Consumables for use in aerosol delivery systems

Abstract

The present disclosure relates to a consumable (1) for use in an aerosol delivery system. The consumable (1) comprises one or more pouches containing first and second aerosol-generating materials (4, 5). The second aerosol-generating material (4, 5) has a higher density than the first aerosol-generating material (4). The present disclosure also relates to a method of manufacturing the consumable (1), a kit of parts comprising the consumable (1) and an aerosol delivery device, and packaging for the consumable (1).

Description

[Technical field]

[0001] The present disclosure relates to consumables for use in aerosol delivery systems. The present disclosure also relates to methods of manufacturing the consumables, kits of parts including the consumables and aerosol delivery devices, and packaging for the consumables.

[0002] Aerosol delivery systems generate an inhalable aerosol or vapour during use by releasing a compound from an aerosol-generating material. These may be referred to, for example, as non-combustible smoking articles, aerosol generating assemblies or aerosol delivery devices.

[0003] According to some embodiments described herein, there is provided a consumable for use in an aerosol delivery system, the consumable comprising one or more pouches containing a first aerosol generating material and a second aerosol generating material, the second aerosol generating material having a higher density than the first aerosol generating material.

[0004] In some embodiments, the consumable product comprises a first pouch containing a first aerosol-generating material and a second pouch containing a second aerosol-generating material.

[0005] In some embodiments, the consumable comprises a first pouch that contains both the first and second aerosol-generating materials. The consumable may optionally comprise another pouch that may contain, for example, the first and / or the second aerosol-generating material.

[0006] The present disclosure also provides a consumable for use in an aerosol delivery system, the consumable comprising a pouch and a first aerosol generating material and a second aerosol generating material contained in the pouch, the second aerosol generating material having a higher density than the first aerosol generating material.

[0007] In some embodiments, the or each pouch comprises a sheet material.

[0008] In some embodiments, the sheet material constitutes a wall of a pouch.

[0009] In some embodiments, the sheet material comprises paper.

[0010] In some embodiments, the sheet material has a thickness in the range of 20 to 100 microns, preferably in the range of 30 to 80 microns, 35 to 55 microns, or 40 to 50 microns.

[0011] In some embodiments, the sheet material is gas breathable.

[0012] In some embodiments, the sheet material has an air permeability in the range of 10 to 25000 Coresta units, optionally in the range of 25 to 100 Coresta units.

[0013] In some embodiments, the sheet material is folded and / or wrapped to define the or each pouch.

[0014] In some embodiments, the sheet material is porous, hi some embodiments, the sheet material has one or more openings through which gas can flow.

[0015] In some embodiments, at least one edge of the sheet material is attached to another portion of the sheet material so as to retain the first aerosol-generating material and / or the second aerosol-generating material in the or each pouch.

[0016] In some embodiments, the at least one edge of the sheet material is attached by adhesive, crimping, stapling, or sewing.

[0017] In some embodiments, the sheet material is a flexible material. In some embodiments, the first and second aerosol-generating materials are different materials and / or have one or more different properties.

[0018] In some embodiments, the or each pouch is formed from a single sheet of material.

[0019] In some embodiments, the or each pouch is formed from two or more sheets of material joined together.

[0020] In some embodiments, two or more sheets of material may be glued, sewn, and / or stapled together.

[0021] In some embodiments, the sheet material of the or each pouch completely encases the aerosol-forming material contained in the pouch.

[0022] In some embodiments, the sheet of material defines the entire boundary of a containment area that contains the aerosol-forming material.

[0023] In some embodiments, no other components are necessary to hold the aerosol-forming material in the or each pouch.

[0024] In some embodiments, the or each pouch constitutes the exterior of the consumable.

[0025] In some embodiments, the first aerosol-forming material and / or the second aerosol-forming material are free materials.

[0026] In some embodiments, the second aerosol-forming material comprises an extruded and / or compressed aerosol-forming material.

[0027] In some embodiments, the second aerosol-generating material comprises beads.

[0028] In some embodiments, the beads have a diameter in the range of 0.5 to 3 mm, preferably in the range of 1 to 2 mm.

[0029] In some embodiments, the first aerosol-forming material comprises, consists of, or consists essentially of tobacco material.

[0030] In some embodiments, the tobacco material of the first aerosol-forming material is derived only from tobacco lamina and not from other types of tobacco material.

[0031] In some embodiments, the first aerosol-forming material includes tobacco lamina and reconstituted tobacco.

[0032] In some embodiments, the second aerosol-forming material comprises, consists of, or consists essentially of tobacco material.

[0033] In some embodiments, the first aerosol-generating material and the second aerosol-generating material together have an average nicotine level in the range of 0.5% to 2.5% by weight of the first aerosol-generating material and the second aerosol-generating material, preferably in the range of 1% to 2.1% by weight.

[0034] In some embodiments, the tobacco material of the second aerosol-forming material is derived only from tobacco lamina and not from other types of tobacco material.

[0035] In some embodiments, the second aerosol-forming material comprises laminar tobacco and / or reconstituted tobacco.

[0036] In some embodiments, the consumable contains in the range of about 20 to about 330 mg of the first aerosol-generating material, preferably in the range of about 50 to about 300 mg or about 40 to about 125 mg of the first aerosol-generating material.

[0037] In some embodiments, the consumable contains in the range of about 20 to about 330 mg of the second aerosol-generating material, preferably in the range of about 50 to about 300 mg or about 40 to about 125 mg of the second aerosol-generating material.

[0038] In some embodiments, the first aerosol-forming material and / or the second aerosol-forming material are solid materials.

[0039] In some embodiments, the consumable does not include plastic.

[0040] In some embodiments, the density of the second aerosol-generating material is at least 25% greater than the density of the first aerosol-generating material.

[0041] In some embodiments, the first aerosol-forming material has a density of about 0.1 g / cm 3 ~Approx. 1g / cm 3 has a density of

[0042] In some embodiments, the second aerosol-generating material has a density of about 0.4 g / cm 3 ~Approx. 2g / cm 3 has a density of

[0043] In some embodiments, heating of the consumable results in a relatively constant release of volatile compounds into the inhalable medium.

[0044] In some embodiments, the second aerosol-forming material comprises extruded tobacco.

[0045] In some embodiments, the second aerosol-generating material comprises beads.

[0046] In some embodiments, the first aerosol-forming material comprises one or more tobacco materials selected from the group consisting of lamina and reconstituted tobacco materials.

[0047] In some embodiments, at least one of the first aerosol-forming material and / or the second aerosol-forming material comprises a combination of lamina and reconstituted tobacco material, hi some embodiments, the lamina and reconstituted tobacco material are present in the aerosol-forming material in a weight ratio of 1:4 to 4:1.

[0048] In some embodiments, the first and second aerosol-forming materials have the same level of a volatile compound, hi some embodiments, the volatile compound is nicotine.

[0049] In some embodiments, the release of volatile compounds from the first and second aerosol-forming materials occurs at the same rate when the materials reach a given temperature.

[0050] In some embodiments, the first and second aerosol-forming materials are present in the article in a weight ratio of from 1:10 to 10:1.

[0051] In some embodiments, one pouch contains a first aerosol-forming material and a second aerosol-forming material.

[0052] In some embodiments, the first aerosol-forming material and the second aerosol-forming material are mixed together in the one pouch.

[0053] In some embodiments, the first aerosol-forming material and the second aerosol-forming material are provided in discrete regions within the single pouch.

[0054] In some embodiments, a pouch contains the first and second aerosol generating materials, and the consumable includes another pouch that may also contain the first and / or second aerosol generating materials or another aerosol generating material, hi other embodiments, the pouch containing the first and second aerosol generating materials is the only pouch in the consumable.

[0055] In some embodiments, the first region and the second region are discrete regions.

[0056] In some embodiments, the first region is located at a first end of the pouch and the second region is located at a second end of the pouch.

[0057] In some embodiments, one of the first region or the second region surrounds or at least partially surrounds the other of the first region and the second region.

[0058] In some embodiments, the pouch comprises a divider separating the first region and the second region. The divider may be a dividing wall.

[0059] In some embodiments, the consumable product comprises a first pouch containing a first aerosol-generating material and a second pouch containing a second aerosol-generating material.

[0060] In some embodiments, the first pouch and the second pouch are connected. For example, the first pouch and the second pouch may be directly connected, such as by gluing, sewing, or stapling the first pouch and the second pouch together, or by forming at least a portion of the first pouch and the second pouch from the same sheet material. In other embodiments, the first pouch and the second pouch may be joined together by attaching the first pouch and the second pouch to the same substrate (e.g., a paper substrate).

[0061] In some embodiments, the first aerosol-forming material and the second aerosol-forming material are produced from the same aerosol-forming starting material that has been processed to have different morphologies.

[0062] In some embodiments, the first aerosol-generating material and / or the second aerosol-generating material comprise an aerosol-forming material.

[0063] In some embodiments, the first aerosol-forming material and / or the second aerosol-forming material comprises about 10 to about 50% by weight of the aerosol-forming material, about 15 to about 60% by weight of the gelling agent, and optionally a filler, the weight percentages being calculated on a dry weight basis.

[0064] In some embodiments, the first aerosol-forming material and / or the second aerosol-forming material comprises a flavorant.

[0065] The present disclosure also provides a method for manufacturing a consumable for use in an aerosol delivery system, the method including forming one or more pouches containing a first aerosol generating material and a second aerosol generating material, the second aerosol generating material having a higher density than the first aerosol generating material.

[0066] In some embodiments, one of the pouches contains a first aerosol-forming material and the other of the pouches contains a second aerosol-forming material.

[0067] In some embodiments, the or each pouch contains a first aerosol-forming material and a second aerosol-forming material.

[0068] In some embodiments, the or each pouch comprises a sheet material.

[0069] In some embodiments, the method includes forming the sheet material of the or each pouch as a tube containing the first aerosol-forming material and / or the second aerosol-forming material.

[0070] In some embodiments, the method includes forming a sheet of material as a structure having one end closed and the other end open, and the first aerosol-generating material and / or the second aerosol-generating material are disposed within the sheet of material structure.

[0071] In some embodiments, the construct is a continuous tube of sheet material that is closed at one end, and the first aerosol-forming material and / or the second aerosol-forming material can be inserted into the continuous tube through the open end of the continuous tube.

[0072] In some embodiments, the method includes feeding the first aerosol-generating material and / or the second aerosol-generating material into the arrangement under gravity.

[0073] In some embodiments, the method includes providing a first aerosol-generating material and / or a second aerosol-generating material to an open end of the arrangement.

[0074] In some embodiments, the sheet material construct is a continuous tube of sheet material.

[0075] In some embodiments, the method includes providing a continuous stream of a first aerosol-generating material and / or a second aerosol-generating material to the arrangement.

[0076] In some embodiments, the method includes sealing and cutting the construction of sheet material at a location spaced from the closed end of the construction to form a pouch.

[0077] In some embodiments, the step of sealing the construct comprises collapsing the construct, preferably collapsing the construct such that opposed walls of the sheet material of the construct are integrated. The step of sealing the construct may optionally comprise crimping the sheet material of the construct.

[0078] In some embodiments, the steps of sealing and cutting the construct of sheet material forms a second closed end of the construct.

[0079] In some embodiments, the first and second aerosol-generating materials are contained in the pouch between the closed end and a later sealed and cut portion of the sheet material.

[0080] In some embodiments, the sheet material construction is repeatedly sealed and cut to form multiple pouches.

[0081] In some embodiments, the construction of sheet material is sealed and cut simultaneously.

[0082] In some embodiments, the step of sealing the configuration includes manipulating the configuration such that aerosol-generating material in the configuration moves axially downstream and / or upstream of the portion of the configuration to be sealed.

[0083] In some embodiments, the manipulation of the construct may include collapsing the construct.

[0084] In some embodiments, the method includes depositing a first aerosol-generating material and / or a second aerosol-generating material onto the sheet material, preferably depositing a metered amount of the first aerosol-generating material and / or the second aerosol-generating material onto the sheet material.

[0085] In some embodiments, the method includes wrapping a sheet material around the first aerosol-generating material and / or the second aerosol-generating material.

[0086] In some embodiments, the method includes attaching a first portion and a second portion of the sheet material together such that the first aerosol-generating material and / or the second aerosol-generating material is held between the first portion and the second portion of the sheet material.

[0087] The present disclosure also provides consumable products manufactured according to the methods disclosed herein.

[0088] Also provided in accordance with the present disclosure is a package comprising a plurality of the consumable products disclosed herein, hi some embodiments, the package is hermetically sealed.

[0089] The present disclosure also provides a kit of parts comprising a consumable as disclosed herein and an aerosol delivery device.

[0090] In some embodiments, the aerosol delivery device includes a heating zone for receiving the consumables and heating the first and second aerosol generating materials.

[0091] Embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0092] [Figure 1] FIG. 2 is a top view of one embodiment of a consumable for use with the aerosol delivery system. [Diagram 2] FIG. 2 is a side cross-sectional view of the consumable of FIG. 1. [Diagram 3] FIG. 2 is a top view of the consumable sheet material of FIG. 1 laid flat. [Figure 4] FIG. 2 is a perspective view of a bead of aerosol-generating material of the consumable of FIG. [Diagram 5] Figures 5A, 5B, and 5C are top views of a first, second, and third steps of a method of making a consumable item for use with an aerosol delivery system. [Figure 6] 1 is a schematic cross-sectional view of a continuous method of manufacturing an article for use with an aerosol delivery system. [Figure 7] FIG. 1 is a schematic diagram of an apparatus for manufacturing an article for use with an aerosol delivery system. [Figure 8]13 is a side cross-sectional view of another embodiment of a consumable for use with the aerosol delivery system. FIG. [Figure 9] 13 is a side cross-sectional view of another embodiment of a consumable for use with the aerosol delivery system. FIG. [Figure 10] 13 is a side cross-sectional view of another embodiment of a consumable for use with the aerosol delivery system. [Figure 11] FIG. 1 is a cross-sectional view of one embodiment of a non-flammable aerosol delivery device. [Figure 12] FIG. 12 is a simplified schematic diagram of components within a housing of the aerosol delivery device shown in FIG. [Figure 13] 12 is a cross-sectional view of the non-flammable aerosol delivery device shown in FIG. 11 with the article shown in FIG. 1 inserted therein. Detailed Description

[0093] As used herein, the term "delivery system" is intended to include a system that delivers at least one substance to a user; Combustible aerosol delivery systems, such as cigarettes, cigarillos, cigars, and pipe tobacco or tobacco for home-rolled or home-made cigarettes, whether or not based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smoking materials; non-combustible aerosol delivery systems that release compounds from aerosol-generating materials without combustion (such as e-cigarettes, tobacco heating products, and hybrid systems that generate aerosols through a combination of aerosol-generating materials); an aerosol-free delivery system (including, but not limited to, oral products such as lozenges, gums, patches, articles containing inhalable powders, and oral tobacco products, including snus or moist snuff) that delivers at least one substance to a user orally, nasally, transdermally, or otherwise without the formation of an aerosol (the at least one substance may or may not contain nicotine); Includes.

[0094] According to the present disclosure, a "non-flammable" aerosol delivery system is one in which the aerosol-generating material (or components thereof) that constitutes the aerosol delivery system is not combusted or burned to facilitate delivery of at least one substance to a user.

[0095] In some embodiments, the delivery system is a non-flammable aerosol delivery system, such as a powered non-flammable aerosol delivery system.

[0096] In some embodiments, the non-combustible aerosol delivery system is an e-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.

[0097] 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.

[0098] In some embodiments, the non-combustible aerosol delivery system is a hybrid system that generates aerosol by a combination of aerosol-generating materials, one or more of which may be adapted to be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form, and may or may not contain nicotine. In some embodiments, the hybrid system includes liquid or gel aerosol-generating materials as well as solid aerosol-generating materials. The solid aerosol-generating materials may include plant-based materials (e.g., tobacco or non-tobacco products).

[0099] 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.

[0100] 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.

[0101] As used herein, the terms "upstream" and "downstream" are relative terms defined with respect to the direction of mainstream aerosol drawn through an article or device in use. References to the "distal end" refer to the upstream end of the device, while the "proximal end" refers to the downstream end of the device.

[0102] In some embodiments, the non-flammable aerosol delivery system (e.g., the non-flammable 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 in proximity to the heat generating power source.

[0103] In some embodiments, the non-flammable aerosol delivery system comprises an area for receiving a consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0104] In some embodiments, consumables for use with the non-flammable aerosol delivery device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0105] The consumable contains a substance to be delivered. The substance to be delivered is an aerosol-generating material. This material may also optionally contain one or more active constituents, one or more flavorings, one or more aerosol-forming materials, and / or one or more other functional materials.

[0106] In some embodiments, the substance to be delivered comprises an active substance. 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 derived. 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, cannabis, or another plant. In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0107] As described herein, the active material 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, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, pods, etc. Alternatively, the material may include active compounds naturally present 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, damiane, marjoram, olive, lemon balm, lemon basil, chives, ribeye, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0108] 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 tobacco.

[0109] In some embodiments, the active agent comprises or is derived from one or more botanical substances or constituents, derivatives or extracts thereof, the plant being selected from eucalyptus, star anise, cocoa, and hemp.

[0110] 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.

[0111] In some embodiments, the substance to be delivered comprises a fragrance.

[0112] As used herein, the terms "flavour" and "flavourant" refer to materials that can be used to produce a desired flavour, aroma, or other sensory experience in products intended for adult consumers, where local regulations permit.These include naturally occurring flavoring materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, peppermint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, limes, tropical fruits, and the like). Roots, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberries, mulberries, citrus fruits, drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-yi Orchid, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, oil of any mint 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 or black tea, thyme, juniper, elderberry, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiogamagamagamagama, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, damias. In some embodiments, the additives may be selected from the group consisting of sucrose, marjoram, olive, lemon balm, lemon basil, chives, ribes, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulators, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.These may be of imitation, synthetic or natural origin, 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 gel.

[0113] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavor components extracted from tobacco. In some embodiments, the flavoring comprises flavor components extracted from cannabis.

[0114] In some embodiments, the fragrance may include sensates intended to achieve the sensations usually chemically induced and perceived by stimulating the fifth cranial nerve (trigeminal nerve) in addition to or instead of the olfactory or gustatory nerves, and these may include agents that produce a heating, cooling, tingling, or numbing effect.Suitable heating agents may be, but are not limited to, vanillyl ethyl ether.Suitable cooling agents may be, but are not limited to, eucalyptol, WS-3.

[0115] The aerosol-generating material may include or be an "amorphous solid." In some embodiments, the aerosol-generating material includes an aerosol-generating film that is an amorphous solid. The amorphous solid may be a "monolithic solid." The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dry gel. The amorphous solid is a solid material that can retain some fluid therein, such as a liquid. In some embodiments, the amorphous solid may include, for example, about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% amorphous solid. The aerosol-generating material may also be referred to as an aerosolizable material.

[0116] An aerosol-generating material is a material capable of generating an aerosol when energized, for example by heating, irradiation, or in any other manner. The aerosol-generating material may be in the form of a solid, liquid, or gel, and may or may not contain active substances and / or flavorings. The aerosol-generating material is incorporated into an article for use in an aerosol generating system.

[0117] As used herein, the term "tobacco material" refers to any material that includes tobacco or a derivative or substitute thereof. The tobacco material may be in any suitable form. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Tobacco material includes one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco lamina, reconstituted tobacco, and / or tobacco extract.

[0118] A consumable is an article that includes or consists of an aerosol-generating material, some or all of which is intended to be consumed upon use by a user. A consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating 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 (particularly a heating element) that releases heat upon use to generate an aerosol from the aerosol-generating material. The heater may include a material or susceptor that can be heated by electrical conduction.

[0119] 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.

[0120] The aerosolizable material may be present on a substrate, which may be or include, for example, paper, cardboard, paperboard, recycled aerosolizable material, a plastic material, a ceramic material, a composite material, glass, a metal, or an alloy.

[0121] 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 mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0122] 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.

[0123] A consumable is an article that includes or is composed of an aerosol-generating material, some or all of which is intended to be consumed upon use by a user. A consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating 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. The heater may include, for example, a combustible material, a material that can be heated by electrical conduction, or a susceptor.

[0124] A susceptor is a material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be 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.

[0125] An aerosol modifier is a substance that is 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 that is operable to selectively release the aerosol modifier.

[0126] 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 thread, or a granule. The aerosol modifier may not have a filter material.

[0127] The aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to apply thermal energy to the aerosol-generating material to release one or more volatile substances from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without 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.

[0128] The filamentary tow material described herein may include cellulose acetate fiber tow. The filamentary tow may also be formed using other materials used to form fibers, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1-4 butanediol succinate) (PBS), poly(butylene adipate co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers, or combinations thereof. The filamentary tow may be plasticized with a plasticizer suitable for the tow (e.g., triacetin in the case of cellulose acetate tow), or may be unplasticized. The tow can have any suitable specifications, such as the fibers having other cross sections, such as a "Y" shape or an "X" shape, a filament fineness value per filament of 2.5 to 15 denier (e.g., 8.0 to 11.0 denier), and a total fineness value of 5,000 to 50,000 (e.g., 10,000 to 40,000).

[0129] In the drawings described herein, the same reference numbers are used to denote like features, items or components.

[0130] Fig. 1 is a top view of a consumable 1 for use in an aerosol delivery system comprising an aerosol delivery device 200 (see Figs. 11-13). Fig. 2 is a side cross-sectional view of the consumable 1 of Fig. 1.

[0131] The consumable 1 has an upstream or distal end "D" and a downstream or proximal end "P". In some embodiments, the proximal end P is located relatively closer to the mouthpiece 207 of the aerosol delivery device 200 in use than the distal end D. In another embodiment (not shown), the proximal end P of the consumable 1 comprises the mouthpiece. In some embodiments (not shown), the proximal end P of the consumable 1 constitutes the mouthpiece.

[0132] It will be appreciated that in some embodiments, the consumable 1 can be used with the aerosol delivery device 200 in any orientation, such that either end of the consumable 1 can be upstream and either can be downstream.

[0133] The consumable product 1 comprises a pouch 2 including a space 3 that contains first and second aerosol-generating materials 4, 5. The second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4, as explained in more detail below.

[0134] The first and second aerosol-generating materials 4, 5 are configured to be heated in the space 3 to generate an aerosol. The space 3 may be filled or at least partially filled with the first and second aerosol-generating materials 4, 5. The space 3 may form a storage area 3 for the first and second aerosol-generating materials 4, 5.

[0135] In an alternative embodiment (not shown), the consumable comprises a first pouch containing a first aerosol-generating material and a second pouch containing a second aerosol-generating material. In some embodiments, the first and second pouches are connected. For example, the first and second pouches may be directly connected, such as by gluing, sewing, or stapling the first and second pouches together, or by forming at least a portion of the first and second pouches from the same sheet material. In other embodiments, the first and second pouches may be joined together by attaching the first and second pouches to the same substrate (e.g., a paper substrate).

[0136] In this example, the pouch 2 includes a sheet material 6. In this example, the sheet material 6 includes paper. Optionally, the sheet material 6 may consist of, or consist essentially of, paper. It will be appreciated that in other embodiments, the sheet material 6 may additionally or alternatively include another material, such as metal foil, a woven material (e.g., cotton), or a laminate material (e.g., a laminate of paper and metal foil). In some embodiments, the sheet material 6 does not include plastic.

[0137] In some embodiments, the sheet material 6 is gas-permeable. This allows gas to enter the pouch 2 through the breathable sheet material 6, interact with the first and second aerosol-generating materials 4, 5, and then exit the pouch 2, where it can be inhaled by a user. In some embodiments, the sheet material 6 has an air permeability in the range of 10 to 25,000 Coresta units. In some embodiments, the sheet material 6 has an air permeability of at least 10 Coresta units, preferably at least 100, 200, 500, 1000, 2000, 5000, 10000, 15000, 20000, or 25,000 Coresta units. In some embodiments, the sheet material 6 has an air permeability of up to 25,000 Coresta units, preferably up to 20,000, 15,000, 10,000, 5000, 2000, 1000, 500, 200, 100, 75, or 50 Coresta units. In some embodiments, the sheet material 6 has a breathability in the range of 25 to 100 Coresta units.

[0138] In some embodiments, the sheet material 6 is porous to facilitate breathability of the sheet material 6. Alternatively or additionally, in some embodiments, the sheet material 6 has one or more openings (not shown) through which gas can flow.

[0139] In some embodiments, the sheet material 6 has a thickness (and thus the pouch wall has this thickness) in the range of 20-100 microns, optionally in the range of 30-80 microns, 35-55 microns, or 40-50 microns. In some embodiments, the thickness of the sheet material 6 (i.e., the thickness of the pouch wall) is at least 20 microns, preferably at least 30, 40, or 50 microns. In some embodiments, the thickness of the sheet material 6 (i.e., the thickness of the pouch wall) is up to 100 microns, preferably up to 90, 80, 70, 60, or 50 microns.

[0140] It has been found that increasing the air permeability of the sheet material 6 enhances the transfer of heat through the sheet material 6 to the aerosol-generating materials 4, 5. It has also been found that reducing the thickness of the sheet material 6 enhances the transfer of heat through the sheet material 6 to the aerosol-generating materials 4, 5. Enhanced heat transfer through the sheet material 6 is advantageous because it improves the efficiency of heating the first and second aerosol-generating materials 4, 5.

[0141] The sheet material 6 is configured to form a pouch 2, for example by folding and / or rolling.

[0142] In some embodiments, at least one edge 6A, 6B, 6C, 6D of the sheet of material 6 is attached to another portion of the sheet of material 6 so as to retain the first and second aerosol-generating materials 4, 5 in the space 3 of the pouch 2. In some embodiments, the at least one edge 6A, 6B, 6C, 6D of the sheet of material 6 is attached by adhesive, crimping, stapling, or sewing.

[0143] In this example, the sheet material 6 is a flexible material. In this example, the walls of the pouch 2 are flexible.

[0144] In some embodiments, the pouch 2 constitutes the outer surface of the consumable 1. In this example, a first side of the sheet material 6 faces inwardly and constitutes the boundary of the space 3, and a second side of the sheet material 6 faces outwardly and constitutes said outer surface 1A of the consumable 1.

[0145] In some embodiments, the first and / or second aerosol-forming materials 4, 5 are free materials. The first and / or second aerosol-forming materials 4, 5 may be in the form of discrete particles.

[0146] In this example, the second aerosol-generating material 5 comprises an extruded and / or compressed aerosol-generating material, as described in more detail below, although it will be appreciated that in other embodiments, the second aerosol-generating material 5 may have a different form.

[0147] In some embodiments, the first and / or second aerosol-generating materials 4, 5 comprise beads, which may be cylindrical or of another shape (e.g., spherical, pyramidal, or rectangular).

[0148] In this example, the second aerosol-forming material 5 comprises beads 5 (as shown in FIG. 3).

[0149] In some embodiments, the beads 5 have a diameter (indicated by arrow "D" in FIG. 4) in the range of 0.5 to 3 mm, preferably in the range of about 1 to 2 mm.

[0150] In some embodiments, the bead 5 has an axial length (indicated by arrow "L" in FIG. 4) in the range of 0.5 to 3 mm, preferably in the range of about 1 to 2 mm.

[0151] In some embodiments, the beads 5 have a particle size (measurable by sieving) in the range of 0.5 to 3 mm, preferably in the range of about 1 to 2 mm.

[0152] In some embodiments, the first and / or second aerosol-forming materials 4, 5 comprise, consist of, or consist essentially of tobacco material.

[0153] In some embodiments, the tobacco material of the first and / or second aerosol-forming materials 4, 5 is derived only from tobacco lamina and not from other types of tobacco material.

[0154] In some embodiments, the first and / or second aerosol-forming materials 4, 5 include tobacco lamina and reconstituted tobacco.

[0155] In some embodiments, the first and second aerosol-generating materials 4, 5 together have an average nicotine level in the range of 0.5% to 2.5% by volume of the first and second aerosol-generating materials 4, 5, preferably in the range of 1% to 2.1% by volume.

[0156] In some embodiments, the first aerosol-generating material 4 has a nicotine level in the range of 0.5% to 2.5% by volume of the first aerosol-generating material 4, preferably in the range of 1% to 2.1% by volume.

[0157] In some embodiments, the second aerosol-generating material 5 has a nicotine level in the range of 0.5% to 2.5% by volume of the second aerosol-generating material 5, preferably in the range of 1% to 2.1% by volume.

[0158] In some embodiments, the article contains from about 20 to about 330 mg of the first aerosol-generating material 4, preferably from about 50 to about 300 mg, from about 100 to about 200 mg, or from about 40 to about 125 mg of the first aerosol-generating material 4.

[0159] In some embodiments, the article comprises from about 20 to about 330 mg of the second aerosol-generating material 5, preferably from about 50 to about 300 mg, from about 100 to about 200 mg, or from about 40 to about 125 mg of the second aerosol-generating material 5.

[0160] In some embodiments, the total mass of aerosol-forming materials 4, 5 in space 3 ranges from 80 to 300 mg. In some embodiments, the total mass of tobacco material in space 3 ranges from 80 to 300 mg or 150 to 270 mg.

[0161] In some embodiments, the first and / or second aerosol-forming materials 4, 5 are solid materials.

[0162] In some embodiments, the first and second aerosol-generating materials 4, 5 are different materials and / or have one or more different properties.

[0163] The consumable 1 may have an axial length (indicated by arrow "X" in Figure 1) of at least 10mm, preferably at least 12, 14, 16, 18, 20, 22, or 23mm.

[0164] The consumable 1 may have an axial length of up to 36mm, preferably up to 34, 32, 30, 28, 26, 24 or 23mm.

[0165] The consumable 1 may have an axial length in the range of 10 to 36 mm, preferably in the range of 14 to 32 mm, in the range of 20 to 26 mm, or in the range of 22 to 24 mm.

[0166] In some embodiments, the sheet material 6 is plastic-free, which makes the consumable 1 more environmentally friendly and is also advantageous in embodiments where the entire consumable 1 is heated by the aerosol delivery device 200 (as described below).

[0167] In some embodiments, the sheet material 6 does not include cellulose acetate.

[0168] In some embodiments, the entire consumable 1 is plastic-free. In some embodiments, neither the sheet material 6 nor the entire consumable 1 is cellulose acetate-free.

[0169] In some embodiments, the first and / or second aerosol-forming materials 4, 5 may comprise, consist of, or consist essentially of tobacco material. The term "tobacco material" refers to any material that includes tobacco or a derivative or substitute thereof. The tobacco material may be in any suitable form. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Tobacco material includes one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco lamina, reconstituted tobacco, and / or tobacco extract.

[0170] In some embodiments, the first and / or second aerosol-generating material 4, 5 or another material (not shown) in the space 6 may include one or more aerosol-forming materials. For example, the first and / or second aerosol-generating material 4, 5 or the other material may include one or more constituents capable of forming an aerosol. 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 mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The aerosol-forming material may be glycerol or propylene glycol.

[0171] The first and / or second aerosol-generating materials 4, 5 may be provided in the space 3 as loose materials held therein by a sheet material 6 forming the wall of the pouch 2. The first and / or second aerosol-generating materials 4, 5 may be, for example, discrete strands or particles of aerosol-generating material. Another example of a loose aerosol-generating material includes beads / pellets of aerosol-generating material that have been extruded and subsequently cut into beads / pellets. Yet another example of an aerosol-generating material is a sheet of aerosol-generating material that has been cut into individual pieces (e.g. individual strips) of aerosol-generating material. The sheet of aerosol-generating material may be a sheet of reconstituted tobacco.

[0172] In this example, the first aerosol-forming material 4 comprises shredded tobacco material (eg, shredded lamina and / or shredded reconstituted tobacco).

[0173] In this example, the second aerosol-generating material 5 comprises extruded and / or compressed tobacco. In such embodiments, the second aerosol-generating material 5 may comprise a single body of aerosol-generating material or may comprise multiple bodies of aerosol-generating material.

[0174] In this example, the second aerosol-generating material 5 comprises beads / pellets / granules of aerosol-generating material (hereinafter referred to as "beads" of aerosol-generating material).

[0175] The second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4. This has been found to cause the second aerosol-generating material 5 to heat up more slowly than the first aerosol-generating material 4 when the heater of the device 200 operates to heat the consumable 1. This means that when the first aerosol-generating material 4 and the second aerosol-generating material 5 are subjected to the same heating power, the first aerosol-generating material 4 will initially release one or more volatile compounds (e.g., nicotine) faster than the second aerosol-generating material 5. It also means that the first aerosol-generating material 4 will relatively deplete the volatile compound(s) more quickly than the second aerosol-generating material 5. However, when the first aerosol-generating material 4 starts to relatively deplete the volatile compound(s), the second aerosol-generating material 5 will start to reach a temperature at which it starts to release the volatile compound(s) faster. The effect of this is a more consistent release of the volatile compound(s) over the consumption period of the consumable 1, with the first aerosol-generating material 4 releasing a greater proportion of the volatile compound(s) towards the start of consumption of the consumable 1 and the second aerosol-generating material 5 releasing a greater proportion of the volatile compound(s) towards the end of consumption of the consumable 1. This is particularly advantageous as it allows the pouch 1 to be relatively small while still providing a relatively consistent and / or sufficient release of the volatile compound(s) over the consumption period.

[0176] In some embodiments, the density of the second aerosol-forming material 5 is at least 25% higher than the density of the first aerosol-forming material 4 .

[0177] In some embodiments, the first aerosol-forming material 4 has a density of about 0.1 g / cm 3 ~Approx. 1g / cm 3 has a density of

[0178] In some embodiments, the second aerosol-forming material 5 has a density of about 0.4 g / cm 3 ~About 2g / cm3 has a density of

[0179] In some embodiments, the one or more volatile compounds emitted by first aerosol-generating material 4 are the same as the volatile compound(s) emitted by second aerosol-generating material 5.

[0180] In some embodiments, the first aerosol-generating material 4 is heated (e.g., by a first heater) during a first period of the consumption session, and the second aerosol-generating material 5 is heated (e.g., by a second heater) during a second period of the consumption session. For example, in some embodiments, the first and second aerosol-generating materials 4, 5 are provided in separate regions that are heated separately. In other embodiments, the first and second aerosol-generating materials 4, 5 are heated simultaneously, but may be, for example, mixed together.

[0181] In some embodiments, the second aerosol-generating material 5 comprises an aerosol-generating material that has been compressed or extruded (with no or relatively little / minimal subsequent expansion) to have a higher density than the first aerosol-generating material 4.

[0182] In some embodiments, the first aerosol-generating material 4 comprises one or more of tobacco lamina, tobacco stems, or reconstituted tobacco. In one such embodiment, the first aerosol-generating material 4 comprises a mixture of tobacco lamina and reconstituted tobacco. The first aerosol-generating material 4 may comprise shredded or chopped material. However, it is to be appreciated that in other embodiments, the first aerosol-generating material 4 comprises a compressed or extruded aerosol-generating material that is less dense than the second aerosol-generating material 5 (e.g., less compressed than the second aerosol-generating material 5, which may optionally be extruded or compressed).

[0183] In some embodiments, the first and second aerosol-generating materials 4, 5 may comprise the same material (e.g., tobacco) but are processed to have different densities. In one such embodiment, the first and second aerosol-generating materials 4, 5 may be in different forms. For example, the first aerosol-generating material 4 may be a shredded free material (e.g., shredded laminar tobacco and / or shredded reconstituted tobacco) while the second aerosol-generating material 5 may be compressed or extruded (with or without minimal expansion) to have a higher density than the first aerosol-generating material 4.

[0184] For example, the second aerosol-generating material 5 may be in the form of an extruded / compressed bead of aerosol-generating material (e.g., tobacco or another material) and the first aerosol-generating material 4 may be in the form of, for example, a strand or strip of aerosol-generating material (e.g., tobacco or another material), a sheet of aerosol-generating material collected as a plug or cut into strips, a loose material (e.g., cut rag tobacco), a dense end of a rod of aerosol-generating material (e.g., tobacco), or tobacco lamina and / or stem material formed as a plug, although it will be appreciated that the first, second, and / or third aerosol-generating materials 4, 5 may alternatively have the same form (e.g., both cut rag tobacco) while still being of different densities.

[0185] In some embodiments, the first aerosol-generating material 4 has at least one other different property relative to the second aerosol-generating material 5. The different property may be one or more of the shape, size, water content, amount (by weight), material(s), or ratio of materials that make up the first and second aerosol-generating materials 4, 5 (including the method of making the aerosol-generating materials 4, 5 if each is made from two or more materials). In a preferred embodiment, the first and second aerosol-generating materials 4, 5 have no different properties other than density, and are identical in that respect.

[0186] The first and / or second aerosol-generating materials 4, 5 may comprise multiple strands or strips of aerosol-generating material. For example, the first and / or second aerosol-generating materials 4, 5 may comprise multiple strands or strips of aerosolizable material and / or multiple strands or strips of an amorphous solid.

[0187] The first and / or second aerosol-generating materials 4, 5 may comprise a plant-based material, such as a tobacco material. The first and / or second aerosol-generating materials 4, 5 may be sheets or shredded sheets of aerosolizable material including a plant-based material, such as a tobacco material. The sheet material may be processed such that the second aerosol-generating material 5 is denser than the first aerosol-generating material 4.

[0188] The plant-based material may be a particulate or granular material. In some embodiments, the plant-based material is a powder. Alternatively or additionally, the plant-based material may comprise tobacco strips, strands, or fibers. For example, where tobacco material is provided, the tobacco material may comprise tobacco particles, granules, fibers, strips, and / or strands. In some embodiments, the tobacco material consists of particles or granules of tobacco material.

[0189] The tobacco material of the first and / or second aerosol-forming materials 4, 5 may include tobacco obtained from any part of the tobacco plant, hi some embodiments, the tobacco material includes tobacco leaf.

[0190] The sheet or shredded sheet may contain from 5% to about 90% tobacco leaf by weight.

[0191] In some embodiments, both the first and / or second aerosol-forming materials 4, 5 comprise, consist of, or consist essentially of tobacco material.

[0192] In some embodiments, the first and / or second aerosol-generating material 4, 5 comprises a sheet or chopped sheet of aerosolizable material that includes an aerosol-forming material. Optionally, the aerosol-forming material is provided in an amount of up to about 50% by weight of the sheet or chopped sheet on a dry weight basis. In some embodiments, the aerosol-forming material is provided in an amount of about 5% to about 40% by weight of the sheet or chopped sheet on a dry weight basis, about 10% to about 30% by weight of the sheet or chopped sheet on a dry weight basis, or about 10% to about 20% by weight of the sheet or chopped sheet on a dry weight basis.

[0193] The first and / or second aerosol-generating materials 4, 5 may include a filler. The filler is generally a non-tobacco component, i.e., a component that does not contain tobacco-derived inclusions. The filler may include one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents, such as molecular sieves. The filler may be a non-tobacco fiber, such as wood fiber, i.e., pulp or wheat fiber. The filler may be a material that includes cellulose or a derivative of cellulose. The filler component may also be a non-tobacco cast material or a non-tobacco extrusion material. In some embodiments, the first and / or second aerosol-generating materials 4, 5 are in the form of a sheet or shredded sheet that includes the filler.

[0194] The first and / or second aerosol-generating materials 4, 5 may include an aerosol modifying agent, such as any of the flavorings described herein. In one embodiment, the first and / or second aerosol-generating materials 4, 5 include menthol. When the first and / or second aerosol-generating materials 4, 5 are incorporated into a consumable product 1 for use in an aerosol delivery system, the article may be referred to as a menthol consumable product or article 1. The first and / or second aerosol-generating materials 4, 5 may include between 0.5 mg and 20 mg of menthol, between 0.7 mg and 20 mg of menthol, between 1 mg and 18 mg, or between 8 mg and 16 mg of menthol.

[0195] In some embodiments, article 1 comprises an aerosol-forming composition that includes aerosol-forming materials, which may include first and / or second aerosol-forming materials 4, 5.

[0196] An aerosol-generating material is a material capable of generating an aerosol when energized, for example, by heating, irradiating, or in any other manner. The aerosol-generating materials (e.g., first and / or second aerosol-generating materials 4, 5) may be, for example, in solid, liquid, or semi-solid (such as gel) form, and may or may not contain active substances and / or flavorings.

[0197] The aerosol-generating materials (e.g., the first and / or second aerosol-generating materials 4, 5) may include a binder and an aerosol former. Optionally, active materials and / or fillers may also be present. Optionally, a solvent, such as water, may also be present, in which one or more other components of the aerosol-generating materials may or may not be soluble. In some embodiments, the aerosol-generating materials (e.g., the first and / or second aerosol-generating materials 4, 5) are substantially free of plant material. In particular, in some embodiments, the aerosol-generating materials (e.g., the first and / or second aerosol-generating materials 4, 5) are substantially free of tobacco.

[0198] The aerosol-generating material (e.g., first and / or second aerosol-generating materials 4, 5) may include or be an "amorphous solid." The amorphous solid may be a "monolithic solid." In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material capable of retaining some fluid therein, such as a liquid. In some embodiments, the aerosol-generating material may include, for example, about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% amorphous solid. The amorphous solid may be substantially non-fibrous.

[0199] The aerosol-generating material (e.g., first and / or second aerosol-generating material 4, 5) may include or be an aerosol-generating film. The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-forming agent, and one or more other ingredients (e.g., an active agent) to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent. The slurry may be such that upon heating, at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent is removed. The aerosol-generating film may be a continuous film or a discontinuous film (such as a configuration of discrete film portions on a support). The aerosol-generating film may be substantially free of tobacco.

[0200] The aerosol-generating film may comprise or be a sheet, optionally chopped to form a chopped sheet.

[0201] The aerosol-generating materials (e.g., the first and / or second aerosol-generating materials 4, 5) may include one or more active substances and / or fragrances, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0202] In each of the embodiments of article 1 described herein, the article may include first and / or second aerosol-forming materials 4, 5 as described above, and may also include an aerosol-forming composition as described above.

[0203] The first and / or second aerosol-generating materials 4, 5 may comprise reconstituted tobacco paper material. The composition may alternatively or additionally comprise any of the tobacco forms described herein. The first and / or second aerosol-generating materials 4, 5 may comprise a sheet or shredded sheet comprising tobacco material comprising 10% to 90% by weight of tobacco leaf, although the aerosol-generating material may be provided in an amount up to about 20% by weight of the sheet or shredded sheet, with the remainder of the tobacco material comprising reconstituted tobacco paper.

[0204] When the first and / or second aerosol-forming materials 4, 5 comprise an amorphous solid material, the amorphous solid material may be a dry gel comprising menthol.

[0205] In some embodiments, the first and / or second aerosol-generating materials 4, 5 comprise extruded aerosol-generating materials that are cut into pellet beads.

[0206] 5A-5C, which illustrate a method of manufacturing a consumable 1 for an aerosol delivery device 200. As shown in FIG.

[0207] In a first step, a sheet of material 6 is prepared and laid flat or in a U-shape. In a second step (as shown in FIG. 5A), first and second aerosol-generating materials 4, 5 are deposited onto the sheet of material 6. In some embodiments, predetermined amounts or portions of the first and second aerosol-generating materials 4, 5, respectively, are deposited onto the sheet of material 6 on a metering drum, which may include, for example, a pneumatic or pocket wheel.

[0208] The first and second aerosol-generating materials 4, 5 may be premixed prior to deposition onto the sheet material 6. Alternatively, the first and second aerosol-generating materials 4, 5 may be mixed together during or after deposition onto the sheet material 6. In some embodiments, the first and second aerosol-generating materials 4, 5 may be mixed during storage, transportation, and / or use of the consumable 1. In still other embodiments, the first and second aerosol-generating materials 4, 5 may be provided in separate regions 4A, 5A to form the consumable 1 of any of Figures 8-10, for example.

[0209] In a third step, a sheet of material 6 is wrapped around the first and second aerosol-generating materials 4, 5 to form a generally tubular, open-ended construction (as shown in FIG. 5B ). In this example, a first edge 6A of the sheet of material 6 is positioned over an opposing second edge 6B to form a tube, which is then held in place, for example by applying an adhesive to the sheet of material 6 in the region of one or both of the first and second edges 6A, 6B, or by stapling, welding or sewing the sheet of material 6 in the region of the first and second edges 6A, 6B.

[0210] In a fourth step, the open ends of the tubes are sealed to form a pouch 2 containing the first and second aerosol-generating materials 4, 5. In this example, a third edge 6C of the sheet material 6 is folded over and held in place, for example, by adhesive, sewing or stapling the sheet material 6. Similarly, an opposite fourth edge 6D of the sheet material 6 is folded over and held in place, for example, by adhesive, sewing or stapling the sheet material 6. However, it will be appreciated that in alternative embodiments, one or both of the open ends are not folded over, but instead are sealed (for example, by adhesive, welding the sheet material 6, sewing or stapling) without first folding the third and fourth edges 6C, 6D of the sheet material 6.

[0211] Reference is now made to Figures 6 and 7, which show another method of manufacturing a consumable 1 for an aerosol delivery device 200, and an apparatus 300 for carrying out the method.

[0212] A continuous web W of sheet material is provided from a reel R of sheet material 6. Web W is provided along a transport path (indicated by arrow "P" in Figures 6 and 7). For example, web W may be transported along transport path P by one or more rollers 301, 302.

[0213] In a first step S1, a web W is formed into a configuration of sheet material 6, which in this example is a continuous tube T of sheet material 6. For example, the web W may be fed through a forming device 303 (e.g., a cone, garniture, or tongue that forms the initially flat web W into a tube T). The forming device 303 may have a conical or O-shaped cross-section that forms the web W into the tube T.

[0214] The forming device 303 may be configured to apply an adhesive to the web W to hold the web W in a tubular shape. Alternatively or additionally, the adhesive may be pre-applied to the web W and activated after or while a portion of the web W is formed into the tube T to hold the web W in a tubular shape. In some embodiments, the adhesive is applied to the tube T downstream of the forming device 303, for example by a separate adhesive applicator (not shown).

[0215] In a second step S2, the first and second aerosol-generating materials 4, 5 are fed into the tube T. In this example, the first and second aerosol-generating materials 4, 5 are fed into the tube T from above such that they fall under the effect of gravity and are provided in a lower region of the tube T. However, it will be appreciated that in other embodiments the first and second aerosol-generating materials 4, 5 may additionally or alternatively be fed by, for example, air pressure.

[0216] In this example, the first and / or second aerosol-forming materials 4,5 are supplied to the tube T as a continuous stream of the first and / or second aerosol-forming materials 4,5.

[0217] In this example, the first and second aerosol-generating materials 4, 5 are fed through a shaping device 303 into the tube T. For example, the first and second aerosol-generating materials 4, 5 may be fed through a cone-shaped member that shapes the web W into the tube T.

[0218] The first and second aerosol-generating materials 4, 5 are disposed within a tube T such that at least a portion of the tube T is adapted to be transported in series with the first and second aerosol-generating materials 4, 5 disposed therein.

[0219] In this example, a first aerosol-generating material 4 is delivered to tube T by a first delivery device 304, and a second aerosol-generating material 4 is delivered to tube T by a second delivery device 305. However, it will be appreciated that in other embodiments, the first and second aerosol-generating materials 4, 5 may be premixed and then delivered together to tube T via a single delivery device (not shown).

[0220] The or each delivery device 304, 305 may be configured to transfer the aerosol-generating material 4, 5 by gravity feed and / or alternative or additional means (e.g., air pressure). The or each delivery device 304, 305 may be configured to deliver a continuous flow of aerosol-generating material, or may be configured to provide a metered amount of aerosol-generating material (e.g., using a metering wheel).

[0221] In a third step S3, the portion of the tube T containing the first and second aerosol-generating materials 4, 5 passes through a sealing device 306. The sealing device 306 is configured to collapse the tube T such that the first and second aerosol-generating materials 4, 5 contained therein are forced axially upstream and downstream of the sealing device 306 (i.e., upstream and downstream in the direction of the transport path P) such that the wall of the tube T may seal against itself. For example, the tube T may be sealed by crimping the ends of the tube T.

[0222] In this example, the tube T is sealed at the dashed line "Z1-Z1" shown in FIG.

[0223] The sealing device 306 is configured to hold the ends of the tube T in a sealed configuration. For example, the sealing device 306 may be configured to apply adhesive (e.g., a suitable adhesive such as PVA), stitch, or staple to the crimped / compressed portions of the tube T, or may be configured to weld the portions of the tube T. In some embodiments, the web W is pre-applied with adhesive. In one such embodiment, the sealing device 306 is configured to activate a hot melt adhesive at the crimped / compressed portions of the tube T such that the adhesive holds the tube T in the sealed configuration.

[0224] In this example, sealing device 306 comprises a pair of sealing members 307, 308 that reciprocate towards each other to intermittently compress and seal a portion of tube T and then move away from each other to allow the portion of tube T containing aerosol-generating material 4, 5 to pass uncompressed. In other embodiments (not shown), the sealing members are provided on a rotating wheel, with successive pairs of sealing members intermittently aligned to compress and seal a portion of tube T.

[0225] In this example, each sealing member 307, 308 comprises a wedge-shaped member 307A, 308A. The shape of each wedge-shaped member 307A, 308A is such that the first and second aerosol-generating materials 4, 5 contained in the tube T are forced axially upstream and downstream of the wedge-shaped members 307A, 308A of the sealing device (i.e., upstream and downstream in the direction of the transport path P).

[0226] In a fourth step S4, the sealed portion of the tube T passes through a cutting device 309 which cuts the tube T at the sealed portion to form individual consumables 1 (e.g., the tube T may be cut along the dashed line "Z2-Z2" shown in FIG. 6).

[0227] In this example, the cutting device 309 comprises a pair of cutting rollers 310, 311 having cutting blades 310A, 311A, respectively, that intermittently meet to sever the tube T at its sealed end, although it will be appreciated that in alternative embodiments (not shown), the cutting device 309 may have another configuration (e.g., comprising one or more reciprocating cutting knives or one or more lasers that intermittently cut the tube T).

[0228] It is to be appreciated that in alternative embodiments, a single device performs the functions of both the sealing device 306 and the cutting device 309 described above. For example, in one alternative embodiment, the cutting device 309 is omitted, and instead, the wedge-shaped members 307A, 308A each have a sharp cutting edge that cuts the tube T when they meet.

[0229] 1 and 2, the first and second aerosol-generating materials 4, 5 are mixed together in the space 3 of the pouch 2. In other embodiments, one of the first and second aerosol-generating materials 4, 5 may be interspersed throughout or with the other of the first and second aerosol-generating materials 4, 5.

[0230] Reference is now made to Figure 8, which illustrates an alternative embodiment of the consumable 1. The consumable 1 has similar features to the consumable 1 described above with respect to Figures 1 and 2, and similar features are given the same reference numbers. The difference is that rather than the first and second aerosol-generating materials 4, 5 being mixed together, the first aerosol-generating material 4 is provided in a first region 4A and the second aerosol-generating material 5 is provided in a second region 5A. The first and second regions 4A, 5A may be discrete and, optionally, spaced apart from one another. In this example, the first and second regions 4A, 5A are in contact with one another rather than spaced apart.

[0231] The first region 4A is provided on a first end side of the consumable 1, and the second region 5A is provided on a second end side of the consumable 1. For example, the first region 4A may be provided on one side of the proximal end P and the distal end D of the consumable 1, and the second region 5A may be provided on the other side of the proximal end P and the distal end D of the consumable 1.

[0232] Reference is now made to Figure 9, which shows another embodiment of a consumable 1. The consumable 1 has similar features to the consumable 1 described above with respect to Figure 8, and similar features are given the same reference numbers. Again, first and second aerosol-generating materials 4, 5 are provided in first and second regions 4A, 5A, respectively. The difference is that rather than the first region 4A being provided at a first end side of the consumable 1 and the second region 5A being provided at a second side of the consumable 1, both regions 4A, 5A extend between the first and second ends of the consumable 1. In some embodiments, the first and second regions 4A, 5A are on either side of a central axis of the consumable 1.

[0233] Reference is now made to FIG. 10, which illustrates another embodiment of the consumable 1. The consumable 1 has similar features to the consumable 1 described above with respect to FIG. 8, and similar features are given the same reference numbers. Again, the first and second aerosol-generating materials 4, 5 are provided in first and second regions 4A, 5A, respectively. The difference is that a divider 7 is provided to facilitate separation of the first and second aerosol-generating materials 4, 5. The divider 7 may be gas permeable, for example comprising a mesh or a portion of sheet material (optionally porous and / or provided with one or more openings to facilitate gas flow through the consumable 1). Optionally, the divider 7 may be a sheet material that is integrally formed with the remainder of the sheet material 6 of the pouch 2.

[0234] By providing the first and second aerosol-generating materials 4, 5 in separate regions 4A, 5A (e.g., as shown in Figures 8-10), the first and second aerosol-generating materials 4, 5 can be heated separately, e.g., at different times using first and second heaters. For example, the first region 4A containing the relatively low density first aerosol-generating material 4 can be heated first with the first heater to generate aerosol towards the beginning of a consumption session. The second region 5A containing the relatively high density second aerosol-generating material 5 can then be heated, or heated simultaneously and for longer, to generate aerosol towards the end of the consumption session, facilitating more consistent aerosol generation over the duration of the consumption session. However, it will be appreciated that in other embodiments, the first and second aerosol-generating materials 4, 5 are not in separate regions and the different densities of the first and second aerosol-generating materials 4, 5 still facilitate more consistent aerosol generation over the duration of a consumption session.

[0235] It is to be appreciated that the above method and apparatus can be modified such that the first aerosol-generating material 4 is contained in a first pouch and the second aerosol-generating material 5 is contained in a second pouch. The first and second pouches can be connected, for example, by stapling, sewing, welding, and / or adhesive. In another embodiment, the first and second pouches can be formed from the same sheet material. For example, the method and apparatus of Figures 6 and 7 can be modified such that a quantity of the first aerosol-generating material 4 is first provided in a sheet material arrangement (e.g., a continuous tube) and then a portion of the sheet material 6 is sealed to form a first pouch containing the first aerosol-generating material 4, and then a quantity of the second aerosol-generating material 5 is provided in a sheet material arrangement (e.g., a continuous tube) and then a portion of the sheet material 6 is sealed to form a second pouch containing the second aerosol-generating material 5 adjacent to the first pouch. The sheet material may then be cut to form the consumable comprising the first and second patches (e.g., cut downstream of the first pouch and upstream of the second pouch). In other embodiments, the first and second pouches containing the first and second aerosol-generating materials 4, 5, respectively, may be manufactured separately and then joined together to form the consumable.

[0236] 11-13, which show one embodiment of an aerosol delivery device 200. As shown in FIG.

[0237] The consumable 1 is configured for use in an aerosol delivery device 200 (see FIG. 11 ) that includes an aerosol generator in the form of a heating element 203 for heating the consumable 1. In this example, the heating element 203 at least partially surrounds a heating area 202 (e.g., a heating chamber 202). The heating element 203 may be adapted to be resistively and / or inductively heated.

[0238] In other embodiments (not shown), the heating element 203 may alternatively comprise a blade or pin that is inserted into the consumable 1, for example, the blade or pin may be inserted through (e.g., penetrating) the sheet material 10 and, optionally, the first and / or second aerosol-generating materials 4, 5. In other embodiments (not shown), the consumable 1 may comprise a heating element that may be embedded in, for example, the first and / or second aerosol-generating materials 4, 5.

[0239] In Figure 11, components of one embodiment of an aerosol delivery device 200 are shown in a simplified manner. Notably, the components of the aerosol delivery device 200 depicted in Figure 11 are not drawn to scale. To simplify Figure 11, components that are not relevant to understanding the present embodiment have been omitted.

[0240] 11, aerosol delivery device 200 is a non-combustible aerosol delivery device 200. Non-combustible aerosol delivery device 200 comprises a housing 201 including an area 202 for receiving consumable 1.

[0241] When the consumable 1 is received in the heating area 202, at least a portion of the consumable 1 is in thermal proximity to the heater 203. Thus, at least a portion of the aerosol-generating material 4, 5 is in thermal proximity to the heater 203. In some embodiments, the heater 203 is spaced apart from the consumable 1 (e.g., it defines the boundary of the consumable 1, but is spaced apart due to its large diameter). In other embodiments, the heater 203 is in direct contact with the consumable 1 (e.g., in contact with the outer surface of the sheet material 6 of the consumable 1). In another embodiment, the heater 203 comprises a blade or pin that contacts the inside of the consumable 1 (e.g., contacts the aerosol-generating material 4, 5).

[0242] When the consumable 1 is heated, the first and / or second aerosol generating materials 4, 5 in the space 3 of the pouch 2 may release one or more volatile compounds, and may release different volatile compounds at different temperatures. By controlling the maximum operating temperature of the electrically heated aerosol generating system 200, the selective release of undesirable compounds may be controlled by preventing the release of certain volatile compounds.

[0243] As shown in FIG. 12, within the housing 201 is an electrical energy source 204 (e.g., a rechargeable lithium ion battery). A controller 205 is connected to the heater 203, the electrical energy source 204, and a user interface 206 (e.g., a button or a display). The controller 205 controls the power supplied to the heater 203 to regulate its temperature. Typically, the aerosol-forming substrate is heated to a temperature of 250-450°C.

[0244] Figure 13 is a schematic cross-section of a non-combustible aerosol delivery device 200 as shown in Figure 11, with a consumable 1 received in a heated area 202 of the device 200 for heating by a heater 203. The non-combustible aerosol delivery device 200 receives the aerosol generating consumable 1 as shown, for consumption of the aerosol generating consumable 1 by a user.

[0245] The housing 201 of the non-combustible aerosol delivery device 200 defines an area 202 in the form of a cavity that is open at a proximal end (or mouth end) for receipt of an aerosol generating consumable 1 for consumption by a user.

[0246] In this example, aerosol delivery device 200 includes a mouthpiece 207 that is removable from the remainder of device 200 to allow access to area 202 for insertion and removal of consumable 1 into and from area 202. After consumable 1 has been delivered to area 202, mouthpiece 207 can be reattached. In some embodiments, mouthpiece 207 is removably attached to housing 201 of device 200, for example by a threaded or bayonet connection.

[0247] When a user utilizes the mouthpiece 207, air is drawn into the consumable 1 and the volatile materials condense to form an inhalable aerosol that passes through the mouthpiece 207 of the device 200 and into the user's mouth.

[0248] It is to be appreciated that in other embodiments, the mouthpiece 207 of the device 200 may be omitted. In some embodiments, the consumable 1 may comprise the mouthpiece and be adapted to contact the user's mouth.

[0249] In all of the above examples, the first and / or second aerosol-forming materials 4, 5 may comprise, consist of or consist essentially of an extruded or compressed body of tobacco material, and preferably the extruded or compressed body of tobacco material comprises beads of tobacco material.

[0250] In each of the above examples, the first and / or second aerosol-forming material 4, 5 may comprise a body or rod of aerosol-forming material.

[0251] In each of the above examples, the first and / or second aerosol-forming materials 4, 5 may comprise, consist of, or consist essentially of reconstituted tobacco, and preferably comprise shredded sheets of reconstituted tobacco.

[0252] In all of the above examples, the first and / or second aerosol-forming materials 4, 5 may comprise, consist of, or consist essentially of laminar tobacco.

[0253] In all of the above examples, the first and / or second aerosol-forming materials 4, 5 may comprise, consist of, or consist essentially of reconstituted and laminar tobacco, and preferably have an integral mixture of reconstituted and laminar tobacco.

[0254] In all of the above examples, the first and / or second aerosol-generating materials 4, 5 may comprise, consist of or consist essentially of a sheet of aerosol-generating material collected to form a body of material, preferably a laminated sheet of material, the sheet being preferably a sheet of reconstituted tobacco.

[0255] In all of the above examples, the first and / or second aerosol-generating material 4, 5 may comprise, consist of or consist essentially of a sheet of aerosol-generating material cut into strips, the sheet being preferably a sheet of reconstituted tobacco.

[0256] In all of the above examples, the first and / or second aerosol-forming materials 4, 5 may comprise tobacco material, which is made only from tobacco lamina and not from other types of tobacco material.

[0257] In all of the above examples, the first and second aerosol-forming materials 4, 5 are produced from the same aerosol-forming starting material that has been processed to have different morphologies.

[0258] In each of the example articles discussed above (including each of the articles shown in Figures 1-10 and 13), the second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4. Otherwise, the aerosol-generating materials of the articles may be the same or different.

[0259] It has been found that the second aerosol-generating material 5 having a higher density than the first aerosol-generating material 4 means that when both materials are exposed to the same heat, the higher density material will heat up more slowly and therefore release the volatile compound (e.g., nicotine) at a lower rate than the lower density material. Thus, the second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4 such that when exposed to the same heat, the second aerosol-generating material 5 will heat up more slowly and release the volatile compound (e.g., nicotine) at a lower rate than the first aerosol-generating material 4. Thus, by combining aerosol-generating materials with different densities, the release of the volatile compound(s) is more consistent and longer lasting. In some embodiments, aerosol-generating materials with different densities may be combined, optionally with separate heating with different times and / or temperatures, to further tailor the release of the volatile compound(s), for example, over the consumption period of the article. Alternatively, it may be desirable to release the volatile material more quickly or in greater quantities towards the beginning of consumption of the article, thereby providing a greater initial effect on the user upon use. The ability to control the generation of aerosol and release of volatile compounds may be particularly advantageous as it allows the article to be relatively small while still providing a specific desired release of volatile compound(s) over the period of consumption.

[0260] In some embodiments, the second aerosol-generating material 5 has a density that is at least about 25%, and optionally at least about 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, or 75% higher than the density of the first aerosol-generating material 4. The second aerosol-generating material 5 may have a density that is up to about 200%, and optionally up to about 150%, 125%, 100%, or 75% higher than the density of the first and second aerosol-generating materials 4. In some embodiments, the second aerosol-generating material 5 has a density that is between about 25% and about 75% higher than the density of the first aerosol-generating material 4.

[0261] In some embodiments, the second aerosol-forming material 5 has a viscosity of at least about 0.4 g / cm 3 , optionally at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2 g / cm 3 The second aerosol-forming material 5 has a density of about 2 g / cm 3 Optionally, about 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6, or 0.5 g / cm 3 In some embodiments, the density of the second aerosol-generating material 5 is between about 0.4 and 1.99 g / cm. 3 It is.

[0262] In some embodiments, the first aerosol-forming material 4 has a density of at least about 0.1 g / cm 3 , optionally at least about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, or 0.9 g / cm 3 The first aerosol-forming material 4 has a density of about 1 g / cm 3 Optionally, about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, or 0.2 g / cm 3 In some embodiments, the density of the first aerosol-generating material 4 is about 0.1 to 0.9 g / cm.3 It is.

[0263] In some embodiments, the first and second aerosol-generating materials 4, 5 contain the same ingredients and therefore will emit very similar aerosols upon heating, potentially with the same content of actives and / or flavors, etc. Due to their different densities, aerosols may be generated at different rates and / or for different periods of time from the two materials upon heating.

[0264] In other embodiments, the first and / or second aerosol-generating materials 4, 5 comprise different components (which may have the same or different densities) and thus will emit different aerosols upon heating, potentially with different compositions of actives and / or flavors, etc. The different densities may result in different aerosols being generated from the two materials upon heating at different rates and / or for different periods of time, potentially resulting in changes in the aerosol provided during use.

[0265] In some embodiments, the first aerosol-forming material 4 and the second aerosol-forming material 5 each comprise tobacco. Tobacco comprises volatile components including nicotine, aroma, and flavor. The tobacco may be any type of tobacco and any part of the tobacco plant, including tobacco leaves, lamina, stems, stalks, ribs, scraps, and shorts, or a mixture of two or more thereof. Suitable tobacco materials include types such as Virginia or flue-cured tobacco, Burley tobacco, Oriental tobacco, or blends of tobacco materials, optionally including those described herein. The tobacco may be expanded, such as Dry-Ice Expanded Tobacco (DIET), or processed by any other means. In some embodiments, the tobacco material may be reconstituted tobacco material. The tobacco may be pretreated or untreated, for example, solid stem (SS), shredded dried stem (SDS), steam treated stem (STS), or any combination thereof. The tobacco material may be fermented, cured, uncured, roasted, or pretreated.

[0266] The first and second aerosol-generating materials 4, 5 may contain different tobacco, or the tobacco may be the same but provided in a different form such that the second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4.

[0267] In some embodiments, the first aerosol-generating material 4 has at least one different property relative to the second aerosol-generating material 5. The different property may be one or more of the shape, size, water content, amount (weight), material(s), or ratio of materials that make up the first and second aerosol-generating materials 4, 5 (including the method of manufacture of the aerosol-generating materials, if each is made from two or more materials). In some embodiments, the first and second aerosol-generating materials 4, 5 do not have any different property other than their different densities.

[0268] In some embodiments, the first aerosol-generating material 4 includes one or more tobaccos in the form of cut rags. The tobacco material may be lamina or reconstituted tobacco material. In some embodiments, the first aerosol-generating material 4 is a blend that includes both lamina and reconstituted tobacco. For example, the ratio of lamina to reconstituted tobacco may be about 1:4 to about 4:1.

[0269] The second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4. In some embodiments, this high-density second aerosol-generating material 5 may include particles or may be in the form of beads or one or more sheets. Each bead or sheet may be formed by agglomerated small particles. In some embodiments, both the first and second aerosol-generating materials 4, 5 may be in the form of beads or one or more sheets, and may optionally be processed so that the second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4.

[0270] As used herein, the term "bead" is meant to include beads, pellets, or other small discrete units that are molded, shaped, compressed, or otherwise shaped into a desired shape. Beads may have a smooth, regular outline (e.g., spherical, cylindrical, ovoid, etc.) and / or irregular outline.

[0271] In some embodiments, the beads have a diameter of at least about 0.5 mm (e.g., as measured by sieving), optionally at least about 1, 1.5, 2, 2.5, or 3 mm. The beads may have a diameter of about 5 mm or less (e.g., as measured by sieving), optionally about 4.5, 4, 3.5, 3, 2.5, 2, or 1.5 mm or less. In some embodiments, the diameter of each bead may range from about 0.5 mm to about 3 mm, or from about 1 mm to about 2 mm. The size of the beads may refer to the average size of each, such as the average size by number or volume.

[0272] In some embodiments, the desired density of the aerosol-generating material 4, 5 is achieved or controlled by the method(s) by which the material is formed and / or processed. Processes that involve agglomeration, particularly agglomeration that involves the application of some compressive force, tend to increase the density of the material.

[0273] Thus, in some embodiments, the first and / or second aerosol-forming materials 4, 5 comprise particles of agglomerated material.

[0274] In the case of a sheet material, the sheet may be formed by particles of material that are bonded and optionally compressed to form a sheet having the desired dimensions and density.

[0275] In some embodiments, the beads or pellets may be formed through use of the so-called marumarising process.

[0276] In some embodiments, the agglomeration is by pelleting. Pelletization is an agglomeration process that converts fine particles of material, optionally with excipients, into free-flowing units called pellets. Pellet formation and growth can occur in many ways, depending on the type of equipment and process selected. These pellets may be formed by agitation, where agglomerates form when particles are rotated and tumbled in the presence of an appropriate amount of liquid. Balling can involve the use of equipment such as pans, disks, drums, or mixers that produce pellets. Compression pelleting is a form of pressure agglomeration, where particles are held together by mechanical forces, optionally with the use of forming aids. The compression force means that the density of the formed pellets is higher than the starting material.

[0277] In some embodiments, the agglomeration is by extrusion. In some embodiments, the pellets formed by pelletization may be extruded to form a denser molded article.

[0278] The extruded particles may have a size selected to produce a denser aerosol-generating material (e.g., denser second aerosol-generating material 5), which will affect heat transfer and release of volatile components within the material.

[0279] In extrusion, the extruded product is produced by feeding a composition (also called a precursor composition) through a die, a process in which pressure is applied to the composition in combination with shear forces.

[0280] Extrusion may be carried out using one of the major classes of extruders: screw, screen and basket, roll, ram, and pin barrel extruders. Single screw or twin screw extruders may be used. Forming tobacco beads by extrusion has the advantage that the process combines compression, mixing, conditioning, homogenization, and shaping of the composition.

[0281] In some embodiments, during extrusion, a free-flowing composition including particles, such as tobacco particles, is subjected to high pressure and temperature and forced through an orifice, such as a forming nozzle or die, to form a shaped article, which in some embodiments is in the form of a rod and may be cut into segments of desired length.

[0282] In some embodiments, the composition is exposed in the extruder to a temperature of about 40° C. to about 150° C., about 80° C. to about 130° C., or about 60° C. to about 95° C. In some embodiments (including those using dual extrusion), the precursor composition is exposed in the extruder to a temperature of about 70° C. to about 95° C. In some embodiments (including those using single extrusion), the precursor composition is exposed in the extruder to a temperature of about 60° C. to about 80° C.

[0283] The composition may be exposed to a pressure (just before the die or nozzle) ranging from about 2 bar to about 100 bar, or from about 5 bar to about 60 bar, depending on the design of the die or nozzle used. The higher the pressure, the higher the density of the molded article is likely to be. Thus, the extrusion process may be adjusted to provide an extruded aerosol-generating material having a desired density.

[0284] In some embodiments in which tobacco particles are extruded, due to the relatively high density of the extruded article and the relatively open surfaces of the tobacco particles therein, the tobacco beads formed from the extruded article exhibit good heat and mass transfer, favorably affecting the release of tobacco constituents such as flavors and nicotine.

[0285] In some embodiments, extrusion may be a generally dry process, such that the composition including the aerosol-forming particles is dry or substantially dry. The composition may optionally include other particulate materials, including, for example, bases, diluents, solid aerosol formers, solid flavor modifiers, and the like.

[0286] In some embodiments, a liquid may be added to the composition before or during the extrusion process. For example, water may be added as a processing aid to help dissolve or solubilize the components of the composition or to help bind or aggregate. Alternatively or additionally, a wetting agent may be added to the composition.

[0287] In some embodiments, the liquid may be an aerosol-forming material as discussed herein, such as glycerol. When the liquid is added to the composition in this manner, not only is the liquid applied to the surface, but the liquid is also impregnated into the molded part as a result of the combination of vigorous mixing due to high shear forces and the pressure of the extruder. If the liquid is an aerosol-forming material, this results in a high probability of aerosol-forming material in the resulting beads and promotes evaporation of volatile components.

[0288] In some embodiments, the amount of aerosol-forming material incorporated into the extruded beads may be up to about 30% by weight, or even up to about 40% by weight. Typically, such a large amount of aerosol-forming material makes the composition difficult to handle. However, this is less of a problem if the particles are impregnated with the aerosol-forming material as a result of extrusion. If the beads generate aerosols other than releasing volatile components, it may be desirable to include an amount of aerosol-forming material such as at least about 10% by weight or at least about 20% by weight. If the primary function of the beads is to release volatile constituents carried by the beads into an existing aerosol or air stream, a small amount of aerosol-forming material, such as up to about 5% by weight, may be sufficient.

[0289] In some embodiments, the mass does not include a binder or binding additive. For example, extruded beads may not require a binder to maintain their structural integrity. In other embodiments, the mass includes a binder or binding additive. The binding additive may be selected to aid in the formation of a cohesive structure by aiding in the adhesion of the particles to each other and to other components in the composition. Suitable binding additives include thermoreversible gelling agents such as gelatin, starch, polysaccharides, pectin, alginates, wood pulp, cellulose, and cellulose derivatives such as carboxymethylcellulose.

[0290] In some embodiments, the extrusion process is sufficient to densify the second aerosol-generating material 5, if desired, although in other embodiments, additional processing of the molded article may be used to further densify the second aerosol-generating material 5.

[0291] For example, in some embodiments, the extruded aerosol-forming material is spheronized. In spheronization, extruded cylindrical particles are crushed to uniform length and gradually deformed into spherical shapes by plastic deformation. If the article is first crushed to uniform length, the spheronization step produces spheres of uniform diameter.

[0292] According to one specific example of the embodiments discussed herein, a sample of the second aerosol-generating material 5 was generated as follows (although in some embodiments a sample may be generated as follows and alternatively used for the first aerosol-generating material):

[0293] Three sample formulations, one with and one without binder, are shown in Table 1, with amounts given as wet weight ratios (WWB).

[0294] [Table 1] The tobacco was ground into a fine powder, taking care not to overheat it. The ground tobacco particles were sieved to select the desired size, for example, particle sizes less than 250 μm, less than 100 μm, or less than 60 μm.

[0295] All of the dry (non-liquid) ingredients of the formulation were then combined and mixed or blended in a mixer. In this particular case, the mixture was mixed at a speed of 75 RPM for 1 minute. This is to ensure that the dry ingredients are evenly distributed in the mixture.

[0296] Next, half of the glycerol and half of the water were added to the dry mix and mixed. Specifically, the mix was mixed for an additional minute at 75 RPM. The remaining glycerol and water were then added and mixed again for 1 minute at 75 RPM. Mixing was continued until the mix was crumbly enough to squeeze together to obtain a homogenous mix. In this particular case, mixing was continued for an additional 3 minutes.

[0297] The mixture was then extruded using a Caleva Multilab, which was operated at approximately 1500 rpm to produce spaghetti-like lengths.

[0298] The extruded product emerged from the extruder broken into small pieces of various lengths. These pieces were then spheronized. Spheronization was carried out until spherical beads were formed. In this case, the extruded product was first spheronized for 1 minute in a Caleva Multilab operating at 2,500 RPM and then the beads were checked for defects. Spheronization was then continued for another 1-2 minutes. This spheronization step broke the extruded tobacco into individual pieces and formed dense spherical beads.

[0299] In a final step, the spheronized beads were dried in an oven at 65° C. for 30 minutes. After each drying period, the beads were weighed and the drying was stopped when the desired reduction in water weight was achieved. Typically, such drying will require about 1 hour.

[0300] In some embodiments, the other of the first and / or second aerosol-generating materials 4, 5 is in the form of discrete particles or particle agglomerates. These particles may share various properties, such as particle size, with the (higher density) second aerosol-generating material 5, but will have a lower density. As mentioned above, there are various ways to adjust the density of the aerosol-generating materials 4, 5, such as forming and / or processing the materials as particles, beads, or pellets.

[0301] In some embodiments, the first aerosol-forming material 4 comprises a combination of 60% reconstituted tobacco and 40% laminar tobacco, and the density of this material is about 0.1 to about 0.9 g / cm. 3 The second aerosol-forming material 5 contains about 30 to about 90% tobacco and has a density in the range of about 0.4 to about 1.99 g / cm 3 The amount of aerosol-generating material in one of the first and / or second aerosol-generating materials 4, 5 may be about 8 to about 15%. The second aerosol-generating material 5 may comprise large spherical beads having a particle size of about 0.5 to about 3 mm. In some embodiments, the aerosol-generating material in the article comprises about 50% by weight of the first aerosol-generating material 4 and about 50% by weight of the second aerosol-generating material 5. Thus, for example, an article containing 260 mg of aerosol-generating material may comprise 130 mg of the first aerosol-generating material 4 and 130 mg of the second aerosol-generating material 5.

[0302] In some embodiments in which the aerosol-forming material includes tobacco, the tobacco is present in an amount between about 10% and about 90% by weight of the aerosol-forming material.

[0303] In some embodiments, tobacco may be present in an amount of at least about 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, or finally about 35% tobacco, based on the weight of the aerosol-forming material.

[0304] In some embodiments, tobacco may be present in an amount of about 90%, 89%, 88%, 87%, 86%, 85%, 84%, 83%, 82%, 81%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45% or less, or may be present in an amount of about 40% or less, based on the weight of the aerosol-forming material.

[0305] The tobacco described herein may contain nicotine. In some embodiments, the nicotine content may be 0.5-2% by volume of the tobacco, such as 0.5-1.75% by volume of the tobacco, 0.8-1.2% by volume of the tobacco, or about 0.8 to about 1.75% by volume of the tobacco. In some embodiments, the nicotine content may be 0.8-1% by volume of the tobacco.

[0306] In some embodiments, the first and second aerosol-forming materials 4, 5 have the same nicotine content.

[0307] In some embodiments, the first and second aerosol-generating materials 4, 5 include one or more volatile components. In some embodiments, the first and second aerosol-generating materials 4, 5 have the same content of volatile components.

[0308] In some embodiments, the first and / or second aerosol-generating material 4, 5 comprises tobacco. For example, the first and / or second aerosol-generating material 4, 5 may comprise from about 80 to about 350 mg of tobacco. In some particular embodiments, the aerosol-generating material in the article or consumable has a weight of 260 mg, comprising a combination of 130 mg of a first aerosol-generating material 4 (e.g., comprising a blend of lamina and reconstituted tobacco) and 130 mg of a second aerosol-generating material 5 (e.g., comprising higher density tobacco beads).

[0309] In some embodiments, the article may include regions of aerosol-generating material, each region including an equal amount of tobacco. In alternative embodiments, the regions may include different amounts of tobacco. For a total amount of tobacco of about 80 to about 350 mg, one region of aerosol-generating material may include about 20 to about 330 mg, about 50 to about 300 mg, or about 40 to about 125 mg of tobacco, and another region of aerosol-generating material may include about 20 to about 330 mg, about 30 to about 300 mg, or about 40 to about 125 mg of tobacco.

[0310] The present disclosure also provides a kit of parts comprising a consumable 1 according to any of the examples described herein and an aerosol delivery device 200.

[0311] The present disclosure also provides a package including a plurality of consumables according to any of the examples described herein. In some embodiments, the package is hermetically sealed. The package may include a container including a body and a lid, the container body having a space therein for receiving the plurality of consumables. The lid may be, for example, a hinged lid, a snap-fit ​​lid, or a lid connected by a screw thread.

[0312] The various embodiments described herein are presented only as an aid in understanding and teaching the features of the claims. These embodiments are provided as a representative sample of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, features, features, structures, and / or other aspects described herein should not be considered 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 can be utilized and improved 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 that are not currently claimed but may be claimed in the future.

Claims

1. 1. A consumable for use in an aerosol delivery system, the consumable comprising one or more pouches containing a first aerosol generating material and a second aerosol generating material, the second aerosol generating material having a higher density than the first aerosol generating material.

2. 10. The consumable product of claim 1, wherein the or each pouch comprises a sheet material.

3. The consumable product of claim 1 or 2, wherein the sheet material comprises paper.

4. A consumable product according to claim 2 or 3, wherein the sheet material has a thickness in the range of 20 to 100 microns, preferably in the range of 30 to 80 microns, 35 to 55 microns or 40 to 50 microns.

5. The consumable according to any one of claims 1 to 4, wherein the sheet material is gas permeable.

6. 6. The consumable product of claim 5, wherein the sheet material has an air permeability in the range of 10 to 25,000 Coresta units, optionally in the range of 25 to 100 Coresta units.

7. A consumable product according to any one of claims 2 to 6, wherein the sheet material is folded and / or wrapped to define the or each pouch.

8. 8. A consumable product according to any one of claims 2 to 7, wherein at least one edge of the sheet material is attached to another portion of the sheet material so as to retain the first aerosol-generating material and / or the second aerosol-generating material in the or each pouch.

9. A consumable product according to any one of claims 2 to 8, wherein the or each pouch is formed from a single sheet of material.

10. A consumable product according to any one of claims 2 to 9, wherein the or each pouch is formed from two or more sheets of material joined together.

11. A consumable product according to any one of claims 2 to 10, wherein the sheet material of the or each pouch completely encases the aerosol-forming material contained in the pouch.

12. A consumable product according to any preceding claim, wherein the or each pouch constitutes an outer surface of the consumable product.

13. The consumable product of any one of claims 1 to 12, wherein the first aerosol-forming material and / or the second aerosol-forming material are free materials.

14. The consumable product of any one of claims 1 to 13, wherein the second aerosol-forming material comprises an extruded and / or compressed aerosol-forming material.

15. The consumable product of any one of claims 1 to 14, wherein the second aerosol-generating material comprises beads.

16. The consumable product according to claim 12, wherein the beads have a diameter in the range of 0.5 to 3 mm, preferably in the range of 1 to 2 mm.

17. The consumable product of any preceding claim, wherein the first aerosol-forming material comprises, consists of, or consists essentially of tobacco material.

18. 20. The consumable product of claim 17, wherein the tobacco material of the first aerosol-forming material is derived only from tobacco lamina and not from other types of tobacco material.

19. 20. The consumable product of claim 17, wherein the first aerosol-forming material comprises tobacco lamina and reconstituted tobacco.

20. 20. The consumable product of any one of claims 1 to 19, wherein the second aerosol-forming material comprises, consists of, or consists essentially of tobacco material.

21. 21. The consumable product of claim 20, when dependent on any one of claims 17 to 19, wherein the first aerosol-generating material and the second aerosol-generating material together have an average nicotine level in the range of 0.5% to 2.5%, preferably in the range of 1% to 2.1%, by weight of the first aerosol-generating material and the second aerosol-generating material.

22. 22. The consumable product of claim 20 or 21, wherein the tobacco material of the second aerosol-forming material is derived only from tobacco lamina and not from other types of tobacco material.

23. 23. The consumable product of any one of claims 20 to 22, wherein the second aerosol-forming material comprises laminar tobacco and / or reconstituted tobacco.

24. 24. The consumable according to any one of claims 1 to 23, wherein the consumable comprises in the range of about 20 to about 330 mg of the first aerosol-generating material, preferably in the range of about 50 to about 300 mg or about 40 to about 125 mg of the first aerosol-generating material.

25. 25. The consumable according to any one of claims 1 to 24, wherein the consumable comprises in the range of about 20 to about 330 mg of the second aerosol-generating material, preferably in the range of about 50 to about 300 mg or about 40 to about 125 mg of the second aerosol-generating material.

26. The consumable of any one of claims 1 to 25, wherein the consumable is plastic-free.

27. The consumable product of any one of claims 1 to 26, wherein the density of the second aerosol-generating material is at least 25% higher than the density of the first aerosol-generating material.

28. The first aerosol-forming material has a density of about 0.1 g / cm ３ ~Approx. 1g / cm ３ 28. The consumable product of any one of claims 1 to 27, having a density of

29. The second aerosol-forming material has a density of about 0.4 g / cm ３ ~Approx. 2g / cm ３ 29. The consumable product of any one of claims 1 to 28, having a density of

30. The consumable product of any one of claims 1 to 29, wherein a single pouch contains the first aerosol-forming material and the second aerosol-forming material.

31. 31. The consumable product of claim 30, wherein the first aerosol-forming material and the second aerosol-forming material are mixed together in the one pouch.

32. 31. The consumable product of claim 30, wherein the first aerosol-forming material and the second aerosol-forming material are provided in discrete regions within the one pouch.

33. The consumable product of any one of claims 1 to 29, comprising a first pouch containing the first aerosol-generating material and a second pouch containing the second aerosol-generating material.

34. The consumable product of any one of claims 1 to 33, wherein the first aerosol-generating material and the second aerosol-generating material are produced from the same aerosol-generating starting material that has been processed to have different morphologies.

35. The consumable product of any one of claims 1 to 34, wherein the first aerosol-generating material and / or the second aerosol-generating material comprises an aerosol-forming material.

36. 36. The consumable product of any one of claims 1 to 35, wherein the first aerosol-forming material and / or the second aerosol-generating material comprise from about 10 to about 50% by weight of an aerosol-forming material, from about 15 to about 60% by weight of a gelling agent, and optionally a filler, the weight percentage values ​​being calculated on a dry weight basis.

37. 37. The consumable product of claim 36, wherein the first aerosol-forming material and / or the second aerosol-forming material comprises a flavoring.

38. 1. A method of manufacturing a consumable for use in an aerosol delivery system, comprising:

11. A method comprising: forming one or more pouches containing a first aerosol-generating material and a second aerosol-generating material, the second aerosol-generating material having a higher density than the first aerosol-generating material.

39. 40. The method of claim 38, wherein the or each pouch comprises a sheet material.

40. 40. The method of claim 39, comprising forming the sheet material of the or each pouch as a tube containing the first aerosol-forming material and / or the second aerosol-forming material.

41. 41. A method according to claim 39 or 40, comprising forming the sheet material as a construction having one end closed and the other end open, the first aerosol-generating material and / or the second aerosol-generating material being provided within the construction of the sheet material.

42. 42. The method of claim 41, comprising feeding the first aerosol-forming material and / or the second aerosol-forming material into the arrangement under gravity.

43. 43. The method of claim 42, comprising supplying a continuous flow of the first aerosol-forming material and / or the second aerosol-forming material to the arrangement.

44. A method according to any one of claims 41 to 43, comprising sealing and cutting the construction of sheet material at a location spaced from the closed end of the construction to form a pouch.

45. 45. The method of claim 44, wherein said construction of sheet material is repeatedly sealed and cut to form a plurality of pouches.

46. 46. ​​A method according to claim 44 or 45, wherein the construction of sheet material is sealed and cut simultaneously.

47. 47. The method of any one of claims 44 to 46, wherein the step of sealing the arrangement comprises manipulating the arrangement such that aerosol-forming material in the arrangement moves axially downstream and / or upstream of the portion of the arrangement to be sealed.

48. 41. A method according to claim 39 or 40, comprising depositing a first aerosol-generating material and / or a second aerosol-generating material onto the sheet material, preferably depositing a metered amount of the first aerosol-generating material and / or the second aerosol-generating material onto the sheet material.

49. 49. The method of any one of claims 39 to 48, comprising wrapping the sheet material around the first aerosol-forming material and / or the second aerosol-forming material.

50. 50. A method according to any one of claims 39 to 49, comprising attaching together the first and second portions of sheet material such that the first aerosol-generating material and / or the second aerosol-generating material are held between the first and second portions of sheet material.

51. A consumable product manufactured according to the method of any one of claims 38 to 50.

52. A package comprising a plurality of consumable products according to any one of claims 1 to 37 or 51, preferably said package being sealed.

53. A kit of parts comprising a consumable product according to any one of claims 1 to 37 or 51 and an aerosol delivery device.

54. 54. The kit of parts of claim 53, wherein the aerosol delivery device comprises a heating zone for receiving the consumable and heating the first aerosol-generating material and the second aerosol-generating material.

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