Aerosol-generating component

Abstract

To provide an aerosol-generating component for use with a non-combustible aerosol provision device, an article including such a component, and a non-combustible aerosol provision system including an aerosol provision device and such an article.SOLUTION: An aerosol-generating component 1 includes a first sheet 11 including an aerosol-generating material and a second sheet 12 including a heating material that is heatable by penetration with a varying magnetic field. A wrapper 20 including paper circumscribes the first and second sheets and has a permeability below 500 Coresta units. In an alternative component, each of multiple strips of a laminate material comprises: a first layer comprising aerosol-generating material; and a second layer comprising heating material that is heatable by penetration with a varying magnetic field.SELECTED DRAWING: Figure 1a

Description

[Technical Field]

[0001] The present invention relates to aerosol generating components for use with non-flammable aerosol delivery devices, articles including such components, and non-flammable aerosol delivery systems including aerosol delivery devices and such articles. The present invention also relates to methods of making aerosol generating components for use with non-flammable aerosol delivery devices.

[0002] Certain tobacco industry products generate an aerosol during use, which is inhaled by the user. For example, tobacco heating devices heat an aerosol-forming material, such as tobacco material, to form an aerosol by heating, rather than by combustion, of the aerosol-forming material.

[0003] According to an embodiment of the present invention, there is provided an aerosol-generating component for use with a non-flammable aerosol delivery device, the aerosol-generating component comprising: a first sheet containing an aerosol-generating material; a second sheet containing a heating material heatable by the penetration of a fluctuating magnetic field; and a wrapper comprising paper, enclosing the first and second sheets, and having an air permeability of less than 500 Coresta units.

[0004] According to an embodiment of the present invention, there is provided an aerosol generating component for use with a non-combustible aerosol delivery device, the aerosol generating component comprising multiple strips of laminate material, each strip having a first layer comprising an aerosol-generating material and a second layer comprising a heating material heatable by the penetration of a varying magnetic field.

[0005] According to an embodiment of the present invention, there is provided an aerosol generating component for use with a non-combustible aerosol delivery device, the aerosol generating component comprising a first plurality of strips of aerosol-generating material and a second plurality of strips of heating material heatable by the penetration of a varying magnetic field.

[0006] According to an embodiment of the present invention, there is provided an aerosol generating component for use with a non-combustible aerosol delivery device, the aerosol generating component comprising a core or cavity containing a first aerosol-generating material, a sheath containing a second aerosol-generating material surrounding the core, and a boundary material surrounding the core between the core and the sheath.

[0007] According to an embodiment of the present invention, there is provided an article for use with a non-flammable aerosol delivery device, the article comprising a component as described above.

[0008] According to an embodiment of the present invention, there is provided a non-flammable aerosol delivery system comprising a non-flammable aerosol delivery device and an article as described above.

[0009] According to an embodiment of the present invention, there is provided a method for manufacturing an aerosol generating component for use with a non-flammable aerosol delivery device, the method comprising the steps of: providing a first sheet comprising an aerosol generating material; providing a second sheet comprising a heating material that can be heated by the penetration of a fluctuating magnetic field; and wrapping the first sheet and the second sheet in a wrapper comprising paper and having an air permeability of less than 500 Coresta units.

[0010] According to an embodiment of the present invention, there is provided a method of manufacturing an aerosol-generating component for use with a non-flammable aerosol delivery device, the method comprising: forming a sheet of laminate material, the sheet having a first layer comprising an aerosol-generating material and a second layer comprising a heating material that can be heated by the penetration of a fluctuating magnetic field; and slicing the sheet to form a plurality of strips of laminate material, each of the plurality of strips having a first layer comprising an aerosol-generating material and a second layer comprising a heating material that can be heated by the penetration of a fluctuating magnetic field.

[0011] According to an embodiment of the present invention, there is provided a method of manufacturing an aerosol generating component for use with a non-combustible aerosol supply device, the method including: shredding a first sheet of aerosol generating material to form a first plurality of strips; and shredding a second sheet of heating material that can be heated by the intrusion of a variable magnetic field to form a second plurality of strips.

[0012] According to an embodiment of the present invention, there is provided a method of manufacturing an aerosol generating component for use with a non-combustible aerosol supply device, the method including: preparing a core portion including an optional first aerosol generating material; disposing a boundary material around the core portion; and disposing a sheath portion including a second aerosol generating material around the core portion, wherein the boundary material is disposed between the core portion and the sheath portion.

[0013] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings, which are merely examples.

Brief Description of the Drawings

[0014] [Figure 1a] It is an end cross-sectional view of an aerosol generating component. [Figure 1b] It is an end cross-sectional view of an aerosol generating component. [Figure 2] It is a cross-sectional view of an example of the sheet shown in Fig. 1b. [Figure 3] It is a cross-sectional view of another example of the sheet shown in Fig. 1b. [Figure 4a] It is a side cross-sectional view of an aerosol generating component. [Figure 4b] It is a side cross-sectional view of an aerosol generating component. [Figure 4c] It is a plan view of an example of sheet material. [Figure 4d] It is a side cross-sectional view of an aerosol generating component formed using the sheet material shown in Fig. 4c. [Figure 5] It is a side cross-sectional view of an aerosol generating component. [Figure 6a] FIG. 1 is a cross-sectional side view of an aerosol generation component. [Figure 6b] FIG. 6b is a cross-sectional end view of the aerosol generation component shown in FIG. 6a. [Figure 6c] FIG. 1 is a cross-sectional end view of an aerosol generation component. [Figure 6d] FIG. 1 is a cross-sectional end view of an aerosol generation component. [Figure 6e] FIG. 1 is a cross-sectional end view of an aerosol generation component. [Figure 7] FIG. 1 is a cross-sectional side view of an article including an aerosol-generating component. [Figure 8] FIG. 8 is a schematic diagram of a system including the article and aerosol delivery device shown in FIG. 7. [Figure 9] FIG. 1 is a flow diagram illustrating a method for manufacturing an aerosol-generating component. [Figure 10] FIG. 1 is a flow diagram illustrating a method for manufacturing an aerosol-generating component. [Figure 11] FIG. 1 is a flow diagram illustrating a method for manufacturing an aerosol-generating component. [Figure 12] FIG. 1 is a flow diagram illustrating a method for manufacturing an aerosol-generating component. Detailed Description

[0015] According to the present disclosure, a "non-flammable" aerosol delivery system is one in which the aerosol-generating material (or components thereof) that constitute the aerosol delivery system is not combusted to facilitate delivery of at least one substance to a user.

[0016] In some embodiments, the delivery system is a non-flammable aerosol delivery system, such as a powered non-flammable aerosol delivery system.

[0017] In some embodiments, the non-combustible aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although 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. One example of such a system is a tobacco heating system.

[0019] In some embodiments, the non-combustible aerosol delivery system is a hybrid system that generates aerosol through a combination of aerosol-forming materials, one or more of which may be heated. Each aerosol-forming material 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 as well as a solid aerosol-forming material. The solid aerosol-forming material may include, for example, tobacco or a non-tobacco product.

[0020] Generally, a non-flammable aerosol delivery system may include a non-flammable aerosol delivery device and a consumable item for use with the non-flammable aerosol delivery device.

[0021] In some embodiments, the present disclosure relates to consumables that include aerosol-generating materials and are configured for use with non-flammable aerosol delivery devices. Throughout this disclosure, these consumables may be referred to as articles.

[0022] A consumable is an article containing or consisting of an aerosol-forming material, intended to be consumed, in part or in whole, upon use by a user. A consumable may include one or more other components, such as an aerosol-forming material storage area, an aerosol-forming material transfer component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater, that releases heat upon use to generate an aerosol from the aerosol-generating material. A heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0023] In some embodiments, a non-combustible aerosol delivery system (e.g., a non-combustible 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 provide power in the form of heat to an aerosol-generating material or a heat transfer material proximate the heat-generating power source.

[0024] In some embodiments, the non-flammable 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 modifying agent.

[0025] In some embodiments, consumables for use with non-flammable aerosol delivery devices may include an aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol-generating area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0026] A heating material (or susceptor) is a material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that the penetration of the varying magnetic field results in inductive heating of the heating material. The heating material may be a magnetic material, such that the penetration of the varying magnetic field results in magnetic hysteresis heating of the heating material. The susceptor may be bi-directional, such that it can be heated by both conductive and magnetic heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0027] Induction heating is a process by which a conductive object is heated by the penetration of a varying magnetic field. This process is described by Faraday's law of induction and Ohm's law. An induction heater may include an electromagnet and a device for passing a varying current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are suitably positioned relative to one another so that the resulting varying magnetic field generated by the electromagnet penetrates the object, one or more eddy currents are generated inside the object. The object has a resistance to the flow of current. Therefore, when such eddy currents are generated in the object, they flow against the object's electrical resistance, causing the object to heat. This process is referred to as Joule heating, Ohmic heating, or resistive heating. An object that can be inductively heated is known as a susceptor.

[0028] In one embodiment, the susceptor is in the form of a closed circuit, which has been found to enhance magnetic coupling between the susceptor and the electromagnet during use, thereby increasing or enhancing Joule heating.

[0029] Magnetic hysteresis heating is the process by which an object composed of a magnetic material is heated by the penetration of a fluctuating magnetic field. Magnetic materials can be thought of as containing many atomic-scale magnets, or magnetic dipoles. When a magnetic field penetrates such a material, the magnetic dipoles become aligned with the magnetic field. Thus, when a fluctuating magnetic field, such as an alternating magnetic field generated by an electromagnet, penetrates a magnetic material, the orientation of the magnetic dipoles changes with the application of the fluctuating magnetic field. This reorientation of the magnetic dipoles generates heat in the magnetic material.

[0030] If an object is both conductive and magnetic, the penetration of a fluctuating magnetic field into the object can cause both Joule heating and magnetic hysteresis heating in the object. Furthermore, the use of magnetic materials can increase Joule heating due to the stronger magnetic field.

[0031] In some embodiments, the heating material may be a metal, such as aluminum, gold, or silver, for example, in foil form. In some embodiments, the heating material may be a ferromagnetic material. Examples of ferromagnetic materials include metals such as iron, nickel, and cobalt, as well as alloys such as certain types of stainless steel. In some embodiments, the heating material may be a ferromagnetic stainless steel, for example, in foil form. For example, 430 grade stainless steel or other ferritic metals or grades of stainless steel can be used as the heating material.

[0032] In some examples, the thermal conductivity of the heating material may be in the range of 1 W / (m·K) to 500 W / (m·K). For example, the thermal conductivity of the heating material may be in the range of 10 W / (m·K) to 60 W / (m·K), 100 W / (m·K) to 250 W / (m·K), 150 W / (m·K) to 250 W / (m·K), or 200 W / (m·K) to 250 W / (m·K). In some examples, the specific heat capacity of the heating material may be in the range of 100 J / (kg·K) to 1000 J / (kg·K). For example, the specific heat capacity of the heating material may be in the range of 450 J / (kg·K) to 550 J / (kg·K), 800 J / (kg·K) to 1000 J / (kg·K), or 900 J / (kg·K) to 1000 J / (kg·K).

[0033] In each of the above processes, because heat is generated within the object itself rather than by heat transfer from an external heat source, rapid heating and more uniform heat distribution within the object can be achieved, particularly by selection of a suitable object material and shape and a suitable varying magnetic field magnitude and orientation relative to the object. Furthermore, induction heating and magnetic hysteresis heating do not require a physical connection between the varying magnetic field source and the object, thereby increasing design freedom and control of the heating profile and potentially reducing costs.

[0034] As used herein, the terms "upstream" and "downstream" are relative terms defined relative to the direction of mainstream aerosol drawn through the article or device in use.

[0035] In the drawings described herein, the same reference numbers are used to denote like features, items or components.

[0036] Figure 1a is a cross-sectional end view of an aerosol-generating component comprising first and second sheet materials, the aerosol-generating component being used in an article for use with a non-combustible aerosol delivery device.

[0037] The aerosol-generating component 1 includes a first sheet 11 containing an aerosol-forming material and a second sheet 12 containing a heating material. The aerosol-generating material may be any of the aerosol-generating materials described herein, and the heating material may be any of the heating materials described herein. In this example, the aerosol-generating material is tobacco material and the heating material is stainless steel foil. In another example, the heating material may be aluminum foil. The aerosol-generating material can be, for example, reconstituted tobacco material. The aerosol-generating material can include an aerosol-forming agent in an amount of 10% to 30% by weight of the aerosol-generating material, measured on a dry weight basis.

[0038] In this example, a single first sheet and a single second sheet may be provided, but this is not intended to be limiting. In some examples, multiple first sheets and / or multiple second sheets may be provided.

[0039] In this example, first sheet 11 and second sheet 12 are separate sheets of material. In other words, first sheet 11 may be in contact with second sheet 12, but is not bonded or adhered to second sheet 12. The surface of first sheet 11 may be in contact with the surface of second sheet 12 at one or more points. This aids in heat transfer between the heating material of the second sheet and the aerosol-forming material of the first sheet, allowing for efficient heating of the aerosol-forming material.

[0040] The first sheet may have a thickness of at least approximately 100 μm. The first sheet may have a thickness of at least approximately 120 μm, 140 μm, 160 μm, 180 μm, or 200 μm. In some embodiments, the first sheet has a thickness of approximately 150 μm to approximately 300 μm, approximately 151 μm to approximately 299 μm, approximately 152 μm to approximately 298 μm, approximately 153 μm to approximately 297 μm, approximately 154 μm to approximately 296 μm, approximately 155 μm to approximately 295 μm, approximately 156 μm to approximately 294 μm, approximately 157 μm to approximately 293 μm, approximately 158 μm to approximately 292 μm, approximately 159 μm to approximately 291 μm, or approximately 160 μm to approximately 290 μm. In some embodiments, the first sheet has a thickness of about 170 μm to about 280 μm, about 180 μm to about 270 μm, about 190 μm to about 260 μm, about 200 μm to about 250 μm, or about 210 μm to about 240 μm. In this example, the first sheet has a thickness of about 200 μm.

[0041] The thickness of the sheet can be determined using ISO 534:2011 "Paper and Board - Determination of Thickness".

[0042] The second sheet 12 may have a thickness of approximately 1 μm to approximately 150 μm (e.g., approximately 1 μm to approximately 100 μm or approximately 1 μm to approximately 50 μm). In this example, the second sheet 12 has a thickness of approximately 7 μm. In other examples, the second sheet may have a thickness of approximately 1 μm, 2 μm, 3 μm, 4 μm, 5 μm, 6 μm, 8 μm, 9 μm, or 10 μm. In some embodiments, it may be advantageous to use a thickness of less than approximately 50 μm for the heating material to improve the efficiency of heating the material when exposed to a varying magnetic field. Without being bound by theory, it is hypothesized that this is due to an enhanced "skin effect," in which current flow through the surface of a material increases resistive heating at the surface of the material.

[0043] In some examples, the second sheet may include a plurality of openings extending through the thickness of the sheet. For example, the second sheet may be in the form of a mesh. In some examples, the second sheet may include a plurality of embossments, pleats, perforations, or deformations.

[0044] In some examples, the first sheet may include a plurality of apertures. In some examples, the first sheet may include a plurality of embossments, pleats, perforations, or deformations.

[0045] In some instances, the total area of ​​the first sheet is greater than the total area of ​​the second sheet. In some instances, the total area of ​​the first sheet is less than the total area of ​​the second sheet.

[0046] In this example, the aerosol-generation component 1 is substantially cylindrical and has a substantially circular cross-section, as shown in Figure 1a. In other examples, the aerosol-generation component may have other cross-sections, such as an oval or elliptical cross-section. In some examples, the aerosol-generation component may have a rectangular, square, triangular, or star-shaped cross-section. In some examples, the aerosol-generation component may have an irregular cross-section.

[0047] In this example, the aerosol-generation component is elongate and has a longitudinal axis (not shown). The first sheet 11 and the second sheet 12 extend substantially parallel to the longitudinal axis of the aerosol-generation component 1.

[0048] The first sheet 11 and the second sheet 12 may be formed into the aerosol-generating component 1 by corrugating and collecting the first and second sheets 11,12.

[0049] The length of the aerosol-generation component 1 may be between approximately 8 mm and approximately 150 mm. In this example, the aerosol-generation component has a length of approximately 12 mm.

[0050] The width (or diameter) of the aerosol-generation component may be between approximately 4 mm and approximately 10 mm. In this example, the aerosol-generation component has a width (or diameter) of approximately 7.3 mm.

[0051] The aerosol-generating component 1 further comprises a wrapper 20 surrounding the first and second sheets 11, 12. The wrapper 20 surrounds the first and second sheets 11, 12, thereby encasing them. This may help to prevent separation of the first and second sheets. The wrapper 20 may also help to guide air and / or aerosol into the component 1.

[0052] In this example, the wrapper 20 comprises paper. The wrapper 20 has an air permeability of less than 500 Coresta units (CU). In some examples, the wrapper may have an air permeability of less than 400 CU, 300 CU, 200 CU, or 100 CU. Using a wrapper with an air permeability of less than 500 Coresta units makes the wrapper less flammable, minimizing the risk of the wrapper igniting if, for example, a consumer attempts to light the component 1 with a flame. In this example, the wrapper 20 has an air permeability of approximately 0 CU. In other examples, the wrapper may have an air permeability of 30 CU, 40 CU, 60 CU, 70 CU, or 80 CU. In addition to or as an alternative to paper with an air permeability of less than 500 CU, the wrapper 20 can include a fire retardant additive. The fire retardant additive can prevent or limit combustion of the wrapper 20 when exposed to, for example, a flame.

[0053] In some instances, the wrapper may consist solely of paper. In other instances, the wrapper may include a metal layer in addition to paper. For example, the wrapper may include a layer of aluminum foil. Such a metal layer may aid in uniform heat transfer throughout the aerosol-forming material of the component. This may help prevent any particular region of the aerosol-forming material from reaching its combustion temperature.

[0054] The metal layer may have a thickness of about 1 μm to about 50 μm. For example, in some examples, the metal layer may have a thickness of 7 μm. In other examples, the metal layer may have a thickness of 1 μm, 2 μm, 3 μm, 4 μm, 5 μm, 6 μm, 8 μm, 9 μm, or 10 μm.

[0055] Figure 1b is a cross-sectional end view of an aerosol-generating component including laminate material 10. The aerosol-generating component is used in an article for use with a non-flammable aerosol delivery device.

[0056] The aerosol-generating component 1 shown in FIG. 1b is similar to the aerosol-generating component shown in FIG. 1a and includes a first sheet containing an aerosol-generating material and a second sheet containing a heating material. The aerosol-generating material may be any of the aerosol-generating materials described herein, and the heating material may be any of the heating materials described herein. In this example, the aerosol-generating material is tobacco material, and the heating material is stainless steel foil. In another example, the heating material may be aluminum foil. The aerosol-generating material can be, for example, reconstituted tobacco material. The aerosol-generating material can include an aerosol-forming agent in an amount of 10% to 30% by weight of the aerosol-generating material, measured on a dry weight basis.

[0057] In this example, the first sheet and the second sheet are joined to form laminate material 10. Thus, the surface of the first sheet may be in full contact with the surface of the second sheet or in close proximity to the surface of the second sheet. This relatively greater contact or proximity between the first and second sheets aids in heat transfer between the heating material of the second sheet and the aerosol-forming material of the first sheet, allowing for efficient heating of the aerosol-forming material.

[0058] The aerosol-generating component 1 shown in Figure 1b further comprises a wrapper 20 surrounding the first and second sheets. The wrapper 20 may be the same as the wrapper described above with respect to Figure 1a.

[0059] FIG. 2 is a cross-sectional view of an example of the laminate material 10 shown in FIG. 1b. A first sheet (or layer) 11 and a second sheet (or layer) 12 are bonded together. In this example, the first sheet and the second sheet are bonded together by an adhesive (not shown). The adhesive may be an adhesive such as polyvinyl acetate (PVA) or ethylene vinyl acetate (EVA). In other examples, adhesives such as polysaccharide adhesives may be used. The adhesive may include, for example, guar gum, pectin, alginate, or a combination thereof. The alginate may include, for example, sodium alginate.

[0060] Figure 3 is a cross-sectional view of another example of laminate material 10 shown in Figure 1b. In this example, laminate material 10 comprises a first sheet (or layer) 11 and a second sheet (or layer) 12, as well as a third sheet (or layer) 13.

[0061] The sheets are configured such that second sheet 12 is disposed between first sheet 11 and third sheet 13. Third sheet 13 contains an aerosol-forming material, which may be the same as or different from the aerosol-forming material of first sheet 11. In this example, the aerosol-forming material of third sheet 13 is tobacco material.

[0062] The second sheet 12 is bonded to the first sheet 11 and the third sheet 13. In this example, the second sheet 12 is bonded to the first sheet 11 and the third sheet 13 by an adhesive (not shown) as described above.

[0063] 4a and 4b are cross-sectional side views of aerosol-generating components 1'a and 1'b, respectively, each comprising multiple strips of laminate material, and are used in articles for use with non-combustible aerosol delivery devices.

[0064] The aerosol-generating components 1'a and 1'b comprise multiple strips (or strands) 10, 10' of laminate material. The strips 10 of laminate material in Fig. 4a are shorter than the length of component 1'a. The strips 10 of laminate material in Fig. 4a are arranged in various orientations on component 1'a. The strips 10' of laminate material in Fig. 4b extend the entire length or substantially the entire length of component 1'b. The strips 10' of laminate material in Fig. 4b are arranged parallel or substantially parallel to the longitudinal axis (not shown) of component 1'b.

[0065] Each of the plurality of strips 10, 10' includes a first layer including an aerosol-forming material and a second layer including a heating material. The aerosol-forming material may be any of the aerosol-forming materials described herein, and the heating material may be any of the heating materials described herein. In this example, the aerosol-forming material is tobacco material, and the heating material is stainless steel foil. In another example, the heating material may be aluminum foil. The aerosol-forming material can be, for example, reconstituted tobacco material. The aerosol-forming material may include an aerosol-forming agent in an amount of 10% to 30% by weight of the aerosol-forming material, measured on a dry weight basis.

[0066] In this example, the first and second layers are secured together by an adhesive as described above with reference to Figures 2 and 3. When viewed in cross section, strips 10, 10' may have a structure similar to that shown and described with respect to Figures 2 and 3.

[0067] The strips of laminate material 10, 10' are surrounded by a wrapper 20. The wrapper 20 surrounds and thereby encases the strips of laminate material 10, 10'. This may help prevent separation of the strips of laminate material. The wrapper 20 may also help direct air and / or aerosols to the components 1'a, 1'b. The wrapper may be the same as the wrapper described above with respect to Figures 1a and 1b.

[0068] In this example, the aerosol-generation components 1'a, 1'b are substantially cylindrical and have a longitudinal axis (not shown).

[0069] The strip may have an aspect ratio of 1:1. In one embodiment, the strip is elongated, i.e., has an aspect ratio greater than 1:1. In some embodiments, the strip has an aspect ratio of about 1:5 to about 1:16, or about 1:5, 1:6, 1:7, 1:8, 1:9, 1:10, 1:11, or 1:12. When the aspect ratio is greater than 1:1, the strip has a longitudinal dimension or length extending between the first and second ends of the strip. In this example, the strip is rectangular in shape, but may be formed in other shapes.

[0070] The first dimension or cut width of the strip is from about 0.9 mm to about 2 mm. In one preferred embodiment, the cut width of the strip is from about 1 mm to about 1.5 mm.

[0071] The strips may be formed by shredding a sheet of laminate material. The sheet of laminate material may be cut widthwise, for example, in a cross-cut shredding process, defining the cut width as well as the cut length of the strip of laminate material. The cut length of the shredded laminate material is preferably at least 5 mm (e.g., at least 10 mm or at least 20 mm). The cut length of the shredded laminate material can be less than 60 mm, less than 50 mm, or less than 40 mm.

[0072] In some embodiments, at least one of the plurality of strips of laminate material has a length greater than approximately 10 mm. Alternatively or additionally, at least one of the plurality of strips of laminate material may have a length between approximately 10 mm and approximately 60 mm, or between approximately 20 mm and approximately 50 mm. Each of the plurality of strips of laminate material may have a length between approximately 10 mm and approximately 60 mm, or between approximately 20 mm and approximately 50 mm.

[0073] The sheet or chopped sheet of laminate material has a thickness of at least approximately 100 μm. The sheet or chopped sheet may have a thickness of at least approximately 120 μm, 140 μm, 160 μm, 180 μm, or 200 μm. In some embodiments, the sheet or chopped sheet has a thickness of from approximately 150 μm to approximately 300 μm, from approximately 151 μm to approximately 299 μm, from approximately 152 μm to approximately 298 μm, from approximately 153 μm to approximately 297 μm, from approximately 154 μm to approximately 296 μm, from approximately 155 μm to approximately 295 μm, from approximately 156 μm to approximately 294 μm, from approximately 157 μm to approximately 293 μm, from approximately 158 μm to approximately 292 μm, from approximately 159 μm to approximately 291 μm, or from approximately 160 μm to approximately 290 μm. In some embodiments, the sheet or shredded sheet has a thickness of from about 170 μm to about 280 μm, from about 180 μm to about 270 μm, from about 190 μm to about 260 μm, from about 200 μm to about 250 μm, or from about 210 μm to about 240 μm.

[0074] The thickness of the sheet or chopped sheet may vary between the first and second surfaces of the sheet. In some embodiments, the individual strips or pieces of laminate material have a minimum thickness of approximately 100 μm across their area. Optionally, the individual strips or pieces of laminate material have a minimum thickness of approximately 0.05 mm to approximately 0.1 mm across their area. Optionally, the individual strips, strands, or pieces of laminate material have a maximum thickness of approximately 1.0 mm across their area. Optionally, the individual strips or pieces of laminate material have a maximum thickness of approximately 0.5 mm to approximately 0.3 mm across their area.

[0075] Figure 4c is a plan view of an example of a sheet material that can be formed into a rod for use in an aerosol generation component, and Figure 4d is a cross-sectional side view of an aerosol generation component formed using the sheet material shown in Figure 4c.

[0076] The sheet material comprises a continuous sheet of aerosol-forming material (in this example, tobacco material). Disposed on the sheet of aerosol-forming material 11 is a strip of heating material 12 (in this example, aluminum foil). In this example, the strip of heating material 12 is in contact with the aerosol-forming material 11 but is not joined or adhered to the aerosol-forming material 11.

[0077] The sheet material of FIG. 4c can be corrugated and gathered into a rod, or cut into longitudinal strips, for example, to form a rod. When cut into strips and assembled into a rod, the strips of heating material 12 are dispersed throughout the aerosol-generating material 11, as shown in FIG. 4d. This provides good thermal contact between the aerosol-generating material 11 and the heating material 12, aiding in heat transfer from the heating material to the aerosol-generating material. The strips of heating material 12 are preferably disposed near the outer surface of the aerosol-generating component 1'c. This can aid in inductive heating of the heating material by the non-flammable aerosol delivery device during use.

[0078] 5 is a cross-sectional side view of an aerosol-generating component 1''. The aerosol-generating component is used in an article for use with a non-flammable aerosol delivery device.

[0079] The aerosol-generating component 1'' comprises a first plurality of strips (or strands) of aerosol-generating material 11 and a second plurality of strips (or strands) of heating material 12. The aerosol-generating material may be any of the aerosol-generating materials described herein, and the heating material may be any of the heating materials described herein. In this example, the aerosol-generating material is tobacco material and the heating material is stainless steel foil. In another example, the heating material may be aluminum foil.

[0080] The first strip 11 and the second strip 12 are surrounded by a wrapper 20. The wrapper 20 surrounds the first strip 11 and the second strip 12, thereby encasing the first strip 11 and the second strip 12. This may help prevent separation of the first strip 11 and the second strip 12. The wrapper 20 may also help guide air and / or aerosol into the component 1. The wrapper may be the same as the wrapper described above with respect to FIG. 1a.

[0081] In this example, the aerosol-generation component 1" is substantially cylindrical and has a longitudinal axis (not shown). The first strips 11 and second strips 12 are randomly oriented but substantially aligned with the longitudinal axis of the aerosol-generation component 1". In an alternative embodiment, the first strips 11 and second strips 12 can be provided similar to those shown in Figure 4b, with the strips 11, 12 extending parallel or substantially parallel to the longitudinal axis of the component 1" and each extending over the entire length or substantially the entire length of the component 1".

[0082] The first strip 11 is dispersed within the second strip 12. In other words, the first strip 11 and the second strip 12 are intermingled. This provides good thermal contact between the aerosol-forming material of the first strip 11 and the heating material of the second strip 12, aiding in the transfer of heat from the heating material to the aerosol-forming material.

[0083] The first strip 11 may have dimensions (e.g., length, width, thickness) similar to those described above with respect to the strip shown in Figures 4a and 4b, and therefore a detailed description of the dimensions of the first strip 11 will be omitted.

[0084] The second strip 12 may have a length and / or width similar to those described above with respect to the strip shown in Figures 4a and 4b, and therefore a detailed description of the length and / or width of the second strip will not be provided.

[0085] The second strips 12 may have a thickness of about 1 μm to about 150 μm (e.g., about 1 μm to about 100 μm or about 1 μm to about 50 μm). In this example, the second strips each have a thickness of about 7 μm. In other examples, the second strips may each have a thickness of 1 μm, 2 μm, 3 μm, 4 μm, 5 μm, 6 μm, 8 μm, 9 μm, or 10 μm.

[0086] FIG. 6a is a cross-sectional side view of an aerosol-generating component 1'''. FIG. 6b is a cross-sectional end view of the aerosol-generating component 1''' shown in FIG. 6a. The aerosol-generating component is used in an article for use with a non-combustible aerosol delivery device. Alternatively, the aerosol-generating component 1''' can be used directly in a non-combustible aerosol delivery device without being incorporated into an article.

[0087] The aerosol-generating component 1''' comprises a core portion 14 containing a first aerosol-generating material and a sheath portion 15 containing a second aerosol-generating material. The sheath portion 15 surrounds the core portion 14. In this example, the sheath portion 15 extends around the entire periphery of the core portion 14. In other examples, the sheath portion may extend around only a portion of the periphery of the core portion. In alternative examples, the core portion 14 can be omitted.

[0088] The first and second aerosol-generating materials may be any of the aerosol-generating materials described herein. In this example, the first and second aerosol-generating materials each include tobacco material. In some examples, the second aerosol-generating material may include a heating material (e.g., particles or strips of heating material dispersed within the second aerosol-generating material).

[0089] The characteristics of the first aerosol-generating material may be different from the characteristics of the second aerosol-generating material. The characteristics may be density, type, or flavor. For example, the first aerosol-generating material and the second aerosol-generating material may contain different flavors. Alternatively, only one of the first aerosol-generating material and the second aerosol-generating material may contain a flavor. If the first aerosol-generating material and the second aerosol-generating material contain tobacco material, they may contain different types of tobacco material. For example, the first aerosol-generating material may contain tobacco, such as laminar tobacco, while the second aerosol-generating material may contain a reconstituted tobacco sheet. For example, the first aerosol-generating material may contain cut rag tobacco formed using laminar tobacco material. The second aerosol-generating material may contain a reconstituted tobacco sheet in the form of a strip of aerosol-generating material, as described herein.

[0090] The aerosol-generating component 1''' further comprises a boundary material (in this example, an inner wrapper 16) surrounding the core portion 14. In this example, the boundary material extends around the entire periphery of the core portion 14. In other examples, the boundary material may extend only around a portion of the periphery of the core portion. The boundary material 16 defines a boundary between the core portion 14 and the sheath portion 15.

[0091] In this example, the aerosol-generating component 1''' further comprises an outer wrapper 20 that surrounds the core portion 14, the boundary material 16, and the sheath portion 15. The outer wrapper 20 surrounds and thereby encases the core portion 14, the boundary material 16, and the sheath portion 15. This may help to prevent separation of the core portion 14, the boundary material 16, and the sheath portion 15. The wrapper 20 may also help to guide air and / or aerosol into the component 1'''.

[0092] In this example, the aerosol-generation component 1''' is substantially cylindrical and has a substantially circular cross-section, as shown in Figure 6b. In other examples, the aerosol-generation component may have other cross-sections, such as an oval or elliptical cross-section. In some examples, the aerosol-generation component may have a rectangular, square, triangular, or star-shaped cross-section. In some examples, the aerosol-generation component may have an irregular cross-section.

[0093] In this example, the aerosol-generation component 1''' is elongated and has a longitudinal axis (not shown). The core portion 14, the boundary material 16, and the sheath portion 15 all extend substantially parallel to the longitudinal axis of the aerosol-generation component 1'''.

[0094] In some examples, the core portion 14 comprises a rod of a first aerosol-generating material and the sheath portion 15 comprises a sheet of a second aerosol-generating material. In this example, the core portion 14 comprises a rod of tobacco material and the sheath portion 15 comprises a sheet of tobacco material. In other examples, the core portion 14 may comprise a rod formed from one or more corrugated and collecting sheets, similar to the configurations described with reference to Figures 1a or 1b, where the first material comprises an aerosol-generating material. The sheath portion 15 may also be formed from one or more corrugated and collecting sheets, or from any of the strips described herein (e.g., including a strip of a second aerosol-generating material).

[0095] In some examples, the core portion 14 includes multiple strips of aerosol-generating material and / or heating material, and / or the sheath portion 15 includes multiple strips of aerosol-generating material and / or heating material, such as the relevant strips described with reference to Figures 4a, 4b, and 5. The interface material 16 can be used to simultaneously heat the core portion 14 and the sheath portion 15 by including a heating material as described herein. If the core portion 14 and the sheath portion 15 are comprised of aerosol-generating material (e.g., do not include any heating material), the interface material 16 can be the only heat source for the core portion 14 and the sheath portion 15. Alternatively, the core portion and / or the sheath portion can include a separate heating material in addition to the heating material included in the interface material.

[0096] In this example, interface material 16 contacts both the first aerosol-generating material and the second aerosol-generating material, which aids in heat transfer between the materials of the component''.

[0097] The core portion may be substantially cylindrical and have a diameter of about 2 mm to about 6 mm (e.g., about 3 mm to about 6 mm or about 4 mm to about 6 mm). In this example, the core portion 14 is substantially cylindrical with a diameter of about 5 mm. In other examples, the core portion 14 may have other cross-sectional shapes, such as an ellipse, an oval, a triangle, or a square. This may mean that the lateral dimensions of the core and sheath portions vary radially around each portion, aiding in more uniform aerosol generation during use by diversifying the exposure of the first and second aerosol-generating materials to heat.

[0098] The core and sheath portions may have approximately the same volume. For example, for a component with a diameter of approximately 7.3 mm, a core diameter of 5 mm would result in the core and sheath portions having approximately the same volume, meaning that these portions can be effectively heated via an interface material, such as a heating material as described herein. The core portion 14 may have an outer diameter that is approximately 65% ​​to 75% of the outer diameter of the sheath portion 15. The interface material may have a diameter at its maximum that is approximately 65% ​​to 75% of the maximum outer diameter of the sheath portion 15. In an alternative embodiment, the core diameter may be 6 mm to 7 mm, allowing the sheath portion to be made of, for example, a sheet material.

[0099] Alternatively, the core portion 14 may have an outer diameter that is approximately half the outer diameter of the sheath portion 15. The core portion 14 may have an outer diameter that is, for example, approximately 30% to approximately 70% of the outer diameter of the sheath portion 15, approximately 40% to approximately 60% of the outer diameter of the sheath portion 15, or approximately 45% to approximately 55% of the outer diameter of the sheath portion 15. The interface material may have a diameter at its largest diameter that is approximately 30% to approximately 70%, approximately 40% to approximately 60%, or approximately 45% to approximately 55% of the largest outer diameter of the sheath portion 15. The core portion 14 may include an aerosol-generating material that has a lower thermal conductivity than the sheath portion 15. This may mean that, for example, if the sheath portion 15 has a larger volume than the core portion 14, the heat distribution within the component 1''' during use will be more uniform overall.

[0100] The sheath may be substantially tubular and, if provided as a substantially single-thickness sheet of material, may have a thickness of about 100 μm to about 300 μm, or, if provided in other forms, may have a thickness of about 1 mm to about 5 mm. In this example, the sheath 13 is a sheet of aerosol-generating material that is about 200 μm thick.

[0101] The interface material 16 can have a thickness of approximately 1 μm to approximately 500 μm (e.g., approximately 50 μm to approximately 450 μm). In some examples, the thickness of the interface material is approximately 1 μm to approximately 150 μm or approximately 100 μm to approximately 400 μm. In this example, the interface material 16 is a sheet of material having a thickness of approximately 50 μm. In other examples, the interface material 16 is a sheet of material having a thickness of approximately 150 μm, approximately 200 μm, approximately 250 μm, approximately 300 μm, approximately 350 μm, approximately 400 μm, or approximately 450 μm. The interface material 16 can include a sheet of heating material (e.g., a ferromagnetic heating material). In this example, the interface material 16 is a continuous sheet of stainless steel foil. In other examples, the interface material 16 can be a sheet of aluminum foil or can be provided in other forms, such as a mesh formed by wires of heating material. The wires may have a diameter of, for example, about 50 μm to about 500 μm. Such a mesh can be provided with parallel wires extending laterally and longitudinally across the entire mesh, spaced about 0.3 mm to about 2 mm (e.g., about 0.5 mm to about 1.5 mm or about 1 mm). The mesh may be provided with a backing sheet material, such as paper, to which the mesh is adhered.

[0102] In some examples, interface material 16 may be a sheet of material including a plurality of openings extending through its thickness. For example, interface material 16 may be in the form of a perforated or porous sheet. This configuration may allow aerosols generated by the first aerosol-generating material and the second aerosol-generating material to mix within the component. In some examples, interface material 16 may include a plurality of embossments, pleats, perforations, or deformations.

[0103] The interface material 16 can be formed as a continuous tube of sheet material and / or heating material, which can be fed to a source of a second aerosol-generating material during the manufacture of component 1'". For example, the second aerosol-generating material can be multiple strips of aerosol-generating material, such as reconstituted tobacco material, and interface material 16 can be fed as a continuous tube to a continuous source of strips and then wrapped in outer wrapper 20. Interface material 16 can be supplied as an elongated sheet that is bent to form a tube and then seam-welded and / or mechanically and / or electrically connected in an "online" process shortly before inserting the tube into the second aerosol-generating material. The tube can be filled or partially filled with the first aerosol-generating material during this process (just before forming the tube from the elongated sheet of interface material) or once the process is complete and embedded in the second aerosol-generating material. Alternatively, the tube can remain hollow and form a boundary between the second aerosol-generating material and an internal cavity that extends through component 1'".

[0104] In some examples, the aerosol-generating component may include one or more airflow paths defined by the inner wrapper. The airflow paths may extend along the longitudinal axis of the aerosol-generating component and may allow air and / or aerosol to flow in a direction substantially parallel to the longitudinal axis of the aerosol-generating component.

[0105] In some examples, the interface material may have a pleated inner surface, as shown in Figure 6c. In this example, the inner surface of the interface material 16 includes a plurality of depressions (or grooves) 16a spaced circumferentially about the interface material 16. Each depression 16a forms a space between the inner surface of the interface material 16 and the outer surface of the core 14. Each of these spaces extends longitudinally to define an airflow path.

[0106] In some examples, the interface material 16 may have a pleated outer surface, as shown in Figure 6d. In this example, the outer surface of the interface material 16 includes a plurality of depressions (or grooves) 16b spaced circumferentially about the interface material 16. Each depression 16b defines a space between the outer surface of the interface material 16 and the inner surface of the sheath portion 15. Each of these spaces extends longitudinally to define an airflow path.

[0107] In some examples, the interface material 16 is a pleated sheet, such as a pleated sheet of heating material with aerosol-generating material on both the interior and exterior sides of the interface material 16, as shown in FIG. 6e, where the article 1''' includes this form of interface material 16. The pleats in this and other pleated sheet examples can help increase the surface area of ​​the interface material 16 in contact with the core 14 and sheath 15 (e.g., the aerosol-generating material of the core and / or sheath on the interior and / or exterior sides of the interface material 16). The pleats can also help provide structural strength to the interface material 16. The interface material can be a sheet of heating material or other sheet material, such as a plant-based material sheet, a tobacco material sheet, a sheet material containing an aerosol-forming agent, a sheet material containing a flavoring, a gelling sheet, or the like. In some examples, the pleated sheet material is a ferritic sheet material, such as a pleated ferritic stainless steel sheet having a thickness of about 20 μm to about 500 μm (e.g., about 40 μm to about 300 μm).

[0108] In some examples, interface material 16 may comprise multiple layers, one or more of which may have pleated surfaces to form longitudinally extending spaces within interface material 16. Each of these spaces defines an airflow path within the interface material.

[0109] FIG. 7 is a cross-sectional side view of an article 100 for use with a non-flammable aerosol delivery device.

[0110] Article 100 comprises a mouthpiece 102 and an aerosol-generating unit connected to mouthpiece 102. In this example, the aerosol-generating unit comprises an aerosol-generating component 103, which may be any of the aerosol-generating components described herein. In this example, aerosol-generating component 103 comprises a wrapper 103a.

[0111] In some examples, the article may include carbon chips (not shown) that can provide heat to the aerosol-generating component through combustion. When the article is inserted into a non-combustible aerosol-delivery device, the carbon chips may be ignited by heating from a heater in the non-combustible aerosol-delivery device. In such articles, the heating material of the aerosol-generating component (e.g., aluminum foil or stainless steel foil) may help distribute heat from the carbon chips throughout the aerosol-generating material of the aerosol-generating component. Additionally, such articles may be inserted into non-combustible aerosol-delivery devices that include a configuration such as an induction coil that creates a varying magnetic field; in this case, the heating material acts as a susceptor, and heating from the carbon chips is not necessary.

[0112] Tipping paper 105 is wrapped around the entire length of mouthpiece 102 and part of aerosol-generating component 103, with adhesive provided on its inner surface to connect mouthpiece 102 and aerosol-generating component 103. In this example, aerosol-generating component 103 has a wrapper 103a that forms a first wrapping material, and tipping paper 105 forms an outer wrapping material that extends at least partially over aerosol-generating component 103 to connect mouthpiece 102 and aerosol-generating component 103. In some examples, the tipping paper can be stretched only partially over aerosol-generating component 103.

[0113] In this example, the tipping paper 105 extends 5 mm over the aerosol-generating component 103; alternatively, it may extend 3 mm to 10 mm, more preferably 4 mm to 6 mm, over the aerosol-generating component 103 to securely connect the mouthpiece 2 and the aerosol-generating component 103. The tipping paper may have a basis weight of greater than 20 gsm (e.g., greater than 25 gsm), preferably greater than 30 gsm (e.g., 37 gsm). These basis weight ranges have been found to provide acceptable tensile strength while remaining flexible enough to wrap around the article 100 and adhere to itself along its longitudinal seam. In this example, the circumference of the tipping paper 105 wrapped around the mouthpiece 102 is approximately 23 mm.

[0114] The mouthpiece 102 comprises a cooling section 108, also referred to as a cooling element, positioned immediately downstream of and adjacent to the aerosol generation component 103. In this example, the cooling section 108 is adjacent to the aerosol generation component 103. In this example, the mouthpiece 102 also comprises a body of material 106 downstream of the cooling section 108 and a hollow tubular element 104 downstream of the body of material 106 at the mouth end of the article 100.

[0115] The cooling section 108 comprises a hollow channel having an inner diameter of approximately 1 mm to approximately 4 mm (e.g., approximately 2 mm to approximately 4 mm). In this example, the inner channel has an inner diameter of approximately 3 mm. The hollow channel extends along the entire length of the cooling section 108. In this example, the cooling section 108 comprises a single hollow channel. In alternative embodiments, the cooling section may comprise multiple channels (e.g., two, three, or four channels). In this example, the single hollow channel is substantially cylindrical, although other channel shapes / cross-sections may be used in alternative embodiments. The hollow channel may provide space in which aerosol entrained in the cooling section 108 may be cooled by expansion. In all embodiments, the cooling section is configured to restrict the cross-sectional area of ​​the hollow channel / channels, thereby restricting the movement of tobacco into the cooling section in use.

[0116] The cooling portion 108 preferably has a radial wall thickness that can be measured, for example, with a caliper. The wall thickness of the cooling portion 108 defines the inner diameter of the cavity enclosed by the walls of the cooling portion 108 for a given outer diameter of the cooling portion. The cooling portion 108 may have a wall thickness of at least approximately 1.5 mm and at most approximately 2 mm. In this example, the cooling portion 108 has a wall thickness of approximately 1.5 mm.

[0117] Cooling region 108 is formed from filamentary tow. Other configurations may be used, such as multiple parallel paper layers wound seam-to-seam to form cooling region 108, or spirally wound paper layers, cardboard tubes, tubes formed by a paper mache process, molded or extruded plastic tubes, etc. Cooling region 108 is manufactured to be sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacturing and use of article 100.

[0118] The wall material of the cooling section 108 may be relatively non-porous, such that at least 90% of the aerosol generated by the aerosol-generation component 103 passes longitudinally through the one or more hollow channels rather than through the wall material of the cooling section 108. For example, at least 92% or at least 95% of the aerosol generated by the aerosol-generation component 103 may pass longitudinally through the one or more hollow channels.

[0119] The filamentous tows making up the cooling section 108 preferably have a total fineness of less than 45,000, more preferably less than 42,000. This total fineness has been found to produce a cooling section 108 that is not too dense. The total fineness is preferably at least 20,000, more preferably at least 25,000. In a preferred embodiment, the filamentous tows making up the cooling section 108 have a total fineness of 25,000 to 45,000, more preferably 35,000 to 45,000. The cross-sectional shape of the filaments of the tow is preferably "Y" shaped, although other shapes, such as "X" shaped filaments, can be used in other embodiments.

[0120] The filamentary tows making up the cooling section 108 preferably have a fineness per filament greater than 3. It has been found that this fineness per filament allows for the formation of tubular elements 104 that are not too dense. The fineness per filament is at least 4, more preferably at least 5. In a preferred embodiment, the filamentary tows making up the hollow tubular elements 104 have a fineness per filament between 4 and 10, more preferably between 4 and 9. In one example, the filamentary tows making up the cooling section 108 are made from cellulose acetate and have an 8Y40,000 tow containing 18% plasticizer (e.g., triacetin).

[0121] The density of the material comprising the cooling region 108 is preferably at least approximately 0.20 grams per cubic centimeter (g / cc), and more preferably at least approximately 0.25 g / cc. The density of the material comprising the cooling region 108 is preferably less than approximately 0.80 grams per cubic centimeter (g / cc), and more preferably less than 0.6 g / cc. In some embodiments, the density of the material comprising the cooling region 108 is between 0.20 and 0.8 g / cc, more preferably between 0.3 and 0.6 g / cc, 0.4 and 0.6 g / cc, or 0.5 g / cc. These densities provide a good balance between the increased stiffness provided by a higher density material and minimizing the overall weight of the article. For purposes of this invention, the "density" of the material comprising the cooling region 108 refers to the density of any filamentary tow comprising the element, including any plasticizers incorporated therein. The density can be determined by dividing the total weight of the material comprising the cooling region 108 by the total volume of the material comprising the cooling region 108, which can be calculated using appropriate measurements of the material comprising the cooling region 108, for example, obtained with a caliper. If desired, appropriate dimensions can be measured with a microscope.

[0122] Preferably, the length of the cooling section 108 is less than approximately 30 mm. More preferably, the length of the cooling section 108 is less than approximately 25 mm. Even more preferably, the length of the cooling section 108 is less than approximately 20 mm. Additionally or alternatively, the length of the cooling section 108 is preferably at least approximately 10 mm. Preferably, the length of the cooling section 108 is at least approximately 15 mm. In some preferred embodiments, the length of the cooling section 108 is between approximately 15 mm and approximately 20 mm, more preferably between approximately 16 mm and approximately 19 mm. In this example, the length of the cooling section 108 is 19 mm.

[0123] The cooling portion 108 is disposed around and defines a cavity within the mouthpiece 102 that it serves as a cooling portion. The cavity provides a chamber through which heated volatile components generated by the aerosol-generating component 103 flow. The cooling portion 108 is hollow and provides an aerosol accumulation chamber that is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and use of the article 100. The cooling portion 108 provides a physical displacement between the aerosol-generating material 103 and the body of material 106. The physical displacement provided by the cooling portion 108 may result in a thermal gradient across the length of the cooling portion 108.

[0124] The mouthpiece 102 has an internal volume of 110 mm 3 Preferably, the mouthpiece 102 includes a larger cavity. It has been found that providing a cavity of at least this volume allows for improved aerosol formation. More preferably, the mouthpiece 102 has an internal volume of 110 mm. 3 More than 130mm, preferably 3 Further improvements in aerosolization can be achieved by including a cavity larger than 130 mm (e.g., a cavity formed within the cooling section 108). In some examples, the internal cavity is approximately 130 mm. 3 ~approximately 230mm 3 (For example, approximately 134 mm 3 or 227 mm 3 ) volume.

[0125] Cooling section 108 can be configured to provide a temperature difference of at least 40° C. between the heated volatile components entering the first upstream end of cooling section 108 and the heated volatile components exiting the second downstream end of cooling section 108. Cooling section 108 is preferably configured to provide a temperature difference of at least 60° C., more preferably at least 80° C., and even more preferably at least 100° C. between the heated volatile components entering the first upstream end of cooling section 108 and the heated volatile components exiting the second downstream end of cooling section 108. This temperature difference across the length of cooling section 108 protects temperature-sensitive body of material 106 from the high temperatures of aerosol-generating material 103 when heated.

[0126] The body of material 106 and the hollow tubular element 104 each define a substantially cylindrical overall outer shape and share a common longitudinal axis. The body of material 106 is wrapped in a first plug wrap 107. The first plug wrap 107 preferably has a basis weight of less than 50 gsm, more preferably between approximately 20 gsm and 40 gsm. The first plug wrap 107 preferably has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. In some examples, the first plug wrap 107 is non-porous (e.g., has an air permeability of less than 100 Coresta units, e.g., less than 50 Coresta units). However, in other embodiments, the first plug wrap 107 can be porous (e.g., has an air permeability of greater than 200 Coresta units).

[0127] Preferably, the length of the body of material 106 is less than approximately 15 mm. More preferably, the length of the body of material 106 is less than approximately 12 mm. Additionally or alternatively, the length of the body of material 106 is at least approximately 5 mm. Preferably, the length of the body of material 106 is at least approximately 8 mm. In some preferred embodiments, the length of the body of material 106 is between approximately 5 mm and approximately 15 mm, more preferably between approximately 6 mm and approximately 12 mm, even more preferably between approximately 6 mm and approximately 12 mm, and most preferably between approximately 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. In this example, the length of the body of material 106 is 10 mm.

[0128] In this example, the body of material 106 is formed from filamentary tow. In this example, the tow used in the body of material 106 has a fineness per filament (dpf) of 5 and a total fineness of 25,000. In this example, the tow may include plasticized cellulose acetate tow. The plasticizer used in the tow constitutes approximately 9% by weight of the tow. In this example, the plasticizer is triacetin. In other examples, different materials can be used to form the body of material 106. For example, rather than tow, the body 106 can be formed from paper, similar to paper filters known for use in cigarettes. For example, a cellulose-based material such as paper can be provided as one or more portions of a sheet material that is folded and / or corrugated to form the body 106. The sheet material can have a basis weight of 15 gsm to 60 gsm (e.g., 20 gsm to 50 gsm). The sheet material may have a basis weight ranging from, for example, 15 to 25 gsm, 25 to 30 gsm, 30 to 40 gsm, 40 to 45 gsm, and 45 to 50 gsm. Additionally or alternatively, the sheet material may have a width ranging from 50 mm to 200 mm (e.g., 60 mm to 150 mm or 80 mm to 150 mm). For example, the sheet material may have a basis weight of 20 to 50 gsm and a width of 80 mm to 150 mm. This may allow, for example, the cellulose-based body to have an appropriate pressure drop for an article having dimensions as described herein.

[0129] Alternatively, the body 106 can be formed from a tow other than cellulose acetate (e.g., polylactic acid (PLA), other materials described herein for filamentary 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. To achieve a sufficiently uniform body 106 of material, the tow preferably has a fineness per filament of 12 d.pf or less, preferably 11 d.pf or less, and more preferably 10 d.pf or less.

[0130] The tow comprising the body of material 106 preferably has a total fineness of up to 30,000, more preferably up to 28,000, and even more preferably up to 25,000. These total fineness values ​​result in a tow that occupies a reduced percentage of the cross-sectional area of ​​the mouthpiece 102, thereby reducing the pressure drop across the mouthpiece 102 compared to tows with higher total fineness values. To provide the body of material 106 with an appropriate stiffness, the tow preferably has a total fineness of at least 8,000, more preferably at least 10,000. The fineness per filament is preferably between 5 and 12, while the total fineness is preferably between 10,000 and 25,000. The cross-sectional shape of the filaments of the tow is preferably "Y" shaped, although in other embodiments, other shapes, such as "X" shaped filaments, can be used with the same dpf and total fineness values ​​described herein.

[0131] Regardless of the material used to construct body 106, the pressure drop across body 106 can be, for example, 0.3-5 mmWG / mm per length of body 106 (e.g., 0.5-2 mmWG / mm per length of body 106). The pressure drop can be, for example, 0.5-1 mmWG / mm per length, 1-1.5 mmWG / mm per length, or 1.5-2 mmWG / mm per length. The total pressure drop across body 106 can be, for example, 3-8 mmWG or 4-7 mmWG. The total pressure drop across body 106 can be approximately 5, 6, or 7 mmWG.

[0132] As shown in Figure 7, the mouthpiece 102 of the article 100 has an upstream end 102a adjacent the aerosol-generation component 103 and a downstream end 102b distal from the aerosol-generation component 103. At the downstream end 102b, the mouthpiece 102 has a hollow tubular element 104 formed from filamentary tow. This has been found to be advantageous because it significantly reduces the temperature of the outer surface of the mouthpiece 102 at the downstream end 102b, which contacts the consumer's mouth when the article 100 is in use. It has also been found that the use of the tubular element 104 significantly reduces the temperature of the outer surface of the mouthpiece 102 upstream of the tubular element 104. Without being bound by theory, it is hypothesized that this is because the tubular element 104 moves the aerosol closer to the center of the mouthpiece 102, thereby reducing heat transfer from the aerosol to the outer surface of the mouthpiece 102.

[0133] The "wall thickness" of the hollow tubular element 104 corresponds to the thickness of the wall of the tube 104 in the radial direction. This may be measured, for example, using a caliper. The wall thickness is advantageously greater than 0.9 mm, and more preferably 1.0 mm or greater. The wall thickness is preferably substantially constant around the entire wall of the hollow tubular element 104. However, if the wall thickness is not substantially constant, it is preferably greater than 0.9 mm, and more preferably 1.0 mm or greater, at any point around the hollow tubular element 104. In this example, the wall thickness of the hollow tubular element 104 is approximately 1.3 mm.

[0134] Preferably, the length of the hollow tubular element 104 is less than approximately 20 mm. More preferably, the length of the hollow tubular element 104 is less than approximately 15 mm. Even more preferably, the length of the hollow tubular element 104 is less than approximately 10 mm. Additionally or alternatively, the length of the hollow tubular element 104 is at least approximately 5 mm. Preferably, the length of the hollow tubular element 104 is at least approximately 6 mm. In some preferred embodiments, the length of the hollow tubular element 104 is between approximately 5 mm and approximately 20 mm, more preferably between approximately 6 mm and approximately 10 mm, even more preferably between approximately 6 mm and approximately 8 mm, and most preferably approximately 6 mm, 7 mm, or approximately 8 mm. In this example, the length of the hollow tubular element 104 is 7 mm.

[0135] The density of the hollow tubular element 104 is preferably at least approximately 0.25 grams per cubic centimeter (g / cc), and more preferably at least approximately 0.3 g / cc. The density of the hollow tubular element 104 is preferably less than approximately 0.75 grams per cubic centimeter (g / cc), and more preferably 0.6 g / cc. In some embodiments, the density of the hollow tubular element 104 is between 0.25 and 0.75 g / cc, more preferably between 0.3 and 0.6 g / cc, and even more preferably between 0.4 and 0.6 g / cc or 0.5 g / cc. These densities provide a good balance between the increased stiffness of a higher density material and the lower heat transfer characteristics of a lower density material. For purposes of this invention, the "density" of the hollow tubular element 104 refers to the density of the filamentary tow comprising the element, including any plasticizers incorporated therein. The density can be determined by dividing the total weight of the hollow tubular element 104 by the total volume of the hollow tubular element 104, which can be calculated using appropriate measurements of the hollow tubular element 104, for example, taken with a caliper. If necessary, appropriate dimensions can be measured with a microscope.

[0136] The filamentary tows making up the hollow tubular element 104 preferably have a total fineness of less than 45,000, more preferably less than 42,000. This total fineness has been found to allow for the formation of a tubular element 104 that is not very dense. The total fineness is at least 20,000, more preferably at least 25,000. In a preferred embodiment, the filamentary tows making up the hollow tubular element 104 have a total fineness of 25,000 to 45,000, more preferably 35,000 to 45,000. The cross-sectional shape of the filaments in the tow is preferably "Y" shaped, although other shapes, such as "X" shaped filaments, can be used in other embodiments.

[0137] The filamentary tows making up the hollow tubular elements 104 preferably have a fineness per filament greater than 3. This fineness per filament has been found to allow for the formation of tubular elements 4 that are not too dense. The fineness per filament is preferably at least 4, more preferably at least 5. In a preferred embodiment, the filamentary tows making up the hollow tubular elements 104 have a fineness per filament between 4 and 10, more preferably between 4 and 9. In one example, the filamentary tows making up the hollow tubular elements 104 are made from cellulose acetate and have a 7.3Y36,000 tow containing 18% plasticizer (e.g., triacetin).

[0138] Preferably, hollow tubular element 104 has an inner diameter greater than 3.0 mm. Smaller diameters unnecessarily increase the velocity of the aerosol passing through mouthpiece 102 and into the consumer's mouth, potentially causing the aerosol to heat up too much, for example, reaching temperatures greater than 40° C. or 45° C. More preferably, hollow tubular element 104 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, hollow tubular element 104 has an inner diameter of approximately 4.7 mm.

[0139] Preferably, hollow tubular element 104 comprises 15% to 22% by weight of plasticizer. For cellulose acetate tow, the plasticizer is preferably triacetin, although other plasticizers, such as polyethylene glycol (PEG), can also be used. More preferably, hollow tubular element 104 comprises 16% to 20% by weight of plasticizer (e.g., approximately 17%, approximately 18%, or approximately 19% plasticizer).

[0140] In this example, the first hollow tubular element 104, the body of material 106, and the second hollow tubular element 108 are joined by a second plug wrap 109 that is wrapped around all three sections. The second plug wrap 109 preferably has a basis weight of less than 50 gsm, more preferably between approximately 20 gsm and 45 gsm. The second plug wrap 109 preferably has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The second plug wrap 109 is preferably a non-porous plug wrap having an air permeability of less than 100 Coresta units (e.g., less than 50 Coresta units). However, in alternative embodiments, the second plug wrap 109 can be a porous plug wrap (e.g., having an air permeability of greater than 200 Coresta units).

[0141] In this example, the article 100 has a circumference of approximately 23 mm. In other examples, the article can be provided in any of the forms described herein (e.g., a circumference of 20 mm to 26 mm). By using an article with a smaller circumference within this range (e.g., a circumference less than 23 mm) to heat the article and release the aerosol, heating efficiency can be improved. It has also been found that articles with circumferences greater than 19 mm are particularly effective for achieving improved aerosol delivery upon heating while maintaining a suitable product length. It has been found that articles with circumferences of 20 mm to 24 mm, more preferably 20 mm to 23 mm, provide a good balance between efficient heating and effective aerosol delivery. The length of the aerosol-generating component 103 is preferably less than approximately 25 mm, more preferably less than approximately 20 mm, and even more preferably less than approximately 15 mm. In this example, the aerosol-generating component 103 is approximately 12 mm in length.

[0142] The article has a ventilation level such that approximately 10% of the aerosol is drawn through the article. In an alternative embodiment, the article may have a ventilation level such that 1% to 20% (e.g., 1% to 12%) of the aerosol is drawn through the article. These levels of ventilation help to improve the consistency of the aerosol inhaled by the user at the mouth end 102b while also aiding in the aerosol cooling process. This ventilation is provided directly to the mouthpiece 102 of the article 100. In this example, this ventilation is provided to the cooling section 108, which has been found to be particularly beneficial in facilitating the aerosol generation process. This ventilation is provided by perforations 112, formed in this example as a single row of laser perforations located 13 mm downstream from the mouth end 102b of the mouthpiece 102. In an alternative embodiment, more than one row of ventilation perforations may be provided. These perforations pass through the tipping paper 105, the second plug wrap 109, and the cooling section 108. In alternative embodiments, this ventilation can be provided elsewhere in the mouthpiece (e.g., in the body of material 106 or the first tubular element 104). The article 100 is preferably configured so that the perforations are located approximately 28 mm or less from the upstream end of the article, preferably between 20 mm and 28 mm from the upstream end of the article. In this example, the openings are located approximately 25 mm from the upstream end of the article.

[0143] 8 is a schematic cross-sectional side view of an example system according to one embodiment of the present invention. System 1000 includes article 100 and non-combustible aerosol delivery device 200. In this example, article 100 is the article shown in FIG. 7. In other examples, article 100 may include any one of the aerosol-generating components described herein.

[0144] Non-combustible aerosol delivery device 200 includes a body 210 and a heating zone 211 that receives item 100. Non-combustible aerosol delivery device 200 also includes a magnetic field generator 212 configured to generate a varying magnetic field that penetrates the heating material of item 100 when item 100 is placed in heating zone 211.

[0145] Device 200 may include an air inlet (not shown) fluidly connecting heating zone 211 with the exterior of device 200. Such air inlet may be defined by body 210. A user may inhale an aerosol generated by the aerosol-generating material of article 100 by drawing the aerosol through mouthpiece 102 of article 100. Once the aerosol is removed from article 100, air may be drawn into heating zone 211 via the air inlet of device 200.

[0146] In this example, the body 210 includes a heating zone 211. In this example, the heating zone 211 includes a recess that receives at least a portion of the article 100. In other examples, the heating zone 211 may be a shelf, a surface, or a protrusion, and may require mechanical engagement with the article to cooperate with or receive the article. In this example, the heating zone 211 is elongated and sized and shaped to receive a portion of the article 100. In other examples, the heating zone 211 may be sized to receive the entire article.

[0147] In this example, the magnetic field generator 212 comprises a power source 213, a coil 214, a device 216 for passing a varying current, such as an alternating current, through the coil 214, a controller 217, and a user interface 218 for user operation of the controller 217.

[0148] In this example, power source 213 is a rechargeable battery. In other examples, power source 213 may be another non-rechargeable battery, a capacitor, a battery-capacitor hybrid, or a connection to a mains power source.

[0149] The coil 214 may have any suitable configuration. In this example, the coil 214 is a helical coil of a conductive material, such as copper. In some examples, the magnetic field generator 212 may include a magnetically permeable core around which the coil 214 is wound. Such a magnetically permeable core concentrates the magnetic flux generated by the coil 214 during use, producing a stronger magnetic field. The magnetically permeable core may be composed of, for example, iron. In some examples, the magnetically permeable core may extend only partially along the length of the coil 214, concentrating the magnetic flux in a particular area. In some examples, the coil may be a flat coil. That is, the coil may be a two-dimensional spiral. In this example, the coil 214 surrounds the heating zone 211. The coil 214 extends along a longitudinal axis that is substantially aligned with the longitudinal axis of the heating zone 211. The aligned axes are coincident. In other examples, the aligned axes may be parallel or oblique to each other.

[0150] In this example, device 216, which passes a varying current through coil 214, is electrically connected between power source 213 and coil 214. Also in this example, controller 217 is electrically connected to power source 213 and communicatively connected to device 216 to control device 216. More specifically, in this example, controller 217 is configured to control device 216, thereby controlling the supply of power from power source 213 to coil 214. In this example, controller 217 comprises an integrated circuit (IC), such as an IC on a printed circuit board (PCB). In other examples, controller 217 may take a different form. In some examples, the non-flammable aerosol delivery device may have only one electrical or electronic component, including device 216 and controller 217.

[0151] In this example, controller 217 is operated by user operation of user interface 218. In this example, user interface 218 is located on the exterior of main body 210. User interface 218 may include push buttons, toggle switches, dials, a touch screen, or the like. In other examples, a user interface may be provided that is separate from the non-combustible aerosol delivery device. Such a user interface may be connected to the non-combustible aerosol delivery device using a wireless communication method such as Bluetooth. For example, such a user interface may be implemented as part of a mobile electronic device such as a mobile phone that can communicate with the non-combustible aerosol delivery device using a wireless communication method such as Bluetooth. A user may be able to remotely control the non-combustible aerosol delivery device using the user interface of their mobile phone.

[0152] In this example, user operation of user interface 218 causes controller 217 to cause device 216 to pass an alternating current through coil 214, which in turn generates an alternating magnetic field. Coil 214 and heating zone 211 of non-burning aerosol delivery device 200 are suitably positioned relative to one another such that when item 100 is placed in heating zone 211, the varying magnetic field generated by coil 214 penetrates the heated material of item 100. In this example, the varying magnetic field generated by coil 214 penetrates the heated material of aerosol generation component 103.

[0153] In some examples, the heating material of the article is a conductive material, such as aluminum foil. In such examples, when a magnetic field penetrates the heating material, one or more eddy currents are generated in the heating material. The flow of eddy currents in the heating material relative to the electrical resistance of the heating material causes the heating material to heat by Joule heating. In some examples, the heating material is a magnetic material, such as ferromagnetic stainless steel (e.g., type 430 stainless steel). In such examples, heat is generated in the heating material because the orientation of magnetic dipoles in the heating material changes with the applied, varying magnetic field.

[0154] Non-combustible aerosol delivery device 200 includes a temperature sensor 219 configured to sense the temperature of heated zone 211. Temperature sensor 219 is communicatively coupled to controller 217 so that controller 217 can monitor the temperature of heated zone 211. Based on one or more signals received from temperature sensor 219, controller 217 may cause device 216 to adjust the characteristics of the fluctuating or alternating current passing through coil 214 as needed to maintain the temperature of heated zone 211 within a predetermined temperature range. This characteristic may be, for example, amplitude, frequency, or duty cycle. When used within the predetermined temperature range, sufficient heating of the aerosol-generating material within an item placed in heated zone 211 volatilizes at least one component of the aerosol-generating material without combustion of the aerosol-generating material. Thus, controller 217 (and device 200 as a whole) is configured to volatilize at least one component of the aerosol-generating material by heating the aerosol-generating material without combustion of the aerosol-generating material. In some embodiments, the temperature range is from about 50°C to about 300°C, such as from about 50°C to about 250°C, from about 50°C to about 150°C, from about 50°C to about 120°C, from about 50°C to about 100°C, from about 50°C to about 80°C, or from about 60°C to about 70°C. In some embodiments, the temperature range is from about 170°C to about 220°C. In other embodiments, the temperature range may be outside of this range. In some embodiments, the upper limit of the temperature range may be greater than 300°C. In some embodiments, the temperature sensor 219 may be omitted. In some embodiments, the heating material may have a Curie point temperature selected based on the highest temperature to which it is desired to heat the heating material, and further heating beyond that temperature by induction heating of the heating material is inhibited or prevented.

[0155] Also provided herein is a method of manufacturing an aerosol-generating component for use with a non-flammable aerosol delivery device. The method, shown in Figure 8, includes the steps of providing a first sheet (S101) containing an aerosol-generating material, providing a second sheet (S102) containing a heating material, and encasing the first and second sheets in a wrapper (S103). The wrapper comprises paper and has a permeability of less than 500 Coresta units.

[0156] Also provided herein is a method of manufacturing an aerosol-generating component for use with a non-flammable aerosol delivery device. The method, shown in Figure 9, includes forming a sheet of laminate material (S201), the sheet having a first layer including an aerosol-generating material and a second layer including a heating material, and slitting the sheet (S202) to form a plurality of strips of laminate material. Each of the plurality of strips includes a first layer including an aerosol-generating material and a second layer including a heating material.

[0157] Also provided herein is a method of manufacturing an aerosol-generating component for use with a non-combustible aerosol delivery device, shown in Figure 10, which includes chopping a first sheet of aerosol-generating material to form a first plurality of strips (S301) and chopping a second sheet of heating material to form a second plurality of strips (S302).

[0158] Also provided herein is a method for manufacturing an aerosol-generating component for use with a non-burning aerosol delivery device. This method, illustrated in FIG. 11 , includes providing a core portion containing a first aerosol-generating material (S401), disposing a boundary material around the core portion (S402), and disposing a sheath portion containing a second aerosol-generating material around the core portion (S402). The boundary material is disposed between the core portion and the sheath portion. As previously described, boundary material 16 can be formed as a continuous tube of sheet material and / or heating material, and can be continuously wrapped around the core portion in step S401, for example, during the manufacture of component 1'''. The second aerosol-generating material can be multiple strips of aerosol-generating material, such as reconstituted tobacco material, and boundary material 16 and optional core portion 14 can be supplied as a continuous tube from a continuous supply of strips and then wrapped in outer wrapper 20 (S402). The interface material 16 can be supplied as an elongated sheet that is bent to form a tube and then seam-welded and / or mechanically and / or electrically connected in an "online" process shortly before inserting the tube into the second aerosol-generating material. The tube can be filled or partially filled with the first aerosol-generating material during this process (just before forming the tube from the elongated sheet of interface material) or once the process is complete and embedded in the second aerosol-generating material. Alternatively, the tube can remain hollow and form a boundary between the second aerosol-generating material and an internal cavity that extends through component 1'".

[0159] Articles (e.g., rod-shaped) are often named according to the length of the product ("regular" (usually in the 68-75 mm range (e.g., about 68 mm to about 72 mm)), "short" or "mini" (68 mm or less), "king size" (usually in the 75-91 mm range (e.g., about 79 mm to about 88 mm)), "long" or "super king" (usually in the 91-105 mm range (e.g., about 94 mm to about 101 mm)), and "ultra long ...110 mm to about 121 mm range)).

[0160] These are also named according to the circumference of the product: "regular" (approximately 23-25mm), "wide" (over 25mm), "slim" (approximately 22-23mm), "demi-slim" (approximately 19-22mm), "super slim" (approximately 16-19mm), and "micro slim" (approximately less than 16mm).

[0161] Thus, a king size super slim item would, for example, be approximately 83mm in length and approximately 17mm in circumference.

[0162] Each mold may be produced with a mouthpiece of a different length. The mouthpiece length will be approximately 30 mm to 50 mm. The tipping paper connects the mouthpiece to the aerosol-generating material and will typically have a length greater than the mouthpiece (e.g., 3 to 10 mm longer) so as to cover the mouthpiece and overlap the aerosol-generating material (e.g., in the form of a rod of substrate material) to connect the mouthpiece to the rod.

[0163] The articles and their respective aerosol-forming materials and mouthpieces described herein can be configured in any of the above types, without being limited to these.

[0164] In some embodiments, the substance being delivered may be an aerosol-generating material or a material not subject to aerosolization, either of which may optionally include one or more active ingredients, one or more flavoring agents, one or more aerosol-forming materials, and / or one or more other functional materials.

[0165] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to apply thermal energy to the aerosol-generating material to release one or more volatile substances from the aerosol-generating material and form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to apply one or more of vibrational, high pressure, or electrostatic energy to the aerosol-generating material.

[0166] 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 in the form of, for example, 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 capable of retaining some fluid, such as a liquid, within it. In some embodiments, the aerosol-generating material may comprise, for example, approximately 50 wt%, 60 wt%, or 70 wt% to approximately 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0167] The aerosol-generating material may include one or more active agents and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0168] The aerosol-forming material may include one or more constituents 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 sulfate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The total amount of aerosol-forming material provided can range from 10% to 30% (e.g., 12% to 22%) by weight of the aerosol-generating material, such as tobacco material.

[0169] The one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0170] The material may be on or in a support to form a substrate. The support may be or include, for example, paper, cardboard, paperboard, cardboard, recycled material, plastic material, ceramic material, composite material, glass, metal, or alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or both sides of the material.

[0171] Aerosol modifiers are substances typically located downstream of the aerosol-generation area and configured to modify the generated aerosol, for example by altering the taste, flavor, acidity, or another characteristic of the aerosol. The aerosol modifier may be provided in an aerosol modifier-releasing component operable to selectively release the aerosol modifier.

[0172] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavoring, a coloring, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, a string, or a granule. The aerosol modifier may not have a filter material.

[0173] As used herein, the term "tobacco material" refers to any material containing tobacco or its derivatives or substitutes. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Tobacco materials include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco lamina, reconstituted tobacco, and / or tobacco extract.

[0174] In some embodiments, the substance to be delivered comprises an active agent.

[0175] As used herein, an active substance may be a physiologically active material (a material intended to produce or enhance a physiological response). The active substance may be selected from, for example, a dietary supplement, a psychotropic drug, or a psychoactive agent. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may include one or more constituents, derivatives, or extracts of tobacco or another plant.

[0176] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0177] As described herein, the active agent may include or be derived from one or more botanical substances or constituents, derivatives, or extracts thereof. As used herein, the term "botanical" may include any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, pods, etc. Alternatively, the material may include active compounds naturally occurring in plants or synthetically obtained. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, chips, strips, sheets, etc. Exemplary plants include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice, matcha, yerba mate, orange skin, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, Saffron, lavender, lemon peel, mint, juniper, elderberry, vanilla, wintergreen, sedge, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiene, marjoram, olive, lemon balm, lemon basil, chives, kalbi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint can be selected from 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.

[0178] In some embodiments, the active agent comprises or is derived from one or more plant substances or constituents, derivatives or extracts thereof, and the plant is tobacco.

[0179] In some embodiments, the active agent comprises or is derived from one or more botanical substances or constituents, derivatives or extracts thereof, the plants being selected from eucalyptus, star anise, cocoa, and hemp.

[0180] In some embodiments, the active agent comprises or is derived from one or more botanical substances or constituents, derivatives or extracts thereof, and the plant is selected from rooibos and fennel.

[0181] In some embodiments, the substance to be delivered comprises a fragrance.

[0182] As used herein, the terms "flavor" and "flavorant" refer to materials that can be used, where local regulations permit, to produce a desired flavor, aroma, or other sensory experience in products intended for adult consumers.These include naturally occurring flavoring materials, botanicals, plant extracts, synthetically derived materials, or combinations thereof (e.g., tobacco, hemp, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, peppermint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, etc.). Roots, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang Orchid, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil of any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, yerba mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderberry, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, sedge, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, Damier Ingredients include but are not limited to: citric acid, citric acid, citric acid salts, citric acid derivative ...They may be imitation, synthetic or natural ingredients, or a mixture thereof. They may be in any suitable form, for example a liquid such as an oil, a solid such as a powder, or a gas.

[0183] In some embodiments, the flavoring agent comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring agent comprises cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavoring agent comprises eugenol. In some embodiments, the flavoring agent comprises flavor components extracted from tobacco. In some embodiments, the flavoring agent comprises flavor components extracted from cannabis.

[0184] In some embodiments, the fragrance may include sensates intended to produce the sensations typically perceived by chemically induced stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of olfactory or gustatory nerves, including agents that produce heating, cooling, tingling, and numbing effects. Suitable heating agents include, but are not limited to, vanillyl ethyl ether. Suitable cooling agents include, but are not limited to, eucalyptol and WS-3.

[0185] The various embodiments described herein are presented solely to aid in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments and are not intended to be exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be construed as limitations on the scope of the invention as defined by the claims or limitations on the equivalents of the claims, and it is understood that other embodiments may be utilized and improved upon without departing from the scope of the claimed invention. The various embodiments of the present invention may suitably include, consist of, or essentially consist of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. The present disclosure may also include other inventions not currently claimed but which may be claimed in the future.

[0186] This specification discloses the following embodiments. [1] 1. An aerosol generating component for use with a non-flammable aerosol delivery device, comprising: a first sheet including an aerosol-forming material; and a second sheet including a heating material that can be heated by the penetration of a fluctuating magnetic field; a wrapper comprising paper, surrounding the first sheet and the second sheet, and having an air permeability of less than 500 Coresta units; An aerosol generating component comprising: [2] Item 1. The aerosol-generating component according to item 1, wherein the surface of the first sheet is in contact with the surface of the second sheet. [3] Item 1 or 2. The aerosol-generating component according to item 1 or 2, wherein the first sheet has a thickness of approximately 100 μm to approximately 300 μm, and / or the second sheet has a thickness of approximately 1 μm to approximately 150 μm. [4] An aerosol-generating component according to any one of items 1 to 3, further comprising an adhesive for joining the first sheet and the second sheet together, or the first sheet and the second sheet do not contain an adhesive. [5] Item 5. The aerosol-generating component according to any one of items 1 to 4, wherein the first sheet has a plurality of openings or a plurality of embossed portions. [6] Item 6. The aerosol-generating component according to any one of items 1 to 5, wherein the total area of ​​the first sheet is larger or smaller than the total area of ​​the second sheet. [7] An aerosol generating component for use with a non-flammable aerosol delivery device, comprising multiple strips of laminated material, each strip having a first layer including an aerosol generating material and a second layer including a heating material that can be heated by the penetration of a varying magnetic field. [8] Item 8. An aerosol generation component as described in item 7, wherein the aerosol generation component has a longitudinal axis and the plurality of strips are substantially aligned with the longitudinal axis. [9] Item 9. The aerosol-generating component according to item 7 or 8, wherein each of the plurality of strips has a length of approximately 10 mm to approximately 60 mm.

[10] Item 10. An aerosol generation component according to any one of items 7 to 9, wherein each of the plurality of strips has a width of approximately 0.9 mm to approximately 2 mm.

[11] 11. The aerosol-generating component according to any one of items 7 to 10, wherein each of the plurality of strips has a thickness of approximately 100 μm to approximately 300 μm.

[12] Item 12. An aerosol generation component according to any one of items 7 to 11, wherein each of the plurality of strips is substantially rectangular.

[13] Item 13. An aerosol-generating component according to any one of items 7 to 12, wherein each of the plurality of strips comprises an adhesive that bonds the first layer to the second layer.

[14] 1. An aerosol generating component for use with a non-flammable aerosol delivery device, comprising: a first plurality of strips of aerosol-generating material; a second plurality of strips of heating material heatable by the penetration of a varying magnetic field; An aerosol generating component comprising:

[15] Item 15. The aerosol-generating component of item 14, wherein the second plurality of strips are dispersed within the first plurality of strips.

[16] Item 16. An aerosol generation component according to item 14 or 15, wherein the aerosol generation component has a longitudinal axis and the first plurality of strips and / or the second plurality of strips are substantially aligned with the longitudinal axis.

[17] 17. The aerosol generation component according to any one of items 14 to 16, wherein the first plurality of strips and / or the second plurality of strips each have a length of approximately 10 mm to approximately 60 mm.

[18] 18. An aerosol generation component according to any one of items 14 to 17, wherein the first plurality of strips and / or the second plurality of strips each have a width of approximately 0.9 mm to approximately 2 mm.

[19] Item 19. An aerosol-generating component according to any one of items 14 to 18, wherein the first plurality of strips and / or the second plurality of strips each have a thickness of approximately 1 μm to approximately 150 μm.

[20] 20. The aerosol-generating component according to any one of claims 14 to 19, wherein the first plurality of strips and / or the second plurality of strips are each substantially rectangular, and / or the first plurality of strips and / or the second plurality of strips are each free of adhesive. [twenty one] 1. An aerosol generating component for use with a non-flammable aerosol delivery device, comprising: a core or cavity containing a first aerosol-forming material; a sheath portion including a second aerosol-forming material surrounding the core portion; a boundary material surrounding the core portion between the core portion and the sheath portion; An aerosol generating component comprising: [twenty two] Item 22. The aerosol-generating component of item 21, wherein the properties of the first aerosol-generating material are different from the properties of the second aerosol-generating material. [twenty three] Item 23. The aerosol-generating component according to item 22, wherein the characteristic is at least one of density, type, or fragrance. [twenty four] the core portion comprises a plurality of strips of the first aerosol-forming material, and / or the sheath portion comprises a plurality of strips of the second aerosol-forming material; or Item 24. The aerosol-generating component of any one of items 21 to 23, wherein the core comprises laminar tobacco in the form of cut rag tobacco, and the sheath comprises reconstituted tobacco sheet material. [twenty five] Item 25. The aerosol-generating component according to any one of items 21 to 24, wherein the interface material is in contact with the first aerosol-generating material and / or the second aerosol-generating material.

[26] 26. The aerosol-generating component according to any one of claims 21 to 25, wherein the boundary material is porous and / or comprises a plurality of openings.

[27] Item 27. The aerosol-generating component according to any one of items 21 to 26, wherein the core has a diameter of approximately 4 mm to approximately 6 mm.

[28] 28. An aerosol-generating component according to any one of claims 21 to 27, wherein the sheath portion has a thickness of approximately 100 μm to approximately 300 μm, the sheath portion has a thickness greater than 200 μm, and / or the boundary material has a thickness of approximately 1 μm to approximately 150 μm.

[29] Item 29. The aerosol-generating component according to any one of items 21 to 28, wherein the core is substantially cylindrical and / or the sheath is substantially tubular.

[30] 30. An aerosol generation component according to any one of claims 21 to 29, wherein the boundary material defines one or more air flow paths extending in a direction parallel to the longitudinal axis of the aerosol generation component and / or the boundary material is a pleated sheet material.

[31] Item 31. The aerosol-generation component according to any one of items 21 to 30, wherein the boundary material and / or the sheath portion comprises a heating material.

[32] Item 32. The aerosol-generating component according to any one of items 1 to 20 and 31, wherein the heating material comprises a conductive material and / or a magnetic material.

[33] Item 32. The aerosol-generating component of any one of items 1 to 20 and 31, wherein the heating material comprises a metal or an alloy.

[34] Item 34. The aerosol generating component of item 33, wherein the heating material comprises stainless steel or aluminum.

[35] Item 35. An aerosol-generating component according to any one of items 1 to 34, wherein the outer diameter of the core or cavity is approximately 30% to approximately 70%, approximately 40% to approximately 60%, or approximately 45% to approximately 55% of the outer diameter of the sheath.

[36] Item 35. An aerosol-generating component according to any one of items 1 to 34, wherein the outer diameter of the core or cavity is approximately 60% to approximately 80%, approximately 65% ​​to approximately 75%, or approximately 70% of the outer diameter of the sheath.

[37] Item 37. The aerosol-generating component according to any one of items 1 to 36, wherein the aerosol-generating material is regenerated, cellulosic, or in gel form.

[38] Item 38. The aerosol-generating component of any one of items 1 to 37, wherein the aerosol-generating material comprises tobacco material.

[39] Item 39. The aerosol-generation component according to any one of items 1 to 38, wherein the aerosol-generation component is substantially cylindrical.

[40] 40. An article for use with a non-flammable aerosol delivery device, comprising an aerosol-generating component according to any one of paragraphs 1 to 39.

[41] a non-flammable aerosol delivery device; Item 40: The article according to item 40 and / or the component according to any one of items 1 to 39, A non-flammable aerosol delivery system comprising:

[42] 1. A method of making an aerosol generating component for use with a non-flammable aerosol delivery device, comprising: providing a first sheet including an aerosol-forming material; providing a second sheet including a heating material that can be heated by the penetration of a fluctuating magnetic field; wrapping the first sheet and the second sheet in a wrapper comprising paper and having a permeability of less than 500 Coresta units; A method comprising:

[43] 1. A method of making an aerosol generating component for use with a non-flammable aerosol delivery device, comprising: forming a sheet of laminate material, the sheet comprising a first layer including an aerosol-generating material and a second layer including a heating material heatable by the penetration of a varying magnetic field; slitting the sheet to form a plurality of strips of laminate material, each of the plurality of strips comprising a first layer including an aerosol-generating material and a second layer including a heating material heatable by the penetration of a varying magnetic field; A method comprising:

[44] 1. A method of making an aerosol generating component for use with a non-flammable aerosol delivery device, comprising: chopping a first sheet of aerosol-generating material to form a first plurality of strips; Slitting a second sheet of heating material heatable by the penetration of a varying magnetic field to form a second plurality of strips; A method comprising:

[45] 1. A method of making an aerosol generating component for use with a non-flammable aerosol delivery device, comprising: Providing a core including an optional first aerosol-forming material; disposing an interface material around the core; disposing a sheath containing a second aerosol-forming material around the core; Including, The method wherein the interface material is disposed between the core portion and the sheath portion.

[46] 46. ​​The method of claim 45, wherein the step of disposing a sheath portion around the core portion includes supplying the boundary material and core portion sequentially to a source of the second aerosol-forming material.

[47] 47. The method of claim 45 or 46, wherein the step of disposing the interface material around the core comprises wrapping the interface material around the core.

Claims

1. 1. An aerosol generating component for use with a non-flammable aerosol delivery device, comprising: a first sheet including an aerosol-forming material; and a second sheet including a heating material that can be heated by the penetration of a fluctuating magnetic field; a wrapper comprising paper, surrounding the first sheet and the second sheet, the wrapper having an air permeability of less than 500 Coresta units; An aerosol generating component comprising:

2. The aerosol-generating component of claim 1 , wherein a surface of the first sheet is in contact with a surface of the second sheet.

3. 3. The aerosol-generating component according to claim 1, wherein the first sheet has a thickness of approximately 100 μm to approximately 300 μm and / or the second sheet has a thickness of approximately 1 μm to approximately 150 μm.

4. An aerosol-generating component according to any one of claims 1 to 3, further comprising an adhesive bonding the first sheet and the second sheet together, or the first sheet and the second sheet do not contain an adhesive.

5. An aerosol-generating component according to any one of claims 1 to 4, wherein the first sheet comprises a plurality of openings or a plurality of embossments.

6. An aerosol-generating component according to any one of claims 1 to 5, wherein the total area of ​​the first sheet is greater than or less than the total area of ​​the second sheet.

7. An aerosol generating component for use with a non-flammable aerosol delivery device, comprising multiple strips of laminated material, each strip having a first layer including an aerosol generating material and a second layer including a heating material that can be heated by the penetration of a fluctuating magnetic field.

8. 8. The aerosol generation component according to claim 7, wherein the aerosol generation component has a longitudinal axis and the plurality of strips are substantially aligned with the longitudinal axis.

9. 9. The aerosol-generating component according to claim 7 or 8, wherein each of the plurality of strips has a length of between approximately 10 mm and approximately 60 mm.

10. An aerosol-generating component according to any one of claims 7 to 9, wherein each of the plurality of strips has a width of between approximately 0.9 mm and approximately 2 mm.

11. 11. An aerosol-generating component according to any one of claims 7 to 10, wherein each of the plurality of strips has a thickness of approximately 100 μm to approximately 300 μm.

12. An aerosol-generating component according to any one of claims 7 to 11, wherein each of the plurality of strips is substantially rectangular.

13. An aerosol-generating component according to any one of claims 7 to 12, wherein each of the plurality of strips comprises an adhesive bonding the first layer to the second layer.

14. 1. An aerosol generating component for use with a non-flammable aerosol delivery device, comprising: a first plurality of strips of aerosol-forming material; a second plurality of strips of heating material heatable by the penetration of a varying magnetic field; An aerosol generating component comprising:

15. 15. The aerosol-generating component of claim 14, wherein the second plurality of strips are interspersed within the first plurality of strips.

16. 16. An aerosol generation component according to claim 14 or 15, wherein the aerosol generation component has a longitudinal axis and the first plurality of strips and / or the second plurality of strips are substantially aligned with the longitudinal axis.

17. An aerosol-generating component according to any one of claims 14 to 16, wherein the first plurality of strips and / or the second plurality of strips each have a length of between approximately 10 mm and approximately 60 mm.

18. 18. An aerosol-generation component according to any one of claims 14 to 17, wherein the first plurality of strips and / or the second plurality of strips each have a width of between approximately 0.9 mm and approximately 2 mm.

19. 19. An aerosol-generating component according to any one of claims 14 to 18, wherein the first plurality of strips and / or the second plurality of strips each have a thickness of approximately 1 μm to approximately 150 μm.

20. 20. An aerosol generation component according to any one of claims 14 to 19, wherein the first plurality of strips and / or the second plurality of strips are each substantially rectangular and / or the first plurality of strips and / or the second plurality of strips are each free of adhesive.

21. 1. An aerosol generating component for use with a non-flammable aerosol delivery device, comprising: a core or cavity containing a first aerosol-forming material; a sheath portion including a second aerosol-forming material and surrounding the core portion; a boundary material surrounding the core portion between the core portion and the sheath portion; An aerosol generating component comprising:

22. 22. The aerosol-generating component of claim 21, wherein the properties of the first aerosol-generating material are different from the properties of the second aerosol-generating material.

23. 23. The aerosol-generating component of claim 22, wherein the characteristic is at least one of density, type, or flavor.

24. the core portion comprises a plurality of strips of the first aerosol-forming material, and / or the sheath portion comprises a plurality of strips of the second aerosol-forming material; or An aerosol-generating component according to any one of claims 21 to 23, wherein the core comprises laminar tobacco in the form of cut rag tobacco and the sheath comprises reconstituted tobacco sheet material.

25. 25. An aerosol-generating component according to any one of claims 21 to 24, wherein the interface material is in contact with the first aerosol-generating material and / or the second aerosol-generating material.

26. An aerosol-generating component according to any one of claims 21 to 25, wherein the boundary material is porous and / or comprises a plurality of openings.

27. 27. An aerosol-generating component according to any one of claims 21 to 26, wherein the core has a diameter of between approximately 4 mm and approximately 6 mm.

28. 28. An aerosol generation component according to any one of claims 21 to 27, wherein the sheath portion has a thickness of approximately 100 μm to approximately 300 μm, the sheath portion has a thickness of more than 200 μm, and / or the boundary material has a thickness of approximately 1 μm to approximately 150 μm.

29. An aerosol-generating component according to any one of claims 21 to 28, wherein the core is substantially cylindrical and / or the sheath is substantially tubular.

30. An aerosol generation component as described in any one of claims 21 to 29, wherein the boundary material defines one or more air flow paths extending in a direction parallel to the longitudinal axis of the aerosol generation component and / or the boundary material is a pleated sheet material.

31. An aerosol generation component according to any one of claims 21 to 30, wherein the boundary material and / or the sheath portion comprises a heating material.

32. An aerosol-generating component according to any one of claims 1 to 20 and 31, wherein the heating material comprises an electrically conductive material and / or a magnetic material.

33. An aerosol-generating component according to any one of claims 1 to 20 and 31, wherein the heating material comprises a metal or alloy.

34. 34. The aerosol generating component of claim 33, wherein the heating material comprises stainless steel or aluminum.

35. 35. An aerosol generation component according to any one of claims 1 to 34, wherein the outer diameter of the core or cavity is approximately 30% to approximately 70%, approximately 40% to approximately 60%, or approximately 45% to approximately 55% of the outer diameter of the sheath.

36. 35. An aerosol generation component according to any one of claims 1 to 34, wherein the outer diameter of the core or cavity is approximately 60% to approximately 80%, approximately 65% ​​to approximately 75%, or approximately 70% of the outer diameter of the sheath.

37. An aerosol-generating component according to any preceding claim, wherein the aerosol-forming material is regenerated, cellulosic, or in gel form.

38. An aerosol-generating component according to any preceding claim, wherein the aerosol-forming material comprises tobacco material.

39. An aerosol-generating component according to any one of the preceding claims, wherein the aerosol-generating component is substantially cylindrical.

40. An article for use with a non-flammable aerosol delivery device, the article comprising an aerosol generating component according to any one of claims 1 to 39.

41. a non-flammable aerosol delivery device; an article according to claim 40 and / or a component according to any one of claims 1 to 39; A non-flammable aerosol delivery system comprising:

42. 1. A method of making an aerosol generating component for use with a non-flammable aerosol delivery device, comprising: Providing a first sheet including an aerosol-forming material; providing a second sheet including a heating material that can be heated by the penetration of a fluctuating magnetic field; wrapping the first sheet and the second sheet in a wrapper comprising paper and having a permeability of less than 500 Coresta units; A method comprising:

43. 1. A method of making an aerosol generating component for use with a non-flammable aerosol delivery device, comprising: forming a sheet of laminate material, the sheet comprising a first layer including an aerosol-generating material and a second layer including a heating material heatable by the penetration of a varying magnetic field; slitting the sheet to form a plurality of strips of laminate material, each of the plurality of strips comprising a first layer including an aerosol-generating material and a second layer including a heating material heatable by the penetration of a varying magnetic field; A method comprising:

44. 1. A method of making an aerosol generating component for use with a non-flammable aerosol delivery device, comprising: chopping a first sheet of aerosol-generating material to form a first plurality of strips; Slitting a second sheet of heating material heatable by the penetration of a varying magnetic field to form a second plurality of strips; A method comprising:

45. 1. A method of making an aerosol generating component for use with a non-flammable aerosol delivery device, comprising: Providing a core including an optional first aerosol-forming material; disposing an interface material around the core; disposing a sheath containing a second aerosol-forming material around the core; Including, The method, wherein the interface material is disposed between the core portion and the sheath portion.

46. 46. ​​The method of claim 45, wherein the step of disposing a sheath portion around the core portion comprises supplying the boundary material and core portion sequentially to a source of the second aerosol-forming material.

47. 47. The method of claim 45 or 46, wherein the step of disposing the interface material around the core comprises wrapping the interface material around the core.

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