Articles for use in non-combustible aerosol provision systems

Abstract

To provide articles for use in non-combustible aerosol provision systems.SOLUTION: An article for use with a non-combustible aerosol provision system is provided, comprising an aerosol-generating material prepared from one or more botanical materials. At least one of the botanical materials has a fill value of greater than about 6 mL / g. Further, the aerosol-generating material is prepared from a composition comprising the one or more botanical materials. The one or more botanical materials having a fill value of greater than about 6 mL / g are present in an amount of from about 1% to about 30% or from about 5% to about 25% by weight of the composition.SELECTED DRAWING: Figure 3

Description

[Technical Field]

[0001] The present invention relates to articles for use in non-combustion aerosol delivery systems and to aerosol-forming materials for use in such articles.

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco to produce tobacco smoke during use. Alternative smoking articles produce inhalable aerosols or vapors by releasing compounds from a substrate material without combustion. These articles are sometimes referred to as non-combustion smoking articles or aerosol delivery systems. Such articles generally include a portion that contains an aerosol-forming composition. Overview

[0003] According to a first aspect of the present disclosure, there is provided an article for use with a non-combustion aerosol delivery system, the article comprising an aerosol-generating material prepared from one or more botanical matter materials, at least one of the botanical matter materials having a fill value of greater than about 6 mL / g.

[0004] According to a second aspect of the present disclosure, there is provided an article for use with a non-combustion aerosol delivery system, the article comprising an aerosol-generating material including one or more botanical matter materials, at least one of the botanical matter materials having a fill value greater than about 6 mL / g.

[0005] According to a third aspect of the present disclosure, there is provided an article for use with a non-combustion aerosol delivery system, the article comprising an aerosol-generating material comprising a first plant matter material prepared by a method comprising elevating a temperature of the second plant matter material to cause release of at least a portion of a fluid from the second plant matter material to form the first plant matter material.

[0006] According to a fourth aspect of the present disclosure, there is provided a method for manufacturing an article for use with a non-combustion aerosol delivery system, the method including combining two or more plant matter materials to form an aerosol-generating material, wherein at least one of the plant matter materials has a fill value of at least about 6 mL / g; and wrapping the aerosol-generating material with wrapping paper to form a rod of the aerosol-generating material.

[0007] According to a fifth aspect of the present disclosure, there is provided a method for manufacturing an article for use with a non-combustion aerosol delivery system, the method comprising: elevating the temperature of a plant matter material to cause release of at least a portion of a fluid from the plant matter material to form an expanded plant matter material; and wrapping the aerosol-generating material including the expanded plant matter material with wrapping paper to form a rod of aerosol-generating material.

[0008] According to a sixth aspect of the present disclosure, there is provided an article for use with a non-combustion aerosol delivery system prepared according to the method of the fourth or fifth aspect.

[0009] According to a seventh aspect of the present disclosure, there is provided a non-combustion aerosol delivery system comprising an article according to the first, second or sixth aspect and a non-combustion aerosol delivery device.

[0010] According to an eighth aspect of the present disclosure, there is provided the use of a botanical matter material having a loading value of greater than about 6 mL / g in an article for use with a non-combustion aerosol delivery system.

[0011] According to a ninth aspect of the present disclosure, there is provided the use of a botanical matter material having a loading value of greater than about 6 mL / g in an article for use with a non-combustion aerosol delivery system.

[0012] According to a tenth aspect of the present disclosure, there is provided the use of a plant matter material prepared by an expansion process in an article for use with a non-combustion aerosol delivery system. [Brief explanation of the drawings]

[0013] [Figure 1] 1 is a process flow diagram for the production of reconstituted tobacco. [Figure 2] 1 is a process flow diagram for the production of extruded tobacco. [Figure 3] 1 is a method flow diagram for the manufacture of an article for use in a non-combustion aerosol delivery system. [Figure 4] 1 is a process flow diagram for the production of expanded tobacco. [Figure 5] 1 is a process flow diagram for the production of expanded stem tobacco. [Figure 6] 1 is a process flow diagram for the production of charred tobacco. [Figure 7] 4 is a cross-sectional view of an article formed by the method shown in FIG. 3. [Figure 8] FIG. 8 is a perspective view of a non-combustion aerosol delivery device for generating aerosol from the aerosol-forming material of the article of FIG. 7. [Figure 9] 9 shows the device of FIG. 8 with the outer cover removed and no item present. [Figure 10] FIG. 9 is a side view in partial cross section of the device of FIG. 8. [Figure 11] FIG. 9 is an exploded view of the device of FIG. 8, omitting the outer cover. [Figure 12A] FIG. 9 is a cross-sectional view of a portion of the device of FIG. 8. [Figure 12B] FIG. 9 is an enlarged view of a region of the device of FIG. 8. Detailed Description

[0014] According to aspects of the present disclosure, an article is provided for use with a non-combustion aerosol delivery system, which releases compounds from an aerosol-forming material without burning the aerosol-forming material. These are often known as "electronic cigarettes," "tobacco heating products," and "hybrid systems," which use a combination of aerosol-forming materials to generate the aerosol.

[0015] According to this disclosure, a "non-combustion" aerosol delivery system is one in which the component aerosol-forming materials (or components thereof) of the aerosol delivery system are not combusted or burned to facilitate delivery of at least one substance to a user.

[0016] In some embodiments, the delivery system is a non-combustion aerosol delivery system, for example, a powered non-combustion aerosol delivery system.

[0017] In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as an electronic smoking device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0018] 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.

[0019] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-forming materials, one or more of which may be heated. Each of the aerosol-forming materials may be, for example, in solid, liquid, or gel form, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-forming material and a solid aerosol-forming material. The solid aerosol-forming material may include, for example, tobacco or a non-tobacco product.

[0020] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and an article for use with the non-combustion aerosol delivery device.

[0021] 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, an electrical power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that can be energized to distribute power in the form of heat to a heat conducting material proximate to the aerosol-generating material or the heat generating power source.

[0022] In some embodiments, the present disclosure relates to articles that include aerosol-generating materials and are configured for use with non-combustion aerosol delivery devices. These articles may be referred to as consumables throughout this disclosure.

[0023] The articles disclosed herein may have a lower overall weight than conventional articles for use in non-combustion aerosol delivery systems, yet still have acceptable hardness / firmness and sensory properties. It is desirable to reduce the overall weight of articles for use in non-combustion aerosol delivery systems. Reducing the overall weight can provide numerous benefits, such as reduced transportation costs. Furthermore, reducing the weight of an article can also have a positive effect on the environment, as less energy may be required to transport the article. In addition, consumers may prefer to carry and use lighter articles.

[0024] In some embodiments, the non-combustion aerosol delivery system may include a consumable receiving area, an aerosol generator, an aerosol generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0025] The consumable comprises substances to be delivered, at least one of which is an aerosol-generating material. The consumable may also include other substances to be delivered, such as materials that are not intended to be aerosolized. Optionally, any of the materials may include one or more active ingredients, one or more flavorings, one or more aerosol-forming materials, and / or one or more other functional materials.

[0026] In some embodiments, the substance to be delivered comprises an active agent.

[0027] As used herein, an active substance may be a bioactive material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, and psychotropic drugs. The active substance may be naturally occurring or synthetically derived. The active substance may include, for example, nicotine, caffeine, taurine, thiamin, vitamins such as B6, B12, C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, hemp, or other botanical materials.

[0028] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0029] An article for use in a non-combustion aerosol delivery system includes an aerosol-forming material. The article may also include an aerosol-forming material storage area, an aerosol-forming material transfer component, an aerosol generator, an aerosol-generating area, a housing, a paper wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0030] An aerosol-generating material is a material capable of generating an aerosol when energized, for example, by heating, irradiation, or any other method. The aerosol-generating material may be, for example, in the form of a solid, liquid, or gel, and may or may not contain active substances and / or flavorings. In some embodiments, the aerosol-generating material may comprise an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can retain some fluid, e.g., a liquid, within it. In some embodiments, the aerosol-generating material may comprise, for example, about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0031] The aerosol-forming materials may include one or more aerosol-forming agents, one or more active substances and / or fragrances, and optionally one or more other functional materials.

[0032] The aerosol-forming agent may include one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming material may include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, 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. Preferably, the aerosol-forming agent is glycerol or glycerin.

[0033] The aerosol-forming material can include any suitable amount of aerosol-forming agent. In preferred embodiments, the aerosol-forming material includes the aerosol-forming agent in an amount of about 5% to about 30% by weight of the aerosol-forming material. Preferably, the aerosol-forming material includes the aerosol-forming agent in an amount of about 10% to about 20% by weight of the aerosol-forming material. More preferably, the aerosol-forming material includes the aerosol-forming agent in an amount of about 13% to about 18% by weight of the aerosol-forming material, or about 14%, about 15%, about 17%, or about 18% by weight of the aerosol-forming material. In some embodiments, the aerosol-forming material is present in an amount of about 15% by weight of the aerosol-forming material.

[0034] The inclusion of an aerosol-forming agent in an amount of about 5% to about 30% by weight of the aerosol-forming material has been found to further enhance the sensory properties of the aerosol-forming material when heated by an aerosol-generating device. Advantageously, an amount of aerosol-forming agent added of about 10% to about 30% by weight of the aerosol-generating material can make the sensory properties of the composition similar to those of a conventional combustible smoking article.

[0035] The aerosol-forming material may include a flavoring. As used herein, the terms "flavoring" and "flavoring agent" refer to materials that may be used, where local regulations permit, to create a desired taste or odor in products intended for adult consumers. These include extracts (e.g., licorice, hydrangea, magnolia leaf, chamomile, fenugreek, clove, menthol, peppermint, aniseed, cinnamon, herbs, wintergreen, cherry, berry, peach, apple, Drambuie, bourbon, Scotch, whiskey, spearmint, peppermint, lavender, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, honey essence, rose oil, vanilla, lemon oil, orange oil, cassia, caraway, cognac, jasmine). These include: ylang-ylang, sage, fennel, bell pepper, ginger, anise, coriander, coffee, or mint oil from any species of Mentha; 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. They may be imitation, synthetic, or natural ingredients, or blends thereof. They may be in any suitable form, such as an oil, liquid, or powder.

[0036] The aerosol-forming material may include flavoring in an amount of about 0.1% to about 5% by weight of the aerosol-forming material. Preferably, the aerosol-forming material includes flavoring in an amount of about 0.5% to about 1.5%.

[0037] The aerosol-forming material is prepared from one or more botanical materials. One or more botanical materials are used to create the aerosol-forming material. Thus, the aerosol-forming material may comprise or consist of one or more botanical materials used to prepare the aerosol-forming material. In some embodiments, the aerosol-forming composition consists of a composition including one or more botanical materials.

[0038] The aerosol-forming material may be prepared from a composition comprising one plant material or two or more plant materials, for example, two, three, four, five or more plant materials. The resulting aerosol composition can be prepared by blending two or more plant materials.

[0039] As used herein, the term "botanical material" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, peels, etc. Alternatively, the material may include active compounds naturally occurring in the plant material or synthetically obtained. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, shreds, strips, sheets, etc. Examples of botanical materials include tobacco, eucalyptus, star anise, hemp, cacao, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, etc. biloba), hazel, hibiscus, bay leaf, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea, e.g., green tea or black tea, bamboo, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen Lean, shiso, turmeric, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, karvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.Mint includes the following mint varieties: Mentha arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens. In a preferred embodiment, the plant matter material is tobacco.

[0040] As used herein, the term "tobacco material" refers to material derived from a plant of the Nicotiana species. The selection of the plant of the Nicotiana species is not limited, and the type or types of tobacco used may vary. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, leaf tobacco, tobacco stems, reconstituted tobacco, and / or tobacco extract. As used herein, "leaf tobacco" refers to cut laminar tobacco.

[0041] In some embodiments, the tobacco material is selected from flue-cured or Virginia, burley, sun-cured, Maryland, dark (fire-cured), dark (air-cured), light (air-cured), Indian (air-cured), Red Russian, and rustica tobaccos, and mixtures thereof, as well as various other rare or specialty tobaccos (green or cured). Tobacco materials produced through any other type of tobacco processing that can modify the tobacco taste, such as fermented tobacco or genetic engineering or hybridization techniques, are also within the scope of this disclosure. For example, it is contemplated that tobacco plants may be genetically engineered or hybridized to increase or decrease the production of a component, property, or attribute.

[0042] In some embodiments, the tobacco material is sun-cured tobacco selected from Indian Kurnool and Oriental tobaccos, including Izmir, Basma, Samsun, Katerini, Prelip, Komotini, Xanthi, and Yambol tobaccos. In some embodiments, the tobacco material is dark (air-cured) tobacco selected from Passanda, Cubano, Jatin, and Beski tobaccos. In some embodiments, the tobacco material is light (air-cured) tobacco selected from North Wisconsin and Galpao tobaccos.

[0043] In some embodiments, the tobacco material is selected from Brazilian tobacco, including Mata Fina and Bahia tobacco, hi some embodiments, the tobacco material is selected from Criollo, Pilotto Cubano, Olor, Green River, Isabela DAC, White Pata, Elul, Jatim, Madura, Kasturi, Connecticut Seed, Broadleaf, Connecticut, Pennsylvania, Italian (air-cured), Paraguayan (air-cured), and Wansucker tobacco.

[0044] For the preparation of smokeable / electronic smoking or smokeless tobacco products, plants of the Nicotiana species may be subjected to a curing method. Certain types of tobacco may be subjected to other types of curing methods, such as flue-curing or sun-drying. Preferably, but not necessarily, the cured harvested tobacco is aged.

[0045] Tobacco can be harvested at different stages of growth, for example, when the plant reaches a level of maturity and the lower leaves can be harvested while the upper leaves are still growing.

[0046] In some embodiments, at least a portion of a plant of a Nicotiana species (e.g., at least a portion of the tobacco material) is used in an immature form, that is, in some embodiments, the plant or at least a portion of the plant is harvested before it reaches a stage normally considered ripe or mature.

[0047] In some embodiments, at least a portion of a plant of a Nicotiana species (e.g., at least a portion of a tobacco material) is used in a mature form. That is, in some embodiments, the plant or at least a portion of the plant is harvested when the plant (or plant portion) has reached a point traditionally considered ripe, overripe, or mature, and harvesting can be done using tobacco harvesting techniques traditionally used by farmers. Both Oriental and Burley tobacco plants can be harvested. Additionally, Virginia tobacco leaves can be harvested or picked according to the position of their petioles.

[0048] Nicotiana species may be selected for the content of various compounds present in the plant. For example, plants may be selected based on the fact that they produce relatively large amounts of one or more compounds (i.e., volatile compounds of interest) that are desired to be isolated. In certain embodiments, Nicotiana species plants are particularly cultivated because they are rich in leaf surface compounds. Tobacco plants may be grown in greenhouses, growth chambers, or outdoor fields, or grown hydroponically.

[0049] Various parts or portions of a Nicotiana species plant may be utilized. In some embodiments, the whole plant or substantially the whole plant is harvested and used as is. As used herein, the term "substantially the whole plant" means that at least 90% of the plant is harvested, such as at least 95% of the plant, for example, at least 99% of the plant. Alternatively, in some embodiments, various parts or pieces of the plant are harvested or separated for further use after harvest. In some embodiments, the tobacco material is selected from the leaves, stems, petioles, and various combinations of these parts of the plant. Thus, the tobacco material of the present disclosure may comprise the whole Nicotiana species plant or any part of the plant.

[0050] The tobacco material can be reconstituted tobacco, extruded tobacco, band-cast reconstituted tobacco, or a combination of band-cast reconstituted tobacco and another form of tobacco such as tobacco granules.

[0051] Reconstituted tobacco paper refers to tobacco material formed by a process in which tobacco raw material is extracted with a solvent to obtain a residue containing a soluble extract and fibrous material, and then the extract (usually after concentration and optionally further processing) is recombined with the fibrous material from the residue (usually after purification of the fibrous material and optionally with the addition of a portion of non-tobacco fiber) by depositing the extract onto the fibrous material. The recombination process is similar to that for papermaking.

[0052] The reconstituted tobacco may be any type of reconstituted tobacco known in the art. In certain embodiments, the reconstituted tobacco is made from raw materials including one or more of tobacco strip, tobacco stem, and whole leaf tobacco. In further embodiments, the reconstituted tobacco is made from raw materials consisting of tobacco strip and / or whole leaf tobacco, and tobacco stem. However, in other embodiments, scrap, fines, and winnowing may be used instead of or in addition to the raw materials.

[0053] In some embodiments, the reconstituted tobacco is made from expanded tobacco. For example, the reconstituted tobacco can be made from ground expanded tobacco. Examples of expanded tobacco are provided herein.

[0054] 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.

[0055] Referring to FIG. 1 , tobacco furnish, such as leaves, strips, stems, scraps, fines, and / or rice bran (in some embodiments, leaves, strips, and stems), is first mixed with an aqueous solvent (e.g., water, or a water-miscible solvent, such as water and ethanol). Distilled water, deionized water, or tap water may be used. For example, to increase the rate of extraction of the soluble portion of the tobacco from the fibrous portion, the suspension of tobacco in the solvent is agitated by stirring or shaking. Agitation is typically carried out for 30 minutes to 6 hours. Agitation may be achieved with a vessel and an agitator equipped with blades to achieve agitation. The amount of solvent in the suspension can vary widely, from about 75 to 99% by weight of the suspension, depending on the type of tobacco furnish, solvent, and agitation equipment (particularly the type of blade), as well as the temperature of the suspension. A typical range for suspension temperature is from about 10°C to about 100°C.

[0056] The soluble portion of the tobacco feedstock is separated from the insoluble fibrous portion of the tobacco by, for example, compression with an air, hydraulic, or mechanical press, or by filtration. After separation, the tobacco fibrous portion is typically subjected to mechanical refining to produce a fibrous pulp. Suitable refiners can typically be disk refiners or conical refiners. The fibrous pulp is then formed into a base web comprising tobacco fibrous pulp in a papermaking station, such as a Fourdrinier papermaking machine. The base web is typically loaded onto a flat wire belt, where excess water is removed by gravity drainage and suction drainage. Non-tobacco fibers, such as cellulose, wheat fiber, or wood fiber, may also be included at this stage along with the tobacco-derived fibrous portion. The soluble portion of the tobacco feedstock is concentrated using any known type of concentration device, such as a film evaporator or a vacuum evaporator. After concentration, ingredients such as aerosol-forming materials (as defined herein), casings, acids such as cocoa, licorice, and malic acid, or flavorings (as defined herein) may be added and mixed with the concentrated tobacco solubles. The concentrated tobacco solubles, potentially containing aerosol-forming materials and / or casings and / or flavorings, are then recombined with the dry tobacco fibrous sheet to form reconstituted tobacco. The concentrated solubles can be added back to the fibrous web by a variety of methods, such as spraying, coating, dipping, sizing, etc.

[0057] Finally, the reconstituted tobacco is dried. Optionally, the reconstituted tobacco may be cut into strips or wound into rolls, which may then be slit into bobbins or shredded into cut lugs.

[0058] The reconstituted tobacco may include one or more aerosol-forming agents, as described herein. In some embodiments, the reconstituted tobacco may include an aerosol-forming agent in an amount of about 5% to about 40% based on the weight of the reconstituted tobacco.

[0059] The aerosol-forming material may be prepared from and / or comprise a composition comprising reconstituted tobacco in an amount of about 0% to about 90% by weight of the composition. In some embodiments, the aerosol-forming material is prepared from and / or comprises a composition comprising reconstituted tobacco in an amount of 10% to 90%, 10% to 80%, or 20% to 70% by weight of the composition. In some embodiments, the aerosol-forming material is prepared from and / or comprises a composition comprising reconstituted tobacco in an amount of about 50% to about 90% by weight of the composition.

[0060] In some embodiments, the aerosol-forming material is prepared from and / or comprises a composition comprising reconstituted tobacco in an amount of about 10% to about 89%, about 20% to about 88%, about 30% to about 87%, about 40% to about 86%, about 50% to about 85%, about 60% to about 84%, or about 70% to about 83% by weight of the composition. In some embodiments, the aerosol-forming material is prepared from and / or comprises a composition comprising reconstituted tobacco in an amount of about 75% to about 85% by weight of the composition.

[0061] In some embodiments, the aerosol-forming material is prepared from and / or comprises a composition comprising reconstituted tobacco in an amount of about 70%, about 71%, about 72%, about 73%, about 74%, about 75%, about 76%, about 77%, about 78%, about 79%, about 80%, about 81%, about 82%, about 83%, about 84%, or about 85% by weight of the composition.

[0062] In some embodiments, the aerosol-forming material is prepared from and / or comprises a composition comprising tobacco leaf and reconstituted tobacco paper, the weight ratio of tobacco leaf to reconstituted tobacco paper being 10:90, 11:89, 12:88, 13:87, 14:86, 15:85, 16:84, 17:83, 18:82, 19:81, 20:80, 21:79, 22:78, 23:77, 24:76, 25:75, 26:74, 27:73, 28: 72, 29:71, 30:70, 31:69, 32:68, 33:67, 34:66, 35:65, 36:64, 37:63, 38:62, 39:61, 40:60, 41:59, 42:58, 43:57, 44:56, 45:55, 46:54, 47:53, 48:52, 49:51, 50:50 , 51:49, 52:48, 53:47, 54:46, 55:45, 56:44, 57:43, 58:42, 59:41, 60:40, 61:39, 62:38, 63:37, 64:36, 65:35, 66:34, 67:33, 68:32, 69:31, 70:30, 71:29, 72:28, 73:39 The ratio may be 3:27, 74:26, 75:25, 76:24, 77:23, 78:22, 79:21, 80:20, 81:19, 82:18, 83:17, 84:16, 85:15, 86:14, 87:13, 88:12, 89:11 or 90:10 (weight of leaf tobacco:weight of reconstituted tobacco).

[0063] In some embodiments, the aerosol-forming material is prepared from and / or comprises a composition comprising expanded plant matter material and a mixture of reconstituted and leaf tobacco.

[0064] The composition may comprise expanded plant material in an amount of about 10% by weight of the composition, and a blend of reconstituted tobacco and leaf tobacco in an amount of about 90% by weight of the composition, wherein the weight ratio of reconstituted tobacco to leaf tobacco can be 90:10, 80:20, 70:30, 60:40, 50:50, 40:60, 30:70, 20:80, or 10:90.

[0065] The reconstituted tobacco material may have a density of less than about 700 milligrams per cubic centimeter (mg / cc).

[0066] Such tobacco materials have been found to be particularly effective in producing aerosol-generating materials that can be heated quickly to release an aerosol, compared to denser materials. The properties of various aerosol-generating materials, such as band-cast regenerated tobacco materials and paper regenerated tobacco materials, were tested when heated. It was found that for each given aerosol-generating material, during the application of heat to the material, there exists a specific zero heat flow temperature below which the net heat flow is endothermic, meaning the material gains more heat than it loses, and above which the net heat flow is exothermic, meaning the material loses more heat than it gains. Materials with densities less than 700 mg / cc had lower zero heat flow temperatures. Because the majority of the heat flow leaving the material is via aerosol formation, a lower zero heat flow temperature has a beneficial effect on the time it takes for an aerosol to initially be released from the aerosol-generating material. For example, aerosol-forming materials having densities less than 700 mg / cc were found to have zero heat flow temperatures less than 164°C, compared to materials having densities greater than 700 mg / cc that had zero heat flow temperatures greater than 164°C.

[0067] The density of the plant matter material also has an effect on the rate at which heat is conducted through the material; at lower densities, such as below 700 mg / cc, heat is conducted more slowly through the material, thus allowing for a more sustained release of the aerosol.

[0068] In some embodiments, the plant matter material is extruded tobacco. The aerosol-forming material may be prepared from or include extruded tobacco in an amount of 10-30% by weight, or 10-20% by weight, of the aerosol-forming material. The extruded tobacco that may be used in the tobacco compositions described herein may be prepared by methods known to those skilled in the art for preparing extruded tobacco. In some embodiments, the extruded tobacco may be prepared as follows: The tobacco feed may include Virginia (flue-cured) tobacco, Burley tobacco, and / or Oriental tobacco. The tobacco feed may be stem, scrap, strip, fines, or rice bran. Additional components may include non-tobacco fiber, such as straw fiber or wheat fiber; binders, such as cellulose or modified cellulose, such as hydroxypropyl cellulose and carboxymethyl cellulose; and casings, such as acids, such as malic acid.

[0069] As shown in Figure 2, the tobacco feed and any additional components are mixed in a mixing silo and transported by a dosing screw and a conveyor screw to the extruder where they are mixed with water, at which stage aerosol-forming materials may also be added. After extrusion, the extruded tobacco is cooled on a cooling belt.

[0070] Materials similar to those described in the above section, but made using only non-tobacco fibers, such as wheat fiber or wood fiber, may also be used in the filter component of the tobacco composition.

[0071] As used herein, the term "fill value" is a measure of a material's ability to occupy a specific volume at a given moisture content. A high fill value indicates that a lower weight of material is required to produce a rod of a given circumference, volume, and length at an acceptable hardness / firmness level than would be required with a lower fill value material.

[0072] Many of the above plant material materials typically have a fill value of less than about 6 mL / g. For example, leaf tobacco, reconstituted tobacco, and extruded tobacco may typically have a fill value of less than 6 mL / g. These materials may have a fill value of about 3 mL / g to about 5.9 mL / g. For example, reconstituted tobacco may typically have a fill value of about 2.5 to about 5.6 mL / g. Laminar tobacco, such as Virginia leaf, may typically have a fill value of about 4.5 mL / g to about 5.6 mL / g.

[0073] At least one of the plant matter materials has a fill value of greater than about 6 mL / g. In some embodiments, at least one of the plant matter materials has a fill value of at least about 7 mL / g, at least about 8 mL / g, or at least about 9 mL / g to about 10 mL / g. For example, the fill value of at least one of the plant matter materials can be from about 6 mL / g to about 10 mL / g, from about 6.5 mL / g to about 9 mL / g, or from about 7 mL / g to about 8 mL / g.

[0074] Any plant matter material having a fill value of at least 6 mL / g may be used in the present invention. In particular, the plant matter material may be formed from expanded plant matter material having a fill value of at least about 6 mL / g.

[0075] As shown in Figure 3, an aerosol-forming material may be prepared by combining a botanical material having a fill value of at least 6 mL / g and a botanical material having a fill value of less than 6 mL / g. Optionally, one or more flavorings or aerosol-forming agents can be added. The aerosol-forming material can then be incorporated into an article for use in a non-combustion aerosol delivery system.

[0076] The composition may be formed by blending two or more different botanical materials.

[0077] For example, a first plant material including tobacco may be mixed with a second plant material including expanded tobacco material. An aerosol-forming material may be formed from a combination of a third plant material with the first and second plant material. For example, in one embodiment, an aerosol-forming material may be formed by combining tobacco, reconstituted tobacco, and expanded tobacco material.

[0078] The aerosol-generating material may be formed entirely from plant matter material, such as expanded plant matter material, having a fill value of greater than about 6 mL / g. For example, the aerosol-generating material may be formed from 1% to 10%, or about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, or 90% by weight of the plant matter material having a fill value of greater than about 6 mL / g.

[0079] Because a lower mass expansion plant material is required to fill a given volume of an article compared to a plant material having a relatively low fill value, using a plant material having a relatively high fill value can lead to a reduction in the weight of the aerosol-generating material, and therefore the article.

[0080] However, using too much plant material (e.g., expanded tobacco) with a relatively high fill value, for example, a fill value greater than about 6 mL / g, can negatively affect the sensory properties of the aerosol-forming material when used in an article for use with a non-combustion aerosol delivery system. Furthermore, the relatively low density of this plant material, when incorporated in relatively large amounts, can reduce the hardness or firmness of the aerosol-generating section of the article, negatively affecting the pressure drop across the aerosol-generating section of the article. Because the article is intended for use with a non-combustion aerosol delivery system, the hardness of the aerosol-generating section of the article is important. If the hardness of the aerosol-generating section is too low, the article may have insufficient structural integrity. An article with insufficient structural integrity may be unsuitable for use with a non-combustion aerosol delivery system.

[0081] The inventors have found that it is possible to balance the beneficial weight savings obtained by utilizing plant matter materials having relatively high loading values with the negative effects observed when using relatively large amounts of material.

[0082] In particular, the inventors have discovered that preparing an aerosol-generating material from a composition comprising up to about 30% by weight, preferably up to about 25% by weight, and more preferably up to about 20% by weight of botanical material having a fill value greater than about 6 mL / g, while achieving a desirable weight reduction, can provide satisfactory sensory results and acceptable article firmness. The aerosol-generating material can be prepared from a composition comprising about 1% to about 30%, about 25%, about 20%, or about 15% by weight of the composition of botanical material having a fill value greater than about 6 mL / g. In some embodiments, the aerosol-generating material is prepared from a composition comprising about 2% to about 14%, about 3% to about 13%, about 4% to about 12%, or about 5% to about 11% by weight of the composition of botanical material having a fill value greater than about 6 mL / g. In some embodiments, the composition comprises or is prepared from botanical matter material having a loading value of greater than about 6 mL / g in an amount of about 10% by weight of the composition.

[0083] When incorporated into an article, the aerosol-generating section comprising the aerosol-generating material can have a hardness of about 55% to about 75%. Preferably, the hardness is as close as possible to about 70%. In some embodiments, the hardness is about 61%, 62%, 63%, 64%, 65%, 66%, 67%, 68%, 69%, or 70%.

[0084] The plant material used to form the aerosol-generating material is preferably a mixture of two or more plant materials. The plant material may include a first plant material having a fill value greater than 6 mL / g in an amount of about 1% to about 30%, or about 1% to about 25%, by weight of the plant material.

[0085] The remainder of the composition used to form the aerosol-generating material may include one or more other plant matter materials described herein. As a result, the plant matter materials may have different properties, such as different fill values. For example, an aerosol-generating material may be prepared from a composition including a first plant matter material having a fill value greater than about 6 mL / g and a second plant matter material having a lower fill value. The relatively high fill value of the first plant matter material may reduce the total mass of tobacco material required to fill the volume of the aerosol-generating section of the article. As a result, the overall weight of the article may be reduced by using a plant matter material having a relatively high fill value.

[0086] The aerosol-generating section of the article may define a continuous volume containing the aerosol-generating material. The aerosol-generating material substantially fills this volume. The aerosol-generating material may fill at least about 30%, 40%, 50%, 60%, 70%, 80%, 90%, 95%, or 98% of the volume of the aerosol-generating section. The aerosol-generating section may consist of or consist essentially of the aerosol-generating material. The article may comprise a single continuous aerosol-generating section defining a volume substantially filled with the aerosol-generating material.

[0087] The aerosol-generating section may include additional components, for example, a heater, such as a wrapper and / or a susceptor, that surrounds the aerosol-generating material.

[0088] The aerosol-generating material in the aerosol-generating section includes botanical material having a fill value greater than about 6 mL / g. The aerosol-generating material may also include other botanical material having a fill value less than 6 mL / g. Thus, the fill value of the aerosol-generating material in the aerosol-generating section may be greater than about 6 mL / g, about 6 mL / g, or less than about 6 mL / g. The aerosol-generating material may have a fill value of about 2 mL / g to about 10 mL / g, 2 mL / g to about 9 mL / g, 2 mL / g to about 8 mL / g, 2 mL / g to about 7 mL / g, 3 mL / g to about 6 mL / g, or about 4 mL / g to about 6 mL / g. For example, the aerosol-generating material may have a fill value of about 5 mL / g to about 6 mL / g. The fill value of the aerosol-generating material may be controlled by varying the relative amounts of botanical material having a fill value greater than 6 mL / g and botanical material having a fill value less than 6 mL / g.

[0089] The fill value of the aerosol-generating material of the aerosol-generating section may be determined by separating it from the other components of the article (e.g., the wrapper, susceptor, filter, etc., if present) and then measuring the fill value according to the fill value measurement method described herein.

[0090] Any plant matter material having a fill value of greater than about 6 mL / g may be used. A particular material that may be used is an expanded plant matter material.

[0091] Expanded plant material is plant material that has been subjected to an expansion process. The expansion involves an increase in the area of the plant material and the spacing between its fibers. After being subjected to the expansion process, the plant material has a higher fill value but a lower density than the plant material before the expansion process.

[0092] Typically, expansion methods involve rapidly increasing the temperature and / or pressure of a solid material containing a fluid (e.g., water) such that the fluid is rapidly released from the material. This usually involves a change in phase of the fluid (e.g., water changes from a liquid to a gas) and an increase in the volume of the fluid. The rapid release and expansion of the fluid causes the fluid to be released from the solid material. Simultaneously, the solid material expands to occupy a larger volume. While the fluid is often naturally present in the solid material, additional fluid can be introduced by impregnation or absorption (optionally under pressure) of the fluid into the solid material.

[0093] One such expansion method that can be used to prepare the botanical matter material is dry ice expansion.

[0094] Dry ice expansion involves infusing plant matter with liquid carbon dioxide followed by warming. The resulting carbon dioxide gas expands the plant matter. Additional methods include treating the plant matter with solid materials that, when heated, decompose to produce gases that aid in expanding the plant matter. Other methods include treating the plant matter with gas-containing liquids, such as carbon dioxide-containing water, to impregnate the plant matter with the liquid under pressure. The impregnated plant matter is then heated or the pressure is reduced, causing the release of gases and the expansion of the tobacco. Additional techniques have been developed for expanding plant matter, including treating the plant matter with gases that react within the plant matter to form solid chemical reaction products, such as carbon dioxide and ammonia, to form ammonium carbonate. These solid reaction products can then be decomposed by heating to produce gases within the plant matter that, upon their release, cause the plant matter to expand.

[0095] The plant matter material to be expanded can be in various forms, such as lamina or stems. For example, tobacco stems may be expanded by various types of heat treatment or by utilizing microwave energy. Freeze drying of the plant matter material may also be used to obtain an increase in volume (and therefore fill value). Continuous drying techniques, such as air drying and fluidized bed drying, may also be used to expand chopped stems.

[0096] The plant matter material may be tobacco. In a preferred embodiment, the plant matter material is dry ice expanded tobacco material (DIET) or expanded tobacco stems.

[0097] The expansion process reduces the density of the plant matter material and also results in the plant matter material having a higher fill value than the plant matter material prior to the expansion process.

[0098] The expanded plant matter material may have a fill value of at least about 6 mL / g, at least about 7 mL / g, at least about 8 mL / g, or at least about 9 mL / g up to about 15 mL / g, up to about 14 mL / g, up to about 13 mL / g, up to about 12 mL / g, up to about 11 mL / g, or up to about 10 mL / g.

[0099] FIG. 4 illustrates a method for preparing dry ice expanded tobacco. The method can be applied to other plant materials. A bale of tobacco material is sliced, and then the bale is conditioned using water and steam. The tobacco material can be any of the tobacco materials described herein. Laminar tobacco, particularly laminar Virginia tobacco, is particularly preferred. One reason for this is that Virginia tobacco exhibits desirable organoleptic characteristics and relatively low levels of compounds considered undesirable compared to other tobacco varieties. Another advantage of using Virginia tobacco is that it tends to expand easily during the expansion process. In some embodiments, stem tobacco can be used rather than, or even in addition to, lamina. After conditioning, the conditioned tobacco material is blended with other conditioned tobacco materials or mixed before being fed to a cutter. Preferably, the cutter cuts the tobacco material at 25 to 28 cuts per inch (CPI). A cutting width of 25 CPI is particularly preferred, although other cutting widths can be used. Cutting the tobacco material increases the surface area of the tobacco material, thus reducing the time it takes for the tobacco material to be impregnated with liquid during the impregnation step. These cut widths may also increase the fill value of the final material.

[0100] After wetting the cut material and blending the wet-cut material, the material has a moisture content of approximately 26%. This material is then fed into an impregnation vessel, which is subsequently charged with carbon dioxide at a temperature of -20°C under pressure for approximately 6 minutes. These conditions ensure that the carbon dioxide remains in liquid form and has sufficient time to penetrate and be absorbed into the tobacco material. Following this, the impregnated tobacco material is fed into a sublimator, where it is immediately heated in a gas stream at a temperature of 330°C. This results in the rapid volatilization of the moisture and carbon dioxide in the tobacco material, causing the tobacco material to expand.

[0101] Other gas temperatures may be used. For example, the gas temperature may be about 250°C to about 400°C or higher. The maximum temperature is preferably below the combustion temperature of the plant material. Higher temperatures may improve the expansion rate and, therefore, the process efficiency. The fill value of the plant material may also be controlled by varying the temperature. Increasing the temperature removes more moisture from the material, thus resulting in a higher fill value of the final material. Conversely, using lower temperatures may reduce the fill value of the final material.

[0102] The high gas temperature can be achieved by any suitable means (e.g., by heating the air using a hot plate or burner). At the end of sublimation, the tobacco material is relatively dry, having a moisture content of about 6%. The moisture content is increased to about 12%-14% (the target value is often 13.6%) by hydrating the tobacco material in a reconstitution cylinder to produce the final expanded tobacco material. The expanded material may have a fill value of at least about 6 mL / g.

[0103] When referring to "moisture," it is important to understand that there are diverse and conflicting definitions and terminology in use. "Moisture" or "moisture content" is commonly used to refer to the water content of a material; however, for certain industries, such as the tobacco industry, a distinction must be made between "moisture" as water content and "moisture" as oven volatiles. Water content is defined as the percentage of water contained in the total mass of a solid material. Volatiles are defined as the percentage of volatile components contained in the total mass of a solid material. This includes water and all other volatile compounds. Oven dry mass is the mass remaining after volatiles have been removed by heating. It is expressed as a percentage of the total mass. Oven volatiles (OV) is the mass of volatiles removed.

[0104] The moisture content (oven volatiles) can be measured as the loss in mass when the sample is dried in a forced air oven for 3 hours ± 0.5 minutes at a temperature controlled at 110°C ± 1°C. After drying, the sample is cooled to room temperature in an oven for approximately 30 minutes to allow the sample to cool.

[0105] Unless otherwise stated, references to moisture content herein are references to oven volatiles (OV).

[0106] The plant matter material may include expanded plant matter stems, such as expanded tobacco stems. Methods of forming expanded stems typically involve treating the stems with steam, thereby causing the material to expand and increase its fill value.

[0107] FIG. 5 illustrates one such method for expanding tobacco stems. The method can be applied to other plant material. Tobacco is added to a feeder. The tobacco stems can be from any of the tobacco varieties described herein. After the addition of water, the moisture content of the steam is about 34%. The mixture is then blended and / or thoroughly mixed with stems from other batches, at which point the stems have a moisture content of about 30% to about 40%, preferably about 32% to about 36%, and preferably about 36%. The material is then cut to ensure consistent dimensions of the stem sections. This cutting can help further increase the fill value of the material. Water is then applied to the cut stems, increasing their moisture content to about 35% to about 45%, preferably about 38% to about 40%. The relatively high moisture level achieved in this step helps increase the expansion of the stems during the subsequent expansion step. Following this, the material is subjected to steam treatment (e.g., using steam or superheated steam) at temperatures above 100°C. This results in the expansion of the stems and an increase in the filling value of the stems. The stems may be applied at a rate of at least 200 kg / hr, preferably greater than 300 kg / hr, and more preferably greater than 350 kg / hr. In some embodiments, steam is applied at a rate of about 375 kg / hr to about 500 kg / hr. Higher application rates may also be used. Throughput rates may be increased by using higher steam application rates. After dedusting using a deduster, the expanded stems may be stored.

[0108] The plant matter material may include toasted plant matter material such as tobacco, for example toasted stem tobacco.

[0109] The flowchart shown in Figure 6 summarizes an exemplary method for producing a charred tobacco material. The tobacco starting material optionally undergoes pre-processing, such as a conventional primary manufacturing (PMD) process, which includes, for example, green stem conditioning, followed by one or more of rolling, cutting, and expanding / drying, and mixing. In some embodiments, lamina pre-processing may include slicing, conditioning, casing (optional), cutting, drying, cooling, and mixing.

[0110] The moisture content of the tobacco starting material may be, for example, in the region of 14.5% OV. The starting material (e.g., stems) is fed into a processing device where it is processed by intermittent contact with a heated surface. During processing, the tobacco material is agitated to create intermittent contact with the heated surface. As a result of processing, the moisture content is reduced to as low as 0% OV. Once processing of the tobacco material by intermittent contact with the heated surface is complete, the processed tobacco material may optionally undergo conditioning. In the illustrated method, this involves adding water or steam to the processed tobacco material to increase its moisture content, for example, to the region of 14.5% OV, to produce a charred tobacco material.

[0111] The charred stem tobacco may have a fill value of greater than about 6 mL / g. In some embodiments, the charred stem tobacco has a fill value of greater than about 7 mL / g, greater than 8 mL / g, or greater than 9 mL / g.

[0112] In some embodiments, a plant material having a fill value greater than about 6 mL / g has a moisture content of about 10% to about 20% oven volatiles (OV). Typically, the moisture content of this plant material is about 11% to about 16% oven volatiles. Preferably, the moisture content of the plant material is about 11.5% to about 14.5% oven volatiles. Expanded plant material, such as expanded tobacco, typically has such moisture contents. In some embodiments, the plant material has a fill value of about 7.4 mL / g and a moisture content of about 13.4% oven volatiles (OV). In some embodiments, the plant material has a fill value of about 7.4 mL / g and a moisture content of about 12.5% oven volatiles (OV).

[0113] In some embodiments, the plant matter has a fill value of about 6 mL / g to about 10 mL / g, 6 mL / g to about 9 mL / g, 6 mL / g to about 8 mL / g, or about 6 mL / g to about 7 mL / g, and a moisture content of about 10% to about 20%. In some embodiments, the plant matter has a fill value of about 6 mL / g to about 10 mL / g, 6 mL / g to about 9 mL / g, 6 mL / g to about 8 mL / g, or about 6 mL / g to about 7 mL / g, and a moisture content of about 10% to about 15%.

[0114] In some embodiments, the aerosol-forming material comprises an amorphous solid, such as a dry gel.

[0115] The amorphous solid may include a gelling agent. In some embodiments, the gelling agent includes one or more compounds selected from the group including alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent includes one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some embodiments, the gelling agent includes a hydrocolloid. In some cases, the gelling agent includes alginate and / or pectin, which may be combined with a solidifying agent (e.g., a calcium source) during the formation of the amorphous solid. In some cases, the amorphous solid may include calcium-crosslinked alginate and / or calcium-crosslinked pectin.

[0116] In some embodiments, the gelling agent comprises alginate, and the alginate is present in the amorphous solid in an amount of 10-30 wt%, 20-35 wt%, or 25-30 wt% (calculated on a dry weight basis) of the slurry / amorphous solid. In some embodiments, the alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginate and at least one additional gelling agent, such as pectin.

[0117] The gelling agent may comprise one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum, and mixtures thereof.

[0118] In some embodiments, the cellulosic gelling agent is selected from the group consisting of hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof.

[0119] In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethyl cellulose, guar gum, or acacia gum.

[0120] In some embodiments, the gelling agent comprises (or is) one or more non-cellulosic gelling agents, including, but not limited to, agar, xanthan gum, gum arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginate, and combinations thereof. In preferred embodiments, the non-cellulosic gelling agent is alginate or agar.

[0121] The amorphous solid can be formed by forming a slurry and then drying the slurry to form the amorphous solid. The inclusion of a gelling agent in the slurry results in an aerosol-forming material formed from a dried gel. It has been found that by including a gel in the aerosol-forming material, flavor compounds, such as menthol, are stabilized within the gel matrix, allowing for higher flavor loadings to be achieved than with non-gel compositions. The flavoring (e.g., menthol) is stabilized at a high concentration, and the product has a good shelf life.

[0122] In some examples, the alginate is present in the gelling agent in an amount of about 5-40 wt% or 15-40 wt% of the amorphous solid. That is, the amorphous solid comprises alginate in an amount of about 5-40 wt% or 15-40 wt% by dry weight of the amorphous solid. In some examples, the amorphous solid comprises alginate in an amount of about 20-40 wt% or about 15-35 wt% of the amorphous solid.

[0123] In some instances, the pectin is present in the gelling agent in an amount of about 3-15 wt% of the amorphous solids, i.e., the amorphous solids comprise pectin in an amount of about 3-15 wt% by dry weight of the amorphous solids, hi some instances, the amorphous solids comprise pectin in an amount of about 5-10 wt% of the amorphous solids.

[0124] In some examples, the guar gum is included in the gelling agent in an amount of about 3-40 wt% of the amorphous solids. That is, the amorphous solids contain guar gum in an amount of about 3-40 wt% by dry weight of the amorphous solids. In some examples, the amorphous solids contain guar gum in an amount of about 5-10 wt% of the amorphous solids. In some examples, the amorphous solids contain guar gum in an amount of about 15-40 wt%, or about 20-40 wt%, or about 15-35 wt% of the amorphous solids.

[0125] In some embodiments, the alginate is present in an amount of at least about 50 wt% of the gelling agent. In some embodiments, the amorphous solid comprises alginate and pectin, and the ratio of alginate to pectin is 1:1 to 10:1. The ratio of alginate to pectin is typically greater than 1:1, i.e., the alginate is present in an amount greater than the amount of pectin. In some embodiments, the ratio of alginate to pectin is about 2:1 to 8:1, or about 3:1 to 6:1, or about 4:1.

[0126] The amorphous solid typically comprises an aerosol-forming agent (also referred to herein as aerosol-forming material) in an amount up to about 80 wt% of the amorphous solid, e.g., from about 0.1 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt%, or 10% to about 80 wt%, 75 wt%, 70 wt%, 65 wt%, 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt% of the aerosol-forming material. In some embodiments, the amorphous solid comprises an aerosol-forming agent in an amount of about 40-80 wt%, 40-75 wt%, 50-70 wt%, or 55-65 wt%.

[0127] The aerosol-forming material can act as a plasticizer. In some cases, the aerosol-forming material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some cases, the aerosol-forming material comprises, consists essentially of, or consists of glycerol. It has been established that if the plasticizer content is too high, the amorphous solid can absorb water, resulting in a material that does not create a suitable consumption experience during use. It has been established that if the plasticizer content is too low, the amorphous solid can become brittle and easily break. The plasticizer content specified herein provides the amorphous solid with flexibility, allowing the sheet to be wound onto a bobbin, which may be useful for producing consumable products or allowing the sheet to be transported before shredding.

[0128] The aerosol-forming material typically includes one or more of glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In certain examples, the aerosol-forming material includes or consists of glycerol.

[0129] In some embodiments, the aerosol-forming material includes one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin, esters of polyhydric alcohols, such as glycerol mono-, di-, or triacetate, and / or aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0130] The aerosol-forming agent can enhance the mouthfeel, and generally the sensory properties, of the aerosol generated by the aerosol-forming material when heated and inhaled by a user, particularly when the amorphous solid contains a relatively large amount (e.g., >40 wt%) of the aerosol-forming agent. The ability of the amorphous solid to retain a large amount of the aerosol-forming agent can reduce the need to add other components of the aerosol-forming material, such as expanded plant matter material, along with large amounts of the aerosol-forming agent. This can improve manufacturing efficiency.

[0131] The amorphous solid may include a flavoring. The inventors have found that using the component ratios described herein means that as the gel solidifies, the flavoring compounds are stabilized within the gel matrix, making it possible to achieve higher flavor loadings than with non-gel compositions. The flavoring (e.g., menthol) is stabilized at high concentrations, and the product has a good shelf life.

[0132] The amorphous solid may include a filler. In some cases, the amorphous solid includes 5-50 wt%, 10-40 wt%, or 15-30 wt% of the filler. In some such cases, the amorphous solid includes at least 1 wt% of the filler, e.g., at least 5 wt%, at least 10 wt%, at least 20 wt%, at least 30 wt%, at least 40 wt%, or at least 50 wt% of the filler. In exemplary embodiments, the amorphous solid includes 5-25 wt% of the filler, including fibers. Preferably, the filler consists of fibers or is in the form of fibers.

[0133] In some embodiments, the amorphous solid comprises less than 60 wt% of 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%.

[0134] In other embodiments, the amorphous solid comprises less than 20% by weight of filler, preferably less than 10% by weight, or less than 5% by weight.

[0135] The filler may include one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives (e.g., methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)). Inorganic fillers, such as calcium carbonate or chalk, may also be used. In certain cases, the amorphous solid does not include calcium carbonate, such as chalk.

[0136] Preferably, the filler is a fiber. For example, the filler may be a fibrous organic filler material, such as wood pulp, hemp fiber, cellulose, or a cellulose derivative (e.g., methylcellulose, hydroxypropyl cellulose, and carboxymethylcellulose (CMC)). Without wishing to be bound by theory, it is believed that including a fibrous filler in the amorphous solid can increase the tensile strength of the material. Furthermore, it has been found that including a fibrous filler improves the handling of the amorphous solid during manufacturing. In particular, it has been found that the resulting amorphous solid is less "sticky" and, as a result, more easily shredded during manufacturing. Therefore, including a fibrous filler increases manufacturing efficiency and reduces the likelihood of machine stoppages during shredding. Including a fibrous filler in the amorphous solid also means that the amorphous solid is less likely to clump together (e.g., less likely to clump) when shredded. When shredded amorphous solids are included in a consumable product, the reduced clumping optimizes the distribution of the shredded amorphous solids in the consumable product. Therefore, having each consumable contain a similar amount of chopped amorphous solids can likely improve the uniformity of flavor loading within a batch of consumables and / or within a given consumable.

[0137] In some embodiments, the amorphous solid may comprise up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% flavoring. In some cases, the amorphous solid may comprise at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% flavoring (all calculated on a dry weight basis). For example, the amorphous solid may comprise 1-80 wt%, 10-80 wt%, 20-70 wt%, 30-60 wt%, 35-55 wt%, or 30-45 wt% flavoring. In exemplary embodiments, the amorphous solid comprises 35-50 wt% flavoring. In some cases, the flavoring comprises, consists essentially of, or consists of menthol.

[0138] In some embodiments, the amorphous solid alternatively or additionally comprises an active substance. For example, in some cases, the amorphous solid further comprises tobacco material and / or nicotine. In some cases, the amorphous solid may comprise 5 to 60 wt% tobacco material and / or nicotine (calculated on a dry weight basis). In some cases, the amorphous solid may 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 the active substance. In some cases, the amorphous solid may 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 tobacco material. For example, the amorphous solid may comprise 10-50 wt%, 15-40 wt%, or 20-35 wt% of tobacco material. In some cases, the amorphous solid may comprise from about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% of nicotine (calculated on a dry weight basis). For example, the amorphous solid may comprise 1-20 wt%, 2-18 wt%, or 3-12 wt% of nicotine.

[0139] In some cases, the amorphous solid includes an active substance such as tobacco extract. In some cases, the amorphous solid may include 5 to 60 wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the amorphous solid may 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 may include 10 to 50 wt%, 15 to 40 wt%, or 20 to 35 wt% of tobacco extract. The tobacco extract may contain nicotine in a concentration such that the amorphous solid 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). In some cases, no nicotine other than that obtained from the tobacco extract may be present in the amorphous solid.

[0140] In some embodiments, the amorphous solid does not contain tobacco material but does contain nicotine. In some such cases, the amorphous solid may contain 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 may contain from 1 to 20 wt%, 2 to 18 wt%, or 3 to 12 wt% nicotine.

[0141] In some cases, the total active and / or flavor content may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt% amorphous solids, and in some cases, the total active and / or flavor content 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).

[0142] The aerosol-forming composition or amorphous solid may include an acid. The acid may be an organic acid. In some of these embodiments, the acid may be at least one of a monobasic acid, a dibasic acid, and a tribasic acid. In some such embodiments, the acid may contain at least one carboxyl functional group. In some such embodiments, the acid may be at least one of an alpha-hydroxy acid, a carboxylic acid, a dicarboxylic acid, a tricarboxylic acid, and a keto acid. In some such embodiments, the acid may be an alpha-keto acid.

[0143] In some such embodiments, the acid may be at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic acid, and pyruvic acid.

[0144] Preferably, the acid is lactic acid. In other embodiments, the acid is benzoic acid. In other embodiments, the acid may be an inorganic acid. In some of these embodiments, the acid may be a mineral acid. In some such embodiments, the acid may be at least one of sulfuric acid, hydrochloric acid, boric acid, and phosphoric acid. In some embodiments, the acid is levulinic acid.

[0145] The inclusion of an acid is particularly preferred in embodiments in which the aerosol-generating composition or amorphous solid includes nicotine. In such embodiments, the presence of an acid can stabilize dissolved species in the slurry from which the aerosol-generating composition or amorphous solid is formed. The presence of an acid can reduce or substantially prevent evaporation of nicotine during drying of the slurry, thereby reducing nicotine loss during manufacturing.

[0146] In certain embodiments, the aerosol-forming composition or amorphous solid comprises a gelling agent, including a cellulosic gelling agent and / or a non-cellulosic gelling agent, an active agent, and an acid.

[0147] The amorphous solid may include a colorant. The addition of a colorant can change the appearance of the amorphous solid. The presence of a colorant in the amorphous solid can enhance the appearance of the amorphous solid and the aerosol-forming composition. By adding a colorant to the amorphous solid, the amorphous solid can be color-matched to other components of the aerosol-forming composition or other components of an article comprising the amorphous solid.

[0148] Various colorants may be used depending on the desired color of the amorphous solid. The color of the amorphous solid may be, for example, white, green, red, purple, blue, brown, or black. Other colors are also contemplated. Natural or synthetic colorants may be used, such as natural or synthetic dyes, food-grade colorants, and pharmaceutical-grade colorants. In certain embodiments, the colorant is caramel, which may impart a brown appearance to the amorphous solid. In such embodiments, the color of the amorphous solid may be similar to the color of other components (e.g., tobacco material) in the aerosol-forming composition that includes the amorphous solid. In some embodiments, the addition of a colorant to the amorphous solid makes the amorphous solid visually indistinguishable from other components in the aerosol-forming composition.

[0149] The colorant may be incorporated during the formation of the amorphous solid (e.g., when forming a slurry containing the material that will form the amorphous solid), or the colorant may be applied to the amorphous solid after its formation (e.g., by spraying the colorant onto the amorphous solid).

[0150] The amorphous solid may comprise 1 to 60 wt% gelling agent, 0.1 to 70 wt% aerosol-forming material, 5 to 50% filler in the form of fibers, and 0.1 to 80 wt% flavoring and / or active agent.

[0151] The amorphous solid may comprise 10-40 wt% gelling agent, 10-70 wt% aerosol-forming material, 20-40 wt% bulking agent, and optionally 10-50 wt% flavoring agent.

[0152] In certain embodiments, the amorphous solid comprises alginate in an amount of 32.8 wt %, glycerol in an amount of 19.2 wt %, and menthol in an amount of 48 wt %.

[0153] In one embodiment, the amorphous solid comprises alginate in an amount of 26.2 wt%, glycerol in an amount of 15.4 wt%, menthol in an amount of 38.4 wt%, and fiber (derived from wood pulp) in an amount of 20 wt%.

[0154] In one embodiment, the amorphous solid comprises alginate in an amount of 32 wt%, pectin in an amount of 8 wt%, and glycerol in an amount of 60 wt%.

[0155] In one embodiment, the amorphous solid comprises alginate in an amount of 24 wt%, pectin in an amount of 6 wt%, cellulose fiber in an amount of 10 wt%, and glycerol in an amount of 60 wt%.

[0156] In certain embodiments, the amorphous solid comprises carboxymethyl cellulose (CMC) in an amount of about 7 wt%, cellulose fiber (derived from wood pulp) in an amount of about 43 wt%, and glycerol in an amount of about 50 wt%.

[0157] The amorphous solid may be prepared by (a) forming a slurry containing the components of the amorphous solid or precursors thereof, (b) forming a layer of the slurry, (c) solidifying the slurry to form a gel, and (d) drying to form the amorphous solid. Optionally, the step of solidifying the slurry includes applying a solidifying agent to the slurry. In some embodiments, the solidifying agent is sprayed onto the slurry, e.g., onto the top surface of the slurry.

[0158] In examples, the solidifying agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the solidifying agent comprises or consists of calcium formate and / or calcium lactate. In particular examples, the solidifying agent comprises or consists of calcium formate. It has been determined that the use of calcium formate as a solidifying agent typically results in an amorphous solid having higher tensile strength and higher elongation resistance.

[0159] The total amount of solidifying agent, such as a calcium source, may be 0.5 to 5 wt % (calculated on a dry weight basis). Preferably, the total amount may be about 1 wt %, 2.5 wt %, or 4 wt % to about 4.8 wt %, or 4.5 wt %. It has been found that adding too little solidifying agent may not stabilize the amorphous solid components, resulting in an amorphous solid in which these components fall off the amorphous solid. It has been found that adding too much solidifying agent may result in an amorphous solid that is very sticky and therefore difficult to handle.

[0160] If the amorphous solid does not contain tobacco, a larger amount of solidifying agent may need to be applied. Thus, in some cases, the total amount of solidifying agent may be 0.5 to 12 wt%, for example, 5 to 10 wt%, calculated on a dry weight basis. Suitably, the total amount may be about 5 wt%, 6 wt%, or 7 wt% to about 12 wt%, or 10 wt%. In this case, the amorphous solid generally does not contain tobacco.

[0161] (b) The step of forming the layer of slurry typically involves spraying, casting, or extruding the slurry. In examples, the slurry layer is formed by electrostatically spraying the slurry. In examples, the slurry layer is formed by casting the slurry.

[0162] In some instances, (b) and / or (c) and / or (d) are performed at least partially simultaneously (e.g., during electrospraying). In some instances, (b), (c) and (d) are performed sequentially.

[0163] In some instances, the slurry is applied to a substrate, and a layer may be formed on the substrate.

[0164] The amorphous solid may be provided as a shredded sheet. The shredded sheet may be formed by drying the amorphous solid and then shredding it. In certain instances, providing the amorphous solid includes shredding a sheet of the amorphous solid to provide the amorphous solid as a shredded sheet.

[0165] Alternatively, the amorphous solid may be provided as an inner wrap in an article for use in a non-combustion aerosol delivery device. For example, the amorphous solid may be a continuous sheet of material surrounding a rod containing other components of the aerosol-generating material, such as expanded plant material. The inclusion of the amorphous solid in the aerosol-generating material can help enhance the sensory properties, such as mouthfeel and taste, of the aerosol generated when the aerosol-generating material is heated. The incorporation of expanded plant material into the aerosol-generating material may result in a decrease in the sensory properties of the aerosol compared to a composition that does not include the expanded plant material. The inclusion of the amorphous solid in the aerosol-generating material, in addition to the expansion material, can help counteract the decrease in sensory properties that may be attributed to the inclusion of expanded plant material.

[0166] Because amorphous solids may have a lower packing value than expanded plant matter materials, the inclusion of amorphous solids in the aerosol-forming material may contribute to maintaining the rigidity and structural integrity of the rod of aerosol-forming material.

[0167] The aerosol-forming material may be prepared by combining and blending chopped sheets of amorphous solid and expanded plant matter material.

[0168] The aerosol-forming material may include expanded plant matter material and an amorphous solid. In some embodiments, the aerosol-forming material includes a diet and an amorphous solid; a diet, expanded / charred stems and an amorphous solid; or expanded / charred stems and an amorphous solid.

[0169] In some embodiments, the aerosol-forming material comprises DIET, expanded and / or charred stems, and an amorphous solid comprising alginate in an amount of 32.8 wt%, glycerol in an amount of 19.2 wt%, and menthol in an amount of 48 wt%.

[0170] In one embodiment, the aerosol-forming material comprises an amorphous solid comprising DIET, expanded and / or charred stems, and alginate in an amount of 26.2 wt%, glycerol in an amount of 15.4 wt%, menthol in an amount of 38.4 wt%, and fiber (derived from wood pulp) in an amount of 20 wt%.

[0171] In one embodiment, the aerosol-forming material comprises DIET, expanded and / or charred stems, and an amorphous solid comprising alginate in an amount of 32%, pectin in an amount of 8%, and glycerol in an amount of 60%.

[0172] In one embodiment, the aerosol-forming material comprises DIET, expanded and / or charred stems, and an amorphous solid comprising alginate in an amount of 24%, pectin in an amount of 6%, cellulose fiber in an amount of 10%, and glycerol in an amount of 60%.

[0173] In some embodiments, the aerosol-forming material comprises DIET, expanded and / or charred stems, and an amorphous solid comprising carboxymethylcellulose (CMC) in an amount of about 7 wt%, cellulose fiber (derived from wood pulp) in an amount of about 43 wt%, and glycerol in an amount of about 50 wt%.

[0174] The amorphous solids may be included in the aerosol-forming material in any suitable amount in combination with the expanded plant matter material. In some embodiments, the aerosol-forming material may include, for example, from about 1 wt% to about 90 wt%, 1 wt% to about 80 wt%, 1 wt% to about 70 wt%, 1 wt% to about 60 wt%, 1 wt% to about 50 wt%, 1 wt% to about 40 wt%, 1 wt% to about 30 wt%, 1 wt% to about 20 wt%, or 1 wt% to about 10 wt% of the amorphous solids, with the remainder comprising or consisting of the expanded plant matter material and lamina and / or reconstituted tobacco material.

[0175] In some embodiments, the amorphous solids comprise from about 1% to about 50% amorphous solids and from about 1% to about 50% expanded plant matter material.

[0176] The weight ratio of amorphous solids to expanded plant matter may be 1:1, 1:2, 1:3, 1:4, 1:5, 1:6, 1:7, 1:8 or 1:9, or the weight ratio of expanded plant matter material to amorphous solids may be 1:2, 1:3, 1:4, 1:5, 1:6, 1:7, 1:8 or 1:9.

[0177] In some embodiments, the aerosol-forming material comprises up to about 20 wt% or up to about 30 wt% amorphous solids, hi some embodiments, the aerosol-forming material comprises between about 10 wt% and about 25 wt% amorphous solids.

[0178] In some embodiments, the aerosol-forming material comprises up to about 30 wt% amorphous solids, about 1 wt% to 30 wt% expanded plant matter material, and the remainder lamina and / or reconstituted tobacco. For example, the aerosol-forming material may comprise about 10 wt% to about 20 wt% amorphous solids, about 10 wt% expanded plant matter material (e.g., DIET), and about 70 wt% to 80 wt% lamina and / or reconstituted tobacco.

[0179] In some embodiments, the aerosol-forming material comprises a mixture of up to about 30 wt% amorphous solids, about 1 wt% to 30 wt% expanded plant matter material, and the balance lamina and reconstituted tobacco.

[0180] For example, the aerosol-forming material may include a mixture comprising about 10 wt% amorphous solids, about 10 wt% expanded plant matter material with a DIET, and 80 wt% lamina and reconstituted tobacco. In some embodiments, the aerosol-forming material includes about 10 wt% amorphous solids, about 10 wt% expanded plant matter material with a DIET, and about 80 wt% lamina tobacco.

[0181] The weight ratio of reconstituted tobacco to lamina can be, for example, 90:10, 80:20, 70:30, 60:40, 50:50, 40:60, 30:70, 20:80, or 10:90. Using a greater amount of lamina relative to reconstituted tobacco can improve the sensory characteristics of the aerosol-forming material and provide a more robust flavor.

[0182] When the aerosol-forming material is incorporated into an article for use in a non-combustion aerosol delivery system, the aerosol-forming material may be compressed.

[0183] In addition to the aerosol-forming material, the article may also include an aerosol-forming material storage area, an aerosol-forming material transfer component, an aerosol generator, an aerosol-generating area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0184] An article for use in a non-combustion aerosol delivery system is shown in Figure 7. Article 1 comprises a mouthpiece 2 and a cylindrical rod of aerosol-forming material 3 connected to mouthpiece 2 in the aerosol-generating section of the article.

[0185] The aerosol-forming material includes expanded tobacco (in this case, DIET) in an amount of about 10% by weight of the aerosol-forming material. The aerosol-generating section of the article may have a pressure drop across the aerosol-generating section of about 35 to about 70 mmWg.

[0186] The aerosol generation section is approximately 100 mm 3 , 200m 3 , 300mm 3 , 400mm 4 , 500mm 3 , 600mm 3 or 700mm 3 ~approx. 800mm 3 , 900mm 3 , 1000mm 3 , 1100mm 3 , 1200mm 3 , 1300mm 3, 1400mm 3 or 1500mm 3 In some embodiments, the volume of the aerosol-generation section may define a volume of up to about 800 mm 3 ~approx. 1300mm 3 is.

[0187] In the illustrated embodiment, the aerosol-forming material 3 includes at least one aerosol-forming agent. In this example, the aerosol-forming agent is glycerol. In alternative examples, the aerosol-forming agent can be another material described herein or a combination thereof. It has been found that aerosol-forming agents improve the sensory performance of an article by aiding in the transfer of compounds, such as flavor compounds, from the aerosol-forming material to the consumer. However, adding such an aerosol-forming agent to an aerosol-generating material within an article for use in a non-combustion aerosol delivery system can present a problem in that the aerosol-forming agent becomes aerosolized upon heating, potentially increasing the mass of aerosol delivered by the article, which may maintain a higher temperature as it passes through the mouthpiece. As the aerosol passes through the mouthpiece, it transfers heat to the mouthpiece, which warms the outer surface of the mouthpiece, including the area that contacts the consumer's lips during use. Mouthpiece temperatures can be significantly higher than a consumer may be accustomed to when smoking, for example, a conventional cigarette, which can be an undesirable effect caused by the use of such aerosol-forming agents.

[0188] The portion of the mouthpiece that contacts the consumer's lips is usually a cardboard tube that is either hollow or surrounds a cylinder of filter material.

[0189] As shown in Figure 7, the mouthpiece 2 of the article 1 has an upstream end 2a adjacent the aerosol-generating substrate 3, and a downstream end 2b distal to the aerosol-generating substrate 3. At the downstream end 2b, the mouthpiece 2 has a hollow tubular element 4 formed from filament tow. This has been found to advantageously significantly reduce the temperature of the outer surface of the mouthpiece 2 at the downstream end 2b of the mouthpiece, which contacts the consumer's mouth when the article 1 is in use. In addition, the tubular element 4 has also been found to significantly reduce the temperature of the outer surface of the mouthpiece 2, even upstream of the tubular element 4. Without wishing to be bound by theory, it is believed that this is due to the tubular element 4 channeling the aerosol closer to the center of the mouthpiece 2, thus reducing the transfer of heat from the aerosol to the outer surface of the mouthpiece 2.

[0190] In this example, Article 1 has a perimeter of approximately 21 mm (i.e., the Article is in a demi-slim format). In other examples, the Article can be provided in any of the formats described herein, for example, having a perimeter of 15 mm to 25 mm. Because the Article is heated to release the aerosol, improved heating efficiency can be achieved using an Article with a shorter perimeter within this range, for example, a perimeter of less than 23 mm. To achieve improved aerosol delivery through heating while maintaining a suitable product length, an Article perimeter greater than 19 mm has also been found to be particularly effective. Articles with a perimeter 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 while allowing efficient heating. The perimeter of Mouthpiece 2 is substantially the same as the perimeter of the rod of aerosol-generating material 3, with a smooth transition between these components. In this example, the perimeter of Mouthpiece 2 is approximately 20.8 mm. The tipping paper 5 is wrapped around the entire length of the mouthpiece 2 and a portion of the rod of aerosol-generating material 3, and has adhesive on its inner surface for connecting it to the mouthpiece 2 and the rod 3. In this example, the tipping paper 5 extends 5 mm around the rod of aerosol-generating material 3, but can alternatively extend 3 mm to 10 mm, or more preferably 4 mm to 6 mm, over the rod 3, to provide a secure attachment between the mouthpiece 2 and the rod 3. The tipping paper 5 can have a basis weight higher than that of the plug wrap used in the article 1, for example, 40 gsm to 80 gsm, more preferably 50 gsm to 70 gsm, in this example 58 gsm. It has been found that these basis weight ranges result in tipping paper that has acceptable tensile strength while being flexible enough to wrap around the article 1 and adhere to itself along the paper's longitudinal lap seam. The perimeter of the tipping paper 5 wrapped around the mouthpiece 2 is approximately 21 mm.

[0191] The "wall thickness" of the hollow tubular element 4 corresponds to the thickness of the wall of the tube 4 in the radial direction. This can be measured, for example, using a vernier caliper. The wall thickness is advantageously greater than 0.9 mm, more preferably greater than or equal to 1.0 mm. Preferably, the wall thickness is 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 or equal to 1.0 mm, at any point around the hollow tubular element 4.

[0192] Preferably, the length of the hollow tubular element 4 is less than about 20 mm. More preferably, the length of the hollow tubular element 4 is less than about 15 mm. Even more preferably, the length of the hollow tubular element 4 is less than about 10 mm. Additionally or alternatively, the length of the hollow tubular element 4 is at least about 5 mm. Preferably, the length of the hollow tubular element 4 is at least about 6 mm. In some preferred embodiments, the length of the hollow tubular element 4 is between about 5 mm and about 20 mm, more preferably between about 6 mm and about 10 mm, even more preferably between about 6 mm and about 8 mm, and most preferably about 6 mm, 7 mm, or about 8 mm. In this example, the length of the hollow tubular element 4 is 6 mm.

[0193] Preferably, the density of the hollow tubular element 4 is at least about 0.25 grams per cubic centimeter (g / cc), more preferably at least about 0.3 g / cc. Preferably, the density of the hollow tubular element 4 is less than about 0.75 grams per cubic centimeter (g / cc), more preferably less than 0.6 g / cc. In some embodiments, the density of the hollow tubular element 4 is between 0.25 and 0.75 g / cc, more preferably between 0.3 and 0.6 g / cc, more preferably between 0.4 g / cc and 0.6 g / cc, or about 0.5 g / cc. These densities have been found to provide a good balance between the improved stiffness provided by higher density materials and the lower heat transfer characteristics of lower density materials. For purposes of this invention, the "density" of the hollow tubular element 4 refers to the density of the filament tow forming the element, including any incorporated plasticizers. The density can be determined by dividing the total weight of the hollow tubular element 4 by the total volume of the hollow tubular element 4, which can be calculated using appropriate measurements of the hollow tubular element 4, for example taken using a vernier caliper. If necessary, appropriate dimensions can also be measured using a microscope.

[0194] The filament tow forming the hollow tubular element 4 preferably has a total fineness of less than 45,000, more preferably less than 42,000. This total fineness has been found to allow the formation of a tubular element 4 that is not too dense. Preferably, the total fineness is at least 20,000, more preferably at least 25,000. In a preferred embodiment, the filament tow forming the hollow tubular element 4 has a total fineness of 25,000 to 45,000, more preferably 35,000 to 45,000. Preferably, the cross-sectional shape of the filaments of the tow is "Y" shaped, although in other embodiments other shapes, such as "X" shaped filaments, may be used.

[0195] The filament tows forming the hollow tubular elements 4 preferably have a monofilament fineness greater than 3. This monofilament fineness has been found to allow for the formation of tubular elements 4 that are not too dense. Preferably, the monofilament fineness is at least 4, more preferably at least 5. In a preferred embodiment, the filament tows forming the hollow tubular elements 4 have a monofilament fineness of 4 to 10, more preferably 4 to 9. In one example, the filament tows forming the hollow tubular elements 4 are formed from cellulose acetate and have an 8Y40,000 tow containing 18% plasticizer, such as triacetin.

[0196] The hollow tubular element 4 preferably has an inner diameter greater than 3.0 mm. A smaller diameter would undesirably increase the rate at which the aerosol passes through the mouthpiece 2 towards the consumer's mouth, which could result in the aerosol becoming too warm, for example reaching temperatures greater than 40° C. or 45° C. More preferably, the hollow tubular element 4 has an inner diameter greater than 3.1 mm, and even more preferably greater than 3.5 mm or 3.6 mm. In one embodiment, the inner diameter of the hollow tubular element 4 is about 3.9 mm.

[0197] The hollow tubular element 4 preferably contains 15% to 22% by weight of plasticizer. In the case of cellulose acetate tow, the plasticizer is preferably triacetin, although other plasticizers such as polyethylene glycol (PEG) can be used. More preferably, the tubular element 4 contains 16% to 20% by weight of plasticizer, for example, about 17%, about 18%, or about 19%.

[0198] The pressure drop or differential (also referred to as draw resistance) across the mouthpiece, e.g., the portion of the article 1 downstream of the aerosol-generating material 3, is preferably less than about 40 mmH2O. Such a pressure drop has been found to allow sufficient aerosol containing desirable compounds, such as flavor compounds, to pass through the mouthpiece 2 toward the consumer. More preferably, the pressure drop across the mouthpiece 2 is less than about 32 mmH2O. In some embodiments, particularly improved aerosols have been achieved using mouthpieces 2 having pressure drops of less than 31 mmH2O, e.g., about 29 mmH2O, about 28 mmH2O, or about 27.5 mmH2O. Alternatively or additionally, the pressure drop across the mouthpiece can be at least 10 mmH2O, preferably at least 15 mmH2O, and more preferably at least 20 mmH2O. In some embodiments, the pressure drop across the mouthpiece can be between about 15 mmH2O and 40 mmH2O. These values allow the mouthpiece 2 to slow the aerosol as it passes through the mouthpiece 2, allowing the aerosol time to cool before it reaches the downstream end 2b of the mouthpiece 2.

[0199] The mouthpiece 2 in this example includes a body of material 6 upstream of the hollow tubular element 4, adjacent to and in abutting relationship with the hollow tubular element 4. The body of material 6 and the hollow tubular element 4 each define a substantially cylindrical overall outer shape and share a common longitudinal axis. The body of material 6 is wrapped around a first plug wrap 7. Preferably, the first plug wrap 7 has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. Preferably, the first plug wrap 7 has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. Preferably, the first plug wrap 7 is a non-porous plug wrap having a breathability of, for example, less than 100 Coresta units, e.g., less than 50 Coresta units. However, in other embodiments, the first plug wrap 7 may be a porous plug wrap having a breathability of, for example, greater than 200 Coresta units.

[0200] Preferably, the length of the body of material 6 is less than about 15 mm. More preferably, the length of the body of material 6 is less than about 10 mm. Additionally or alternatively, the length of the body of material 6 is at least about 5 mm.

[0201] Preferably, the length of the body of material 6 is at least about 6 mm. In some preferred embodiments, the length of the body of material 6 is about 5 mm to about 15 mm, more preferably about 6 mm to about 12 mm, even more preferably about 6 mm to about 12 mm, and most preferably about 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. In this example, the length of the body of material 6 is 10 mm. In this example, the body of material 6 is formed from filament tow. In this example, the tow used in the body of material 6 has a single filament fineness (dpf) of 8.4 and a total filament fineness of 21,000. Alternatively, the tow may have, for example, a single filament fineness (dpf) of 9.5 and a total filament fineness of 12,000. In this example, the tow comprises plasticized cellulose acetate tow. The plasticizer used in the tow comprises about 7% by weight of the tow. In this example, the plasticizer is triacetin. In other examples, different materials may be used to form the body of material 6. For example, rather than tow, the body 6 may be formed from paper, for example, in a manner similar to paper filters known for use in cigarettes.

[0202] Alternatively, the body 6 can be formed from a tow other than cellulose acetate, e.g., polylactic acid (PLA), other materials described herein with respect to filament tow, or similar materials. The tow is preferably formed from cellulose acetate. Whether formed from cellulose acetate or another material, the tow preferably has a dpf of at least 5, more preferably at least 6, and even more preferably at least 7. These values of monofilament fineness result in tow with relatively coarse, thick fibers with a smaller surface area, resulting in a lower pressure drop across the mouthpiece 2 than tow with lower dpf values. Preferably, to achieve a sufficiently uniform body 6, the tow has a monofilament fineness of 12 dpf or less, preferably 11 dpf or less, and even more preferably 10 dpf or less.

[0203] The total fineness of the tow forming the body of material 6 is preferably at most 30,000, more preferably at most 28,000, and even more preferably at most 25,000. These total fineness values result in a tow that occupies a reduced proportion of the cross-sectional area of the mouthpiece 2, resulting in a lower pressure drop across the mouthpiece 2 than tows having higher total fineness values. For adequate stiffness of the body of material 6, the tow preferably has a total fineness of at least 8,000, more preferably at least 10,000. Preferably, the single fineness is 5 to 12, while the total fineness is 10,000 to 25,000. More preferably, the single fineness is 6 to 10, while the total fineness is 11,000 to 22,000. Preferably, the cross-sectional shape of the filaments of the tow is "Y" shaped, although in other embodiments, other shapes, such as "X" shaped filaments, may be used with the same dpf and total fineness values provided herein.

[0204] In this example, the hollow tubular element 4 is a first hollow tubular element 4, and the mouthpiece includes a second hollow tubular element 8, also referred to as a cooling element, upstream of the first hollow tubular element 4. In this example, the second hollow tubular element 8 is upstream of, adjacent to, and in abutting relationship with the body of material 6. The body of material 6 and the second hollow tubular element 8 each define a substantially cylindrical overall outer shape and share a common longitudinal axis. The second hollow tubular element 8 is formed from multiple layers of paper that are wound in parallel with their seams butted together to form the tubular element 8. In this example, the first and second paper layers are provided in a two-ply tube, although in other examples, three, four, or more paper layers may be used to form a three, four, or more layer tube. Other constructions may be used, such as spirally wound paper layers, cardboard tubes, tubes formed using a paper mache method, molded or extruded plastic tubes, or the like. The second hollow tubular element 8 can also be formed using stiff plug wrap and / or tipping paper as the second plug wrap 9 and / or tipping paper 5 described herein, i.e., a separate tubular element is not required. The stiff plug wrap and / or tipping paper is manufactured to have sufficient stiffness to withstand axial compressive forces and bending moments that may occur during manufacture and while the article 1 is in use. For example, the stiff plug wrap and / or tipping paper may have a basis weight of 70 gsm to 120 gsm, more preferably 80 gsm to 110 gsm. Additionally or alternatively, the stiff plug wrap and / or tipping paper may have a thickness of 80 μm to 200 μm, more preferably 100 μm to 160 μm, or 120 μm to 150 μm. It may be desirable for both the second plug wrap 9 and the tipping paper 5 to have values within these ranges to achieve an acceptable overall level of stiffness for the second hollow tubular element 8.

[0205] The second hollow tubular element 8 preferably has a wall thickness of at least about 100 μm up to about 1.5 mm, preferably 100 μm to 1 mm, more preferably 150 μm to 500 μm, or about 300 μm, which can be measured in the same way as the first hollow tubular element 4. In this example, the second hollow tubular element 8 has a wall thickness of about 290 μm.

[0206] Preferably, the length of the second hollow tubular element 8 is less than about 50 mm. More preferably, the length of the second hollow tubular element 8 is less than about 40 mm. Even more preferably, the length of the second hollow tubular element 8 is less than about 30 mm. Additionally or alternatively, the length of the second hollow tubular element 8 is preferably at least about 10 mm. Preferably, the length of the second hollow tubular element 8 is at least about 15 mm. In some preferred embodiments, the length of the second hollow tubular element 8 is between about 20 mm and about 30 mm, more preferably between about 22 mm and about 28 mm, even more preferably between about 24 mm and about 26 mm, and most preferably about 25 mm. In this example, the length of the second hollow tubular element 8 is 25 mm.

[0207] The second hollow tubular element 8 is disposed around and defines a cavity within the mouthpiece 2, which acts as a cooling segment. The cavity provides a chamber through which heated volatilized components generated by the aerosol-generating material 3 flow. The second hollow tubular element 8 is hollow to provide a chamber for aerosol accumulation, yet rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and while the article 1 is in use. The second hollow tubular element 8 provides a physical displacement between the aerosol-generating material 3 and the body of material 6. The physical displacement provided by the second hollow tubular element 8 results in a thermal gradient across the length of the second hollow tubular element 8.

[0208] Preferably, the mouthpiece 2 is 450 mm 3The mouthpiece 2 includes 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 allows for exposure of the aerosol-generating material 3 to higher temperatures than would otherwise be possible, providing sufficient space within the mouthpiece 2 for the heated volatilized components to cool, which would otherwise result in an overheated aerosol. In this example, the cavity is formed by the second hollow tubular element 8, although in alternative constructions the cavity may be formed within a different portion of the mouthpiece 2. More preferably, the mouthpiece 2 has a cavity of at least 500 mm. 3 More than, and even more preferably, 550mm 3 Further improvements in aerosolization can be achieved by providing a cavity formed within the second hollow tubular element 8, for example, having an internal volume of more than about 550 mm. In some examples, the internal volume is about 550 mm. 3 ~about 750mm 3 , for example, about 600 mm 3 or 700mm 3 It has a volume of

[0209] The second hollow tubular element 8 can be configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatilized component entering the first upstream end of the second hollow tubular element 8 and the heated volatilized component exiting the second downstream end of the second hollow tubular element 8. The second hollow tubular element 8 is preferably configured to provide a temperature difference of at least 60 degrees Celsius, preferably at least 80 degrees Celsius, and more preferably at least 100 degrees Celsius between the heated volatilized component entering the first upstream end of the second hollow tubular element 8 and the heated volatilized component exiting the second downstream end of the second hollow tubular element 8. The temperature difference across the length of the second hollow tubular element 8 protects the temperature-sensitive body of material 6 from the high temperatures of the aerosol-forming material 3 when the aerosol-forming material 3 is heated.

[0210] In an alternative article, the second hollow tubular element 8 may be replaced by an alternative cooling element, for example an element formed from a body of material, which allows the aerosol to pass longitudinally and also performs the function of cooling the aerosol.

[0211] In this example, the first hollow tubular element 4, the body of material 6, and the second hollow tubular element 8 are combined using a second plug wrap 9 wrapped around all three sections. Preferably, the second plug wrap 9 has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 45 gsm. Preferably, the second plug wrap 9 has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The second plug wrap 9 is preferably a non-porous plug wrap having an air permeability of less than 100 Coresta units, for example less than 50 Coresta units. However, in alternative embodiments, the second plug wrap 9 may be a porous plug wrap having an air permeability of, for example, greater than 200 Coresta units.

[0212] In this example, the aerosol-generating material 3 is wrapped in a cigarette paper 10. The cigarette paper 10 can be, for example, paper or a foil cigarette paper with a backing. In this example, the cigarette paper 10 is substantially air-impermeable. In an alternative embodiment, the cigarette paper 10 preferably has an air permeability of less than 100 Coresta units, more preferably less than 60 Coresta units. It has been found that low-air-permeability cigarette paper, for example, having an air permeability of less than 100 Coresta units, more preferably less than 60 Coresta units, results in improved aerosol formation in the aerosol-generating material 3. Without wishing to be bound by theory, this is presumed to be due to reduced loss of aerosol compounds through the cigarette paper 10. The air permeability of the cigarette paper 10 can be measured in accordance with ISO 2965:2009, relating to determination of air permeability of materials used as cigarette paper, filter plug wrappers, and filter bonding papers.

[0213] In this embodiment, the wrapper paper 10 comprises aluminum foil. Aluminum foil has been found to be particularly effective in enhancing aerosol formation within the aerosol-generating material 3. In this example, the aluminum foil has a metal layer having a thickness of approximately 6 μm. In this example, the aluminum foil has a backing paper. However, in alternative constructions, the aluminum foil can be of other thicknesses, for example, between 4 μm and 16 μm. The aluminum foil also need not have a backing paper, but may have a backing formed from another material, for example, to help provide the foil with adequate tensile strength, or may have no backing material at all. Metal layers or foils other than aluminum can also be used. The total thickness of the wrapper paper is preferably between 20 μm and 60 μm, more preferably between 30 μm and 50 μm, which provides a wrapper paper with adequate structural integrity and heat transfer properties. The tensile force that can be applied to the paper wrapper before it breaks can be greater than 3,000 grams force, for example, from 3,000 to 10,000 grams force, or from 3,000 to 4,500 grams force.

[0214] The article may have a ventilation level of about 75% of the aerosol drawn through the article. In alternative embodiments, the article may have a ventilation level of 50% to 80%, e.g., 65% to 75%, of the aerosol drawn through the article. These levels of ventilation help slow the aerosol flow drawn through the mouthpiece 2, allowing the aerosol to cool sufficiently before reaching the downstream end 2b of the mouthpiece 2. Ventilation is provided directly to the mouthpiece 2 of the article 1. In this example, ventilation is provided to the second hollow tubular element 8, which has been found to be particularly beneficial in supporting the aerosol generation method. Ventilation is provided via first and second parallel rows of perforations 12, formed in this example as laser perforations, located 17.925 mm and 18.625 mm, respectively, from the downstream mouth end 2b of the mouthpiece 2. These perforations penetrate the tipping paper 5, the second plug wrap 9, and the second hollow tubular element 8. In alternative embodiments, ventilation may be provided to the mouthpiece at other locations, for example in the body of material 6 or the first tubular element 4 .

[0215] In this example, the aerosol-forming agent added to the aerosol-generating substrate 3 constitutes 15% by weight of the aerosol-generating substrate 3. Preferably, the aerosol-forming agent constitutes at least 5% by weight of the aerosol-generating substrate, more preferably at least 10%. Preferably, the aerosol-forming agent constitutes less than 25% by weight of the aerosol-generating substrate, more preferably less than 20%, for example 10% to 20%, 12% to 18%, or 13% to 16%.

[0216] Preferably, the aerosol-generating material 3 is provided as a cylindrical rod of aerosol-generating material. Regardless of the form 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 in the range of about 25 mm to 50 mm, more preferably in the range of about 30 mm to 45 mm, and even more preferably in the range of about 30 mm to 40 mm.

[0217] The volume of the aerosol-generating material 3 provided is approximately 200 mm 3 ~approx. 4300mm 3 , preferably about 500 mm 3 ~1500mm 3 , more preferably about 1000 mm 3 ~approx. 1300mm 3 The aerosol-forming material can vary in these volumes, e.g., about 1000 mm 3 ~approx. 1300mm 3 It has been advantageously shown that achieving a superior aerosol with higher visibility and sensory performance compared to that achieved at volumes selected from the lower end ranges.

[0218] The mass of the provided aerosol-forming material 3 may be greater than 200 mg, for example, between about 200 mg and 400 mg, preferably between about 230 mg and 360 mg, and more preferably between about 250 mg and 360 mg. Advantageously, it has been found that providing a higher mass of aerosol-forming material improves sensory performance compared to aerosols generated from lower masses of tobacco material.

[0219] Preferably, the aerosol-forming material is formed from a tobacco material as described herein, including tobacco components.

[0220] In some embodiments, the aerosol-generating material is a sheet or shredded sheet of material comprising first and second plant matter materials.

[0221] In some embodiments, the aerosol-generating material comprises an intimate mixture of the first plant matter material and the second plant matter material.

[0222] Including plant matter material in a rod having a packing value greater than about 6 mL / g increases the tendency of the aerosol-generating material to shed or spill off the rod. Without wishing to be bound by theory, this may be due to the relatively small particle size of the expanded plant matter material and the lower total weight of the aerosol-generating material. To limit the amount of aerosol-generating material that sheds off the rod, the packing density of the aerosol-generating material may be higher at the distal end of the rod.

[0223] Thus, the packing density of the aerosol-generating material 3 may vary throughout the rod. In particular, the density of the aerosol-generating material 3 may be higher at the distal end of the rod of aerosol-generating material than at the proximal end. The packing density of the aerosol-generating material at the distal end of the rod may be increased by applying pressure to the tobacco material in this region of the rod during manufacture.

[0224] A non-combustion aerosol delivery device is used to heat the aerosol-generating material of the articles described herein, and preferably comprises a coil, as it has been found that coils can improve heat transfer to the article compared to other configurations.

[0225] In some examples, the coil is configured to cause heating of at least one electrically conductive heating element during use, such that thermal energy can be conducted from the at least one electrically conductive heating element to the aerosol-generating material, thereby causing heating of the aerosol-generating material.

[0226] In some examples, the coil is configured to generate, in use, a varying magnetic field that penetrates at least one heating element, thereby causing inductive heating and / or magnetic hysteresis heating of the at least one heating element. In such configurations, the or each heating element may be referred to as a "susceptor," as defined herein. A coil that is configured, in use, to generate a varying magnetic field that penetrates at least one electrically conductive heating element, thereby causing inductive heating of the at least one electrically conductive heating element, may be referred to as an "induction coil" or "inductor coil."

[0227] The device may include heating element(s), e.g., electrically conductive heating element(s), which may suitably be positioned or positionable relative to the coil to enable such heating of the heating element(s). The heating element(s) may be in a fixed position relative to the coil. Alternatively, at least one heating element, e.g., at least one electrically conductive heating element, may be included in an article for insertion into a heating zone of the device, which article also comprises the aerosol-generating material 3 and can be removed from the heating zone after use. Alternatively, both the device and such article may comprise at least one respective heating element, e.g., at least one electrically conductive heating element, and the coil may cause heating of the respective heating element(s) of the device and article when the article is in the heating zone.

[0228] In some examples, the coil is helical. In some examples, the coil encircles at least a portion of a heating zone of a device configured to receive the aerosol-forming material. In some examples, the coil is a helical coil encircling at least a portion of a heating zone.

[0229] In some examples, the device includes an electrically conductive heating element at least partially surrounding the heating zone, and the coil is a helical coil that encircles at least a portion of the electrically conductive heating element. In some examples, the electrically conductive heating element is tubular. In some examples, the coil is an inductor coil.

[0230] In some examples, the use of a coil allows a non-combustion aerosol delivery device to reach an operating temperature more quickly than a non-coil aerosol delivery device. For example, a non-combustion aerosol delivery device including a coil as described above can reach an operating temperature so as to deliver the first puff in less than 30 seconds, more preferably less than 25 seconds, from the start of a device heating program. In some examples, the device can reach an operating temperature in less than 20 seconds from the start of a device heating program.

[0231] The use of a coil as described herein in a device for heating an aerosol-generating material has been found to enhance the aerosol generated. For example, consumers have reported that the aerosol generated by a device including a coil, such as the coil described herein, feels closer to that generated in a factory-made cigarette (FMC) product than to that generated by other non-combustion aerosol delivery systems. Without wishing to be bound by theory, this is presumed to be the result of the shorter time required to reach the required heating temperature when a coil is used, the higher heating temperatures that are achievable when a coil is used, and / or the coil allowing a relatively large volume of aerosol-generating material to be heated simultaneously in such systems, resulting in aerosol temperatures similar to those of an FMC product. In an FMC product, burning charcoal generates a thermal aerosol that heats the tobacco in the tobacco rod behind the charcoal as the aerosol is drawn through the rod. It is understood that this thermal aerosol releases flavor compounds from the tobacco in the rod behind the burning charcoal. It is believed that devices including coils as described herein are also capable of heating aerosol-forming materials, such as the tobacco materials described herein, to release flavor compounds, resulting in aerosols that are reported to more closely resemble FMC aerosols.

[0232] The use of an aerosol delivery system including a coil, e.g., an induction coil, as described herein, that heats at least a portion of the aerosol-forming material to at least 200°C, more preferably at least 220°C, may enable the generation of an aerosol from the aerosol-forming material having certain properties believed to more closely resemble those of FMC products. For example, when an induction heater was used to heat an aerosol-forming material containing nicotine to at least 250°C for 2 seconds while under an airflow of at least 1.50 L / m, one or more of the following properties were observed: At least 10 μg of nicotine is aerosolized from the aerosol-generating material; the weight ratio of aerosol-forming material to nicotine in the generated aerosol is at least about 2.5:1, preferably at least 8.5:1; At least 100 μg of the aerosol-forming material can be aerosolized from the aerosol-generating material; The average particle or droplet size in the generated aerosol is less than about 1000 nm; and Aerosol density is at least 0.1 μg / cc.

[0233] In some cases, at least 10 μg of nicotine, preferably at least 30 μg or 40 μg of nicotine, is aerosolized from the aerosol-forming material while under an airflow of at least 1.50 L / m. In some cases, less than about 200 μg of nicotine, preferably less than about 150 μg or less than about 125 μg of nicotine, is aerosolized from the aerosol-forming material while under an airflow of at least 1.50 L / m.

[0234] In some cases, the aerosol comprises at least 100 μg of aerosol-forming material, preferably at least 200 μg, 500 μg, or 1 mg of aerosol-forming material, while being aerosolized from the aerosol-generating material under an airflow of at least 1.50 L / m. Preferably, the aerosol-forming material may comprise or consist of glycerol.

[0235] As defined herein, the term "average particle or droplet size" refers to the average size of the solid or liquid components of the aerosol (i.e., the components suspended in the gas). When the aerosol contains droplets of suspended liquid and suspended solid particles, the term refers to the average size of all components together.

[0236] In some cases, the average particle size or droplet size in the generated aerosol may be less than about 900 nm, 800 nm, 700 nm, 600 nm, 500 nm, 450 nm, or 400 nm. In some cases, the average particle size or droplet size may be greater than about 25 nm, 50 nm, or 100 nm.

[0237] In some cases, the aerosol density generated during the period is at least 0.1 μg / cc. In some cases, the aerosol density is at least 0.2 μg / cc, 0.3 μg / cc, or 0.4 μg / cc. In some cases, the aerosol density is less than about 2.5 μg / cc, 2.0 μg / cc, 1.5 μg / cc, or 1.0 μg / cc.

[0238] The non-combustion aerosol delivery device is preferably configured to heat the aerosol-forming material 3 of the article 1 to a maximum temperature of at least 160°C.

[0239] Preferably, the non-combustion aerosol delivery device is configured to heat the aerosol-forming material 3 of the article 1 to a maximum temperature of at least about 200°C, or about 220°C, or at least about 240°C, more preferably at least about 270°C, at least once during the heating method with the non-combustion aerosol delivery device.

[0240] Use of an aerosol delivery system including a coil, e.g., an induction coil, described herein that heats at least a portion of the aerosol-generating material to at least 200°C, more preferably at least 220°C, may enable the generation of an aerosol from the aerosol-generating material in article 1 as described herein that has a higher temperature as the aerosol leaves the oral end of mouthpiece 2 than existing devices, contributing to the generation of an aerosol that is believed to more closely resemble the characteristics of an FMC product. For example, the maximum temperature of the aerosol measured at the oral end of article 1 may preferably be greater than 50°C, more preferably greater than 55°C, even more preferably greater than 56°C or 57°C. Additionally or alternatively, the maximum temperature of the aerosol measured at the oral end of article 1 may be less than 62°C, more preferably less than 60°C, and more preferably less than 59°C. In some embodiments, the maximum temperature of the aerosol measured at the oral end of article 1 may preferably be between 50°C and 62°C, more preferably between 56°C and 60°C.

[0241] 8 shows an example of a non-combustion aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium / material, such as the aerosol-generating material 3 of article 1 described herein. Broadly speaking, device 100 may be used to heat a replaceable article 110 comprising an aerosol-generating medium, such as article 1 described 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.

[0242] Device 100 comprises a housing 102 (in the form of an outer cover) that surrounds and contains the various components of device 100. Device 100 has an opening 104 at one end through which an article 110 can be inserted for heating by the heating assembly. During use, article 110 may be fully or partially inserted into the heating assembly, where it can be heated by one or more components of the heater assembly. The heater assembly comprises a heater configured to supply heat to the article and volatilize at least a portion of the aerosol-forming material.

[0243] The heater may comprise one or more electrical resistance heaters, including, for example, one or more nichrome resistance heater(s) and / or one or more ceramic heater(s). The one or more heaters may comprise one or more induction heaters, including a structure comprising one or more susceptors that may form a chamber into which, during use, an article comprising the aerosolizable material is inserted or otherwise disposed. Alternatively, or in addition, the one or more susceptors may be disposed within the aerosolizable material. Other heating structures may also be used.

[0244] The device 100 in this example includes a first end member 106 with a lid 108 that is movable relative to the first end member 106 closer to the opening 104 when the item 110 is not in position. In Figure 8, the lid 108 is shown in an open configuration; however, 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."

[0245] Device 100 may also include a user-operable control element 112, such as a button or switch, which, when pressed, operates device 100. For example, a user can activate device 100 by operating switch 112.

[0246] Device 100 may also include an electrical component, such as a socket / port 114, which can accept a cable for charging a battery in device 100. For example, socket 114 may be a charging port, such as a USB charging port.

[0247] 9 shows the device 100 of FIG. 8 with the outer cover 102 removed and without the article 110 present. The device 100 defines a longitudinal axis 134.

[0248] 9 , the first end member 106 is disposed at one end of the device 100, and the second end member 116 is disposed at the opposite end of the device 100. The first and second end members 106, 116 together at least partially define an end surface of the device 100. For example, the bottom surface of the second end member 116 at least partially defines the bottom surface of the device 100. An edge of the outer cover 102 may also define a portion of the end surface. In this example, the lid 108 also defines a portion of the top surface of the device 100.

[0249] The end of the device closest to opening 104 may also be known as the proximal end (or mouth end) of device 100, as it will be closest to the user's mouth during use. During use, a user inserts article 110 into opening 104 and operates user control 112 to initiate heating of the aerosol-generating material and inhale the aerosol generated by the device, causing the aerosol to flow through device 100 along a flow path toward the proximal end of device 100.

[0250] The other end of the device, furthest from opening 104, may also be known as the distal end of device 100, as it is furthest from the user's mouth during use. When a user inhales the aerosol generated in the device, the aerosol flows away from the distal end of device 100.

[0251] Device 100 further includes a power source 118. Power source 118 may be, for example, a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (e.g., lithium-ion batteries), nickel batteries (e.g., nickel-cadmium batteries), and alkaline batteries. The battery is electrically coupled to the heating assembly and provides power to heat the aerosol-forming material when needed under the control of a controller (not shown). In this example, the battery is connected to a central support 120 that holds battery 118 in place.

[0252] The device further includes at least one electronics module 122. The electronics module 122 may include, for example, a printed circuit board (PCB). The PCB 122 may support at least one controller, such as a processor, and a memory. The PCB 122 may also include one or more electrical tracks that electrically connect the various electronic components of the device 100 together. For example, battery terminals may be electrically connected to the PCB 122 so that power can be distributed throughout the device 100. The socket 114 may also be electrically coupled to a battery via electrical tracks.

[0253] In this example device 100, the heating assembly is an induction heating assembly, comprising various components that heat the aerosol-generating material of the article 110 via induction heating. Induction heating is a method of heating an electrically conductive object (e.g., a susceptor) by electromagnetic induction. The induction heating assembly may comprise an induction element, e.g., one or more inductor coils, and a device that passes a varying current, such as an alternating current, through the induction element. The varying current in the induction element generates a varying magnetic field. The varying magnetic field penetrates a susceptor suitably positioned with respect to the induction element, generating eddy currents within the susceptor. The susceptor has an electrical resistance to eddy currents, and therefore, the flow of eddy currents against this resistance causes the susceptor to heat due to Joule heating. If the susceptor comprises a ferromagnetic material, such as iron, nickel, or cobalt, heat may also be generated by magnetic hysteresis losses in the susceptor, i.e., by the varying orientation of magnetic dipoles in the magnetic material as a result of the alignment of the magnetic material with the varying magnetic field. In induction heating, heat is generated inside the susceptor, allowing for rapid heating, as compared to, for example, heating by conduction. Furthermore, there is no need for physical contact between the induction heater and the susceptor, allowing for greater flexibility in construction and application.

[0254] The induction heating assembly of this example device 100 includes a susceptor structure 132 (referred to herein as a "susceptor"), a first inductor coil 124, and a second inductor coil 126. The first and second inductor coils 124, 126 are made from an electrically conductive material. In this example, the first and second inductor coils 124, 126 are made from litz wire / cable wound in a helical fashion to result in the helical inductor coils 124, 126. The litz wire comprises multiple individual wires that are individually insulated and twisted together to form a single wire. The litz wire is designed to reduce skin effect losses in the conductors. In this example device 100, the first and second inductor coils 124, 126 are made from copper litz wire having a rectangular cross-section. In other examples, the litz wire may have a cross-section of other shapes, such as circular.

[0255] The first inductor coil 124 is configured to generate a first varying magnetic field for heating a first section of the susceptor 132, and the second inductor coil 126 is configured to generate a second varying magnetic field for heating a second section of the susceptor 132. In this example, the first inductor coil 124 is adjacent to the second inductor coil 126 in a direction along a longitudinal axis 134 of the device 100 (i.e., the first and second inductor coils 124, 126 do not overlap). The susceptor structure 132 may comprise a single susceptor or two or more separate susceptors. Ends 130 of the first and second inductor coils 124, 126 may be connected to the PCB 122.

[0256] It will be appreciated that in some examples, the first and second inductor coils 124, 126 may have at least one characteristic that differs from one another. For example, the first inductor coil 124 may have at least one characteristic that differs from the second inductor coil 126. More specifically, in one example, the first inductor coil 124 may have a different inductance value than the second inductor coil 126. In FIG. 9 , the first and second inductor coils 124, 126 are of different lengths, so the first inductor coil 124 is wound around a smaller section of the susceptor 132 than the second inductor coil 126. Thus, the first inductor coil 124 may have a different number of turns than the second inductor coil 126 (assuming the spacing between individual turns is substantially the same). In yet another example, the first inductor coil 124 may be made of a different material than the second inductor coil 126. In some examples, the first and second inductor coils 124, 126 may be substantially identical.

[0257] In this example, the first inductor coil 124 and the second inductor coil 126 are wound in opposite directions. This can be useful if the inductor coils are active at different times. For example, the first inductor coil 124 may initially operate to heat a first section / portion of the article 110, and at a later time, the second inductor coil 126 may operate to heat a second section / portion of the article 110. Winding the coils in opposite directions can help reduce current induced in inactive coils when used in conjunction with certain types of control circuitry. In the device 100 of FIG. 9, the first inductor coil 124 is a right-handed spiral and the second inductor coil 126 is a left-handed spiral. However, in other embodiments, the inductor coils 124, 126 may be wound in the same direction, or the first inductor coil 124 may be a left-handed spiral and the second inductor coil 126 may be a right-handed spiral.

[0258] The susceptor 132 in this example is hollow, thus defining a reservoir for receiving the aerosol-generating material. For example, the article 110 can be inserted into the susceptor 132. In this example, the susceptor 120 is tubular with a circular cross section.

[0259] The susceptor 132 may be made from one or more materials. Preferably, the susceptor 132 comprises carbon steel with a coating of nickel or cobalt.

[0260] In some examples, the susceptor 132 may comprise at least two materials capable of being heated at two different frequencies for selective aerosolization of at least two materials. For example, a first section of the susceptor 132 (heated by the first inductor coil 124) may comprise a first material, and a second section of the susceptor 132 (heated by the second inductor coil 126) may comprise a second, different material. In another example, the first section may comprise first and second materials, which may be heated separately based on operation of the first inductor coil 124. The first and second materials may be adjacent along an axis defined by the susceptor 132 or may form different layers within the susceptor 132. Similarly, the second section may comprise third and fourth materials, which may be heated separately based on operation of the second inductor coil 126. The third and fourth materials may be adjacent along an axis defined by the susceptor 132, or may form different layers within the susceptor 132. For example, the third material may be the same as the first material, and the fourth material may be the same as the second material. Alternatively, each of the materials may be different. The susceptor may comprise, for example, carbon steel or aluminum.

[0261] 9 further includes an insulating member 128 that may be generally tubular and at least partially surround the susceptor 132. The insulating member 128 may be constructed from any insulating material, such as, for example, plastic. In this particular example, the insulating member is constructed from polyetheretherketone (PEEK). The insulating member 128 may help insulate the various components of the device 100 from heat generated in the susceptor 132.

[0262] The insulating member 128 may also fully or partially support the first and second inductor coils 124, 126. For example, as shown in FIG. 9 , the first and second inductor coils 124, 126 are disposed around the insulating member 128 and are in contact with the radially outward surface of the insulating member 128. In some examples, the insulating member 128 does not abut the first and second inductor coils 124, 126. For example, there may be a small gap between the outer surface of the insulating member 128 and the inner surfaces of the first and second inductor coils 124, 126.

[0263] In a particular example, the susceptor 132 , the insulating member 128 , and the first and second inductor coils 124 , 126 are coaxial about a central longitudinal axis of the susceptor 132 .

[0264] 10 shows a side view in partial cross section of device 100. In this example, outer cover 102 is present. The rectangular cross-sectional shapes of first and second inductor coils 124, 126 can be more clearly seen.

[0265] The device 100 further includes a support 136 that fits over one end of the susceptor 132 to hold the susceptor 132 in place. The support 136 is connected to the second end member 116.

[0266] The device may also include a second printed circuit board 138 associated within the control element 112 .

[0267] The device 100 further includes a second lid / cap 140 arranged toward the distal end of the device 100 and a spring 142. The spring 142 allows the second lid 140 to be opened to provide connection to the susceptor 132. A user can open the second lid 140 to clean the susceptor 132 and / or the support 136.

[0268] The device 100 further includes an expansion chamber 144 extending from the proximal end of the susceptor 132 toward the opening 104 of the device. A gripping clip 146 is disposed at least partially within the expansion chamber 144 for abutting and holding the article 110 when received within the device 100. The expansion chamber 144 is connected to the end member 106.

[0269] FIG. 11 is an exploded view of the device 100 of FIG. 8, omitting the outer cover 102.

[0270] Figure 12A shows a cross-sectional view of a portion of the device 100 of Figure 8. Figure 12B shows an enlarged view of a region of Figure 12A. Figures 12A and 12B show an article 110 received within a susceptor 132, with the article 110 sized so that the outer surface of the article 110 abuts the inner surface of the susceptor 132. This ensures that heating is most efficient. The article 110 in this example comprises an aerosol-generating material 110a. The aerosol-generating material 110a is disposed within the susceptor 132. The article 110 may also comprise other components, such as a filter, packaging material, and / or cooling structure.

[0271] 12B shows that the outer surface of the susceptor 132 is spaced from the inner surfaces of the inductor coils 124, 126 by a distance 150 measured perpendicular to a longitudinal axis 158 of the susceptor 132. In particular examples, the distance 150 is about 3 mm to 4 mm, about 3 mm to 3.5 mm, or about 3.25 mm.

[0272] 12B further shows that the outer surface of the insulating member 128 is spaced from the inner surfaces of the inductor coils 124, 126 by a distance 152 measured perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 152 is approximately 0.05 mm. In another example, the distance 152 is substantially 0 mm, and the inductor coils 124, 126 abut and contact the insulating member 128.

[0273] In one example, the susceptor 132 has a wall thickness 154 of between about 0.025 mm and 1 mm, or about 0.05 mm.

[0274] In one example, the susceptor 132 has a length of about 40 mm to 60 mm, about 40 mm to 45 mm, or about 44.5 mm.

[0275] In one example, the insulating member 128 has a wall thickness 156 of between about 0.25 mm and 2 mm, between 0.25 mm and 1 mm, or about 0.5 mm.

[0276] In use, an article 1 described herein can be inserted into a non-combustion aerosol delivery device, such as device 100 described with reference to Figures 8-12. At least a portion of mouthpiece 2 of article 1 protrudes from non-combustion aerosol delivery device 100 and can be placed in the mouth of a user. An aerosol is generated by heating aerosol-generating material 3 using device 100. The aerosol generated by aerosol-generating material 3 passes through mouthpiece 2 toward the user's mouth.

[0277] The article 1 described herein has particular advantages when used with a non-combustion aerosol delivery device, such as, for example, the device 100 described with reference to Figures 8-12. In particular, it has been surprisingly found that the first tubular element 4 formed from filament tow has a significant effect on the temperature of the outer surface of the mouthpiece 2 of the article 1. For example, when the hollow tubular element 4 formed from filament tow is wrapped with an outer wrapper, such as tipping paper 5, it has been found that the outer surface of the outer wrapper reaches a maximum temperature of less than 42°C, preferably less than 40°C, and more preferably less than 38°C, or less than 36°C during use. [Example]

[0278] Test Method A In the following examples, the loading values of the plant matter materials were determined according to the following method. A 15g sample of plant material was placed in the 60mm diameter cylinder of the density meter, and then the plant material was compressed with a 1kg piston for 30 seconds. The height of the piston of the density meter and the moisture content of the sample were measured. The packing value of the sample was calculated according to the following formula:

[0279] The volume occupied by the plant matter material when compressed was determined using the following equation 1: formula 1

number

[0280] The fill value was then determined using the measured volume and mass of the plant matter material according to Equation 2 below: formula 2

number

[0281] The loading value was calibrated to take into account its water content using the following equation 3: formula 3

number

[0282] Moisture content (oven volatiles) is measured as the loss in mass when the sample is dried in a forced air oven for 3 hours ± 0.5 minutes at a temperature controlled temperature of 110°C ± 1°C. After drying, the sample is cooled to room temperature in an oven for approximately 30 minutes to allow the sample to cool.

[0283] Example 1 A selection of aerosol-generating materials was developed. These are shown in Table 1. Each material contained glycerol in an amount of 15% by weight of the material and flavoring in an amount of 2% by weight of the material. The loading value of the bulking material (DIET) was 7.3 mL / g at 12.5% moisture.

[0284] [Table 1]

[0285] A selection of articles for use in the non-combustion aerosol delivery system was made using the aerosol-generating materials listed in Table 1. The properties of these articles are shown in Table 2. Hardness was measured using a Sodimat device.

[0286] [Table 2]

[0287] Table 2 shows that aerosol-forming materials containing expanded tobacco material can be incorporated into articles at lower weights than aerosol-forming materials that do not contain expanded tobacco material without significantly detrimentally affecting the hardness of the aerosol-forming section of the article. Furthermore, the inclusion of relatively high levels of expanded tobacco material did not detrimentally affect the sensory (e.g., organoleptic) properties of the aerosol-forming material when aerosolized.

[0288] Example 2 Two amorphous solids, Amorphous Solid A and Amorphous Solid B, were prepared by forming a slurry of the components in water, solidifying the slurry, drying the slurry to form a sheet, and then shredding the sheet.

[0289] Amorphous Solid A contained an alginate / pectin mixture (26.2%), glycerol (15.4%), cellulose fiber (20%), and menthol (38.4%). The slurry was solidified by spraying calcium lactate onto its surface.

[0290] Amorphous solid B contained alginate (24%), pectin (6%), cellulose fiber (10%), and glycerol (60%).

[0291] Selection of articles for use in non-combustion aerosol delivery systems can be made including aerosol-forming materials including amorphous solid A or amorphous solid B and DIET, such as those shown in Table 3.

[0292] [Table 3]

[0293] Compared to the comparative article, amorphous solids A and B are expected to enhance the organoleptic properties of the aerosol generated by the aerosol-forming material when heated in a non-combustion aerosol delivery device. In addition, the article is expected to exhibit acceptable hardness.

[0294] To address various problems and advance the art, this disclosure is presented throughout by way of illustration of various embodiments in which the claimed invention may be practiced to provide superior methods, apparatus, and processed tobacco materials and extracts thereof. The advantages and features of the present disclosure are merely a representative sample of embodiments and are not intended to be exhaustive and / or exclusive. They are presented solely to aid in the understanding and teaching of the claimed features. It is understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects of the present disclosure are not to be construed as limitations on the present disclosure as defined by the claims or equivalents thereof, and that other embodiments may be utilized and changes may be made without departing from the scope and / or spirit of the present disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of various combinations of the elements, components, features, parts, steps, means, etc. of the present disclosure. Furthermore, the present disclosure encompasses other inventions not currently claimed but which may be claimed in the future.

Claims

1. 1. An article for use with a non-combustion aerosol delivery system, comprising an aerosol-generating material prepared from one or more botanical matter materials, at least one of the botanical matter materials having a fill value greater than about 6 mL / g.

2. 10. The article of claim 1, wherein the aerosol-forming material is prepared from a composition comprising the one or more botanical matter materials, and the one or more botanical matter materials having a fill value of greater than about 6 mL / g are present in an amount of from about 1% to about 30%, or from about 5% to about 25%, by weight of the composition.

3. 3. The article of claim 1 or 2, wherein at least one of the plant matter materials is an expanded plant matter material.

4. 4. The article of claim 3, wherein the expanded plant matter material is expanded lamina and / or expanded stem tobacco.

5. The article of any one of claims 1 to 4, wherein at least one of the plant matter materials has a loading value of less than about 6 mL / g.

6. The article of any one of claims 1 to 5, wherein at least one of the plant matter materials has a loading value of about 4 mL / g to 6 mL / g.

7. The article of any one of claims 1 to 6, wherein at least one of the plant material materials is a recycled paper plant material.

8. The article of any one of claims 1 to 7, wherein at least one of the plant matter materials is laminar tobacco.

9. The article of any one of claims 1 to 8, wherein the aerosol-forming material comprises an aerosol-forming agent in an amount of at least about 10% by weight of the aerosol-forming material.

10. The article of any one of claims 1 to 9, wherein the aerosol-forming material comprises a composition comprising the one or more botanical matter materials.

11. The article of any one of claims 1 to 10, comprising an aerosol-generating section comprising the aerosol-generating material.

12. The article of claim 11 , wherein the aerosol-generating section comprises a wrapper surrounding the aerosol-generating material.

13. The article of claim 11 or 12, wherein the aerosol-generating section has a hardness of about 50% to 80%.

14. The article of any one of claims 11 to 13, wherein the pressure drop across the aerosol-generation section is from about 35 to about 70 mmWg.

15. 15. The article of any one of claims 1 to 14, wherein said at least one of said plant material materials is prepared by a method comprising elevating a temperature of said first plant material to cause release of at least a portion of a fluid from said first plant material to form a second plant material.

16. 16. The article of claim 15, wherein the second plant matter material is the plant matter material having a fill value of greater than about 6 mL / g.

17. 1. An article for use with a non-combustion aerosol delivery system, comprising an aerosol-generating material comprising one or more botanical matter materials, at least one of the botanical matter materials having a fill value greater than about 6 mL / g.

18. 18. The article of claim 17, wherein the botanical matter material having a fill value of greater than about 6 mL / g is present in the aerosol-forming material in an amount from about 1% to about 30%, or from about 5% to about 25%, by weight of the aerosol-forming material.

19. The article of any one of claims 1 to 18, comprising the aerosol-forming material in an amount of from about 200 mg to about 400 mg.

20. The article of any one of claims 1 to 19, wherein the aerosol-forming material has a fill value of from about 2 mL / g to about 10 mL / g.

21. The article of any one of claims 1 to 20, comprising an aerosol-generating section defining a continuous volume, said volume being substantially filled with said aerosol-generating material.

22. The volume is about 100 mm ３ ~Approx. 1500mm ３ 22. The article of claim 21, wherein:

23. 1. An article for use with a non-combustion aerosol delivery system, comprising an aerosol-generating material comprising a first plant material prepared by a method comprising: elevating a temperature of a second plant material to cause release of at least a portion of a fluid from the second plant material to form a first plant material.

24. 24. The article of claim 23, wherein the method is an expansion method.

25. The article of any one of claims 1 to 24, wherein the aerosol-forming material comprises an amorphous solid.

26. 26. The article of claim 25, wherein the aerosol-forming material comprises the amorphous solid in an amount of from about 5 wt % to about 30 wt %.

27. 27. The article of claim 25 or 26, wherein the aerosol-forming material comprises the amorphous solid in an amount of about 5 wt % to about 30 wt %, a plant matter material having a fill value of greater than about 6 mL / g in an amount of about 1 wt % to about 30 wt %, and a tobacco material comprising laminar tobacco and / or reconstituted tobacco in an amount of up to about 70 wt %.

28. The amorphous solid is 1 to 60 wt % of a gelling agent, and 0.1 to 80 wt % of an aerosol former The article of any one of claims 25 to 27, comprising:

29. The amorphous solid is 0.1-80% fragrance and / or active substances 30. The article of claim 28, comprising:

30. The amorphous solid is 0-50 wt% filler 30. The article of claim 28 or 29, comprising:

31. 31. The article of any one of claims 1 to 30, wherein the moisture content of the plant matter material having a fill value of greater than about 6 mL / g is from about 8% to about 15%.

32. The article of any one of claims 1 to 31, wherein the fill value is measured according to test method A.

33. 1. A method for manufacturing an article for use with a non-combustion aerosol delivery system, comprising: combining two or more botanical matter materials to form an aerosol-generating material, wherein at least one of the botanical matter materials has a loading value of at least about 6 mL / g; wrapping the aerosol-forming material with a wrapping paper to form a rod of aerosol-forming material; A method comprising:

34. 1. A method for manufacturing an article for use with a non-combustion aerosol delivery system, comprising: elevating the temperature of the plant matter material to cause release of at least a portion of fluid from the plant matter material to form an expanded plant matter material; wrapping the expanded plant matter material in a wrapping paper to form a rod of aerosol-forming material; A method comprising:

35. impregnating a plant matter material with a fluid to form an impregnated plant matter material; elevating the temperature of the impregnated plant matter material to cause release of at least a portion of fluid from the plant matter material to form the expanded plant matter material; 35. The method of claim 34, comprising:

36. 36. The method of claim 35, wherein the step of impregnating the plant matter material is carried out at subatmospheric pressure.

37. A method according to any one of claims 34 to 36, wherein the expanded plant matter material has a fill value that is higher than the fill value of the plant matter material before the treatment method.

38. 38. A method according to any one of claims 35 to 37, wherein the step of impregnating the plant matter material is carried out at a temperature below 0°C.

39. 39. The method of any one of claims 35 to 38, wherein the temperature of the impregnated plant matter material is increased to a temperature of from about 250°C to about 400°C, from about 290°C to about 350°C, or from about 200°C to about 240°C.

40. A method according to any one of claims 35 to 39, wherein the fluid is a liquid.

41. 41. A method according to any one of claims 34 to 40, wherein the expanded plant matter material is combined with at least one other plant matter material to form the aerosol-generating material.

42. 42. A method according to any one of claims 33 to 41, comprising adding an aerosol forming agent to the plant matter material.

43. The method of any one of claims 33 to 42, wherein the article is any one of the articles of any one of claims 1 to 24.

44. 44. The method of any one of claims 33 to 43, wherein the aerosol-forming material comprises an amorphous solid according to any one of claims 25 to 28.

45. 45. The method of claim 44, wherein the amorphous solid is a shredded sheet.

46. 46. The method of claim 45, wherein the shredded sheets of amorphous solid are blended with the plant matter material.

47. 47. The method of claim 46, wherein the amorphous solid is in the form of a sheet, the method comprising surrounding at least a portion of the plant matter material with the sheet of the amorphous solid.

48. 48. An article for use with a non-combustion aerosol delivery system prepared according to the method of any one of claims 33 to 47.

49. A non-combustion aerosol delivery system comprising the article of any one of claims 1 to 30 and 48 and a non-combustion aerosol delivery device.

50. 1. Use of a plant matter material having a loading value of greater than about 6 mL / g in an article for use with a non-combustion aerosol delivery system.

51. 1. Use of a plant matter material prepared by an expansion process in an article for use with a non-combustion aerosol delivery system.

52. 42. The use of claim 50 or 41, wherein the article is a rod and the plant matter material is surrounded by a wrapping paper.

53. 53. The use according to claim 50 or 52, wherein the article is an electrically heated article.

54. 54. The use according to claim 53, wherein the electrically heated article is heated in an electrically operated aerosol generating device comprising an aerosol generator.

55. 55. The use of claim 54, wherein the aerosol generator supplies heat to the aerosol-forming material and volatilizes at least a portion of the aerosol-forming material.

56. 56. Use according to any one of claims 50 to 55, comprising inserting the article into an electrically heated aerosol generating system and removing the article from the electrically heated aerosol generating system.

Images