Manufacturing method and manufacturing device for aerosol-generating matrix

Abstract

A manufacturing method and a manufacturing device for an aerosol-generating matrix. The manufacturing method comprises extruding a mixed material at a high temperature to form an extruded matrix; and performing hot air drying on the extruded matrix. During the high-temperature extrusion molding, the amount of water added to the mixed material can be reduced, and even extrusion can be performed without adding water. The mixed material having a low moisture content is conducive to feeding, and the high-temperature extrusion molding can lower the extrusion pressure and increase the extrusion speed, thereby improving the production efficiency. In addition, at a high temperature, the mixed material may undergo a Maillard reaction, thereby generating more aroma components and improving the mouthfeel of the medium. Hot air drying can be performed on the extruded matrix in batches, and the drying speed is high.

Description

Method and equipment for manufacturing aerosol-generating substrate

[0001] This disclosure is based on and claims the priority of Chinese patent application with application number 202311828391.1 and application date December 27, 2023. The entire content of this Chinese patent application is incorporated herein by reference into this disclosure. Technical Field

[0002] The present disclosure relates to the technical field of aerosol generating substrates, and in particular to a method and equipment for manufacturing an aerosol generating substrate. Background Art

[0003] The aerosol-generating substrate can form an aerosol by ignition or by heating without combustion. In the heat-without-combustion aerosol-generating substrate, the aerosol-generating substrate is heated by an external heat source to a degree sufficient to emit an aerosol, but does not burn. The aerosol-generating substrate is loaded with a smoke agent, and upon use, the smoke agent is released by heating the aerosol-generating substrate to form an aerosol.

[0004] Existing manufacturing systems primarily rely on casting, coating, and roller pressing. These methods require hot air drying to control the substrate's moisture content and shape, and require gathering or filling equipment to create a cylindrical aerosol-generating substrate. These methods and systems suffer from lengthy process steps, numerous intermediates involved in the transition from raw materials to finished product, high system investment, and the potential for loss of active ingredients during the manufacturing process.

[0005] Summary of the Invention

[0006] In view of this, the embodiments of the present disclosure are intended to provide a method and apparatus for manufacturing an aerosol generating substrate that can improve the yield rate.

[0007] To this end, the present disclosure provides a method for manufacturing an aerosol-generating substrate, comprising:

[0008] The mixed material is extruded at high temperature to form an extruded matrix;

[0009] The extruded matrix is ​​subjected to hot air drying.

[0010] In some embodiments, the extrusion temperature of the high-temperature extrusion is greater than 90°C and less than or equal to 200°C.

[0011] In some embodiments, the extrusion temperature of the high-temperature extrusion is between 100°C and 150°C.

[0012] In some embodiments, the extrusion pressure of the high-temperature extrusion is between 10 bar and 300 bar.

[0013] In some embodiments, the extrusion pressure of the high-temperature extrusion is between 20 bar and 150 bar.

[0014] In some embodiments, the hot air drying temperature is between 50°C and 200°C.

[0015] In some embodiments, the water content of the mixed material is between 5% and 15%.

[0016] In some embodiments, the hot air drying temperature is between 75°C and 125°C.

[0017] In some embodiments, the moisture content of the extruded matrix after drying is between 3% and 13%.

[0018] In some embodiments, the extruded matrix has an air channel running through at least one end thereof in the longitudinal direction, and during the hot air drying process, the flow direction of the hot air is parallel to the longitudinal direction of the extruded matrix.

[0019] In some embodiments, after the mixed material is extruded at high temperature to form an extruded matrix, the manufacturing method includes:

[0020] The extruded matrix is ​​cut into pieces.

[0021] In some embodiments, before hot air drying the extruded matrix, the manufacturing method includes:

[0022] The extruded matrix hardens by cooling.

[0023] In some embodiments, the hardness of the extruded matrix after hardening is between 1HB and 200HB.

[0024] In some embodiments, the extruded matrix is ​​extruded in a horizontal direction; or

[0025] The extruded matrix is ​​extruded in a vertical direction; or,

[0026] The extruded matrix is ​​extruded in an oblique direction.

[0027] In some embodiments, the mixture comprises, by weight, 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 flavor raw materials.

[0028] The present disclosure also provides an apparatus for manufacturing an aerosol-generating substrate, the apparatus comprising:

[0029] An extrusion device, wherein the extrusion device is used to extrude the mixed material at a high temperature to form an extruded matrix;

[0030] A drying device is used for drying the extruded matrix with hot air.

[0031] In some embodiments, the drying device comprises:

[0032] The box body has a drying chamber;

[0033] A fan, used to drive the air flow in the drying chamber;

[0034] A heating element is disposed in the drying chamber and is used to heat the airflow in the drying chamber.

[0035] In some embodiments, the number of the heating elements is at least two, and the at least two heating elements are spaced apart in the vertical direction to form a space for conveying the extruded matrix.

[0036] In some embodiments, the extruded matrix has an air passage running through at least one longitudinal end thereof, and the drying device includes a guide channel for guiding hot air, wherein the air outlet of the guide channel is located on one side of the extruded matrix along the longitudinal direction.

[0037] In some embodiments, the drying device includes a conveyor belt for conveying the extruded matrix, wherein a plurality of grooves are formed on a surface of the conveyor belt facing the extruded matrix, each groove being used to place a strip of the extruded matrix, and at least a portion of the extruded matrix is ​​located in the groove.

[0038] In some embodiments, the manufacturing apparatus includes a microwave device at least partially located within the drying chamber, the microwave device drying the extruded matrix by emitting microwave radiation.

[0039] In some embodiments, the manufacturing apparatus includes an ultrasonic device at least partially located within the drying chamber, the ultrasonic device drying the extruded matrix by emitting ultrasonic radiation.

[0040] In some embodiments, the manufacturing apparatus includes an infrared device at least partially located within the drying chamber, wherein the infrared device dries the extruded matrix by emitting infrared rays.

[0041] The manufacturing method provided by the disclosed embodiment is to carry out high temperature extrusion to form an extrusion matrix, wherein the mixture is a component mixture of an aerosol-generating matrix, and then the extrusion matrix is ​​subjected to hot air drying. When extruded by high temperature, the water added in the mixture can be reduced, and even no water can be added to extrude, and the mixture with low moisture content is conducive to feeding, and high temperature extrusion can reduce the extrusion pressure, and by reducing the extrusion pressure, an extrusion matrix with lower density can be obtained, and by improving the extrusion speed, production efficiency can be improved. In addition, due to the low water content in the mixture, the strength of the extrusion matrix formed by high temperature extrusion can maintain its form, and the low-intensity shaping process can meet the needs of subsequent production steps (such as cutting), and can even be directly cut (i.e., the step of not needing to shape), thereby being conducive to shaping, and further improving production efficiency. Furthermore, due to the low water content in the mixture, the corresponding reduction of the moisture that needs to be deviated from is reduced, and the drying strength is low, which is more conducive to the retention of the aroma substances in the extrusion matrix, and when the mixture is not added with water, it can even be not dried. And at high temperatures, the Maillard reaction will occur in the mixture, producing more aroma components, thereby improving the yield rate. Hot air drying allows for batch drying of extruded matrices at a rapid drying speed. This process reduces the moisture content of the extruded matrix, facilitating storage and use of the aerosol-generating matrix. The aerosol-generating matrix obtained through high-temperature extrusion and hot air drying is a one-piece structure. This ensures that the aerosol-generating matrix remains a single unit during use, such as during heated extraction or after heating, making it less susceptible to disintegration and dropout. BRIEF DESCRIPTION OF THE DRAWINGS

[0042] FIG1 is a flowchart of a manufacturing method in one embodiment of the present disclosure;

[0043] FIG2 is a schematic structural diagram of a manufacturing system according to an embodiment of the present disclosure, wherein the extrudate is extruded vertically;

[0044] FIG3 is a schematic cross-sectional view of the structure shown in FIG2 ;

[0045] FIG4 is a schematic structural diagram of a manufacturing system according to another embodiment of the present disclosure, wherein the extrudate is extruded in a horizontal direction;

[0046] FIG5 is a schematic structural diagram of a guide channel and a conveyor belt in an embodiment of the present disclosure;

[0047] Figure 6 is an enlarged schematic diagram of point A in Figure 5;

[0048] FIG7 is a schematic structural diagram of a die in one embodiment of the present disclosure;

[0049] FIG8 is a schematic structural diagram of the die and extruded matrix shown in FIG7 ;

[0050] FIG9 is a schematic structural diagram of a mouth mold and a bottom mold in one embodiment of the present disclosure;

[0051] FIG10 is a schematic structural diagram of an adapter, a mouth mold, and a bottom mold in one embodiment of the present disclosure;

[0052] FIG11 is a schematic structural diagram of a hardening device in one embodiment of the present disclosure;

[0053] FIG12 is a schematic structural diagram of a hardening device in another embodiment of the present disclosure. DETAILED DESCRIPTION

[0054] It should be noted that, unless there is a conflict, the embodiments and technical features in the embodiments of the present disclosure can be combined with each other, and the detailed description in the specific implementation methods should be understood as an explanation of the purpose of the present disclosure and should not be regarded as an improper limitation on the present disclosure.

[0055] In this disclosure, the temperature unit "°C" stands for degrees Celsius. The pressure unit "bar" stands for bar. The unit "μm" stands for micrometer. The viscosity unit "pa.s" stands for Pascal-second. The unit "pa" stands for Pascal.

[0056] The aerosol-generating substrate is used to generate an aerosol upon heating. For example, the aerosol-generating substrate can be used to generate aerosols by heating and combustion. Alternatively, the aerosol-generating substrate can be used to generate aerosols by heating without combustion. That is, the aerosol-generating substrate is heated to a temperature below its ignition point to generate the aerosol. The aerosol-generating substrate does not burn during the aerosol generation process.

[0057] The aerosol-generating substrate provided in embodiments of the present disclosure is used in an aerosol-generating article. The aerosol-generating article includes an aerosol-generating substrate and a functional segment. The functional segment is disposed at one longitudinal end of the aerosol-generating substrate and includes a filter segment for filtering aerosols. The filter segment is used to filter aerosols generated by the aerosol-generating substrate.

[0058] Of course, in some embodiments, the aerosol-generating article may not include a functional segment.

[0059] Aerosol-generating articles are designed to allow users to inhale aerosols generated by an aerosol-generating substrate. For example, users can hold a filter segment in their mouth and inhale the filtered aerosol. The aerosol generated by the aerosol-generating substrate is transported to the filter segment under the influence of negative pressure.

[0060] The aerosol-generating article is used in conjunction with an aerosol-generating device having a heating component. Specifically, the heating component heats and atomizes an aerosol-generating substrate to generate an aerosol.

[0061] There are various heating methods for the heating assembly, including, for example, central heating, peripheral heating, and / or bottom heating. Central heating involves inserting the heating assembly into the aerosol-generating article to heat it from the inside out. Peripheral heating involves placing the heating assembly around the periphery of the aerosol-generating article to heat it from the outside in. Bottom heating involves placing the heating assembly at the bottom of the aerosol-generating article, heating the air first, and then heating the aerosol-generating article from the bottom up.

[0062] It should be noted that the bottom of the aerosol-generating article is the end thereof that is away from the functional section in the longitudinal direction.

[0063] The heating methods of the heating component include but are not limited to resistance heating, electromagnetic heating, infrared heating, microwave heating or laser heating.

[0064] In some embodiments, the functional segment may only be provided with a filtering segment.

[0065] In other embodiments, the functional section further includes a cooling section, located between the filtration section and the aerosol-generating matrix. The cooling section is used to cool the aerosol before filtering it by the filtration section. The cooling section can reduce the "burning mouth" phenomenon when the user inhales the aerosol.

[0066] The cooling materials used in the cooling section include but are not limited to one or more combinations of PE (polyethylene), PLA (Polylactic Acid), PBAT (Polybutylene Adipate Terephthalate), PP (Polypropylene), acetate fiber, acrylic fiber and the like.

[0067] The filter material used in the filter section includes but is not limited to one or more combinations of PE (polyethylene), PLA (Polylactic Acid), PBAT (Polybutylene Adipate Terephthalate), PP (Polypropylene), acetate fiber, acrylic fiber and the like.

[0068] The materials of the cooling section and the filtering section can be the same or different.

[0069] Referring to FIG1 , an embodiment of the present disclosure provides a method for manufacturing an aerosol generating substrate, the method comprising:

[0070] S100: The mixed material is extruded at high temperature to form an extruded matrix;

[0071] The mixed material is a component of the aerosol-generating matrix. High-temperature extrusion is used to shape the mixed material into an extruded matrix 1000, which has the same cross-sectional shape as the aerosol-generating matrix. In other words, the cross-sectional shape of the extruded matrix 1000 is the same as the cross-sectional shape of the aerosol-generating matrix. The extrusion process is used to shape the mixed material without changing the chemical properties of the mixed material.

[0072] It should be noted that the longitudinal direction refers to the direction in which the aerosol-generating substrate extends. For example, if the aerosol-generating substrate is formed by extrusion, the longitudinal direction is the direction in which the extruded substrate 1000 extends. The cross-sectional shape refers to the shape of the extruded substrate 1000 when taken along a plane perpendicular to the longitudinal direction.

[0073] 2 to 4 , extrusion molding refers to a processing method in which a mixed material is pushed forward by the screw through the action between the barrel and the extrusion screw 12 of the extrusion device 1 and formed into an extruded matrix 1000 of various cross-sectional shapes through the die 13 of the discharge port 11 c.

[0074] High temperature extrusion means that the extrusion temperature is higher than 90°C.

[0075] It should be noted that in the field of extrusion, extrusion temperatures above 90°C are considered high-temperature extrusion. Extrusion temperatures between 10°C and 90°C (inclusive) are considered room-temperature extrusion. The extrusion temperature is the temperature inside the extrusion chamber 11a of the extruder 1.

[0076] Temperature affects parameters such as the retention rate of volatile aroma compounds in the extruded material, extrusion pressure, and extrusion speed. High and low temperature extrusion can reduce extrusion pressure and increase extrusion speed. Lowering the extrusion pressure can produce an extruded matrix 1000 with a lower density, while increasing the extrusion speed can improve production efficiency.

[0077] At the same extrusion speed, the extrusion pressure required for high-temperature extrusion is lower than that for room-temperature extrusion or low-temperature extrusion, and an extruded matrix 1000 with a lower density can be obtained; at the same extrusion pressure, high-temperature extrusion can have a faster extrusion speed.

[0078] During by high temperature extrusion molding, can reduce the water that adds in mixture, even can extrude without adding water, the mixture of low moisture, is conducive to charging, and high temperature extrusion molding can reduce extrusion pressure and promote extrusion speed, by reducing extrusion pressure, can obtain the lower extrusion matrix 1000 of density, by promoting extrusion speed, can improve production efficiency.In addition, because the water content in mixture is low, the intensity of the extrusion matrix 1000 that high temperature extrudes formation can keep its form, and the shaping of low intensity can meet subsequent production step (such as cutting) demand, even directly cutting (i.e., not needing the step of shaping), thereby is conducive to shaping, further improves production efficiency.Moreover, because the water content in mixture is low, the corresponding minimizing of the moisture that needs to deviate from, dry strength is low, is more conducive to the reservation of the aroma substance in extrusion matrix 1000, when mixture does not add water, can even be not dry.And at high temperature, Maillard reaction can occur in mixture, produces more aroma components, can effectively improve medium mouthfeel.

[0079] It's important to note that the Maillard reaction, also known as non-enzymatic browning, is a widespread non-enzymatic browning process in the food industry. It involves the reaction between carbonyl compounds (reducing sugars) and amino compounds (amino acids and proteins). Through a complex process, it ultimately produces brown or even black macromolecules called melanoidins, also known as pseudo-melanins. This reaction, also known as the carbonyl-amino reaction, produces a certain aroma component.

[0080] Exemplarily, the extrusion temperature of high temperature extrusion is greater than 90° C. and less than or equal to 200° C. (i.e., not greater than 200° C.). For example, the extrusion temperature of high temperature extrusion is 91° C., 100° C., 120° C., 130° C., 140° C., 150° C., 155° C., 160° C., 165° C., 170° C., 175° C., 180° C., 184° C., 188° C., 190° C., 196° C., or 200° C., etc.

[0081] When the extrusion temperature is greater than 90°C and less than or equal to 200°C (i.e., not greater than 200°C), the extrusion pressure can be at an equilibrium point, and the extruded extruded matrix 1000 has a uniform shape and a stable structure. When the temperature is greater than 90°C, the mixture does not need to add more water. By reducing the extrusion pressure, an extruded matrix 1000 with a lower density can be obtained. When the temperature is not greater than 200°C, the temperature of the mixture is appropriate, has a certain degree of adhesion, is not prone to loosening or cracking, and does not lose more low-volatile aroma components, thereby reducing manufacturing energy consumption. In other words, by controlling the extrusion temperature to be greater than 90°C and less than or equal to 200°C, it is possible to obtain extruded matrices 1000 of different densities and different aroma components by matching the appropriate extrusion speed, which can effectively improve the yield rate.

[0082] More preferably, the extrusion temperature of the high-temperature extrusion is between 100° C. and 150° C. (inclusive).

[0083] In one embodiment, the extrusion pressure of the high temperature extrusion is between 10 bar and 300 bar (inclusive). Exemplarily, the extrusion pressure of the high temperature extrusion is 10 bar, 20 bar, 40 bar, 50 bar, 55 bar, 60 bar, 70 bar, 75 bar, 80 bar, 86 bar, 90 bar, 95 bar, 110 bar, 140 bar, 170 bar, 200 bar, 210 bar, 220 bar, 230 bar, 240 bar, 250 bar, 260 bar, 270 bar, 280 bar, 290 bar or 300 bar, etc.

[0084] The extrusion pressure described in the embodiment of the present disclosure refers to the extrusion pressure of the extrusion die (such as the die 13 ) located at the discharge port 11 c of the extrusion device 1 .

[0085] The extrusion pressure will affect the molding shape, surface smoothness, yield rate, production rate and density of the aerosol generating matrix. When the extrusion pressure is lower than 10 bar, the extruded matrix 1000 may crack after molding due to loose adhesion; when the extrusion pressure is higher than 300 bar, the extruded matrix 1000 is too dense (that is, the density of the extruded matrix 1000 is too large), which reduces the user experience. In addition, the material of the extrusion device 1 needs to be resistant to high pressure, and the transmission structure load of the extrusion device 1 is high (the torque required to be provided is high), which leads to a reduced service life of the extrusion device 1 and a high investment cost of the extrusion device 1. Therefore, controlling the extrusion pressure within the range of 10 bar to 300 bar can not only improve the yield rate of the aerosol generating matrix, but also extend the service life of the extrusion device 1.

[0086] More preferably, the extrusion pressure of high-temperature extrusion is 20 bar to 150 bar (including 20 bar and 150 bar).

[0087] In some embodiments, the water content of the mixed material is between 5% and 15% (inclusive). Exemplary, the water content of the mixed material is 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%, 13%, 14% or 15%, etc.

[0088] It can be understood that the mixed material is extruded at high temperature to form the extruded matrix 1000, which can reduce the amount of water added to the mixed material, and can even be extruded without adding water. High-temperature extrusion molding can reduce the extrusion pressure and reduce the extrusion speed. By reducing the extrusion pressure, an extruded matrix 1000 with a lower density can be obtained. By increasing the extrusion speed, production efficiency can be improved.

[0089] When the moisture content of the mixed material is less than 5%, the mixed material becomes loose and difficult to shape. Extrusion pressure is too high, resulting in slow extrusion speeds and reduced production efficiency and yield. When the moisture content of the mixed material is higher than 15%, the mixed material is too high in moisture. Extrusion at high temperatures results in poor viscosity of the slurry, making it difficult to shape. Therefore, controlling the moisture content of the mixed material within the range of 5% to 15% can improve both the production efficiency and yield of the aerosol-generating substrate and the yield rate of the aerosol-generating substrate.

[0090] S200: The extruded matrix is ​​subjected to hot air drying.

[0091] If the aerosol-generating substrate contains excessive liquid, such as water, it will be difficult to store and transport, may be easily deformed by stress, and may even burn the mouth when heated. Therefore, if the extruded substrate 1000 contains a high amount of solvent, such as water and / or other volatile lubricants, it is necessary to remove the solvent and / or lubricant to obtain a dry aerosol-generating substrate for use or storage.

[0092] Hot air drying refers to the use of a hot air flow to dry the extruded matrix 1000. The hot air flow can contact the extruded matrix 1000 to transfer heat to the extruded matrix 1000, causing the solvent and / or lubricant in the extruded matrix 1000 to evaporate or sublime, thereby reducing the solvent content and / or lubricant content in the extruded matrix 1000 and achieving the purpose of drying the extruded matrix 1000.

[0093] The manufacturing method that the disclosed embodiment provides, mixed material is carried out high temperature extrusion to form extrusion matrix 1000, wherein, mixed material is the constituent mixed material of aerosol generation matrix, then extrusion matrix 1000 is carried out hot air drying.By high temperature extrusion molding, the water added in mixed material can be reduced, even can be extruded without adding water, the mixed material of low moisture content, is conducive to feeding, and high temperature extrusion molding can reduce extrusion pressure and reduce extrusion speed, by reducing extrusion pressure, can obtain the extrusion matrix 1000 with lower density, by promoting extrusion speed, can improve production efficiency.In addition, due to the low water content in mixed material, the intensity of the extrusion matrix 1000 formed by high temperature extrusion can keep its form, and the shaping of low intensity can meet subsequent production step (such as cutting) demand, even can directly cut (i.e., do not need to carry out shaping step), thus is conducive to shaping, further improves production efficiency.Moreover, due to the low water content in mixed material, the corresponding reduction of the moisture that needs to be deviated from, drying strength is low, is more conducive to the retention of the aroma substance in extrusion matrix 1000, when mixed material does not add water, can even not dry. Furthermore, at high temperatures, the mixed material undergoes a Maillard reaction, producing more aroma components and improving the medium's mouthfeel. Hot air drying allows for batch drying of the extruded matrix 1000 at a rapid drying speed. Hot air drying reduces the moisture content of the extruded matrix 1000, facilitating storage and use of the aerosol-generating matrix. The aerosol-generating matrix obtained through high-temperature extrusion and hot air drying is an integrally molded structure. This ensures that the aerosol-generating matrix remains a single unit during use, such as during heated extraction or after heating has ceased, making it less susceptible to disintegration and falling.

[0094] For example, in one embodiment, referring to FIG8 , the aerosol-generating substrate is formed with an air channel 1000a, which extends through at least one longitudinal end of the aerosol-generating substrate. For example, the air channel 1000a extends through one longitudinal end of the aerosol-generating substrate. In another example, the air channel 1000a extends through both longitudinal ends of the aerosol-generating substrate. Airflow can flow longitudinally from one end of the aerosol-generating substrate to the other end of the aerosol-generating substrate. In this way, the airflow formed by the aerosol carried by the air can flow more smoothly, with less airflow resistance, which can significantly reduce the suction resistance during the inhalation process and enhance the inhalation experience.

[0095] In one embodiment, the air channel 1000a may be formed inside the aerosol-generating substrate or on the outer peripheral surface of the aerosol-generating substrate.

[0096] In one embodiment, the air channel 1000a is a linear air channel 1000a extending in a straight line. The linear air channel 1000a is easy to form, which can reduce manufacturing difficulty. The flow resistance of the airflow in the linear air channel 1000a is relatively small.

[0097] In one embodiment, airway 1000a is a curved airway 1000a, wherein at least a portion of the aperture of curved airway 1000a is curved with a curvature of 0.001. Curved airway 1000a can significantly increase the flow path of the airflow without significantly increasing the length of the aerosol-generating substrate, thereby extending the contact time between the airflow and the aperture wall of curved airway 1000a and improving the aerosol extraction rate.

[0098] In one embodiment, the curved airway 1000a is in the shape of a spiral line. That is, the three-dimensional shape of the curved airway 1000a is in the shape of a spatial spiral line. For example, during the extrusion process, the curved airway 1000a of the extruded matrix 1000 is formed by rotating the die 13. The line connecting any point of the spiral curved airway 1000a and the starting point has an inclination angle relative to its axis. The spiral curved airway 1000a can greatly extend the flow path of the airflow, precipitate the aerosol from the aerosol generating matrix into the curved airway 1000a, increase the flow velocity of the aerosol in the aerosol generating matrix, thereby increasing the impact force of the airflow, so that the aerosol can be evenly mixed, improve the uniformity of the aerosol, and enhance the user's inhalation experience.

[0099] It should be understood that the extruded matrix 1000 is a semi-finished product of the aerosol-generating matrix. The extruded matrix 1000 has the same morphology as the aerosol-generating matrix. In the case where the aerosol-generating matrix has air channels 1000a, the extruded matrix 1000 also has the same air channels 1000a.

[0100] There is no limitation on the cross-sectional shape of the airway 1000a located inside the aerosol generating matrix. For example, the cross-sectional shape can be circular, polygonal (including but not limited to triangle, square, prism, etc.), elliptical, runway-shaped or irregular, etc., where irregular refers to other symmetrical or asymmetrical shapes other than the shapes listed above.

[0101] The cross-sectional shape of the airway 1000a located on the outer peripheral surface of the aerosol generating substrate can be semicircular, semi-elliptical, polygonal or irregular, wherein irregular refers to other symmetrical or asymmetrical shapes other than the shapes listed above.

[0102] The number of airways 1000a is not limited, and there can be one or more airways 1000a. Plural refers to the number including two or more.

[0103] It should be noted that micropores exist within the aerosol-generating matrix. For example, in the aerosol-generating matrix of a particle assembly, the gaps between the particles constitute the micropores. However, the airway 1000a described in the present disclosure is different from the micropores. The airway 1000a described in the present disclosure is a pore in the macroscopic sense, while the micropores are pores in the microscopic sense. The cross-sectional area and length of the airway 1000a are much larger than those of the micropores. The airway 1000a is primarily formed by, for example, processing through the die 13. Therefore, the cross-sectional area and length of the airway 1000a can be changed according to design requirements. The size of the micropores is determined by the gaps between the particles. For example, if the mixed material is a granular material, the extrudate formed by extrusion of the mixed material has micropores. The cross-sectional area and length of the micropores are difficult to significantly change through processing.

[0104] In one embodiment, the mixed material is extruded at high temperature to form an extruded matrix, comprising:

[0105] The mixed material is extruded at high temperature through the extrusion device 1 to form an extruded matrix 1000 .

[0106] In one embodiment, the mixed material is extruded at high temperature through an extrusion device 1 to form an extruded matrix 1000, comprising:

[0107] S101: First, multiple raw materials are mixed into a mixed material;

[0108] S102: Add the mixed material into the extrusion device.

[0109] In this embodiment, multiple raw materials such as plant raw materials, auxiliary raw materials and smoke agent raw materials are pre-mixed and formed into a mixed material, which is then added to the extrusion device 1 for extrusion molding, that is, a slurry feeding method is adopted. The advantage of the slurry feeding method is that the material has good consistency, which can ensure the uniformity and stability of the product.

[0110] In one embodiment, the mixed material is extruded at high temperature through an extrusion device 1 to form an extruded matrix 1000, comprising:

[0111] S103: Adding a plurality of raw materials into a plurality of feed ports of an extruder respectively to form a mixed material in the extruder.

[0112] In this embodiment, the plant raw material, auxiliary raw material and smoke agent raw material are added to the extrusion device 1 in modules, and the multiple raw materials are mixed in the extrusion device 1. That is, a module feeding method is adopted.

[0113] For example, please refer to Figures 2 to 4. One of the multiple feed ports 11b is a solid feed port 11b1 for adding solid material, and one of the multiple feed ports 11b is a liquid feed port 11b2 for adding liquid material. The liquid feed port 11b2 is located downstream of the solid feed port 11b1 along the material flow direction. When adding materials, the solid material is first added through the solid feed port 11b1, and when the solid material reaches the liquid feed port 11b2, the liquid material is added. In addition, the feeding amount and speed can also be determined according to the production speed of the equipment and the material formula ratio. The advantage of this modular feeding method is that it can reduce the cost of material pre-treatment, ensure the continuity of the production process, and at the same time improve product production efficiency.

[0114] In some embodiments, referring to Figures 2 to 4, the extruder 1 includes a feeding screw 14 rotatably disposed in the feed port 11b. The feeding screw 14 can further homogenize the raw material and better ensure continuous and stable feeding of the raw material.

[0115] In one embodiment, referring to FIG4 , the extruded matrix 1000 is extruded horizontally. For example, the discharge port 11c is oriented horizontally, and the die 13 can be disposed horizontally. For example, for an extruded matrix 1000 having a curved, such as a spiral airway 1000a, the extruded matrix 1000 is extruded horizontally. The die 13 can be rotated so that the extruded matrix 1000 directly enters the next device, such as the hardening device 5. Since the rotation of the die 13 generates a certain amount of stress in the extruded matrix 1000, horizontal extrusion can reduce the stress generated by the extruded matrix 1000 and directly release it (the generated stress can be eliminated by heating), thereby improving the yield rate of the aerosol-generating matrix having the spiral airway 1000a.

[0116] In one embodiment, referring to Figures 2 and 3 , the extruded matrix 1000 is extruded in a vertical direction. For example, the discharge port 11c faces downward, and the die 13 can be arranged in a vertical direction. In other words, the extruded matrix 1000 is extruded in the direction of gravity. For example, for an extruded matrix 1000 having a linear air channel 1000a, extruding the extruded matrix 1000 in a vertical direction can improve the yield rate, reduce the investment cost of the extrusion device 1, and further reduce the floor space occupied by the extrusion device 1.

[0117] In one embodiment, the extruded matrix 1000 is extruded along an oblique direction. The oblique direction refers to an angle between the extrusion direction of the extruded matrix 1000 and the horizontal plane that is greater than 0° and less than 90°. Inclined extrusion not only reduces the extrusion pressure of the mixed material but also facilitates the spatial design of other devices, such as the drying device 2.

[0118] In one embodiment, the mixture comprises, by weight, 30 to 90 parts of a plant raw material, 1 to 15 parts of an auxiliary agent raw material, 5 to 30 parts of a smoke-generating agent raw material, 1 to 10 parts of an adhesive raw material, and 1 to 15 parts of a flavoring raw material. Specifically, the total weight of the plant raw material, the auxiliary agent raw material, the smoke-generating agent raw material, the adhesive raw material, and the flavoring raw material is 100 parts.

[0119] Plant materials are used to generate aerosols when heated. Auxiliary materials provide a skeletal support for the plant materials. Smoke-generating agents generate smoke when heated. Adhesive materials bind the component materials. Flavoring materials provide a characteristic aroma. Together, the plant materials and smoke-generating agents ensure aerosol production, while the flavorings enhance the aroma release during inhalation, improving the user experience. Auxiliary materials not only improve the fluidity of the mixture but also create a porous structure within the aerosol-generating matrix, facilitating aerosol extraction and flow. Adhesive materials ensure a stable mixture of plant material powder and auxiliary materials, preventing a loose structure.

[0120] In one embodiment, the plant raw material is one or more combinations of particles formed from crushed tobacco leaves, tobacco leaf fragments, tobacco stems, tobacco dust, and aromatic plants. Plant raw materials are the core source of flavor. Endogenous substances in plant raw materials can provide users with a sense of physiological satisfaction. Endogenous substances, such as alkaloids, enter the human bloodstream and stimulate the pituitary gland to produce dopamine, thereby achieving a sense of physiological satisfaction.

[0121] In one embodiment, the auxiliary agent raw material can be one or more combinations of inorganic fillers, lubricants, and emulsifiers. Inorganic fillers include one or more combinations of heavy calcium carbonate, light calcium carbonate, zeolite, attapulgite, talc, and diatomaceous earth. Inorganic fillers can provide skeletal support for the plant material and also have micropores, which can increase the porosity of the aerosol-generating matrix, thereby improving the aerosol release rate.

[0122] The lubricant includes one or more of candelilla wax, carnauba wax, shellac, sunflower wax, rice bran, beeswax, stearic acid, and palmitic acid. The lubricant can increase the fluidity of the plant material powder, reduce the friction between the plant material powders, make the overall density of the plant material powder distribution more uniform, and reduce the pressure required during the extrusion molding process, thereby reducing the wear of the die 13.

[0123] Emulsifiers include one or more combinations of polyglycerol fatty acid esters, Tween-80, and polyvinyl alcohol. Emulsifiers can, to a certain extent, slow down the loss of flavor substances during storage, increase the stability of flavor substances, and improve the sensory quality of the product.

[0124] In one embodiment, the smoke-generating agent raw material may include: a monohydric alcohol (such as menthol); a polyhydric alcohol (such as propylene glycol, glycerol, triethylene glycol, 1,3-butylene glycol and tetraethylene glycol); an ester of a polyhydric alcohol (such as triacetin, triethyl citrate, a mixture of diacetin esters, triethyl citrate, benzyl benzoate, tributyrin); a monocarboxylic acid; a dicarboxylic acid; a polycarboxylic acid (such as lauric acid, myristic acid) or an aliphatic ester of a polycarboxylic acid (such as dimethyl dodecanedioate, dimethyl tetradecanedioate, erythritol, 1,3-butylene glycol, tetraethylene glycol, triethyl citrate, propylene carbonate, ethyl laurate, triactin, meso-erythritol, a mixture of diacetin esters, diethyl suberate, triethyl citrate, benzyl benzoate, benzyl phenylacetate, ethyl vanillate, tributyrin, lauryl acetate) or one or more combinations thereof.

[0125] In one embodiment, the binder material wetting the interface with the component materials creates close contact, generating intermolecular attraction, thereby bonding the component materials, such as powders and liquids. The binder material can be a natural plant extract, a non-ionically modified viscous polysaccharide, or a combination thereof, including tamarind polysaccharide, guar gum, and modified cellulose (e.g., carboxymethyl cellulose). The binder serves to bond the particles together, preventing them from loosening. Furthermore, it improves the water resistance of the aerosol-generating matrix and is harmless to the human body.

[0126] In one embodiment, the flavoring raw materials are solid or liquid substances used to provide characteristic aromas, such as hay, roasted sweet, or nicotine. The flavoring raw materials may include one or more combinations of tobacco, aromatic plant extracts, extracts, essential oils, and absolutes. The flavoring raw materials may also include monomeric flavoring substances, such as one or more combinations of megastigmatrienone, neophytadiene, geraniol, and nerol.

[0127] For example, in one embodiment, the hot air drying temperature is between 50° C. and 200° C. For example, the hot air drying temperature is 50° C., 60° C., 61° C., 63° C., 65° C., 70° C., 72° C., 74° C., 85° C., 90° C., 95° C., 100° C., 128° C., 130° C., 135° C., 140° C., 145° C., 150° C., or 200° C., etc. If the hot air drying temperature is less than 50° C., the drying time is long, the production efficiency is low, the drying device 2 occupies a large area, and the equipment cost is high. When the hot air drying temperature is greater than 200°C, the moisture on the surface of the extruded matrix 1000 evaporates quickly, while the moisture inside the extruded matrix 1000 evaporates slowly, resulting in rapid shrinkage of the outer surface of the extruded matrix 1000, which is not conducive to the uniformity and stability of the shape and composition of the extruded matrix 1000. In addition, the aroma components and effective ingredients in the mixed material, such as alkaloids and / or smoke-generating agents, are easily lost due to heat, resulting in high manufacturing costs and reduced quality of the finished aerosol-generating matrix, and a decreased user experience.

[0128] Illustratively, in one embodiment, the hot air drying temperature is between 75°C and 125°C. For example, the hot air drying temperature is 75°C, 76°C, 80°C, 81°C, 82°C, 83°C, 86°C, 91°C, 94°C, 96°C, 98°C, 99°C, 101°C, 105°C, 106°C, 110°C, 120°C, or 125°C, etc. Using the above-mentioned temperatures for hot air drying allows the extruded matrix 1000 to dry slowly. While ensuring high drying efficiency, the evaporation rate of the liquid inside the extruded matrix 1000 and the evaporation rate of the liquid on the outer surface of the extruded matrix 1000 tend to be consistent, reducing the probability of the morphology of the extruded matrix 1000 changing during hot air drying. Furthermore, the aroma components and active ingredients in the mixture, such as alkaloids and / or smoke-generating agents, are not easily lost due to heat, thereby preserving the effective substances as much as possible and ensuring the quality of the finished aerosol-generating matrix.

[0129] In one embodiment, the dried extruded matrix 1000 has a moisture content of 3% to 13%. Preferably, the dried extruded matrix 1000 has a moisture content of 4% to 13%. Exemplary embodiments include extruded matrix 1000 having a moisture content of 3%, 4%, 5%, 10%, 11%, or 13%, among others. If the dried extruded matrix 1000 has a moisture content of less than 3%, not only will the dried extruded matrix 1000 be fragile during subsequent production and processing, resulting in a high defect rate for the dried extruded matrix 1000 and increased production costs, but also, during the heated puffing process, the aerosol-generating matrix will produce a high level of impurities, impacting the puffing experience. If the dried extruded matrix 1000 has a moisture content greater than 13%, the aerosol produced during the heated puffing process will have a high moisture content, which can easily cause a "burning mouth" sensation during puffing, reducing the puffing experience.

[0130] In one embodiment, the extruded substrate 1000 has an air channel 1000a extending through at least one longitudinal end thereof. During the hot air drying process, the hot air flows in a direction parallel to the longitudinal direction of the extruded substrate 1000. The hot air not only contacts the outer circumference of the extruded substrate 1000 but also enters the air channel 1000a, thereby increasing the contact area between the hot air and the extruded substrate 1000 and improving drying efficiency.

[0131] In one embodiment, after the mixed material is extruded at high temperature to form the extruded matrix 1000, the manufacturing method includes:

[0132] S300: cutting the extruded matrix.

[0133] 2 and 3 , the extruded matrix 1000 can be cut into a set length by the cutting tool 61 of the cutting device 6. In this way, the extruded matrix 1000 of the set length can be applied to the subsequent drying device 2 or packaging device 7, reducing the requirements for the subsequent devices.

[0134] It is understandable that the specific value of the set length is not limited, and the set length can be set according to the aerosol generating matrix or according to the conditions of the manufacturing equipment.

[0135] In some embodiments, the extruded matrix 1000 formed by high-temperature extrusion is a continuous structure. That is, during the extrusion process, the extruded matrix 1000 is continuously extruded, resulting in a continuous structure. Continuous extrusion can improve extrusion efficiency, and the extruded matrix 1000 can be subsequently cut to a desired length to shorten the length.

[0136] In some embodiments, the extruded matrix 1000 has a segmented structure with a preset length. That is, during the extrusion process, the extruded matrix 1000 naturally separates upon reaching the preset length. For example, the extruded matrix 1000 may separate from the die 13 upon reaching a critical length. In this way, the preset length of the extruded matrix 1000 can be the length of the aerosol-generating matrix, and the extruded matrix 1000 may not need to be segmented, thereby eliminating the need for a segmenting device 6 and reducing equipment costs.

[0137] It should be understood that the preset length may be greater than, less than, or equal to the set length.

[0138] It should be noted that, in some embodiments, step S300 may be before step S200, that is, the extruded matrix 1000 may be cut before hot air drying the extruded matrix 1000. In some embodiments, step S300 may be after step S200, that is, the extruded matrix 1000 may be cut after hot air drying the extruded matrix 1000.

[0139] For example, in one embodiment, the manufacturing method includes: S500, correcting the shape of the extruded matrix 1000. Correcting the shape refers to correcting the circumference and / or straightness of the extruded matrix 1000 using a jig. Straightness refers to the degree of curvature of the extruded matrix 1000 in the longitudinal direction.

[0140] Since the texture of the extruded matrix 1000 is usually relatively soft, during the manufacturing process of the extruded matrix 1000, the circumference of the extruded matrix 1000 may be deformed and / or the extruded matrix 1000 may be bent in the longitudinal direction. For example, during the process of slitting the extruded matrix 1000 by the slitting device 6, the circumference of the extruded matrix 1000 may be deformed and / or the extruded matrix 1000 may be bent in the longitudinal direction. Therefore, the extruded matrix 1000 can be calibrated for circumference and / or straightness by a jig.

[0141] It should be noted that step S500 can be performed after step S100 at any time when correction is required. Step S500 can be performed once or multiple times throughout the entire aerosol-generating substrate manufacturing process. For example, step S500 can be performed before and / or after step S300. For another example, step S500 can be performed before step S200.

[0142] In one embodiment, before hot air drying the extruded matrix 1000, the manufacturing method includes:

[0143] S400: Hardening the extruded matrix by cooling.

[0144] Referring to Figures 2 to 4 , the extruded matrix 1000 is cooled and hardened by the hardening device 5. Since the mixed material is a solid-liquid mixture, the hardness of the extruded matrix 1000 after high-temperature extrusion is relatively low. This makes the extruded matrix 1000 susceptible to deformation and difficult to maintain its shape. To improve the stability of the extruded matrix 1000 and facilitate subsequent production steps, the extruded matrix 1000 is cooled and hardened to increase its hardness.

[0145] In some embodiments, the hardness of the extruded matrix 1000 before hardening is between 0HB and 100HB (including 0HB and 100HB), which makes the extruded matrix 1000 before hardening soft and easy to deform.

[0146] In one embodiment, the hardness of the hardened extruded matrix 1000 is between 1HB and 200HB. For example, the hardness of the hardened extruded matrix 1000 is 1HB, 10HB, 20HB, 30HB, 40HB, 50HB, 80HB, 100HB, 150HB, or 200HB, etc. Within this hardness range, the hardened extruded matrix 1000 can well maintain its shape, preventing the outer surface of the hardened extruded matrix 1000 from adhering to other structures. The hardened extruded matrix 1000 is easy to cut and is not easily deformed after cutting, and the end faces formed by cutting are integrated and complete.

[0147] Preferably, the hardness of the extruded matrix 1000 before cooling and hardening can be 1HB to 60HB (inclusive), and after cooling and hardening, the hardness of the extruded matrix 1000 can be 40HB to 120HB (inclusive), and after hot air drying, the hardness of the extruded matrix 1000 can be 40HB to 300HB (inclusive). Preferably, the hardness of the extruded matrix 1000 after hot air drying can be 80HB to 250HB (inclusive).

[0148] It should be noted that HB is the Brinell hardness.

[0149] In some embodiments, hardening the extruded matrix 1000 by cooling includes placing the extruded matrix 1000 in a cooling environment for cooling and hardening, wherein the cooling environment temperature is lower than the hardening temperature of the extruded matrix 1000 .

[0150] For example, under the premise that the cooling environment temperature is lower than the hardening temperature of the extruded matrix 1000, if the hardening temperature of the extruded matrix 1000 is -100°C to 10°C (including -100°C and 10°C), the cooling environment temperature can be -270°C to 10°C (including -270°C and 10°C).

[0151] More preferably, if the hardening temperature of the extruded matrix 1000 is -30°C to 5°C (inclusive), the cooling environment temperature may be -50°C to 5°C (inclusive).

[0152] In one embodiment, the temperature of the extruded matrix 1000 before hardening is between 0° C. and 40° C., and the temperature of the extruded matrix 1000 after hardening is between -50° C. and 5° C. Exemplarily, the temperature of the extruded matrix 1000 after hardening is -50° C., -45° C., -40° C., -39° C., -35° C., -30° C., -25° C., -20° C., -15° C., -10° C., -5° C., 0° C., 1° C., 3° ​​C., or 5° C., etc.

[0153] The following are several specific embodiments to illustrate the manufacturing method of the present disclosure, which are described in detail as follows:

[0154] In the first specific embodiment, an aerosol-generating substrate is obtained through steps S100, S400, S300, and S200. In this embodiment, extrusion molding is performed in step S100, and the extruded substrate 1000 is hardened in step S400. The hardening increases the hardness of the extruded substrate 1000 to facilitate slitting in step S300. Finally, the moisture content of the extruded substrate 1000 is reduced in step S200 to obtain the finished aerosol-generating substrate.

[0155] In the second embodiment, steps S100, S300, and S200 are sequentially performed to obtain an aerosol-generating substrate. This embodiment differs from the first embodiment in that the hardening step is omitted. That is, the extruded substrate 1000 extruded from the extrusion device 1 can be directly cut. For example, if the aerosol-generating substrate is short in the longitudinal direction, the hardening step can be omitted if the slight deformation caused by cutting has no impact on subsequent production.

[0156] In the third embodiment, steps S100, S200, and S300 are sequentially performed to obtain an aerosol-generating substrate. This embodiment differs from the second embodiment in that the hot air drying and slitting steps are reversed. In this embodiment, the extruded substrate 1000 extruded in step S100 is first subjected to hot air drying in step S200 before being slitting. Hot air drying may cause volume shrinkage in the extruded substrate 1000. By prioritizing hot air drying and slitting, the longitudinal dimensional consistency of the aerosol-generating substrate after slitting can be improved.

[0157] In the fourth specific embodiment: an aerosol generating matrix is ​​obtained by sequentially performing steps S100 and S200. The difference between this embodiment and the first specific embodiment is that the hardening step and the slitting step are reduced, that is, the extruded matrix 1000 is subjected to hot air drying to obtain a finished aerosol generating matrix. Exemplarily, the extruded matrix 1000 is extruded in a vertical direction, and when the extruded matrix 1000 reaches a preset length (for example, when the extruded matrix 1000 reaches a critical value), the extruded matrix 1000 will naturally detach (separate), and the preset length of the extruded matrix 1000 is the length required for the aerosol generating matrix. In this way, there can be no hardening step and slitting step, thereby reducing subsequent processing processes and lowering production costs.

[0158] In one embodiment, the manufacturing method includes:

[0159] A wrapping layer is wrapped around the outer surface of the aerosol generating substrate.

[0160] 2 to 4 , a wrapping layer is wrapped around the outer surface of the aerosol generating substrate by a packaging device 7 , and the wrapping layer can protect the aerosol generating substrate.

[0161] The wrapping layer includes but is not limited to one or more combinations of materials such as fiber paper, metal foil, metal foil composite fiber paper, polyethylene composite fiber paper, PE (Polyethylene), PBAT (Polybutylene Adipate Terephthalate), etc.

[0162] In some embodiments, the outer surface of the aerosol-generating substrate may be wrapped with a wrapping layer and then combined with the functional segment to form an aerosol-generating article.

[0163] In other embodiments, the aerosol-generating substrate may be first combined with the functional segment, and then the outer surfaces of the aerosol-generating substrate and the functional segment are wrapped with a wrapping layer to form an aerosol-generating product.

[0164] In some other embodiments, a wrapping layer may be first wrapped around the outer surface of the aerosol-generating substrate, and then combined with the functional segment and wrapped with the wrapping layer to form an aerosol-generating article. In other words, the outer surface of the aerosol-generating substrate may be wrapped with multiple wrapping layers.

[0165] Referring to FIG. 2 to FIG. 4 , an embodiment of the present disclosure further provides a manufacturing device for an aerosol-generating substrate, the manufacturing device including an extrusion device 1 and a drying device 2 .

[0166] The extrusion device 1 is used for extruding the mixed material at high temperature to form an extruded matrix 1000 .

[0167] The drying device 2 is used to dry the extruded matrix 1000 with hot air.

[0168] The manufacturing equipment provided by the disclosed embodiment, extrusion device 1 carries out high temperature extrusion by mixture, can reduce the water added in mixture, can extrude even without adding water, low moisture mixture, is conducive to feeding, and high temperature extrusion molding can reduce extrusion pressure and reduce extrusion speed, by reducing extrusion pressure, can obtain the extrusion matrix 1000 with lower density, by promoting extrusion speed, can improve production efficiency. In addition, due to the low water content in mixture, the intensity of the extrusion matrix 1000 formed by high temperature extrusion can maintain its form, low-intensity shaping can meet subsequent production steps (such as cutting) demand, can even directly cut (i.e., do not need to carry out shaping step), thus is conducive to shaping, further improves production efficiency. Moreover, due to the low water content in mixture, the corresponding reduction of the moisture that needs to be deviated from, drying strength is low, is more conducive to the retention of the aroma substances in extrusion matrix 1000, when mixture does not add water, can even not dry. And at high temperature, Maillard reaction can occur in mixture, produces more aroma components, improves yield rate. Hot air drying allows for batch drying of the extruded matrix 1000 at a rapid drying speed. Hot air drying reduces the moisture content of the extruded matrix 1000, facilitating storage and use of the aerosol-generating matrix. The aerosol-generating matrix obtained through high-temperature extrusion and hot air drying is a one-piece structure. This ensures that the aerosol-generating matrix remains a single unit during use, such as during heated extraction or after heating, making it less susceptible to disintegration and dropout.

[0169] In one embodiment, referring to Figures 2 to 4 , a drying device 2 includes a housing 21, a fan 22, and a heater 23. Housing 21 defines a drying chamber 21a. Fan 22 is configured to drive airflow within drying chamber 21a. Heater 23 is disposed within drying chamber 21a and is configured to heat the airflow within drying chamber 21a. Heat generated by heater 23 heats the airflow within drying chamber 21a, while fan 22 accelerates the flow of air within drying chamber 21a.

[0170] In one embodiment, referring to Figures 3 and 4 , there are at least two heating elements 23 , spaced apart in the vertical direction to form a space for transporting the extruded matrix 1000. Specifically, the extruded matrix 1000 is transported in the space, with the at least two heating elements 23 positioned above and below the extruded matrix 1000. This allows the at least two heating elements 23 to simultaneously heat the extruded matrix 1000 from above and below, ensuring uniform heating of the extruded matrix 1000, improving the morphological stability of the extruded matrix 1000, and enhancing dehydration efficiency while reducing the load on each individual heating element 23.

[0171] In some embodiments, only one heating element 23 may be provided. Similarly, when the heating efficiency of the heating element 23 is very high, a better drying effect can be achieved.

[0172] The heating element 23 can be of any shape. For example, as shown in Figures 3 and 4 , the heating element 23 is plate-shaped. The heating element 23 can be a flat plate or a curved plate. The plate-shaped heating element 23 can be positioned horizontally. In other words, the thickness of the plate-shaped heating element 23 is perpendicular to the horizontal direction.

[0173] In one embodiment, referring to Figures 5 and 6 , the drying device 2 includes a conveyor belt 25 for conveying the extruded substrate 1000. The surface of the conveyor belt 25 facing the extruded substrate 1000 is formed with a plurality of grooves 25a. Each groove 25a is configured to accommodate a strip of extruded substrate 1000, with at least a portion of the extruded substrate 1000 located within the grooves 25a. The conveyor belt 25 is capable of rotating to cause the extruded substrate 1000 to move. For example, the plurality of grooves 25a are spaced apart along the conveying direction of the conveyor belt 25, with the lengthwise direction of the grooves 25a intersecting the conveying direction. The longitudinal ends of the grooves 25a extend through the widthwise ends of the conveyor belt 25. On one hand, the walls of the grooves 25a can restrict the movement of the extruded substrate 1000, preventing displacement of the extruded substrate 1000 during conveyance. On the other hand, each groove 25a is configured to accommodate a strip of extruded substrate 1000, and the grooves 25a can prevent multiple extruded substrates 1000 from contacting and sticking to each other.

[0174] In one embodiment, the groove 25a is formed with an inlet 51a, and the extruded matrix 1000 is placed into the groove 25a through the inlet 51a.

[0175] For example, the cross-sectional shape of the groove 25 a is not limited, and the cross-sectional shape of the groove 25 a may be semicircular or semi-elliptical, etc.

[0176] In some embodiments, the drying device 2 may also include a clamping member for clamping the extruded matrix 1000 to fix the extruded matrix 1000 on the conveyor belt 25. The clamping member limits the movement of the extruded matrix 1000 relative to the conveyor belt 25.

[0177] In one embodiment, referring to Figures 3 and 4 , the housing 21 is formed with an inlet 21b and outlets 21c51c, both of which are connected to the drying chamber 21a. A portion of a conveyor belt 25 is disposed in the space between the two heating elements 23. The conveyor belt 25 is used to transport the extruded substrate 1000 from the inlet 21b to the outlets 21c51c. The extruded substrate 1000 is placed onto the conveyor belt 25 through the inlet 21b and transported to the outlets 21c51c by the conveyor belt 25. The conveyor belt 25 enables continuous transport of the extruded substrate 1000.

[0178] In one embodiment, referring to Figures 5, 6, and 8, the extruded substrate 1000 has an air passage 1000a extending longitudinally through at least one end thereof. The drying device 2 includes a guide channel 24 for guiding hot air. The air outlet 24a of the guide channel 24 is located on one side of the extruded substrate 1000 in the longitudinal direction. In other words, the air outlet 24a of the guide channel 24 faces the opening of the air passage 1000a of the extruded substrate 1000. This allows the airflow from the air outlet 24a of the guide channel 24 to enter the air passage 1000a through the opening. For example, during the hot air drying process, the hot air flows in a direction parallel to the longitudinal direction of the extruded substrate 1000. This increases the contact area between the hot air and the extruded substrate 1000, improving drying efficiency.

[0179] For example, in one embodiment, referring to FIG5 , the outlet 51 c of the fan 22 is connected to the air inlet 24 b of the guide channel 24, so that the airflow from the fan 22 can flow out from the air outlet 24 a of the guide channel 24. The heater 23 can be disposed within the guide channel 24 or within the housing of the fan 22.

[0180] It is understandable that the air outlet direction of the air outlet 24a of the guide channel 24 can also be inclined at a certain angle to the longitudinal direction of the extruded matrix 1000. In this way, the inner and outer surfaces of the extruded matrix 1000 can be heated simultaneously to improve the drying efficiency.

[0181] In one embodiment, referring to Figures 3 and 4 , the manufacturing apparatus includes a microwave device 3 at least partially located within a drying chamber 21a. The microwave device 3 dries the extruded matrix 1000 by emitting microwave radiation. Microwave radiation drying involves using microwaves to induce intense vibrations in the polar molecules within the extruded matrix 1000, generating heat and promoting the volatilization of moisture within the extruded matrix 1000. This can reduce the hot air drying temperature and drying time, and improve the retention of aroma components and active ingredients in the aerosol-generating matrix.

[0182] For example, in some embodiments, microwave radiation drying can be performed before or simultaneously with hot air drying.

[0183] In one embodiment, referring to Figures 3 and 4 , the manufacturing apparatus includes an ultrasonic device 4 located at least partially within a drying chamber 21a. The ultrasonic device 4 radiates ultrasonic waves to dry the extruded matrix 1000. Ultrasonic radiation drying involves using ultrasound to create a cavitation effect within the extruded matrix 1000, lowering the temperature and promoting its evaporation. This can reduce hot air drying temperatures, shorten drying times, and enhance the retention of aroma components and active ingredients in the aerosol-generating matrix.

[0184] For example, in some embodiments, ultrasonic radiation drying may be performed before or simultaneously with hot air drying.

[0185] In one embodiment, referring to Figures 3 and 4 , the manufacturing apparatus includes an infrared device (not shown) at least partially located within the drying chamber 21a. The infrared device dries the extruded matrix 1000 by emitting infrared rays. The infrared device is an infrared generator that emits infrared rays. When the vibration frequency of the infrared rays equals the natural frequency of water, a phenomenon similar to resonant motion in vibration theory occurs. Molecular collisions occur within the extruded matrix 1000, generating a self-heating effect. Some molecules break free from the constraints of the extruded matrix 1000, and water escapes from the extruded matrix 1000, thereby rapidly and efficiently heating the material.

[0186] For example, in some embodiments, infrared radiation drying may be performed before or simultaneously with hot air drying.

[0187] 3 and 4 , the microwave device 3 can be disposed above or below any one of the heating elements 23. With this design, the microwave device 3 emits microwaves, such as electromagnetic waves, with a wider range, which can heat the extruded matrix 1000 more evenly.

[0188] In one embodiment, the microwave devices 3 can be disposed on both sides of the conveyor belt 25 along its width direction. With such a design, the microwave devices 3 emit microwaves, such as electromagnetic waves, with less energy loss, which can improve the overall heating rate.

[0189] 3 and 4 , the ultrasonic device 4 can be disposed above or below any one of the heating elements 23. With this design, the ultrasonic device 4 emits ultrasonic waves in a wider range, allowing the extruded matrix 1000 to be heated more evenly.

[0190] In one embodiment, the ultrasonic device 4 can be disposed on both sides of the conveyor belt 25 along its width direction. With such a design, the ultrasonic energy loss emitted by the ultrasonic device 4 is smaller, which can improve the overall heating rate.

[0191] 3 and 4 , the infrared device can be positioned above or below any one of the heating elements 23. With this design, the infrared device emits a wider range of infrared rays, allowing the extruded matrix 1000 to be heated more evenly.

[0192] In one embodiment, the infrared devices can be installed on both sides of the conveyor belt 25 along its width direction. With such a design, the infrared energy loss emitted by the infrared devices is smaller, which can improve the overall heating rate.

[0193] In one embodiment, referring to Figures 2 to 4 , an extrusion device 1 includes an extrusion barrel 11, an extrusion screw 12, and a die 13. The extrusion barrel 11 includes an extrusion chamber 11a for accommodating a mixed material and a discharge port 11c connected to the extrusion chamber 11a. The extrusion screw 12 is rotatably disposed within the extrusion chamber 11a. The die 13 is disposed at the discharge port 11c. The extrusion screw 12 pushes the mixed material out of the die 13 to form an extruded matrix 1000. The extrusion barrel 11 is formed with a feed port 11b connected to the extrusion chamber 11a. The extrusion screw 12 is used to push the mixed material toward the discharge port 11c. Exemplarily, during rotation of the extrusion screw 12, the mixed material can flow along the spiral channel on the circumferential surface of the extrusion screw 12 toward the discharge port 11c. The die 13 is used to form the extruded matrix 1000 having a predetermined cross-sectional shape.

[0194] In one embodiment, referring to Figures 3, 4, and 7 to 9, the extrusion device 1 includes a bottom die 15, and the die 13 is disposed on the bottom die 15. The bottom die 15 provides a mounting position for the die 13.

[0195] In one embodiment, the bottom die 15 closes the discharge port 11 c so that the mixed material is extruded through the die 13 .

[0196] In one embodiment, a single die 13 is provided on a single bottom die 15. In other words, a single die and a single die are adopted. In this way, the size of the extrusion screw 12 can be smaller.

[0197] In one embodiment, as shown in FIG9 , a single base die 15 is provided with multiple die openings 13 . In other words, a single die with multiple openings is employed. The mixed material passes through the multiple die openings 13 and simultaneously forms multiple extruded matrices 1000 . This improves production efficiency and is suitable for mass production.

[0198] In one embodiment, as shown in Figure 10 , multiple base dies 15 are provided. The extrusion device 1 includes an adapter 16 . Multiple base dies 15 are mounted on the adapter 16 , which seals the discharge port 11c . In other words, a multi-die, multi-port system is employed. Compared to a single-die, multi-port system, a multi-die, multi-port system can accommodate more dies 13 , thereby simultaneously forming more extruded matrices 1000 . This improves production efficiency and is more suitable for mass production.

[0199] In one embodiment, referring to FIG. 2 to FIG. 4 , the manufacturing apparatus includes a hardening device 5 , which is used to cool and harden the extruded matrix 1000 .

[0200] In one embodiment, referring to Figures 3, 4, and 11, the hardening device 5 includes a housing 51 and a conveyor belt 52. The housing 51 is formed with an inlet 51a, a cold chamber 51b, and an outlet 51c. The inlet 51a and the outlet 51c are both connected to the cold chamber 51b. The conveyor belt 52 is at least partially located within the cold chamber 51b and is used to transport the extruded matrix 1000 from the inlet 51a to the outlet 51c. The extruded matrix 1000 is placed onto the conveyor belt 52 through the inlet 51a and is then transported to the outlet 51c by the conveyor belt 52. The conveyor belt 52 enables continuous transport of the extruded matrix 1000, allowing the extruded matrix 1000 to be continuously hardened through the hardening device 5, achieving continuous production.

[0201] In one embodiment, referring to Figures 3, 4, and 11, the housing 51 is formed with an injection port 51d, which communicates with the cold chamber 51b for injecting a refrigerant into the cold chamber 51b. The refrigerant can contact the extruded matrix 1000, absorbing heat from the extruded matrix 1000, thereby cooling and hardening the extruded matrix 1000. This allows for rapid cooling of the outer surface of the hardened extruded matrix 1000, maintaining the stability of the extruded matrix 1000's morphology, facilitating continuous production, and improving production efficiency.

[0202] The refrigerant may be in liquid, gaseous or solid state. For example, the refrigerant includes but is not limited to liquid nitrogen or liquefied air.

[0203] Exemplarily, in one embodiment, referring to FIG. 11 , the injection port 51 d extends in a direction intersecting with the conveying direction of the conveyor belt 52 .

[0204] In one embodiment, referring to FIG11 , the injection port 51 d may be formed on the upper surface of the housing 51 . In this way, the refrigerant may enter the cooling chamber 51 b from top to bottom to contact the extruded substrate 1000 on the conveyor belt 52 .

[0205] In one embodiment, referring to Figure 11, the conveyor belt 52 is formed with a plurality of guide grooves 52a towards the surface of the extruded matrix 1000. Each guide groove 52a is used to place an extruded matrix 1000, and at least a portion of the extruded matrix 1000 is located in the guide grooves 52a. On the one hand, the groove wall of the guide grooves 52a can limit the extruded matrix 1000 and move to avoid the extruded matrix 1000 from being displaced during the transmission process. On the other hand, each guide groove 52a is used to place an extruded matrix 1000, and the guide grooves 52a can prevent a plurality of extruded matrices 1000 from contacting and adhering.

[0206] 11 , the length direction of the guide groove 52a is consistent with the conveying direction of the conveyor belt 52. A plurality of guide grooves 52a are arranged at intervals along the width direction of the conveyor belt 52.

[0207] In one embodiment, the guide groove 52a is formed with a take-in / put-out opening, through which the extruded matrix 1000 is placed into the guide groove 52a.

[0208] For example, the cross-sectional shape of the guide groove 52a is not limited, and the cross-sectional shape of the guide groove 52a can be semicircular or semi-elliptical, etc.

[0209] In one embodiment, referring to Figure 12 , the housing 51 is formed with a refrigerant passage 51e. The cold chamber 51b is isolated from and located within the refrigerant passage 51e, and the extruded matrix 1000 contacts the wall of the cold chamber 51b. In other words, the refrigerant does not contact the extruded matrix 1000. The refrigerant flows within the refrigerant passage 51e, and heat is transferred between the extruded matrix 1000 and the refrigerant via the wall of the cold chamber 51b. This prevents the extruded matrix 1000 from directly contacting the refrigerant, which could cause expansion, deformation, and cracking after rapid cooling.

[0210] In one embodiment, referring to FIG. 12 , the housing 51 includes an outer shell 511 and an inner shell 512. The inner shell 512 defines a cooling chamber 51b. The inner shell 512 is located within the outer shell 511 and together define a refrigerant passage 51e. The housing 51 has a double-shell structure. The outer shell 511 and the inner shell 512 define a refrigerant passage 51e for the flow of refrigerant. The cooling chamber 51b and the refrigerant passage 51e are separated by the inner shell 512. The extruded matrix 1000 contacts the inner surface of the inner shell 512 to transfer heat to the refrigerant through the inner shell 512.

[0211] In one embodiment, the smoothness of the wall surface of the cold cavity 51b is between Ra 1.2 μm and Ra 0.08 μm. Ra refers to the surface roughness average, which indicates the smoothness and roughness of a surface. Exemplary smoothness of the wall surface of the cold cavity 51b is Ra 1.2 μm, Ra 1.1 μm, Ra 1.0 μm, Ra 0.5 μm, Ra 0.3 μm, Ra 0.1 μm, or Ra 0.08 μm, etc. The wall surface of the cold cavity 51b is smooth, and the friction between the wall surface of the cold cavity 51b and the outer surface of the extruded matrix 1000 is minimal, preventing deformation of the extruded matrix 1000.

[0212] In one embodiment, the curing device 5 includes a refrigerant supply device, which is connected to the injection port 51d or the refrigerant supply device is connected to the refrigerant channel 51e. In other words, the refrigerant supply device is used to inject refrigerant into the injection port 51d. Alternatively, the refrigerant supply device is used to inject refrigerant into the refrigerant channel 51e.

[0213] In one embodiment, referring to FIG. 3 and FIG. 4 , the manufacturing apparatus includes a slitting device 6 having a slitting tool 61 . The slitting tool 61 slits the extruded matrix 1000 by physical contact or non-physical contact.

[0214] Physical contact refers to slitting the extruded matrix 1000 by direct contact of the slitting tool 61 with the extruded matrix 1000. For example, the slitting tool 61 can be a rotating roller, a cutting blade, a cutting wire, a roller cutter, or an extruder.

[0215] Non-physical contact means that the slitting tool 61 does not need to directly contact the extruded matrix 1000 to slit the extruded matrix 1000. For example, the slitting tool 61 releases laser, plasma, air knife or water knife to cut the extruded matrix 1000.

[0216] The manufacturing equipment used in the embodiments of the present disclosure can be used in the manufacturing methods of the embodiments of the present disclosure. The description of the manufacturing equipment embodiments is similar to the description of any of the manufacturing method embodiments and has the same beneficial effects as the manufacturing method embodiments. For technical details not disclosed in the manufacturing methods of the embodiments of the present disclosure, please refer to the description of the extrusion device 1, drying device 2, hardening device 5, and slitting device 6 in the embodiments of the present disclosure.

[0217] In the description of the present disclosure, the descriptions with reference to the terms "in one embodiment", "in some embodiments", "in other embodiments", "in yet other embodiments", or "exemplary" etc. mean that the specific features, structures, materials or characteristics described in conjunction with the embodiment or example are included in at least one embodiment or example of the embodiments of the present disclosure. In the present disclosure, the schematic expressions of the above terms do not necessarily refer to the same embodiment or example. Moreover, the specific features, structures, materials or characteristics described may be combined in a suitable manner in any one or more embodiments or examples. In addition, those skilled in the art may combine different embodiments or examples described in the present disclosure and the features of different embodiments or examples, unless they are mutually inconsistent.

[0218] The foregoing description is merely a preferred embodiment of the present disclosure and is not intended to limit the present disclosure. Those skilled in the art will readily appreciate that various modifications and variations are possible. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present disclosure are intended to be within the scope of protection of the present disclosure.

Claims

1. A method for manufacturing an aerosol - generating substrate, comprising: Extruding a mixture of materials at a high temperature to form an extruded substrate; Performing hot - air drying on the extruded substrate.

2. The manufacturing method according to claim 1, wherein, The extrusion temperature of the high - temperature extrusion is greater than 90°C and less than or equal to 200°C.

3. The manufacturing method according to claim 2, wherein, The extrusion temperature of the high - temperature extrusion is between 100°C and 150°C.

4. The manufacturing method according to claim 1, wherein, The extrusion pressure of the high - temperature extrusion is between 10 bar and 300 bar.

5. The manufacturing method according to claim 4, wherein, The extrusion pressure of the high - temperature extrusion is between 20 bar and 150 bar.

6. The manufacturing method according to claim 1, wherein, The temperature of the hot - air drying is between 50°C and 200°C; and / or, The water content of the mixture of materials is between 5% and 15%.

7. The manufacturing method according to claim 1, wherein, The temperature of the hot - air drying is between 75°C and 125°C; and / or, The water content of the dried extruded substrate is between 3% and 13%.

8. The manufacturing method according to claim 1, wherein, The extruded substrate has an air passage penetrating at least one end along its longitudinal direction. During the hot - air drying process, the flow direction of the hot air is parallel to the longitudinal direction of the extruded substrate.

9. The manufacturing method according to claim 1, wherein After the mixture of materials is extruded at a high temperature to form an extruded substrate, the manufacturing method includes: Cutting the extruded substrate.

10. The manufacturing method according to claim 1, wherein Before performing hot - air drying on the extruded substrate, the manufacturing method includes: Hardening the extruded substrate by cooling.

11. The manufacturing method according to claim 10, wherein, The hardness of the hardened extruded substrate is between 1 HB and 200 HB.

12. The manufacturing method according to claim 1, wherein, The extruded substrate is extruded horizontally; or, The extruded substrate is extruded vertically; or, The extruded substrate is extruded obliquely.

13. The manufacturing method according to claim 1, wherein, The mixture of materials includes, by weight parts: 30 to 90 parts of plant raw materials, 1 to 15 parts of auxiliary raw materials, 5 to 30 parts of fuming agent raw materials, 1 to 10 parts of binder raw materials, and 1 to 15 parts of spice raw materials.

14. A manufacturing device for an aerosol - generating substrate, the manufacturing device comprising: An extrusion device for extruding a mixture of materials at a high temperature to form an extruded substrate; A drying device for hot - air drying the extruded substrate.

15. The manufacturing apparatus according to claim 14, wherein, The drying device includes: A box body having a drying chamber; A fan for driving the air flow in the drying chamber; A heating element disposed in the drying chamber, the heating element being used to heat the air flow in the drying chamber.

16. The manufacturing apparatus according to claim 15, wherein, The number of the heating elements is at least two, and at least two of the heating elements are spaced apart in the up - and - down direction to form a spaced - apart space for conveying the extruded substrate.

17. The manufacturing apparatus according to claim 14, wherein, The extruded substrate has an air passage penetrating at least one end along its longitudinal direction. The drying device includes a diversion channel for guiding the hot air, and the air outlet of the diversion channel is located on one side of the extruded substrate along its longitudinal direction.

18. The manufacturing apparatus according to claim 14, wherein, The drying device includes a conveyor belt for conveying the extruded substrate. A plurality of grooves are formed on the surface of the conveyor belt facing the extruded substrate, and each groove is used to place one extruded substrate, and at least a part of the extruded substrate is located in the groove.

19. The manufacturing apparatus according to claim 15, wherein, The manufacturing device includes a microwave device at least partially located in the drying chamber, and the microwave device dries the extruded substrate by emitting microwave radiation; and / or, The manufacturing device includes an ultrasonic device at least partially located in the drying cavity, and the ultrasonic device dries the extruded matrix by emitting ultrasonic radiation; and / or, The manufacturing device includes an infrared device at least partially located in the drying cavity, and the infrared device dries the extruded matrix by emitting infrared rays.

Images