Article for or as non-combustible aerosol supply system

Abstract

The present disclosure relates to an article for or for use as a non-combustible aerosol supply system, the article comprising a rod of aerosol-generating material and an end cap comprising a first portion configured to extend at least partially over an end face of the rod of aerosol-generating material. Methods of making the articles are also provided.

Description

Technical Field

[0001] The present invention relates to articles for use in or as non-flammable aerosol delivery systems. Background Art

[0002] Some products generate an aerosol during use, which is inhaled by the user. For example, a tobacco heating device heats an aerosol-generating substrate (such as tobacco) to form an aerosol by heating but not burning the substrate. Such products typically include a mouthpiece through which the aerosol passes into the user's mouth. Summary of the invention

[0003] According to a first aspect of the present disclosure, there is provided an article for or as a non-flammable aerosol delivery system, the article comprising an aerosol generating material rod and an end cap, the end cap comprising a first portion configured to extend at least partially over an end surface of the aerosol generating material rod.

[0004] In some embodiments, the end cap is configured to at least reduce removal of aerosol-generating material from the rod of aerosol-generating material.

[0005] In some embodiments, the first portion of the end cap partially covers the end surface of the rod of aerosol-generating material such that at least a portion of the end surface of the rod of aerosol-generating material defines an outer surface of the article.

[0006] In some embodiments, the first portion of the end cap extends at an angle to the longitudinal axis of the rod of aerosol generating material.

[0007] In some embodiments, the first portion of the end cap extends substantially perpendicular to the longitudinal axis of the rod of aerosol generating material.

[0008] In some embodiments, the first portion of the end cap partially covers the end surface of the rod of aerosol generating material to form an orifice in the first portion.

[0009] In some embodiments, the orifice comprises a diameter of at least about 0.5 mm, at least about 1 mm, or at least about 2 mm, optionally at most about 8 mm, optionally at least about 1 mm or 2 mm and at most 5 mm.

[0010] In some embodiments, the first portion covers a range from about 13% of the area of ​​the end face of the rod of aerosol-generating material to about 84% of the area of ​​the end face of the rod of aerosol-generating material.

[0011] In some embodiments, the first portion covers a range from about 26% of the area of ​​the end face of the rod of aerosol-generating material to about 84% of the area of ​​the end face of the rod of aerosol-generating material.

[0012] In some embodiments, the first portion covers a range from about 49% of the area of ​​the end face of the rod of aerosol-generating material to about 84% of the area of ​​the end face of the rod of aerosol-generating material.

[0013] In some embodiments, the first portion of the end cap forms a generally annular cap covering the end face of the rod of aerosol generating material.

[0014] In some embodiments, the orifice is an annular portion of the annular cap, and the width of the annular portion is in the range of about 0.5 mm to about 4 mm.

[0015] In some embodiments, the orifice is an annular portion of the annular cap, and the width of the annular portion is in the range of about 1 mm to about 3 mm.

[0016] In some embodiments, the orifice is an annular portion of the annular cap, and the width of the annular portion is in the range of about 2 mm to about 3 mm.

[0017] In some embodiments, the orifice is centrally located within the first portion.

[0018] In some embodiments, the orifice and the rod of aerosol generating material are concentrically aligned.

[0019] In some embodiments, the first portion of the end cap forms a continuous annular portion over the end surface of the rod of aerosol generating material.

[0020] In some embodiments, the first portion of the endcap includes an iris-fold such that segments of the first portion are folded over each other.

[0021] In some embodiments, the first portion includes a plurality of segments.

[0022] In some embodiments, the first portion comprises a plurality of segments such that the end cap forms a discontinuous annular portion covering the end surface of the rod of aerosol generating material.

[0023] In some embodiments, the first portion of the end cap completely covers the end surface of the rod of aerosol generating material.

[0024] In some embodiments, the first portion of the end cap overlaps itself over the center of the end face of the rod of aerosol generating material.

[0025] In some embodiments, the end cap further comprises a second portion extending circumferentially around at least a portion of the rod of aerosol generating material.

[0026] In some embodiments, the end cap is formed by a wrapping of the rod of aerosol generating material.

[0027] In some embodiments, the end cap extends over the downstream end of the rod of aerosol generating material.

[0028] In some embodiments, the end cap is formed from a filter tipping wrap of the article.

[0029] In some embodiments, the end cap extends over the upstream end of the rod of aerosol generating material.

[0030] In some embodiments, the end cap further includes a second portion formed by two arms attached to the outer circumferential surface of the article.

[0031] In some embodiments, the end cap is formed from a porous material.

[0032] In some embodiments, the end caps are formed from a perforated material.

[0033] In some embodiments, the end cap is formed of a material having a porosity greater than 3,000 Cu, or greater than 6,000 Cu, or greater than 12,000 Cu, or greater than 24,000 Cu.

[0034] In some embodiments, the end cap is formed from a material having a weight in a range from about 20 gsm to about 60 gsm.

[0035] In some embodiments, the end cap is formed from a plugwrap.

[0036] In some embodiments, the end caps are formed from tipping paper.

[0037] In some embodiments, the end caps are formed from aluminum foil.

[0038] In some embodiments, the rod of aerosol-generating material comprises a plurality of elongated strips of aerosol-generating material.

[0039] In some embodiments, the plurality of elongated strips extend substantially the length of the rod of aerosol generating material.

[0040] In some embodiments, the aerosol-generating material is adhered to a wrapper that surrounds the aerosol-generating material.

[0041] In some embodiments, the adhesive adheres the aerosol-generating material to the wrapper and the adhesive is applied to the wrapper in a spiral pattern.

[0042] In some embodiments, the aerosol generating material is configured to receive an aerosol generator of a non-flammable aerosol delivery device, and the aerosol generating material is configured to compress when inserted into the aerosol generator.

[0043] According to a second aspect of the present disclosure, a method for manufacturing an article is provided, the method comprising providing an aerosol generating material rod comprising a plurality of elongated strips; providing a wrapper around the aerosol generating material rod such that a first portion of the wrapper hangs over an end of the aerosol generating material rod; and folding the first portion of the wrapper hanging over the end of the aerosol generating material rod to at least partially cover the end surface of the aerosol generating material rod.

[0044] In some embodiments, the step of folding the first portion comprises rotating the rod of aerosol-generating material on a drum through at least one folding device.

[0045] In some embodiments, the step of folding the first portion comprises rolling the rod of aerosol-generating material on a roll through at least one folding device.

[0046] In some embodiments, the step of folding the first portion comprises moving the die longitudinally relative to the rod of aerosol-generating material to fold the first portion inwardly over an end of the rod of aerosol-generating material.

[0047] In some embodiments, the folding step further comprises compressing the first portion of the wrap.

[0048] In some embodiments, compression is performed during the packaging step of the article.

[0049] According to a third aspect of the present disclosure, there is provided an article for use with a non-flammable aerosol delivery device manufactured by the method according to the third aspect.

[0050] According to a fourth aspect of the present disclosure, a non-flammable aerosol supply system is provided, comprising the product according to the first or third aspect and a non-flammable aerosol supply device.

[0051] In some embodiments, the non-flammable aerosol delivery device comprises an aerosol generator, and the aerosol generator extends into an aerosol generating section of the article and is in direct contact with the aerosol generating material.

[0052] In some embodiments, the aerosol generator is a needle or blade heater.

[0053] According to a fifth aspect of the present disclosure, there is provided a method comprising inserting an aerosol generator of a non-flammable aerosol supply device into an aerosol generating material of an article according to the first or third aspect.

[0054] In some embodiments, during insertion of the aerosol generator into the aerosol generating material, the aerosol generating material is compressed.

[0055] According to a sixth aspect of the present disclosure, there is provided use of the product according to the first or third aspect and a non-flammable aerosol supply device. BRIEF DESCRIPTION OF THE DRAWINGS

[0056] Figure 1a is a side cross-sectional view of an article for use with a non-flammable aerosol delivery device inserted in an aerosol providing device;

[0057] Figure 1b is a side cross-sectional view of an article for use with a non-flammable aerosol delivery device inserted in an aerosol providing device;

[0058] Figure 1c is a perspective view of an end cap of an article for use with a non-flammable aerosol delivery device;

[0059] Figure 2 is a side cross-sectional view of an article for use with a non-flammable aerosol delivery device as it is inserted into the aerosol delivery device;

[0060] Figure 3 is an end view of the upstream end of the article shown in Figure 1;

[0061] Figure 4 and Figure 5 is a side cross-sectional view of an article for use with a non-flammable aerosol delivery device inserted in an aerosol providing device;

[0062] Figure 6a is a perspective view of an expanded end plug of an article for use with a non-flammable aerosol delivery device;

[0063] Figure 6b Shows Figure 6a The end plug is shown in the case when it is partially folded;

[0064] Figure 6c yes Figure 6a A side cross-sectional view of an end plug is shown in FIG. 1 after it has been fully folded to form the end plug.

[0065] Figure 7 is a side cross-sectional view of the downstream end of an article for use with a non-flammable aerosol delivery device.

[0066] Figure 8a and Figure 8b is a perspective view of the die for folding and the end plugs unfolded;

[0067] Fig. 9 and Fig.10 is a schematic side view of an apparatus for folding an unfolded end plug to form a folded end plug.

[0068] Fig.11 is used Fig.10 an end view of the device shown in folded end plugs; and

[0069] Fig.12 is a schematic side cross-sectional view of a non-flammable aerosol supply device. DETAILED DESCRIPTION

[0070] In the drawings described herein, like reference numerals are used to identify equivalent features, articles or components.As used herein, the terms "upstream" and "downstream" are relative terms defined relative to the direction of mainstream aerosol drawn by an article or device in use.

[0071] Disclosed herein is an article for use in or as a non-flammable aerosol delivery system, the article comprising:

[0072] a first end and a second end;

[0073] an aerosol-generating section comprising an aerosol-generating material and located between the first end and the second end; and

[0074] An end cap includes a first portion configured to extend at least partially over an end surface of the first end.

[0075] Figure 1a is a side cross-sectional view of an article 1 for or as an aerosol delivery system, which is inserted into a receiving portion 2 (in this case a recess) of a non-flammable aerosol supply device 3. The article 1 includes a first end 1a and a second end 1b located downstream of the first end 1a. The aerosol generating section 4 is arranged between the first end 1a and the second end 1b. The downstream section 5 is located downstream of the aerosol generating section 4. The downstream section 5 (also referred to herein as the downstream part) can be or include a mouthpiece designed to be inserted into the mouth of a user in use, or alternatively, it can be arranged to work with a separate mouthpiece (such as a mouthpiece provided as a separate attachment to the downstream section 5 or as a part of the device 3). The article 1 includes a longitudinal axis XX'.

[0076] The downstream section 5 may include filter materials and / or other components, at least some of which are described herein but omitted from some figures for clarity. For example, in some embodiments, the article includes one or more filter segments. One of the plurality of filter segments may be located downstream of the aerosol generating section, for example in the downstream section.

[0077] In the present example, the aerosol generating section 4 includes an aerosol generating material source in the form of a cylindrical rod of aerosol generating material. In other examples, the aerosol generating section 4 may include a cavity for receiving the aerosol generating material source. The aerosol generating section includes an end face 8. In the present example, the end face includes a continuous flat surface including a substantially circular perimeter. In some embodiments, including the present example, the end face does not include any significant indentation or void. In other words, the entire surface of the end face can be planar.

[0078] In some embodiments, including the present example, the aerosol generating section comprises or consists of a rod of aerosol generating material that is substantially uniformly distributed throughout the aerosol generating section. In some embodiments, the entire volume of the aerosol generating section comprises aerosol generating material. In the present example, a cross section through the article 1 represented by a dotted line A defines the outer perimeter of the rod of aerosol generating material. The rod comprises aerosol generating material substantially uniformly distributed within the perimeter. In some embodiments, the aerosol generating section does not include a cavity or void configured to receive an aerosol generator of an aerosol providing device.

[0079] Aerosol-generating materials are materials that are capable of generating an aerosol when, for example, they are heated, irradiated or energized in any other way. Aerosol-generating materials may, for example, be in the form of a solid, liquid or semisolid (eg a gel), which may or may not contain active substances and / or flavouring agents.

[0080] The aerosol generating material may include one or more active substances and / or flavorings, one or more aerosol forming agent materials, and optionally one or more other functional materials. The aerosol generating material may include multiple strands or strips of the aerosol generating material. The aerosol generating material may include multiple elongated strands or strips. For example, the aerosol generating material may include multiple strands or strips of aerosolizable material and / or multiple strands or strips of amorphous solids, as described below. In some embodiments, the aerosol generating material is composed of multiple strands or strips of aerosolizable material. In other embodiments, the aerosol generating material is composed of a single strand, strip or sheet of aerosolizable material. The strands or strips of the aerosol generating material may be arranged so that their longitudinal dimensions are substantially parallel to the longitudinal axis of the article. The aerosol generating material may be in the form of a reconstituted sheet-like plant material (such as a tobacco material) or another plant material (such as Louis Boss tea). In some embodiments, the sheet is a band-like (bandcast) reconstituted tobacco. In some embodiments, the sheet is reconstituted rooibos in ribbon form.In some embodiments, the sheet is reconstituted tobacco or rooibos, and the sheet is made using a papermaking process.

[0081] For example, the plurality of elongate strips of aerosol-generating material may extend substantially the length of the rod of aerosol-generating material.

[0082] In some embodiments, the plant material may include one or more of expanded plant material, reconstituted plant material, or plant substitutes. The plant material may include one or more of ground plant material, plant fiber, cut plant material (e.g., cut leaves), extruded plant material, plant stems, leaf layers, reconstituted plant products, and / or plant extracts. In any embodiment, the plant material may be rooibos tea or tobacco in any of these forms.

[0083] In some embodiments, the aerosol-generating material comprises shredded tobacco.

[0084] The aerosol generating material is configured to generate an aerosol when heated, which aerosol can be inhaled by a user. The aerosol generating material can be configured to generate an inhalable aerosol when heated to a temperature of about 150° C. to about 500° C. In some embodiments, the aerosol generating material is configured to generate an aerosol when heated to a temperature of about 200° C. to any temperature of about 500° C. or up to about 450° C.

[0085] The aerosol generating material includes an aerosol former material. The aerosol former material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol former material may include one or more of the following: glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In particular, the aerosol former material includes glycerol.

[0086] The aerosol-generating material may comprise at least 5% aerosol-forming material by weight of the aerosol-generating material calculated on a dry weight basis, the aerosol-forming material being, for example, one of the aerosol-forming materials described herein. In some embodiments, the aerosol-generating material comprises from about 5% to about 80% aerosol-forming material. The aerosol-generating material may comprise from about 10% to about 30% aerosol-forming material.

[0087] The aerosol generating section of the article may contain at least 5% aerosol former material based on the total weight (calculated on a dry weight basis) of the aerosol generating material in the aerosol generating section. In some embodiments, the aerosol generating section of the article contains about 5% to about 80% aerosol former material based on the total weight of the aerosol generating material in the aerosol generating section. In some embodiments, the aerosol generating section of the article contains about 10% to about 30% aerosol former material based on the total weight of the aerosol generating material in the aerosol generating section.

[0088] As previously mentioned, the aerosol generating material may comprise a plurality of elongate strips of aerosol generating material, which may extend substantially the length of the rod of aerosol generating material.

[0089] refer to Figure 1b In the present example, a plurality of strands or strips of aerosol generating material 4a are aligned within the aerosol generating section 4 so that their longitudinal dimension is aligned parallel to the longitudinal axis XX' of the article 1. Alternatively, the strands or strips may be generally arranged so that their aligned longitudinal dimension is transverse to and optionally perpendicular to the longitudinal axis of the article 1.

[0090] The majority of the strands or strips may be arranged such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the article 1. In some embodiments, about 95% to about 100% of the plurality of strands or strips are arranged such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the article 1. In some embodiments, substantially all of the strands or strips are arranged in the aerosol generating section such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the aerosol generating section of the article 1.

[0091] When most of the strands or strips are arranged in the aerosol generating section 4 so that their longitudinal axes are parallel to the longitudinal axis of the aerosol generating section 4 of the article 1, the force required to insert an aerosol generator (such as the heating element 2a in this example) into the aerosol generating material may be relatively low. This may result in an article 1 that is easier to use.

[0092] In the present example, a wrap of tipping paper 6 is wrapped around the entire length of the aerosol generating material. The tipping paper 6 is also wrapped around the entire length of the downstream portion 5 and has an adhesive on its inner surface for connecting the downstream portion 5 and the rod. For example, the downstream portion 5 may include at least one filter segment (not shown). The filter segment may include a filter material and the tipping paper 6 may be wrapped around the filter material.

[0093] In some embodiments, the rod of aerosol-generating material is wrapped in a wrapper (not shown) that forms a first wrapping material, and the tipping paper 6 forms an outer wrapping material that extends at least partially over the rod of aerosol-generating material to connect the downstream portion 5 and the rod. In some examples, the tipping paper may extend completely over the rod of aerosol-generating material.

[0094] In the present example, the tipping paper 6 comprises a moisture-impermeable wrapper comprising aluminum foil. In other embodiments, the tipping paper 6 comprises a paper wrapper, which is optionally a paper wrapper comprising a barrier coating to make the material of the wrapper substantially moisture-impermeable. When the wrapper comprises paper or a paper backing, i.e., a cellulose-based material, the wrapper may have a basis weight greater than about 30 gsm. For example, the wrapper may have a basis weight in the range of about 40 gsm to about 70 gsm.

[0095] In the present example, the moisture-impermeable tipping paper 6 is also substantially air-impermeable. The tipping paper 6 preferably has a permeability of less than 100 Coresta units, more preferably less than 60 Coresta units. It has been found that low permeability wrappers (e.g. wrappers having a permeability of less than 100 Coresta units, more preferably less than 60 Coresta units) lead to improved aerosol formation in the aerosol-generating material. The permeability of the tipping paper 6 can be measured according to ISO 2965:2009 on the determination of the air permeability of materials used as cigarette papers, filter plug wrappers and filter joint papers.

[0096] In the present example, the tipping paper 6 extends 5 mm above the rod of aerosol generating material, but it may alternatively extend 3 to 10 mm, or more preferably 4 to 6 mm, above the rod to provide a secure attachment. The basis weight of the tipping paper may be greater than 20 gsm, such as greater than 25 gsm, or preferably greater than 30 gsm, such as 37 gsm. These basis weight ranges have been found to result in tipping paper having acceptable tensile strength while being flexible enough to wrap around the article 1 and adhere to itself along the longitudinal lap seam on the paper.

[0097] The article 1 includes an end cap 9, which includes a first portion 9a, which is configured to extend at least partially over the end face 8 of the first end portion 1a. In some embodiments (such as the present embodiment), the end cap 9 does not completely cover the end face 8. In other words, at least a portion of the end face 8 of the end cap 9 can be seen from the outside of the article 1. In such embodiments, the end cap 9 includes an opening 10. The opening 10 can be configured to receive an aerosol generator, such as a heater. The end cap extends over the upstream end of the aerosol generating material rod.

[0098] In the present example, the end cap 9 comprises an end cap wrap which surrounds the first end 1a of the article 1. A portion of the end cap wrap is folded to provide a first portion 9a which extends partially over the end face 8 of the rod of aerosol generating material. A second portion 9b of the end cap extends parallel to the longitudinal axis XX' of the article 1.

[0099] In the present example, the end cap 9 comprises a second portion 9b which extends circumferentially around at least a portion of the rod of aerosol-generating material. The second portion 9b may be attached to the tipping paper 6 by any suitable means. For example, the second portion 9b may be glued to the tipping paper 6, or the second portion 9b may be held in place by friction between the tipping paper 6 and the second portion 9b.

[0100] In some embodiments, the second portion does not extend continuously around the entire circumference of the aerosol generating material rod. In some embodiments, the second portion includes two arms attached to the peripheral surface of the article. The two arms may be attached to the outer surface of the wrapper. This reduces the mass of the end cap, thereby reducing the mass of the article.

[0101] For example, see Figure 1c , the end cap 9 comprises a first portion 9a, an orifice 10 and a second portion 9b. The second portion 9b is in the form of two arms extending substantially perpendicularly to the inner surface of the first portion 9a. As previously described, the two arms may be adhered to the outer surface of the article wrapper, so that the end cap 9 is fixed to the upstream end of the aerosol generating material rod and the first portion extends at least partially over the end surface of the aerosol generating material rod.

[0102] The orifice can take a variety of forms. For example, it can be circular, square or cross-shaped. In some embodiments, the end cap does not include an orifice, but rather includes a perforation in the central portion of the end cap, which is configured to form an orifice when the aerosol generator of the non-flammable aerosol supply device is inserted into the aerosol generation section through the first portion of the end cap. In such embodiments, when the aerosol generator is withdrawn from the aerosol generation section, the orifice formed in the end cap due to the insertion of the aerosol generator is retained.

[0103] In some embodiments, the first portion of the end cap partially covers the end surface of the aerosol generating material rod, so that at least a portion of the end surface of the aerosol generating material rod defines the outer surface of the article. Therefore, this outer surface is visible on the outside of the article. In some embodiments, the portion of the end surface of the aerosol generating material rod that defines the outer surface of the article is planar and / or extends in a direction perpendicular to the longitudinal axis of the article 1.

[0104] See again Figure 1a , the first portion 9a of the end cap 9 extends at an angle relative to the longitudinal axis of the rod of aerosol-generating material. In the present example, the first portion 9a is transverse to the longitudinal axis XX' of the article 1 and the rod of aerosol-generating material. In the present example, the first portion 9a is about 90° to the longitudinal axis XX' of the article 1 and the rod of aerosol-generating material.

[0105] The first portion may extend at an angle between about 1° and about 120° relative to the longitudinal axis of the article. In some embodiments, the first portion of the end cap extends at an angle between about 80° and about 100°. In some embodiments, the first portion of the end cap extends at an angle of about 90°. An angle of about 90° helps ensure that the article has a total length suitable for use with a non-flammable aerosol supply device. For example, in the case where the first portion of the end cap has an angle of less than about 90° relative to the longitudinal axis of the article, the first portion effectively extends the total length of the article. As a result, when the article is inserted into the non-flammable aerosol supply device, the article may not be properly aligned with respect to features of the device (such as an aerosol generator). In contrast, in the case where the first portion has an angle greater than about 90°, the material of the first portion of the end cap can extend into the aerosol generating material of the rod, which means that the volume for storing aerosol generating material in the aerosol generating section is smaller.

[0106] Thus, preferably, the first portion of the end cap extends substantially perpendicularly to the longitudinal axis of the rod of aerosol generating material.

[0107] See again Figure 1a , the end cap includes an orifice 10, which is also referred to herein as an opening or annular portion. The first portion of the end cap may partially cover the end face of the aerosol generating material rod to form an orifice in the first portion. The orifice may be configured to receive an aerosol generator of an aerosol providing device, such as a needle heater. For example, the total area of ​​the orifice may be greater than or approximately equal to the cross-sectional area of ​​the aerosol generator. This allows the aerosol generator of the aerosol providing device to be inserted into the aerosol generating material with minimal resistance.

[0108] In the present example, the orifice 10 is centrally located in the first portion.

[0109] The orifice may be circular, oval or any other shape. The orifice may have a shape identical to the cross-sectional shape of at least a portion of the aerosol generator. In the present example, the first portion of the end cap forms a generally annular cap covering the end face of the rod of aerosol generating material, so that the orifice is generally circular.

[0110] The orifice of the aerosol generating material and the rod may be concentrically aligned. For example, the centre of the orifice (eg the orifice may be circular and the focus of the circle is the centre of the orifice) may be aligned with the central longitudinal axis XX' of the article.

[0111] The orifice may be configured to receive an aerosol generator of the aerosol providing device such that, when the aerosol generator is received, the aerosol generator is also centrally positioned within the orifice and is also aligned with the central longitudinal axis XX' of the article. This enables the heat generated by the aerosol generator in use to be evenly distributed throughout the aerosol generating material in a radial manner.

[0112] In some embodiments, including the present example, the first portion 9a extends partially over the face 8 of the aerosol generating material rod. That is, the end face 8 of the aerosol generating material rod is not completely covered by the first portion 9a of the end cap 9. In some embodiments, the face 8 of the aerosol generating material rod is completely covered by the first portion 9a of the end cap 9. As explained below, the end cap 9 is configured to at least reduce the aerosol generating material removed from the aerosol generating section via the first end 1a. In some embodiments, the end cap 9 is configured to prevent the aerosol generating material from being removed from the aerosol generating section. In other words, the aerosol generating material can be prevented from falling out of the first end 1a of the article 1.

[0113] The orifice may have a diameter of at least about 0.5 mm and at most about 8 mm. In some embodiments, the orifice has a diameter of at least about 1 mm or 2 mm and at most 5 mm. In the present example, the orifice has a diameter of about 2 mm, which is approximately the same as the diameter of the aerosol generator of the aerosol providing device. The diameter of the aerosol generator is defined as the longest straight line between the two outer edges of the aerosol generator and through the cross section of the aerosol generator. In some embodiments, the diameter of the aerosol generator of the aerosol providing device is about 1.5, 1.6, 1.7, 1.8, 1.9, 2.0, 2.1, 2.2, 2.3, 2.4, 2.5, 2.6, 2.7, 2.8, 2.9 or 3 mm, and the orifice is the same as the diameter of the aerosol generator or slightly larger than the diameter of the aerosol generator. In some embodiments, the diameter of the aerosol generator is 5% to 20% larger than the diameter of the aerosol generator, for example, 5%, 10%, 15% or 20% larger than the diameter of the aerosol generator. An orifice having a larger diameter relative to the aerosol generator may be useful to avoid interaction between the aerosol generator and the material forming the orifice when the aerosol generator is in use (e.g., heating the material forming the end cap).

[0114] Reference Figure 2, in the present example, the article 1 is inserted into the receiving portion 2 of the non-flammable aerosol supply device 3 by moving the article 1 in the direction of the mark D. The receiving portion 2 is a recess in the device 3, which includes an aerosol generator, which is a needle heater 2a in the present example. The needle heater 2a passes through the opening 10 of the end cap 9 and penetrates the aerosol generating section 4. The needle heater 2a is resistively heated in the present example, but may alternatively be formed by a heating material (e.g., a susceptor) that can be inductively heated as described herein. In other examples, the aerosol generating section 4 of the article 1 may include a heating material, such as a heating material that can be inductively heated, such as a susceptor.

[0115] In the present example, the aerosol-generating section 4 comprises relatively tightly packed strands or strips of aerosol-generating material 4a. Inserting the needle heater 2a into the aerosol-generating section 4 disturbs the strands or strips of aerosol-generating material 4a. In the present example, as the needle heater 2a is inserted into the aerosol-generating section, the strands or strips of aerosol-generating material 4a move outwardly toward the tipping paper 6. The needle heater 2a then occupies the space previously occupied by the aerosol-generating material.

[0116] To generate an aerosol from the aerosol generating material, the needle heater is activated and supplies heat to the aerosol generating material, and as a result, the aerosol generating material generates an aerosol when the aerosol generating material reaches an aerosol generating temperature.

[0117] The article 1 can be removed from the aerosol providing device 3 (e.g. at the end of a section) by moving the article 1 relative to the device in a direction opposite to the direction marked D. To remove the article 1 from the aerosol providing device 3, the article 1 is withdrawn from the receiving portion 2. As the article 1 is withdrawn from the receiving portion 2, the needle heater 2a is withdrawn from the aerosol generating section 4 through the opening 10 of the end plug.

[0118] Although the aerosol-generating material is relatively strong and tightly packed within the aerosol-generating section 4 (particularly when the aerosol-generating material is in the form of a strand or strip), heating the material to an aerosol-generating temperature together with the forces exerted on the aerosol-generating material by the needle heater can reduce the structural integrity of the aerosol-generating material and cause it to decompose. For example, inserting the needle heater into the aerosol-generating section can damage (e.g., tear) the aerosol-generating material. When the needle heater is withdrawn from the aerosol-generating section 4, the aerosol-generating material is again disturbed and tends to shift and move relative to the packaging.

[0119] The first part 9a of the end plug 9 at least partially covers the end face 8 of the aerosol generating section and thus prevents aerosol generating material from falling out of the article 1, in particular when the needle heater 9a is withdrawn from the aerosol generating section 4. This improves the overall hygiene of the system because fragments of aerosol generating material (e.g. particles or flakes) are prevented from leaving the article and entering other parts of the system, such as the aerosol providing device.

[0120] When the first part is annular, the orifice is an annular portion provided by the first part. In other words, the first part may comprise an annular portion.

[0121] Reference Figure 3 , the annular first portion 9a includes an inner circumference 9c and an outer circumference 9d. The inner circumference 9c is smaller than the outer circumference 9d. In this example, the outer circumference 9d is slightly larger than the outer circumference of the aerosol generating section of the article 1. In some embodiments, the outer circumference is substantially the same as the outer circumference of the aerosol generating section of the article 1, or slightly smaller than the outer circumference of the aerosol generating section of the article 1.

[0122] The diameter of the annular portion (also referred to herein as the width of the annular portion) is the longest straight-line distance between the first point on the inner circumference 9c and the second point on the circumference 9c. The diameter is defined by the radial distance r between the inner circumference 9c and the outer circumference 9d of the first portion 9a. For example, a larger radial distance r provides an annular portion with a smaller diameter w. A smaller radial distance r provides an annular portion with a larger width w. The diameter w of the annular portion can be in the range of about 0.5mm to about 4mm. In some embodiments, the diameter w of the annular portion is in the range of about 1mm to about 3mm. In some specific embodiments, the diameter w of the annular portion is in the range of about 2mm to about 3mm.

[0123] The width of the annular portion is proportional to the area of ​​the end face covered by the first portion. That is, increasing the width of the annular portion increases the proportion of the area of ​​the end face covered by the first portion.

[0124] The first portion of the end cap may cover at least about 1% to about 90% of the end face. In some embodiments, the first portion covers at least about 1%, 10%, 20%, 30%, or 40% to about 85%, 75%, 65%, 55% of the end face. In a preferred embodiment, the first portion covers about 5% to about 50% of the end face.

[0125] Increasing the coverage of the end face by the first portion can reduce the tendency of aerosol-generating material to be drawn out of the aerosol-generating portion. However, complete coverage of the end face can result in a higher resistance to draw of gas through the article when in use (also referred to herein as pressure drop). Complete coverage of the end face with the first portion also makes it difficult to insert and remove the aerosol generator of the aerosol supply device.

[0126] In contrast to completely covering the end face with the first part, partially covering the end face with the first part reduces the increase in the resistance to draw and allows the aerosol generator to be inserted into the aerosol generating material relatively easily. However, if the first part does not fully cover the end face, the aerosol generating material may be unintentionally drawn out of the aerosol generating part during use of the article. Therefore, by controlling the percentage of the area of ​​the end face covered by the first part, the resistance to draw through the article can also be at least partially controlled.

[0127] Covering at least about 5% to about 50% of the end surface can substantially mitigate unintentional withdrawal of aerosol generating material from the aerosol generating portion while having a minimal impact on the resistance to draw.

[0128] In particular, it has been found that a good balance between these factors can be achieved when the first portion covers from about 13% of the area of ​​the end face of the rod of aerosol generating material to about 84% of the area of ​​the end face of the rod of aerosol generating material. In particular, when the first portion covers a range of from about 26% of the area of ​​the end face of the rod of aerosol generating material to about 84% of the area of ​​the end face of the rod of aerosol generating material. It is particularly preferred that the first portion covers from about 49% of the area of ​​the end face of the rod of aerosol generating material to about 84% of the area of ​​the end face of the rod of aerosol generating material.

[0129] In some embodiments, the first portion of the end cap forms a continuous annular portion on the end surface of the aerosol generating material rod. For example, the surface of the entire first portion may not include irregularities, such as wrinkles or folds. In such embodiments, the end cap can be formed by, for example, molding a pulp material and then drying it to form a continuous annular portion.

[0130] In some embodiments, the first portion of the end cap is made by folding a sheet of material to form the end cap. This may include folding the sheet to form segments that are folded over each other. Thus, in some embodiments, the first portion includes a plurality of segments. Each segment of the plurality of segments may be folded over an adjacent segment. This arrangement may be described as an iris fold, and the technical method of folding the sheet to form an iris fold may be referred to as an "iris fold" technique. In these embodiments, the first portion forms a discontinuous annular portion that covers the end face of the aerosol generating material rod.

[0131] In some embodiments, the end cap includes a second portion that extends circumferentially around at least a portion of the rod of aerosol-generating material. Referring again to Figure 1, the end cap includes a second portion 9b that extends around at least a portion of the tipping paper 6 of the article 1. In this example, the second portion is at least partially formed separately from the tipping paper 6 of the article 1 and is attached to the tipping paper 6 during the manufacturing process. The second portion 9b may be attached to the tipping paper 6 by any suitable means. For example, the second portion 9b may be glued to the tipping paper 6, or the second portion 9b may be held in place by friction between the tipping paper 6 and the second portion 9b.

[0132] In some embodiments, the end cap includes a second portion that extends around the rod of aerosol generating material but does not extend around the wrapper.The second portion of the end cap may extend around the aerosol generating material and be disposed between the aerosol generating material and the wrapper.

[0133] For example, refer to Figure 4 , the article 1 comprises an end cap 9 comprising a wrapper extending beyond the end face 8 of the first end 1a. The portion of the wrapper extending from the end face 8 is folded inwardly to form a first portion 9a of the end cap 9. The end cap 9 comprises a second portion 9b between the aerosol generating material and the tipping paper 6. The tipping paper 6 surrounds the second portion 9b of the end cap 9. The second portion 9b is sandwiched between the tipping paper 6 and the aerosol generating material. This can improve the reliability of the attachment between the end cap 9 and the rest of the article 1. Furthermore, this increases safety, making it unnecessary to glue the end cap 9 to the tipping paper 6.

[0134] In some embodiments, the end cap is attached to the wrapper during the manufacturing process. The second portion 9b may be attached to the tipping paper 6 by any suitable means. For example, the second portion 9b may be glued to the tipping paper 6, or the second portion 9b may be held in place by friction between the tipping paper 6 and the second portion 9b.

[0135] In some embodiments, the end cap is formed by the wrapping of the article. In other words, in such embodiments, the end cap is not formed by a component separate from the wrapping.

[0136] For example, refer to Figure 5 , the article 1 comprises a wrap extending beyond the end face 8 of the first end 1a. The portion of the wrap extending from the end face 8 is folded inwardly to form a first portion 9a of the end cap 9.

[0137] Forming the end cap from the same body of material as the wrapper can reduce manufacturing costs and complexity because, for example, a completely separate end cap does not have to be manufactured and then secured to the end face of the rod. The first portion of the end cap partially covers the end face of the rod of aerosol-generating material such that at least a portion of the end face of the rod of aerosol-generating material defines an outer surface of the article.

[0138] Figure 6a It is shown how to make the end filter segment of some or all of the references and embodiments. For clarity, other features of the article 1 are omitted. An unfolded end filter segment 9 is provided. In this example, the unfolded end filter segment 9 is the upstream end of the wrapper (not shown) of the article 1, which extends beyond the end face of the first end. The unfolded wrapper includes an unfolded first portion 9a and a second portion 9b, the first portion extending beyond the end face of the first end, and the second portion surrounding the aerosol generating material. The dotted line 9c represents a portion of the wrapper that is aligned with the end face cross-section of the first end of the article. The unfolded first portion 9a will become the first portion 9a of the end filter segment.

[0139] refer to Figure 6b , the unfolded first portion 9a is folded along folding creases 9d from line 9c inwardly toward the central longitudinal axis of the article. The first portion 9a comprises segments defined by folding lines 9d which overlap each other when folded.

[0140] refer to Figure 6c , the first portion 9a is folded until it is perpendicular to the longitudinal axis of the rod of aerosol generating material to provide an end filter segment 9 comprising the first portion 9a and the aperture 10.

[0141] In some embodiments, the first portion of the end cap completely covers the end surface of the rod of aerosol-generating material.Thus, in such embodiments, inadvertent removal of aerosol-generating material from the article may be reduced.

[0142] In some embodiments, the first portion of the end cap overlaps itself over the center of the end face of the rod of aerosol generating material.This can reduce manufacturing costs, complexity and efficiency because the first portion of the end cap does not have to be precisely folded to form a ring.

[0143] The end cap may be formed of any suitable material. In some embodiments, the end cap is formed of a porous material. Forming the end cap from a porous material may reduce the effect of the end filter segment on the draw resistance of the article when in use. Forming the end cap from a material having a relatively high porosity may enable the end cap to cover more surface area of ​​the end face of the aerosol generating material rod while minimizing the effect on the draw resistance.

[0144] In some embodiments, the end cap is formed of a perforated material. Forming the end cap from a perforated material can also reduce the effect of the end filter segment on the suction resistance of the article when in use. In some embodiments, the end cap is formed of a porous and perforated material. The perforations can be suitable for receiving an aerosol generator of a non-flammable aerosol supply device, while the porous nature of the material enables fluid (e.g., gas) to pass through the end filter segment, thereby minimizing the increase in pressure drop.

[0145] In some embodiments, the end cap is formed of a material having a porosity greater than 3,000 CU, or greater than 6,000 CU, or greater than 12,000 CU, or greater than 24,000 CU. In some embodiments, it is preferred to form the end cap from a material having a relatively low porosity (e.g., less than 3,000 CU). Using a lower porosity material, such as a material having a porosity less than 3,000 CU, can help reduce the increase in pressure drop observed when using the end cap.

[0146] The end cap may be formed from a material having an areal density that enables the end cap to be formed by folding a sheet of the material to form the end cap. In particular, the areal density may be selected to allow the first portion of the end cap to fold inwardly toward the central longitudinal axis of the article with minimal force. The areal density may also be selected to reduce the tendency of the folded first portion to expand outwardly away from the central longitudinal axis of the article back to its pre-folded shape.

[0147] The material forming the end caps may have a surface density of about 20gsm to about 100gsm. In a preferred embodiment, the material forming the end caps has a surface density of about 20gsm to about 60gsm. In some embodiments, the surface density of the material forming the end caps is about 25gsm to about 50gsm, for example, about 30gsm to about 45gsm. If the material forming the end caps has a GSM greater than 60GSM, it can still be folded to form the first part. However, it may have a tendency to return to its unfolded state over time. Therefore, in the case where the folded first part includes a material having a surface density within this range, the folded first part is unlikely to return to its pre-folded shape.

[0148] In some embodiments, the end cap is formed of paper. The paper may be the same as filter tipping paper or paper used to wrap the aerosol generating material. The end cap may be formed by molding a pulp comprising a cellulosic material and water and then drying the molded pulp. In some embodiments, the end cap is formed of plug wrap or tipping paper. In some embodiments, the end cap is formed of cigarette paper.

[0149] In some embodiments, the end caps may be formed from a non-combustible material or a material that has been treated to reduce combustion or its tendency to burn.

[0150] In some embodiments, the end cap is formed from a metal sheet and / or a laminate sheet comprising metal and cellulose material. In some embodiments, the end cap is formed from a sheet comprising aluminum and optionally paper. According to some embodiments, the end cap is formed from aluminum foil.

[0151] For example, forming the end cap from an aluminium sheet can prevent it from being ignited by a user and prevent the article from being used like a conventional combustible article. Aluminium is also particularly suitable because it is relatively soft and can be easily folded to form the first portion. Furthermore, it has been found that aluminium is unlikely to unfold from a folded state, so where the portion is made of or includes an aluminium sheet, the folded first portion is unlikely to return to its pre-folded shape.

[0152] To further reduce the likelihood of accidental extraction of the aerosol-generating material from the article, a portion of the aerosol-generating material may be adhered to a wrapper surrounding the aerosol-generating material. The wrapper may include glue on its inwardly facing surface (the surface of the wrapper closest to and facing the aerosol-generating material) that adheres the aerosol-generating material thereto. For example, the inwardly facing surface of the wrapper may include a continuous coating of glue on its inner surface. Alternatively, to reduce manufacturing costs and the overall weight of the article, the wrapper may include a discontinuous coating of glue on its inner surface. The discontinuous coating of glue may include a spiral pattern of glue on the inwardly facing surface of the wrapper.

[0153] In some embodiments, such as the examples described thus far, the rod of aerosol-generating material has a circumference of about 22.1 mm. In alternative embodiments, the rod of aerosol-generating material may have any suitable circumference, such as a circumference of about 15 mm to about 26 mm. In some embodiments, the rod of aerosol-generating material has a circumference of about 20 mm to about 24 mm.

[0154] The article can be a "regular" (about 23mm to 25mm), "wide" (greater than 25mm), "slim" (about 22mm to 23mm), "semi-slim" (about 19mm to 22mm), "ultra-slim" (about 16mm to 19mm), or "micro-slim" (less than about 16mm) article.

[0155] As previously described, in some embodiments, including the examples described herein, the downstream portion or nozzle may include multiple components. For example, the downstream portion may include one or more chambers in the form of one or more hollow tubes. The hollow tubes may help promote the formation of aerosols when the aerosol-generating material is heated. In order to further assist in the formation of aerosols, the downstream portion may include one or more vents that draw fresh air into the downstream portion during use. The downstream portion may also include a filter material. Therefore, in some embodiments, the article includes a hollow chamber that is configured to promote the formation of an aerosol in the downstream portion of the article.

[0156] Now refer to Figure 7Describing the various components of the downstream portion of the article in more detail, the following figure shows the downstream portion or nozzle of the article as described herein. For clarity, features of the upstream end of the rod, including features such as the end cap, are omitted.

[0157] See also Figure 7 , the downstream portion 5 includes a first tubular element 12a immediately downstream of the aerosol generating material portion 4, the first tubular element 12a defining a first hollow cavity. In this example, the first tubular element 12a is in abutment with the aerosol generating material. The first tubular element 12a has a first tubular wall. The mouthpiece or downstream portion 5 also includes a second tubular element 12b immediately downstream of the first tubular element 12a. In this example, the second tubular element 12b is in abutment with the first tubular element 12a. The second tubular element 12b has a second tubular wall with a wall thickness of less than about 320 μm. The axial length of the second tubular element 12b is greater than about 15 mm, for example, about 15 mm to about 25 mm. In this example, the material body 13 is disposed at the downstream end 5b of the downstream portion 5. In this example, the first tubular element 12a and the second tubular element 12b and the material body 13 each define a cylindrical outer shape and are arranged end to end on a common axis. The first and second tubular elements 12a, 12b, the aerosol generating material portion 4 and the body of material 13 have substantially the same outer diameter.

[0158] The first second tubular element 12a and the second tubular element 12b together define a chamber into which the aerosol formed in the aerosol generating portion is sucked and expands and cools. The provision of separate first and second tubular elements 12a, 12b enables these components to be designed to achieve different functional effects. For example, the first tubular element 12a can be arranged to provide functions such as helping to reduce the movement of aerosol material in use because the article 1 is inserted into the recess and the pin heater penetrates the aerosol generating material portion 4 (as described above).

[0159] For this purpose, the first tubular element 12a may have a wall thickness of, for example, 1 mm to 3.5 mm or 1.5 mm to 2.5 mm. Alternatively or additionally, the first tubular element 12a may be arranged to help provide rigidity to the article 1. Alternatively or additionally, the first tubular element 12a may be arranged to promote the aerosol to flow mainly through the axial region of the second tubular element 12b, for example to help form the aerosol. The second tubular element 12b may be designed to define a relatively large chamber compared to the first tubular element 12a, thereby providing a larger space into which the aerosol formed in the aerosol generating portion 4 can be drawn for expansion and cooling. In addition, for a given weight of the second tubular element 12b, providing a relatively thin wall thickness of less than 320 μm enables the material to be concentrated in the outer region of the second tubular element 12b, which can provide a higher bending stiffness than a component with a thicker wall and the same weight.

[0160] In one example, reference Figure 1a The articles described have specific characteristics listed in Table 1 below.

[0161] parameter value Product circumference (mm) 22.1 Length of aerosol generating material part (mm) 12 First tubular element length (mm) 7 First tubular element wall thickness (mm) 1.6 Diameter of the first tubular element cavity (mm) 3.9 Second tubular element length (mm) 17 Second tubular element wall thickness (mm) 0.2 Second tubular element cavity diameter (mm) 6.6 Material body length (mm) 12 Product insertion depth in the device (mm from upstream end) 25 Vent hole position (mm from downstream end) 21

[0162] Table 1

[0163] Although in the present case the body of material 13 is provided at the mouth or downstream end 1 b of the article 1, in other examples additional components may be provided downstream of the body of material 13. For example, another body of material may be provided.

[0164] In this example, the first tubular element has an axial length of about 7 mm, but in other examples, the first tubular element may have an axial length of about 5 mm to about 14 mm. In this example, the first tubular element 12a has a wall thickness of about 1.6 mm, and the inner diameter of the hollow cavity defined by the first tubular element 12a is about 1.95 mm. This results in a ratio of the thickness of the first tubular wall to the inner radius of the first hollow cavity of about 0.82. In other examples, the ratio of the thickness of the first tubular wall to the inner radius of the first hollow cavity may be about 0.6 to about 1.1 or about 0.7 to about 0.9.

[0165] In this example, the volume of the second hollow cavity defined by the second tubular element 12b is approximately 588 mm 3 The volume of the first hollow cavity defined by the first tubular element 12a is about 84 mm 3Thus, the ratio of the volume of the second hollow cavity to the volume of the first hollow cavity is about 7 times. Alternatively, the ratio of the volume of the second hollow cavity to the volume of the first hollow cavity may be about 6.5 to about 8. This provides an arrangement in which an aerosol can expand from a relatively small cavity within the first tubular element 12a to a much larger cavity in the second tubular element 12b. The second tubular element 12b may define a cavity having at least about 520 mm. 3 The combined volume of the first hollow cavity and the second hollow cavity may be, for example, at least about 580 mm 3 Or at least about 620mm 3 Or at least about 650mm 3 .

[0166] The second tubular wall may include at least a first overlapping paper layer and a second overlapping paper layer, each paper layer substantially extending around the entire circumference of the second tubular element 12b. The at least first overlapping paper layer and the second overlapping paper layer may each have a thickness of 30 μm to 150 μm. Alternatively or additionally, the at least first overlapping paper layer and the second overlapping paper layer may each have a basis weight of 25 gsm to 130 gsm. The at least first overlapping paper layer and the second overlapping paper layer may be connected to each other by a layer of glue. The first overlapping paper layer and the second overlapping paper layer may each be non-porous.

[0167] The aerosol generating portion 4 may be in the form of a rod, the axial length of which is less than or equal to the axial length of the second tubular element 12b. For example, the aerosol generating material portion 4 may be in the form of a rod, the axial length of which is 50% to 80% of the axial length of the second tubular element 12b. These arrangements result in the article having a relatively large cavity size defined by the second tubular element 12b compared to the volume occupied by the aerosol generating material. Such a cavity may allow for improved expansion of the aerosol volume through the article 1 and better formation of the aerosol. Preferably, the vent is disposed in the wall of the second tubular element 12b so that cold air enters the cavity defined by the second tubular element 12b during use, thereby further enhancing the formation of the aerosol by the condensation of the aerosol components in the cavity. The second tubular element 12b may have an axial length greater than about 16mm or greater than about 16.5mm. For example, in some examples, the second tubular element 12b may have an axial length greater than the axial length of the first tubular element 12a by at least 1.5 times or at least 2 times.

[0168] The use of a second tubular element 12b immediately downstream of the first tubular element 12a (which has a wall thickness of less than about 320 μm and an axial length of greater than about 15 mm) can produce an article with a relatively low total weight. In this example, the weight of the aerosol generating material portion 4 is about 304 mg, and the total weight of the non-aerosol generating material components of the article 1 is about 320 mg. Therefore, the total weight of the article 1 with a total length of 48 mm is 624 grams, resulting in an average weight of 13 mg / mm. In some examples, the average weight per mm of axial length of the article may be less than about 14.5 mg / mm or less than about 14 mg / mm. The weight of the non-aerosol generating material of the article may be 45% to 55%, for example 48% to 53%, of the total weight of the article.

[0169] In this example, the tubular wall of the second tubular element 12b is formed from the first and second overlapping sheets of paper, resulting in a total thickness of about 200 μm. In an alternative example, the second tubular wall may have a thickness of about 160 μm to about 250 μm.

[0170] The article 1 includes one or more ventilation holes 12 extending through the second tubular element 8b at a position in the second tubular element 8b outside the housing 9 when the article 1 is fully inserted into the non-flammable aerosol supply device 3. The one or more ventilation holes 12 may be arranged as one or more rows of holes, such as laser or mechanically formed perforations, around the article 1. In some examples, the ventilation level is about 10% to about 60%, such as about 20% to about 55%, of the mainstream aerosol.

[0171] The first tubular element 12a is formed from a filament tow, in this example a plasticized cellulose acetate tow. Other configurations may be used, such as a tubular element 12a formed as an inner paper tube and an outer paper tube having a curled paper material sandwiched therebetween. The wall of the first tubular element may be relatively non-porous so that at least 80% of the aerosol generated by the aerosol generating material passes longitudinally through the hollow passage of the tube, rather than through the wall material itself. For example, at least 92% or at least 95% of the aerosol generated by the aerosol generating material may pass longitudinally through the first hollow cavity.

[0172] The filament tow forming first tubular element 12a preferably has a total denier of 25,000 to 45,000, preferably 35,000 to 45,000. Preferably, the cross-sectional shape of the filaments of the tow is "Y" shaped, although other shapes, such as "X" shaped filaments, may be used in other embodiments.

[0173] The filament tow forming the first tubular element 12a preferably has a single filament denier of 4 to 10, more preferably 4 to 9. In one example, the filament tow forming the first tubular element 8a has a 8Y40,000 tow formed of cellulose acetate and containing 18% plasticizer (eg, triacetin).

[0174] Preferably, the density of the material forming the first tubular element 12a is at least about 0.20 grams per cubic centimeter (g / cc), more preferably at least about 0.25g / cc.Preferably, the density of the material forming the first tubular element 8a is less than about 0.80 grams per cubic centimeter (g / cc), more preferably less than 0.6g / cc.In some embodiments, the density of the material forming the first tubular element 12a is 0.20g / cc to 0.8g / cc, more preferably 0.3g / cc to 0.6g / cc, or 0.4g / cc to 0.6g / cc or about 0.5g / cc.It has been found that these densities provide good balance between the improved hardness provided by denser materials and the gross weight of the articles minimized.For the purposes of the present invention, the "density" of the material forming the first tubular element 12a refers to the density of any filament bundle or other materials forming the element with any incorporated plasticizer. The density can be determined by dividing the total weight of the material forming the first tubular element 12a by the total volume of the material forming the first tubular element 12a, where the total volume can be calculated using appropriate measurements of the material forming the first tubular element 8a, for example using a caliper. If necessary, a microscope can be used to measure appropriate dimensions.

[0175] The first tubular element 12a and the second tubular element 12b may be configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile components entering the first upstream end of the first tubular element 12a and the second tubular element 12b and the heated volatile components exiting the second downstream end of the first tubular element 12a and the second tubular element 12b. The first tubular element 12a and the second tubular element 12b are preferably configured to provide a temperature difference of at least 60 degrees Celsius, preferably at least 80 degrees Celsius, and more preferably at least 100 degrees Celsius between the heated volatile components entering the first upstream end of the first tubular element 12a and the second tubular element 12b and the heated volatile components exiting the second downstream end of the first tubular element 12a and the second tubular element 12b. Such a temperature difference over the length of the first tubular element 12a and the second tubular element 12b protects the temperature sensitive material body 13 from the high temperature of the aerosol generating material when it is heated.

[0176] The aerosol-generating portion 4 may exhibit a pressure drop of about 15 mm H 2 O to about 40 mm H 2 O. In some embodiments, the aerosol-generating portion 4 exhibits a pressure drop of about 15 mm H 2 O to about 30 mm H 2 O across the aerosol-generating portion 4 .

[0177] In the aerosol generating portion, the aerosol generating material may have a density of about 400 mg / cm 3 To about 900mg / cm 3A packing density or bulk density of less than 400 mg / cm2. A packing density higher than this may make it difficult to insert the aerosol generator of the aerosol supply device into the aerosol generating material and increase the pressure drop. 3 A packing density of 0.1% can reduce the rigidity of the article. In addition, if the packing density is too low, the aerosol generating material may not be able to effectively clamp the aerosol generator of the aerosol supply device.

[0178] At least about 70% of the volume of the aerosol-generating portion is filled with aerosol-generating material. In some embodiments, about 75% to about 85% of the volume of the cavity is filled with aerosol-generating material.

[0179] In this embodiment, the moisture impermeable tipping paper 6 surrounding the rod of aerosol generating material comprises aluminium foil. In other embodiments, the tipping paper 6 comprises a paper wrapper, optionally including a barrier coating to render the material of the wrapper substantially moisture impermeable. Where the wrapper comprises paper or a paper backing, i.e. a cellulose-based material, the basis weight of the wrapper may be greater than about 30 gsm. For example, the basis weight of the wrapper may be in the range of about 40 gsm to about 70 gsm.

[0180] In this embodiment, the moisture-impermeable tipping paper 6 is also substantially air-impermeable. The tipping paper 6 preferably has an air permeability of less than 100 Coresta units, more preferably less than 60 Coresta units. It has been found that low air permeability wrappers, for example having an air permeability of less than 100 Coresta units, more preferably less than 60 Coresta units, lead to improved aerosol formation in the aerosol-generating material. The air permeability of the tipping paper 6 can be measured according to ISO 2965:2009 on the determination of air permeability of materials used as cigarette papers, filter plug wrapping papers and filter tipping papers.

[0181] In this embodiment, the body of material 13 is wrapped in a first plug wrap 14. A second plug wrap 15 is provided to connect the body of material 13, the first tubular element 12a and the second tubular element 12b. Preferably, the first plug wrap 14 and the second plug wrap 15 each have a basis weight of less than 50 gsm, more preferably a basis weight between about 20 gsm and 40 gsm. Preferably, the first plug wrap 14 and the second plug wrap 15 each have a thickness of 30 μm to 60 μm, more preferably 35 μm to 45 μm. Preferably, the first plug wrap 14 and the second plug wrap 15 are non-porous plug wraps, for example having an air permeability of less than 100 Coresta units (e.g., less than 50 Coresta units). However, in other embodiments, the first plug wrap 14 and / or the second plug wrap 15 may be porous plug wraps, for example having an air permeability of greater than 200 Coresta units.

[0182] Preferably, the length of the body of material 13 is less than about 15 mm. More preferably, the length of the body of material 13 is less than about 14 mm. Additionally, or alternatively, the length of the body of material 13 is at least about 5 mm. Preferably, the length of the body of material 13 is at least about 8 mm. In some preferred embodiments, the length of the body of material 13 is from about 5 mm to about 15 mm, more preferably from about 8 mm to about 14 mm, even more preferably from about 10 mm to about 14 mm, and most preferably about 10 mm, 11 mm, or 12 mm. In this example, the length of the body of material 13 is 12 mm.

[0183] In this example, the material body 13 is formed by a filament tow. In this example, the tow used in the material body 13 has a single filament denier (dpf) of 5 and a total denier of 25,000. In this example, the tow includes a plasticized cellulose acetate tow. The plasticizer used for the tow accounts for about 9% of the weight of the tow. In this example, the plasticizer is triacetin. In other examples, different materials can be used to form the material body 13. For example, the body 13 can be formed by paper instead of a tow, for example in a manner similar to paper filters known for cigarettes. For example, paper or other cellulose-based materials can be provided as one or more portions of a sheet that is folded and / or curled to form the body 13. The sheet may have a basis weight of 15gsm to 60gsm (e.g., 20gsm to 50gsm). For example, the sheet can have a basis weight in any range between 15 gsm and 25 gsm, between 25 gsm and 30 gsm, between 30 gsm and 40 gsm, between 40 gsm and 45 gsm, and between 45 gsm and 50 gsm. Additionally or alternatively, the sheet can have a width between 50 mm and 200 mm, such as between 60 mm and 150 mm or between 80 mm and 150 mm. For example, the sheet can have a basis weight of 20 gsm to 50 gsm and a width of 80 mm to 150 mm. For example, this can allow the cellulose-based object to have a suitable pressure drop for an article having dimensions as described herein.

[0184] Alternatively, the body 13 may be formed from a tow other than cellulose acetate, such as polylactic acid (PLA), other materials described herein for the filament tow, or similar materials. The tow is preferably formed from cellulose acetate. Whether formed from cellulose acetate or other materials, the tow preferably has a dpf of at least 5. Preferably, in order to obtain a sufficiently uniform material body 13, the single filament denier of the tow does not exceed 12 d.pf, preferably does not exceed 11 d.pf, and more preferably does not exceed 10 d.pf.

[0185] The total denier of the tow forming the body of material 13 is preferably at most 30,000, more preferably at most 28,000 and still more preferably at most 25,000. These total denier values ​​provide drag, which occupies a reduced proportion of the cross-sectional area of ​​the mouthpiece 5, resulting in a lower pressure drop of the tow with a higher total denier value than the entire mouthpiece 5. For the consideration of the appropriate firmness of the body of material 13, the total denier of the tow is preferably at least 8,000 and more preferably at least 10,000. Preferably, the denier of each filament is between 5 and 12, and the total denier is between 10,000 and 25,000. Preferably, the cross-sectional shape of the tow filaments is a 'Y' shape, but in other embodiments, other shapes such as 'X'-shaped filaments can be used, with the same dpf and total denier values ​​provided herein. In some embodiments, it may be preferred to use filters with different filtration efficiencies to control the overall filtration efficiency. This may be beneficial, for example, for certain aerosol generating materials that may not require high filtration efficiency. For example, "O" or "C" shaped filaments may be used (alone or in combination with each other, or in combination with "X" and "Y" shaped filaments), but filaments having these shapes may generally have lower filtration efficiency than, for example, "Y" shaped filaments.

[0186] Regardless of the material used to form the body 13, the pressure drop in the entire body 13 can be, for example, between 0.3 and 5 mmWG / mm of the length of the body 13, for example, between 0.5 mmWG and 2.5 mmWG / mm of the length of the body 13. The pressure drop can be, for example, averaged between 1.5 and 2.5 mmWG / mm of length. The total pressure drop in the entire body 13 can be, for example, between 12 mmWG and 30 mmWG, or between 15 mmWG and 25 mmWG. In the case where the body 13 includes an additive release component, the pressure drop refers to the average or total pressure drop before any rupture of the component. The material body 13 and / or the tube 12a and / or the tube 12b can include paper or be composed of paper. In some embodiments, the material body 13 and / or the tube 12a and / or the tube 12b can include woven or nonwoven materials or be composed of woven or nonwoven materials. The use of paper and woven / nonwoven materials can contribute to the biodegradability of the article 1. In some embodiments, the woven or nonwoven material is crimped and the grammage is between about 20 to 50 GSM, preferably 30 to 45 GSM, which can further enhance biodegradability.

[0187] The tipping paper 6 is wrapped around the entire length of the downstream portion 5 and a portion of the rod of aerosol-generating material and has an adhesive on its inner surface to connect the downstream portion 5 to the rod. In the present example, the rod of aerosol-generating material is wrapped in a tipping paper 6', which forms a first wrapping material, and the tipping paper 6 forms an outer wrapping material, which extends at least partially over the rod of aerosol-generating material to connect the downstream portion 5 to the rod. In some examples, the tipping paper may extend completely over the rod of aerosol-generating material.

[0188] In the present example, the tipping paper 6 extends 5 mm over the rod of aerosol generating material, but it may alternatively extend 3 to 10 mm, or more preferably 4 to 6 mm over the rod to provide a secure attachment. The basis weight of the tipping paper may be greater than 20 gsm, such as greater than 25 gsm, or preferably greater than 30 gsm, such as 37 gsm. It has been found that these basis weight ranges result in a tipping paper having an acceptable tensile strength while being sufficiently flexible to wrap around the article 1 and adhere to itself along the longitudinal lap seam on the paper.

[0189] The ventilation level of the article 1 is about 25% of the aerosol inhaled through the article 1. The article 1 preferably includes ventilation apertures provided into the second tubular element 12b. In alternative embodiments, the ventilation level of the article 1 may be between 10% and 60% of the aerosol inhaled through the article 1, for example between 20% and 50%.

[0190] In this example, the aerosol modifier is provided within the body of material 6, in this example in the form of an additive release component, in this case a capsule 16. However, the capsule 16 may be omitted in other embodiments. Where the capsule 16 is provided, the first wadding wrap 14 may be an oil-resistant first wadding wrap 14. In other examples, the aerosol modifier may be provided in other forms, such as by injecting the material into the body of material 13 or providing it on a thread, for example, the thread carries a flavoring or other aerosol modifier, which may also be disposed within the body of material 13.

[0191] Capsule 16 may include a frangible capsule, such as a capsule having a solid brittle shell around a liquid payload. In the present example, a single capsule 16 is used. Capsule 16 is entirely embedded within the material body 13. In other words, capsule 16 is completely surrounded by the material forming body 13. In other examples, multiple frangible capsules may be disposed within the material body 13, such as two, three or more frangible capsules. The length of the material body 6 may be increased to accommodate the number of desired capsules. In examples where multiple capsules are used, the individual capsules may be identical to one another, or may differ from one another in size and / or capsule payload. In other examples, multiple material bodies 13 may be provided, each of which contains one or more capsules.

[0192] The capsule 16 has a core-shell structure. In other words, the capsule 16 includes a shell encapsulating a liquid agent, such as a flavoring agent or other agent, which can be any of the flavoring agents or aerosol modifiers described herein. The user can rupture the shell of the capsule to release the flavoring agent or other agent in the material body 13.

[0193] In the present example, capsule 16 is spherical and has a diameter of about 3 mm. In other examples, capsules of other shapes and sizes may be used. For example, the diameter of the capsule may be less than 4 mm, or less than 3.5 mm, or less than 3.25 mm. In alternative embodiments, the diameter of the capsule may be greater than about 3.25 mm, such as greater than 3.5 mm, or greater than 4 mm. The gross weight of capsule 16 may be in the range of about 10 mg to about 50 mg.

[0194] In this example, capsule 16 is located at a non-longitudinal center position within the body of material 13. In this example, capsule 16 is located closer to the upstream end of the body of material 13 than the downstream end. That is, capsule 16 is positioned so that its center is 5 mm from the upstream end of the body of material 13 and 7 mm from the downstream end, which can help ensure that the capsule cannot be seen from the downstream end of the article 1.

[0195] The article 1 includes one or more ventilation apertures 17 extending through the second tubular element 12b at a position in the second tubular element 12b, which is outside the housing of the aerosol supply device (not shown) when the article 1 is fully inserted into the non-flammable aerosol supply device. The one or more ventilation apertures 17 can be provided as one or more rows of apertures surrounding the article 1, such as laser or mechanically formed perforations. In some examples, the ventilation level is between about 10% and about 60% of the mainstream aerosol, for example between about 20% and about 55%.

[0196] Reference again Figure 1a , the non-flammable aerosol supply device 3 and the product 1 together form a non-flammable aerosol supply system. The non-flammable aerosol supply device 3 includes a heating element 2a configured to be inserted into the aerosol generating material of the product 1. In this example, the heating element is a needle heater 2a that penetrates the aerosol generating material. The non-flammable aerosol supply device 3 includes a housing 11 and an orifice 12 in the housing 11, into which the product 1 is inserted in use.

[0197] The articles disclosed herein can be manufactured using any suitable means. According to some embodiments, a method of manufacturing an article comprises:

[0198] providing a rod of aerosol generating material comprising a plurality of elongated strips;

[0199] providing a wrap around the rod of aerosol-generating material such that a first portion of the wrap depends from an end of the rod of aerosol-generating material; and

[0200] The first portion of the wrapper overhanging the end of the rod of aerosol-generating material is folded to at least partially cover an end surface of the rod of aerosol-generating material.

[0201] As described herein, the first portion of the wrap that overhangs the end of the rod once folded becomes the first portion of the end cap of the article. Therefore, the first portion of the wrap can also be referred to as the unfolded first portion of the end cap.

[0202] In some embodiments, the step of folding the first portion of the wrapper comprises moving the mold longitudinally relative to the rod of aerosol-generating material to fold the first portion inwardly onto the end of the rod of aerosol-generating material. The mold applies a linear force to the first portion, which causes the first portion to move inwardly and onto the end surface of the rod of aerosol-generating material. The mold may include a series of ridges and grooves that may help form the fold in the first portion and reduce the amount of linear force required to fold the first portion inwardly.

[0203] For example, refer to Figure 8a , the die 18 includes a die 19, which includes a recess in a body of solid material. The recess includes a series of ridges 20a and grooves 20b, which in this example form a 10-sided inverted pyramid die pattern. In this example, there are five ridges and five grooves. The die can be made of any hard material such as metal or plastic. In this example, the die 18 is made of aluminum. In other embodiments, the die pattern can be different. For example, the die pattern can be a four-sided inverted pyramid die with no ridges and four grooves. The die pattern can determine the number and position of fold lines on the first part.

[0204] Referring again to FIG. 8 , to form the first portion of the end cap, the mold 18 is aligned so that its central longitudinal axis is aligned with the central longitudinal axis of the distal end of the article 1. The mold moves linearly in direction d1 and contacts the peripheral edge of the first portion of the wrap 9a′. Continued movement of the mold in direction d1 causes the first portion of the wrap 9a′ to fold inwardly from the fold line 9b′ and form a folded end plug, the first portion being aligned with the end face of the article as described above. During folding, the first portion 9a will adopt the same shape as the fold line 9b′. Figure 6b To facilitate the folding of the first portion of the wrapper 9a', the mold 9 can be rotated about its central longitudinal axis relative to the first portion of the wrapper 9a' while it moves in direction d1.

[0205] like Figure 8bIn the embodiment shown, the die 19 protrudes from the body of the solid material and also forms a 10-sided pyramidal die pattern including a series of ridges 20a and grooves 20b. In this example, the die can rotate around the central axis a. Alternatively, the die may be able to rotate around the central axis in a direction opposite to the indicated direction. In this example, the die 8 is positioned at an angle relative to the longitudinal axis XX' so that the central axis a extends at an oblique angle relative to the longitudinal axis XX' of the end cap 9. In some embodiments, the central axis is centrally aligned with the longitudinal axis XX' of the end cap 9.

[0206] When the mold 18 rotates, it moves linearly relative to the end cap 9 in the direction d1. The end cap 9 (and therefore, in this embodiment, the entire product) also rotates around its central longitudinal axis XX' in the same direction as the mold 18 rotates. The mold 18 eventually contacts the peripheral edge of the first portion of the wrap 9a'. The continuous movement of the mold 18 along the direction d1 causes the first portion of the wrap 9a' to fold inward from the crease line 9b' aligned with the end face of the product as described above, and forms a folded end plug. In this example, both the mold and the end cap rotate. In some embodiments, the mold can rotate relative to the end cap and the end cap can remain stationary. In some embodiments, the mold does not move linearly relative to the end cap. On the contrary, as described above, both the mold and the end cap rotate around their respective axes a and XX' in the same rotational direction, and the end cap moves laterally relative to the mold. During this lateral movement, the mold contacts the end cap and folds the first portion 9a.

[0207] In some embodiments, the folding step may include compressing the first portion of the wrapper. The unfolded first portion of the wrapper, when suspended from the end of the aerosol generating material rod, may be compressed by applying a lateral force and / or a linear force to the first portion of the wrapper. This may result in the first portion being pushed inwardly toward the central longitudinal axis of the article.

[0208] For example, one or more articles disclosed herein may be packaged in a box. In some embodiments, when the article is placed in the box, a first portion of the overhang of the wrapper at the end of the rod of aerosol-generating material is folded inwardly.

[0209] Thus, the compressing step may be performed during the packaging step of the article. In such embodiments, the article is inserted into the package so that the upstream end of the article abuts against an internal component of the box, such as an inner wall of the box. A linear force is applied to the downstream end of the article, which results in the first portion of the wrapper being compressed between the end face of the article and the internal component of the box. As a result, the first portion of the wrapper is folded to at least partially cover the end face of the aerosol generating material rod. Folding the first portion in this manner may reduce manufacturing complexity and cost, as it may not be necessary to use complex folding equipment.

[0210] In some embodiments, the step of folding the first portion may comprise rotating the rod of aerosol-generating material on a drum through at least one folding device.

[0211] Fig. 9 A schematic diagram of an example of a folding apparatus is shown. A rotating drum 21 carries a plurality of articles 1 as described herein in vacuum grooves on its surface, which is used in conjunction with a static rolling plate 22. Each article 1 protrudes from the surface of the drum 21. In this embodiment, a first portion of the wrapper 1 (as previously described) protrudes from the surface of the drum 21.

[0212] A static rolling plate 22 is disposed adjacent to the rotating drum 21. The rolling plate 22 is provided with a plough folder 23. The plough folder 23 is fixed to the rolling plate 22 and comprises a surface extending from the curved surface of the rolling plate 22, the surface being located in the plane of the first end of the product 1, so that when the product 1 is rolled on the rolling plate 22, the first part of the wrapping of the product abuts against the surface.

[0213] The surface of the plow clamp 23 has an edge that starts from the surface of the rolling plate and converges to the surface of the drum, so that the distal end of the plow clamp extends through at least half of the space between the rolling plate 22 and the drum 21. When the product 1 is transported onto the rolling plate 22 by the rotation of the drum 21, the front end of the plow clamp 23 engages with the first portion of the wrapper, gradually pushing it down and inwardly against the end surface of the product 1.

[0214] As the article 1 rolls on the rolling plate 22, the edge of the plow clamp 23 continuously engages with a new portion of the first portion and folds it against the end face. As the article 1 advances through the plow clamp 23, the converging edges gradually extend through more of the end of the article 1, thereby folding the first portion over along its entire length. In this way, a continuous fold is formed around the entire circumference of a and the first portion is flat against the end face of the article. When the article 1 comes out of the end of the plow clamp 23, its end face is at least partially covered by the first portion.

[0215] Fig.10 A schematic diagram of another example of a folding device is shown. Fig. 9The embodiment of the invention is similar to the embodiment of the invention in that it utilizes a rotating roller 21 to press the article 1 over the surface of a static rolling plate 22. However, in this example, the plow clamp is replaced by a series of teeth 24. Like the plow clamp, the teeth 24 extend inwardly from the surface of the rolling plate 22 and have a surface that is in the same plane as the end face of the article 1. Each tooth 24 has an edge that starts on the surface of the rolling plate 22 and converges to the surface of the roller, so that the distal end of each tooth 24 extends through at least half of the space between the rolling plate 22 and the roller 21. Therefore, each tooth 24 can be considered as a separate plow clamp. However, the length of each tooth in the direction of travel of the article is less than the circumference of the article 1, so each tooth 24 can only fold over a portion of the unfolded end of the article 1. The next tooth 24 engages the unfolded end where the previous tooth has stopped folding and forms a new separate fold that overlaps the previous fold. Each tooth 24 forms a separate fold that overlaps the previous fold. Therefore, there must be enough teeth to fold over all the unfolded ends, so the total length of the teeth must be at least the circumference of the article 1.

[0216] This gives an iris-style fold that includes the same number of folds as the number of teeth on the rolling plate 22. The number of teeth is not limited to five. The number of teeth can be increased or decreased depending on the number of folds required. For example, an article with a relatively small circumference may require fewer teeth to complete the fold. In addition, the teeth can be of any suitable shape. For example, they can be longitudinal bars.

[0217] Fig.11 A schematic end view of an article whose ends are closed with iris-type folds is shown. The first portion of the end cap comprises five overlapping folds, which are used, for example, Fig.10 The five teeth 24 on the rolling plate 22 are shown to be formed in the order of a to e. In this example, the first portion partially overlaps the end surface of the article to provide the hole 10.

[0218] In some embodiments, the step of folding the first portion may include rolling the article on the drum through at least one folding device. For example, instead of rotating the article relative to the drum as described in the previous example, the article can be fixed relative to the drum, and the folding device can move relative to the article and the drum to wrap the first portion of the article.

[0219] As previously explained, the articles described herein are suitable for use with a non-flammable aerosol delivery device.

[0220] Fig.12 yes Figure 1a A simplified schematic diagram of the components within the housing 11 of the non-flammable aerosol supply device 3 is shown.

[0221] like Fig.12As shown, within the housing 11 there is an electrical energy supply 25, such as a rechargeable lithium ion battery. A controller 26 is connected to the heating element 2a, the electrical energy supply 25 and a user interface 27, such as a touch sensitive display. The controller 26 controls the power supplied to the heating element 2a to regulate its temperature. Typically, the aerosol generating material is heated to a temperature between 250 and 450 degrees Celsius.

[0222] The heating element 2a is configured to be inserted into the aerosol-generating material of the article 1. In this example, the heating element 2a is in the form of a pin heater, but in an alternative example it may be formed in the form of a blade terminating at a point. That is, the length dimension of such a blade heater may be greater than its width dimension, which in turn may be greater than its thickness dimension.

[0223] When the heater is activated, the aerosol-generating material of the product is heated and generates or releases volatile substances. When the user draws on the mouthpiece, air is drawn into the product and the volatile substances condense to form an inhalable aerosol. The aerosol passes through the mouthpiece of the product and enters the user's mouth.

[0224] As used herein, the term "non-flammable aerosol delivery system" is intended to cover systems that deliver at least one substance to a user by releasing compounds from an aerosol generating material without burning the aerosol generating material, such as electronic cigarettes, tobacco heating products, and hybrid systems that use a combination of aerosol generating materials to generate an aerosol.

[0225] According to the present disclosure, a "non-flammable" aerosol supply system is a system in which aerosol generating material components of the aerosol supply system (or components thereof) are not combusted or burned to facilitate delivery of at least one substance to a user.

[0226] In some embodiments, the delivery system is a non-flammable aerosol delivery system, such as a powered non-flammable aerosol delivery system. In some embodiments, the non-flammable aerosol delivery system is an electronic cigarette, also known as a hookah device or an electronic nicotine delivery system (END), although it is noted that the presence of nicotine in the aerosol generating material is not a requirement.

[0227] In some embodiments, the non-flammable aerosol supply system is an aerosol generating material heating system, also referred to as a heat-not-burn system. The example of such a system is a tobacco heating system. In some embodiments, the non-flammable aerosol supply system is a hybrid system to generate an aerosol using a combination of aerosol generating materials, one or more of which can be heated. Each of the aerosol generating materials can be, for example, in the form of a solid, liquid or gel, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol generating material and a solid aerosol generating material. The solid aerosol generating material can include, for example, tobacco or non-tobacco products.

[0228] Generally, a non-flammable aerosol delivery system may include a non-flammable aerosol delivery device and a consumable for use with the non-flammable aerosol delivery device, such as the article 1 described herein.

[0229] In some embodiments, the present disclosure relates to consumables containing an aerosol generating material and configured for use with a non-flammable aerosol delivery device. These consumables are referred to as articles throughout the disclosure.

[0230] In some embodiments, the non-flammable aerosol delivery system, such as a non-flammable aerosol delivery device thereof, may include a power source and a controller. The power source may, for example, be an electric power source or an exothermic power source. In some embodiments, the exothermic power source includes a carbon substrate that can be energized to distribute power in the form of heat to the aerosol generating material or a heat transfer material adjacent to the exothermic power source. The exothermic power source includes a carbon substrate that can be energized to distribute electricity in the form of heat to the aerosol generating material or a heat transfer material adjacent to the exothermic power source.

[0231] In some embodiments, the non-flammable aerosol delivery system includes an area for receiving an article, an aerosol generator, an aerosol generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0232] In some embodiments, an article for use with a non-flammable aerosol delivery device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a shell, a wrapper, a filter, a mouthpiece and / or an aerosol modifier.

[0233] In some embodiments, the article comprises a substance to be delivered. The substance to be delivered may be an aerosol-generating material or a material not intended to be aerosolized. Where appropriate, either material may comprise one or more active ingredients, one or more flavorings, one or more aerosol-forming materials, and / or one or more other functional materials.

[0234] In some embodiments, the substance to be delivered includes an active substance.

[0235] Active substances as used herein can be physiologically active materials, which are materials intended to achieve or enhance physiological responses. Active substances can be, for example, selected from nutrients, nootropics, psychoactive substances. Active substances can be naturally occurring or synthetically obtained. Active substances can include, for example, nicotine, caffeine, taurine, theaconic acid, vitamins such as B6 or B12 or C, melatonin, derivatives or combinations. Active substances can include one or more components, derivatives or extracts of tobacco or another plant.

[0236] In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin, or vitamin B12.

[0237] As described herein, the active substance may include or be derived from one or more plants or components, derivatives or extracts thereof. As used herein, the term "plant" includes any material derived from a plant, including but not limited to extracts, leaves, skins, fibers, stems, roots, seeds, flowers, fruits, pollen, shells, husks, etc. Alternatively, the material may include an active compound naturally present in a plant obtained by synthesis. The material may be in the form of a liquid, gas, solid, powder, dust, crushed grains, granules, pellets, fragments, strips, sheets, etc. Exemplary plants are tobacco, eucalyptus, star anise, cocoa, fennel, lemongrass, mint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, laurel, licorice (licorice root), matcha, mate, orange peel, papaya, rose, sage, tea (such as green or black tea), thyme, cloves, cinnamon, coffee, anise seed (fennel), basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, Mint, juniper, elderflower, vanilla, wintergreen, basil, turmeric, turmeric root, sandalwood, cilantro, bergamot, orange blossom, myrtle, black currant, valerian, bell pepper, mace, damien, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, geranium, mulberry, ginseng, theanine, theophylline, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. The mint may be selected from the following mint species: field mint (Mentha arvensis), mint cultivar (Mentha cv), Egyptian mint (Mentha niliaca), peppermint (Mentha piperita), peppermint lemon cultivar (Mentha piperita citrata cv), peppermint cultivar (Mentha piperita cv), wrinkled green mint (Mentha spicata cripa), heart mint (Mentha cardifolia), European peppermint (Mentha longifolia), variegated pineapple mint (Mentha suaveolens variegata), lip calyx mint (Mentha pulegium), green mint cultivar (Mentha spicata cv) and apple mint (Mentha suaveolens).

[0238] In some embodiments, the active substance comprises or is derived from one or more plants or components, derivatives, or extracts thereof, and the botanical is tobacco.

[0239] In some embodiments, the active comprises or is derived from one or more plants, or components, derivatives or extracts thereof, and the plant is selected from eucalyptus, star anise and cocoa.

[0240] In some embodiments, the active comprises or is derived from one or more plants, or components, derivatives or extracts thereof, and the plants are selected from rooibos and fennel.

[0241] In some embodiments, including the examples described herein, the aerosol-generating material may include plant material. As used herein, the term "plant" or "plant material" includes any material derived from a plant, including but not limited to extracts, leaves, skins, fibers, stems, roots, seeds, flowers, fruits, pollen, shells, husks, etc. In some embodiments, the plant material is preferably a leaf of a plant.

[0242] In some embodiments, the plant material is derived from a tobacco plant. For example, the method is particularly suitable for processing threshed tobacco leaves. In some embodiments, the tobacco is one or more of any tobacco type, including common tobacco types, such as Virginia tobacco, burley tobacco and oriental tobacco.

[0243] In other embodiments, the plant material is or is derived from a plant or material (plant) including: eucalyptus, star anise, cocoa, fennel, lemongrass, mint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, laurel, liquorice (licorice root), matcha, mate, orange peel, papaya, rose, sage, tea (such as green tea or black tea), thyme, cloves, cinnamon, coffee, anise seed (fennel), basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, Rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, basil, turmeric, turmeric root, sandalwood, cilantro, bergamot, orange blossom, myrtle, black currant, valerian, bell pepper, mace, damien, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, geranium, mulberry, ginseng, theanine, theophylline, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. The mint may be selected from the following mint species: field mint (Mentha arvensis), mint cultivar (Mentha cv), Egyptian mint (Mentha niliaca), peppermint (Mentha piperita), peppermint lemon cultivar (Mentha piperita citrata cv), peppermint cultivar (Mentha piperita cv), wrinkled green mint (Mentha spicatacripa), heart mint (Mentha cardifolia), European peppermint (Mentha longifolia), variegated pineapple mint (Mentha suaveolens variegata), lip calyx mint (Mentha pulegium), green mint cultivar (Menthaspicata cv) and apple mint (Mentha suaveolens).

[0244] In some embodiments, the plant is selected from eucalyptus, star anise, and cocoa. In some embodiments, the plant is selected from rooibos and fennel.

[0245] In some embodiments, the substance to be delivered includes a flavoring agent.

[0246] As used herein, the terms "flavoring agent" and "flavoring" refer to materials that can be used in products for adult consumers to produce a desired taste, aroma or other physical sensation, where permitted by local regulations. They can include naturally occurring flavoring materials, plants, plant extracts, synthetically obtained materials or combinations thereof (e.g., tobacco, licorice (licorice root), hydrangea, eugenol, Japanese white magnolia leaf, chamomile, fenugreek, clove, maple, matcha, mint, Japanese mint, anise seed (fennel), cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, cranberry, cranberry, peach, apple, orange, mango, tangerine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit , cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, gin, tequila, rum, spearmint, mint, lavender, aloe vera, cardamom, celery, bittersweet, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel nut, hookah, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia seed, caraway seed caraway, cognac, jasmine, perfume tree, sage, fennel, mustard, coloring, ginger, coriander, coffee, peppermint oil from any mint species, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazelnut, hibiscus, laurel, mate, orange peel, rose, tea such as green and black, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, basil, turmeric, coriander, myrtle, black Currant, valerian, bell pepper, nutmeg, damian, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, limonene, thymol, camphor), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, sodium cyclamate, lactose, sucrose, glucose, fructose, sorbitol or mannitol), and other additives such as charcoal, chlorophyll, minerals, plants or breath fresheners. They can be imitation, synthetic or natural ingredients or blends thereof. They can be in any suitable form, for example, liquids such as oils, solids such as powders, or gases.

[0247] In some embodiments, flavorings include menthol, spearmint and / or peppermint oil. In some embodiments, flavorings include flavoring components of cucumber, blueberry, citrus fruit and / or cranberry. In some embodiments, flavorings include eugenol. In some embodiments, flavorings include flavoring components extracted from tobacco.

[0248] In some embodiments, flavoring agents may include sensates, which are intended to achieve somatosensory sensations, which are chemically induced and sensed by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or in place of aroma or taste nerves, and these may include substances that provide heating, cooling, tingling, numbing effects. Suitable thermal effect agents may be, but are not limited to, vanillyl ethyl ether, and suitable cooling agents may be, but are not limited to, eucalyptus oil WS-3.

[0249] An aerosol-generating material is a material that is capable of generating an aerosol, for example when heated, irradiated or energized in any other way. The aerosol-generating material may be in the form of a solid, liquid or gel, and may or may not contain an active substance and / or a flavoring agent. The aerosol-generating material may be incorporated into an article for use in an aerosol-generating system.

[0250] As used herein, the term "tobacco material" refers to any material comprising tobacco or its derivative or substitute.Tobacco material can be in any suitable form.The term "tobacco material" can include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstructed tobacco or tobacco substitutes.Tobacco material can include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco sheets, reconstructed tobacco and / or tobacco extract.

[0251] A consumable is an article containing or consisting of an aerosol generating material, part or all of which is intended to be consumed by a user during use. A consumable may include one or more other components, such as an aerosol generating material storage area, an aerosol generating material delivery component, an aerosol generating area, a housing, a wrapper, a mouthpiece, a filter and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater, which emits heat during use to cause the aerosol generating material to generate an aerosol. The heater may, for example, include a combustible material, a material that can be heated by electrical conduction, or a susceptor.

[0252] A susceptor is a material that can be heated by penetration of a changing magnetic field, such as an alternating magnetic field. The susceptor can be a conductive material, such that penetration of the changing magnetic field through the susceptor causes inductive heating of the heated material. The heated material can be a magnetic material, such that penetration of the changing magnetic field through it causes hysteresis heating of the heated material. The susceptor can be conductive and magnetic, such that the susceptor can be heated by both heating mechanisms. A device configured to generate a changing magnetic field is hereinafter referred to as a magnetic field generator.

[0253] Aerosol modifiers are substances typically located downstream of an aerosol generation region that are configured to adjust the generated aerosol, for example by changing the taste, flavor, acidity or another characteristic of the aerosol. The aerosol modifier may be disposed in an aerosol modifier release component that is operable to selectively release the aerosol modifier.

[0254] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may, for example, include one or more of a flavoring agent, a colorant, water, and a carbon adsorbent. The aerosol modifier may, for example, be a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, a string, or a granule. The aerosol modifier may not contain a filter material.

[0255] An aerosol generator is a device configured to generate an aerosol from an aerosol generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol generating material to thermal energy so as to release one or more volatiles from the aerosol generating material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol generating material without heating. For example, the aerosol generator can be configured to subject the aerosol generating material to one or more of vibration, increased pressure, or electrostatic energy.

[0256] Filament tow material as described herein can include cellulose acetate fiber tow. Other materials for forming fiber can also be used to form filament tow, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly (1-4 butylene glycol succinate) (PBS), poly (butylene adipate-co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials and polysaccharide polymers or combinations thereof. Filament tow can be plasticized with a plasticizer suitable for tow, such as triacetin, wherein the material is cellulose acetate tow, or the tow can be non-plasticized. The tow may have any suitable specifications, such as fibers having a "Y" shape or other cross-section such as an "X" shape, with a filament denier value of between 2.5 and 15 denier per filament, for example between 8.0 and 11.0 denier per filament, and a total denier value of 5,000 to 50,000 denier, for example between 10,000 and 40,000.

[0257] The various embodiments described herein are given only to help understand and teach the claimed features. These embodiments are provided only as representative samples of embodiments, and are not exhaustive and / or exclusive. It is to be understood that the advantages, embodiments, examples, functions, features, structures and / or other aspects described herein are not considered to be limitations on the scope of the invention defined by the claims or limitations on the equivalents of the claims, and other embodiments may be utilized and may be modified without departing from the claimed scope of the invention. In addition to those specifically described herein, various embodiments of the present invention may suitably include appropriate combinations of disclosed elements, parts, features, assemblies, steps, devices, etc., and consist of or substantially consist of appropriate combinations of disclosed elements, parts, features, assemblies, steps, devices, etc. In addition, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. A product for use in or as a non-flammable aerosol delivery system, the product comprising: aerosol generating material rod; and An end cap includes a first portion configured to extend at least partially over an end surface of the rod of aerosol generating material.

2. The article of claim 1, wherein the end cap is configured to at least reduce removal of aerosol-generating material from the aerosol-generating material rod.

3. An article according to claim 1 or claim 2, wherein the first portion of the end cap partially covers the end surface of the aerosol generating material rod, so that at least a portion of the end surface of the aerosol generating material rod defines the outer surface of the article.

4. An article according to any one of the preceding claims, wherein the first portion of the end cap extends at an angle to the longitudinal axis of the rod of aerosol-generating material.

5. An article according to claim 4, wherein the first portion of the end cap extends substantially perpendicular to the longitudinal axis of the rod of aerosol generating material.

6. An article according to any one of the preceding claims, wherein the first portion of the end cap partially covers an end face of the rod of aerosol generating material to form an orifice in the first portion.

7. The article of claim 6, wherein the orifice comprises a diameter of at least about 0.5 mm, at least about 1 mm, or at least about 2 mm, optionally at most about 8 mm, optionally at least about 1 mm or 2 mm and at most 5 mm.

8. An article according to claim 6 or claim 7, wherein the first portion covers a range from about 13% of the area of ​​the end face of the rod of aerosol generating material to about 84% of the area of ​​the end face of the rod of aerosol generating material.

9. The article according to any one of claims 6 to 8, wherein the first portion covers a range from about 26% of the area of ​​the end face of the rod of aerosol generating material to about 84% of the area of ​​the end face of the rod of aerosol generating material.

10. An article according to any one of claims 6 to 9, wherein the first portion covers a range from about 49% of the area of ​​the end face of the rod of aerosol generating material to about 84% of the area of ​​the end face of the rod of aerosol generating material.

11. An article according to any one of claims 6 to 10, wherein the first portion of the end cap forms a generally annular cap covering the end face of the rod of aerosol generating material.

12. The article of claim 11, wherein the orifice is an annular portion of the annular cap, and the width of the annular portion is in the range of about 0.5 mm to about 4 mm.

13. An article according to claim 11 or claim 12, wherein the aperture is an annular portion of the annular cap and the width of the annular portion is in the range of about 1 mm to about 3 mm.

14. The article of any one of claims 11 to 13, wherein the orifice is an annular portion of the annular cap, and the width of the annular portion is in the range of about 2 mm to about 3 mm.

15. The article of any one of claims 6 to 14, wherein the orifice is centrally located within the first portion.

16. An article according to claim 15, wherein the orifice and the rod of aerosol generating material are concentrically aligned.

17. An article according to any one of the preceding claims, wherein the first portion of the end cap forms a continuous annular portion over the end surface of the rod of aerosol generating material.

18. The article of claim 17, wherein the first portion of the end cap includes an iris-like fold such that segments of the first portion are folded over one another.

19. The article of any preceding claim, wherein the first portion comprises a plurality of segments.

20. An article according to any preceding claim, wherein the first portion comprises a plurality of segments such that the end cap forms a discontinuous annular portion covering the end face of the rod of aerosol-generating material.

21. The article of any one of claims 1 to 5, wherein the first portion of the end cap completely covers the end surface of the rod of aerosol generating material.

22. An article according to claim 21, wherein the first portion of the end cap overlaps itself over the center of the end face of the rod of aerosol generating material.

23. The article of any preceding claim, wherein the end cap further comprises a second portion extending circumferentially around at least a portion of the rod of aerosol-generating material.

24. An article according to any preceding claim, wherein the end cap is formed by a wrapping of the rod of aerosol-generating material.

25. An article according to any preceding claim, wherein the end cap extends over the downstream end of the rod of aerosol-generating material.

26. The article of any one of claims 1 to 24, wherein the end cap is formed by a filter tipping wrap of the article.

27. An article according to any preceding claim, wherein the end cap extends over the upstream end of the rod of aerosol-generating material.

28. The article of any one of claims 1 to 22, wherein the end cap further comprises a second portion formed by two arms attached to an outer circumferential surface of the article.

29. The article of any preceding claim, wherein the end cap is formed from a porous material.

30. The article of any preceding claim, wherein the end cap is formed from a perforated material.

31. An article according to claim 29 or claim 30, wherein the end cap is formed from a material having a porosity greater than 3,000 CU, or greater than 6,000 CU, or greater than 12,000 CU, or greater than 24,000 CU.

32. The article of any one of the preceding claims, wherein the end cap is formed from a material having a weight in the range of about 20 gsm to about 60 gsm.

33. The article of any preceding claim, wherein the end cap is formed from a plug wrap.

34. The article of any one of claims 1 to 32, wherein the end cap is formed from tipping paper.

35. The article of any one of claims 1 to 32, wherein the end cap is formed from an aluminum foil.

36. An article according to any preceding claim, wherein the rod of aerosol-generating material comprises a plurality of elongated strips of aerosol-generating material.

37. An article according to claim 36, wherein the plurality of elongated strips extend substantially the length of the rod of aerosol generating material.

38. The article of any preceding claim, wherein the aerosol-generating material is adhered to a wrapper surrounding the aerosol-generating material.

39. The article of claim 38, wherein an adhesive adheres the aerosol-generating material to the wrapper, and the adhesive is applied to the wrapper in a spiral pattern.

40. The article according to any of the preceding claims, wherein the aerosol generating material is configured to receive an aerosol generator of a non-flammable aerosol delivery device, and the aerosol generating material is configured to compress when inserted into the aerosol generator.

41. A method of manufacturing an article, the method comprising: providing a rod of aerosol generating material comprising a plurality of elongated strips; providing a wrap around the rod of aerosol-generating material such that a first portion of the wrap depends from an end of the rod of aerosol-generating material; as well as The first portion of the wrapper overhanging the end of the rod of aerosol-generating material is folded to at least partially cover an end surface of the rod of aerosol-generating material.

42. A method according to claim 41, wherein the step of folding the first portion comprises rotating the rod of aerosol generating material on a drum through at least one folding device.

43. A method according to claim 41 or claim 42, wherein the step of folding the first portion comprises rolling the rod of aerosol generating material on a drum through at least one folding device.

44. A method according to claim 41, wherein the step of folding the first portion comprises moving a die longitudinally relative to the rod of aerosol generating material to fold the first portion inwardly over the end of the rod of aerosol generating material.

45. The method of any one of claims 41 to 44, wherein the step of folding further comprises compressing the first portion of the wrapper.

46. ​​The method of claim 45, wherein the compressing is performed during a packaging step of the article.

47. An article for use with a non-flammable aerosol delivery device made by the method of any one of claims 41 to 46.

48. A non-flammable aerosol delivery system comprising a product as claimed in any one of claims 1 to 40 or 47 and a non-flammable aerosol delivery device.

49. The non-flammable aerosol delivery system according to claim 48, wherein the non-flammable aerosol delivery device comprises an aerosol generator, and the aerosol generator extends into the aerosol generating section of the article and is in direct contact with the aerosol generating material.

50. A non-flammable aerosol delivery system as claimed in claim 49, wherein the aerosol generator is a needle or blade heater.

51. A method comprising inserting an aerosol generator of a non-flammable aerosol delivery device into the aerosol generating material of an article as claimed in any one of claims 1 to 40 or 47.

52. A method as claimed in claim 51, wherein the aerosol generating material is compressed during insertion of the aerosol generator into the aerosol generating material.

53. Use of an article as claimed in any one of claims 1 to 40 or 47 with a non-flammable aerosol supply device.

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