finished aerosol-generating substrate.

[0172] In some embodiments, the extruded substrate wrapped in a packaging layer can also be combined with other functional sections, such as a cooling section or a filtering section, to form an aerosol-generating product.

[0173] For example, the extruded substrate can also be sealed and packaged.

[0174] In other words, the extruded substrate can be directly sealed without wrapping a packaging layer around its outer surface; for example, the extruded substrate can be sealed in a blister pack container. The sealed extruded substrate is equivalent to a finished aerosol-generating substrate. After removing the packaging, the sealed extruded substrate can be used directly in an electron atomizer.

[0175] In the description of this application, any reference to terms such as “in one embodiment,” “in several embodiments,” “in other embodiments,” “in yet another embodiment,” or “exemplary” means that the specific features, structures, materials, or properties described in relation to such embodiment or example are included in at least one embodiment or example of the embodiments of this application. In this application, the exemplary expressions of the above terms do not necessarily refer to the same embodiment or example. Furthermore, the specific features, structures, materials, or properties described may be combined in an appropriate manner in any one or more embodiments or examples. Furthermore, a person skilled in the art may combine different embodiments or examples and features of different embodiments or examples described in this application, provided that they do not conflict with each other.

[0176] The foregoing describes only preferred embodiments of this application and does not limit it; to those skilled in the art, this application is subject to various modifications and changes. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of this application should all be included within the scope of protection of this application.

Claims

1. A method for producing an aerosol-generating substrate, The mixed material is subjected to room-temperature extrusion molding to form an extrusion substrate on the mixed material, A method for producing an aerosol-generating substrate, comprising performing cool curing on the extruded substrate.

2. Performing cooling and curing on the extruded substrate is, This includes cooling the extruded substrate by placing it in a low-temperature environment, wherein the temperature of the low-temperature environment is lower than the curing temperature of the extruded substrate. The manufacturing method according to claim 1.

3. The curing temperature is -100°C to 60°C, and the temperature of the low-temperature environment is -270°C to 60°C. The manufacturing method according to claim 2.

4. Performing cooling and curing on the extruded substrate is, This includes directly exchanging heat between the extruded substrate and the refrigerant, or indirectly exchanging heat between the extruded substrate and the refrigerant. The manufacturing method according to claim 1.

5. Direct heat exchange between the extrusion substrate and the refrigerant is, This includes spraying the refrigerant onto the outer surface of the extruded substrate, The manufacturing method according to claim 4.

6. The hardness of the extruded substrate after cooling and curing is 1 HB to 200 HB, and / or The temperature of the extruded substrate after cooling and curing is -50°C to 5°C. The manufacturing method according to any one of claims 1 to 5.

7. The extrusion temperature for the aforementioned room-temperature extrusion molding is 35°C to 70°C, and / or The extrusion pressure for the aforementioned room-temperature extrusion molding is 0.5 bar to 300 bar. The manufacturing method according to any one of claims 1 to 5.

8. The extrusion pressure is between 20 bar and 80 bar. The manufacturing method according to claim 7.

9. The extrusion method for the aforementioned room-temperature extrusion molding is one of the following: horizontal extrusion, vertical extrusion, and inclined extrusion. The manufacturing method according to any one of claims 1 to 5.

10. After cooling and curing the extruded substrate, the manufacturing method is as follows: The method further includes performing hot air drying on the extruded substrate. The manufacturing method according to any one of claims 1 to 5.

11. The temperature for the hot air drying is 50°C to 200°C. The manufacturing method according to claim 10.

12. In the hot air drying process, the manufacturing method is The method further includes performing auxiliary drying using at least one of microwaves and ultrasound. The manufacturing method according to claim 10.

13. The water content of the extruded substrate after hot air drying is 3% to 20% of the total weight of the extruded substrate. The manufacturing method according to claim 10.

14. Before performing hot air drying on the extruded substrate, the manufacturing method is as follows: The further method includes performing a fragmentation on the extruded substrate after cooling and curing. The manufacturing method according to claim 10.

15. In 100 parts by weight of the aforementioned mixed material, 30 to 90 parts of plant raw materials, 1 to 15 parts of auxiliary raw materials, 5 to 30 parts of smoke generating agent raw materials, 1 to 10 parts of adhesive raw materials, and 1 to 15 parts of fragrance raw materials are included. The manufacturing method according to any one of claims 1 to 5.

16. Apparatus for producing aerosol-generating substrates, An extruder configured to perform room-temperature extrusion molding on a mixed material to form an extrusion substrate on the mixed material, An apparatus for producing an aerosol-generating substrate, comprising a curing apparatus configured to perform cooling and curing on the extruded substrate.

17. The curing apparatus comprises a refrigerant supply and a container, the container having a containment cavity for containing the extruded substrate, and the refrigerant supply is used to supply a refrigerant into the containment cavity. The manufacturing apparatus according to claim 16.

18. The container is provided with a liquid injection groove that communicates with the containment cavity. The manufacturing apparatus according to claim 17.

19. The manufacturing apparatus comprises a first transport device having a first conveyor belt, and a portion of the structure of the first conveyor belt is located within the containment cavity. The manufacturing apparatus according to claim 17.

20. Multiple media storage grooves are provided on the first conveyor belt, and each media storage groove extends along the conveying direction of the first conveyor belt. The manufacturing apparatus according to claim 19.

21. The curing apparatus comprises a refrigerant supply and a first cooling pipe, the first cooling pipe comprising a pipe body having a first cooling channel and a refrigerant injection port provided on the side wall of the pipe body and communicating with the first cooling channel, the first cooling channel is used to contain the extruded substrate, and the refrigerant supply injects refrigerant into the first cooling channel via the refrigerant injection port. The manufacturing apparatus according to claim 16.

22. The number of refrigerant injection ports is multiple, some of the refrigerant injection ports are provided at intervals in the circumferential direction of the pipe body, some of the refrigerant injection ports are provided at intervals in the extending direction of the first cooling flow path, and / or The refrigerant injection port has an inlet end and an outlet end that communicates with the first cooling passage, the refrigerant injection port is provided at an inclination with respect to the extending direction of the first cooling passage, and the outlet end is located on the side away from the inlet of the first cooling passage from the inlet end. The manufacturing apparatus according to claim 21.

23. The curing apparatus comprises a refrigerant supply and a second cooling pipe, the second cooling pipe comprising a first inner pipe and a first outer pipe, the first inner pipe having a second cooling channel for containing the extruded substrate, a first refrigerant cavity formed between the first inner pipe and the first outer pipe, a communication channel connecting the first refrigerant cavity and the second cooling channel provided in the side wall of the first inner pipe, and the refrigerant supply communicates with the first refrigerant cavity. The manufacturing apparatus according to claim 16.

24. The number of the aforementioned communication channels is multiple, some of the communication channels are provided at intervals in the circumferential direction of the first inner pipe, some of the communication channels are provided at intervals in the extending direction of the second cooling channel, and / or The communication channel has an inlet end that communicates with the first refrigerant cavity and an outlet end that communicates with the second cooling channel, the communication channel is provided at an inclination with respect to the extending direction of the second cooling channel, and the outlet end is located on the side away from the inlet of the second cooling channel from the inlet end. The manufacturing apparatus according to claim 23.

25. The curing apparatus comprises a refrigerant supply and a third cooling pipe, the third cooling pipe comprising a second inner pipe and a second outer pipe, the second inner pipe having a heat exchange channel, a second refrigerant cavity for storing refrigerant formed between the second inner pipe and the second outer pipe, the heat exchange channel used to accommodate the extruded substrate, and the refrigerant supply communicates with the second refrigerant cavity. The manufacturing apparatus according to claim 16.

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