Consumable for aerosol provision system

Abstract

To provide a consumable for use in a non-combustible aerosol provision system, a non-combustible aerosol provision system, a method for producing the consumable.SOLUTION: A consumable 1 includes at least one section of an amorphous solid material 3, and at least one portion comprising at least one aerosol-generating material 4. The invention also relates to a non-combustible aerosol provision system employing such a consumable, a method for producing the consumable, and use of a section of an amorphous solid material.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a consumable for use in an aerosol delivery system, a non-combustible aerosol delivery system, a method for manufacturing the consumable, and the use of a section of amorphous solid material. [Background technology]

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco to produce tobacco smoke when used. Attempts have been made to provide alternatives to such smoking articles by creating products that release compounds without combustion. Examples of such products are the so-called "heat-not-burn" products or tobacco heating devices or products, which release compounds by heating, rather than burning, smoking material. Summary of the Invention

[0003] According to a first aspect of the invention described herein, there is provided a consumable for use in a non-combustible aerosol delivery system, comprising at least one section of an amorphous solid material and at least one portion including at least one aerosol-generating material.

[0004] In some embodiments, the consumable has the form of a rod having a first end and a second end, the rod including a plurality of portions, one of the plurality of portions including a section of amorphous solid material and at least one portion including at least one aerosol generating material.

[0005] In some embodiments, the section of amorphous solid material comprises a collected sheet of amorphous solid material.

[0006] In some embodiments, the section of amorphous solid material comprises an elongated strip of amorphous solid material. Optionally, the elongated strip is substantially aligned with a longitudinal axis of the consumable.

[0007] In some embodiments, the amorphous solid material has a thickness of about 0.5 mm to about 2 mm, or about 1 mm to about 2 mm.

[0008] In some embodiments, the amorphous solid material is provided on a support material. Optionally, the support material is paper or foil.

[0009] In some embodiments, the support material comprises a susceptor.

[0010] In some embodiments, the amorphous solid material is compressed.

[0011] In some embodiments, the section of amorphous solid material comprises beads of amorphous solid material. Optionally, the beads are disposed in a hollow tube to form the section of amorphous solid material.

[0012] In some embodiments, the amorphous solid material comprises a gelling agent. Optionally, the gelling agent is one or more selected from the group consisting of carboxymethylcellulose, alginate, pectin, gelatin, polysaccharides, guar gum, and carrageenan.

[0013] In some embodiments, the amorphous solid material comprises an aerosol-forming material. Optionally, the aerosol-forming material is one or more selected from the group consisting of erythritol, propylene glycol, glycerol, vegetable glycerin, triacetin, sorbitol, and xylitol.

[0014] In some embodiments, the amorphous solid material comprises a flavorant, and optionally the flavorant is menthol.

[0015] In some embodiments, at least one aerosol-forming material in the portion comprises a tobacco material. Optionally, the tobacco material comprises a reconstituted tobacco material, optionally a paper reconstituted tobacco material.

[0016] In some embodiments, the consumable further comprises a mouthpiece segment. Optionally, the mouthpiece segment comprises a body of fibrous material.

[0017] In some embodiments, the mouthpiece segment comprises a hollow tubular element.

[0018] In some embodiments, the consumable further comprises a hollow tubular element.

[0019] In some embodiments, the hollow tubular element is a paper tube or is formed from filament tow.

[0020] In some embodiments, the hollow tubular element is disposed between the section of amorphous solid material and the portion containing the aerosol-forming material.

[0021] In some embodiments, the section of amorphous solid material and the portion including the aerosol-forming material are immediately adjacent to one another.

[0022] In some embodiments, the section of amorphous solid material is located upstream of the portion containing the aerosol-forming material.

[0023] In some embodiments, the section of amorphous solid material is located downstream from the portion containing the aerosol-forming material.

[0024] According to a second aspect of the invention described herein, there is provided a non-combustible aerosol delivery system comprising a non-combustible aerosol delivery device and a consumable according to the first aspect.

[0025] According to a third aspect of the invention described herein there is provided a method for producing a consumable product according to the first aspect comprising collecting a sheet of amorphous solid material to form a section of amorphous solid material.

[0026] According to a fourth aspect of the invention described herein there is provided a method for manufacturing a consumable product according to the first aspect comprising cutting a sheet of amorphous solid material to form a plurality of strips of amorphous solid material from which sections of amorphous solid material are formed.

[0027] In some embodiments, the strips have a cut length of at least about 5 mm.

[0028] According to a fifth aspect of the invention described herein, there is provided use of a section of amorphous solid material in a consumable to generate an aerosol to be added to an aerosol generated by heating a portion of at least one aerosol-generating material of the consumable using a non-combustible aerosol delivery device.

[0029] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0030] [Figure 1] 1 is a side cross-sectional view of a first embodiment of a consumable for use with a non-combustible aerosol delivery device. [Diagram 2] 1 is a side cross-sectional view of a second embodiment of a consumable for use with a non-combustible aerosol delivery device. [Diagram 3] 13 is a side cross-sectional view of a third embodiment of a consumable for use with a non-combustible aerosol delivery device. FIG. [Figure 4] 13 is a side cross-sectional view of a fourth embodiment of a consumable for use with a non-combustible aerosol delivery device. FIG. [Diagram 5] FIG. 5 is a perspective view of a non-combustion aerosol delivery device for generating aerosol from the consumable aerosol-generating material of FIGS. 1-4. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0031] The present invention relates to a consumable comprising at least one section or plug of amorphous solid material and at least one further portion containing at least one aerosol-forming material, the consumable being for use in a non-combustible aerosol delivery system.

[0032] In some embodiments, the consumable comprises an aerosol-generating segment including a section or plug of amorphous solid material and at least one further portion including at least one aerosol-generating material, and a mouthpiece segment.

[0033] An aerosol-generating material is a material that can generate an aerosol when, for example, heated, irradiated, or in any other way energized. An aerosol-generating material can include one or more active substances and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0034] Amorphous solid materials are aerosol-generating materials because they can generate an aerosol when heated, irradiated, or in any other way energized. As explained below, amorphous solid materials have a high content of aerosol-forming material and can generate aerosols with desirable properties such as volume or feel and mouthfeel.

[0035] Upon use of the consumable, the aerosol generated from the amorphous solid material upon heating can be combined with an aerosol generated by heating further aerosol-forming materials of the consumable to provide an aerosol having desirable properties including sensory and mouthfeel, and actives and / or flavors from portions of the aerosol-forming materials.

[0036] The presence of sections of amorphous solid material in the consumables disclosed herein improves the aerosols generated by so-called tobacco heating products, providing an aerosol that is more similar to that generated by hybrid devices that include liquid aerosol-forming materials in addition to solid aerosol-forming materials, including, for example, tobacco.

[0037] In addition to improved mouthfeel, the consumables can have several advantages, including, for example, improved nicotine delivery. For example, by ensuring that the sections of amorphous solid material are not packed too tightly, the sections of amorphous solid material can be readily provided in a form that does not adversely affect the closing pressure drop of the consumable. This means that less tobacco is required to deliver a desired level of nicotine.

[0038] Providing a high content of aerosol-forming material in the amorphous solid material has the advantage that migration during handling and storage is prevented and a predictable amount of the aerosol-forming material in the consumable is heated upon use, resulting in a more predictable and consistent delivery and user experience. A further advantage is that there is no leakage of aerosol-forming material, and therefore no mess or unsightly staining of the consumable.

[0039] The inclusion of a section of amorphous solid material also has the advantage that this portion of the consumable can have a dedicated heating zone for heating the material to an appropriate temperature, in some embodiments, the section of amorphous solid material has a target temperature to which the amorphous solid material would ideally be heated to generate an aerosol, which is higher than the target temperature to which one or more further aerosol-generating materials are heated.

[0040] For example, in some embodiments, a section of the amorphous solid material has a high content of vegetable glycerin and is heated to about 250° C. to form an aerosol, whereas a section containing aerosol-forming material including tobacco may be heated, for example, to a temperature of up to about 350° C., but more preferably to about 180-200° C.

[0041] A consumable containing these materials in separate parts means that the heating device can heat these materials separately to different temperatures. This has the advantage that energy can be saved by selectively heating the parts to the required temperature and not exceeding it. There are also advantages of reduced odor and rapid heating. In addition, different heating profiles can be selected, which can affect the release of the perfume.

[0042] Amorphous Solid Materials An amorphous solid material may also be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid material may be a dry gel. An amorphous solid material is a solid material that can retain some fluid, such as a liquid, within it.

[0043] The amorphous solid material comprises one or more aerosol-forming materials. Optionally, the amorphous solid material can further comprise one or more active agents and / or flavorings, and / or optionally one or more other functional materials.

[0044] 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.

[0045] Suitably, the amorphous solid material can comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, or 35 wt% of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid material can comprise from 1 to 50 wt%, 5 to 45 wt%, 10 to 40 wt%, or 15 to 35 wt% of a gelling agent. In some embodiments, the gelling agent comprises a hydrocolloid.

[0046] In some embodiments, the amorphous solid material can include two or more gelling agents, for example, a first gelling agent in an amount of about 15 to about 30 wt % and a second gelling agent in an amount of about 1 to about 10 wt %.

[0047] In some embodiments, the gelling agent comprises one or more compounds selected from the group including alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, gum arabic, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some embodiments, the gelling agent comprises alginate and / or pectin, which may be mixed with a hardening agent (such as a calcium source) during the formation of the amorphous solid material. In some embodiments, the amorphous solid material may comprise calcium cross-linked alginate and / or calcium cross-linked pectin.

[0048] In some embodiments, the gelling agent comprises alginate, and the alginate is present in the amorphous solid material in an amount of 10-30 wt% of the amorphous solid material (calculated on a dry weight basis). In some embodiments, the alginate is the only gelling agent present in the amorphous solid material. In other embodiments, the gelling agent comprises alginate and at least one additional gelling agent, such as pectin. In some embodiments, the gelling agent comprises alginate, pectin, and calcium.

[0049] In some embodiments, the amorphous solid material can include a gelling agent that includes carrageenan.

[0050] Suitably, the amorphous solid material can comprise from about 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, or 40% to about 75 wt%, 70 wt%, 65 wt%, 60 wt%, 55 wt%, or 50 wt% of the aerosol-forming material (all calculated on a dry weight basis). For example, the amorphous solid material can comprise from 20 to 70 wt%, 40 to 60 wt%, or 50 to 60 wt% of the aerosol-forming material. These figures are for the amorphous solid material and do not include carrier materials, etc.

[0051] As used herein, the aerosol forming material can 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 mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0052] It should be noted that in addition to the aerosol-forming materials mentioned above, the amorphous solid material also includes water, which also contributes to the formation of the aerosol.

[0053] In some cases, the aerosol forming material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, vegetable glycerin (VG), triacetin, sorbitol, and xylitol. In some cases, the aerosol forming material comprises, consists essentially of, or consists of glycerol.

[0054] In some embodiments, the amorphous solid material includes a flavoring agent. Suitably, the amorphous solid material can include up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% flavoring agent. In some cases, the amorphous solid material can include at least about 0.01 wt%, 0.05 wt%, 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% flavoring agent (all calculated on a dry weight basis).

[0055] For example, the amorphous solid material may include 0.1-10 wt% flavoring that is not menthol. The amorphous solid material may include 1-80 wt%, 10-80 wt%, 20-70 wt%, 30-60 wt%, 35-55 wt%, or 30-45 wt% menthol. In some cases, the flavoring comprises, consists essentially of, or consists of menthol.

[0056] Flavours provided in the amorphous solid material may be more stably retained within the amorphous solid material than flavours added directly to the tobacco material, resulting in a more consistent flavour profile among the consumables disclosed herein.

[0057] In some cases, the amorphous solid material may further include an emulsifier that emulsifies the molten flavor during manufacture. For example, the amorphous solid material may include about 5 wt% to about 15 wt%, preferably about 10 wt%, of an emulsifier (calculated on a dry weight basis). The emulsifier may include gum arabic.

[0058] In some embodiments, the amorphous solid material is a hydrogel and contains less than about 20 wt% water, calculated on a wet weight basis. In some cases, the hydrogel can contain less than about 15 wt%, 12 wt%, or 10 wt% water, calculated on a wet weight basis. In some cases, the hydrogel can contain at least about 1 wt%, 2 wt%, or at least about 5 wt% water (wet weight basis) (WWB).

[0059] In some embodiments, where local regulations permit, the amorphous solid material further comprises an active substance. For example, in some cases, the amorphous solid material further comprises tobacco material and / or nicotine. In some cases, the amorphous solid material can comprise 5-60 wt% tobacco material and / or nicotine (calculated on a dry weight basis). In some cases, the amorphous solid material can comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of an active substance. In some cases, the amorphous solid material can include from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% tobacco material (calculated on a dry weight basis). For example, the amorphous solid material can include from 10 to 50 wt%, 15 to 40 wt%, or 20 to 35 wt% tobacco material. In some cases, the amorphous solid material can include from about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% nicotine (calculated on a dry weight basis). For example, the amorphous solid material can include 1-20 wt%, 2-18 wt%, or 3-12 wt% nicotine.

[0060] In some cases, where local regulations permit, the amorphous solid material includes an active agent such as tobacco extract. In some cases, the amorphous solid material can include 5-60 wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the amorphous solid material can include about 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of tobacco extract. For example, the amorphous solid material can include 10-50 wt%, 15-40 wt%, or 20-35 wt% of tobacco extract. The tobacco extract can contain nicotine in a concentration such that the amorphous solid material contains from 1 wt%, 1.5 wt%, 2 wt%, or 2.5 wt% to about 6 wt%, 5 wt%, 4.5 wt%, or 4 wt% nicotine (calculated on a dry weight basis).

[0061] In some cases, no nicotine other than that obtained from the tobacco extract may be present in the amorphous solid material.

[0062] In some embodiments, the amorphous solid material does not include tobacco material, but does include nicotine. In some such cases, the amorphous solid material can include from about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% nicotine (calculated on a dry weight basis). For example, the amorphous solid can include from 1 to 20 wt%, 2 to 18 wt%, or 3 to 12 wt% nicotine.

[0063] In some cases, the total content of actives and / or fragrances may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of actives and / or fragrances may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0064] In some cases, the total content of tobacco material, nicotine, and flavorings may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of actives and / or flavorings may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0065] The amorphous solid material may be made of a gel, which may further include a solvent present at 0.1-50 wt%. However, the inventors have found that the inclusion of a solvent in which the fragrance dissolves may reduce the stability of the gel and may cause the fragrance to crystallize from the gel. Thus, in some cases, the gel does not include a solvent in which the fragrance dissolves.

[0066] In some embodiments, the amorphous solid material comprises less than 60 wt% of the filler, for example, between 1 wt% and 60 wt%, or between 5 wt% and 50 wt%, or between 5 wt% and 30 wt%, or between 10 wt% and 20 wt%.

[0067] In other embodiments, the amorphous solid material comprises less than 20 wt%, preferably less than 10 wt% or less than 5 wt% of a filler. In some cases, the amorphous solid material comprises less than 1 wt% of a filler, and in some cases, no filler.

[0068] When present, the filler may include one or more inorganic filler materials, such as suitable inorganic adsorbents, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and molecular sieves. The filler may include one or more organic filler materials, such as wood pulp, cellulose and cellulose derivatives, including microcrystalline cellulose. In certain cases, the amorphous solid material does not include calcium carbonate, such as chalk.

[0069] In certain embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material, such as wood pulp, hemp fiber, cellulose, or a cellulose derivative. Without wishing to be bound by theory, it is believed that the inclusion of a fibrous filler in an amorphous solid material can increase the tensile strength of the material.

[0070] In some embodiments, the amorphous solid material does not include tobacco fiber.

[0071] In some embodiments, the amorphous solid material is provided in the form of a sheet.

[0072] In some embodiments, such as where the amorphous solid material does not include a filler, the amorphous solid material may have a tensile strength of from 200 N / m to 400 N / m, or from 200 N / m to 300 N / m, or about 250 N / m. Such tensile strengths may be particularly suitable for embodiments in which the amorphous solid material is formed into a sheet that is subsequently chopped and incorporated into an aerosol product.

[0073] In some embodiments where the amorphous solid material is used in the form of a sheet, a filler is included to provide high tensile strength. In some embodiments, the amorphous solid material can have a tensile strength of at least about 2000 N / m and / or up to about 5000 N / m. In some embodiments, the tensile strength can be about 3000 to about 4000 N / m. Such tensile strengths can be particularly suitable for embodiments where the amorphous solid material is included in a consumable product as a rolled sheet.

[0074] In some cases, the amorphous solid material may consist essentially of, or consist of, a gelling agent, water, an aerosol forming material, a flavoring agent, and optionally an active agent.

[0075] In some cases, the amorphous solid material may consist essentially of or consist of a gelling agent, water, an aerosol forming material, flavorings, and optionally tobacco material and / or a nicotine source.

[0076] In some examples, the amorphous solid material comprises 1-30 wt.% gelling agent, 10-50 wt.% aerosol forming agent, 0-20 wt.% bulking agent, and 0-70 wt.% flavoring agent, these weights calculated on a dry weight basis.

[0077] In some further embodiments, the amorphous solid material comprises 10-20 wt% gelling agent, 10-20 wt% aerosol former, 10-20 wt% filler, and 40-70 wt% flavoring, the weights calculated on a dry weight basis. In certain embodiments, the amorphous solid material comprises 30 wt% gelling agent, 60 wt% aerosol former, and 20 wt% filler, the weights calculated on a dry weight basis.

[0078] A plug of amorphous solid material As previously mentioned, the consumable includes a section or plug of amorphous solid aerosol-generating material. In some embodiments, the section or plug of amorphous solid material is formed from a sheet of amorphous solid material. In some embodiments, the section or plug consists of or consists essentially of a sheet of amorphous solid material. In other embodiments, the amorphous solid material is in the form of beads or strands of material.

[0079] In some embodiments, the section or plug of amorphous solid material comprises, for example, about 25%, 30%, 35%, 40%, 45%, 50%, 60%, or 70% by volume of amorphous solid material to about 70%, 75%, or 80% by volume of amorphous solid material. This ensures that the pressure drop across the consumable is not affected by the section of amorphous solid material. In embodiments where the amorphous solid material is in the form of a sheet or chopped sheet, the section or plug comprises about 25% to about 70% by volume of amorphous solid material. In embodiments where the amorphous solid material is in the form of beads, the section or plug comprises at least about 50% by volume, optionally about 50% to about 80% by volume of amorphous solid material.

[0080] In some embodiments, the sheets of amorphous solid material are incorporated into the sections or plugs as collected or bundled sheets, as pressed sheets. The sheets may be in collected, rolled, or coiled form. In other embodiments, the sheets are chopped and then collected into sections or plugs, optionally surrounded by a wrapper or another sheet material that holds the material together. In some embodiments, the sections or plugs may further include an inert sheet or other inert filler in addition to the amorphous solid material to provide a desired fill volume. The inclusion of such fillers may also reduce the overall weight of the sections and consumables.

[0081] In some embodiments, the section or plug of amorphous solid material comprises, for example, about 50 wt%, 60 wt%, or 70 wt% amorphous solid material to about 90 wt%, 95 wt% amorphous solid material. In some embodiments, the section or plug consists essentially of amorphous solid material. In some embodiments, the section or plug consists of amorphous solid material.

[0082] In some embodiments, the amorphous solid material in the form of a sheet has a mass of about 30 g / m 2 ~Approx. 150g / m2 In some cases, the sheet may have an areal density of about 55 g / m 2 ~Approx. 135g / m 2 , or about 80 to about 120 g / m 2 , or about 70 to about 110 g / m 2 , or in particular from about 90 to about 110 g / m 2 or preferably about 100 g / m 2 Such areal densities may be particularly suitable where the amorphous solid material is included in the aerosol product as chopped sheets.

[0083] A section or plug of amorphous solid material may have a thickness of 30 g / m 2 ~Approx. 120g / m 2 In some cases, the sheet may have a density of 80 to 120 g / m 2 , or about 70 to 110 g / m 2 , or in particular about 90 to 110 g / m 2 or preferably about 100 g / m 2 The mass per unit area may be 0.1 to 0.5.

[0084] In some cases, the sheet of amorphous solid material may include a carrier layer, which may be substantially or completely impermeable to gases and / or aerosols, preventing aerosols or gases from passing through the carrier, thereby controlling the flow and ensuring good delivery to the user.

[0085] The carrier may be any suitable material that can be used to support the amorphous solid material. In some cases, the carrier may be formed from a material selected from metal foil, paper, carbon paper, greaseproof paper, ceramic, carbon allotropes such as graphite and graphene, plastic, cardboard, wood, or a combination thereof. In some cases, the carrier may include or be composed of tobacco material, such as a sheet of reconstituted tobacco. In some cases, the carrier may be formed from a material selected from metal foil, paper, cardboard, wood, or a combination thereof. In some cases, the carrier itself may be a laminated structure that includes layers of materials selected from the aforementioned list. In some cases, the carrier may also function as a flavor carrier. For example, the carrier may be impregnated with flavorings or tobacco extracts.

[0086] In some embodiments, the carrier or support includes a susceptor. In some embodiments, the susceptor is embedded in the carrier. In some alternative embodiments, the susceptor is on one or both sides of the carrier.

[0087] In some cases, the amorphous solid material layer in the carrier layer can have a thickness of about 0.015 mm to about 1.5 mm, preferably about 0.05 mm to about 1.5 mm or 0.05 mm to about 1 mm. Suitably, the thickness can be about 0.1 mm or 0.15 mm to about 1 mm, 0.5 mm, or 0.3 mm. The amorphous solid material may include two or more layers, and the thicknesses described herein refer to the total thickness of these layers.

[0088] In embodiments where the sheet of amorphous solid material does not include a carrier layer, the amorphous solid material can have a thickness of at least about 1 mm and / or no more than about 2 mm. The amorphous solid material may include two or more layers, and the thicknesses described herein refer to the total thickness of those layers of amorphous solid material.

[0089] The thickness of the amorphous solid material can be measured using calipers or a microscope, such as a scanning electron microscope (SEM), as known to those of skill in the art, or any other suitable technique known to those of skill in the art.

[0090] The inventors have determined that if the amorphous solid material is too thick, the heating efficiency may decrease. This may adversely affect the power consumption during use, for example, the power consumption to release the fragrance from the amorphous solid material. Conversely, if the amorphous solid material for aerosol formation is too thin, it may be difficult to manufacture and handle. Very thin materials are more difficult to cast, are more likely to break, and may interfere with aerosol formation during use. In some cases, the individual strips or slices of the amorphous solid material have a minimum thickness of about 0.015 across their area. In some cases, the individual strips or slices of the amorphous solid material have a minimum thickness of about 0.05 mm or about 0.1 mm across their area. In some cases, the individual strips or slices of the amorphous solid material have a maximum thickness of about 1.0 mm across their area. In some cases, the individual strips or slices of the amorphous solid material have a maximum thickness of about 0.5 mm or about 0.3 mm across their area.

[0091] For the avoidance of doubt, when areal density is referred to herein it refers to the average areal density calculated for a given strip, piece or sheet of amorphous solid material, which are calculated by measuring the surface area and weight of a given strip, piece or sheet of amorphous solid material.

[0092] The thicknesses defined herein are the average thickness of the material. In some cases, the thickness of the amorphous solid material may vary by less than 25%, 20%, 15%, 10%, 5%, or 1%.

[0093] In embodiments where the amorphous solid material is provided in the form of beads, the beads may be provided in a hollow tube to form a section of the amorphous solid material. The hollow tube may be made from a sheet of the amorphous solid material. Alternatively, the hollow tube may be formed from paper or filament tow.

[0094] Portion of aerosol-generating material The consumable includes at least one portion that includes at least one aerosol-forming material in addition to a section or plug of amorphous solid material.

[0095] In some embodiments, the aerosol-generating material included in the further portion of the consumable product comprises one or more actives and / or flavors. In some embodiments, the material comprises tobacco or other plant-derived material. When the aerosol-generating material comprises tobacco, heating the material releases volatile tobacco components including nicotine and flavor or aroma compounds.

[0096] In some embodiments, the portion of the consumable that includes at least one aerosol-generating material includes tobacco material. As used herein, the term "tobacco material" refers to any material that includes tobacco or a derivative or substitute thereof. The term "tobacco material" can include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material can include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco lamina, reconstituted tobacco, and / or tobacco extract.

[0097] The tobacco material may be provided in the form of cut rag tobacco. The cut rag tobacco may have a cut width of at least 15 cuts per inch (about 5.9 cuts per cm, equivalent to a cut width of about 1.7 mm). The cut rag tobacco preferably has a cut width of at least 18 cuts per inch (about 7.1 cuts per cm, equivalent to a cut width of about 1.4 mm), more preferably at least 20 cuts per inch (about 7.9 cuts per cm, equivalent to a cut width of about 1.27 mm). In one example, the cut rag tobacco has a cut width of 22 cuts per inch (about 8.7 cuts per cm, equivalent to a cut width of about 1.15 mm). The cut rag tobacco preferably has a cut width of no more than 40 cuts per inch (about 15.7 cuts per cm, equivalent to a cut width of about 0.64 mm). It has been found that a cut width of 0.5 mm to 2.0 mm, for example 0.6 mm to 1.7 mm or 0.6 mm to 1.5 mm, provides a preferred tobacco material, particularly with respect to surface area to volume ratio when heated, and overall density and pressure drop of the rod of aerosol-generating material. The cut rag tobacco can be formed from a mixture of tobacco material forms, for example a mixture of one or more of reconstituted tobacco, leaf tobacco, extruded tobacco, and band-cast tobacco. Preferably, the tobacco material comprises reconstituted tobacco or a mixture of reconstituted tobacco and leaf tobacco.

[0098] The tobacco material can have any suitable thickness. The tobacco material can have a thickness of at least about 0.145 mm, such as at least about 0.15 mm or at least about 0.16 mm. The tobacco material can have a maximum thickness of about 0.25 mm, for example, the tobacco material can have a thickness of less than about 0.22 mm or less than about 0.2 mm. In some embodiments, the tobacco material can have an average thickness of 0.175 mm to 0.195 mm. Such thicknesses can be particularly suitable when the tobacco material is a reconstituted tobacco material.

[0099] The tobacco material can include a reconstituted tobacco material, such as a paper reconstituted tobacco material, having a density of less than about 700 mg / cc. For example, the aerosol-forming material can include a reconstituted tobacco material having a density of less than about 600 mg / cc. Alternatively or in addition, the aerosol-forming material 3 can include a reconstituted tobacco material having a density of at least 350 mg / cc.

[0100] In some embodiments, the aerosol-forming material includes a filler component. The filler component is generally a non-tobacco component, i.e., a component that does not include tobacco-derived materials. The filler component may be a non-tobacco fiber, such as wood fiber or pulp or wheat fiber. The filler component may be an inorganic material, such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, etc. The filler component may be a non-tobacco cast material or a non-tobacco extrusion material. The filler component may be present in an amount of 0-20% by weight of the tobacco material, or 1-10% by weight of the composition. In some embodiments, no filler component is present.

[0101] In some embodiments, the aerosol-generating material comprises an aerosol-forming material.

[0102] In some embodiments, the aerosol-forming material included with the tobacco material may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. Glycerol may be present in an amount of 0.1 to 10% by weight of the tobacco material, such as 1 to 9% by weight of the composition. Propylene glycol, when present, may be present in an amount of 0.1 to 0.3% by weight of the composition.

[0103] The tobacco material may contain 10% to 90% by weight of tobacco leaf, with the aerosol-forming material being provided in an amount of up to about 10% by weight of the tobacco leaf. To achieve an overall level of aerosol-forming material of 10% to 20% by weight of the tobacco material, it has been found to be advantageous to add a greater weight percentage of the aerosol-forming material to another component of the tobacco material, such as a reconstituted tobacco material.

[0104] The tobacco material described herein contains nicotine. The nicotine content may be 0.5-1.75% by weight of the tobacco material, for example 0.8-1.5% by weight of the tobacco material. In the case of lamina, the nicotine content may be higher, i.e. about 2-4%. Additionally or alternatively, the tobacco material contains 10%-90% by weight of tobacco leaf, with a nicotine content higher than 1.5% by weight of the tobacco leaf. It has been found advantageous to use tobacco leaf with a nicotine content higher than 1.5% in combination with a lower nicotine base material, such as reconstituted tobacco, to provide a tobacco material with a suitable nicotine level, but with better sensory performance than reconstituted tobacco alone. Tobacco leaf, for example cut rag tobacco, may have a nicotine content of, for example, 1.5%-5% by weight of the tobacco leaf.

[0105] The tobacco material described herein may contain an aerosol modifying agent, such as any of the flavorants described herein. In one embodiment, the tobacco material contains menthol to form a mentholated article. The tobacco material may contain 3 mg to 20 mg of menthol, preferably 5 mg to 18 mg, more preferably 8 mg to 16 mg of menthol. In this example, the tobacco material comprises 16 mg of menthol. The tobacco material may contain 2% to 8% by weight of menthol, preferably 3% to 7% by weight of menthol, more preferably 4% to 5.5% by weight of menthol. In one embodiment, the tobacco material comprises 4.7% by weight of menthol. Such high levels of menthol loading may be achieved by using a high percentage of reconstituted tobacco material, for example more than 50% by weight of the tobacco material. Alternatively or in addition, using a larger amount of aerosol-generating material, such as tobacco material, may increase the level of menthol loading that may be achieved, for example about 500 mm. 3 More than, or preferably about 1000 mm 3 In one embodiment, an aerosol-forming material such as a tobacco material is used.

[0106] In an embodiment, the tobacco material comprises a tobacco component as defined herein and an aerosol-forming material as defined herein. In an embodiment, the tobacco material consists essentially of a tobacco component as defined herein and an aerosol-forming material as defined herein. In an embodiment, the tobacco material consists of a tobacco component as defined herein and an aerosol-forming material as defined herein.

[0107] The reconstituted tobacco paper may be present in the tobacco component of the tobacco material described herein in an amount of 10% to 100% by weight of the tobacco component. In an embodiment, the reconstituted tobacco paper is present in an amount of 10% to 80% by weight or 20% to 70% by weight of the tobacco component. In a further embodiment, the tobacco component consists essentially of reconstituted tobacco paper or consists of reconstituted tobacco paper. In a preferred embodiment, the leaf tobacco is present in the tobacco component of the tobacco material in an amount of at least 10% by weight of the tobacco component. For example, the leaf tobacco may be present in an amount of at least 10% by weight of the tobacco component, with the remainder of the tobacco component comprising reconstituted tobacco paper, banded cast reconstituted tobacco, or a combination of tobacco in another form, such as banded cast reconstituted tobacco and tobacco granules. The leaf tobacco may be present in an amount of up to 40% to 60% of the tobacco material, with the remainder of the tobacco component suitably comprising reconstituted tobacco paper, banded cast reconstituted tobacco, or a combination of tobacco in another form, such as banded cast reconstituted tobacco and tobacco granules.

[0108] Reconstituted tobacco paper refers to tobacco material formed by a process of extracting tobacco raw materials with a solvent to obtain a residue containing an extract of solubles and fibrous material, and then recombining the extract with the fibrous material from the residue (usually after purification of the fibrous material, optionally with the addition of a portion of non-tobacco fiber) by depositing the extract on the fibrous material (usually after concentration, optionally after further processing). The recombination process is similar to the papermaking process.

[0109] The reconstituted tobacco paper may be any type of reconstituted tobacco paper known in the art. In certain embodiments, the reconstituted tobacco paper is made from raw materials including one or more of tobacco shreds, tobacco stems, and whole tobacco. In further embodiments, the reconstituted tobacco paper is made from raw materials consisting of tobacco shreds and / or whole tobacco, and tobacco stems. However, in other embodiments, chips, fines, and rice husks may be used instead or in addition to the raw materials.

[0110] Reconstituted tobacco for use in the tobacco materials described herein may be prepared by methods known to those skilled in the art for preparing reconstituted tobacco.

[0111] The density of the tobacco material affects the rate at which heat is conducted through the material, with lower densities, for example densities below 700 mg / cc, allowing for a more sustained aerosol release as heat is conducted through the material more slowly.

[0112] In some embodiments, the aerosol-generating material comprises a mixture of at least two aerosol-generating materials. In such embodiments, the mixture can comprise a first component comprising a tobacco material and a second component comprising an amorphous solid material as described herein. Such aerosol-generating materials can provide an aerosol having a desired flavor profile upon use, for example, by incorporating additional flavorings into the aerosol-generating material by inclusion in the amorphous solid material component. As previously mentioned, tobacco materials having a density of at least 350 mg / cc to less than about 700 mg / cc have been found to be advantageous, leading to more sustained aerosol release. To provide an aerosol with a consistent flavor profile, the amorphous solid material component of the aerosol-generating material should be uniformly distributed throughout the rod. This can be achieved by casting the amorphous solid material to have an areal density similar to that of the tobacco material, and processing the amorphous solid material to ensure uniform distribution throughout the aerosol-generating material.

[0113] In some embodiments, a uniform mixture of the tobacco material components and the amorphous solid material components can be achieved when the amorphous solid material in the form of a sheet is shredded. The chopped amorphous solid material preferably has a cut width of 0.75 mm to 2 mm, for example 1 mm to 1.5 mm. The strands of amorphous solid material formed by shredding may be cut transversely, for example in a cross-cut shredding process, to define a chop length of the chopped amorphous solid material in addition to the chop width. The chopped amorphous solid material preferably has a cut length of at least 5 mm, for example at least 10 mm, or at least 20 mm. The chopped amorphous solid material may have a cut length of less than 60 mm, less than 50 mm, or less than 40 mm. In some embodiments, the chopped amorphous solid material preferably has a non-uniform cut length to achieve a uniform mixture of the chopped amorphous solid material and the cut rag tobacco. Although referred to as the cut length, the length of the pieces or strips of amorphous solid material may alternatively or additionally be determined by a dimension of the material determined during manufacture, for example the width of the sheet of material being produced.

[0114] In an exemplary embodiment, the portion of aerosol-generating material includes a first component comprising tobacco material, for example provided as cut rag tobacco, in an amount of 50% to 98%, for example 80% to 95%, and a second component comprising shredded amorphous solid material in an amount of 2% to 50%, for example 5% to 20%.

[0115] Substances delivered Consumables for use with non-combustible aerosol delivery devices include or consist of aerosol-forming materials that are intended to be consumed, in whole or in part, by a user during use.

[0116] In some embodiments, the substance to be delivered comprises an active agent. The substance to be delivered may be present in any one or more of the aerosol-forming materials included in the consumable.

[0117] An active substance as used herein 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, psychoactive substances. An active substance may be naturally derived or synthetically obtained. 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. In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0118] 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, stems, roots, seeds, flowers, fruits, pollen, husks, shells, and the like. Alternatively, the material may include active compounds naturally occurring in synthetically obtained botanical materials. The material may be in the form of a liquid, gas, solid, powder, fine powder, ground particles, granules, pellets, pieces, strips, sheets, and the like. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, 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, and lavender. , lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, bell pepper, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, kavi, 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 arvensis, 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 cordifolia), Horse mint (Mentha longifolia), Pineapple mint (Mentha suaveolens variegata), Pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata cv), and Apple mint (Mentha suaveolens).

[0119] 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.

[0120] 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 eucalyptus, star anise, cocoa, and hemp.

[0121] 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.

[0122] In some embodiments, the aerosol-generating material in the first portion of the consumable comprises an active agent, hi some embodiments, the amorphous solid material does not comprise an active agent.

[0123] In some embodiments, the substance to be delivered comprises a fragrance.

[0124] As used herein, the terms "flavor" and "flavoring agent" refer to materials that may be used, where local regulations permit, to create a desired taste, odor, or other somatosensory sensation in products intended for adult consumers.These materials may be naturally derived flavoring materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherries, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, limes, tropical fruits, and the like). , papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberries, mulberries, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, 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, any type of mint oil of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, bell pepper, mace, damian, marjoram, olive, lemon balm, lemon basil, chives, caraway, 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., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.The materials may be replicas, synthetic or natural ingredients, or mixtures thereof. The materials may be in any suitable form, for example, a liquid such as an oil, a solid such as a powder, or a gas.

[0125] 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 ingredients. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavor ingredients extracted from tobacco. In some embodiments, the flavoring comprises flavor ingredients extracted from cannabis.

[0126] In some embodiments, the flavorings may include sensory elicitors intended to achieve somatosensory sensations that are typically chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the scent or taste nerves, and may include agents that provide a heating, cooling, tingling, or anesthetic effect. A suitable heating 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.

[0127] In some embodiments, the aerosol-generating material in the first portion of the consumable comprises a flavoring. In some embodiments, the amorphous solid material comprises a flavoring. In other embodiments, the amorphous solid material does not comprise a flavoring.

[0128] In some embodiments, the consumable may further comprise, in addition to the aerosol-generating material(s), one or more of an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol-generating area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0129] An aerosol modifier is a substance that is typically located 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-emitting component that is operable to selectively emit the aerosol modifier.

[0130] 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, a liquid, or a gel. The aerosol modifier may be in the form of a powder, a string, or a granule. The aerosol modifier may not include a filter material.

[0131] In some embodiments, the aerosol modifier can be provided as an injected material in the consumable or can be provided in a thread that can also be disposed within the mouthpiece segment, such as a thread that carries a flavoring or other aerosol modifier.

[0132] In some embodiments, the aerosol modifier is provided in a breakable capsule, e.g., a capsule having a solid, frangible shell surrounding a liquid payload. A single capsule or multiple capsules may be used. In some embodiments, one or more capsules are disposed in a mouthpiece segment, e.g., embedded in a plug of fibrous material.

[0133] In other embodiments, the aerosol modifier or other sensation eliciting material is provided in a wrapper that surrounds the consumable, such as a mouthpiece wrapper. The aerosol modifier may be located on either the inward facing surface or the outward facing surface.

[0134] Consumable Design Consumables, also referred to herein as articles, may be in the form of rods. Such rods are often named according to the length of the product, such as "regular" (usually 68-75 mm, e.g., about 68 mm to about 72 mm), "short" or "mini" (68 mm or less), "king size" (usually 75-91 mm, e.g., about 79 mm to about 88 mm), "long" or "super king" (usually 91-105 mm, e.g., about 94 mm to about 101 mm), and "ultra long" (usually about 110 mm to about 121 mm).

[0135] The articles are also named 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).

[0136] Thus, a king size, super slim format article, for example, would have a length of about 83 mm and a circumference of about 17 mm. The articles described herein, as well as their aerosol-forming materials and mouthpieces, can be made in any of the above formats, without being limited thereto.

[0137] Each format may be manufactured with portions of different lengths. As previously described, there is a first portion that includes at least one aerosol-generating material and a first plug or section of amorphous solid material. The rod is comprised of cylindrical portions that can be aligned and placed in abutment to form a rod-shaped consumable.

[0138] The consumable may comprise a further portion comprising the aerosol-generating material and / or the amorphous solid material. Additionally or alternatively, the further portion of the consumable may comprise a mouthpiece segment, which may optionally include one or more cooling portions.

[0139] As used herein, the terms "upstream" and "downstream" are relative terms defined with respect to the direction in which mainstream aerosol is drawn through an article or device during use.

[0140] The mouthpiece segment may have a length of about 30mm to 50mm. Tipping paper may connect the mouthpiece segment to an adjacent portion of the consumable.

[0141] In some embodiments, the mouthpiece segment comprises a filament tow material, such as cellulose acetate fiber tow. The filament tow may 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-cotrephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers, or combinations thereof. If the material is cellulose acetate tow, the filament tow may be plasticized with a suitable plasticizer for the tow, such as triacetin, or the tow may be unplasticized.

[0142] In some embodiments, the mouthpiece segment comprises a plug or body of material, such as a filament tow material.

[0143] In some embodiments, the mouthpiece segment can include one or more hollow tubular elements. The hollow tubular element(s) can extend over a portion of the length of the mouthpiece segment or can extend over the entire length of the mouthpiece segment.

[0144] In some embodiments, the mouthpiece segment comprises a hollow tubular element at the oral end. Alternatively or additionally, the mouthpiece segment comprises a hollow tubular element at the distal end, positioned adjacent to an adjacent portion of the consumable.

[0145] In some embodiments, the hollow tubular is a paper tube, hi other embodiments, the hollow tubular element is formed from a filament tow.

[0146] It has been found that a hollow tubular portion disposed in the mouthpiece segment is advantageous in that it significantly reduces the temperature of the outer surface of the mouthpiece at the downstream end of the mouthpiece that contacts the consumer's mouth during use of the article. In addition, it has also been found that the use of a tubular element significantly reduces the temperature of the outer surface of the mouthpiece upstream of the hollow tubular element. Without wishing to be bound by theory, it is hypothesized that this is because the tubular element passes the aerosol near the center of the mouthpiece, thereby inhibiting the transfer of heat from the aerosol to the outer surface of the mouthpiece.

[0147] The "wall thickness" of a hollow tubular element corresponds to the thickness of the tube wall in the radial direction. This can be measured, for example, using a caliper. The wall thickness is advantageously greater than 0.9 mm, more preferably greater than 1.0 mm. The wall thickness is preferably substantially constant around the entire wall of the hollow tubular element 4. However, if the wall thickness is not substantially constant, the wall thickness is preferably greater than 0.9 mm, more preferably greater than 1.0 mm, at any point around the hollow tubular element 4.

[0148] In some embodiments, the length of the hollow tubular element is less than about 20 mm. Optionally, the length of the hollow tubular element is less than about 15 mm or less than about 10 mm. Additionally or alternatively, the length of the hollow tubular element is at least about 5 mm, at least about 6 mm, or between about 5 mm and about 20 mm, between about 6 mm and about 10 mm, between about 6 mm and about 8 mm, or has a length of about 6 mm, 7 mm, or about 8 mm.

[0149] In some embodiments, the density of the hollow tubular element is at least about 0.25 grams per cubic centimeter (g / cc), at least about 0.3 g / cc, and / or less than about 0.75 grams per cubic centimeter (g / cc), or less than 0.6 g / cc. In some embodiments, the density of the hollow tubular element is 0.25-0.75 g / cc, 0.3-0.6 g / cc, 0.4 g / cc-0.6 g / cc, or about 0.5 g / cc. These densities have been found to provide a good balance between the high hardness imparted by the higher density material and the lower heat transfer characteristics of the lower density material. For purposes of the present invention, the "density" of the hollow tubular element refers to the density of the filament tow forming the element with any plasticizer incorporated therein. The density can be determined by dividing the total weight of the hollow tubular element by the total volume of the hollow tubular element, which can be calculated using appropriate measurements of the hollow tubular element, for example, obtained with a caliper. If necessary, the appropriate dimensions can be measured using a microscope.

[0150] In some embodiments, the hollow tubular element has an inner diameter of more than 3 mm. Smaller inner diameters may result in the aerosol passing through the mouthpiece to the consumer's mouth at a faster rate than desired, causing the aerosol to become too warm, for example reaching temperatures of more than 40° C. or more than 45° C. In some embodiments, the hollow tubular element has an inner diameter of more than 3.1 mm, more preferably more than 3.5 mm or 3.6 mm. In one embodiment, the hollow tubular element has an inner diameter of about 3.9 mm.

[0151] In a particular embodiment, the mouthpiece comprises two hollow tubular parts: a first hollow tubular element and a second hollow tubular element, sometimes called a cooling element, upstream of the first hollow tubular element, which abuts adjacent to and upstream of a plug of material, such as a filter material.

[0152] In some embodiments, the hollow tubular element defines a void within the mouthpiece that acts as a cooling segment. The void provides a chamber through which heated volatile components generated by the aerosol-generating material flow. The hollow tubular element is hollow to provide a chamber for aerosol accumulation, but is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and use of the consumable. The hollow tubular element provides a physical displacement between the aerosol-generating material and the plug of filter material. The physical displacement provided by the hollow tubular element provides a temperature gradient over the length of the hollow tubular element.

[0153] In some embodiments, the mouthpiece is at least 450 mm 3 The mouthpiece has a cavity having an internal volume of at least this volume. It has been found that providing a cavity of at least this volume allows for improved aerosol formation. Such a cavity size provides sufficient space within the mouthpiece to allow cooling of heated volatile components that may result in an aerosol that is too warm, thus allowing the aerosol-generating material to be exposed to higher temperatures than would otherwise be possible.

[0154] In some embodiments, the hollow tubular element may be configured to provide a temperature difference of at least 40° C. between the heated volatilized components entering the first, upstream end of the hollow tubular element and the heated volatilized components exiting the second, downstream end of the hollow tubular element. Preferably, the hollow tubular element is configured to provide a temperature difference of at least 60° C., at least 80° C., or at least 100° C. This temperature difference over the length of the hollow tubular element protects the plug of temperature sensitive filter material from the high temperatures of the aerosol-generating material when heated.

[0155] In the alternative, the hollow tubular element may be replaced by an alternative cooling element, for example an element formed from a body of material through which the aerosol can pass longitudinally and which also serves to cool the aerosol.

[0156] In some embodiments, the sections of amorphous solid material are disposed adjacent to the mouthpiece segment. The sections of amorphous solid material can have a length of about 5 mm to about 20 mm. In some embodiments, the sections can have a length of about 7 to about 15 mm. Alternatively, the consumable can include two or more shorter sections of amorphous solid material.

[0157] In some embodiments, the portion including at least one aerosol-generating material is disposed at the distal end of the consumable. The portion including at least one aerosol-generating material can have a length of about 5 mm to about 20 mm. In some embodiments, the portion can have a length of about 7 to about 15 mm. Alternatively, the consumable can include two or more shorter portions of aerosol-generating material. In some embodiments, the portion of aerosol-generating material is longer than the section of amorphous solid material.

[0158] In some embodiments, the portion containing at least one aerosol-generating material may be located immediately adjacent to a section of amorphous solid material, or these portions of the consumable may be separated by a further portion containing, for example, a hollow tubular section or a plug of fibrous tow.

[0159] In some embodiments, the location of the portion including at least one aerosol-forming material and the section of amorphous solid material are swapped so that the portion including the aerosol-forming material is adjacent to the mouthpiece segment.

[0160] In some embodiments, the consumable includes a plurality of alternating portions including an aerosol-generating material and a section of amorphous solid material.

[0161] In some embodiments, the overall length of the portion of the consumable containing the aerosol-forming material and the amorphous solid material is between about 10 mm and about 50 mm, or between about 25 mm and about 40 mm.

[0162] In some embodiments, the aerosol-generating material is wrapped in a wrapper. The wrapper may be, for example, a paper or paper-backed foil wrapper. In this example, the wrapper is substantially non-breathable. In alternative embodiments, the wrapper has a breathability of less than 100 Coresta units, or less than 60 Coresta units. It has been found that such low breathability wrappers enhance aerosol formation in the aerosol-generating material. Without wishing to be bound by theory, it is hypothesized that this is due to less loss of aerosol compounds through the wrapper. The breathability of the wrapper can be measured according to ISO 2965:2009 for measuring the breathability of materials used as cigarette paper, filter plug wrap, and filter bonding paper.

[0163] In some embodiments, the wrapper comprises an aluminum foil. Aluminum foil has been found to be particularly effective in enhancing the formation of an aerosol within the aerosol-generating material. For example, the aluminum foil may have a metal layer about 6 μm thick. In some embodiments, the aluminum foil has a paper backing. However, in alternative configurations, the aluminum foil may be of other thicknesses, for example, between 4 μm and 16 μm thick. The aluminum foil need not have a paper backing, but may have a backing formed from other materials that help provide the foil with suitable tensile strength, or may have no backing material. Metal layers or foils other than aluminum may be used. The total thickness of the wrapper is preferably between 20 μm and 60 μm, more preferably between 30 μm and 50 μm, to provide a wrapper with suitable structural integrity and heat transfer properties. The tensile force that can be applied to the wrapper before it breaks may be greater than 3,000 grams of force, for example between 3,000 and 10,000 grams of force, or between 3,000 and 4,500 grams of force.

[0164] In some embodiments, the consumable is vented. For example, the consumable can have a ventilation level of about 75% of the aerosol drawn through the article. In alternative embodiments, the consumable can have a ventilation level of 50% to 80%, such as 65% to 75%, of the aerosol drawn through the article. These levels of ventilation help to slow down the flow of aerosol drawn through the mouthpiece, so that the aerosol can be sufficiently cooled before it reaches the downstream end of the mouthpiece. The ventilation may be provided directly in the mouthpiece of the article. In some embodiments, the ventilation is provided in a hollow tubular element of the mouthpiece, which has been found to be particularly advantageous in aiding the aerosol generation process.

[0165] In some embodiments, the vent is provided by first and second parallel rows of perforations, for example formed as laser perforations located 15mm to 20mm from the downstream oral end of the mouthpiece. In alternative embodiments, the vent may be provided in other locations of the mouthpiece, for example in the body of material or in the hollow tubular element at the oral end.

[0166] In some embodiments, the aerosol-generating material provided in the consumable is provided as a cylindrical rod of aerosol-generating material. The rod includes both a section of amorphous solid material and a portion of aerosol-generating material. Regardless of the form or configuration of the aerosol-generating material, the aerosol-generating material preferably has a length of about 10 mm to 100 mm. In some embodiments, the length of the aerosol-generating material is preferably about 25 mm to 50 mm, more preferably about 30 mm to 45 mm, and even more preferably about 30 mm to 40 mm.

[0167] The volume of the aerosol-generating material provided is approximately 200 mm 3 ~ approx. 4300mm 3 , about 500 mm 3 ~1500mm 3 , or about 1000 mm 3 ~ approx. 1300mm 3These volumes can vary, for example, around 1000 mm 3 ~ approx. 1300mm 3 It has been found advantageous to provide a superior aerosol with better visibility and perception performance than that achieved with a volume selected from the lower end of the range.

[0168] The amount of aerosol-generating material included in the consumable may be reduced by including a section or plug of amorphous solid material. In some embodiments, the mass of aerosol-generating material provided may be at least 100 mg, for example between about 100 mg and 400 mg, or between about 100 mg and 360 mg. Providing a greater mass of aerosol-generating material has been found to be advantageous in improving sensory performance compared to aerosols generated from smaller masses of tobacco material.

[0169] The mass of amorphous solid material provided on the consumable may be at least greater than 50 mg, for example between about 50 mg and 200 mg.

[0170] The placement of the consumable portions is selected based on the nature of the device being used to heat the consumable, as described in more detail below.

[0171] Delivery System As used herein, the term "delivery system" is intended to encompass systems that deliver at least one substance to a user, including non-combustion aerosol delivery systems that release compounds from an aerosol-forming material without combusting the aerosol-forming material, such as electronic cigarettes, tobacco heating products, and hybrid systems for generating an aerosol using a combination of aerosol-forming materials.

[0172] According to the present disclosure, a "non-combustible" aerosol delivery system is one in which the aerosol-generating materials (or components thereof) that are components of the aerosol delivery system do not burn or ignite to facilitate delivery of at least one substance to a user.

[0173] In some embodiments, the delivery system is a non-combustible aerosol delivery system, such as a powered non-combustible aerosol delivery system.

[0174] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a tobacco heating system.

[0175] In some embodiments, the non-combustion aerosol delivery system generates an aerosol using a combination of aerosol-generating materials, one or more of which may be heated, each of which may or may not contain nicotine.

[0176] Generally, 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.

[0177] A non-combustion aerosol delivery device, also referred to herein as an aerosol generator, is an apparatus configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to apply thermal energy to the aerosol-generating material to release one or more volatile substances 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 applying heat. For example, the aerosol generator may be configured to apply one or more of vibration, high pressure, or electrostatic energy to the aerosol-generating material.

[0178] In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, can include a power source and a controller. The power source can be, for example, a power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate to which energy can be applied to dissipate power in the form of heat to an aerosol-generating material or a heat transfer material proximate to the heat generating power source.

[0179] In some embodiments, the non-combustible aerosol delivery system can include an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0180] In some embodiments, the non-combustion aerosol delivery device heats different portions of the consumable separately, e.g., for different times and / or at different temperatures, and the design of the consumable accommodates heating arrangements that ensure that the different aerosol-generating materials are heated to the correct temperatures to provide an aerosol for inhalation having the desired composition.

[0181] In some embodiments, the purpose of the section of amorphous solid material is to improve the aerosol generated by heating the portion containing at least one aerosol-forming material. In some aerosol-forming materials, such as those containing tobacco material, it is not practical to include high levels of aerosol-forming material. This is because the aerosol-forming material often makes the tobacco material sticky and difficult to handle and process. Aerosol-forming materials also tend to migrate when included in high proportions in fibrous aerosol-forming materials, so the shelf life of such materials may be relatively short.

[0182] It is therefore desirable to include at least a portion of the aerosol-forming material in a separate section of the consumable, i.e., in the section of amorphous solid material that may contain a high content of aerosol-forming material. For example, the amount of aerosol-forming material may be 60 wt% in the amorphous solid material. Because this material is dry to the touch, the aerosol-forming material does not migrate and the shelf life of the product is increased.

[0183] In some embodiments, the non-combustible aerosol delivery system comprises a device with two or more heating zones. The heating zones apply different heat to different parts of the consumable. This means that the design of the consumable can be configured to best utilize the heating zones. For example, a section of the amorphous solid material can be heated to a first temperature and a section of the aerosol-generating material can be heated to a second, different temperature.

[0184] Alternatively, the heating zones may be activated at different times. For such devices, the consumable may have a section of amorphous solid material and a portion of aerosol generating material arranged to provide a combined aerosol having a desired composition of aerosols generated from such different materials. This also allows for adjustment of the aerosol mass over the session time. For example, this allows the system to deliver more nicotine at the beginning of a session, then reduce over the session, and towards the end of the session, increase the aerosol forming material, such as glycerol.

[0185] In the drawings described herein, the same reference numerals are used to denote like features, items or components.

[0186] FIG. 1 is a cross-sectional side view of a consumable or article 1 for use in an aerosol delivery system.

[0187] Article 1 comprises a mouthpiece segment 2 and a cylindrical rod including a section or plug of amorphous solid material 3 and a portion of aerosol-forming material 4. In an exemplary embodiment of the invention, aerosol-forming material 4 is different from amorphous solid material 3, although both of these materials are capable of generating an aerosol when heated.

[0188] Although described above in the form of a rod, the aerosol-forming material may be provided in other forms, such as a plug, pouch, or packet of material within the article.

[0189] In some embodiments, the aerosol-forming material 4 is a tobacco material. In the illustrated example, the tobacco material preferably comprises reconstituted tobacco paper material and / or tobacco lamina sprayed with the aerosol-forming material. In some embodiments, the tobacco material is comprised of lamina sprayed with the aerosol-forming material. Alternatively or additionally, the tobacco material may comprise any of the forms described herein. The tobacco material contains between 10% and 90% by weight of tobacco leaf, the aerosol-forming material being provided in an amount of up to about 10% by weight of the leaf tobacco, and the remainder of the tobacco material comprises reconstituted tobacco paper.

[0190] In the illustrated example, the amorphous solid material is a dry gel that includes menthol. In alternative embodiments, the amorphous solid material can have any of the compositions described herein.

[0191] In the embodiments described herein, the amorphous solid material can be incorporated into the article in the form of a sheet. The sheet of amorphous solid material can be incorporated as a flat sheet, as a collected or bound sheet, as a pressed sheet, or as a rolled sheet (i.e., in the form of a tube). In some such cases, the amorphous solid material of these embodiments can be included in the aerosol product article as a sheet, such as a sheet surrounding a rod of aerosolizable material (e.g., tobacco). For example, the sheet of amorphous solid material can be formed into a paper wrapper that surrounds an aerosolizable material such as tobacco. Alternatively, the amorphous solid material in the form of a sheet can be shredded before being incorporated into the article. In some embodiments, the shredded material comprises elongated strips of amorphous solid material. The elongated strips can be substantially aligned with the longitudinal axis of the consumable product.

[0192] The portion containing the aerosol-forming material 4 may be provided in the form of a rod containing cut rag reconstituted tobacco. The aerosol-forming material may be any of the materials described herein.

[0193] In the illustrated embodiment, the mouthpiece segment 2 includes a body of material 6, such as fibrous or filament tow.

[0194] 1, the portion containing the aerosol-forming material is slightly longer than the section of amorphous solid material, in other embodiments they may be the same length, or the section of amorphous solid material may be longer.

[0195] In the embodiment shown in Figure 1, the portion containing the aerosol-forming material is located between the mouthpiece and the section of amorphous solid material. In other embodiments, the locations of the portion containing the aerosol-forming material and the section of amorphous solid material may be interchanged.

[0196] FIG. 2 is a side cross-sectional view of an alternative embodiment of a consumable or article 1 for use in an aerosol delivery system.

[0197] In this embodiment, the article 1 comprises a mouthpiece 2 formed from a plug of filament tow 6 at the oral end of the mouthpiece and a hollow tubular element 7 at the distal end. The article 1 further comprises a section or plug of amorphous solid material 3 adjacent the hollow tubular element 7 and a portion of aerosol-forming material 4.

[0198] As shown in FIG. 3, in a further embodiment, the mouthpiece 2 of the article 1 comprises a hollow tubular element 8 at its mouth end adjacent to a plug of material such as a filament tow 6, the other end of which abuts a further hollow tubular element 7.

[0199] In the embodiment shown in FIG. 3, the mouthpiece is downstream of the portion containing aerosol-forming material 4 , which is downstream of the section of amorphous solid material 3 .

[0200] 4, in a further embodiment, the article 1 can include alternating portions of aerosol-forming material 4 and sections of amorphous solid material 3. The sections of amorphous solid material can include the same or different amorphous solid materials. For example, one section can include a high content of aerosol-forming material and another section can include a flavoring such as menthol.

[0201] In the embodiment shown in Figures 1-4, the article 1 has a circumference of about 21 mm (i.e., the article is in a demi-slim format). In other embodiments, the article may be provided in any of the formats described herein, for example, having a circumference of 15 mm to 25 mm. Since the article is heated to release the aerosol, improved heating efficiency can be achieved using articles with smaller circumferences within this range, for example circumferences less than 23 mm. It has also been found that article circumferences of more than 19 mm are particularly effective for achieving improved aerosol upon heating while maintaining an adequate product length. Articles with circumferences of 19 mm to 23 mm, more preferably 20 mm to 22 mm, have been found to provide a good balance between providing effective aerosol delivery and allowing efficient heating.

[0202] The circumference of each section of the rod is approximately the same, providing a smooth transition between each section. In the embodiment shown, the circumference of each section is approximately 20.8 mm. One or more wrappers are wrapped around the rod of consumable material and attached to hold each section in place. The wrapper is selected to have acceptable tensile strength while being flexible enough to wrap around the article 1 and attach to itself along the longitudinal lap seam of the paper. Once wrapped, the circumference of the rod is approximately 21 mm.

[0203] According to embodiments described herein, a pack may be provided that includes a plurality of consumables or articles described herein.

[0204] 5 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 of the consumables 110 described herein. Generally described, device 100 can be used to heat a replaceable article 110 containing an aerosol-generating medium, such as article 1 shown in any one of FIGS. 1-4 or described elsewhere herein, to generate an aerosol or other inhalable medium that is inhaled by a user of device 100. Device 100 and replaceable article 110 together form a system.

[0205] 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 an item 110 can be inserted for heating by a heating assembly. In use, the item 110 can be fully or partially inserted into the heating assembly and the item 110 can be heated by one or more components of the heating assembly.

[0206] The device 100 of this example includes a first end member 106 including a lid 108 that is movable relative to the first end member 106 to close the opening 104 when the item 110 is not in place. In Figure 5, 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."

[0207] Device 100 may include a user-operable control element 112, such as a button or switch that, when pressed, operates device 100. For example, a user may turn device 100 on by operating switch 112.

[0208] The device 100 may include an electrical component, such as a socket / port 114, that can accept a cable for charging a battery of the device 100. For example, the socket 114 may be a charging port, such as a USB charging port.

[0209] In the compositions described herein, when amounts are given in weight percent (wt%), for the avoidance of doubt, this refers to a dry weight basis, unless otherwise specified. Thus, any water that may be present in the tobacco material, or any component thereof, is completely ignored for the purposes of determining the wt%. The moisture content of the tobacco material described herein may vary, and may be, for example, 5-15 wt%. The moisture content of the tobacco material described herein may vary, for example, depending on the temperature, pressure, and humidity conditions in which the composition is maintained. The moisture content may be determined by Karl-Fischer analysis, as known to those skilled in the art. However, for the avoidance of doubt, even if the aerosol-forming material is a liquid phase component, such as glycerol or propylene glycol, any component other than water is included in the weight of the tobacco material. However, when the aerosol-forming material is provided in the tobacco component of the tobacco material, or in the filler component of the tobacco material (if present), instead of or in addition to being added separately to the tobacco material, the aerosol-forming material is not included in the weight of the tobacco component or filler component, but is included in the weight of the "aerosol-forming material" at wt% as defined herein. Any other materials present in the tobacco component are included in the weight of the tobacco component, even if they are of non-tobacco origin (eg, non-tobacco fiber in the case of reconstituted tobacco).

[0210] Various embodiments described herein are presented merely to aid in the understanding and teaching of the claimed features. These embodiments are presented merely as representative examples of embodiments and are not all-inclusive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limiting the scope of the invention as defined in the claims or to the equivalents of the claims, and it is understood that other embodiments may be used and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably include, consist of, or consist essentially of any suitable combination of the disclosed elements, parts, features, portions, steps, means, etc., other than those expressly set forth herein. In addition, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. 1. A consumable for use in a non-flammable aerosol delivery system, comprising: at least one section of amorphous solid material; at least one portion including at least one aerosol-forming material; Equipped with, consumables.

2. 10. The consumable of claim 1, having the form of a rod having a first end and a second end, the rod including a plurality of portions, one of the plurality of portions including a section of the amorphous solid material and at least one portion including at least one aerosol-forming material.

3. 3. The consumable of claim 1 or 2, wherein the section of amorphous solid material comprises a collected sheet of amorphous solid material.

4. 3. The consumable product of claim 1 or 2, wherein the section of amorphous solid material comprises an elongated strip of amorphous solid material.

5. The consumable of claim 4 , wherein the elongated strip is substantially aligned with a longitudinal axis of the consumable.

6. The consumable product of any one of claims 1 to 5, wherein the amorphous solid material has a thickness of about 0.5 mm to about 2 mm or about 1 mm to about 2 mm.

7. The consumable product of any one of claims 1 to 6, wherein the amorphous solid material is provided on a support material.

8. The consumable of claim 7 , wherein the support material is paper or foil.

9. The consumable of claim 7 or 8, wherein the support material comprises a susceptor.

10. The consumable product of any one of claims 1 to 9, wherein the amorphous solid material is compressed.

11. 3. The consumable of claim 1 or 2, wherein the section of amorphous solid material comprises a bead of amorphous solid material.

12. The consumable of claim 11 , wherein the beads are disposed in a hollow tube to form a section of the amorphous solid material.

13. The consumable product of any one of claims 1 to 12, wherein the amorphous solid material comprises a gelling agent.

14. 14. The consumable product of claim 13, wherein the gelling agent is one or more selected from the group consisting of carboxymethylcellulose, alginate, pectin, gelatin, polysaccharides, guar gum, and carrageenan.

15. The consumable product of any one of claims 1 to 14, wherein the amorphous solid material comprises an aerosol-forming material.

16. 16. The consumable product of claim 15, wherein the aerosol forming material is one or more selected from the group consisting of erythritol, propylene glycol, glycerol, vegetable glycerin, triacetin, sorbitol, and xylitol.

17. The consumable product of any one of claims 1 to 16, wherein the amorphous solid material comprises a flavouring, optionally the flavouring is menthol.

18. The consumable product of any one of claims 1 to 17, wherein the at least one aerosol-forming material in the portion comprises tobacco material.

19. 20. The consumable product of claim 18, wherein the tobacco material comprises reconstituted tobacco material, and optionally comprises paper reconstituted tobacco material.

20. The consumable of any one of claims 1 to 19, further comprising a mouthpiece segment.

21. 21. The consumable of claim 20, wherein the mouthpiece segment comprises a body of fibrous material.

22. 21. A consumable product according to claim 19 or 20, wherein the mouthpiece segment comprises a hollow tubular element.

23. The consumable of any one of claims 1 to 22, further comprising a hollow tubular element.

24. 24. The consumable product of claim 22 or 23, wherein the hollow tubular element is a paper tube or is formed from a filament tow.

25. 25. The consumable product of claim 23 or 24, wherein the hollow tubular element is disposed between the section of amorphous solid material and the portion containing the aerosol-forming material.

26. The consumable product of any preceding claim, wherein the section of amorphous solid material and the portion containing the aerosol-forming material are immediately adjacent to each other.

27. The consumable product of any preceding claim, wherein the section of amorphous solid material is located upstream of the portion containing the aerosol-forming material.

28. The consumable product of any preceding claim, wherein the section of amorphous solid material is located downstream from the portion containing the aerosol-forming material.

29. A non-flammable aerosol delivery device; The consumable product according to any one of claims 1 to 28. A non-flammable aerosol delivery system comprising:

30. A method for manufacturing a consumable product according to any one of claims 1 to 28, comprising collecting a sheet of amorphous solid material to form a section of amorphous solid material.

31. 29. A method for manufacturing a consumable product according to any one of claims 1 to 28, comprising cutting a sheet of amorphous solid material to form a plurality of strips of amorphous solid material from which sections of amorphous solid material are formed.

32. 32. The method of claim 31 , wherein the strips have a cut length of at least about 5 mm.

33. The use of a section of amorphous solid material in a consumable to generate an aerosol that is added to an aerosol generated by heating a portion of at least one aerosol-generating material of the consumable using a non-combustible aerosol delivery device.

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