WO2024250637A1 - Manufacturing method and manufacturing system for aerosol generating matrix - Google Patents

Abstract

A manufacturing method for an aerosol generating matrix, which method comprises: extruding a mixed material at room temperature to form an extruded matrix, wherein the mixed material is a component of an aerosol generating matrix; and subjecting the extruded matrix to hot air drying. The mixed material is extruded at room temperature and has good fluidity, the surface smoothness of the extruded matrix is good, and the extrusion forming effect is good, thereby ensuring good extrusion efficiency and a relatively fast production speed, improving the yield. Hot air drying enables the extruded matrix to be dried in batches, and the drying speed is fast; and the water content of the extruded matrix is reduced by means of hot air drying, facilitating storage and use of the aerosol generating matrix. In addition, further provided is a manufacturing system for an aerosol generating matrix.

Description

A method and system for manufacturing an aerosol-generating substrate

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is based on the Chinese patent application with application number 202310686754.6 and application date June 9, 2023, and claims the priority of the above-mentioned Chinese patent application. The entire content of the above-mentioned Chinese patent application is hereby introduced into this application as a reference.

Technical Field

The present application relates to the technical field of aerosol generating substrates, and in particular to a method and system for manufacturing an aerosol generating substrate.

Background Art

Aerosol generating substrates include aerosol generating substrates that form aerosols by ignition and aerosol generating substrates that form aerosols by heating without burning. Among them, in a typical aerosol generating substrate that is heated without burning, the aerosol generating substrate is heated by an external heat source so that the aerosol generating substrate is just heated to a degree sufficient to emit an aerosol, and the aerosol generating substrate does not burn. By loading a smoky raw material, the smoky raw material is released by heating the aerosol generating substrate during use to form an aerosol. In the related art, the manufacturing method of the aerosol generating substrate is complicated, the production efficiency is low, and the manufactured aerosol generating substrate is prone to disintegration and falling during use.

Summary of the invention

In view of this, embodiments of the present application hope to provide a method and system for manufacturing an aerosol generating substrate that can improve production efficiency.

To achieve the above-mentioned purpose, the present application provides a method for manufacturing an aerosol generating substrate, comprising:

The mixed material is extruded at room temperature to form an extruded matrix, wherein the mixed material is a component of the aerosol generating matrix;

The extruded matrix is subjected to hot air drying.

In some embodiments, the extrusion temperature of the room temperature extrusion is between 35°C and 70°C.

In some embodiments, the extrusion pressure of the room temperature extrusion is between 0.5 bar and 300 bar.

In some embodiments, the extrusion pressure of the room temperature extrusion is between 20 bar and 80 bar.

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

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

In some embodiments, the moisture content of the extruded matrix after drying is 3% to 20%.

In some embodiments, the extruded matrix has air channels running through two opposite ends 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.

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

The extruded matrix is cut.

In some embodiments, before the extruded matrix is subjected to hot air drying, the manufacturing method comprises:

The extruded matrix is subjected to a hardening process.

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

In some embodiments, the extruded matrix is subjected to a hardening treatment, comprising:

The extruded matrix hardens by cooling.

In some embodiments, the extruded matrix is extruded in a horizontal direction; or,

The extruded matrix is extruded in a vertical direction relative to a horizontal direction; or,

The extruded matrix is extruded in an inclined direction relative to the horizontal direction.

In some embodiments, the mixture includes, 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.

The present application also provides a manufacturing system for an aerosol generating substrate, the manufacturing system comprising:

An extrusion device, the extrusion device is used to extrude the mixed material at room temperature to form an extruded matrix;

A hot air drying device is used to perform hot air drying on the extruded matrix.

In some embodiments, the hot air drying device comprises:

A box body having a drying chamber;

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

A heating element is disposed in the drying chamber, and is used to heat the airflow in the drying chamber.

In some embodiments, the number of the heating elements is at least two, the at least two heating elements are spaced apart in the up-down direction, and the extruded matrix is transferred between the at least two heating elements.

In some embodiments, the extruded matrix has air passages running through opposite longitudinal ends thereof, and the hot air drying device includes a guide channel for guiding hot air, wherein an air outlet of the guide channel is located on one side of the extruded matrix along the longitudinal direction.

In some embodiments, the hot air drying device comprises a conveyor belt, a surface of the conveyor belt facing the extruded matrix is formed with a plurality of grooves, each of the grooves is used to place a corresponding strip of the extruded matrix, and at least a portion of the extruded matrix is located in the groove.

In some embodiments, the manufacturing system includes a microwave-assisted device at least partially located in the drying chamber, wherein the microwave-assisted device dries the extruded matrix by emitting microwave radiation; and/or,

The manufacturing system includes an ultrasonic assist device at least partially located within the drying chamber, the ultrasonic assist device drying the extruded matrix by emitting ultrasonic radiation.

In some embodiments, the manufacturing system includes a hardening device for hardening the extruded matrix.

In some embodiments, the hardening device includes a housing, the housing is formed with an inlet, a cold chamber and an outlet, the inlet and the outlet are both connected to the cold chamber, and the cold chamber is used to cool and harden the extruded matrix.

In some embodiments, the shell is formed with an injection port, and the injection port is connected to the cold cavity to inject the refrigerant into the cold cavity.

In some embodiments, the shell includes a conveyor belt, at least a portion of which is located in the cold chamber, and the conveyor belt is used to convey the extruded matrix from the inlet to the outlet. A plurality of guide grooves are formed on the surface of the conveyor belt facing the extruded matrix, each of which is used to place a strip of the extruded matrix, and at least a portion of the extruded matrix is located in the guide groove.

In some embodiments, the shell is formed with a refrigerant channel, the cold cavity is isolated from the refrigerant channel and is located in the refrigerant channel, and the extruded matrix is in contact with a cavity wall surface of the cold cavity.

In some embodiments, the shell includes an outer shell and an inner shell, the inner shell forms the cold cavity, and the inner shell is located inside the outer shell and together defines a refrigerant channel.

In some embodiments, the smoothness of the cavity wall of the cold cavity is between Ra1.2 μm and Ra0.08 μm.

The manufacturing method provided in the embodiment of the present application extrude the mixed material at room temperature, the mixed material has good fluidity, the surface smoothness of the extruded matrix is good, and the extrusion molding effect is good, thereby ensuring good extrusion efficiency and faster production speed, and improving the yield rate. Hot air drying can dry the extruded matrix in batches, and the drying speed is fast. The water content of the extruded matrix is reduced by hot air drying, so as to facilitate the storage and use of the aerosol generating matrix. The aerosol generating matrix obtained by room temperature extrusion and hot air drying is an integrated molding structure. In this way, during the use of the aerosol generating matrix, for example, after being heated and sucked or stopped being heated, it is an integrated medium, and the problem of disintegration and falling is not easy to occur.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG1 is a flowchart of a manufacturing method in one embodiment of the present application;

FIG2 is a schematic diagram of the structure of a manufacturing system in one embodiment of the present application, wherein the extruded matrix is extruded in a horizontal direction;

FIG3 is a schematic structural diagram of a manufacturing system in another embodiment of the present application, wherein the extruded matrix is extruded in a vertical direction;

FIG4 is a schematic structural diagram of a guide channel and a conveyor belt in an embodiment of the present application;

FIG5 is an enlarged schematic diagram of point A in FIG4 ;

FIG6 is a schematic diagram of the structure of a die in one embodiment of the present application;

FIG7 is a schematic diagram of the structure of the die and the extruded matrix shown in FIG6 ;

FIG8 is a schematic structural diagram of a mouth mold and a bottom mold in one embodiment of the present application;

FIG9 is a schematic structural diagram of an adapter, a mouth mold and a bottom mold in one embodiment of the present application;

FIG10 is a schematic structural diagram of a hardening device in an embodiment of the present application;

FIG11 is a schematic structural diagram of a hardening device in another embodiment of the present application;

FIG. 12 is a half-section view of the structure shown in FIG. 11 .

DETAILED DESCRIPTION

It should be noted that, in the absence of conflict, the embodiments and technical features in the embodiments of the present application can be combined with each other, and the detailed description in the specific implementation method should be understood as an explanation of the purpose of the present application and should not be regarded as an improper limitation on the present application.

In this application, the temperature unit "°C" is Celsius. The pressure unit "bar" is bar. The unit "μm" is micrometer.

The aerosol generating substrate is used to generate aerosol by heating. Exemplarily, the aerosol generating substrate can be used to generate aerosol by heating without burning. That is, the aerosol generating substrate is heated below the ignition point to generate aerosol. The aerosol generating substrate does not burn during the process of generating aerosol. In some application scenarios, the aerosol generating substrate can be used to generate aerosol by ignition. The aerosol generating substrate of the present application is more used to generate aerosol by heating without burning.

The aerosol generating substrate provided in the embodiment of the present application is used for an aerosol generating product. The aerosol generating product includes an aerosol generating substrate and a functional segment. The functional segment is arranged at one end of the aerosol generating substrate in the longitudinal direction, and the functional segment includes a filter segment for filtering aerosol. The filter segment is used to filter the aerosol generated by the aerosol generating substrate.

The aerosol generating article is used for users to inhale the aerosol generated by the aerosol generating matrix. For example, the user can inhale the filtered aerosol by holding the filter section in the mouth. The aerosol generated by the aerosol generating matrix is transported to the filter section under the action of the suction negative pressure.

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

There are many heating methods for the heating component. Exemplarily, the heating methods include central heating, peripheral heating and/or bottom heating. The central heating method refers to the heating component being inserted into the interior of the aerosol generating product to bake and heat the aerosol generating product from the inside out. Exemplarily, the heating component can be inserted into the interior of the aerosol generating substrate for heating. The peripheral heating method refers to the heating component being arranged at the periphery of the aerosol generating product to bake and heat the aerosol generating product from the outside in. Exemplarily, the heating component can be arranged at the periphery of the aerosol generating substrate for heating. The bottom heating method refers to the heating component being located at the aerosol generating product. The bottom of the sol-generating product, for example, in one embodiment, uses a heating component (resistance or electromagnetic) to heat the air first, and then the hot air bakes and heats the aerosol-generating product from the bottom to the top (i.e., heat is transferred in the form of heat convection). Bottom heating can also transfer heat to the product in the form of heat conduction through a heating component such as a resistance or electromagnetic.

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.

The heating method of the heating component includes, but is not limited to, resistance heating, electromagnetic heating, infrared heating, microwave heating or laser heating. Among them, resistance heating and electromagnetic heating mainly transfer heat to the substrate in the form of heat conduction. Infrared heating, microwave heating or laser heating mainly transfer heat to the substrate in the form of thermal radiation. That is, the heating component can heat the substrate in one or more of the three forms of conduction, convection and radiation.

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

In some other embodiments, the functional section further includes a cooling section, which is located between the filtering section and the aerosol generating matrix, and is used to cool the aerosol before the filtering section filters the aerosol. The cooling section can improve the "hot mouth" phenomenon when the user inhales the aerosol.

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, propylene fiber and other materials.

The filter materials used in the filter 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 other materials.

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

Referring to FIG. 1 , an embodiment of the present application provides a method for manufacturing an aerosol generating substrate, the manufacturing method comprising:

S100: the mixed material is extruded at room temperature to form an extruded matrix, wherein the mixed material is a component of the aerosol generating matrix;

7, the extruded matrix 100 has the same cross-sectional shape as the aerosol generating matrix. That is, the cross-sectional shape of the extruded matrix 100 is the same as the cross-sectional shape of the aerosol generating matrix. The mixed material is structured and shaped using an extrusion process without changing the chemical properties of the mixed material.

It should be noted that the longitudinal direction refers to the extension direction of the aerosol generating matrix. For example, if the aerosol generating matrix is formed by extrusion, the longitudinal direction is the extension direction of the extruded matrix 100. The cross-sectional shape refers to the shape of the extruded matrix 100 with a plane perpendicular to the longitudinal direction as the cross section.

Referring to Figures 2 and 3, the mixed material is extruded at room temperature using an extrusion device 1 to form an extruded matrix 100. Extrusion molding refers to a processing method in which the mixed material is plasticized by heat and pushed toward the discharge port 12b by the extrusion screw 13 through the interaction between the barrel of the extrusion device 1 and the extrusion screw 13, and is formed into an extruded matrix 100 with a preset cross-sectional shape and corresponding airway holes through a die 14 (as shown in Figure 6).

During the extrusion process, the temperature will affect the fluidity of the mixture and the smoothness of the outer surface of the extruded matrix 100. Normal temperature extrusion can take into account both the fluidity of the mixture during the extrusion process and the smoothness of the outer surface of the extruded matrix 100.

Exemplarily, the extrusion temperature of room temperature extrusion is between 10°C and 90°C. For example, the extrusion temperature of room temperature extrusion is 10°C, 12°C, 15°C, 16°C, 18°C, 20°C, 25°C, 30°C, 40°C, 45°C, 50°C, 70°C, 75°C, 80°C, 85°C or 90°C, etc. If the temperature during extrusion is lower than 10°C, the mixed material has poor fluidity, slow production speed and low efficiency. If the temperature during extrusion is higher than 90°C, the mixed material flows too fast, and the pressure of the mixed material at the discharge port 12b is too small, which is not conducive to extrusion molding, resulting in a decrease in the yield rate. Therefore, the temperature of room temperature extrusion is between 10°C and 90°C, and both the fluidity of the mixed material during extrusion and the smoothness of the outer surface of the extruded matrix 100 can be taken into account.

It should be noted that in the field of extrusion, an extrusion temperature of 90°C or above is considered high-temperature extrusion, and an extrusion temperature of 10°C or below is considered low-temperature extrusion. The extrusion temperature is the temperature in the extrusion cavity of the extrusion device.

S200: hot air drying the extruded matrix.

The extruded substrate 100 is dried with hot air to reduce the liquid content. If the aerosol-generating substrate contains excessive liquid, the aerosol-generating substrate is difficult to store and transport, and is easily deformed by force because water is a component with a high heat capacity. It is also easy to "burn the mouth" when the aerosol-generating substrate is heated. Therefore, the extruded matrix 100 contains a lot of solvents such as water and/or other volatile lubricants, and the solvents and/or lubricants need to be removed to obtain a dry aerosol-generating matrix for use or storage.

Hot air drying refers to using a hot air flow to dry the extruded matrix 100. The hot air flow can contact the extruded matrix 100 to transfer heat to the extruded matrix 100, so that the solvent and/or lubricant in the extruded matrix 100 is heated to a gaseous state, thereby reducing the content of the solvent and/or the content of the lubricant in the extruded matrix 100, and achieving the purpose of drying the extruded matrix 100.

The manufacturing method provided in the embodiment of the present application extrude the mixed material at room temperature, the mixed material has good fluidity, the surface smoothness of the extruded matrix 100 is good, and the extrusion molding effect is good, thereby ensuring good extrusion efficiency and faster production speed, and improving the yield rate. Hot air drying can batch dry the extruded matrix 100, and the drying speed is fast. The water content of the extruded matrix 100 is reduced by hot air drying, so as to facilitate the storage and use of the aerosol generation matrix. The aerosol generation matrix obtained by room temperature extrusion and hot air drying is an integrated molding structure. In this way, during the use of the aerosol generation matrix, for example, after being heated and sucked or stopped being heated, it is an integrated medium, and the problem of disintegration and falling is not easy to occur.

Exemplarily, in one embodiment, please refer to FIG. 7 , the aerosol generating substrate is formed with an air channel 100a, and the air channel 100a runs through the opposite ends of the aerosol generating substrate in the longitudinal direction. The 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 air carrying the aerosol can flow more smoothly, and the airflow flow resistance is smaller, which can significantly reduce the suction resistance during the suction process and improve the suction experience.

In one embodiment, the air channel 100a may be formed inside the aerosol generating substrate or on the outer peripheral surface of the aerosol generating substrate.

In one embodiment, the air channel 100a is a linear air channel 100a extending in a straight line. The linear air channel 100a is easy to form and can reduce the difficulty of manufacturing. The flow resistance of the airflow in the linear air channel 100a is relatively small.

In one embodiment, the airway 100a is a curved airway 100a, and at least part of the hole section of the curved airway 100a is a curved shape with a non-zero curvature. The curved airway 100a can greatly increase the flow path of the airflow without significantly increasing the length of the aerosol generating substrate, and can extend the contact time between the airflow and the hole wall of the curved airway 100a, thereby improving the aerosol extraction rate.

In one embodiment, the curved airway 100a is in a spiral shape. The three-dimensional shape is a spatial spiral line. For example, a spiral curved airway can be formed by rotating the die 14 during the extrusion process. The line connecting any point of the spiral curved airway 100a and the starting point has an inclination angle relative to its axis. The spiral curved airway 100a can greatly extend the flow path of the airflow, precipitate the aerosol from the aerosol generating matrix into the curved airway 100a, increase the flow speed of the aerosol in the aerosol generating matrix, thereby increasing the impact force of the airflow, allowing the aerosol to be evenly mixed, improving the uniformity of the aerosol, and enhancing the user's suction experience.

It should be understood that the extruded substrate 100 has the same cross-sectional shape as the aerosol-generating substrate, the extruded substrate 100 is a semi-finished product of the aerosol-generating substrate, and in the case where the aerosol-generating substrate has air channels 100a, the extruded substrate 100 also has the same air channels 100a.

There is no limitation on the cross-sectional shape of the airway 100a located inside the aerosol generating matrix. For example, the cross-sectional shape may be circular, polygonal (including but not limited to triangle, square, prism, etc.), elliptical, racetrack-shaped or irregular-shaped, etc., wherein irregular-shaped refers to other symmetrical or asymmetrical shapes other than the shapes listed above.

The cross-sectional shape of the airway 100a located on the outer peripheral surface of the aerosol generating substrate can be semicircular, semi-elliptical, polygonal or irregular, etc., wherein irregular refers to other symmetrical or asymmetrical shapes other than the shapes listed above.

The number of the airway 100a is not limited, and the airway 100a may be one or more than one. The term "more than one" means that the number includes two or more than two.

It should be noted that there are micropores inside the aerosol generating matrix. For example, for the aerosol generating matrix of the particle combination, the gaps between the particles constitute micropores. However, the airway 100a described in the present application is different from the micropores. The airway 100a described in the present application belongs to the pores in the macroscopic sense, and the micropores belong to the pores in the microscopic sense. The cross-sectional area and length and other dimensions of the airway 100a are much larger than those of the micropores. The airway 100a is mainly processed by the designed mold, such as the die. Therefore, the cross-sectional area and length and other dimensions of the airway 100a can be changed according to the design requirements, and the size of the micropores is determined by the gaps between the particles. For example, the mixed material is a granular material, and the extruded matrix formed by extrusion of the mixed material has micropores. The cross-sectional area and length and other dimensions of the micropores are naturally formed by the extrusion process and the raw material components. The mixed material is added to the extrusion bin and flows out of the die mouth to generate a certain expansion to form micropores.

In one embodiment, the mixed material is extruded at room temperature using an extrusion device to form an extruded matrix, comprising:

S110: firstly mixing a plurality of raw materials into the mixed material;

S120: Adding the mixed material into the extrusion device.

In this embodiment, various raw materials such as plant raw materials, auxiliary raw materials and smoke agent raw materials are pre-mixed and formed into slurry, and 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 mixed material has good consistency, which can ensure the uniformity and stability of the product.

In one embodiment, the mixed material is extruded at room temperature using an extrusion device 1 to form an extruded matrix 100, including:

S130: Adding a plurality of raw materials into a plurality of feed ports of the extrusion device respectively to form the mixed material in the extrusion device.

In this embodiment, various raw materials such as plant raw materials, auxiliary raw materials and smoke generating agent raw materials are added to the extrusion device 1 in modules, and the raw materials are mixed in the extrusion device 1. That is, a module feeding method is adopted.

Exemplarily, one of the multiple feed ports 12c is a solid material feeding port 12c' for adding solid material, one of the multiple feed ports 12c is a liquid material feeding port 12c", for adding liquid material, and the liquid material feeding port 12c" is located downstream of the solid material feeding port 12c' along the raw material flow direction. When adding materials, the solid material is first added through the solid material feeding port 12c', and when the solid material reaches the liquid material feeding port 12c", the liquid material is started to be added. In addition, the feeding amount and speed can also be determined according to the production speed of the equipment and the raw material formula ratio. The advantage of this modular feeding method is that it can reduce the cost of raw material pre-treatment, ensure the continuity of the production process, and at the same time improve product production efficiency.

In some embodiments, the extruder 1 includes a feeding screw 11 rotatably disposed in the feed port. The feeding screw 11 can further homogenize the raw material and can better ensure continuous and stable feeding of the raw material.

In one embodiment, the mixed material includes, 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. Specifically, the total weight of the plant raw materials, auxiliary raw materials, smoke-generating agent raw materials, adhesive raw materials, and flavor raw materials is 100 parts.

Plant materials are used to generate aerosols when heated. Auxiliary materials are used to provide skeleton support for plant materials. Smoke-generating materials are used to generate large amounts of smoke when heated. Adhesive materials are used to bond component raw materials. The flavor raw materials are used to provide characteristic aroma. In this way, the plant raw materials and smoke-generating agent raw materials can ensure the amount of aerosol generated, while the flavor raw materials can increase the release of aroma during the inhalation process and improve the user experience. The auxiliary raw materials can not only improve the fluidity of the mixed materials, but also make the aerosol generation matrix porous to facilitate the extraction and flow of the aerosol. The adhesive raw materials ensure that the plant raw material powder and the auxiliary agents form a stable mixture to avoid a loose structure.

In one embodiment, the plant raw material is one or more combinations of powders formed by crushing tobacco raw materials, tobacco leaf fragments, tobacco stems, tobacco dust, and aromatic plants. The plant raw material is the core source of flavor. The endogenous substances in the plant raw material can produce physiological satisfaction for the user. The endogenous substances, such as alkaloids, enter the human blood and promote the pituitary gland to produce dopamine, thereby obtaining physiological satisfaction.

In one embodiment, the auxiliary agent raw material can be one or more combinations of inorganic fillers, lubricants, and emulsifiers. Among them, the inorganic filler includes one or more combinations of heavy calcium carbonate, light calcium carbonate, zeolite, attapulgite, talc, and diatomaceous earth. The inorganic filler can provide a skeleton support for the plant raw material, and the inorganic filler also has micropores, which can increase the porosity of the aerosol generation matrix, thereby increasing the aerosol release rate.

The lubricant includes one or more combinations 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 raw material powder, reduce the friction between the plant raw material powders, make the overall density of the plant raw material powder distribution more uniform, and also reduce the pressure required in the extrusion molding process, reducing the wear of the die 14.

The emulsifier includes one or more combinations of polyglycerol fatty acid ester, Tween-80, and polyvinyl alcohol. The emulsifier can slow down the loss of flavor substances during storage to a certain extent, increase the stability of flavor substances, and improve the sensory quality of the product.

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, endotoxin, 1,3-butylene glycol ... One or more combinations of racemic erythritol, diacetin mixture, diethyl suberate, triethyl citrate, benzyl benzoate, benzyl phenylacetate, ethyl vanillate, glyceryl tributyrate, and lauryl acetate).

In one embodiment, the adhesive raw material is in close contact with the component raw material interface by wetting, generating intermolecular attraction, thereby playing the role of bonding the component raw materials such as powders, liquids, etc. The adhesive raw material can be a natural plant extract, a non-ionized modified viscous polysaccharide, including one or more combinations of tamarind polysaccharide, guar gum, and modified cellulose (such as carboxymethyl cellulose). The adhesive is used to bond the particles together, which is not easy to loosen. In addition, it improves the water resistance of the aerosol generation matrix and is harmless to the human body.

In one embodiment, the flavor raw material is used to provide a characteristic aroma, such as a solid or liquid substance of hay aroma, roasted sweet aroma, and nicotine. The flavor raw material may include one or more combinations of tobacco, flavor plant extracts, extracts, essential oils, and absolute oils; the flavor raw material may include one or more combinations of monomer flavor substances, such as megastigmatriene, neophytadiene, geraniol, nerol, and the like.

In one embodiment, the extrusion temperature of room temperature extrusion is between 35°C and 70°C. For example, the extrusion temperature of room temperature extrusion is 35°C, 36°C, 37°C, 40°C, 45°C, 50°C, 55°C, 60°C, 65°C, 68°C or 70°C, etc. Since the higher the extrusion temperature during room temperature extrusion, the greater the energy consumption, and the lower the extrusion temperature, the lower the extrusion efficiency will be. The extrusion temperature of room temperature extrusion is between 35°C and 70°C, which can take into account both energy consumption and extrusion efficiency.

In one embodiment, the extrusion pressure of room temperature extrusion is between 0.5 bar and 300 bar. Exemplarily, the extrusion pressure of room temperature extrusion is 0.5 bar, 35 bar, 40 bar, 45 bar, 50 bar, 55 bar, 60 bar, 65 bar, 70 bar, 75 bar, 80 bar, 85 bar, 90 bar, 95 bar, 100 bar, 150 bar, 200 bar, 250 bar, 280 bar or 300 bar, etc. The extrusion pressure will affect the molding shape, outer surface smoothness, yield rate and production rate of the extruded matrix 100. When the extrusion pressure is less than 0.5 bar, the molding rate of the extruded matrix 100 is low, the defective rate increases, and then the production rate slows down and the production cost increases; when the extrusion pressure is greater than 300 bar, the transmission structure load of the extrusion device 1 is high (i.e., the torque required to be provided is high), resulting in a reduction in the service life of the extrusion device 1.

It should be noted that the extrusion pressure refers to the pressure at the discharge port of the extrusion device, such as the adapter or the die.

In one embodiment, the extrusion pressure of room temperature extrusion is between 20 bar and 80 bar. Exemplarily, the extrusion pressure of room temperature extrusion is 20 bar, 22 bar, 25 bar, 30 bar, 36 bar, 39 bar, 44 bar, 52 bar, 60 bar, 64 bar, 68 bar, 71 bar, 75 bar, 78 bar or 80 bar, etc. When the extrusion pressure is less than 20 bar, the molding rate is not significantly improved; when the extrusion pressure is greater than 80 bar, the energy consumption of the extrusion device 1 increases significantly, while the molding rate does not change much. Therefore, the extrusion pressure of room temperature extrusion is between 1 bar and 30 bar, which can take into account both the molding rate and energy consumption.

Exemplarily, in one embodiment, the temperature of hot air drying is between 50° C. and 200° C. For example, the temperature of hot air drying is 50° C., 60° 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., 160° C., 170° C., 180° C., 190° C. or 200° C., etc. When the temperature of hot air drying is less than 50° C., the drying time is long, the production efficiency is low, the hot air 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 100 evaporates quickly, while the moisture inside the extruded matrix 100 evaporates slowly, resulting in rapid shrinkage of the outer surface of the extruded matrix 100, which is not conducive to the uniformity and stability of the shape and composition of the extruded matrix 100. In addition, the aroma components and effective substances 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 reduced user experience.

Exemplarily, in one embodiment, the temperature of hot air drying is between 75°C and 125°C. For example, the temperature of hot air drying 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. The hot air drying adopts the above temperature, and the extruded matrix 100 can be slowly dried at low temperature. Under the condition of ensuring a high drying efficiency, the evaporation rate of the liquid inside the extruded matrix 100 and the evaporation rate of the liquid on the outer surface of the extruded matrix 100 tend to be consistent, reducing the probability of the morphology of the extruded matrix 100 changing with hot air drying. The aroma components and effective substances in the mixed material, such as alkaloids and/or smoke-generating agents, are not easily lost by heat, and the aroma components and effective substances can be retained as much as possible, ensuring the quality of the finished aerosol-generating matrix.

In one embodiment, the moisture content of the dried extruded matrix 100 is between 3% and 20%. Preferably, the moisture content of the dried extruded matrix 100 is between 4% and 13%. Exemplarily, the moisture content of the dried extruded matrix 100 is 3%, 4%, 5%, 10%, 11%, 13%, 15%, 16%, 18% or 20%, etc. When the moisture content of the dried extruded matrix 100 is less than 3%, not only is the dried extruded matrix 100 fragile during the subsequent production and processing, resulting in a high subsequent production defect rate of the dried extruded matrix 100, thereby increasing production costs; but also during the heating and puffing process, the impurities generated by the aerosol-generating matrix are high, affecting the puffing experience. When the moisture content of the dried extruded matrix 100 is greater than 20%, the moisture content of the aerosol of the dried extruded matrix 100 during the heating and puffing process is high, which is easy to produce a "hot mouth" phenomenon during the puffing process, reducing the puffing experience.

In one embodiment, the extruded substrate 100 has air passages 100a running through opposite ends 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 substrate 100. The hot air can not only contact the outer peripheral surface of the extruded substrate 100, but also enter the air passages 100a, thereby increasing the contact area between the hot air and the extruded substrate 100 and improving the drying efficiency.

In one embodiment, after the mixed material is extruded at room temperature to form an extruded matrix, the manufacturing method includes:

S300: cutting the extruded matrix.

2 and 3, the extruded matrix 100 can be cut by the cutting device 6 so that the extruded matrix 100 reaches a set length. The extruded matrix 100 can be cut into a plurality of media segments so that the media segments have a set length, so that the media segments can be suitable for the subsequent hot air drying device 2, reducing the requirements for the subsequent devices.

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 equipment conditions of the manufacturing system.

In some embodiments, the extruded matrix 100 extruded at room temperature is in a continuous structure. That is, during the extrusion process, the extruded matrix 100 is continuously extruded so that the extruded matrix 100 is in a continuous structure. Continuous extrusion can improve extrusion efficiency, and the extruded matrix 100 is subsequently cut into multiple media segments to shorten the length.

In some embodiments, the extruded matrix 100 is a segmented structure with a preset length. That is, during the extrusion process, the extruded matrix 100 is naturally separated when it reaches the preset length. For example, the extruded matrix 100 may be separated from the die 14 when it reaches a critical value. In this way, the preset length of the extruded matrix 100 may be the length of the aerosol generating matrix, and the extruded matrix 100 may not be segmented, so that the extruded matrix 100 can be saved. About 6 cutting devices are used to reduce equipment costs.

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

It should be noted that, in some embodiments, step S300 may be before step S200, that is, the extruded matrix 100 may be cut before hot air drying the extruded matrix 100. In some embodiments, step S300 may be after step S200, that is, the extruded matrix 100 may be cut after hot air drying the extruded matrix 100.

Exemplarily, in one embodiment, the manufacturing method includes: S500, correcting the shape of the extruded matrix. Correction refers to correcting the circumference and/or straightness of the extruded matrix 100 by a jig. Straightness refers to the degree of curvature of the extruded matrix 100 in the longitudinal direction.

Since the texture of the extruded matrix 100 extruded by room temperature extrusion molding is usually relatively soft, during the manufacturing process of the extruded matrix 100, the circumference of the extruded matrix 100 is deformed and/or the extruded matrix 100 is bent in the longitudinal direction. For example, during the process of slitting the extruded matrix 100 by the slitting device 6, the circumference of the extruded matrix 100 may be deformed and/or the extruded matrix 100 may be bent in the longitudinal direction. Therefore, the extruded matrix 100 can be calibrated for circumference and/or straightness by a jig.

It should be noted that step S500 can be implemented in any case where correction is required after step S100, and step S500 can be implemented once or multiple times during the entire manufacturing process of the aerosol generating substrate. For example, step S500 can be implemented before and/or after step S300. For another example, step S500 can be implemented before step S200.

In one embodiment, before the extruded matrix is subjected to hot air drying, the manufacturing method comprises:

S400: hardening the extruded matrix.

Since the mixed material is a solid-liquid mixture, the hardness of the extruded matrix 100 after room temperature extrusion is relatively low, so that the extruded matrix 100 after room temperature extrusion is prone to deformation and it is difficult to maintain the shape of the extruded matrix 100. In order to improve the stability of the shape of the extruded matrix 100 and facilitate subsequent production processes, the extruded matrix 100 is hardened to increase its hardness.

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

In one embodiment, the hardness of the hardened extruded matrix 100 is between 1HB and 200HB. The hardness of the hardened extruded matrix 100 is between 40HB and 120HB. Exemplarily, the hardness of the hardened extruded matrix 100 is 1HB, 10HB, 20HB, 30HB, 40HB, 50HB, 55HB, 60HB, 70HB, 80HB, 85HB, 90HB, 95HB, 100HB, 110HB, 120HB, 130HB, 140HB, 150HB, 160HB, 170HB, 180HB, 190HB or 200HB, etc. Under this hardness range, the hardened extruded matrix 100 can maintain its shape well, avoid the situation that the outer surface of the hardened extruded matrix 100 will adhere to other structures, the hardened extruded matrix 100 is easy to cut, and the extruded matrix 100 after cutting is not easy to deform, and the end face formed by cutting is integral and complete.

Preferably, the hardness of the extruded matrix 100 before cooling and hardening can be 1HB to 60HB (including 1HB and 60HB), and after cooling and hardening, the hardness of the extruded matrix 100 can be 40HB to 120HB (including 40HB and 120HB), and after hot air drying, the hardness of the extruded matrix 100 can be 40HB to 300HB (including 40HB and 300HB). Preferably, the hardness of the extruded matrix 100 after hot air drying can be 80HB to 250HB (including 80HB and 250HB).

It should be noted that HB is the Brinell hardness.

In one embodiment, the extruded matrix is subjected to a hardening treatment, comprising:

The extruded matrix hardens by cooling.

Specifically, the extruded matrix 100 is placed at a cooling environment temperature for cooling and hardening, and the cooling environment temperature is lower than the hardening temperature of the extruded matrix 100 .

Exemplarily, the hardening temperature of the extruded matrix 100 is -100°C to 60°C (including -100°C and 60°C). Preferably, the hardening temperature of the extruded matrix 100 is -30°C to 40°C (including -30°C and 40°C).

The temperature of the cooling environment is between -270°C and 60°C (including -270°C and 60°C). Preferably, the temperature of the cooling environment is between -100°C and 40°C (including -100°C and 40°C).

In one embodiment, the temperature of the extruded matrix 100 before hardening is between 0° C. and 40° C., and the temperature of the extruded matrix 100 after hardening is between -50° C. and 5° C. Exemplarily, the temperature of the extruded matrix 100 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.

As shown in FIG. 2 , in one embodiment, the extruded matrix 100 is extruded in a horizontal direction. For example, the discharge port 12b is oriented in a horizontal direction, and the die 14 can be arranged in a horizontal direction. For example, the extruded matrix 100 having a spiral airway 100a, after being extruded in the horizontal direction, can pass through a rotating die so that the extruded matrix 100 directly enters the next device, and the horizontal extrusion can reduce the direct release of the stress generated by the rotation of the extruded matrix 100 (the generated stress can be eliminated by heating), thereby improving the yield rate of the aerosol generating matrix having the spiral airway 100a.

As shown in Figure 3, in one embodiment, the extruded matrix 100 is extruded in a vertical direction relative to the horizontal direction. For example, the discharge port 12b faces downward, the extrusion direction is perpendicular to the horizontal plane, and the die 14 can be arranged in the vertical direction. In other words, the extruded matrix 100 is extruded in the direction of gravity. Exemplarily, for the extruded matrix 100 with a linear air channel 100a, the extruded matrix 100 is extruded in the vertical direction to improve the yield rate, reduce the investment cost of the extrusion device 1, and further reduce the floor space of the extrusion device 1.

In one embodiment, the extruded matrix 100 is extruded along an inclined direction relative to the horizontal direction. The inclined direction refers to the angle between the extrusion direction of the extruded matrix 100 and the horizontal plane being greater than 0° and less than 90°. Inclined extrusion can not only reduce the extrusion pressure of the mixed material, but also facilitate the space design of other equipment such as the hot air drying device 2.

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

In the first specific embodiment, the aerosol generating matrix is obtained through steps S100, S400, S300, and S200 in sequence. In this embodiment, the extrusion molding is performed through step S100, and the extruded matrix 100 is hardened through step S400. The hardness of the extruded matrix 100 can be increased by hardening so as to perform the cutting in step S300, and finally the moisture content of the extruded matrix 100 is reduced through S200, and finally the finished aerosol generating matrix is obtained.

In the second specific embodiment, the aerosol generating matrix is obtained by sequentially performing steps S100, S300, and S200. The difference between this embodiment and the first specific embodiment is that the hardening step is reduced, that is, the extruded matrix 100 extruded from the extrusion device 1 can be directly cut, and when the length of the aerosol generating matrix is short, the slight deformation caused by the cutting has no effect on the subsequent production, and the hardening step can be omitted.

In the third specific embodiment, the aerosol-generating matrix is obtained by sequentially performing steps S100, S200, and S300. The difference between this embodiment and the second specific embodiment is that the hot air drying step and the slitting step are switched in order. In this embodiment, the extruded matrix 100 extruded from the extrusion device 1 is first hot-air dried and then slitting. The extruded matrix 100 may shrink in volume after hot-air drying. The slitting method can improve the longitudinal size consistency of the aerosol generating matrix after slitting.

In the fourth specific embodiment: the 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 100 is subjected to hot air drying to obtain a finished aerosol generating matrix. Exemplarily, the extruded matrix 100 is extruded in the vertical direction, and the extruded matrix 100 reaches a preset length (for example, the extruded matrix 100 reaches a critical value), and the extruded matrix 100 will naturally detach (separate), and the preset length of the extruded matrix 100 is the length required for the aerosol generating matrix. In this way, there may be no hardening step and slitting step, thereby reducing the subsequent processing process and reducing the production cost.

In one embodiment, the manufacturing method includes:

A packaging layer is wrapped around the outer surface of the aerosol generating substrate by a packaging device.

Please refer to FIG. 2 and FIG. 3 , the aerosol generating substrate enters the packaging device 7 , and the packaging device 7 wraps the packaging layer to the outer surface of the aerosol generating substrate.

The packaging layer includes but is not limited to one or more combinations of fiber paper, metal foil, metal foil composite fiber paper, polyethylene composite fiber paper, PE (Polyethylene), PBAT (Polybutylene Adipate Terephthalate) and other materials.

In some embodiments, the packaging layer may be wrapped around the outer surface of the aerosol-generating substrate and then combined with the functional segment to form an aerosol-generating product.

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 packaging layer to form an aerosol generating product.

In some other embodiments, the outer surface of the aerosol generating substrate may be first wrapped with a packaging layer, and then combined with the functional segment and wrapped with the packaging layer to form an aerosol generating product. In other words, the outer surface of the aerosol generating substrate may be wrapped with multiple packaging layers.

Please refer to FIG. 2 and FIG. 3 . The embodiment of the present application further provides a system for manufacturing an aerosol-generating substrate. The manufacturing system includes an extrusion device 1 and a hot air drying device 2 .

The extrusion device 1 is used to extrude the mixed material at room temperature to form an extruded matrix 100 .

The hot air drying device 2 is used to dry the extruded matrix 100 with hot air.

In the manufacturing system provided by the embodiment of the present application, if the extrusion temperature is too low, the fluidity of the mixed material will be The production speed of the extrusion device 1 is slow and the efficiency is low, and the torque required to be provided by the extrusion device 1 at this temperature is high, which affects the service life of the equipment; if the extrusion temperature is too high, the energy consumption of the extrusion device 1 is high, resulting in increased production costs. The shrinkage rate of the extruded matrix 100 is small and the drying time is short during hot air drying, which is convenient for continuous production. The combination of room temperature extrusion and hot air drying reduces equipment cost investment, enables continuous production, has high production efficiency, and low manufacturing cost; the extruded matrix 100 is uniform and stable, and has high processability.

In one embodiment, referring to FIG. 2 and FIG. 3 , the hot air drying device 2 includes a housing 21, a fan 22 and a heating element 23. The housing 21 has a drying chamber 21a. The fan 22 is used to drive the airflow in the drying chamber 21a. The heating element 23 is disposed in the drying chamber 21a and is used to heat the airflow in the drying chamber 21a. In this way, the heating element 23 generates heat to heat the airflow in the drying chamber 21a.

In some embodiments, the number of heating elements is at least two, at least two heating elements are arranged at intervals in the up-down direction, and the extruded matrix is transferred between the at least two heating elements. In one embodiment, please refer to Figures 2 and 3, the number of heating elements 23 is two, the two heating elements 23 are arranged at intervals in the up-down direction, and the extruded matrix 100 is transferred between the two heating elements 23. In this way, the two heating elements 23 bake the extruded matrix 100 synchronously from the top and bottom, so that the extruded matrix 100 can be heated evenly, the morphological stability of the extruded matrix 100 can be improved, and the dehydration efficiency can be improved, and the load of a single heating element 23 can be reduced. In other embodiments, the number of heating elements can be more than two, and the number of heating devices can be flexibly set according to the transmission length direction of the hot air drying device 2 and the length of the heating device.

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

The structural shape of the heating element 23 is not limited. For example, please refer to Figures 2 and 3. The heating element 23 is a plate-like structure. The heating element 23 can be a flat plate or a curved plate. The heating element 23 with a plate-like structure can be placed in the horizontal direction. In other words, the thickness direction of the heating element 23 with a plate-like structure is perpendicular to the horizontal direction.

The heating element 23 includes but is not limited to resistive heating.

In one embodiment, referring to FIG. 4 and FIG. 5 , the hot air drying device 2 includes a conveyor belt 25, and a plurality of grooves 25a are formed on the surface of the conveyor belt 25 facing the extruded matrix 100. The plurality of grooves 25a are arranged at intervals along the conveying direction of the conveyor belt 25, and each groove 25a is used to place a corresponding extruded matrix 100, and at least a portion of the extruded matrix 100 is located in the groove 25a. The groove 25a is arranged at intervals in the direction, and the length direction of the groove 25a intersects with the conveying direction. The two ends of the length direction of the groove 25a run through the two ends of the width direction of the conveyor belt 25. On the one hand, the groove wall surface of the groove 25a can limit the movement of the extruded matrix 100, to avoid the displacement of the extruded matrix 100 during the conveying process. On the other hand, each groove 25a is used to place an extruded matrix 100, and the groove 25a can prevent multiple extruded matrices 100 from contacting and sticking. In other embodiments, after the extruded matrix 100 is cut, each groove 25a can place multiple extruded matrices 100, and multiple extruded matrix 100 end faces are arranged at intervals, and the extruded matrix 100 of adjacent grooves 25a can prevent adhesion. A preferred groove 25a is placed an extruded matrix 100.

In one embodiment, the groove 25a is formed with an insertion port, and the extruded matrix 100 is inserted into the groove 25a through the insertion port.

Exemplarily, 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.

In some embodiments, the hot air drying device 2 may also include a clamping member, which is used to clamp the extruded matrix 100 to fix the extruded matrix 100 on the conveyor belt 25. The clamping member limits the movement of the extruded matrix 100 relative to the conveyor belt 25. Exemplarily, the clamping member is formed with a clamping groove for placing the extruded matrix 100.

In one embodiment, referring to Fig. 2 and Fig. 3, the housing 21 is formed with a delivery inlet 21b and a delivery outlet 21c both of which are connected to the drying chamber 21a, and at least part of the conveyor belt 25 is located in the drying chamber 21a, and the conveyor belt 25 is used to transfer the extruded matrix 100 from the delivery inlet 21b to the delivery outlet 21c. Exemplarily, the part of the conveyor belt 25 located in the housing 21 is located between the two heating elements 23. The extruded matrix 100 is placed on the conveyor belt 25 through the delivery inlet 21b, and is transferred to the delivery outlet 21c by the conveyor belt 25. The delivery of the extruded matrix 100 can be achieved by the conveyor belt 25.

In one embodiment, referring to FIG. 4 , the extruded substrate 100 has air passages 100a running through opposite longitudinal ends thereof, and the hot air drying device 2 includes a guide channel 24 for guiding hot air, and an air outlet 24a of the guide channel 24 is located at one side of the extruded substrate 100 in the longitudinal direction. In other words, the air outlet 24a of the guide channel 24 faces the opening of the air passage 100a of the extruded substrate 100. In this way, the air flow blown out of the air outlet 24a of the guide channel 24 can enter the air passage 100a through the opening of the air passage 100a. For example, during the hot air drying process, the flow direction of the hot air is parallel to the longitudinal direction of the extruded substrate 100; thereby, the contact area between the hot air and the extruded substrate 100 can be increased, thereby improving the drying efficiency.

For example, in one embodiment, referring to FIG4 , the outlet of the fan 22 is connected to the air inlet 24b of the guide channel 24, so that the airflow from the fan 22 can flow out from the air outlet 24a of the guide channel 24. The heating element 23 can be disposed in the guide channel 24, and the heating element 23 can also be disposed in the housing of the fan 22.

It is understandable that the air outlet direction of the air outlet 24a of the guide channel 24 may also be inclined at a certain angle to the longitudinal direction of the extruded matrix 100. In this way, the inner and outer surfaces of the extruded matrix 100 may be heated simultaneously, thereby improving the drying efficiency.

In one embodiment, referring to FIG. 2 and FIG. 3 , the manufacturing system includes a microwave auxiliary device 3 at least partially located in the drying chamber 21a, and the microwave auxiliary device 3 dries the extruded matrix 100 by emitting microwave radiation. Microwave radiation drying refers to the use of microwaves to cause the polar molecules inside the extruded matrix 100 to vibrate violently to generate heat to promote the volatilization of water in the extruded matrix 100, which can reduce the hot air drying temperature, reduce the drying time, and improve the retention rate of aroma components and effective substances in the aerosol-generating matrix.

For example, in some embodiments, microwave radiation drying may be performed before or simultaneously with hot air drying.

In one embodiment, referring to FIG. 2 and FIG. 3 , the manufacturing system includes an ultrasonic auxiliary device 4 at least partially located in the drying chamber 21a, and the ultrasonic auxiliary device 4 radiates ultrasonic waves to dry the extruded matrix 100. Ultrasonic radiation drying refers to the use of ultrasonic waves to produce a "cavitation" effect on the water inside the extruded matrix 100, thereby reducing the water volatilization temperature and promoting the volatilization of water, which can reduce the hot air drying temperature, reduce the drying time, and improve the retention rate of aroma components and effective substances in the aerosol-generating matrix.

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

In one embodiment, referring to Figures 2 and 3, the microwave auxiliary device 3 can be disposed above or below any heating element 23. With such a design, the microwave auxiliary device 3 emits microwaves such as electromagnetic waves with a wider range, which can heat the extruded matrix 100 more evenly.

In one embodiment, the microwave auxiliary device 3 can be disposed on both sides of the conveyor belt 25 along its width direction. With such a design, the microwaves emitted by the microwave auxiliary device 3, such as electromagnetic waves, have less energy loss, which can improve the overall heating rate.

In one embodiment, referring to Figures 2 and 3, the ultrasonic auxiliary device 4 can be disposed above or below any one of the heating elements 23. With such a design, the ultrasonic auxiliary device 4 emits a wider range of ultrasonic waves, which can make the extruded matrix 100 heated more uniformly.

In one embodiment, the ultrasonic auxiliary 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 auxiliary device 4 is smaller, and the overall heating rate can be improved.

In one embodiment, referring to Fig. 2, Fig. 3, Fig. 6 and Fig. 7, the extrusion device 1 comprises an extrusion barrel 12, an extrusion screw 13 and a die 14, wherein the extrusion barrel 12 comprises an extrusion chamber 12a for accommodating a mixed material and a discharge port 12b connected to the extrusion chamber 12a. The extrusion screw 13 is rotatably arranged in the extrusion chamber 12a. The die 14 is arranged at the discharge port 12b, and the extrusion screw 13 pushes the mixed material to extrude from the die 14 to form an extruded matrix 100. The extrusion screw 13 is used to push the mixed material toward the discharge port 12b. Exemplarily, during the rotation of the extrusion screw 13, the mixed material can flow toward the discharge port 12b along the threaded channel of the circumferential surface of the extrusion screw 13. The die 14 is used to form an extruded matrix 100 having a set cross-sectional shape.

In one embodiment, referring to Fig. 8, the extrusion device 1 includes a bottom die 15, and the mouth die 14 is disposed on the bottom die 15. The bottom die 15 provides a mounting position for the mouth die 14.

In one embodiment, the bottom die 15 is connected to the discharge port 12b, so that the mixed materials are all extruded through the mouth die 14. The bottom die 15 can gather the mixed materials at the discharge port 12b.

In one embodiment, a single bottom die 15 is disposed on a single die 14. In other words, a single die and a single die are used. In this way, the size of the extrusion screw 13 can be smaller.

In one embodiment, referring to FIG8 , a single bottom die 15 is provided with multiple die openings 14. In other words, a single die with multiple openings is used. After the mixed material passes through the multiple die openings 14, multiple extruded matrices 100 are simultaneously formed. This can improve production efficiency and is suitable for mass production.

In one embodiment, please refer to FIG. 9 , the number of the bottom mold 15 is multiple, and the extrusion device 1 includes an adapter 16, and the multiple bottom molds 15 are arranged on the adapter 16, and the adapter 16 is connected to the discharge port 12b. In other words, a multi-mode multi-port is adopted. Compared with a single-mode multi-port, a multi-mode multi-port can be installed with more dies 14, thereby forming more extruded matrices 100 at the same time. This can improve production efficiency and is more suitable for mass production.

In one embodiment, referring to FIG. 2 , FIG. 3 and FIG. 10 , the manufacturing system includes a hardening device 5 , ... and a hardening device 5 . The device 5 is used to harden the extruded matrix 100. The hardening device 5 is used to harden the extruded matrix 100 to increase the hardness of the extruded matrix 100. The hardening device 5 is located downstream of the extrusion device 1 along the flow direction of the extruded matrix 100.

In one embodiment, referring to FIG. 10 , the hardening device 5 includes a housing 51, and 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, and the cold chamber 51b is used to cool and harden the extruded matrix 100. The extruded matrix 100 enters the cold chamber 51b through the inlet 51a, and flows out of the housing 51 through the outlet 51c after being cooled and hardened in the cold chamber 51b.

In one embodiment, referring to FIG. 10 , the housing 51 is formed with an injection port 51d, which is connected to the cold chamber 51b to inject a refrigerant into the cold chamber 51b. The refrigerant contacts the extruded matrix 100 in the cold chamber 51b to absorb the heat of the extruded matrix 100, thereby cooling and hardening the extruded matrix 100. In this way, the outer surface of the hardened extruded matrix 100 can be quickly cooled, the stability of the shape of the extruded matrix 100 can be maintained, continuous production can be facilitated, and production efficiency can be improved.

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.

In one embodiment, referring to FIG. 10 , the injection port 51 d may be formed on the upper surface of the housing 51 . In this way, the refrigerant may enter the cold chamber 51 b from top to bottom to contact the extruded substrate 100 on the conveyor belt 52 .

In one embodiment, referring to Figure 10, hardening device 5 comprises conveyor belt 52, and at least part of conveyor belt 52 is located in cold chamber 51b, and conveyor belt 52 is used for extruding matrix 100 and being transmitted to outlet 51c from inlet 51a. Extruded matrix 100 is placed on conveyor belt 52 by inlet 51a, and is transmitted to outlet 51c by conveyor belt 52. The continuous transmission of extruded matrix 100 can be realized by conveyor belt 52, so that extruded matrix 100 can be hardened through hardening device 5 in an endless stream, and continuous production is realized. Conveyor belt 52 is formed with a plurality of guide grooves 52a towards the surface of extruded matrix 100, and each guide groove 52a is used for placing an extruded matrix 100, and at least part of extruded matrix 100 is located in guide groove 52a. On the one hand, the groove wall surface of guide groove 52a can limit extruded matrix 100 and move, to avoid extruded matrix 100 displacement during transmission. On the other hand, each guide groove 52a is used to place a strip of extruded matrix 100, and the guide groove 52a can prevent multiple extruded matrixes 100 from contacting and sticking.

Exemplarily, the length direction of the guide groove 52a is consistent with the conveying direction of the conveyor belt 52. The grooves 52 a are arranged at intervals in the width direction of the conveyor belt 52 .

In one embodiment, the guide groove 52a is formed with a take-in and put-out opening, and the extruded matrix 100 is put into the guide groove 52a through the take-in and put-out opening.

Exemplarily, the cross-sectional shape of the guide groove 52a is not limited, and the cross-sectional shape of the guide groove 52a may be semicircular or semi-elliptical, etc.

Exemplarily, in one embodiment, referring to FIG. 10 , the injection port 51 d extends in a direction intersecting with the conveying direction of the conveyor belt 52 .

In one embodiment, referring to FIG. 11 and FIG. 12 , the housing 51 is formed with a refrigerant channel 51e, the cold chamber 51b is isolated from the refrigerant channel 51e and is located in the refrigerant channel 51e, and the extruded matrix 100 is in contact with the cavity wall surface of the cold chamber 51b. In other words, the refrigerant does not contact the extruded matrix 100. The refrigerant flows in the refrigerant channel 51e, and the extruded matrix 100 and the refrigerant transfer heat through the cavity wall surface of the cold chamber 51b. This can avoid the extruded matrix 100 directly contacting the refrigerant, and the problem of expansion deformation and cracking after rapid cooling.

In one embodiment, referring to Figures 11 and 12, the housing 51 includes an outer shell 511 and an inner shell 512, the inner shell 512 is formed with a cold cavity 51b, and the inner shell 512 is located in the outer shell 511 and defines a refrigerant channel 51e together. The housing 51 is a double-layer shell structure, the refrigerant channel 51e defined by the outer shell 511 and the inner shell 512 is used to flow the refrigerant, the cold cavity 51b and the refrigerant channel 51e are isolated by the inner shell 512, and the extruded matrix 100 contacts the inner surface of the inner shell 512 to transfer heat to the refrigerant through the inner shell 512.

In one embodiment, the smoothness of the cavity wall of the cold cavity 51b is between Ra1.2μm and Ra0.08μm. Ra refers to the surface average roughness value, which is used to indicate the smoothness and roughness of the surface. Exemplarily, the smoothness of the cavity wall of the cold cavity 51b is Ra1.2μm, Ra1.1μm, Ra1.0μm, Ra0.5μm, Ra0.3μm, Ra0.1μm or Ra0.08μm, etc. The cavity wall of the cold cavity 51b is a smooth surface, and the friction between the cavity wall of the cold cavity 51b and the outer surface of the extruded matrix 100 is very small, which will not cause the extruded matrix 100 to deform.

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

In one embodiment, referring to FIG. 2 and FIG. 3 , the manufacturing system includes a slitting device 6 having a slitting tool 61 , and the slitting tool 61 slits the extruded matrix 100 by physical contact or non-physical contact.

Physical contact means that the extruded matrix 100 is cut by direct contact between the cutting tool 61 and the extruded matrix 100. For example, the cutting tool 61 can be a rotating roller, a cutting blade, a cutting wire, a roller cut, or an extruder.

Non-physical contact means that the slitting tool 61 does not need to be in direct contact with the extruded matrix 100, but the extruded matrix 100 is cut by the material released by the slitting tool 61. For example, the slitting tool 61 releases laser, plasma, air knife or water knife to cut the extruded matrix 100.

It should be noted that the manufacturing system used in the embodiment of the present application can be used for the manufacturing method of the embodiment of the present application, and the description of the manufacturing system embodiment is similar to the description of any one of the embodiments of the manufacturing method, and has the same beneficial effects as the manufacturing method embodiment. For technical details not disclosed in the manufacturing method in the embodiment of the present application, please refer to the description of the embodiments of the extrusion device 1, hot air drying device 2, hardening device 5 and slitting device 6 in the embodiment of the present application for understanding.

In the description of the present application, the description with reference to the terms "in one embodiment", "in some embodiments", "in other embodiments", "in yet other embodiments", or "exemplary" etc. means 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 application. In the present application, the schematic representation of the above terms does 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 the different embodiments or examples described in the present application and the features of the different embodiments or examples without contradiction.

The above description is only a preferred embodiment of the present application and is not intended to limit the present application. For those skilled in the art, the present application may have various modifications and variations. Any modification, equivalent replacement, improvement, etc. made within the spirit and principle of the present application are included in the protection scope of the present application.

Claims (27)

A method for manufacturing an aerosol generating substrate, comprising: The mixed material is extruded at room temperature to form an extruded matrix, wherein the mixed material is a component of the aerosol generating matrix; The extruded matrix is subjected to hot air drying. According to the manufacturing method of claim 1, the extrusion temperature of the room temperature extrusion is between 35°C and 70°C. According to the manufacturing method of claim 1, the extrusion pressure of the room temperature extrusion is between 0.5 bar and 300 bar. According to the manufacturing method of claim 3, the extrusion pressure of the room temperature extrusion is between 20 bar and 80 bar. According to the manufacturing method of claim 1, the temperature of the hot air drying is between 50°C and 200°C. According to the manufacturing method of claim 5, the temperature of the hot air drying is between 75°C and 125°C. According to the manufacturing method of claim 1, the moisture content of the extruded matrix after drying is 3% to 20%. According to the manufacturing method of claim 1, the extruded matrix has air passages running through opposite ends 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. According to the manufacturing method of claim 1, after the mixed material is extruded at room temperature to form an extruded matrix, the manufacturing method comprises: The extruded matrix is cut. The manufacturing method according to claim 1, wherein the extruded matrix is subjected to hot air drying Previously, the manufacturing method included: The extruded matrix is subjected to a hardening process. According to the manufacturing method of claim 10, the hardness of the extruded matrix after hardening is between 1HB and 200HB. The manufacturing method according to claim 10, wherein the extruded matrix is subjected to a hardening treatment, comprising: The extruded matrix hardens by cooling. The manufacturing method according to claim 1, wherein the extruded matrix is extruded in a horizontal direction; or The extruded matrix is extruded in a vertical direction relative to a horizontal direction; or, The extruded matrix is extruded in an inclined direction relative to the horizontal direction. According to the manufacturing method of claim 1, the mixed material 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. A system for manufacturing an aerosol generating substrate, the manufacturing system comprising: An extrusion device, the extrusion device is used to extrude the mixed material at room temperature to form an extruded matrix; A hot air drying device is used to perform hot air drying on the extruded matrix. According to the manufacturing system of claim 15, the hot air drying device comprises: A box body having a drying chamber; A fan, used to drive the air flow in the drying chamber; A heating element is disposed in the drying chamber, and is used to heat the airflow in the drying chamber. According to the manufacturing system of claim 16, the number of the heating elements is at least two, the at least two heating elements are spaced apart in the up-down direction, and the extruded matrix is transferred between the at least two heating elements. According to the manufacturing system of claim 15, the extruded matrix has air passages running through opposite longitudinal ends thereof, the hot air drying device comprises a guide channel for guiding hot air, and the air outlet of the guide channel is located on one side of the extruded matrix along the longitudinal direction. According to the manufacturing system of claim 15, the hot air drying device comprises a conveyor belt, a surface of the conveyor belt facing the extruded matrix is formed with a plurality of grooves, each of the grooves is used to place a corresponding strip of the extruded matrix, and at least a portion of the extruded matrix is located in the groove. The manufacturing system of claim 16, comprising a microwave assisted device at least partially located within the drying chamber, the microwave assisted device drying the extruded matrix by emitting microwave radiation; and/or, The manufacturing system includes an ultrasonic assist device at least partially located within the drying chamber, the ultrasonic assist device drying the extruded matrix by emitting ultrasonic radiation. The manufacturing system of claim 15, comprising a hardening device for hardening the extruded matrix. According to the manufacturing system of claim 21, the hardening device includes a housing, the housing is formed with an inlet, a cold chamber and an outlet, the inlet and the outlet are both connected to the cold chamber, and the cold chamber is used to cool and harden the extruded matrix. According to the manufacturing system of claim 22, the shell is formed with an injection port, and the injection port is connected to the cold chamber to inject the refrigerant into the cold chamber. According to the manufacturing system of claim 22, the shell includes a conveyor belt, at least a portion of which is located in the cold chamber, the conveyor belt is used to convey the extruded matrix from the inlet to the outlet, and a plurality of guide grooves are formed on the surface of the conveyor belt facing the extruded matrix, each of which is used to place a strip of the extruded matrix, and at least a portion of the extruded matrix is located in the guide groove. According to the manufacturing system of claim 22, the shell is formed with a refrigerant channel, the cold cavity is isolated from the refrigerant channel and is located in the refrigerant channel, the extruded matrix and The cavity wall surface of the cold cavity is in contact. According to the manufacturing system of claim 25, the shell includes an outer shell and an inner shell, the inner shell forms the cold cavity, and the inner shell is located inside the outer shell and together defines a refrigerant channel. According to the manufacturing system of claim 25, the smoothness of the cavity wall of the cold cavity is between Ra1.2μm and Ra0.08μm.