Article for use in aerosol provision system

Abstract

To provide an article for use in an aerosol provision system for obtaining a satisfactory sensory experience.SOLUTION: An article 1 is provided for use with a non-combustible aerosol provision device having a mouth end 8 and a distal end 9 opposite the mouth end, the article including: a first section 2 including a first aerosol generating material, the first aerosol generating material including tobacco; and a second section 4 including a second aerosol generating material, the second aerosol generating material including an aerosol former material; wherein the second section is relatively closer to the distal end than the first section.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an article for use in a non-combustion aerosol delivery system, and to a non-combustion aerosol delivery system including the article. [Background technology]

[0002] Certain tobacco industry products generate an aerosol during use, which is inhaled by the user. For example, tobacco heating devices heat an aerosol-generating substrate, such as tobacco, to form an aerosol by heating the substrate without burning it. Summary of the Invention

[0003] In some embodiments described herein, in a first aspect, a catheter includes an oral end and a distal end, a first section containing a first aerosol-forming material, the first aerosol-forming material comprising tobacco; a second section containing a second aerosol-generating material, the second aerosol-generating material comprising an aerosol-forming material; An article is provided for use with a non-combustible aerosol delivery device, wherein the second section is relatively closer to the distal end than the first section.

[0004] In some embodiments described herein, in the second aspect, a non-combustible aerosol delivery device comprising a heater; The article according to any one of claims 1 to 23. A system is provided comprising:

[0005] In some embodiments described herein, in the third aspect, forming a first aerosol-generating material; dividing the first aerosol-generating material into sections of the first aerosol-generating material; forming a second aerosol-generating material; dividing the second aerosol-generating material into sections of the second aerosol-generating material; combining the section of a first aerosol-generating material with the section of a second aerosol-generating material; A method of making an article for use with a non-combustible aerosol delivery device is provided, comprising:

[0006] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0007] [Figure 1] FIG. 1 is a diagram of an article for use with an aerosol delivery device. [Diagram 2] FIG. 1 is a diagram of an article for use with an aerosol delivery device. [Figure 3a] FIG. 1 is a diagram of an apparatus for manufacturing components of an article for use with an aerosol delivery device. [Figure 3b] FIG. 1 is a diagram of an apparatus for manufacturing components of an article for use with an aerosol delivery device. [Figure 3c] FIG. 1 is a diagram of an apparatus for manufacturing components of an article for use with an aerosol delivery device. [Figure 4] FIG. 1 is a diagram of an apparatus for manufacturing an article for use with an aerosol delivery device. [Diagram 5] FIG. 1 is a diagram of an apparatus for manufacturing an article for use with an aerosol delivery device. [Figure 6] FIG. 1 is a flow diagram of a method of manufacturing an article for use with an aerosol delivery device. [Figure 7] FIG. 1 is a diagram of an aerosol delivery device. [Figure 8] FIG. 2 is a diagram of a portion of an aerosol delivery device. [Figure 9] FIG. 2 is a diagram of a portion of an aerosol delivery device. [Figure 10] FIG. 2 is a diagram of a portion of an aerosol delivery device. [Figure 11] FIG. 11A is a diagram of a portion of an aerosol delivery device, and FIG. 11B is a detailed diagram of a portion of the aerosol delivery device. [Figure 12] FIG. 1 is a diagram of a knitted absorbent material. [Figure 13] FIG. 1 is a diagram of a knitted absorbent material. [Figure 14] FIG. 1 is a diagram of a knitted absorbent material. [Figure 15] FIG. 1 is a diagram of a knitted absorbent material. [Figure 16] FIG. 1 is a diagram of a knitted absorbent material. [Figure 17] FIG. 1 is a diagram of a knitted absorbent material. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] [Detailed Description] As used herein, the term "delivery system" is intended to include a system that delivers at least one substance to a user; Combustible aerosol delivery systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for roll-your-own or hand-made cigarettes, whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smoking materials; a non-combustion aerosol delivery system that releases a compound from an aerosol-generating material without combusting the aerosol-generating material, such as e-cigarettes, tobacco heating products, and hybrid systems that use a combination of aerosol-generating materials to generate an aerosol; "An aerosol-free delivery system that delivers at least one substance, including, but not limited to, lozenges, gums, patches, articles containing inhalable powders, and oral products such as oral tobacco products (including snus and moist snuff), which may or may not contain nicotine, to a user orally, nasally, transdermally, or otherwise, without forming an aerosol." Includes.

[0009] According to the present disclosure, a "combustible" aerosol delivery system is one in which an aerosol-generating component of the aerosol delivery system (or a component thereof) is combusted or burned during use to facilitate delivery of at least one substance to a user.

[0010] According to the present disclosure, a "non-combustible" aerosol delivery system is one in which the aerosol-generating constituent material (or components thereof) of the aerosol delivery system is not combusted or is not combusted to facilitate delivery of at least one substance to a user.

[0011] In the embodiments described herein, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0012] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system, one example of which is a tobacco heating system.

[0013] Typically, a non-combustion aerosol delivery system can include a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device.

[0014] In some embodiments, the present disclosure relates to consumables that include an aerosol generating material and are configured for use with a non-combustible aerosol delivery device. These consumables are sometimes referred to as articles throughout this disclosure.

[0015] A consumable is an article that comprises or consists of an aerosol-generating material, some or all of which is intended to be consumed during use by a user. A consumable may comprise one or more other components, such as an aerosol-generating material storage region, an aerosol-generating material transport component, an aerosol-generating region, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also comprise an aerosol generator, such as a heater that emits heat upon use to cause the aerosol-generating material to generate an aerosol. The heater may comprise, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0016] In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, may include a power source and a controller. The power source may be, for example, an electrical power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that can be energized to deliver power in the form of heat to an aerosol generating material or a heat transfer material in proximity to the heat generating power source.

[0017] In some embodiments, the non-combustible aerosol delivery system may include a consumable, an aerosol generator, an aerosol-generating region, a housing, a mouthpiece, a filter, and / or a region for receiving an aerosol modifier.

[0018] In some embodiments, a consumable for use with a non-combustible aerosol delivery device may comprise an aerosol generating material, an aerosol generating material containment region, an aerosol generating material transport component, an aerosol generator, an aerosol generating region, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0019] In some embodiments, the substance to be delivered may be an aerosol-generating material or a material not intended to be aerosolized, either of which may optionally include one or more active ingredients, one or more flavorings, one or more aerosol-forming materials, and / or one or more other functional materials.

[0020] The 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, thereby releasing one or more volatile components 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 may be configured to subject the aerosol-generating material to one or more of vibration, increased pressure, or electrostatic energy.

[0021] An aerosol-generating material is a material that can generate an aerosol when, for example, heated, irradiated, or energized in any other way. The aerosol-generating material may be, for example, in the form of a solid, liquid, or gel, and may or may not contain actives and / or flavorings. In some embodiments, the aerosol-generating material may comprise an "amorphous solid" (alternatively, sometimes referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can hold some fluid therein, such as a liquid. In some embodiments, the aerosol-generating material may comprise, for example, about 50%, 60%, or 70% to about 90%, 95%, or 100% amorphous solid by weight.

[0022] The aerosol-generating materials may include one or more active agents and / or flavorings, one or more aerosol-forming materials, and, optionally, one or more other functional materials.

[0023] The aerosol forming material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol forming material may include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, 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.

[0024] The one or more other functional ingredients may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0025] The material may be on or in a support to form a substrate. The support may be or include, for example, paper, card, corrugated board, cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or both sides of the material.

[0026] An aerosol modifier is a substance that is typically disposed downstream of the aerosol-generation region and configured to modify the generated aerosol, for example by changing the taste, flavor, acidity, or another characteristic of the aerosol. The aerosol modifier may be provided in an aerosol modifier-releasing component that is operable to selectively release the aerosol modifier.

[0027] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavoring, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, liquid, or gel. The aerosol modifier may be in the form of a powder, threads, or granules. The aerosol modifier may be free of a filtration material.

[0028] A susceptor is a material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material, such that the penetration of the varying magnetic field therein results in induction heating of the heating material. The heating material may be a magnetic material, such that the penetration of the varying magnetic field therein results in magnetic hysteresis heating of the heating material. The susceptor may be both electrically conductive and magnetic, such that the susceptor is heatable by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0029] Induction heating is a process in which a conductive object is heated by penetrating a varying magnetic field into the object. The process is described by Faraday's law of electromagnetic induction and Ohm's law. An induction heater may comprise an electromagnet and a device for passing a varying electric current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are placed in a suitable relative position such that the varying magnetic field produced by the electromagnet penetrates the object, one or more eddy currents are generated in the object. The object has a resistance to the flow of electric current. Thus, when such eddy currents are generated in the object, they flow against the electrical resistance of the object, thereby heating the object. This process is called Joule heating, Ohmic heating, or resistive heating. Objects that can be inductively heated are known as susceptors.

[0030] In one embodiment, the susceptor is in the form of a closed circuit. It has been found that when the susceptor is in the form of a closed circuit, there is a stronger magnetic coupling between the susceptor and the electromagnet in use, which results in increased or improved Joule heating.

[0031] Magnetic hysteresis heating is the process by which an object made of a magnetic material is heated by the penetration of the object into a fluctuating magnetic field. A magnetic material can be thought of as containing many atomic-scale magnets, or magnetic dipoles. When a magnetic field penetrates such a material, the magnetic dipoles align themselves along the magnetic field. Thus, when a fluctuating magnetic field, such as an alternating magnetic field (e.g., produced by an electromagnet), penetrates a magnetic material, the orientation of the magnetic dipoles changes in response to the applied fluctuating magnetic field. This reorientation of the magnetic dipoles generates heat in the magnetic material.

[0032] When an object is both conductive and magnetic, the penetration of a varying magnetic field into the object can cause both Joule heating and magnetic hysteresis heating in the object. Furthermore, the use of magnetic materials can enhance the magnetic field, thereby enhancing Joule heating.

[0033] In each of the above processes, heat is generated within the object itself, rather than by conduction from an external heat source, so that rapid temperature rise and more uniform heat distribution within the object can be achieved, particularly by appropriate choice of object material and geometry, and appropriate choice of magnitude and orientation of the varying magnetic field relative to the object. Furthermore, induction heating and magnetic hysteresis heating do not require a physical connection between the source of the varying magnetic field and the object, allowing greater design freedom and control of the heating profile, as well as lower costs.

[0034] Articles, e.g., rod-shaped articles, are often designated according to the length of the product as "regular" (typically 68-75 mm, e.g., in the range of about 68 mm to about 72 mm), "short" or "mini" (68 mm or less), "king size" (typically 75-91 mm, e.g., in the range of about 79 mm to about 88 mm), "long" or "super king" (typically 91-105 mm, e.g., in the range of about 94 mm to about 101 mm), and "ultra long" (typically in the range of about 110 mm to about 121 mm).

[0035] The articles are also designated according to the circumference of the product: "regular" (approximately 23-25 ​​mm), "wide" (over 25 mm), "slim" (approximately 22-23 mm), "demi-slim" (approximately 19-22 mm), "super slim" (approximately 16-19 mm), and "micro-slim" (less than approximately 16 mm).

[0036] Thus, a king size, super slim format article, for example, has a length of about 83mm and a circumference of about 17mm.

[0037] Each format can be made with a different length of tip, which can be about 30mm to 50mm long. The tipping paper connects the tip to the aerosol-generating material and is usually longer than the tip, for example 3 to 10mm longer, so that the tipping paper covers the tip and overlaps the aerosol-generating material, for example in the form of a rod of substrate, connecting the tip to the rod.

[0038] The articles described herein and their aerosol-forming materials and tips can be made in any of the formats described above, without being limited thereto.

[0039] As used herein, the terms "upstream" and "downstream" are relative terms defined with reference to the direction of mainstream aerosol being drawn through an article or device, when used.

[0040] The filament tow material described herein may include fiber tows of cellulose acetate. The filament tows may also be formed using other materials used to form fibers, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers, or combinations thereof. The filament tows may be plasticized with a suitable plasticizer for the tow, such as triacetin if the material is cellulose acetate tow, or the tows may be unplasticized. The tows may have any suitable specifications, such as fibers with a "Y"-shaped, "X"-shaped, or "O"-shaped cross section. The fibers of the tow have a single fineness value of 2.5 to 15 denier per filament, for example, 8.0 to 11.0 denier per filament, and a total fineness value of 5,000 to 50,000 denier, for example, 10,000 to 40,000 denier. When viewed in cross section, the fibers have an isoperimeter ratio L of 25 or less. 2 / A, which is preferably less than or equal to 20, more preferably less than or equal to 15, where L is the perimeter of the cross section and A is the area of ​​the cross section.

[0041] As used herein, the term "tobacco material" refers to any material that includes tobacco or its derivatives or substitutes. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Tobacco materials may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco stems, reconstituted tobacco, and / or tobacco extracts.

[0042] In some embodiments, the substance to be delivered comprises an active agent.

[0043] As used herein, an active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. An active substance may be selected from, for example, dietary supplements, nootropics, and psychotropic drugs. An active substance may be naturally occurring or synthetically derived. An active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins (such as B6 or B12 or C), melatonin, cannabinoids, or components, derivatives, or combinations thereof. An active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another botanical substance.

[0044] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0045] As described herein, the active material may include or be derived from one or more botanical materials, or components, derivatives, or extracts thereof. As used herein, the term "botanical material" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, petioles, roots, seeds, flowers, fruits, pollen, husks, skins, and the like. Alternatively, the material may include active compounds naturally present in the botanical material or obtained synthetically. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, fragments, strips, sheets, and the like. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cacao, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, laurel, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea (such as green tea or black tea), thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, Lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha arventis, Grapefruit mint (Mentha cv), Egyptian mint (Mentha niliaca), Peppermint (Mentha piperita), Lime mint (Mentha piperita citrata cv), Chocolate mint (Mentha piperita cv), Curly mint (Mentha spicata crispa), Wild mint (Mentha cardifolia), Horse mint (Mentha longifolia), Pineapple mint (Mentha suaveolens variegata), Pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata cv), and Apple mint (Mentha suaveolens).

[0046] In some embodiments, the active agent comprises or is derived from one or more botanical substances, or components, derivatives, or extracts thereof, and the botanical substance is tobacco.

[0047] In some embodiments, the active agent comprises or is derived from one or more botanical substances, or components, derivatives, or extracts thereof, the botanical substances being selected from eucalyptus, star anise, cocoa, and hemp.

[0048] In some embodiments, the active agent comprises or is derived from one or more botanical substances, or components, derivatives, or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0049] In some embodiments, the substance delivered comprises a fragrance.

[0050] As used herein, the terms "flavoring agent" and "flavoring agent" refer to materials that can be used in adult consumer products to create a desired taste, aroma, or other somatic sensation, where permitted by local regulations, including naturally occurring flavoring materials, botanical substances, extracts of botanical substances, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (aniseed), cinnamon, turmeric, Indian spice, Asian spice, herb, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, etc.). , clementine, lemon, lime, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel, shirataki, shiitake mushrooms ... Shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any species of the genus Mentha, eucalyptus, star anise, cacao, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, laurel, yerba mate, orange peel, rose, tea (green or black) etc.), thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil, chives, Calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g.The compositions may contain saccharides such as sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol, as well as other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners. They may be imitation, synthetic, or natural ingredients, or blends thereof. They may be in any suitable form, such as a liquid (such as an oil), a solid (such as a powder), or a gas.

[0051] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavor components extracted from tobacco. In some embodiments, the flavoring comprises flavor components extracted from cannabis.

[0052] In some embodiments, the flavoring may include sensory agents intended to achieve somatic sensations that are usually chemically induced and perceived by stimulating the fifth cranial nerve (trigeminal nerve) in addition to or instead of the olfactory or gustatory nerves, and these may include agents that provide a heating effect, a cooling effect, a tingling effect, a numbing effect. A suitable heating effect agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol, WS-3.

[0053] In the figures described herein, like reference numerals are used to denote equivalent features, items or components.

[0054] 1 shows a rod-shaped article 1 for use with a non-combustion aerosol delivery device. The article 1 comprises a first rod-shaped section 2 containing a first aerosol-generating material 3, where the first aerosol-generating material 3 comprises tobacco, and a second rod-shaped section 4 containing a second aerosol-generating material 5, where the second aerosol-forming material comprises an aerosol-forming material.

[0055] The first section 2 and second section 4 are assembled by a wrapper 7 that is aligned with a third (filter) section 6 and surrounds sections 2, 4, 6. The overlapping edges of the wrapper 7 are adhesively applied to hold the wrapper 7 in place. The filter section 6 forms a mouth end 8 of the article 1. An end 9 opposite the mouth end 8 is referred to herein as the distal end 9.

[0056] The second section 4 is relatively closer to the distal end 9 than the first section 2. The first section 2 is disposed between the second section 4 and the filter section 6.

[0057] The filter section 6 includes a plug of filter material 13. The plug may be any suitable filter material, and in some embodiments the plug comprises cellulose acetate.

[0058] Each section 2, 4, 6 of the article further comprises a respective packaging material: first section 2 is surrounded by first section packaging material 10, second section 4 is surrounded by second section packaging material 11 and filter section 6 is surrounded by filter section packaging material 12.

[0059] To assemble the article 1, each section 2, 4, 6 is assembled in axial alignment with each of the other two sections and then wrapped in packaging material 7. A flow diagram of the assembly process is shown in FIG.

[0060] Each section 2, 4, 6 of the article 1 is manufactured using similar principles, as described below and shown diagrammatically in Figures 2a-2c.

[0061] 3a, to produce the first section 2, a continuous length of the first section of packaging material 10 is pulled from a spool 14a and passed sequentially through a filling station 15a and a packaging station 16a. At the filling station 15a, the packaging material 10 is loaded with a first aerosol-generating material 3. The packaging material 10 and the first aerosol-generating material 3 then pass through a packaging station 16a. At the packaging station 16a, the continuous length of the first section of packaging material 10 is wrapped about its longitudinal axis around the first aerosol-generating material 3. The longitudinal edges of the packaging material 11 overlap and are glued together to form a continuous rod 17a of the first aerosol-generating material. The continuous rod 17a is then cut into individual first sections 2 by a rotating knife 18a.

[0062] 3b, to produce the second section 4, a continuous length of the second section of packaging material 11 is pulled from spool 14b and passed sequentially through filling station 15b and wrapping station 16b, where it is filled with second aerosol-generating material 5 and then wound using the same wrapping techniques as described above in relation to the first section 2 and FIG. 3a to form a continuous rod of second aerosol-generating material 17b. The continuous rod is then cut into individual second sections 4 by rotating knives 18b.

[0063] 3c, to produce filter section 6, a continuous length of filter section packaging material 12 is drawn from spool 14c and passed sequentially through filling station 15c and wrapping station 16c, where the continuous length of filter section packaging material 12 is filled with filter material 13 and then wound using the same wrapping techniques as described above in relation to first section 2 and second section 4 to form a continuous rod of filter material 17c. The continuous rod 17c is then cut into filter sections 3 by a rotating knife 18c.

[0064] In each case, wrapping stations 16a, 16b, 16c include a garniture (not shown) configured to gradually wind the respective wrapping material 10, 11, 12 into a continuous rod 17a, 17b, 17c as the wrapping material passes therethrough, the garniture including a surface that defines a varying profile from a substantially flat surface to a substantially cylindrical shape as the wrapping material passes through the garniture.

[0065] In each case, the respective packaging material 10, 11, 12 may be transported using a continuous garniture tape (not shown) on which the packaging materials 10, 11, 12 are supported. The garniture tape passes in a loop around guide rollers. At least one motorized roller is provided for driving the garniture tape around the guide rollers.

[0066] Two methods for assembling item 1 are described below.

[0067] A first method, shown in Figure 4, involves cutting a continuous length of packaging material 7 into individual packaging portions prior to wrapping the individual packaging portions around respective sections 2, 4, 6 of the article.

[0068] In particular, according to a first method as shown in FIG. 4, each of the individual sections 2, 4, 6 is conveyed by a series of drums 19 to a combining drum 20, after which the combined sections are wrapped into individual portions of packaging material as described below.

[0069] Each drum has a cylindrical outer surface with a number of spaced grooves around its periphery for holding the rod-shaped sections 2, 4, 6 as they are transported. Thus, as the drums rotate, the rod-shaped sections 2, 4, 6 are transported transversely to their longitudinal axes. Each drum is closely spaced relative to the adjacent drums so that the sections can be transferred directly from one drum to another. The grooves may further include suction holes for holding the rod-shaped sections 2, 4, 6 until they are transferred to the adjacent drum.

[0070] A first section feed drum 21 and a second section feed drum 22 deliver the first section 2 and the second section 4, respectively, to the combining drum 20. The groups of first section 2 and second section 4 are combined in their respective channels with a filter section 6 delivered by a filter section delivery drum 23 to form a group of unpackaged sections 2, 4, 6 (referred to herein as unpackaged articles 24).

[0071] Packaging material 7 is supplied on a spool. A continuous length of packaging material is unwound from the spool 25, passes through an adhesive application station 26, and then to a cutting station 27. The cutting station 27 cuts the continuous length of packaging material into individual packaging material portions.

[0072] The combining drum 20 transfers the unpackaged articles 24 to a packaging material supply drum 28. The individual packaging material portions are applied to and adhered to the unpackaged articles 24 at the packaging material supply drum 28.

[0073] The packaging material supply drum 28 then transports the unpackaged articles 24 and the individual packaging material portions to a winding drum 29 of a winding station 30 that includes a roll hand 31. The winding drum 29 wraps the individual packaging material portions around the unpackaged articles 24 between the cylindrical outer surface of the winding drum 29 and the roll hand 31 to form the finished articles 1.

[0074] Alternatively, according to a second method as shown in Figure 5, each of the sections 2, 4, 6 are alternately arranged on a continuous length of packaging material 7 which is then passed through a wrapping station 32. At the wrapping station 32, the continuous length of packaging material 7 is wrapped about its longitudinal axis around the sections 2, 4, 6. The longitudinal edges of the packaging material 7 overlap and are glued together to form a continuous rod 33 of alternating sections. The continuous rod 33 is then cut into individual articles 1 by a rotating knife 34.

[0075] In the illustrated embodiment, the individual sections are placed in the wrapping material in the following sequence: 6-2-4-2-6 (numbering the sections by reference numeral), and so on. Each of the filter sections 6 and each of the second sections 4 are double length, meaning twice the length of each section 4, 6 in the finished product. Once wrapped, the rotating knife 34 then repeatedly cuts the continuous rod 33 as it advances from the wrapping station 32. The speed of rotation of the rotating knife and the advancement speed of the continuous rod are maintained such that the double length sections 4, 6 are cut in half to form back-to-back finished products 1.

[0076] It will be appreciated that in some embodiments, the article 1 may comprise additional sections, such as a tubular mouthpiece section. Thus, the above method is not limited to the assembly of an article comprising only the three sections 2, 4, 6. Those skilled in the art will readily appreciate that the described assembly steps may be modified in a limited manner to provide additional sections. For example, according to the first method, a fourth section feed drum may be provided to feed the fourth section to the combining drum 20, so that the combining drum comprises the first section, the second section, the filter section, and the fourth section. Similarly, according to the second method, the fourth section may be placed on a continuous length of packaging material with the corresponding first section, second section, and filter section.

[0077] In use, the article is inserted into an aerosol delivery device configured to heat the article such that the aerosol-forming material of the second aerosol-generating material 5 generates an aerosol. When a user draws inhalation on the mouth end 8 of the article 1, the aerosol is entrained in the airflow passing through the article 1 and is inhaled by the user.

[0078] In some embodiments, the aerosol-forming material of the second aerosol-generating material 5 is a liquid aerosol-forming material that includes at least one of glycerin, glycerol, or propylene glycol, and thus the second aerosol-generating material 5 is configured to generate a generally unflavored aerosol (referred to herein as a base aerosol).

[0079] In some embodiments, the second aerosol-generating material 5 comprises an absorbent material saturated with a liquid aerosol-forming material. The absorbent material may be a fibrous material, such as natural cotton and / or viscose fibers. Natural cotton and viscose fibers are known to withstand the heater temperatures of the aerosol delivery device.

[0080] In some embodiments, the second aerosol-generating material 5 comprises a knitted absorbent material 50, which is further described below with reference to Figures 12-17.

[0081] In some embodiments, the aerosol-forming material of the second aerosol-generating material may be a gel, which may or may not include an active agent and / or a flavoring. In some embodiments, the gel may include an "amorphous solid" (which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can hold some fluid therein, such as a liquid. In some embodiments, the gel may include, for example, about 50%, 60%, or 70% to about 90%, 95%, or 100% amorphous solid by weight.

[0082] In some embodiments, the second aerosol-forming material 5 includes an active agent, such as nicotine.

[0083] In some embodiments, the length of the second section 4 is configured to be the same as or slightly longer than the length of the heater in the aerosol delivery device such that only the second section 4 is received within the heater of the aerosol delivery device, with the second section 4 being kept at an appropriate distance from the heater.

[0084] Upon inhalation, the base aerosol generated by the second aerosol-generating material 5 passes through the first section 2. Heat from the aerosol vaporizes the volatile elements of the first aerosol-generating material 3. The volatile elements of the first aerosol-generating material augment the base aerosol with additional flavorings and / or active substances such as nicotine.

[0085] In order to obtain a satisfactory sensory experience, it is important to design the first section 2 to have an appropriate pressure drop. The pressure drop across the first section 2 corresponds to the drop in enthalpy of the base aerosol as it passes through the first section 2. The pressure drop across the first section 2 therefore determines the amount of heat released by the base aerosol and therefore the amount of flavouring or active substance volatilized by the first aerosol-generating material 3. A balance must be struck. If the pressure drop across the first section 2 is too large, the resulting loss of enthalpy will cause excessive condensation of the base aerosol at the first aerosol-generating material 3. Condensation in the first section 2 will cause filtration of the volatile elements generated by the first aerosol-generating material 3, thus reducing the performance and taste characteristics of the aerosol. However, if the pressure drop is too small, the base aerosol will pass through the first section 2 for too short a time and not enough heat will be released by the base aerosol to vaporize a satisfactory amount of the volatile elements. Furthermore, if insufficient heat is given off by the base aerosol, the temperature of the aerosol may be uncomfortable for the consumer as it exits the mouth end 8. It is therefore desirable to set a pressure drop that balances these above requirements.

[0086] The pressure drop referred to herein is the "closed pressure drop", i.e., the pressure drop with any vent openings closed or covered. The pressure drop referred to herein is measured when the article 1 is not in the aerosol delivery device. The total pressure drop referred to herein is the closed pressure drop of the finished article 1.

[0087] In some embodiments, the total pressure drop across article 1 is between 80 mm water column and 220 mm water column, or between 100 mm water column and 200 mm water column, or between 120 mm water column and 180 mm water column.

[0088] In some embodiments, the pressure drop across the first section 2 of the article is between 30 mm water column and 100 mm water column, or between 50 mm water column and 80 mm water column, or between 60 mm water column and 70 mm water column. This pressure drop across the first section can thus balance the conflicting requirements discussed above.

[0089] The pressure drop in the first section 2 can be expressed as a percentage of the total pressure drop. In some embodiments, the pressure drop across the first section 2 is between 30% and 70% of the total pressure drop, or between 40% and 60% of the total pressure drop. In some embodiments, the pressure drop in the first section 2 is about 50% of the total pressure drop. Thus, the pressure drop in the first section can balance the conflicting requirements discussed above.

[0090] In some embodiments, the packaging material 11 of the second section includes a susceptor, such as aluminum foil, such that an induction heater of the aerosol delivery device can directly heat the packaging material of the second section to generate an aerosol from the second section 4.

[0091] The first aerosol-forming material comprises a tobacco material. The tobacco material may be provided in any suitable form. The tobacco material may comprise conventional dried tobacco that has been cut or shredded in the usual manner. Such tobacco is similar to tobacco found in cigarettes.

[0092] In another embodiment, the tobacco material may be regenerated into tobacco paper, which is then shredded or cut into strips. The tobacco paper may be further impregnated with an aerosol-forming material, such as glycerin, glycerol, or propylene glycol. Thus, the heat from the aerosol vaporizes the aerosol-forming material as it passes through the first section 2 when inhaled by a user. Advantageously, the aerosol-forming material is flavored by the tobacco paper to impart a tobacco flavor to the aerosol.

[0093] In some embodiments, the tobacco paper comprises longitudinal strips of tobacco paper, each longitudinal strip being arranged substantially parallel to the longitudinal axis of the article, such that the resistance to flow in the first section 2 is reduced, allowing the base aerosol to pass through without requiring significant effort from the user.

[0094] In another embodiment, the tobacco material is reconstituted into tobacco beads. The tobacco beads may have an average diameter of 0.5 mm to 3 mm. It will be appreciated that for a given volume occupied by the tobacco beads, the smaller the average diameter, the greater the total surface area presented by the tobacco beads. Advantageously, the flavoring imparted to the aerosol is proportional to the surface area presented by the tobacco beads.

[0095] 12-17 generally illustrate a braided absorbent material 50 including strands of material 52 braided around the outside of a rod of absorbent material 54 in accordance with the principles of the present disclosure.

[0096] In some embodiments, the second aerosol-generating material 5 of the second section 4 of the article 1 comprises a knitted absorbent material 50, as shown in Figures 12-17. For example, if the second aerosol-generating material 5 comprises a liquid aerosol-forming material or a gel aerosol-forming material, the absorbent material 54 is saturated with the aerosol-forming material, such that the aerosol-forming material is contained within the absorbent material 54 when the knitted absorbent material 50 forms part of the article 1. Thus, the absorbent material 54 is made of a material capable of wicking the aerosol-forming material. In other words, the absorbent material 54 uses capillary action to draw the aerosol-forming material along the length of the absorbent material 54, such that all of the absorbent material 54 is saturated with the aerosol-forming material. This also allows the aerosol-forming material to be applied to one end 50a of the absorbent material 54 and the aerosol-forming material to be drawn through the absorbent material 54, resulting in a uniform distribution of the aerosol-forming material within the absorbent material 54. Thus, the absorbent material 54 can be made of any material having such wicking properties, for example, fibrous materials such as cotton fibers, wool fibers, silk fibers, or other natural fibers, or synthetic fibers such as nylon fibers, polypropylene fibers, or polyester fibers.

[0097] 12-17 have a cylindrical cross-section, it will be understood that rods of other cross-sections are possible, such as square, hexagonal, or octagonal. The outer diameter and shape of the knitted absorbent material 50 may correspond to the outer diameter and shape of the article 1, such that the knitted absorbent material 50 conforms to the outer shape of the article 1. Similarly, the knitted absorbent material 50 may have a different outer shape than the article 1, but may be sized to fit within the overall outer shape of the article 1.

[0098] Woven around the outside of the rod of absorbent material 54 are strands of material 52. In other words, the strands of material 52 are interwoven around or around the rod of absorbent material 54 along the length of the rod of absorbent material 54 (the x-direction as shown in Figures 12-17).

[0099] The threads of material 52 function to strengthen the absorbent material 54 and ensure that the rod of woven absorbent material 50 maintains its rod shape. In other words, the threads of woven material 52 hold the absorbent material 54 in place and prevent the ends of the absorbent material 54 from splaying outwards and losing their shape. The threads of material 52 may be metal wire, such as aluminum, or steel wire, such as stainless steel, or may be of a material similar to the absorbent material 54, such as cotton yarn, wool yarn, yarn from natural fibers, or synthetic yarn, such as nylon. The yarn may be impregnated with a fragrance such that the threads of material 52 act as a fragrance carrier.

[0100] Although the strands 52 of the braided material are shown in FIG. 12 as having a uniform or symmetrical pattern around the outside of the absorbent material 54, this is not required, and FIGS. 13a-13d diagrammatically illustrate alternative braided absorbent materials to the rod of braided material 50.

[0101] FIG. 13a illustrates a braided absorbent material 50 where the pattern of the braided material strands 52 is different in the elongate or x-axis direction at the middle 50c of the rod compared to the ends 50a, 50b of the rod. In other words, the spacing between the strands of material 52 varies from the ends 50a, 50b of the rod to the middle 50c of the rod, resulting in a different density of the strands of material 52 covering the absorbent material 54 between the ends 50a, 50b of the rod and the middle 50c of the rod of the braided absorbent material 50. In the example illustrated in FIG. 13a, the spacing between the strands of material 52 is wider at the middle 50c of the rod compared to the ends 50a, 50b of the rod, and therefore the density of the strands of material 52 covering the absorbent material 54 is lower at the middle 50c of the rod compared to the ends 50a, 50b of the rod. Because absorbent material 54 has a tendency to spread apart at the ends of the rod, decreasing the spacing between the strands of material 52 (and thus increasing the density of the strands of material 52) at the ends 50a, 50b of the rod reduces the amount of spreading of absorbent material 54 that occurs because the absorbent material 54 is held together more tightly by the braided strands of material 52. Alternatively, the spacing between the strands of material 52 may be decreased at the middle portion 50c of the rod as compared to the ends 50a, 50b of the rod.

[0102] 13d shows an alternative example of a braided absorbent material 50 where the pattern of the braided material strands 52 is different at the middle 50c of the rod compared to the ends 50a, 50b of the rod. In this example, the braided material strands 52 at the middle 50c of the rod form a checkerboard or crisscross pattern, while the braided material strands 52 at the ends 50a, 50b of the rod are wrapped around the periphery or outside of the absorbent material 54 with little or no interweaving of the strands. As explained above, this also allows the material strands 52 to be wrapped tighter around the absorbent material 54 at the ends 50a, 50b of the rod, preventing spreading or separation of the absorbent material 54.

[0103] In some instances, the strands of material 52 are tied together at locations around the outside of the absorbent material 54 to secure the strands of material 52 in place and further support the absorbent material 54. For example, the strands of material 52 can be tied at the ends of the rods of braided absorbent material 50 to prevent the absorbent material 54 from spreading outward and to prevent the strands of material 52 from unraveling or otherwise moving away from desired locations.

[0104] Alternatively or additionally, the threads of material 52 can be fixed in place by heating the rod of braided absorbent material 50 such that the threads of material 52 melt and fuse or otherwise bond to one another. For example, one or more of the threads of material 52 can be a material that has a sufficiently low melting point that heat can be applied to the rod of braided absorbent material 50 to melt the material without melting or otherwise damaging other components of the rod of braided absorbent material 50.

[0105] Figures 13b and 13c show a braided absorbent material 50 where the strands of material include a first material and a second material, where the first material is different from the second material. The first material 52a is indicated in Figures 13b and 13c by a thicker line around the outside of the absorbent material 54, and the second material 52b is indicated in Figures 13b and 13c by a thinner line around the outside of the absorbent material 54. This is merely for ease of illustration, and it will be understood that the respective diameters or widths of the first and second materials may be substantially the same, or the diameter or width of the second material may be greater than the diameter or width of the first material.

[0106] First material 52a may be a metal wire, such as aluminum, or a steel wire, such as stainless steel. When braided absorbent material 50 forms part of an article 1 for use with a non-combustible aerosol delivery device, the conductive properties of the metal wire allow it to be used as a susceptor material, as described above.

[0107] The second material 52b may also be a metal wire, but of a different type compared to the first material 52a. For example, the first material may be a stainless steel wire, while the second material 52b may be a magnetic metal wire. Alternatively, the second material 52b may be a material similar to the absorbent material 54, such as cotton thread, nylon thread, or wool thread. As explained above, the thread may be impregnated with a fragrance, such that the first material acts as a susceptor, while the second material acts as a fragrance carrier.

[0108] As shown in Figures 13b and 13c, a first material 52a may be woven around the outside of the rod of absorbent material 54 in a first pattern, and a second material 52b may be woven around the rod of absorbent material 54 in a second pattern.

[0109] In Fig. 13b, the first and second patterns are different. The first pattern is spiral or coiled while the second pattern forms a checkerboard or crisscross pattern. Making the first pattern different from the second pattern allows the distribution of the first material 52a and the second material 52b around the outside of the rod of absorbent material 54 to be optimized based on the respective functions of the first and second materials. For example, if the first material 52a is stainless steel wire and the second material 52b is cotton thread, the first material 52a can function as a susceptor material and the pattern of the first material 52a can be chosen to provide a consistent heating distribution along the rod of absorbent material 54. The second material 52b (cotton thread) can act as structural reinforcement for the rod of absorbent material 54, and thus the pattern of the second material 52b can be selected to provide more support at the ends of the rod compared to the middle of the rod to prevent the absorbent material 54 from spreading at the ends of the rod, as described above with reference to Figures 13a and 13b.

[0110] FIG. 13c shows an alternative example of the pattern of the first material 52a and the second material 52b. In this example, both the first pattern and the second pattern are checkered or crisscrossed with the first material 52a and the second material 52b, but the spacing between the strands of the first material 52a and the second material 52b is different. In other words, both the first pattern and the second pattern are knitted with the first material 52a and the second material 52b, respectively, but the overall density and spacing between the strands of the first material 52a and the strands of the second material 52b is different. As shown in FIG. 13c, between each strand of the first material 52a, there are three strands of the second material 52b, so that the density of the second material 52b around the outside of the absorbent material 54 is greater than the density of the first material 52a around the outside of the absorbent material 54. In other words, the spacing between each strand of the first material is greater than the spacing between each strand of the second material 52b around the outside of the absorbent material. Alternatively, the first and second patterns may differ such that the density of the second material 52b around the outside of the absorbent material 54 is less than the density of the first material 52a around the outside of the absorbent material 54, such that the spacing between each strand of the second material 52b around the outside of the absorbent material 54 is greater than the spacing between each strand of the first material 52a.

[0111] FIG. 14 illustrates diagrammatically a rod of absorbent material 54 formed by wrapping absorbent material 54 around a continuous core 56 of material in accordance with the principles of the present disclosure. The continuous core 56 of material can be formed from metal wire to function as a susceptor material as described above. This may be in addition to or in lieu of the susceptor strands 52 of material braided around the outside of the rod of absorbent material 54. The continuous core 56 of material can be formed from metal wire or a plastic material to function as a structural support for the absorbent material 54 so that the rod of absorbent material 54 maintains its shape. In some applications, the continuous core 56 of material can be a hollow tube, for example made from a plastic or metal material, to provide an additional air path through the rod of absorbent material 54 when the braided rod of absorbent material 50 forms part of an article 1 for use with a non-combustible aerosol delivery device. It will be appreciated that the continuous core of material 56 can serve multiple functions, for example, it can provide a hollow metal tube that acts as a susceptor material and also provides an additional air path.

[0112] Figure 15 illustrates generally a rod of braided absorbent material 50 comprising the rod of absorbent material 54 shown in Figure 14, in accordance with the principles of the present disclosure. As shown in Figure 15, strands of material 52 are braided around the outside of a rod of absorbent material 54 that includes a continuous core of material 56, as described above with reference to Figures 12 and 13.

[0113] FIG. 16 shows a schematic of a rod of woven absorbent material 50 according to the principles of the present disclosure, where one or more additional materials 58a, 58b are disposed on the outside of the rod of absorbent material 54 before the strands of material 52 are woven around the outside of the rod of absorbent material 54. In other words, the additional material 58 is between the rod of absorbent material 54 and the strands of woven material 52. The additional material 58 may include, for example, a metal wire to act as a susceptor and / or a metal or plastic material to provide structural reinforcement to the rod of absorbent material 54. The additional material 58 may include one or more threads, such as cotton or wool yarns, that are impregnated with a finishing agent so that the additional material 58 acts as a fragrance carrier. The additional material 58 may include a hollow plastic or metal tube, where the hollow portion of the tube provides an air path through the rod of woven absorbent material 50 when the rod of woven absorbent material 50 forms part of the consumable 10 for the non-combustible aerosol delivery system 20. When there is more than one additional material 58a, 58b, each material may be the same or different, for example, the first additional material 58a may be a metal wire while the second additional material 58b may be a flavoring-infused thread.

[0114] In FIG. 16, the additional material 58a, 58b is shown as extending in the x-direction along the entire length of the rod of woven absorbent material 50, but this is not required. In other examples, the additional material 58 may be disposed at the middle 50c of the rod of woven absorbent material 50 in the elongate or x-direction, such that the additional material does not extend all the way to the ends 50a, 50b of the rod. Alternatively, the additional material 58 may be disposed at one or more ends 50a, 50b of the rod and not present at the middle 50c of the rod. Similarly, the additional material 58 may not be axially aligned with the rod of woven absorbent material 50. In other words, the additional material 58 may not extend straight along the elongate or x-axis of the rod of woven absorbent material 50. For example, the additional material 58 may be spirally wound around the rod of absorbent material 54, or may be partially or completely wound around or perpendicular to the elongate or x-axis of the rod, around or around the rod of absorbent material 54. If the additional material 58 is spirally wound around the rod of absorbent material 54, the spirals or coils of the additional material 58 may follow a path around the outside of the rod of absorbent material 54 similar to one or more of the strands of material 52 that are braided around the outside of the rod of absorbent material 54.

[0115] Figure 17 illustrates diagrammatically a rod of braided absorbent material 50 including both a continuous core of material 56 as described above in relation to Figure 15 and one or more additional materials 58a, 58b disposed on the exterior of the rod of absorbent material 54 as described above in relation to Figure 16. Thus, the features described above in relation to these figures may be used in combination. It will also be appreciated that any of the features of the braided strands of material 52 and absorbent material 54, particularly those described above with reference to Figures 12 and 13, may be used in combination with the examples shown in Figures 14-17.

[0116] Although two additional materials 58a, 58b are shown in Figures 16 and 17, it will be understood that any number of additional materials, such as one, five, or ten, may be disposed around the exterior of the rod of absorbent material 54. Additionally, although the additional materials 58a, 58b are shown in Figures 16 and 17 as being evenly distributed around or around the rod of absorbent material 54, this is not required. For example, if there are two additional materials 58a, 58b, they may be disposed adjacent to one another around or around the rod of absorbent material 54, rather than diametrically opposed to one another.

[0117] Any of the rods of woven absorbent material 50 described above with reference to Figures 12-17 may form part of the article 1 as described above with reference to Figures 1-6, where the frame of reference in each figure is the same.

[0118] In this example, the article 1 has a circumference of about 21 mm (i.e., the article is in a demi-slim format). It is preferred that the article 1 has a second section 4 with a circumference greater than 19 mm. This has been found to provide a sufficient circumference to generate improved and sustained aerosol over a typical aerosol generating session preferred by consumers. When the article is heated, heat is conducted through the aerosol generating material 5 of the second section 4 to volatilize components of the aerosol generating material 5, and a circumference greater than 19 mm has been found to be particularly effective in generating aerosol in this manner. As the article is heated to release the aerosol, using an article with a circumference less than about 23 mm can improve heating efficiency. To achieve improved aerosol upon heating while maintaining a suitable product length, a circumference greater than 19 mm and less than 23 mm is preferred. In some examples, the circumference can be between 20 mm and 22 mm, which has been found to provide a good balance between providing effective aerosol delivery and allowing efficient heating.

[0119] The circumference of the filter section 6 is substantially the same as the circumference of the first section 2 and the second section 4, resulting in a smooth transition between these components. In this example, the circumference of the filter section 6 is about 20.8 mm.

[0120] The packaging material 7 may have a basis weight that is heavier than the basis weights of the other packaging materials 10, 11, 12 used with the article 1, for example a basis weight of 40 gsm to 80 gsm, more preferably 50 gsm to 70 gsm, in this example 58 gsm. Basis weights in these ranges have been found to result in a packaging material that has acceptable tensile strength whilst being flexible enough to wrap around the article 1 and adhere to itself along the overlapping longitudinal edges of the paper 7.

[0121] In some examples, packaging material 7 includes a citrate salt, such as sodium citrate or potassium citrate. In such examples, packaging material 7 may have a citrate content of 2% by weight or less, or 1% by weight or less. It is believed that reducing the citrate content of packaging material 7 helps reduce charring that may occur during use.

[0122] In some embodiments, the wrapping materials 10, 11, 12 of the first section 2, the second section 4, and the filter section 6, respectively, have a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. The wrapping materials 10, 11, 12 preferably have a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The wrapping materials 10, 11, 12 are preferably non-porous plug wraps, for example having a permeability of less than 100 Coresta units, for example less than 50 Coresta units. However, in other embodiments, the wrapping materials 10, 11, 12 can be porous plug wraps, for example having a permeability of more than 200 Coresta units. The length of the filter section 6 is preferably less than about 20 mm. In this example, the length of the filter section 6 is 16 mm.

[0123] In this example, the filter section 6 includes a body formed from filament tow. In this example, the tow used in the body has a single denier of 8.4 denier per filament (dpf) and a total denier of 21,000. Alternatively, the tow can have, for example, a single denier of 9.5 denier per filament (dpf) and a total denier of 12,000. In this example, the tow includes plasticized cellulose acetate tow. The plasticizer used in the tow constitutes about 7% by weight of the tow. In this example, the plasticizer is triacetin. In other examples, different materials can be used to form the body. For example, the body of the filter section 6 can be formed from paper rather than tow, for example, in a manner similar to paper filters known for use in cigarettes. Alternatively, the body can be formed from tow other than cellulose acetate, for example polylactic acid (PLA), other materials described herein for filament tow, or similar materials. The tow is preferably formed from cellulose acetate. The tow, whether formed from cellulose acetate or other materials, preferably has a fineness of at least 5 dpf, more preferably at least 6 dpf, and even more preferably at least 7 dpf. These fineness values ​​result in tows having relatively coarse, thick fibers with a smaller surface area resulting in a lower pressure drop across the filter section 6 than tows having lower dpf values. To achieve a sufficiently uniform body, the fineness of the tow is preferably 12 dpf or less, preferably 11 dpf or less, and even more preferably 10 dpf or less.

[0124] The total fineness of the tows forming the body of the filter section 6 is preferably at most 30,000 denier, more preferably at most 28,000 denier, and even more preferably at most 25,000 denier. Tows of these total fineness values ​​occupy a small percentage of the cross-sectional area of ​​the filter section 6, resulting in a lower pressure drop across the filter section 6 than tows having higher total fineness values. To provide the filter section 6 with an adequate hardness, the total fineness of the tows is preferably at least 8,000 denier, more preferably at least 10,000 denier. It is preferred that the total fineness is 10,000 to 25,000 denier, while the single fineness is 5 to 12 denier. It is more preferred that the total fineness is 11,000 to 22,000 denier, while the single fineness is 6 to 10 denier. It is preferred that the cross-sectional shape of the filaments in the tow be "Y" shaped, although in other embodiments other shapes such as "X" shaped filaments can be used, having the same dpf and total fineness values ​​as provided herein.

[0125] The cross-section of the filaments of the tow may have an isoperimeter ratio L2 / A of 25 or less, 20 or less, or 15 or less, where L is the circumference of the cross-section and A is the area of ​​the cross-section. The filaments of such a tow have a relatively small surface area for a given value of monofilament denier per filament, which improves aerosol delivery to the consumer. In some examples, the body may include an adsorbent material (e.g., charcoal) dispersed within the tow.

[0126] In some examples, the body of the filter section 6 may comprise a capsule. The capsule may comprise a breakable capsule, for example a capsule having a solid friable shell surrounding a liquid payload. In some examples, a single capsule is used. The capsule is entirely embedded within the body of the filter section 6. In other words, the capsule is completely surrounded by the material forming the body of material. In other examples, multiple breakable capsules, for example two, three or more breakable capsules, may be disposed within the body of the filter section 6. The length of the body of the filter section 6 may be extended to accommodate the number of capsules required. In examples where multiple capsules are used, the individual capsules may be the same as one another or may differ from one another in terms of size and / or capsule payload. In other examples, multiple bodies of material may be provided, each body of material containing one or more capsules.

[0127] The capsule has a core-shell structure. In other words, the capsule comprises a shell that encapsulates a liquid agent, such as a flavoring or other agent, which may be any one of the flavorings or aerosol modifiers described herein. The shell of the capsule can be burst by the user to release the flavoring or other agent into the body of the filter section 6. The packaging material 12 of the filter section 6 may comprise a barrier coating to render the material 12 of the filter section 6 substantially impermeable to the liquid payload of the capsule. Alternatively or additionally, the packaging material 7 may comprise a barrier coating to render the packaging material 7 substantially impermeable to the liquid payload of the capsule.

[0128] In some examples, the capsule is spherical and has a diameter of about 3 mm. In other examples, capsules of other shapes and sizes can be used. The total weight of the capsule can be in the range of about 10 mg to about 50 mg.

[0129] For a given tow specification (such as 8.4Y21000), it is known to generate a tow performance curve that represents the pressure drop through the length of a rod formed using the tow for each of a range of tow weights. Parameters such as the length and circumference of the rod, wrapper thickness, and plasticizer level of the tow are specified and these are combined with the tow specification to generate a tow performance curve. The tow performance curve shows the pressure drop provided by different tow weights between a minimum and a maximum weight achievable using standard filter rod forming machinery. Such tow performance curves can be calculated, for example, using software available from tow suppliers. It has been found to be particularly advantageous to use a body for filter section 6 that includes a filament tow having a weight per mm of body length that is about 10% to about 30% of the range between the minimum and maximum weights of the tow performance curve generated for the filament tow. This can provide an acceptable balance between providing a tow weight sufficient to avoid shrinkage after the body is formed, providing an acceptable pressure drop, while also aiding capsule placement within the tow for capsules of the size described herein.

[0130] In some embodiments, the filter section 6 may further comprise a hollow tubular element 35, as shown in Figure 2. Advantageously, the hollow tubular element 4 may have a length of more than about 10 mm, for example, from about 10 mm to about 30 mm, or from about 12 mm to about 25 mm. It has been found that when drawing aerosol through the article 1, the consumer's lips may in some cases extend up to about 12 mm from the mouth end 8 of the article 1, and therefore a hollow tubular element 4 having a length of at least 10 mm, or at least 12 mm, means that most of the consumer's lips will surround this element 4.

[0131] 7 shows an example of a non-combustion aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium / material, such as the aerosol-generating material 3.5 of the article 1 described herein. Generally, the device 100 can be used to heat a replaceable article 1 comprising an aerosol-generating medium, such as the article 1 described herein, to generate an aerosol or other inhalable medium that is inhaled by a user of the device 100. The device 100 and the replaceable article 1 together form a system.

[0132] The device 100 comprises a housing 102 (in the form of an outer cover) that surrounds and contains the various components of the device 100. The device 100 has an opening 104 at one end through which the item 1 can be inserted for heating by the heating assembly. In use, the item 1 can be fully or partially inserted into the heating assembly and heated by one or more components of the heater assembly.

[0133] The device 100 in this example includes a first end member 106 with a lid 108 movable relative to the first end member 106 to close the opening 104 when the item 1 is not in place. In Figure 7, the lid 108 is shown in an open configuration, but the lid 108 can be moved to a closed configuration. For example, a user can slide the lid 108 in the direction of arrow "B."

[0134] Device 100 may also include user-operable controls 112, such as buttons or switches that, when pressed, operate device 100. For example, a user may turn device 100 on by operating switch 112.

[0135] The device 100 may also include an electrical component, such as a socket / port 114 that can accept a cable to charge a battery of the device 100. For example, the socket 114 may be a charging port, such as a USB charging port.

[0136] FIG. 8 shows the device 100 of FIG. 7 with the outer cover 102 removed and without the article 1 present. The device 100 defines a longitudinal axis 134. As shown in FIG. 8, the first end member 106 is disposed at one end of the device 100 and the second end member 116 is disposed at an opposite end of the device 100. The first end member 106 and the second end member 116 together at least partially define an end surface of the device 100. For example, the bottom surface of the second end member 116 at least partially defines the bottom surface of the device 100. An edge of the outer cover 102 may also define a portion of the end surface. In this example, the lid 108 also defines a portion of the top surface of the device 100.

[0137] The end of the device closest to the opening 104 is sometimes known as the proximal end (or oral end) of the device 100, as it is closest to the user's mouth during use. In use, the user inserts the item 1 into the opening 104 and operates the user control 112 to initiate heating of the aerosol-generating material and draw in the aerosol generated within the device. This causes the aerosol to flow along the flow path through the device 100 towards the proximal end of the device 100.

[0138] The other end of the device furthest from opening 104 is sometimes known as the distal end of device 100, as it is the end furthest from a user's mouth when in use. When a user draws in aerosol generated within the device, the aerosol flows away from the distal end of device 100.

[0139] The device 100 further comprises a power source 118. The power source 118 may be, for example, a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (such as lithium ion batteries), nickel batteries (such as nickel cadmium batteries), and alkaline batteries. The battery is electrically coupled to the heating assembly to provide power to heat the aerosol-generating material when needed under the control of a controller (not shown). In this example, the battery is connected to a central support 120 that holds the battery 118 in place.

[0140] The device further comprises at least one electronic module 122. The electronic module 122 may comprise, for example, a printed circuit board (PCB). The PCB 122 may support at least one controller, such as a processor, and a memory. The PCB 122 may also comprise one or more electrical tracks for electrically connecting various electronic components of the device 100 together. For example, battery terminals may be electrically connected to the PCB 122 so that power can be distributed throughout the device 100. The socket 114 may also be electrically coupled to the battery via electrical tracks.

[0141] In the exemplary device 100, the heating assembly is an induction heating assembly, comprising various components for heating the aerosol-generating material of the article 1 by an induction heating process. Induction heating is a process of heating an electrical conductor (such as a susceptor) by electromagnetic induction. The induction heating assembly may comprise an induction element, for example one or more inductor coils, and a device for passing a varying current, such as an alternating current, through the induction element. The varying current in the induction element produces a varying magnetic field. The varying magnetic field penetrates a susceptor, suitably positioned relative to the induction element, and generates eddy currents in the susceptor. The susceptor has an electrical resistance to the eddy currents, and thus the susceptor is heated by Joule heating due to the eddy currents flowing against this resistance. If the susceptor comprises a ferromagnetic material, such as iron, nickel, or cobalt, heat can also be generated by magnetic hysteresis losses in the susceptor, i.e., the orientation of the magnetic dipoles in the magnetic material varies as a result of aligning with the varying magnetic field. In induction heating, heat is generated inside the susceptor, which allows for rapid heating, as compared to, for example, heating by conduction, and furthermore, no physical contact between the induction heater and the susceptor is required, which allows for greater flexibility in design and application.

[0142] The induction heating assembly of the exemplary device 100 includes a susceptor structure 132 (referred to herein as a "susceptor"), a first inductor coil 124, and a second inductor coil 126. The first inductor coil 124 and the second inductor coil 126 are made from an electrically conductive material. In this example, the first inductor coil 124 and the second inductor coil 126 are made from a Litz wire / cable that is wound in a helical shape to provide the helical inductor coils 124, 126. The Litz wire includes multiple individual wires that are individually insulated and twisted together to form a single wire. The Litz wire is designed to reduce the skin effect losses of the conductor. In the exemplary device 100, the first inductor coil 124 and the second inductor coil 126 are made from a copper Litz wire with a rectangular cross section. In other examples, the Litz wire can have other shaped cross sections, such as circular.

[0143] The first inductor coil 124 is configured to generate a first varying magnetic field for heating a first section of the susceptor 132, and the second inductor coil 126 is configured to generate a second varying magnetic field for heating a second section of the susceptor 132. In this example, the first inductor coil 124 is adjacent to the second inductor coil 126 in a direction along a longitudinal axis 134 of the device 100 (i.e., the first inductor coil 124 and the second inductor coil 126 do not overlap). The susceptor structure 132 may comprise a single susceptor, or two or more separate susceptors. Ends 130 of the first inductor coil 124 and the second inductor coil 126 may be connected to the PCB 122.

[0144] It will be appreciated that in some examples, the first inductor coil 124 and the second inductor coil 126 may have at least one characteristic that differs from one another. For example, the first inductor coil 124 may have at least one characteristic that differs from the second inductor coil 126. More specifically, in one example, the first inductor coil 124 may have a different inductance value than the second inductor coil 126. In FIG. 8, the first inductor coil 124 and the second inductor coil 126 are of different lengths such that the first inductor coil 124 is wound on a smaller section of the susceptor 132 than the second inductor coil 126. Thus, the first inductor coil 124 may include a different number of turns than the second inductor coil 126 (assuming that the spacing between the individual turns is substantially the same). In yet another example, the first inductor coil 124 may be made of a different material than the second inductor coil 126. In some examples, the first inductor coil 124 and the second inductor coil 126 may be substantially identical.

[0145] In this example, the first inductor coil 124 and the second inductor coil 126 are wound in opposite directions. This can be useful when the inductor coils are operating at different times. For example, the first inductor coil 124 may initially be operating to heat a first section / portion of the article 1, and then the second inductor coil 126 may be operating to heat a second section / portion of the article 1. Winding the coils in opposite directions helps reduce current induced in the inactive coil when used with certain types of control circuits. In FIG. 8, the first inductor coil 124 is a right-handed spiral and the second inductor coil 126 is a left-handed spiral. However, in another embodiment, the inductor coil 124 and the inductor coil 126 may be wound in the same direction, or the first inductor coil 124 may be a left-handed spiral and the second inductor coil 126 may be a right-handed spiral.

[0146] The susceptor 132 in this example is hollow and thus defines a receptacle therein for receiving aerosol-generating material. For example, the article 1 can be inserted into the susceptor 132. In this example, the susceptor 120 is tubular with a circular cross section.

[0147] The susceptor 132 may be made from one or more materials, and preferably comprises carbon steel coated with nickel or cobalt.

[0148] In some examples, the susceptor 132 may include at least two materials that can be heated at two different frequencies to selectively aerosolize at least two materials. For example, a first section of the susceptor 132 (heated by the first inductor coil 124) may include a first material, and a second section of the susceptor 132 (heated by the second inductor coil 126) may include a different second material. In another example, the first section may include a first and a second material, and the first and second materials may be heated differently based on the operation of the first inductor coil 124. The first and second materials may be adjacent along an axis defined by the susceptor 132 or may form different layers within the susceptor 132. Similarly, the second section may include a third and a fourth material, and the third and fourth materials may be heated differently based on the operation of the second inductor coil 126. The third material and the fourth material may be adjacent along an axis defined by the susceptor 132 or may form different layers within the susceptor 132. For example, the third material may be the same as the first material and the fourth material may be the same as the second material. Alternatively, each of the materials may be different. For example, the susceptor may include carbon steel or aluminum.

[0149] 8 further includes an insulating member 128, which may be generally tubular and at least partially surround the susceptor 132. The insulating member 128 may be constructed from any insulating material, such as, for example, plastic. In this particular example, the insulating material is constructed from polyether ether ketone (PEEK). The insulating material 128 may help insulate various components of the device 100 from heat generated by the susceptor 132.

[0150] The insulating member 128 can also fully or partially support the first inductor coil 124 and the second inductor coil 126. For example, as shown in FIG. 8, the first inductor coil 124 and the second inductor coil 126 are disposed around the insulating member 128 and are in contact with a radially outward surface of the insulating member 128. In some examples, the insulating member 128 does not abut the first inductor coil 124 and the second inductor coil 126. For example, there may be a slight gap between the outer surface of the insulating member 128 and the inner surfaces of the first inductor coil 124 and the second inductor coil 126.

[0151] In a particular example, the susceptor 132 , the insulating member 128 , and the first and second inductor coils 124 , 126 are concentric about a central longitudinal axis of the susceptor 132 .

[0152] 9 is a partial cross-sectional side view of device 100, in this example without outer cover 102. The rectangular cross-sectional shapes of first inductor coil 124 and second inductor coil 126 can be seen more clearly.

[0153] The device 100 further comprises a support 136 that engages one end of the susceptor 132 to hold the susceptor 132 in place. The support 136 is connected to the second end member 116.

[0154] The device may also include an associated second printed circuit board 138 within the control element 112 .

[0155] The device 100 further includes a second lid / cap 140 and a spring 142 disposed toward the distal end of the device 100. The spring 142 allows the second lid 140 to be opened to access the susceptor 132. A user can open the second lid 140 to clean the susceptor 132 and / or the support 136.

[0156] The device 100 further includes an expansion chamber 144 that extends away from the proximal end of the susceptor 132 toward the opening 104 of the device. A retaining clip 146 is at least partially disposed within the expansion chamber 144 for abutting and retaining the article 1 when the article 1 is received within the device 100. The expansion chamber 144 is connected to the end member 106.

[0157] FIG. 10 is an exploded view of the device 100 of FIG.

[0158] FIG. 11A shows a cross-section of a portion of the device 100 of FIG. 9. FIG. 11B shows an enlarged view of an area of ​​FIG. 11A. FIGS. 11A and 11B show the article 1 received within the susceptor 132, where the article 1 is dimensioned such that the outer surface of the article 1 abuts the inner surface of the susceptor 132. This ensures that heating is most efficient. The article 1 in this example comprises an aerosol-generating material 110a. The aerosol-generating material 110a, such as the second aerosol-generating material 5 of the article 1 described above, is disposed within the susceptor 132. The article 1 may also comprise other components, such as a filter, packaging material, and / or cooling structures.

[0159] 11B shows that the outer surface of the susceptor 132 is spaced from the inner surfaces of the inductor coils 124, 126 by a distance 150 measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 150 is about 3 mm to 4 mm, about 3 mm to 3.5 mm, or about 3.25 mm.

[0160] 11B further shows that the outer surface of the insulating member 128 is spaced from the inner surface of the inductor coils 124, 126 by a distance 152 measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 152 is about 0.05 mm. In another example, the distance 152 is substantially 0 mm, such that the inductor coils 124, 126 are in abutting contact with the insulating member 128.

[0161] In one example, the susceptor 132 has a wall thickness 154 of about 0.025 mm to 1 mm, or about 0.05 mm.

[0162] In one example, the susceptor 132 has a length of about 40 mm to 60 mm, about 40 mm to 45 mm, or about 44.5 mm.

[0163] In one example, the insulating member 128 has a wall thickness 156 of between about 0.25 mm and 2 mm, between 0.25 mm and 1 mm, or about 0.5 mm.

[0164] In use, the article 1 described herein can be inserted into a non-combustible aerosol delivery device, such as the device 100 described with reference to Figures 7-11. At least a portion of the mouthpiece 1 of the article 1 protrudes from the non-combustible aerosol delivery device 100 and can be placed in the mouth of a user. An aerosol is generated by heating an aerosol-generating material 3.5 using the device 100. The aerosol generated by the aerosol-generating material 3.5 passes through the article 1 to the mouth of the user.

[0165] The various embodiments described herein are presented only to aid in the understanding and teaching of the claimed features. These embodiments are provided as merely representative examples of the embodiments, and are not exhaustive or exclusive of all embodiments. The advantages, embodiments, examples, features, structures, and / or other aspects described herein should not be considered as limiting the scope of the invention as defined by the claims, or the equivalents of the claims, and it is understood that other embodiments can be utilized and modifications can be made without departing from the scope of the claimed invention. The various embodiments of the present invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. 1. An article for use with a non-combustible aerosol delivery device having an oral end and a distal end opposite the oral end, comprising: a first section including a first aerosol-forming material, the first aerosol-forming material including tobacco; a second section containing a second aerosol-generating material, the second aerosol-generating material comprising an aerosol-forming material; the second section being relatively closer to the distal end than the first section; The article wherein the second section comprises a rod of woven absorbent material.

2. The article of claim 1 , wherein the aerosol forming material comprises at least one of glycerin, glycerol, or propylene glycol.

3. The article of claim 1 or 2, wherein the second section comprises an absorbent material impregnated with the aerosol-forming material.

4. The article of claim 3 , wherein the absorbent material is a fibrous material.

5. The fibrous material is Natural cotton, and / or Viscose fiber The article of claim 4 comprising one of:

6. The article of claim 1 , wherein the second aerosol-forming material comprises a gel.

7. The article of any one of claims 1 to 6, wherein the second aerosol-forming material comprises nicotine.

8. The article of claim 7 , wherein the rod of braided absorbent material comprises strands of braided material around the outside of the rod of absorbent material.

9. The article of claim 8 , wherein the absorbent material is saturated with the aerosol-forming material.

10. 10. The article of claim 8 or 9, wherein the absorbent material is cotton.

11. The article of any one of claims 8 to 10, wherein at least one of the strands of material is a susceptor.

12. The article of claim 11 , wherein the susceptor is a metal wire.

13. The article of any one of claims 1 to 12, further comprising a susceptor wrapped around the rod of braided absorbent material.

14. The consumable of claim 13 , wherein the susceptor is an aluminum-clad material.

15. The article of any one of claims 1 to 14, wherein the tobacco material comprises tobacco granules.

16. 16. The article of claim 15, wherein the tobacco granules comprise cut tobacco.

17. 16. The article of claim 15, wherein the tobacco granules comprise beads of tobacco.

18. The article of any one of claims 1 to 14, wherein the tobacco material comprises tobacco paper.

19. 20. The article of claim 18, wherein the tobacco paper comprises longitudinal strips of tobacco paper, each longitudinal strip oriented substantially parallel to a longitudinal axis of the article.

20. The article of any one of claims 1 to 19, wherein the first aerosol-generating material comprises an aerosol-forming material.

21. 21. The article of claim 20, wherein the aerosol forming material comprises at least one of glycerin, glycerol, or propylene glycol.

22. The article of any one of claims 1 to 21, which is a rod-shaped article.

23. 23. The article of claim 22, further comprising a filter section forming the mouth end of the article.

24. 24. The article of claim 23, wherein the filter section comprises a tubular body.

25. 25. The article of claim 23 or 24, wherein the filter section comprises a capsule.

26. The article of any one of claims 1 to 25, wherein the first section and the second section are combined by at least one packaging material.

27. The article of claim 26 , wherein the at least one packaging material comprises a susceptor.

28. 28. The article of claim 27, wherein the susceptor comprises aluminum foil.

29. The article of any one of claims 1 to 28, wherein the pressure drop across the first section is between 30% and 70% of the pressure drop across the finished article.

30. a non-combustible aerosol delivery device comprising a heater; An article according to any one of claims 1 to 29. A system comprising:

31. 1. A method of making an article for use with a non-combustible aerosol delivery device, comprising: forming a first aerosol-generating material; dividing the first aerosol-generating material into sections of first aerosol-generating material; forming a second aerosol-generating material; dividing the second aerosol-generating material into sections of second aerosol-generating material; combining the section of a first aerosol-generating material with the section of a second aerosol-generating material; The method includes:

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