Apparatus and method for manufacturing a sheet of aerosol generating substrate for aerosol generating articles.

Abstract

An apparatus for producing a sheet of aerosol-generating substrate for an aerosol-generating article comprises a kneader (5) configured to knead a mixture using a recipe and water to form a soft mass (Do), and rollers operably positioned downstream of the kneader (5) and configured to flatten the soft mass (Do) to form a sheet (10). The rollers comprise a pair of diffusion rollers (28A, 28B) comprising a first diffusion roller (31) having a first rotation axis (XX) and a first radial outer surface, and a second diffusion roller (32) having a second rotation axis (YY) and a second radial outer surface. The first radial outer surface faces the second radial outer surface and defines a passage (33) for the soft mass (Do). One or both of the first and second radial outer surfaces have reliefs and depressions for spreading the soft mass (Do) into a sheet having at least one non-uniform surface.

Description

Technical Field

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

Background Art

[0002] Aerosol generating articles or heat-not-burn tobacco in which the aerosol generating substrate is heated rather than burned are known in the art. The aerosol generating substrate is, for example, a sheet of reconstituted tobacco, a tobacco-free herbaceous or plant-based sheet, or a plastic fiber-based sheet, or a biodegradable fiber-based sheet. The sheets are assembled and enclosed in wrapping to form a rod of the aerosol generating substrate.

[0003] 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 the heat source, within the heat source, around the heat source, 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. When the released compounds cool, they condense to form an aerosol.

[0004] The sheet of the aerosol generating substrate may be prepared by a rolling method or a casting method depending on the amount of water used in the process. When the amount of water in the starting mixture is low, the mixture becomes something like a paste or dough, and thus the sheet is usually obtained by a rolling process. To flatten this doughy material to a certain thickness, the dough is processed through a plurality of successive rolling steps until the desired thickness of the material is obtained.

[0005] For example, document WO2020058814A1 discloses a method for producing reconstituted tobacco, in which the solid components of tobacco are ground to particle size. The ground product thus obtained is mixed with water, at least one binder, and at least one aerosol-forming material until a mixture having a liquid content of about 35-40 percent is obtained. A mixture-forming unit forms multiple parts of the mixture. A first lamination unit 100 is configured to obtain continuous flakes from the parts of the mixture, and a series of further rolling passages through lamination rollers allows for obtaining flakes having a substantially constant thickness. The flakes are then dried to reduce their liquid content to about 8-15 percent.

[0006] It is desirable to have an apparatus and method for manufacturing a sheet of aerosol-generating substrate that allows for precise control of the thickness and quality of the sheet.

[0007] It is desirable to have an apparatus and method for producing an aerosol-generating substrate sheet in which the obtained aerosol-generating substrate sheet has a desired uniform thickness.

[0008] It is desirable to have an apparatus and method for producing an aerosol-generating substrate sheet that is free from defects and inhomogeneity.

[0009] It is desirable to have a method for producing a sheet of aerosol-generating substrate in which the resulting sheet has a target thickness of less than a millimeter.

[0010] Furthermore, it is desirable to achieve the above characteristics of the aerosol-generating substrate sheet through simple and reliable equipment and processes.

[0011] Furthermore, it is desirable to achieve the above characteristics of the sheet through equipment that does not require continuous and accurate calibration of process parameters such as the distance between lamination rollers, the pressure applied to the material, and the speed at which the material passes through the lamination rollers. In fact, in prior art equipment and methods, inefficient calibration of these parameters or non-uniform distribution of the soft mass material across the width of the lamination rollers can result in defects such as holes in the soft mass sheet. [Overview of the Initiative]

[0012] This disclosure also relates to an apparatus for producing a sheet of aerosol-generating substrate for aerosol-generating articles. The apparatus comprises rollers configured to flatten a lump to form a sheet. The apparatus may also comprise a kneader configured to knead a mixture using a recipe and water to form a lump. The rollers may be operably positioned downstream of the kneader. The apparatus may also comprise a dryer operably positioned downstream of the rollers and configured to dry the sheet to obtain a sheet of aerosol-generating substrate for aerosol-generating articles. The apparatus may also comprise a cooler located downstream of the dryer for cooling the sheet of aerosol-generating substrate. The rollers may comprise a pair of diffusion rollers. The pair of diffusion rollers may comprise a first diffusion roller having a first axis of rotation and a first radial outer surface. The pair of diffusion rollers may comprise a second diffusion roller having a second axis of rotation and a second radial outer surface. The first and second axes of rotation may be parallel to each other. The first radial outer surface may face the second radial outer surface to demarcate passages in the lump. At least one of the first radial outer surface and the second radial outer surface has reliefs and depressions for spreading the soft mass onto a sheet provided with at least one non-uniform surface.

[0013] The inventors found that the disclosed apparatus makes it possible to obtain a sheet that is free from defects (such as undesirable holes) and non-uniformity, and that has a desired uniform thickness. In fact, the radial outer surface provided with reliefs and depressions allows for the even distribution of the soft mass material across the width of the roller, even when the soft mass has high consistency.

[0014] The inventors found that the disclosed apparatus enables the manufacture of sheets having target thicknesses of less than a millimeter and controlled thicknesses.

[0015] The inventors found that the disclosed apparatus makes it possible to manufacture sheets as desired through a limited number of rollers.

[0016] The inventors also found that the disclosed apparatus makes it possible to manufacture sheets as desired without requiring precise calibration of process parameters such as the distance between lamination rollers, the pressure applied to the material, and the speed at which the material passes through the lamination rollers.

[0017] The first radial outer surface has a first maximum radius "R1", and the second radial outer surface has a second maximum radius "R2". The distance "d" between the first axis of rotation and the second axis of rotation may be greater than the sum of the first maximum radius "R1" and the second maximum radius "R2". The minimum distance "B" of the passage is B = d - (R1 + R2). The minimum distance "B" may be measured in a plane containing the first axis of rotation and the second axis of rotation, along a direction perpendicular to the first axis of rotation and the second axis of rotation.

[0018] In some embodiments, both the first radial outer surface and the second radial outer surface have reliefs and recesses. In other embodiments, only one of the first radial outer surface and the second radial outer surface has reliefs and recesses.

[0019] In some embodiments, in the passage, the relief of the first diffusion roller is spaced apart from the relief of the second diffusion roller by a minimum distance "B". The minimum distance "B" may be 1 mm to 10 mm, optionally 2 mm to 8 mm, optionally 4 mm to 7 mm, and optionally 6 mm.

[0020] In some embodiments, the relief includes a block.

[0021] In some embodiments, the recess includes a hollow separated between the blocks.

[0022] In some embodiments, the relief includes a protrusion.

[0023] In some embodiments, the recess has a groove separated between the protrusions.

[0024] The protrusion and the groove may extend from the first axial end to the second axial end of the first diffusion roller and / or the second diffusion roller. The protrusion and the groove may cover all or part of the first radially outer surface of the first diffusion roller and / or the second radially outer surface of the second diffusion roller. The first radially outer surface and / or the second radially outer surface has / have a corrugated or wavy shape.

[0025] In some embodiments, the protrusion and the groove are parallel to their respective first rotation axis or second rotation axis.

[0026] In some embodiments, the protrusion and the groove are inclined with respect to their respective first rotation axis or second rotation axis. <00​​​​​​​​​The protrusions and grooves may be circular.

[0030] In a cross-section including each first rotation axis or second rotation axis, the protrusion may have a rectangular contour, a triangular contour, or an arch-shaped contour.

[0031] In a cross-section including each first rotation axis or second rotation axis, the upper part of the protrusion may be flat, may have a rounded shape, or may be edged.

[0032] In a cross-section including each first rotation axis or second rotation axis, the groove may have a rectangular contour, a triangular contour, or an arch-shaped contour.

[0033] In a cross-section including each first rotation axis or second rotation axis, the bottom of the groove may be flat, may have a rounded shape, or may be edged.

[0034] In some embodiments, the upper parts of the protrusions on the first radially outer surface and the upper parts of the protrusions on the second radially outer surface face each other.

[0035] The pitch "C" of the protrusions may be 4 mm to 50 mm, optionally 15 mm to 30 mm, optionally 17 mm to 25 mm, and optionally 20 mm.

[0036] In some embodiments, the recess further includes a plurality of gaps crossing the protrusions and grooves. The gaps may extend partially or completely along the length of each first diffusion roller or second diffusion roller. The gaps may be parallel or oblique to each first rotation axis or second rotation axis.

[0037] The radial distance "A" between the bottom of the recess or groove and the upper part of the relief or protrusion may be 5 mm to 40 mm, optionally 10 mm to 25 mm, optionally 10 mm to 20 mm, and optionally 15 mm.

[0038] The radial depth of the gap may be less than or equal to the radial distance "A", and may optionally be half the radial distance "A".

[0039] The axial length "L" of the first and second diffusion rollers may be between 1000 mm and 2100 mm.

[0040] The diameter "D" of the first and second diffusion rollers may be 100mm to 600mm, or optionally 400mm.

[0041] In some embodiments, the first and second diffusion rollers of a pair of diffusion rollers have the same shape. In other embodiments, the first and second diffusion rollers of a pair of diffusion rollers may have different shapes.

[0042] In some embodiments, the first and second diffusion rollers of a pair of diffusion rollers are the same size. In other embodiments, the first and second diffusion rollers of a pair of diffusion rollers may be different sizes.

[0043] In some embodiments, the reliefs and recesses of the first and second radial outer surfaces have the same shape. In other embodiments, the reliefs and recesses of the first and second radial outer surfaces may have different shapes.

[0044] In some embodiments, the roller comprises multiple pairs of diffusion rollers positioned sequentially.

[0045] In some embodiments, the radial distance "A" between the bottom of the recess or groove and the top of the relief or bulge of a pair of diffusion rollers located upstream is greater than the radial distance "A" between the bottom of the recess or groove and the top of the relief or bulge of a pair of diffusion rollers located downstream.

[0046] In some embodiments, the pitch "C" of the bumps of the upstream pair of diffusion rollers is greater than the pitch "C" of the bumps of the downstream pair of diffusion rollers.

[0047] In some embodiments, the minimum distance "B" of the passage of a pair of diffusion rollers located upstream, measured in a plane including the first and second rotation axes and along a direction perpendicular to the first and second rotation axes, is greater than the minimum distance "B" of the passage of a pair of diffusion rollers located downstream.

[0048] In some embodiments, the roller further comprises at least one pair of flattening rollers positioned downstream of the diffusion roller, and optionally a plurality of pairs of flattening rollers arranged sequentially. The flattening rollers may have flat radial outer surfaces, i.e., straight, parallel surfaces without corrugations separating each of the passages between them.

[0049] The inventors found that by spreading the soft mass with diffusion rollers before the subsequent planarization step, they could ensure stable input to the first pair of planarization rollers and obtain a seamless sheet.

[0050] If multiple pairs of flattening rollers are provided, the thickness is gradually reduced until the target is reached. The width of the sheet may increase while the soft mass sheet is being flattened. A conveyor belt may be placed between the rollers to advance the product.

[0051] Each flattening roller may be equipped with a scraper to clean the roller surface from potential residue.

[0052] This disclosure relates to a method for manufacturing a sheet of an aerosol generating substrate for an aerosol generating article.

[0053] The method can be implemented through an apparatus for manufacturing a sheet of aerosol-generating substrate for aerosol-generating articles.

[0054] The apparatus includes rollers configured to flatten a lump to form a sheet. The apparatus may also include a kneader configured to knead a mixture with a recipe and water to form a lump. The rollers may be operably positioned downstream of the kneader. The apparatus may also include a dryer operably positioned downstream of the rollers and configured to dry the sheet to obtain a sheet of aerosol-generating substrate for aerosol-generating articles. The apparatus may also include a cooler located downstream of the dryer to cool the sheet of aerosol-generating substrate. The rollers may include a pair of diffusion rollers.

[0055] The method involves mixing a recipe with water to form a mixture, the recipe may include, as ingredients, plant particles and / or alkaloid particles, a binder, and an aerosol-forming agent.

[0056] The method may include kneading the mixture in a kneader to form a soft mass. The kneader may be a kneader in an apparatus.

[0057] The method involves flattening the lump by passing it through a roller to form a sheet. The roller may be a roller of an apparatus.

[0058] In some embodiments, the method includes drying the sheet in a dryer to obtain a sheet of aerosol-generating substrate for an aerosol-generating article. The dryer may be a dryer for the apparatus.

[0059] Flattening involves passing the lump through a pair of diffusion rollers rotating in opposite directions to spread the lump onto a sheet that has at least one non-uniform surface.

[0060] A pair of diffusion rollers may comprise a first diffusion roller having a first axis of rotation and a first radial outer surface. A pair of diffusion rollers may comprise a second diffusion roller having a second axis of rotation and a second radial outer surface. The first and second axes of rotation may be parallel to each other. The first radial outer surface may face the second radial outer surface to demarcate passages for the lumps. At least one of the first and second radial outer surfaces has reliefs and depressions for spreading the lumps onto a sheet provided with at least one non-uniform surface.

[0061] The first radial outer surface has a first maximum radius "R1", and the second radial outer surface has a second maximum radius "R2". The distance "d" between the first axis of rotation and the second axis of rotation may be greater than the sum of the first maximum radius "R1" and the second maximum radius "R2". The minimum distance "B" of the passage is B = d - (R1 + R2). The minimum distance "B" may be measured in a plane containing the first axis of rotation and the second axis of rotation, along a direction perpendicular to the first axis of rotation and the second axis of rotation.

[0062] In some embodiments, both the first radial outer surface and the second radial outer surface have reliefs and recesses. In other embodiments, only one of the first radial outer surface and the second radial outer surface has reliefs and recesses.

[0063] In some embodiments, in the passage, the relief of the first diffusion roller is spaced a minimum distance "B" from the relief of the second diffusion roller. This minimum distance "B" may be 1 mm to 10 mm, optionally 2 mm to 8 mm, optionally 4 mm to 7 mm, or optionally 6 mm.

[0064] In some embodiments, the relief includes a block.

[0065] In some embodiments, the recessed area includes a hollow space separated from the blocks.

[0066] In some embodiments, the relief includes a raised area.

[0067] In some embodiments, the recessed area includes a groove separated from the raised area.

[0068] The ridges and grooves may extend from the first axial end to the second axial end of the first and / or second diffusion roller. The ridges and grooves may cover all or part of the first radial outer surface of the first diffusion roller and / or the second radial outer surface of the second diffusion roller.

[0069] In some embodiments, the ridges and grooves are parallel to the first or second axis of rotation, respectively.

[0070] In some embodiments, the ridges and grooves are oblique to the first or second axis of rotation, respectively.

[0071] In some embodiments, the ridges and grooves extend around the respective first or second axis of rotation.

[0072] The ridges and grooves may be located in a plane perpendicular to the respective first or second axis of rotation.

[0073] The ridges and grooves may also be circular.

[0074] In the cross-sections containing each first or second axis of rotation, the bulge may have a rectangular, triangular, or arched profile.

[0075] In each cross-section containing the first or second axis of rotation, the top of the protrusion may be flat, rounded, or edged.

[0076] In the cross-sections containing each first or second axis of rotation, the groove may have a rectangular, triangular, or arched profile.

[0077] In each cross-section including the first or second axis of rotation, the bottom of the groove may be flat, rounded, or edged.

[0078] In some embodiments, the upper part of the first radial outer surface ridge and the upper part of the second radial outer surface ridge face each other.

[0079] The pitch "C" of the ridges may be 4mm to 50mm, optionally 15mm to 30mm, optionally 17mm to 25mm, or optionally 20mm.

[0080] In some embodiments, the recesses further comprise a plurality of gaps spanning the ridges and grooves. The gaps may extend partially or completely along the length of each first or second diffusion roller. The gaps may be parallel or oblique to each first or second rotation axis.

[0081] The radial distance "A" between the bottom of the recess or groove and the top of the relief or protrusion may be 5 mm to 40 mm, optionally 10 mm to 25 mm, optionally 10 mm to 20 mm, or optionally 15 mm.

[0082] The radial depth of the gap may be less than or equal to the radial distance "A", and may optionally be half the radial distance "A".

[0083] The axial length "L" of the first and second diffusion rollers may be between 1000 mm and 2100 mm.

[0084] The diameter "D" of the first and second diffusion rollers may be 100mm to 600mm, or optionally 400mm.

[0085] In some embodiments, the first and second diffusion rollers of a pair of diffusion rollers have the same shape. In other embodiments, the first and second diffusion rollers of a pair of diffusion rollers may have different shapes.

[0086] In some embodiments, the first and second diffusion rollers of a pair of diffusion rollers are the same size. In other embodiments, the first and second diffusion rollers of a pair of diffusion rollers may be different sizes.

[0087] In some embodiments, the reliefs and recesses of the first and second radial outer surfaces have the same shape. In other embodiments, the reliefs and recesses of the first and second radial outer surfaces may have different shapes.

[0088] In some embodiments, the roller comprises multiple pairs of diffusion rollers positioned sequentially.

[0089] In some embodiments, the radial distance "A" between the bottom of the recess or groove and the top of the relief or bulge of a pair of diffusion rollers located upstream is greater than the radial distance "A" between the bottom of the recess or groove and the top of the relief or bulge of a pair of diffusion rollers located downstream.

[0090] In some embodiments, the pitch "C" of the bumps of the upstream pair of diffusion rollers is greater than the pitch "C" of the bumps of the downstream pair of diffusion rollers.

[0091] In some embodiments, the minimum distance "B" of the passage of a pair of diffusion rollers located upstream, measured in a plane including the first and second rotation axes and along a direction perpendicular to the first and second rotation axes, is greater than the minimum distance "B" of the passage of a pair of diffusion rollers located downstream.

[0092] In some embodiments, the roller further comprises at least one pair of flattening rollers positioned downstream of the diffusion roller, and optionally a plurality of pairs of flattening rollers positioned after the other. The flattening rollers may have flat radial outer surfaces.

[0093] A sheet provided with at least one non-uniform surface may have protrusions and depressions with a contour similar to the cross-section of the passage.

[0094] In some embodiments, flattening further includes passing a sheet having at least one non-uniform surface between at least one pair of flattening rollers. The flattening rollers may be flattening rollers of an apparatus.

[0095] The maximum thickness of a sheet provided with at least one non-uniform surface may be 10 to 100 times the final thickness of the sheet downstream of the flattening roller.

[0096] The final thickness of the sheet may be 150 μm to 300 μm, or optionally 170 μm to 290 μm.

[0097] In some embodiments, planarization involves passing the soft mass through multiple pairs of diffusion rollers. The multiple pairs of diffusion rollers may be multiple pairs of diffusion rollers in the apparatus.

[0098] In some embodiments, flattening involves passing the soft mass through multiple pairs of flattening rollers. The multiple pairs of flattening rollers may be multiple pairs of flattening rollers of the apparatus.

[0099] In some embodiments, the pressure applied to the soft mass by a pair of diffusion rollers is 20 N / mm to 150 N / mm across the width of the sheet, and optionally 40 N / mm to 80 N / mm.

[0100] The consistency of the soft mass, when measured with a farinograph, can be up to 14 Nm at 25°. The consistency of the soft mass, when measured with a farinograph, can be greater than 14 Nm at 25°, for example, up to 20 Nm.

[0101] The inventors found that when the consistency of the soft mass is low (less than 14 Nm), it is desirable to select a diffusion roller with a larger pitch C and a shorter radial distance A.

[0102] The inventors found that when the consistency of the material is high (i.e., above 14 Nm), multiple pairs of diffusion rollers can be applied, starting with a roller having a higher radial distance "A" and a larger pitch "C", and ending with a pair of diffusion rollers having a lower radial distance "A" and a lower pitch "C".

[0103] The inventors found that when a sheet has such high consistency, a defect-free sheet of the desired thickness can be produced by spreading the soft mass through a diffusion roller before further planarization.

[0104] This can be determined depending on the characteristics of the soft mass, the number of pairs of diffusion rollers and flattening rollers, the distance between each pair of rollers, the shape of the rollers, the pressure on the material, and the speed at which the material enters the rollers.

[0105] The temperature of the pair of diffusion rollers may be room temperature, or -50°C to +50°C relative to room temperature, or optionally -20°C to +20°C.

[0106] The amount of water within the soft mass can be 7% to 60%, optionally 15% to 50%, or optionally 27% to 35% of 100% of the soft mass.

[0107] According to some embodiments, the method includes winding a sheet of aerosol generating substrate onto a master bobbin, and then cutting the master bobbin into smaller bobbins.

[0108] According to some other embodiments, the method includes slitting a sheet of aerosol generating substrate into multiple tapes and winding each tape onto a small bobbin.

[0109] The aerosol-generating substrate sheet may be cooled before winding in the master bobbin or before slitting. Cooling may be carried out in the device's cooler.

[0110] According to some embodiments, the plant and / or alkaloid is ground before mixing to obtain plant and / or alkaloid particles. Grinding may be carried out in a grinder in an apparatus located upstream of the kneader.

[0111] According to some embodiments, after kneading and before flattening, the soft mass is calendered to form a thick sheet.

[0112] This disclosure also relates to a process for manufacturing components of aerosol-generating articles.

[0113] The process may include producing a sheet of aerosol-generating substrate for an aerosol-generating article using an apparatus for producing a sheet of aerosol-generating substrate for an aerosol-generating article disclosed above, and / or a method for producing a sheet of aerosol-generating substrate for an aerosol-generating article disclosed above.

[0114] The process may include collecting sheets of aerosol-generating substrate and winding the aggregate of aerosol-generating substrate sheets into a wrapper to form a continuous rod.

[0115] The process involves 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.

[0116] This disclosure also relates to aerosol-generating articles manufactured in accordance with the processes disclosed above.

[0117] 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.

[0118] As used herein, the term “soft mass” 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.

[0119] 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]

[0120] 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 other embodiments, forms, or aspects described herein.

[0121] Example 1. An apparatus for manufacturing a sheet of aerosol generating substrate for aerosol generating articles, wherein the apparatus is A kneader configured to knead a mixture using a recipe and water to form a soft mass, A roller is movably positioned downstream of the kneader and configured to flatten the soft mass to form a sheet, Any dryer configured to be movably positioned downstream of the rollers and to dry the sheets to obtain sheets of aerosol-generating substrate for aerosol-generating articles, The aerosol generating substrate sheet is cooled by an optional cooler located downstream of the dryer, The roller is equipped with a pair of diffusion rollers, A first diffusion roller having a first axis of rotation and a first radial outer surface, A second diffusion roller having a second axis of rotation and a second radial outer surface, The first axis of rotation and the second axis of rotation are parallel to each other, and the first radial outer surface faces the second radial outer surface, defining a passage for the soft mass. Apparatus wherein at least one of a first radial outer surface and a second radial outer surface has reliefs and depressions for spreading a soft mass onto a sheet having at least one non-uniform surface. Example 2. The apparatus according to Example 1, wherein the first radial outer surface has a first maximum radius "R1", the second radial outer surface has a second maximum radius "R2", and the distance "d" between the first axis of rotation and the second axis of rotation is greater than the sum of the first maximum radius "R1" and the second maximum radius "R2". Example 3. The apparatus according to Example 2, wherein the minimum distance "B" of the passage, measured in a plane containing the first and second rotation axes and along a direction perpendicular to the first and second rotation axes, is B = d - (R1 + R2). Example 4. The apparatus according to any one of Examples 1 to 3, wherein both the first radial outer surface and the second radial outer surface have reliefs and recesses. Example 5. The apparatus according to Example 4, wherein in the passage, the relief of the first diffusion roller is spaced at a minimum distance "B" from the relief of the second diffusion roller. Example 6. The apparatus described in Example 3, or in Example 4 when Example 4 follows Example 3, or in Example 5, wherein the minimum distance "B" is 1 mm to 10 mm, optionally 2 mm to 8 mm, optionally 4 mm to 7 mm, or optionally 6 mm. Example 7. The apparatus according to any one of Examples 1 to 6, wherein the relief includes blocks and the recesses include hollows separated between the aforementioned blocks. Example 8. The apparatus according to any one of Examples 1 to 7, wherein the relief includes raised areas and the recessed areas include grooves defined between the raised areas. Example 9. The apparatus according to Example 8, wherein the ridges and grooves extend from the first axial end to the second axial end of the first and / or second diffusion roller. Example 10. The apparatus according to Example 8 or 9, wherein the ridges and grooves are parallel to the first or second axis of rotation, respectively. Example 11. The apparatus according to Example 8, 9, or 10, wherein the ridges and grooves are oblique to the respective first or second axis of rotation. Example 12. The apparatus according to any of Examples 8 to 11, wherein the ridges and grooves extend around the respective first or second axis of rotation. Example 13. The apparatus according to Example 12, wherein in a cross-section including each first or second axis of rotation, the bulge has a rectangular, triangular, or arched contour. Example 14. The apparatus according to Example 12 or 13, wherein in a cross-section including each first or second axis of rotation, the upper part of the protrusion is flat, rounded, or edged. Example 15. The apparatus according to any one of Examples 12 to 14, wherein in a cross-section including each first or second axis of rotation, the groove has a rectangular, triangular, or arched profile. Example 16. The apparatus according to any one of Examples 12 to 15, wherein in a cross-section including each first or second axis of rotation, the bottom of the groove is flat, rounded, or edged. Example 17. The apparatus according to any one of Examples 12 to 16, wherein the ridges and grooves are located in a plane perpendicular to the respective first or second axis of rotation. Example 18. The apparatus according to any one of Examples 12 to 17, wherein the ridges and grooves are circular. Example 19. The apparatus according to Example 18, in the case where Example 8 is described in Example 4 or 5, wherein the upper part of the first radial outer surface ridge and the upper part of the second radial outer surface ridge face each other. Example 20. The apparatus according to any of Examples 8 to 19, wherein the pitch "C" of the ridges is 4 mm to 50 mm, optionally 15 mm to 30 mm, optionally 17 mm to 25 mm, or optionally 20 mm. Example 21. The apparatus according to any one of Examples 8 to 20, wherein the recess further includes multiple gaps that cross the ridges and grooves. Example 22. The apparatus according to Example 21, wherein the gap extends partially or completely along the length of each first or second diffusion roller. Example 23. The apparatus according to Example 22, wherein the gap is parallel or oblique to each of the first or second axes of rotation. Example 24. The apparatus according to any of Examples 1 to 23, wherein the radial distance "A" between the bottom of the recess or groove and the top of the relief or protrusion is 5 mm to 40 mm, optionally 10 mm to 25 mm, optionally 10 mm to 20 mm, or optionally 15 mm. Example 25. The apparatus according to Example 22, 23, or 24, wherein the radial depth of the gap is less than or equal to the radial distance "A", and optionally half the radial distance A. Example 26. The apparatus according to any of Examples 1 to 25, wherein the axial length "L" of the first diffusion roller and the second diffusion roller is 1000 mm to 2100 mm. Example 27. The apparatus according to any of Examples 1 to 26, wherein the diameter "D" of the first diffusion roller and the second diffusion roller is 100 mm to 600 mm, optionally 400 mm. Example 28. The apparatus according to any of Examples 1 to 27, wherein the first and second diffusion rollers of a pair of diffusion rollers have the same geometric shape. Example 29. The apparatus according to any of Examples 1 to 28, wherein the first and second diffusion rollers of a pair of diffusion rollers are of the same size. Example 30. The apparatus according to any one of Examples 1 to 29, wherein the reliefs and recesses of the first radial outer surface and the second radial outer surface have the same shape. Example 31. The apparatus according to any one of Examples 1 to 30, wherein the rollers include a plurality of pairs of diffusion rollers positioned sequentially. Example 32. The apparatus according to Example 31, wherein the radial distance "A" between the bottom of the recess or groove and the top of the relief or protrusion of a pair of diffusion rollers located upstream is greater than the radial distance "A" between the bottom of the recess or groove and the top of the relief or protrusion of a pair of diffusion rollers located downstream. Example 33. The apparatus according to Example 31 or 32, wherein the pitch "C" of the bumps of a pair of diffusion rollers positioned upstream is greater than the pitch "C" of the bumps of a pair of diffusion rollers positioned downstream. Example 34. The apparatus according to Example 31, 32, or 33, wherein the minimum distance "B" of the passage of a pair of diffusion rollers located upstream, measured in a plane including the first and second rotation axes and along a direction perpendicular to the first and second rotation axes, is greater than the minimum distance "B" of the passage of a pair of diffusion rollers located downstream. Example 35. The apparatus according to any one of Examples 1 to 34, wherein the rollers further comprises at least one pair of flattening rollers positioned downstream of a diffusion roller, and optionally a plurality of pairs of flattening rollers positioned after the other. Example 36. The apparatus according to Example 35, wherein the flattening roller has a flat radial outer surface. Example 37. A method for manufacturing a sheet of aerosol-generating substrate for an aerosol-generating article through any apparatus described in Examples 1 to 36. Example 38. 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 ingredients. The mixture is kneaded in a kneader to form a soft mass, The process involves flattening the soft mass through a roller to form a sheet, This includes optionally drying the sheet in a dryer to obtain a sheet of aerosol generating substrate for an aerosol generating article, To flatten, The method according to Example 37, comprising passing the lump through a pair of diffusion rollers rotating in opposite directions to spread the lump onto a sheet having at least one non-uniform surface. Example 39. The method according to Example 38, wherein a sheet provided with at least one non-uniform surface has protrusions and depressions with a contour similar to the cross-section of the passage. Example 40. The method according to Example 38 or 40, further comprising passing a sheet having at least one non-uniform surface between at least one pair of flattening rollers. Example 41. The method according to Example 40, wherein the maximum thickness of the sheet provided with at least one non-uniform surface is 10 to 100 times the final thickness of the sheet downstream of the flattening roller. Example 42. The method according to Example 41, wherein the final thickness is 150 μm to 300 μm, and optionally 170 μm to 290 μm. Example 43. The method according to any one of Examples 38 to 42, wherein flattening includes passing the soft mass through a plurality of pairs of diffusion rollers. Example 44. The method according to any one of Examples 38 to 43, wherein flattening includes passing a soft mass through a plurality of pairs of flattening rollers. Example 45. The method according to any one of Examples 38 to 44, wherein the pressure applied to the soft mass by a pair of diffusion rollers is 20 N / mm to 150 N / mm, optionally 40 N / mm to 80 N / mm, across the width of the sheet. Example 46. The method according to any one of Examples 38 to 45, wherein the consistency of the soft mass, as measured by a farinograph, is a maximum of 14 Nm at 25°, and optionally, the consistency of the soft mass, as measured by a farinograph, is greater than 14 Nm at 25°, and optionally, a maximum of 20 Nm. Example 47. The method according to any one of Examples 38 to 46, wherein the temperature of the pair of diffusion rollers is at room temperature. Example 48. The method according to any one of Examples 38 to 47, wherein the temperature is -50°C to +50°C, or optionally -20°C to +20°C, relative to room temperature. Example 49. The method according to any one of Examples 38 to 48, wherein the amount of water in the soft mass is 7% to 60%, optionally 15% to 50%, or optionally 27% to 35% of 100% of the soft mass. Example 50. The method according to any one of Examples 38 to 50, further comprising winding a sheet of aerosol generating substrate onto a master bobbin, and then cutting the master bobbin into smaller bobbins. Example 51. The method according to any one of Examples 38 to 50, further comprising slitting a sheet of aerosol generating substrate into multiple tapes and winding each tape onto a small bobbin. Example 52. The method according to Example 50 or 51, further comprising cooling the sheet of aerosol generating substrate before winding it on a master bobbin or before slitting it. Example 53. The method according to any one of Examples 38 to 52, comprising grinding the plant and / or alkaloid before mixing to obtain plant particles and / or alkaloid particles. Example 54. The method according to any one of Examples 38 to 53, wherein the soft mass is calendered after kneading and before flattening to form a thick sheet. Example 55. A process for manufacturing components of an aerosol-generating article, -A sheet of aerosol generating substrate for an aerosol generating article is manufactured using the apparatus described in any of Examples 1 to 36, or by the method described in any of Examples 37 to 54. - 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 56. An aerosol generating article comprising at least one aerosol generating article component prepared according to the process of Example 55.

[0122] Here, we will further describe the examples with reference to the figures. [Brief explanation of the drawing]

[0123] [Figure 1] Figure 1 schematically shows an apparatus for manufacturing a sheet of aerosol generating substrate for an aerosol generating article according to the present invention. [Figure 2]Figure 2 schematically shows the apparatus for fabricating a rod of aerosol generating substrate. [Figure 3] Figure 3 shows the longitudinal section and cross-section of the aerosol generating article component fabricated from the rod shown in Figure 2. [Figure 4] Figure 4 shows the longitudinal section and cross-section of the aerosol generating article component fabricated from the rod shown in Figure 2. [Figure 5] Figure 5 shows a pair of rollers in the device shown in Figure 1. [Figure 6] Figure 6 shows the deformation of the roller in Figure 5. [Figure 7] Figure 7 shows the deformation of the roller in Figure 5. [Figure 8] Figure 8 shows the deformation of the roller in Figure 5. [Figure 9] Figure 9 shows the deformation of the roller in Figure 5. [Figure 10] Figure 10 shows the deformation of the roller in Figure 5. [Figure 11] Figure 11 shows the deformation of the roller in Figure 5. [Figure 12] Figure 12 shows the deformation of the roller in Figure 5. [Figure 13] Figure 13 shows the deformation of the roller in Figure 5. [Figure 14] Figure 14 shows the deformation of the roller in Figure 5. [Figure 15] Figure 15 shows one embodiment of the roller assembly shown in Figure 1. [Figure 16] Figure 16 is a 3D view of the aerosol-generating substrate sheet at each intermediate work step performed through the rollers in Figure 15. [Figure 17] Figure 17 is a 3D view of the aerosol-generating substrate sheet at each intermediate work step performed through the rollers in Figure 15. [Modes for carrying out the invention]

[0124] The apparatus 1 shown in Figure 1 is a schematic example of an apparatus configured to manufacture a sheet of aerosol generating substrate for an aerosol generating article according to the present invention.

[0125] Apparatus 1 comprises a grinder 2 configured to grind plants and / or alkaloids into particles "T". For example, the plants and / or alkaloids are tobacco flakes, and grinder 2 is a tobacco mill adapted to coarsely grind the tobacco flakes into tobacco particles, the particles having a size of 70-550 μm, with no particles larger than 325 μm.

[0126] 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".

[0127] Apparatus 1 further comprises a container 4, in which a moist mixture is loaded with an aerosol-forming agent "G" such as glycerin, a binder "M" such as carboxymethylcellulose (CMC), and then water "W," and mixed to form a second premix "PM2."

[0128] 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.

[0129] 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 a soft mass "Do".

[0130] Therefore, the soft mass "Do" is prepared by mixing the recipe and water in a kneader 5, the recipe comprising plant particles and / or alkaloid particles "T", an aerosol-forming agent "G", cellulose fibers "F", and a binder "M".

[0131] Table 1 below includes examples of recipe ingredients. [Table 1]

[0132] The total amount of process water used may be 7-60%, more preferably 15-50%, and most preferably 27-35%, of 100% of the soft mass.

[0133] Next, the soft mass "Do" is calendered through a soft mass sheeter or calender roller 7, which may be part of the kneader 5, to form a soft mass "Do" like a thick sheet 8. For example, the thickness of the thick sheet is 2 mm to 20 mm.

[0134] The consistency of the soft mass, as measured with a farinograph, can be up to 14 Nm at 25°. The consistency may also be greater than 14 Nm at 25°, for example, up to 20 Nm, as measured with a farinograph.

[0135] Downstream of the kneader 5, the device 1 includes a flattening roller assembly 9 configured to flatten a thick sheet 8 to form a flattened thin sheet 10.

[0136] The dryer 11 is operably positioned downstream of the flattening roller assembly 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.

[0137] 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.

[0138] Downstream of the dryer 11, the longitudinal end of the sheet 12 is 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 the core 16 to form a master bobbin 17. The master bobbin 17 is slit into several smaller bobbins 19, so that each smaller bobbin 19 contains a tape 20 of the aerosol-generating substrate wound onto each portion of the core 16 (Figure 2).

[0139] 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 a sheet 12 of aerosol-generating substrate into a plurality of tapes 20. A plurality of smaller winders are used to wind each tape 20 onto their respective small bobbins 19.

[0140] The cooler 18 may be positioned between the dryer 11 and the winder so that the aerosol generating substrate sheet 12 is cooled before it is wound up (Figure 1).

[0141] The small bobbin 19 containing the aerosol-generating substrate sheet 12 is used for the manufacture of aerosol-generating article components and aerosol-generating articles.

[0142] Each tape 20 of the aerosol generating substrate may be collected and wound to form a continuous rod 21 through an apparatus 22 for manufacturing aerosol generating article components, for example, as shown in Figure 2.

[0143] The apparatus 22 for manufacturing aerosol-generating article components includes a reel holder 23 that carries smaller bobbins 19 formed by aerosol-generating substrate tapes 20 for aerosol-generating article components. The previously manufactured aerosol-generating substrate tapes 20 are unwound from the bobbins 19 and supplied along the supply path in the supply direction "V".

[0144] Downstream of the reel holder 23, the apparatus 1 includes two rotating cylindrical crimp rollers 24 against which the tape 20 is pressed. These crimp 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 plurality 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.

[0145] Figure 2 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 (shown in Figures 3 and 4) 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 3 and 4).

[0146] The roller assembly 9 comprises a first pair 28A of diffusion rollers positioned immediately downstream of the kneader 5. A second pair 28B of diffusion rollers follows the first pair 28A of diffusion rollers, followed by a first pair 29A and a second pair 29B of flattening rollers.

[0147] Figure 5 shows a first pair of diffusion rollers 28A, comprising a first diffusion roller 31 and a second diffusion roller 32. The first diffusion roller 31 is configured to rotate around a first rotation axis "XX" and has a first radial outer surface. The second diffusion roller 32 is configured to rotate around a second rotation axis "YY" and has a second radial outer surface.

[0148] As shown in Figure 5, the first axis of rotation "XX" and the second axis of rotation "YY" are parallel to each other, and the first radial outer surface faces the second radial outer surface, defining a passage 33 for the soft mass "Do".

[0149] As shown in Figures 1 and 15, the first rotation axis "XX" and the second rotation axis "YY" are perpendicular to the forward direction "P" of the aerosol generating substrate sheet located downstream of the first pair 28A of the diffusion rollers.

[0150] The first diffusion roller 31 and the second diffusion roller 32 in the exemplary embodiment of Figure 5 are identical to each other and both have the same geometric shape and size. Therefore, only the first diffusion roller 31 will be described in detail.

[0151] The first radial outer surface of the first diffusion roller 31 is provided with a plurality of ridges 34 and a plurality of grooves 35 separated between the ridges 34. The ridges 34 and grooves 35 extend from the first axial end to the second axial end of the first diffusion roller 31. The ridges 34 and grooves 35 extend around the first rotation axis "XX" and are located in a plane perpendicular to the first rotation axis "XX". In other words, the ridges 34 and grooves 35 are circular and coaxial with the first rotation axis "XX".

[0152] In the cross-section including the first axis of rotation "XX", the ridge 34 has a triangular contour with a rounded top, and the groove 35 exhibits the shape of the ridge 34 with a rounded bottom. Thus, the first radial outer surface has a corrugated or wavy shape.

[0153] The first diffusion roller 31 has n axial lengths "L" measured parallel to the first rotation axis "XX", and a diameter "D" measured at the top of the ridge 34. For example, the axial length "L" is 1600 mm and the diameter "D" is 400 mm. According to other embodiments, the axial length "L" may be 1000 mm to 2100 mm, and the diameter "D" may be 100 mm to 600 mm.

[0154] As shown in Figure 5, the pitch "C" of the ridges 34, which represents the axial distance between the two consecutive ridges 34, may be 20 mm. The radial distance "A" between the bottom of the groove 35 and the top of the ridge 34, i.e., the height of the ridge 34, may also be 20 mm.

[0155] According to embodiments of the present invention, the pitch "C" may be 4 mm to 50 mm, optionally 15 mm to 30 mm, or optionally 17 mm to 25 mm. The radial distance "A" may be 5 mm to 40 mm, optionally 10 mm to 25 mm, optionally 10 mm to 20 mm, or optionally 15 mm.

[0156] The first diffusion roller 31 and the second diffusion roller 32 are positioned such that the upper parts of the ridges 34 on the first radial outer surface and the upper parts of the ridges 34 on the second radial outer surface face each other, that is, the ridges 34 of the first diffusion roller 31 and the ridges 34 of the second diffusion roller 32 are aligned along directions perpendicular to the first rotation axis "XX" and the second rotation axis "YY".

[0157] Given that the first radial outer surface has a first maximum radius "R1", the second radial outer surface has a second maximum radius "R2", and the distance "d" between the first axis of rotation "XX" and the second axis of rotation "YY", the minimum distance "B" of the passage 33 measured in the plane containing the first axis of rotation "XX" and the second axis of rotation "YY", and along a direction perpendicular to the first axis of rotation "XX" and the second axis of rotation "YY", is B = d - (R1 + R2).

[0158] The minimum distance "B" is the distance between the top of the first radially outer surface bulge 34 and the top of the second radially outer surface bulge 34 (Figure 5).

[0159] For example, the minimum distance "B" is 5 mm. According to embodiments of the present invention, the minimum distance is 1 mm to 10 mm, optionally 2 mm to 8 mm, optionally 4 mm to 7 mm, and optionally 6 mm.

[0160] The first diffusion roller 31 and the second diffusion roller 32 are rotated in opposite directions by actuators or motors to advance the lumps through the passage 33. As the lumps "Do" from the kneader 5 are fed through the passage 33 of the first pair 28A of diffusion rollers, they fill the grooves 35 and spread throughout the passage 33, forming a first intermediate sheet 8' which has an uneven surface, i.e., the surface of the first intermediate sheet 8' has the respective ridges and grooves shown in Figure 16.

[0161] The second pair of diffusion rollers 28B is similar to the first pair of diffusion rollers 28A, that is, the first radial outer surface and the second radial outer surface of the first diffusion roller 31, and the second diffusion roller 32 of the second pair of diffusion rollers 28B, have a corrugated or wavy shape.

[0162] In any case, the radial distance "A", pitch "C", and minimum distance "B" of the second pair of diffusion rollers 28B are smaller than those of the first pair of diffusion rollers 28A. For example, the radial distance "A" is 10 mm, the pitch "C" is 10 mm, and the minimum distance "B" is 3 mm.

[0163] As shown in Figure 17, the second intermediate sheet 8'' exiting the passage 33 of the second pair 28B of the diffusion roller is thinner than the first intermediate sheet 8'', and its respective ridges and grooves are smaller than those of the first intermediate sheet 8''.

[0164] The first pair of flattening rollers 29A comprises a first flattening roller 36 and a second flattening roller 37 having parallel axes of rotation and defining their respective passages. The second pair of flattening rollers 29B also comprises a first flattening roller 36 and a second flattening roller 37 having parallel axes of rotation and defining their respective passages. The radial outer surfaces of the first flattening roller 36 and the second flattening roller 37 of both the first pair 29A and the second pair 29B are flat, i.e., no reliefs or recesses are provided.

[0165] The distance between the first flattening roller 36 and the second flattening roller 37 of the first pair 29A is greater than the distance between the first flattening roller 36 and the second flattening roller 37 of the second pair 29B. Thus, the second intermediate sheet 8'' is flattened and smoothed by the first pair 29A of flattening rollers to become a third intermediate sheet 8'' with a smooth surface. Finally, the second pair 29B of flattening rollers further reduces the thickness of the sheet to produce a thin sheet 10 (Figure 15). The distance between the rollers of the second pair 29B is equal to the desired thickness of the sheet.

[0166] For example, the maximum thickness of the first intermediate sheet 8' is 10 mm, and the final thickness of the thin sheet 10 is 200 μm. Therefore, the maximum thickness of the first intermediate sheet 8' is 50 times the final thickness of the thin sheet 10. Generally, the maximum thickness of a sheet provided with at least one non-uniform surface is 10 to 100 times the final thickness of the sheet downstream of the planarizing roller. The final thickness may be 150 μm to 300 μm, and optionally 170 μm to 290 μm.

[0167] The temperature of the first pair 28A and / or the second pair 28B of the diffusion rollers may be room temperature, or -50°C to +50°C relative to room temperature, optionally -20°C to +20°C. The pressure applied to the soft mass by the first pair 28A and / or the second pair 28B of the diffusion rollers may be 20 N / mm to 150 N / mm across the width of the sheet, optionally 40 N / mm to 80 N / mm.

[0168] The shapes of the first and second radial outer surfaces disclosed above are preferred, but not exclusive. Further possible geometric shapes of the first diffusion roller 31 are shown in Figures 6-14. In particular, the reliefs and recesses of the first and second radial outer surfaces may be other than the grooves 35 and ridges 34 disclosed herein. The same geometric shapes may be applied to the second diffusion roller 32.

[0169] Figure 6 shows a ridge 34 with a rectangular outline and a flat top, and a groove 35 with an arched outline.

[0170] Figure 7 shows a ridge 34 with an arched contour and a groove 35 with a flat bottom.

[0171] Figure 8 shows a ridge 34 and a groove 35 having triangular contours. The ridge has a bordered top. The groove has a bordered bottom.

[0172] Figure 9 shows a wave-like or undulating shape similar to one of the figures in Figure 5, with the upper part of the ridge 34 and the bottom of the groove 5 having a larger radius of curvature than one of the figures in Figure 5.

[0173] Figure 10 shows the ridge 34 and groove 35, both having rectangular contours with flat tops and bottoms.

[0174] The first diffusion roller 31 in Figures 11A and 11B differs from that in Figure 10 by a gap 38 that crosses the ridges 34 and grooves 35. The gap 38 extends entirely along the length of the first diffusion roller 31 and is parallel to the first axis of rotation "XX". The radial depth of the gap 38 may be less than or equal to the radial distance "A". For example, the radial depth of the gap 38 is half the radial distance "A".

[0175] The first diffusion rollers 31 in Figures 12A and 12B differ from those in Figures 11A and 11B because the gap 38 is oblique to the respective first rotation axis "XX".

[0176] The grooves 35 and gaps 38 in Figures 11A, 11B, 12A, and 12B separate the blocks 39 on the first outer surface.

[0177] Figure 13 shows the ridges 34 and grooves 35 located in a plane oblique to the plane perpendicular to the first axis of rotation "XX".

[0178] The grooves 34 in Figure 14 lie in a plane that intersects and is oblique to a plane perpendicular to the first axis of rotation "XX", and thus divides multiple diamond-shaped blocks 39.

[0179] In other embodiments not shown in the accompanying drawings, the ridges 34 and grooves 35 do not extend around their respective first axis of rotation "XX" or second axis of rotation "YY", but may be parallel or oblique to their respective first axis of rotation "XX" or second axis of rotation "YY".

[0180] In other embodiments not shown in the accompanying drawings, the first radial outer surface and / or the second radial outer surface may include blocks and hollows separated by blocks of different shapes and sizes.

[0181] For the purposes of this specification and the appended claims, unless otherwise indicated, all numbers representing amounts, quantities, percentages, etc., are understood to be modified in all cases 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 5 percent of A ± A. In this context, number A may be considered to include a numerical value that falls within the general standard error of the measurement of the characteristic modified by number A. Number A may deviate by the percentages listed above, provided that in some cases, 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, through an apparatus for manufacturing a sheet of aerosol generating substrate for an aerosol generating article, The aforementioned device (1) A kneader (5) configured to knead a mixture using a recipe and water to form a soft mass (Do), The system includes a roller operably positioned downstream of the kneader (5) and configured to flatten the soft mass (Do) to form the sheet (10), The aforementioned roller A first diffusion roller (31) having a first axis of rotation (X-X) and a first radial outer surface, It comprises a second diffusion roller (32) having a second axis of rotation (Y-Y) and a second radial outer surface, The first axis of rotation (X-X) and the second axis of rotation (Y-Y) are parallel to each other, and the first radial outer surface faces the second radial outer surface, defining a passage (33) for the soft mass (Do). The first radial outer surface and the second radial outer surface are provided with a pair of diffusion rollers (28A, 28B) having reliefs and depressions for spreading the soft mass (Do) onto a sheet provided with at least one non-uniform surface, The roller further comprises at least one pair of flattening rollers (29A, 29B) having flat radial outer surfaces, which are located downstream of the diffusion rollers (28A, 28B). The method described above is The process involves mixing the aforementioned recipe with water to form the 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 the kneader (5) to form a soft mass (Do), This includes flattening the soft mass by passing it through the roller to form a sheet, To flatten, The soft mass (Do) is passed through the pair of diffusion rollers (28A, 28B) that rotate in opposite directions, thereby spreading the soft mass (Do) onto a sheet having at least one non-uniform surface. This includes passing the sheet having at least one non-uniform surface between the at least pair of flattening rollers (29A, 29B), A method wherein the maximum thickness of the sheet, which is provided with at least one non-uniform surface, is 10 to 100 times the final thickness of the sheet downstream of the flattening rollers (29A, 29B).

2. The method according to claim 1, wherein the final thickness is 150 μm to 300 μm, and optionally 170 μm to 290 μm.

3. The method according to claim 1 or 2, wherein the pressure applied to the soft mass by the pair of diffusion rollers (28A, 28B) is 20 N / mm to 150 N / mm, and optionally 40 N / mm to 80 N / mm, across the width of the sheet.

4. The method according to any one of claims 1 to 3, wherein the consistency of the soft mass (Do) is a maximum of 14 Nm at 25° when measured with a farinograph instrument.

5. The method according to any one of claims 1 to 4, wherein the amount of water in the soft mass (Do) is 7% to 60%, optionally 15% to 50%, or optionally 27% to 35% of 100% of the soft mass.

6. The method according to any one of claims 1 to 5, wherein the first radial outer surface has a first maximum radius (R1), the second radial outer surface has a second maximum radius (R2), the distance (d) between the first axis of rotation (X-X) and the second axis of rotation (Y-Y) is greater than the sum of the first maximum radius (R1) and the second maximum radius (R2), and the minimum distance (B) of the passage (33) measured in a plane including the first axis of rotation (X-X) and the second axis of rotation (Y-Y) and along a direction perpendicular to the first axis of rotation (X-X) and the second axis of rotation (Y-Y) is B = d - (R1 + R2).

7. The method according to claim 6, wherein both the first radial outer surface and the second radial outer surface have reliefs and recesses, and in the passage (33), the relief of the first diffusion roller (31) is spaced apart from the relief of the second diffusion roller (32) by the minimum distance (B).

8. The method according to claim 6 or 7, wherein the minimum distance (B) is 1 mm to 10 mm, optionally 2 mm to 8 mm, optionally 4 mm to 7 mm, or optionally 6 mm.

9. The method according to any one of claims 1 to 8, wherein the relief comprises a ridge (34), the recess comprises a groove (35) defined between the ridges (34), and the ridges (34) and the groove (35) extend around the first axis of rotation (X-X) or the second axis of rotation (Y-Y), respectively.

10. The method according to claim 9, wherein in a cross-section including the first axis of rotation (X-X) or the second axis of rotation (Y-Y), the ridge (34) has a rectangular, triangular, or arched contour, and in a cross-section including the first axis of rotation (X-X) or the second axis of rotation (Y-Y), the groove (35) has a rectangular, triangular, or arched contour.

11. The method according to any one of claims 9 to 10, wherein the ridge (34) and the groove (35) are located in a plane perpendicular to the first axis of rotation (X-X) or the second axis of rotation (Y-Y), and the upper part of the ridge (34) on the first radial outer surface and the upper part of the ridge (34) on the second radial outer surface face each other.

12. The method according to any one of claims 9 to 11, wherein the pitch (C) of the ridges (34) is 4 mm to 50 mm, optionally 15 mm to 30 mm, or optionally 17 mm to 25 mm.

13. The method according to any one of claims 9 to 12, wherein the radial distance (A) between the bottom of the groove (35) and the top of the protrusion (34) is 5 mm to 40 mm, optionally 10 mm to 25 mm, optionally 10 mm to 20 mm, or optionally 15 mm.

14. The method according to any one of claims 9 to 13, wherein the recess further comprises a plurality of gaps (38) intersecting the ridges (34) and grooves (35), and the gaps (38) extend partially or completely along the length of the first diffusion roller (31) or the second diffusion roller (32), respectively.

15. The method according to claim 13, where claim 13 is dependent on claim 12 and claim 9 is dependent on any of claims 6, 7, or 8, wherein the roller comprises a plurality of sequentially positioned pairs of diffusion rollers (28A, 28B), and the radial distance (A) between the bottom of the groove (35) and the top of the ridge (34) of a pair of diffusion rollers (28A) positioned upstream, the minimum distance (B) of the passage (33), and the pitch (C) of the ridge (34) are greater than the radial distance (A) between the bottom of the groove (35) and the top of the ridge (35) of a pair of diffusion rollers (28B) positioned downstream, the minimum distance (B) of the passage (33), and the pitch (C) of the ridge (34).

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