Method of manufacturing an article for use in an aerosol delivery system and article for use in an aerosol delivery system

Abstract

The present disclosure relates to a method of manufacturing an article for use in an aerosol delivery system, the method comprising the steps of providing a first sheet material, providing a substrate comprising a first aerosol-generating material and attached to the first sheet material, and positioning the first sheet material with the substrate attached such that the first sheet material surrounds the substrate. The present disclosure also relates to an article for an aerosol delivery device. The present disclosure also relates to an assembly for use in manufacturing an aerosol delivery device, a kit of parts including the article and the aerosol delivery device, and a package of the article.

Description

[Technical field]

[0001] The present disclosure relates to a method of making an article for an aerosol delivery device and to an article for an aerosol delivery device. The present disclosure also relates to an assembly for use in making an aerosol delivery device, a kit of parts including the article and an aerosol delivery device, and a package of the article. [Background technology]

[0002] Aerosol delivery systems generate an inhalable aerosol or vapor during use by releasing compounds from an aerosol-generating material, and may be referred to as, for example, a non-combustion smoking article, an aerosol-generating assembly, or an aerosol delivery device. Summary of the Invention

[0003] According to some embodiments described herein, there is provided a method of manufacturing an article for use in an aerosol delivery system, the method including the steps of providing a first sheet material; providing a substrate including the first aerosol-generating material and attached to the first sheet material; and positioning the first sheet material with the substrate attached such that the first sheet material surrounds the substrate.

[0004] In some embodiments, the substrate is adhered to the first sheet material.

[0005] In some embodiments the substrate comprises a second sheet material, and preferably providing the substrate comprises attaching the second sheet material to the first sheet material.

[0006] In some embodiments, the substrate is cast onto a first sheet material. For example, the first sheet material may be provided, and a slurry including the first aerosol-generating material may be provided onto the first sheet material and allowed to dry.

[0007] In some embodiments, the second sheet material is a cast sheet. The method may include casting the second sheet material, for example casting the second sheet material from a slurry.

[0008] In some embodiments, the second sheet material comprises the first aerosol-generating material.

[0009] In some embodiments, the second sheet material is formed from a slurry including the first aerosol-generating material, and preferably the slurry is cast to form the second sheet material.

[0010] In some embodiments, the second sheet material is a cast sheet.

[0011] In some embodiments, the first aerosol-generating material is attached to a surface of the second sheet material, preferably adhered to the surface of the second sheet material.

[0012] In some embodiments, the first aerosol-generating material is attached to a surface of the second sheet material either before or after the second sheet material is attached to the first sheet material.

[0013] In some embodiments, the second sheet material comprises one or more of paper, card, and / or an aerosol-forming material.

[0014] In some embodiments, providing the first sheet material comprises providing a web of the first sheet material.

[0015] In some embodiments, the first sheet material comprises paper or card.

[0016] In some embodiments, the first sheet material comprises a metal.

[0017] In some embodiments, the first sheet material comprises aluminum foil.

[0018] In some embodiments, the first sheet material comprises a co-laminate material including a paper layer and an aluminum layer.

[0019] In some embodiments, attaching the substrate to the first sheet material comprises attaching the substrate to an aluminum layer.

[0020] In some embodiments, the method further includes hollowing out vent openings in the substrate and / or the first sheet of material.

[0021] In some embodiments, providing the substrate comprises applying the substrate to a web of a first sheet material.

[0022] In some embodiments, applying the substrate to the first web of sheet material comprises applying a second web of sheet material to the first web of sheet material.

[0023] In some embodiments, applying the substrate to the web of the first sheet material comprises applying a plurality of portions of a second sheet material to the web of the first sheet material.

[0024] In some embodiments, the portions of the second sheet material are spaced apart from one another on the web of the first sheet material.

[0025] In some embodiments, the portions of the second sheet material are separate. The portions of the second sheet material may be spaced apart from one another in a direction along the transport path of the web of first sheet material.

[0026] In some embodiments, the edges of the substrate are spaced from the edges of the first sheet material such that an area of ​​the first sheet material is not covered by the substrate, and preferably the method includes a step of applying adhesive to said area.

[0027] In some embodiments, the first sheet material has a permeability of at most 100 Coresta units.

[0028] In some embodiments, the first sheet material has a thickness in the range of 20 to 100 microns.

[0029] In some embodiments, the first sheet material forms the outer surface of the article.

[0030] In some embodiments, the first aerosol-forming material comprises aerosol-forming material dust and / or aerosol-forming material fibers.

[0031] In some embodiments, the first aerosol-forming material comprises an extruded and / or compressed aerosol-forming material.

[0032] In some embodiments, the first aerosol-generating material comprises beads.

[0033] 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.

[0034] In some embodiments, the first aerosol-forming material comprises, consists of, or consists essentially of tobacco material.

[0035] In some embodiments, the tobacco material of the first and / or second aerosol-forming materials is derived only from tobacco lamina and not from other types of tobacco material.

[0036] In some embodiments, the first and / or second aerosol-forming materials include tobacco lamina and reconstituted tobacco.

[0037] In some embodiments, both the first and second aerosol generating materials 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 and second aerosol generating materials.

[0038] In some embodiments, the total weight of aerosol-forming material in the article is in the range of 150-350 mg, preferably in the range of 200-300 mg, 220-280 mg, or 230-260 mg.

[0039] In some embodiments, the article contains in the range of 7 mg / mm to 13 mg of aerosol-forming material per mm length of the article, preferably in the range of 8 to 12, 9 to 11.5, 9 to 11, or 9.5 to 10.5 mg of aerosol-forming material per mm length of the article.

[0040] In some embodiments, the first and / or second aerosol-forming materials are solid materials.

[0041] In some embodiments, the article does not include plastic.

[0042] In some embodiments, the article does not include cellulose acetate.

[0043] In some embodiments, the first and second aerosol-generating materials are produced from the same aerosol-generating starting material that has been processed to have different morphologies.

[0044] In some embodiments, the article further comprises a second aerosol-generating material.

[0045] In some embodiments, the density of one of the first and second aerosol-generating materials is at least about 25% higher than the density of the other of the first and second aerosol-generating materials, however, in other embodiments, the densities of the first and second aerosol-generating materials are the same.

[0046] In some embodiments, one of the first and second aerosol-forming materials has a density of about 0.1 g / cm 3 ~Approx. 1g / cm 3 has a density of

[0047] In some embodiments, the other of the first and second aerosol-forming materials has a mass fraction of about 0.4 g / cm3 ~About 2g / cm 3 has a density of

[0048] In some embodiments, heating the article provides a relatively constant release of volatile compounds into the inhalable medium.

[0049] In some embodiments, the first aerosol-forming material comprises extruded tobacco.

[0050] In some embodiments, the first aerosol-generating material comprises beads.

[0051] In some embodiments, the second aerosol-generating material comprises one or more tobacco materials selected from the group consisting of lamina and reconstituted tobacco materials.

[0052] In some embodiments, at least one of the first and second aerosol-generating materials comprises a combination of lamina and reconstituted tobacco material, hi some embodiments, the lamina and reconstituted tobacco material are present in the aerosol-generating materials in a ratio of 1:4 to 4:1 by weight.

[0053] In some embodiments, the first and second aerosol-generating materials have the same level of a volatile compound, hi some embodiments, the volatile compound is nicotine.

[0054] In some embodiments, the release of volatile compounds from the first and second aerosol-generating materials occurs at the same rate when the materials reach a given temperature.

[0055] In some embodiments, the first and second aerosol-forming materials are present in the article in a ratio of 1:10 to 10:1 by weight.

[0056] In some embodiments, the second aerosol-forming material has a higher or lower density than the first aerosol-forming material.

[0057] In some embodiments, the second aerosol-forming material comprises, consists of, or consists essentially of tobacco material.

[0058] In some embodiments, the second aerosol-forming material comprises shredded tobacco and / or reconstituted tobacco.

[0059] In some embodiments, the substrate comprises a second aerosol-forming material.

[0060] In some embodiments, the second sheet material includes the first and / or second aerosol-generating materials. For example, the second sheet material may be formed from a slurry including the first and / or second aerosol-generating materials.

[0061] In some embodiments, the first and / or second aerosol-generating materials are applied to a surface of a second sheet material.

[0062] In some embodiments, the second sheet material includes one of the first and second aerosol-generating materials, and the other of the first and second aerosol-generating materials is applied to a surface of the second sheet material.

[0063] In some embodiments, the step of positioning the first sheet material having the substrate attached thereto comprises providing the first sheet material and the substrate around at least a portion of the body of material, preferably wrapping the first sheet material together with the substrate around the body of material.

[0064] In some embodiments, the first sheet material surrounds the body of material. In some embodiments, the substrate surrounds the body of material.

[0065] In some embodiments, the body of material includes a third sheet material that is assembled to form the body of material.

[0066] In some embodiments, the third sheet material is crimped and / or cut into strips.

[0067] In some embodiments, the substrate is in direct contact with the body of material.

[0068] In some embodiments, the body of material comprises a tobacco rod. For example, the body of material may comprise shredded tobacco material formed into a rod. In some embodiments, the body of material comprises cut rag tobacco formed into a rod.

[0069] In some embodiments, the body of material includes a second aerosol-generating material.

[0070] The present disclosure also provides an assembly for use in a method of manufacturing an article for use in an aerosol delivery system, the assembly comprising a first sheet material and a patch including a first aerosol-generating material and attached to the first sheet material.

[0071] In some embodiments, the patch is adhered to the first sheet material.

[0072] In some embodiments, the first sheet material is laid flat.

[0073] In accordance with the present disclosure, there is also provided an article for use in an aerosol delivery system, comprising a first sheet material and a patch including a first aerosol generating material and attached to the first sheet material, the sheet material and the patch being arranged such that the sheet material surrounds the patch.

[0074] In some embodiments, the patch is adhered to the first sheet material.

[0075] In some embodiments, the first sheet material forms the outer surface of the article.

[0076] In some embodiments, the first sheet material comprises paper or card.

[0077] In some embodiments, the first sheet material comprises a metal.

[0078] In some embodiments, the first sheet material comprises aluminum foil.

[0079] In some embodiments, the first sheet material comprises a co-laminate material including a paper layer and an aluminum layer.

[0080] In some embodiments, the patch is attached to the aluminum layer.

[0081] In some embodiments, the article further comprises a second aerosol-generating material.

[0082] In some embodiments, the first and / or second aerosol-forming materials are substantially free of tobacco.

[0083] In some embodiments, the second aerosol-forming material has a higher or lower density than the first aerosol-forming material.

[0084] In some embodiments, the second aerosol-forming material comprises, consists of, or consists essentially of tobacco material.

[0085] In some embodiments, the second aerosol-forming material comprises shredded tobacco and / or reconstituted tobacco.

[0086] In some embodiments, the article further comprises a body of material, the first sheet material and the patch disposed about at least a portion of the body of material.

[0087] In some embodiments, the first sheet material surrounds the body of material.In some embodiments, the patch surrounds the body of material.

[0088] In some embodiments, the body of material includes a third sheet material that is assembled to form the body of material.

[0089] In some embodiments, the third sheet material is crimped and / or cut into strips.

[0090] In some embodiments, the substrate is in direct contact with the body of material.

[0091] In some embodiments, the body of material comprises a tobacco rod. For example, the body of material may comprise shredded tobacco material formed into a rod. In some embodiments, the body of material comprises cut rag tobacco formed into a rod.

[0092] In some embodiments, the body of material includes a second aerosol-generating material.

[0093] In some embodiments, the patch comprises a second sheet material, preferably the second sheet material is a cast sheet.

[0094] In some embodiments, the second sheet material is attached to the first sheet material, for example by an adhesive.

[0095] In some embodiments, the second sheet material comprises the first aerosol-generating material.

[0096] In some embodiments, the second sheet material is formed from a slurry including the first aerosol-generating material, and preferably the slurry is cast to form the second sheet material.

[0097] In some embodiments, the first aerosol-generating material is attached to a surface of the second sheet material, preferably adhered to the surface of the second sheet material.

[0098] In some embodiments, the second sheet material comprises one or more of paper, card, and / or an aerosol-forming material.

[0099] In some embodiments, the first and / or 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, where the weight percentages are calculated on a dry weight basis. In some embodiments, the first and / or second aerosol-forming material comprises a flavoring agent.

[0100] In some embodiments, the patch includes a first end spaced from a first end of the first sheet material.

[0101] In some embodiments, the patch comprises a second end opposite the first end, the second end being spaced apart from the second end of the first sheet material.

[0102] In some embodiments, the patch extends over a portion of the length of the article, hi some embodiments, the patch extends over the entire length of the article.

[0103] In some embodiments, the edges of the substrate are spaced from the edges of the first sheet material, preferably the edges being longitudinal edges of the substrate and first sheet material, such that no area of ​​the first sheet material is covered by the substrate.

[0104] In some embodiments, the first sheet material has a permeability of at most 100 Coresta units.

[0105] In some embodiments, the first sheet material has a thickness in the range of 20 to 100 microns.

[0106] In some embodiments, the first aerosol-forming material comprises aerosol-forming material dust and / or aerosol-forming material fibers.

[0107] In some embodiments, the first aerosol-forming material comprises an extruded and / or compressed aerosol-forming material.

[0108] In some embodiments, the first aerosol-generating material comprises beads.

[0109] 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.

[0110] In some embodiments, the first aerosol-forming material comprises, consists of, or consists essentially of tobacco material.

[0111] In some embodiments, the tobacco material of the first and / or second aerosol-forming materials is derived only from tobacco lamina and not from other types of tobacco material.

[0112] In some embodiments, the first and / or second aerosol-forming materials include tobacco lamina and reconstituted tobacco.

[0113] In some embodiments, both the first and second aerosol generating materials 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 and second aerosol generating materials.

[0114] In some embodiments, the first and / or second aerosol-forming materials are solid materials.

[0115] In some embodiments, the article does not include plastic, hi some embodiments, the article does not include cellulose acetate.

[0116] In some embodiments, the first and second aerosol-generating materials are produced from the same aerosol-generating starting material that has been processed to have different morphologies.

[0117] In some embodiments, the patch comprises a second aerosol-generating material.

[0118] In some embodiments, the patch includes a second sheet material that includes the first and / or second aerosol-generating materials, for example, the second sheet material may be formed from a slurry that includes the first and / or second aerosol-generating materials.

[0119] In some embodiments, the first and / or second aerosol-generating materials are applied to a surface of a second sheet material.

[0120] In some embodiments, the second sheet material includes one of the first and second aerosol-generating materials, and the other of the first and second aerosol-generating materials is applied to a surface of the second sheet material.

[0121] The present disclosure also provides articles made according to the methods disclosed herein.

[0122] The present disclosure also provides a package comprising a plurality of the articles disclosed herein, hi some embodiments, the package is sealed.

[0123] The present disclosure also provides a kit of parts including an article as disclosed herein and an aerosol delivery device.

[0124] In some embodiments, the aerosol delivery apparatus includes a heating chamber for receiving the articles and heating the first and second aerosol-generating materials.

[0125] Embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0126] [Figure 1] FIG. 1 is a cross-sectional side view of one embodiment of an article for use in an aerosol delivery system. [Diagram 2] FIG. 2 is a top view of a first sheet material of the article of FIG. 1, the first sheet material being laid flat. [Diagram 3]FIG. 2 is a top view of a second sheet material of the article of FIG. 1, the second sheet material being laid flat. [Figure 4] FIG. 2 is a perspective view of one embodiment of the article of FIG. 1. [Diagram 5] FIG. 2 is a top view of the substrate of the article of FIG. 1, the substrate lying flat. [Figure 6] 2 is a top view of an arrangement for use in making the article of FIG. 1, the arrangement comprising a first sheet material and a substrate. [Figure 7] 2 is a perspective view of a bead of aerosol-forming material of the article of FIG. 1. [Figure 8] FIG. 2 is a cross-sectional side view of another embodiment of an article for use in an aerosol delivery system. [Figure 9] FIG. 2 is a cross-sectional side view of another embodiment of an article for use in an aerosol delivery system. [Figure 10] FIG. 1 is a cross-sectional view of one embodiment of a non-combustion aerosol delivery device. [Figure 11] FIG. 11 is a simplified schematic diagram of components within the housing of the aerosol delivery device shown in FIG. [Figure 12] 11 is a cross-sectional view of the non-combustion aerosol delivery device shown in FIG. 10 with the article shown in FIG. 1 inserted therein. [Figure 13] FIG. 2 is a cross-sectional side view of another embodiment of an article for use in an aerosol delivery system. [Figure 14] FIG. 1 is a block diagram illustrating a method of manufacturing an article for use in an aerosol delivery system. [Figure 15A] 1 is a top view of a first step of a method of manufacturing a consumable for use in an aerosol delivery system. FIG. [Figure 15B] FIG. 2 is a top view of a second step of a method of manufacturing an article for use in an aerosol delivery system. [Figure 15C] FIG. 2 is a top view of a third step of a method of manufacturing an article for use in an aerosol delivery system. [Figure 15D] FIG. 13 is a top view of a fourth step of a method of manufacturing a consumable for use in an aerosol delivery system. [Figure 15E] FIG. 11 is a top view of a fifth step of a method of manufacturing an article for use in an aerosol delivery system. [Figure 15F] FIG. 13 is a cross-sectional side view of a sixth step of a method of manufacturing an article for use in an aerosol delivery system. [Figure 15G] FIG. 13 is a cross-sectional side view of a seventh step of a method of manufacturing an article for use in an aerosol delivery system. [Figure 16] FIG. 1 is a schematic diagram of an apparatus for manufacturing articles for use in an aerosol delivery system. [Figure 17] FIG. 2 is a cross-sectional side view of another embodiment of an article for use in an aerosol delivery system. [Figure 18] FIG. 2 is a cross-sectional side view of another embodiment of an article for use in an aerosol delivery system. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0127] As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user, a combustion aerosol delivery system, such as cigarettes, cigars, and tobacco for pipes, roll-up or reel-up cigarettes, whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smokable materials; a non-combustion aerosol delivery system that releases a compound from an aerosol-generating material without combusting the aerosol-generating material, such as an e-cigarette, a tobacco heating product, and a hybrid system that generates an aerosol using a combination of aerosol-generating materials; and aerosol-free delivery systems that deliver at least one substance to a user orally, nasally, transdermally, or otherwise without forming an aerosol, including, but not limited to, oral products such as lozenges, gums, patches, articles containing inhalable powders, and oral tobacco, including snuff or moist snuff, where the at least one substance may or may not contain nicotine.

[0128] According to the present disclosure, a "non-combustion" aerosol delivery system is one in which the constituent aerosol-generating materials (or components thereof) of the aerosol delivery system are not combusted or burned to facilitate delivery of at least one substance to a user.

[0129] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0130] In some embodiments, the non-combustion aerosol delivery system is an e-cigarette, also known as a vaporizer or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0131] 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.

[0132] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which may 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 a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include a plant-based material, such as tobacco or a non-tobacco product.

[0133] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable item for use with the non-combustion aerosol delivery device.

[0134] In some embodiments, the present disclosure relates to consumables that include aerosol-generating materials and are configured for use with non-combustion aerosol delivery devices. These consumables may be referred to as articles throughout this disclosure.

[0135] As used herein, the terms "upstream" and "downstream" are relative terms defined with respect to the direction of mainstream aerosol being drawn through an article or device in use. References to the "distal end" refer to the upstream end of the device, and the "proximal end" refers to the downstream end of the device.

[0136] In some embodiments, a non-combustion aerosol delivery system, such as the non-combustion aerosol delivery device, may include a power source and a controller. The power source may be, for example, a power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that can be energized to deliver power in the form of heat to an aerosol generating material or a heat transfer material in proximity to the heat generating power source.

[0137] In some embodiments, the non-combustion aerosol delivery system comprises an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0138] In some embodiments, consumables for use with non-combustion aerosol delivery devices may include aerosol generating materials, aerosol generating material storage areas, aerosol generating material transfer components, aerosol generators, aerosol generating areas, housings, packaging materials, filters, mouthpieces, and / or aerosol modifiers.

[0139] The consumable contains a substance to be delivered. The substance to be delivered is an aerosol-generating material. Optionally, the material may include one or more active ingredients, one or more flavorings, one or more aerosol-forming materials, and / or one or more other functional materials.

[0140] In some embodiments, the substance to be delivered comprises an active substance. As used herein, an active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, a dietary supplement, a nootropic, or a psychoactive agent. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, 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.

[0141] As described herein, the active material may include or be derived from one or more plants or their components, derivatives or extracts. As used herein, the term "botanical" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc. Alternatively, the material may include active compounds naturally occurring in plants that are synthetically obtained. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, or sheets, etc. Exemplary botanicals include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea, such as green or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. In some embodiments, the active ingredient is an oil-based supplement such as lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil, chives, caraway, 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.

[0142] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substance is tobacco.

[0143] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substances are selected from eucalyptus, star anise, cocoa, and hemp.

[0144] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0145] In some embodiments, the substance delivered comprises a fragrance.

[0146] As used herein, the terms "flavor" and "flavoring agent" refer to materials that may be used, where local regulations permit, to create a desired taste, odor, or other somatic sensation in products intended for adult consumers.They may be any naturally derived flavoring material, botanical substance, extract of botanical substance, synthetically derived material, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese peppermint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, toro, citrus fruit ... Pikar fruit, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascaria, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, Ylang-ylang, sage, fennel, wasabi, pimenta, ginger, coffee, hemp, peppermint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, damiento, marjoram. The flavor enhancers may include other additives such as rum, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), as well as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.They may be of imitation, synthetic or natural origin, or blends thereof. They may be in any suitable form, for example a liquid such as an oil, a solid such as a powder, or a gas.

[0147] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus, and / or red berry flavor ingredients. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavor ingredients extracted from tobacco. In some embodiments, the flavoring comprises flavor ingredients extracted from cannabis.

[0148] In some embodiments, the flavoring may include a sensory elicitor, which is intended to achieve somatic sensations that are usually chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the aroma or taste nerves, and may include agents that produce a heating, cooling, tingling, or numbing effect. A suitable heating agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucoliptol, WS-3.

[0149] 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 may retain some fluid, such as a liquid, within the amorphous solid. In some embodiments, the amorphous solid may include, for example, about 50%, 60%, or 70% amorphous solid to about 90%, 95%, or 100% amorphous solid by weight. The aerosol-generating material may also be referred to as an aerosolizable material.

[0150] An aerosol-generating material is a material that can generate an aerosol when, for example, heated, irradiated, or otherwise energized. The aerosol-generating material may be in the form of a solid, liquid, or gel that 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.

[0151] 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. The tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco lamina, reconstituted tobacco and / or tobacco extract.

[0152] A consumable is an article that includes or consists of an aerosol-generating material, some or all of which are intended to be consumed during 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 transport component, an aerosol-generating area, a housing, a packaging material, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, particularly a heating element, that releases heat during use to cause the aerosol-generating material to generate an aerosol. A heater may include a material that can be heated by electrical conduction, or a susceptor.

[0153] The aerosol-generating materials may include one or more active agents and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0154] The aerosolizable material may be present on a substrate, which may be or include, for example, paper, card, paperboard, cardboard, reconstituted aerosolizable material, a plastic material, a ceramic material, a composite material, glass, a metal, or a metal alloy.

[0155] The aerosol forming material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol forming material may include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0156] 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.

[0157] A consumable is an article that includes or consists of an aerosol-generating material, some or all of which are intended to be consumed during 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 transport component, an aerosol-generating area, a housing, a packaging material, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater that emits heat to cause the aerosol-generating material to generate an aerosol upon use. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0158] The susceptor is a material that can be heated by penetration by a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that penetration of the conductive material by the varying magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, such that penetration of the magnetic material by the varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, such that the susceptor is heatable by both heating mechanisms. An apparatus configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0159] An aerosol modifier is a substance that is typically located downstream of the aerosol-generation region and is configured to modify the generated aerosol, for example by changing the taste, flavor, acidity, or other property of the aerosol. The aerosol modifier may be provided in an aerosol modifier-releasing component that is operable to selectively release the aerosol modifier.

[0160] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavoring, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, liquid, or gel. The aerosol modifier may be in the form of a powder, a string, or granules. The aerosol modifier may not include a filtration material.

[0161] The aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to subject the aerosol-generating material to thermal energy 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 subject the aerosol-generating material to one or more of vibration, pressure increase, or electrostatic energy.

[0162] 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, such as triacetin, where the material is cellulose acetate tow, or the tow may be unplasticized. The tow may have any suitable specification, such as fibers having other cross sections, such as a "Y" or "X" shape, and have a filamentary denier value of 2.5 to 15 denier per filament, e.g., 8.0 to 11.0 denier per filament, and a total denier value of 5,000 to 50,000, e.g., 10,000 to 40,000.

[0163] In the figures described herein, like reference numbers are used to denote equivalent features, items or components.

[0164] FIG. 1 is a cross-sectional side view of an article 1 for use in an aerosol delivery system that includes an aerosol delivery device 200 (see FIGS. 10-12).

[0165] Article 1 has an upstream or distal end "D" and a downstream or proximal end "P". In some embodiments, proximal end P is located relatively closer to the mouthpiece 207 of the aerosol delivery device 200 in use than distal end D. In another embodiment (not shown), proximal end P of article 1 includes a mouthpiece. In some embodiments (not shown), proximal end P of article 1 forms a mouthpiece.

[0166] It should be appreciated that in some embodiments, the article 1 can be used with the aerosol delivery device 200 in either orientation, such that it does not matter which end of the article 1 is upstream and which end is downstream.

[0167] The article 1 comprises a substrate 2 and a body of material 3. The substrate 2 at least partially surrounds the body of material 3.

[0168] In this example, the substrate 2 is in the form of a patch 2 .

[0169] The patch 2 includes a first aerosol-forming material 4. The body of material 3 includes a second aerosol-forming material 5.

[0170] In this example, the first sheet material 6 and patch 2 are arranged such that the patch 2 is provided on an inner surface of the first sheet material 6. That is, the patch 2 is located radially inward of the first sheet material 6. In some embodiments, the first sheet material 6 surrounds or at least partially surrounds the patch 2. However, it should be understood that in alternative embodiments (not shown), the patch 2 may be provided on an outer surface of the first sheet material 6 such that the first sheet material 6 is located radially inward of the patch 2.

[0171] In some embodiments, the first sheet material 6 forms an outer surface 1A of the article 1. In this example, the first sheet material 6 forms the generally cylindrical periphery 1A of the article 1.

[0172] The first sheet material 6 may include paper or card of suitable basis weight and thickness. The basis weight and thickness of the first sheet material 6 may be selected depending on the desired stiffness of the first sheet material 6.

[0173] In some embodiments, the first sheet material 6 may comprise a metal. For example, the first sheet material 6 may be a co-laminate material including a paper layer and a metal layer. In some embodiments, the metal layer may comprise or consist of aluminum. The thickness of the aluminum layer may be selected to provide the first sheet material with necessary structural properties and / or may act as a susceptor to heat the aerosol-generating material 4 during use.

[0174] The patch 2 comprises a second sheet material 7. In this example, the second sheet material 7 is a cast sheet. For example, the second sheet material 7 may be formed from a slurry that is cast and then set (e.g., by heating) to form the second sheet material 7.

[0175] In some embodiments, the slurry is cast and dried to form a second sheet material 7 , which is then attached to the first sheet material 6 .

[0176] In other embodiments, the slurry may be cast in place on the first sheet material 6 such that when the slurry dries, it forms a second sheet material 7 (e.g., patch 2) that is adhered to the first sheet material 6. The first aerosol-generating material 4 may be provided in the slurry before it is applied to the first sheet material 6, or may be applied to or mixed with the slurry after it is applied to the first sheet material 6.

[0177] In the embodiment of Figure 1, as shown in Figures 1-6, the first aerosol-generating material 4 is attached to a first side of the second sheet material 7. In this example, the first aerosol-generating material 4 is adhered to the first side of the second sheet material 7. For example, an adhesive (not shown) may be applied to one or both of the first aerosol-generating material 4 and the second sheet material 7.

[0178] The first aerosol-forming material 4 may be a free aerosol-forming material (eg, dust, fibers or beads / pellets / granules) adhered to a second sheet material 7 .

[0179] In some embodiments, the second sheet material 7 comprises one or more of paper, card, or an aerosol-forming material. The second sheet material 7 may comprise reconstituted tobacco.

[0180] In this example, the body of material 3 is a rod 3 comprising the second aerosol-generating material 5. The body of material 3 may be a tobacco rod 3. For example, the body of material 3 may be a rod comprising shredded tobacco and / or shredded reconstituted tobacco (e.g. shredded reconstituted tobacco sheet).

[0181] In another embodiment (not shown), the body of material 3 includes a third sheet material that is gathered to form the body of material 3. The third sheet material may include a second aerosol-generating material 5, which may include, consist of, or consist essentially of tobacco material. For example, the third sheet material may be reconstituted tobacco that is gathered to form the body of material 3.

[0182] In some embodiments, the third sheet material is crimped to facilitate gathering of the third sheet material to form the body of material 3 .

[0183] In some embodiments, the third sheet material is cut into strips which are then formed into the body of material 3 .

[0184] In some embodiments, the patch 2 is in direct contact with the body of material 3. This helps to facilitate heat transfer between the patch 2 and the body of material 3.

[0185] The patch 2 comprises first and second opposing edges 2A, 2B. In this example, the first edge 2A of the patch 2 is spaced apart from a first end 3A of the body of material 3, and the second edge 2B of the patch 2 is spaced apart from a second end 3B of the body of material 3.

[0186] In this example, the first sheet of material 6 includes opposing first and second edges 6A, 6B. The patch 2 may be disposed on the first sheet of material 6 such that the first edge 2A of the patch 2 is adjacent to but spaced apart from the first edge 6A of the first sheet of material 6, and such that the second edge 2B of the patch 2 is adjacent to but spaced apart from the second edge 6B of the first sheet of material 6. In alternative embodiments, the first edge 2A of the patch 2 is aligned with the first edge 6A of the first sheet of material 6 and / or the second edge 2B of the patch 2 is aligned with the second edge 6B of the second sheet of material 6.

[0187] In this example, the patch 2 extends over a portion of the axial length of the body of material 3. However, it should be appreciated that in other embodiments the patch 2 extends over the entire axial length of the body of material 3.

[0188] In this example, the body of material 3 extends over a portion of the length of the article 1 (indicated by arrow "X" in Figure 1). In an alternative embodiment, the body of material 3 extends over the entire length X of the article 1.

[0189] In some embodiments, the patch 2 includes opposing third and fourth edges 2C, 2D, and the first sheet material 6 includes opposing third and fourth edges 6C, 6D. The third edge 2C of the patch 2 may be spaced from the third edge 6C of the first sheet material 6 such that the first sheet material 6 includes an area 8 that is not covered by the patch 2. The area 8 may be positioned to overlap the fourth edge 6D of the first sheet material 6 and adhered to an outer surface of the first sheet material 6. The fact that the area 8 is not covered by the patch 2 facilitates adhesion between the inner surface of the area 8 of the first sheet material 6 and the outer surface of the first sheet material 6.

[0190] The article 1 is configured to be heated by an aerosol delivery apparatus 200 such that the first and second aerosol-forming materials 4, 5 are heated to generate an aerosol.

[0191] In some embodiments, the first sheet material 6 has a permeability of up to 100 Coresta units, preferably up to 90, 80, 70, 60 or 50 Coresta units. In some embodiments, the first sheet material 6 is a porous material and may have a permeability of more than 100 Coresta units. Alternatively or additionally, the first sheet material 6 may include one or more slits or openings to increase the permeability of the first sheet material 6.

[0192] In some embodiments, the first sheet material 6 has a thickness in the range of 20 to 100 microns. It has been found that reducing the thickness of the first sheet material 6 helps to enhance heat transfer to the first and second aerosol-generating materials 4, 5. In some embodiments, the first sheet material 6 is a porous material.

[0193] Increasing the heat transfer through the sheet material 6 advantageously improves the efficiency of heating of the first and second aerosol-generating materials 4,5.

[0194] In some embodiments, the first sheet material 6 has a basis weight in the range of 20 to 50 gsm.

[0195] In some embodiments, the first and / or second aerosol-forming materials 4, 5 are loose materials.

[0196] In this example, the first aerosol-generating material 4 comprises an extruded and / or compressed aerosol-generating material, as described in more detail below, although it should be appreciated that in other embodiments, the first aerosol-generating material 4 may have a different form.

[0197] In some embodiments, the first and / or second aerosol-generating materials 4, 5 comprise beads, which may be cylindrical or have alternative shapes, such as spherical, pyramidal, or rectangular shapes.

[0198] In this example, the first aerosol-forming material 4 includes beads 4 .

[0199] In some embodiments, the beads 4 have a diameter (indicated by arrow "D" in FIG. 7) in the range of 0.5 to 3 mm, preferably in the range of 1 to 2 mm.

[0200] In some embodiments, the bead 4 has an axial length (indicated by arrow "L" in FIG. 7) in the range of 0.5 to 3 mm, preferably in the range of 1 to 2 mm.

[0201] In some embodiments, the beads 4 have a particle size in the range of 0.5 to 3 mm, preferably in the range of 1 to 2 mm.

[0202] In some embodiments, the first and / or second aerosol-forming materials 4, 5 comprise, consist of, or consist essentially of tobacco material.

[0203] 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.

[0204] In some embodiments, the first and / or second aerosol-forming materials 4, 5 include tobacco lamina and reconstituted tobacco.

[0205] In some embodiments, both the first and second aerosol-generating materials 4, 5 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 and second aerosol-generating materials 4, 5.

[0206] In some embodiments, the first aerosol-generating material 4 has a 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 4.

[0207] In some embodiments, the second aerosol-generating material 5 has a nicotine level in the range of 0.5% to 2.5%, preferably in the range of 1% to 2.1%, by weight of the second aerosol-generating material 5.

[0208] In some embodiments, the aerosol-generating material of article 1 comprises, by weight, about 50% of the first aerosol-generating material 4 and about 50% of the second aerosol-generating material 5. Thus, for example, an article comprising 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.

[0209] In some embodiments, article 1 contains from about 20 to about 330 mg of first aerosol-forming material 4, preferably from about 50 to about 300 mg, or from about 40 to about 125 mg of first aerosol-forming material 4.

[0210] In some embodiments, article 2 comprises about 20 to about 330 mg of the second aerosol-generating material 5, preferably about 50 to about 300 mg, or about 40 to about 125 mg of the second aerosol-generating material 5. In some embodiments, the total mass of the aerosol-generating materials 4, 5 of article 1 is in the range of about 80 to 350 mg, preferably about 120 to 330 mg, or about 150 to 300 mg.

[0211] In some embodiments, the total tobacco mass of article 1 is in the range of about 80-350 mg, preferably in the range of about 120-330 mg, or about 150-300 mg.

[0212] In some embodiments, the first and / or second aerosol-forming materials 4, 5 are solid materials.

[0213] In some embodiments, the first and second aerosol-generating materials are different materials and / or have one or more different properties.

[0214] Article 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.

[0215] The article 1 may have an axial length of up to 36 mm, preferably up to 34, 32, 30, 28, 26, 24 or 23 mm.

[0216] The article 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.

[0217] In some embodiments, one or more of the first sheet material 6, the second sheet material 7, the substrate 2, and / or the body of material 3 are plastic-free. This makes the article 1 more environmentally friendly, and is also advantageous in embodiments where the entire article 1 is heated by the aerosol delivery device 200 (as described below).

[0218] In some embodiments, the entire article 1 is plastic-free. In some embodiments, the body of material 3 or the entire article 1 is cellulose acetate-free.

[0219] In some embodiments, Article 1 does not include cellulose acetate.

[0220] In some embodiments, the first and / or second aerosol-generating materials 4, 5 may comprise, consist of, or consist essentially of plant material. The plant material may be 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. The tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco lamina, reconstituted tobacco, and / or tobacco extract.

[0221] In some embodiments, the first and / or second aerosol-generating material 4, 5 or another material (not shown) of the article 1, such as another material of the body of material 3, may include one or more aerosol-forming materials. For example, the first and / or second aerosol-generating material 4, 5 or said another material may include one or more components capable of forming an aerosol. The aerosol-forming material includes one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The aerosol-forming material may be glycerol or propylene glycol.

[0222] The first and / or second aerosol-generating materials 4, 5 may be provided as loose materials. For example, the first aerosol-generating material 4 may be a loose material that is held in place within the substrate 2 by an adhesive or by being formed with the second sheet material 7. The first and / or second aerosol-generating materials 4, 5 may be, for example, separate strands or particles of aerosol-generating material. Another example of a loose aerosol-generating material is beads / pellets of aerosol-generating material, including aerosol-generating material that has been extruded and then 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, for example cut into individual pieces of aerosol-generating material. The sheet of aerosol-generating material may be a sheet of reconstituted tobacco.

[0223] For example, the body of material 3 may comprise a sheet of the second aerosol-generating material that is brought together to form the body of material 3.

[0224] In some embodiments, the article 1 further comprises a third aerosol-generating material. In one such embodiment, the body of material 3 comprises a second and a third aerosol-generating material. For example, the body of material 3 may be formed from a sheet / strip of one of the second or third aerosol-generating materials, and beads / dust / fibers of the other of the second or third aerosol-generating material may be applied to the sheet / strip.

[0225] In another embodiment, the substrate 2 includes the first and third aerosol-generating materials. For example, the second sheet material 7 of the substrate 2 may be formed from one of the first and third aerosol-generating materials, and beads / dust / fibers of the other of the first and third aerosol-generating materials may be applied (e.g., adhered) to the second sheet material 7.

[0226] In this example, the second aerosol-generating material 4 includes shredded tobacco material (e.g., shredded lamina and / or shredded reconstituted tobacco). The shredded tobacco material is formed into a tobacco rod 3. The patch 2 at least partially surrounds the rod 3.

[0227] In this example, the first aerosol-generating material 4 includes extruded and / or compressed tobacco. In such embodiments, the first aerosol-generating material 4 may include a unitary body of aerosol-generating material. However, in this example, the first aerosol-generating material 4 includes multiple bodies of aerosol-generating material.

[0228] In this example, the first aerosol-generating material 4 comprises beads / pellets / granules of aerosol-generating material (hereinafter referred to as "beads" of aerosol-generating material). The beads 4 may be extruded and / or compressed beads 4.

[0229] Optionally, one of the first and second aerosol-generating materials 4, 5 has a higher density than the other of the first and second aerosol-generating materials 4, 5. It has been found that this causes the more dense aerosol-generating material to heat up more slowly when subjected to a given heating power. This means that the less dense material (e.g., the second aerosol-generating material 5) will initially release one or more volatile compounds (e.g., nicotine) at a higher rate than the more dense material (e.g., the first aerosol-generating material 4). This also means that the less dense material (e.g., the second aerosol-generating material 5) will relatively deplete said volatile compounds more quickly than the more dense material (e.g., the first aerosol-generating material 4). However, once the less dense material (e.g., the second aerosol-generating material 5) begins to relatively deplete said volatile compounds, the more dense material (e.g., the first aerosol-generating material 4) will begin to reach a temperature at which it will begin to release volatile compounds at a higher rate. The effect is a more consistent release of volatile compounds over the period of consumption of article 1, with the less dense material (e.g., second aerosol-generating material 5) releasing a greater proportion of the volatile compounds towards the beginning of consumption of article 1 and the more dense material (e.g., first aerosol-generating material 4) releasing a greater proportion of the volatile compounds towards the end of consumption of article 1. This is particularly advantageous because it allows article 1 to be relatively small while still achieving a relatively consistent and / or sufficient release of volatile compounds over the period of consumption.

[0230] In some embodiments, the one or more volatile compounds emitted by first aerosol-forming material 4 are the same as the volatile compounds emitted by second aerosol-forming material 5.

[0231] In some embodiments, the first aerosol-generating material 4 comprises an aerosol-generating material that has been compressed or extruded (without subsequent expansion or with relatively low / minimal expansion) such that the density of the first aerosol-generating material 4 is higher than the density of the second aerosol-generating material 5.

[0232] In some embodiments, the second aerosol-generating material 5 comprises one or more of tobacco lamina, tobacco stems, or reconstituted tobacco. In one such embodiment, the second aerosol-generating material 5 comprises a mixture of tobacco lamina and reconstituted tobacco. The second aerosol-generating material 5 may comprise shredded or cut material. However, it should be appreciated that in other embodiments, the second aerosol-generating material 5 comprises a compressed or extruded aerosol-generating material having a lower density than the first aerosol-generating material 4 (e.g., having a lower compression than the first aerosol-generating material 4, which may optionally be extruded or compressed). For example, the body of material 3 may comprise an extruded / compressed body of the second aerosol-generating material 5.

[0233] 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 second aerosol-generating material 5 may be a shredded material (e.g., shredded tobacco and / or shredded reconstituted tobacco) formed into the body 3, but the first aerosol-generating material 4 may be compressed or extruded (with minimal expansion) such that the first aerosol-generating material 4 has a higher density than the second aerosol-generating material 5.

[0234] For example, the first aerosol-generating material 4 may be in the form of an extruded / compressed bead of aerosol-generating material (e.g., tobacco or another material) and the second aerosol-generating material 5 may be in the form of, for example, strands or strips of aerosol-generating material (e.g., tobacco or another material), a sheet of aerosol-generating material collected into a plug or cut into strips, a rod of aerosol-generating material (e.g., a rod formed from cut rag tobacco), or tobacco lamina and / or stem material formed into a plug. However, it should be recognized that the first, second and / or third aerosol-generating materials 4, 5 may alternatively have the same form (e.g., both being cut rough tobacco).

[0235] It should be appreciated that in alternative embodiments, the density of the first aerosol-generating material 4 is less than the density of the second aerosol-generating material 5. In yet other embodiments, the densities of the first and second aerosol-generating materials 4, 5 are the same.

[0236] In some embodiments, the first aerosol-generating material 4 has at least one additional different characteristic relative to the second aerosol-generating material 5. The different characteristic may be one or more of the form, size, moisture content, amount (by weight), one or more materials, or proportions of materials that make up the first and second aerosol-generating materials 4, 5 (including recipes for the aerosol-generating materials 4, 5 when each produces more than one material). In some embodiments, the first and second aerosol-generating materials 4, 5 do not have different characteristics other than being of different forms.

[0237] 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.

[0238] 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 comprising 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.

[0239] The plant-based material may be a granular or particulate material. In some embodiments, the plant-based material is a powder. Alternatively or additionally, the plant-based material may comprise tobacco strips, strands or fibres. For example, where tobacco material is provided, the tobacco material may comprise tobacco particles, granules, fibres, strips and / or strands. In some embodiments, the tobacco material consists of particles or granules of tobacco material.

[0240] 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.

[0241] The sheet or shredded sheet can contain from 5% to about 90% tobacco leaf by weight.

[0242] In some embodiments, both the first and / or second aerosol-forming materials 4, 5 comprise, consist of, or consist essentially of tobacco material.

[0243] In some embodiments, the first and / or second aerosol-generating material 4, 5 comprises a sheet or shredded sheet of aerosolizable material comprising an aerosol-forming material. The aerosol-forming material is provided in an amount of up to about 50% by dry weight of the sheet or shredded sheet. In some embodiments, the aerosol-forming material is provided in an amount of about 5% to about 40% by dry weight of the sheet or shredded sheet, about 10% to about 30% by dry weight of the sheet or shredded sheet, or about 10% to about 20% by dry weight of the sheet or shredded sheet.

[0244] 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 include components derived from tobacco. 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 non-tobacco fibers, such as wood fibers or pulp or wheat fibers. The filler may be a material that includes cellulose or a material that includes 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.

[0245] The first and / or second aerosol-generating materials 4, 5 may include an aerosol modifier, 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 an article 1 for use in an aerosol delivery system, the article may be referred to as a mentholated consumable 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.

[0246] In some embodiments, article 1 comprises an aerosol-forming composition that includes an aerosol-forming material. The aerosol-forming material may include a first and / or a second aerosol-forming material 4, 5 (and / or a third aerosol-forming material).

[0247] An aerosol-generating material is a material that can generate an aerosol when, for example, heated, irradiated, or otherwise energized. The aerosol-generating materials (e.g., first and / or second aerosol-generating materials 4, 5) may be, for example, in the form of a solid, liquid, or semi-solid (such as a gel), which may or may not contain active substances and / or flavorants.

[0248] The aerosol-generating materials (e.g., the first and / or second aerosol-generating materials 4, 5) may include a binder and an aerosol-forming agent. Optionally, an active agent and / or a filler may also be present. Optionally, a solvent, such as water, is also present, and one or more other components of the aerosol-generating materials may or may not be soluble in the solvent. 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.

[0249] In some embodiments, the composition of the first and / or second aerosol-generating material 4, 5 comprises an aerosol-forming "amorphous solid." The amorphous solid may be a "monolithic solid." In some embodiments, the amorphous solid may be a dry gel. The amorphous solid is a solid material that may retain some fluid, such as a liquid, within the amorphous solid. In some embodiments, the aerosol-generating material may comprise, for example, about 50%, 60%, or 70% amorphous solid by weight, up to about 90%, 95%, or 100% amorphous solid by weight. The amorphous solid may be substantially non-fibrous.

[0250] In some instances, the amorphous solid is 1 to 60% by weight of a gelling agent; 0.1 to 50 weight percent of an aerosol-forming material; 0.1 to 80% by weight of a fragrance, Here, these weights are calculated on a dry weight basis. In some further embodiments, the amorphous solid is 1 to 50% by weight of a gelling agent; 0.1 to 50 weight percent of an aerosol-forming material; 30 to 60% by weight of a fragrance, Here, these weights are calculated on a dry weight basis.

[0251] The aerosol-generating material (e.g., the first and / or second aerosol-generating materials 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 one or more other ingredients, such as a solvent, such as water, an aerosol-forming agent, and an active agent, to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent to form the aerosol-generating film. The slurry may be heated to remove at least about 60%, 70%, 80%, 85% or 90% of the solvent by weight. The aerosol-generating film may be a continuous film or a discontinuous film, such as an arrangement of discontinuous portions of a film on a substrate. The aerosol-generating film may be substantially free of tobacco.

[0252] The aerosol-generating film may include or be a sheet that can optionally be chopped to form chopped sheets.

[0253] The aerosol-generating materials may include one or more active agents and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0254] In each of the embodiments of article 1 described herein, the article may include such a first and / or second aerosol-generating material 4, 5 (and / or a third aerosol-generating material), and may include such an aerosol-generating composition.

[0255] The amorphous solid material may be provided in a sheet or chopped sheet form. The amorphous solid material may take the same form as the sheet or chopped sheet of aerosolizable material.

[0256] In some embodiments, the aerosol-forming material, such as the first or second aerosol-forming material 4, 5, 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, where the weight percentages are calculated on a dry weight basis.

[0257] The first and / or second aerosol-generating materials 4, 5 may comprise tobacco material reconstituted with paper. 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%-90% tobacco leaf by weight, the aerosol-forming material being provided in an amount of up to about 20% by weight of the sheet or shredded sheet, with the remainder of the tobacco material comprising tobacco reconstituted with paper.

[0258] 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.

[0259] In some embodiments, the first and / or second aerosol-forming materials 4, 5 comprise extruded aerosol-forming materials that are then cut into beads of pellets.

[0260] Referring now to FIG. 8, an alternative article 1 of an aerosol delivery apparatus 200 is shown. The article 1 has similar features to the article 1 described above in relation to FIGS. 1-7, and similar features will retain the same reference numbers and may have any of the feature variations described herein. The difference is that the substrate 2 includes a first aerosol-generating material 4, instead of the first aerosol-generating material 4 being applied to a surface of the second sheet material 7. In one embodiment, the substrate 2 includes a second sheet material 7 that includes the first aerosol-generating material 4. For example, the second sheet material 7 may be formed by the first aerosol-generating material 4. The first aerosol-generating material 4 may be integral with the second sheet material 7.

[0261] In one such embodiment, the substrate 2 including the first aerosol-generating material 4 is printed onto the first sheet material 6. By "printed" it is meant that the first aerosol-generating material 4 is applied in fluid form to the first sheet material 6 and allowed to dry or harden.

[0262] In one such embodiment, the second sheet material 7 is formed from a slurry, the first aerosol-generating material 4 is provided in the slurry, and the second sheet material 7 is then formed from the slurry. For example, the second sheet material 7 may be cast from a slurry including the first aerosol-generating material 4.

[0263] In another embodiment (not shown), the second sheet material 7 includes the first aerosol-generating material 4 (e.g., formed from a slurry including the first aerosol-generating material 4) and a third aerosol-generating material is applied to a surface of the second sheet material 7 (e.g., held in place by an adhesive).

[0264] 9, another article 1 for an aerosol delivery apparatus 200 is shown. The article 1 has similar features to those of the article 1 described above in connection with FIGS. 1-7, and similar features will retain the same reference numbers and may have any of the feature variations described herein. The difference is that the substrate 2 in the embodiment of FIG. 9 extends throughout the entire axial length (indicated by arrow "X") of the article 1. In this embodiment, the second sheet material 7 and the first aerosol-generating material 4 both extend substantially throughout the entire axial length X of the article 1. However, it should be appreciated that in alternative embodiments, the second sheet material 7 may extend substantially throughout the entire axial length X of the article 1, and the first aerosol-generating material 4 may extend only a portion of the axial length of the article 1.

[0265] The embodiment in which the first aerosol-generating material 4 extends over the entire axial length X of the article 1 (or the entire axial length of the body of material 3) provides the advantage of increasing the amount of first aerosol-generating material 4 in the article 1, and therefore the amount of aerosol that can be generated for a given axial length X of the article 1.

[0266] The embodiment in which the first aerosol-generating material 4 spans only a portion of the total axial length X of the article 1 provides the advantage that the first aerosol-generating material 4 is not visible from the ends P, D of the article 1, which also helps reduce the chance of the first aerosol-generating material 4 falling from the ends P, D of the article 1.

[0267] In some embodiments, openings (not shown) are cut in the substrate 2 and / or the first sheet material 6. The openings may be formed in the first sheet material 6. Specifically, the openings may be formed in areas underlying the substrate 2. The openings are formed through the first sheet material, and optionally through the substrate 2. The openings may prevent the substrate from separating from the first sheet material 6 when the article 1 is heated during use.

[0268] 10-12, one embodiment of an aerosol delivery device 200 is shown.

[0269] The article 1 is configured for use in an aerosol delivery device 200 (see FIG. 10 ) that includes an aerosol generator in the form of a heating element 203 for heating the article 1. In this example, the heating element 203 at least partially surrounds a heating region 202, e.g., a heating chamber 202. The heating element 203 may be resistively heated and / or inductively heated.

[0270] In other embodiments (not shown), the heating element 203 instead comprises a blade or pin for insertion into the article 1, for example, the blade or pin may be inserted through the body of material 3. In other embodiments (not shown), the consumable 1 may include a heating element that may be embedded in the body of material 3, for example.

[0271] Components of one embodiment of aerosol delivery device 200 are shown in a simplified form in Figure 10. In particular, the elements of aerosol delivery device 200 are not drawn to scale in Figure 10. Elements that are not relevant to an understanding of this embodiment have been omitted to simplify Figure 10.

[0272] 10, the aerosol dispensing device 200 is a non-combustion aerosol dispensing device 200. The non-combustion aerosol dispensing device 200 comprises a housing 201 including an area 202 for receiving the article 1.

[0273] When the article 1 is received within the heating region 202, at least a portion of the article 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 article 1, e.g., circumscribing the article 1 but having a larger diameter and spaced apart therefrom. In other embodiments, the heater 203 is in direct contact with the article 1, e.g., in contact with an outer surface of the first sheet material 6 of the article. In another embodiment, the heater 203 comprises a blade or pin that contacts the inside of the article 1, e.g., in contact with the body of material 3 and / or the substrate 2.

[0274] When the article 1 is heated, the first and / or second aerosol generating materials 4, 5 release one or more volatile compounds and may release a range of 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 can be controlled by preventing the release of selected volatile compounds.

[0275] As shown in Figure 11, within the housing 201 is an electrical energy source 204, such as a rechargeable lithium ion battery. A controller 205 is connected to the heater 203, the electrical energy source 204, and a user interface 206, such as a button or display. The controller 205 controls the power supplied to the heater 203 to regulate the temperature of the heater 203. Typically, the aerosol-forming substrate is heated to a temperature of between 250°C and 450°C.

[0276] Figure 12 is a schematic cross-sectional view of a non-combustion aerosol delivery device 200 of the type shown in Figure 10, where an item 1 is contained in a heating region 202 of the device 200 for heating by a heater 203. The non-combustion aerosol delivery device 200 is shown receiving an aerosol product item 1 for consumption of the aerosol product item 1 by a user.

[0277] The housing 201 of the non-combustion aerosol delivery device 200 defines an area 202 in the form of a cavity that is open at the proximal end (or mouth end) for receiving the aerosol product 1 for consumption by a user.

[0278] In this example, the aerosol delivery device 200 includes a mouthpiece 207 that is removable from the remainder of the device 200 to allow access to the area 202 so that the article 1 can be brought into and removed from the area 202. Once the article 1 has been provided to the area 202, the mouthpiece 207 can be reattached. In some embodiments, the mouthpiece 207 is removably attached to the housing 201 of the device 200, for example by a screw thread or bayonet connection.

[0279] When a user inhales on the mouthpiece 207, air is drawn into the article 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.

[0280] It should be appreciated that in other embodiments, the mouthpiece 207 of the device 200 may be omitted. In some embodiments, the article 1 may form a mouthpiece and may come into contact with the user's mouth.

[0281] In the embodiment described above, the body of material 3 extends between the ends P, D of the article 1. However, it should be appreciated that in alternative embodiments (not shown), the article 1 may include one or more further segments, for example further segments upstream or downstream of the body of material 3.

[0282] For example, an alternative embodiment of article 1 is shown in Figure 13, which further comprises a cooling section 25, also referred to as a cooling element, disposed immediately downstream of the body of material 3. In this example, the cooling element 25 is immediately downstream and adjacent to the body of material 3. In some such embodiments, the cooling element 25 is in an abutting relationship with the body of material 3. The article 1 may additionally or alternatively include a further body of material 26 downstream of the cooling element 25. The further body of material 26 may include a flavoring material and / or a filtering material, and / or may be provided to obscure the view of the cooling element 25.

[0283] The cooling element 25 includes a hollow channel having an inner diameter of about 1 mm to about 4 mm, for example about 2 mm to about 4 mm. The hollow channel may have an inner diameter of about 3 mm. The hollow channel extends along the entire length of the cooling element 25. The cooling element 25 may include a single hollow channel. In alternative embodiments, the cooling element 25 may include multiple channels, for example 2, 3 or 4 channels. The single hollow channel may be substantially cylindrical, although in alternative embodiments other channel shapes / cross sections may be used. The hollow channel may provide space in which aerosol drawn into the cooling element 25 may expand and cool. The cooling element 25 may be configured to restrict the cross-sectional area of ​​the hollow channel to restrict the movement of tobacco into the cooling element 25 during use.

[0284] The cooling element 25 can have a wall thickness in the radial direction. The wall thickness of the cooling element 25 defines the inner diameter of the chamber enclosed by the walls of the cooling element 25 for a given outer diameter of the cooling element 25. The cooling element 25 can have a wall thickness of at least about 1.5 mm and up to about 2 mm. In this example, the cooling element 25 has a wall thickness of about 2 mm.

[0285] Cooling element 25 may be formed from filamentary tow. Multiple parallel wound paper layers with butt seams or other structures such as spirally wound layers of paper, cardboard tubes, tubes formed using a paper-mache type process, molded or extruded plastic tubes, etc. can be used to form cooling element 25. Cooling element 25 is manufactured to be sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacture and use of article 1.

[0286] The wall material of the cooling element 25 may be relatively non-porous such that at least 90% of the aerosol generated by the aerosol-generating material 3 passes longitudinally through the one or more hollow channels rather than through the wall material of the cooling element 25. For example, at least 92% or at least 95% of the aerosol generated by the first and / or second aerosol-generating materials 4, 5 may pass longitudinally through the one or more hollow channels.

[0287] The cooling element 25 can be configured to provide a temperature differential of at least 40° C. between the heated volatile component entering the first upstream end of the cooling element 25 and the heated volatile component exiting the second downstream end of the cooling element 25. The cooling element 25 can be configured to provide a temperature differential of at least 60° C., or at least 80° C., or at least 100° C., between the heated volatile component entering the first upstream end of the cooling element 25 and the heated volatile component exiting the second downstream end of the cooling element 25. This temperature differential across the length of the cooling element 25 protects the temperature sensitive body of material 26 from the high temperatures of the aerosol generating materials 4, 5 when heated.

[0288] The body of material 26 defines a substantially cylindrical overall outer shape and is encased in a plug wrap 28. The plug wrap 28 may have a basis weight of less than 50 gsm, or between about 20 gsm and 40 gsm. The plug wrap 28 may have a thickness of between 30 μm and 60 μm, or between 35 μm and 45 μm. The plug wrap 28 may be a non-porous plug wrap, for example having a permeability of less than 100 Coresta units, for example less than 50 Coresta units. However, in other embodiments, the plug wrap 28 may be a porous plug wrap, for example having a permeability of greater than 100 Coresta units or greater than 200 Coresta units.

[0289] The cooling element 25 and / or the body of material 26 may form a mouthpiece of the article 1 that is configured to be received in the mouth of a user. In some embodiments, the mouthpiece 207 of the device 200 may be omitted.

[0290] In some embodiments, tipping paper (not shown) may also surround the first sheet of material 6 that is wrapped around the cooling element 25 and body of material 26 and surrounds the substrate 2 and body of material 3, and connected to these components by an adhesive. The tipping paper thus connects the cooling element 25 and body of material 26 to the body of material 3. In other embodiments, the tipping paper is omitted, and instead the first sheet of material 6 extends around the cooling element 25 and body of material 26 to connect these components to the body of material 3 and substrate 2.

[0291] Referring now to FIG. 15, a block diagram illustrating an exemplary embodiment of a method 100 for manufacturing an article 1 for an aerosol delivery device is shown.

[0292] Method 100 includes the step of providing (S1) a first sheet material 6. Method 100 also includes the step of providing (S2) a substrate 2 including a first aerosol-generating material 4, where the substrate 2 is adhered to the first sheet material 6. Method 100 further includes the step of positioning the first sheet material 6 with the adhered substrate such that the first sheet material 6 surrounds the substrate 2. In this example, the substrate 2 is a patch 2.

[0293] In some embodiments, the substrate 2 comprises a second sheet material 7 and providing the substrate 2 comprises attaching the second sheet material 7 to the first sheet material 6 .

[0294] The second sheet material 7 may be a cast sheet.

[0295] In some embodiments, the second sheet material 7 includes the first aerosol-generating material 4. For example, the second sheet material 7 may be formed by the first aerosol-generating material 4. The first aerosol-generating material 4 may be integral with the second sheet material 7. In one such embodiment, the second sheet material 7 is formed from a slurry, the first aerosol-generating material 4 is provided in the slurry, and the second sheet material 7 is then formed from the slurry. For example, the second sheet material 7 may be cast from a slurry including the first aerosol-generating material 4.

[0296] In some embodiments, the first aerosol-generating material 4 is attached to a surface of the second sheet material 7 , preferably adhered to the surface of the second sheet material 7 .

[0297] The first aerosol-generating material 4 may be attached to a surface of the second sheet material 7 either before or after the second sheet material 7 is attached to the first sheet material 6 .

[0298] The first aerosol-generating material 4 may be applied to the first sheet material 6 as or in a slurry that is dried to form a layer on the first sheet material 6 .

[0299] In some embodiments, the second sheet material 7 comprises one or more of paper, card, and / or an aerosol-forming material.

[0300] In some embodiments, providing the first sheet material 6 includes providing a web of the first sheet material.

[0301] In some embodiments, providing the substrate 2 comprises applying the substrate 2 to a web of first sheet material 6 .

[0302] In some embodiments, applying the substrate 2 to the web of first sheet material 6 includes applying a web of second sheet material 7 to the web of first sheet material 6. For example, continuous webs of the first and second sheet materials 6, 7 may be glued together.

[0303] In some embodiments, applying the substrate 2 to the web of first sheet material 6 comprises applying multiple portions of a second sheet material 7 to the web of first sheet material 6 .

[0304] In some embodiments, multiple portions of second sheet material 7 are spaced apart from one another on the web of first sheet material 6 .

[0305] In some embodiments, the portions of the second sheet material 7 are discontinuous. The portions of the second sheet material 7 may be spaced apart from one another in a direction along the transport path of the web of first sheet material 6.

[0306] In some embodiments, the edge of the substrate 2 is spaced from the edge 6C of the first sheet material 6 such that region 8 of the first sheet material 6 is not covered by the substrate 2, and preferably the method includes applying adhesive to said region 8.

[0307] In some embodiments, the substrate 2 includes opposing third and fourth edges 2C, 2D, and the first sheet material 6 includes opposing third and fourth edges 6C, 6D. The third edge 2C of the patch 2 may be spaced from the third edge 6C of the first sheet material 6 such that the first sheet material 6 includes an area 8 that is not covered by the patch 2. The area 8 may be disposed to overlap the fourth edge 6D of the first sheet material 6 and adhered to an outer surface of the first sheet material 6. The area 8 being uncovered by the patch 2 facilitates adhesion between an inner surface of the area 8 of the first sheet material 6 and an outer surface of the first sheet material 6. The method 100 may include applying an adhesive to the area 8.

[0308] In some embodiments, the first sheet material 6 has a permeability in the range of up to 100 Coresta units, preferably up to 90, 80, 70, 60 or 50 Coresta units.

[0309] In some embodiments, the first sheet material 6 has a thickness in the range of 20 to 100 microns.

[0310] In some embodiments, the first sheet material 6 forms the outer surface 1 A of the article 1 .

[0311] In some embodiments, the method 100 includes providing a continuous web of a first sheet material 6. The web may be fed along a transport path. The web of first sheet material 6 may be fed from a reel.

[0312] In some embodiments, the first aerosol-forming material 4 comprises aerosol-forming material dust and / or aerosol-forming material fibers.

[0313] In some embodiments, first aerosol-forming material 4 comprises an extruded and / or compressed aerosol-forming material.

[0314] In some embodiments, the first aerosol-generating material 4 comprises beads 4 .

[0315] In some embodiments, the beads 4 have a diameter in the range of 0.5 to 3 mm, preferably in the range of 1 to 2 mm.

[0316] In some embodiments, the beads 4 have a particle size (measured by sieving) in the range of 0.5 to 3 mm, preferably in the range of 1 to 2 mm.

[0317] In some embodiments, first aerosol-forming material 4 comprises, consists of, or consists essentially of tobacco material.

[0318] 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.

[0319] In some embodiments, the first and / or second aerosol-forming materials 4, 5 include tobacco lamina and reconstituted tobacco.

[0320] In some embodiments, both the first and second aerosol-generating materials 4, 5 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 and second aerosol-generating materials 4, 5.

[0321] In some embodiments, the first and / or second aerosol-forming materials 4, 5 are solid materials.

[0322] In some embodiments, the article 1 does not include plastic.

[0323] In some embodiments, Article 1 does not include cellulose acetate.

[0324] In some embodiments, the first and second aerosol-generating materials 4, 5 are produced from the same aerosol-generating starting material that has been processed to have different morphologies.

[0325] In some embodiments, the article 1 further comprises a second aerosol-forming material 5.

[0326] In some embodiments, the second aerosol-forming material 5 has a higher or lower density than the first aerosol-forming material 4 .

[0327] In some embodiments, the second aerosol-forming material 5 comprises, consists of, or consists essentially of tobacco material.

[0328] In some embodiments, the second aerosol-forming material 5 comprises shredded tobacco and / or reconstituted tobacco.

[0329] In some embodiments, the substrate 2 includes a second aerosol-forming material 5 .

[0330] In some embodiments, the second sheet material 7 includes the first and / or second aerosol-generating materials 4, 5. For example, the second sheet material 7 may be formed from a slurry including the first and / or second aerosol-generating materials 4, 5.

[0331] In some embodiments, the first sheet material 6 and substrate 2 are arranged such that the first sheet material 6 is provided on an inner surface of the first sheet material 6 after the substrate 2 is formed into the article 1. In some embodiments, the first sheet material 6 surrounds or at least partially surrounds the substrate 2.

[0332] In some embodiments, the first and / or second aerosol-generating materials 4 , 5 are applied to a surface of a second sheet material 7 .

[0333] In some embodiments, the second sheet material 7 includes one of the first and second aerosol-generating materials 4, 5, and the other of the first and second aerosol-generating materials 4, 5 is applied to a surface of the second sheet material 7.

[0334] In some embodiments, positioning the first sheet material 6 to which the substrate 2 is adhered includes providing the first sheet material 6 and the substrate 2 around at least a portion of the body of material 3, and preferably includes wrapping the first sheet material 6 having the substrate 2 around the body of material 2.

[0335] The method 100 may include forming the body of material 3 and then wrapping the first sheet material 6 and the substrate 2 around the body of material 3. In another embodiment, the body of material 3 is formed simultaneously with wrapping the first sheet material 6 and the substrate 2 around the body of material 3, for example, by feeding the first sheet material 6 and the substrate through a garniture along with the material to be formed into the body of material 3.

[0336] In some embodiments, the substrate 2 surrounds the entire perimeter of the body of material 3. In some embodiments, the first sheet material 6 circumscribes the body of material 3. In some embodiments, the substrate 2 surrounds the body of material 3.

[0337] In some embodiments, the body of material 3 comprises a third sheet material that is gathered to form the body of material 3. In some embodiments, the third sheet material is crimped and / or cut into strips.

[0338] In some embodiments, the substrate 2 is in direct contact with the body of material 3 .

[0339] In some embodiments, the body of material 3 comprises a tobacco rod. For example, the body of material 3 may comprise shredded tobacco material formed into a rod. In some embodiments, the body of material 3 comprises cut rag tobacco formed into a rod.

[0340] In some embodiments, the body of material 3 includes a second aerosol-generating material 5 .

[0341] In some embodiments, the body of material 3 includes a third sheet material (not shown), and preferably the method 100 includes gathering the third sheet material to form the body of material 3. The third sheet material may optionally be crimped and / or cut into strips.

[0342] In some embodiments, the body of material 3 comprises a tobacco rod. For example, the body of material 3 may comprise shredded tobacco material formed into a rod. In some embodiments, the body of material 3 comprises cut rag tobacco formed into a rod.

[0343] In some embodiments, the article 1 includes a third aerosol-generating material. For example, the substrate 2 or the body of material 3 may include the third aerosol-generating material. In some embodiments, the substrate 2 includes a second sheet material 7 including the first and / or third aerosol-generating materials. For example, the second sheet material 7 may be formed from a slurry including the first and / or third aerosol-generating materials. In some embodiments, the first and / or third aerosol-generating materials are applied to a surface of the second sheet material 7. In some embodiments, the second sheet material 7 includes one of the first and third aerosol-generating materials, and the other of the first and third aerosol-generating materials is applied to a surface of the second sheet material 7.

[0344] In another embodiment, the substrate 2 is provided axially upstream or downstream of the body of material 3. In another embodiment, the article 1 does not include the body of material 3. For example, the substrate 2 may be arranged to define a tube that surrounds an empty space. The empty space can form a passage for the flow of gas therethrough. In another example, the substrate 2 extends around components other than the body of material 3.

[0345] It should be appreciated that the first and second aerosol-generating materials 4, 5 and the body of material 3 can have a variety of features and / or configurations, including any of the features described above, including those described above in connection with Figures 1-14.

[0346] 15A-15G, there is shown one embodiment of a method for manufacturing an article 1 for an aerosol delivery device 200. An example of an apparatus 300 for carrying out this method is shown in FIG.

[0347] The first step (shown in FIG. 15A) is to provide a continuous web W1 of second sheet material 7. In this example, the second sheet material 7 comprises a strip of paper. The continuous web W1 may be supplied from a first reel S1.

[0348] In a second step (shown in FIG. 15B ), the first aerosol-generating material 4 is applied to the surface of the web W1 of the second sheet material 7. For example, an adhesive may be applied to the web W1 and / or the first aerosol-generating material 4 such that the first aerosol-generating material 4 is adhered to the web W1. In this example, the apparatus 300 comprises an applicator 301 that sprays adhesive onto the web W1 and then supplies the first aerosol-generating material 4 under the influence of gravity, for example using a hopper. In another embodiment, the first aerosol-generating material 4 may be pneumatically supplied and optionally sprayed onto the web W1.

[0349] The first aerosol-generating material 4 may be provided as free aerosol-generating material 4, for example free beads / fibers / dust of the first aerosol-generating material 4.

[0350] The second sheet material 7 and the first aerosol-forming material 4 together may form the substrate 2 .

[0351] It should be appreciated that in alternative embodiments, the second sheet material 7 includes the first aerosol-generating material 4. For example, the second sheet material 7 may be cast from a slurry including the first aerosol-generating material 4.

[0352] In a third step (shown in FIG. 15C), multiple successive cuts are made in the web W1 to form multiple individual portions of the substrate 2. In this example, the web W1 is cut along successive cut lines Z1-Z1 (shown in FIG. 15C). The cuts can be made using a cutting device 302. For example, the cutting device 302 can comprise a cutting drum, one or more cutting knives, or one or more lasers. In some embodiments, each individual portion forms a respective patch 2.

[0353] In a fourth step (shown in FIG. 15D), the individual portions of the substrate 2 are spaced apart from one another. In this example, the apparatus 300 comprises a first belt conveyor 303 and a second belt conveyor 304 operating at a faster speed than the first belt conveyor 303. The individual portions of the substrate 2 are transported from the first belt conveyor 303 to the second belt conveyor 304, where the individual portions of the substrate 2 are accelerated and spaced apart from the upstream portion of the substrate 2. In another embodiment (not shown), the individual portions of the substrate 2 are spaced apart using spacer drums. In yet another embodiment, the individual portions of the substrate 2 are not spaced apart from one another.

[0354] In a fifth step (shown in FIG. 15E), the individual portions of substrate 2 are adhered to web W2 of first sheet material 6. The individual portions of substrate 2 are delivered from second belt conveyor 304 onto web W2 of first sheet material 6 as it passes along the transport path. Web W2 may be supplied from a second reel S2.

[0355] The adhesive may be applied to the web W2 of first sheet material 6 and / or to the substrate 2 (eg, applied to the second sheet material 7 of the substrate 2).

[0356] In this example, the adhesive is applied by adhesive applicator 305. The adhesive applicator 305 may be configured to spray adhesive onto the first sheet material 6 and / or substrate 2 as it is fed along the transport path and passes through the adhesive applicator 305, or the adhesive may be applied using one or more brushes or rollers. In another embodiment, the adhesive is pre-applied to the web W2 or substrate 2 as a hot melt adhesive, and the fifth step involves heating the adhesive to activate the adhesive.

[0357] In a sixth step (shown in FIG. 15F), the web W2 of first sheet material 6 upon which the individual portions of substrate 2 are disposed is combined with a second aerosol-generating material 5 to form a continuous rod R.

[0358] In this example, the second aerosol-generating material 5 is a tobacco material provided from a tobacco source S3. The tobacco may include, for example, shredded tobacco. In other embodiments, the tobacco material may include a sheet of tobacco (e.g., reconstituted tobacco) that is gathered to form the body of material 3.

[0359] In this example, the web W2 of first sheet material 6 with the individual portions of substrate 2 thereon is combined with the second aerosol-forming material 5 in a packaging apparatus 306.

[0360] In one embodiment, the wrapping device 306 can include, for example, a garniture tongue 307, a garniture belt (not shown), and a belt drive (not shown) that drives the garniture belt (not shown). The belt drive may include, for example, one or more pulleys or wheels driven by an electric motor to drive the garniture belt. The garniture belt extends through the garniture tongue 307. A web W2 of a first sheet material 6 has thereon individual portions (hereinafter, "arrangements") of substrates 2 and overlies the garniture belt such that the operation of the belt drive feeds the arrangement through the garniture tongue 307. The garniture tongue 307 includes a first portion (not shown) that is shaped to form the arrangement into a U-shape as it passes through the garniture tongue 307. A second aerosol-generating material 5 is fed into the garniture tongue 307 to be received in the U-shaped portion of the arrangement of the web W2 and substrates 2.

[0361] The U-shaped arrangement then passes through a second portion (not shown) of the garniture tongue 307 that is shaped to fold a first longitudinal edge (not shown) of the web W2 over an opposing second longitudinal edge (not shown) such that the arrangement exiting the garniture tongue 307 is formed into a cylinder. In this example, said first longitudinal edge of the web W2 is adjacent to the uncovered region 8 of the web W2 such that the uncovered region 8 of the web W2 is bonded to the outer surface of the web W2 to form a cylinder. In some embodiments, the first portion of the garniture tongue 307 is generally U-shaped in cross section and the second portion of the garniture tongue 307 is generally O-shaped in cross section.

[0362] As the second aerosol-generating material 5 passes through the garniture tongue 307, it is formed into a body of material 3. In this example, the second aerosol-generating material 5 is formed into a cylindrical shape. However, it should be appreciated that in alternative embodiments, the body of material 3 may have a different shape, for example having a square, rectangular, oval or triangular cross-section.

[0363] In some embodiments, the wrapping apparatus 306 further comprises an adhesive applicator (not shown) configured to apply a line of adhesive to the web W2 (e.g., in the uncovered areas 8) such that as the web W2 passes through a second portion (not shown) of the garniture tongue 307, the first longitudinal edge is folded over an opposing second longitudinal edge of the web W2 and glued in place by the line of adhesive. Thus, a continuous rod R is formed that includes a body of material 3 that is circumscribed intermittently by individual portions of the substrate 2 and continuously by the first wrapping material 6.

[0364] In an alternative embodiment (not shown), the packaging apparatus 306 has a different arrangement, for example including one or more drums or conveyor belts configured to transport the first packaging material 6, the substrate 2 and a portion of the second aerosol-generating material 5, with the components being combined into a rod.

[0365] In a seventh step (shown in FIG. 15G), the continuous rod R is cut (optionally before or after combination with further components) to form individual articles 1, or multiple lengths of article 1 can be formed which are then cut to form individual articles 1. In this example, the continuous rod R is cut along dashed line Zz-Z2 (shown in FIG. 15F) by a cutting device 308, such as a cutting drum, a reciprocating blade / knife or a laser.

[0366] The method described above is therefore a continuous process in which a continuous rod R is formed and then the ends of the continuous rod R are repeatedly cut to form a plurality of articles 1.

[0367] It has been found that providing the first aerosol-generating material 4 on the substrate 2 allows for more precise positioning of the first aerosol-generating material 4 and therefore more consistent production of the article 1.

[0368] It should be appreciated that various steps of the method described above may be modified, performed in a different order, or omitted entirely. For example, in an alternative embodiment, the step of cutting and separating individual portions of substrate 2 may be omitted. Instead, first aerosol-generating material 4 is applied to web W1 of second sheet material 7, then combined with web W2 of first sheet material 6, and subsequently fed through packaging apparatus 306 to form article 1 in which substrate 2 extends between first and second ends of body of material 3 (e.g., to produce article 1 in the configuration shown in FIG. 9 ).

[0369] In another alternative, the body of material 3 is pre-formed and then the arrangement of substrate 2 and first sheet material 6 is wrapped around the body of material 3. In some embodiments (not shown), individual portions of first sheet material 6 are formed and each is adhered to an individual portion of substrate 2, and then the individual portions of first sheet material 6 and each individual portion of substrate 2 are wrapped around their respective bodies of material 3.

[0370] 17, an alternative article 1 of an aerosol delivery device 200 is shown. Article 1 has similar features to article 1 described above in relation to FIGS. 1-7, and similar features will retain the same reference numbers and may have any of the feature variations described herein. The difference is that article 1 does not include a body of material 3. Instead, a first sheet material 6 on which a substrate 2 rests is formed cylindrically such that substrate 2 surrounds an open space 10. Space 10 forms a passageway 10 that allows gas to pass through article 1.

[0371] 18, an alternative article 1 of an aerosol delivery device 200 is shown. Article 1 has similar features to article 1 described above in relation to Figures 1-7, where similar features retain the same reference numbers, and may have any of the feature variations described herein. The difference is that the substrate 2 does not circumscribe the body of material 3. Instead, the body of material 3 is provided axially upstream of the substrate 2.

[0372] In an alternative embodiment (not shown), the body of material 3 may be provided downstream of the substrate 2. In yet another embodiment (not shown), a first body of material may be provided upstream of the substrate 2 and a second body of material may be provided downstream of the substrate 2.

[0373] Providing the body of material 3 upstream and / or downstream of the substrate 2 facilitates the body of material 3 being heated separately with respect to the substrate. For example, a first heater may be arranged to heat the body of material 3 and a second heater may be arranged to heat the substrate 2. Thus, the substrate 2 and the body of material 3 may be heated at different times and / or to different temperatures.

[0374] In each of the above embodiments described as having a body of material 3, the body of material is described as including, consisting of, or consisting essentially of a second aerosol-generating material 5. However, it should be recognized that in other embodiments, the body of material 3 does not include, consist of, or consist essentially of an aerosol-generating material. For example, the body of material 3 may be formed from a paper sheet that is assembled to form the body of material 3 without the aerosol-generating material. In another embodiment, the body of material 3 may be formed from a sheet that does not include the aerosol-generating material.

[0375] In the article 1 shown in FIG. 1, in FIGS. 1, 8, 9, 13, and 15G, the body of material 3 is shown compressed radially inward in the region of the substrate 2. That is, as the substrate 2 and the first sheet material 6 are wrapped around the body of material 3, the substrate 2 deforms the body of material 3 radially inward, compressing the body of material 3. However, in other embodiments, less material is provided in the portion of the body of material 3 wrapped around the substrate 2 in order for the body of material 3 to accommodate the substrate 2 without being compressed. In one such embodiment, a circumferential groove can be provided in the body of material 3 that accommodates the substrate 2. In other embodiments, the body of material 3 is a cylindrical rod, and the substrate 2 and the first sheet material 6 are wrapped around the body of material 3 such that the cylindrical rod is not compressed or is not substantially compressed by the substrate 2.

[0376] In all of the above examples, the first and / or second aerosol-forming materials 4, 5 may comprise, consist or consist essentially of an extrudate or compact of tobacco material, and preferably the extrudate or compact of tobacco material may comprise beads of tobacco material.

[0377] 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.

[0378] In all of the above examples, the first and / or second aerosol-forming materials 4, 5 may comprise, consist or consist essentially of tobacco blade.

[0379] 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 tobacco and flake tobacco, and preferably the reconstituted tobacco and flake tobacco are mixed together.

[0380] In all of the above examples, the body of material 3 may comprise, consist or consist essentially of a sheet of aerosol-generating material that is gathered together to form the body of material 3, preferably to which the sheet of material is pressed. Preferably, the sheet is a sheet of reconstituted tobacco.

[0381] 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. Preferably, the sheet is a sheet of reconstituted tobacco. For example, the second aerosol-generating material 5 may be cut into strips arranged to form the body of material 3.

[0382] In all of the above examples, the first and / or second aerosol-forming materials 4, 5 may comprise tobacco material, where the tobacco material is produced from tobacco lamina only and no other types of tobacco material.

[0383] 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.

[0384] In each of the example articles described above (including each of the articles shown in Figures 1-9, 12, 13, 15G, 17, and 18), the first and second aerosol-generating materials 4, 5 may have different densities. Otherwise, the aerosol-generating materials of the articles may be the same or different. In other embodiments, the densities of the first and second aerosol-generating materials 4, 5 may be the same.

[0385] In some embodiments, the article further includes a third aerosol-generating material, which may be of a different density than the first and / or second aerosol-generating materials.

[0386] It has been found that providing first and second aerosol-generating materials 4, 5 of different densities means that the higher density material heats more slowly and therefore releases the volatile compound (e.g., nicotine) at a slower rate than the lower density material when both materials are exposed to the same heat. In some embodiments, the first aerosol-generating material 4 has a greater density than the second aerosol-generating material 5, such that the first aerosol-generating material 4 heats more slowly and releases the volatile compound (e.g., nicotine) at a slower rate than the second aerosol-generating material 5 when exposed to the same heat (however, in other embodiments, the reverse may be true, such that the second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4). Thus, combining aerosol-generating materials of different densities provides a more consistent and longer-lasting release of the volatile compound. In some embodiments, aerosol-generating materials of different densities, possibly in combination with separately heating these materials at different times and / or different temperatures, can provide a more tailored release of the volatile compound, for example, over the consumption period of the article. Alternatively, it may be desirable to have a more rapid or greater release of volatile material toward the beginning of consumption of the article to give the user a greater initial impact of use. The ability to control aerosol generation and volatile compound release can be particularly advantageous as the article can be made relatively small while still achieving a particular desired release of volatile compound over the consumption period.

[0387] In some embodiments, one of the first and second aerosol-generating materials 4, 5 has a density that is at least about 25% higher, and optionally at least about 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70% or 75% higher, than the density of the other of the first and second aerosol-generating materials 4, 5. The one of the first and second aerosol-generating materials 4, 5 may have a density that is no more than about 200% higher, and optionally no more than about 150%, 125%, 100% or 75% higher, than the density of the other of the first and second aerosol-generating materials 4, 5. In some embodiments, one of the first and second aerosol-generating materials 4, 5 has a density that is between about 25% and about 75% higher than the density of the other of the first and second aerosol-generating materials 4, 5.

[0388] In some embodiments, the one of the first and second aerosol-generating materials 4,5 has a density of at least about 0.4 g / cm3, and 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 / cm3. The one of the first and second aerosol-generating materials 4,5 may have a density of about 2 g / cm3 or less, and 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 / cm3 or less. In some embodiments, the density of the one of the first and second aerosol-generating materials 4,5 is between about 0.4 and 1.99 g / cm3.

[0389] In some embodiments, the other of the first and second aerosol-generating materials 4, 5 has a density of at least about 0.1 g / cm, and optionally at least about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, or 0.9 g / cm. The other of the first and second aerosol-generating materials 4, 5 may have a density of about 1 g / cm or less, and optionally about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, or 0.2 g / cm or less. In some embodiments, the density of the other of the first and second aerosol-generating materials 4, 5 is between about 0.1 and 0.9 g / cm.

[0390] In some embodiments, the first and second aerosol-generating materials 4, 5 contain the same components. Thus, upon heating, they release very similar aerosols, potentially with the same content of actives and / or flavors, etc. Their different densities allow aerosols to be generated from the two materials at different rates and / or for different times during heating.

[0391] In other embodiments, the first and second aerosol-generating materials 4, 5 comprise different components (and may have the same or different densities). Thus, upon heating, they emit different aerosols, potentially with different compositions of actives and / or fragrances, etc. Their different densities allow different aerosols to be generated from the two materials at different rates and / or for different times during heating, potentially providing aerosols that vary over the period of use.

[0392] In some embodiments, the first aerosol-forming material 4 and the second aerosol-forming material 5 each comprise a plant material, such as tobacco. Tobacco contains volatile components including nicotine, aromas and flavors. Tobacco may be any type of tobacco and any part of the tobacco plant, including tobacco leaf, blade, stem, stalk, rib, stubble and stubble, or a mixture of two or more thereof. Suitable tobacco materials include the following types: Virginia or flue-cured tobacco, Burley tobacco, Oriental tobacco, or blends of tobacco materials, optionally including those listed 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 a reconstituted tobacco material. The tobacco may be pre-treated 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 otherwise pre-treated.

[0393] The first and second aerosol-generating materials 4, 5 may comprise different tobacco, or the tobacco may be the same but provided in different forms such that one of the first and second aerosol-generating materials 4, 5 has a higher density than the other of the first and second aerosol-generating materials 4, 5.

[0394] In some embodiments, the first aerosol-generating material 4 has at least one (further) different property relative to the second aerosol-generating material 5. The different property may be one or more of the form, size, moisture content, amount (by weight), one or more materials, or proportions of materials that make up the first and second aerosol-generating materials 4, 5 (including the recipes of the aerosol-generating materials when each is made from two or more materials). In some embodiments, the first and second aerosol-generating materials 4, 5 have no different properties other than their different densities. In other embodiments, the densities of the first and second aerosol-generating materials are the same.

[0395] In some embodiments, the second aerosol-generating material 5 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 second aerosol-generating material 5 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.

[0396] In some embodiments, the first aerosol-generating material 4 has a higher density than the second aerosol-generating material 5. In some embodiments, this higher density first aerosol-generating material 4 may comprise particles or may be in the form of beads or one or more sheets. Each bead or sheet may be formed from aggregated smaller particles. However, it should be appreciated that in other embodiments, the second aerosol-generating material 5 may be denser than the first aerosol-generating material 4, e.g., in the form of beads or one or more sheets. 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 optionally, one of the first and second aerosol-generating materials 4, 5 may be processed to have a higher density than the other of the first and second aerosol-generating materials 4, 5. In some embodiments, the beads 4, 5 may be cast into a sheet material.

[0397] As used herein, the term "bead" is meant to include beads, pellets, or other small discrete units that have been molded, shaped, compressed, or otherwise formed into a desired shape. Beads may have a smooth, regular outline (e.g., spherical, cylindrical, ovoid, etc.) and / or may have an irregular outline.

[0398] 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 no greater than about 4.5, 4, 3.5, 3, 2.5, 2, or 1.5 mm. 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 their average size, e.g., number or volume average size.

[0399] In some embodiments, the desired density of the aerosol-generating material 4, 5 is achieved or controlled by the formulation of the material and / or the way the material is processed. Processes involving agglomeration, particularly agglomeration by some application of compressive force, tend to increase the density of the material.

[0400] Thus, in some embodiments, the first and / or second aerosol-generating materials 4, 5 comprise particles of agglomerated material.

[0401] In the case of sheet material, the sheet may be formed from particles of material that are combined and optionally compressed to form a sheet having the desired dimensions and density.

[0402] In some embodiments, the beads or pellets can be formed using a so-called malming process.

[0403] 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. Depending on the type of equipment and process selected, pellet formation and growth can occur in several ways. These pellets may be formed by agitation, where particles are rolled and tumbled in the presence of an appropriate amount of liquid to form agglomerates. Sintering may include the use of equipment such as pans, disks, drums or mixers to produce pellets. Compression pelleting is a form of pressure agglomeration, where particles are brought together by mechanical force, optionally with compounding aids. The compression force means that the formed pellets have an increased density compared to the starting material.

[0404] In some embodiments, the agglomeration is by extrusion. In some embodiments, the pellets formed by pelletization can be extruded to form a denser extrudate.

[0405] The extruded particles may have a size selected to produce a denser aerosol-forming material (e.g., denser first or second aerosol-forming material 4, 5), which affects heat transfer and release of volatile components within the material.

[0406] Extrusion involves feeding a composition (also called a precursor composition) through a die to produce an extruded product. This process applies pressure to the composition in combination with shear forces.

[0407] Extrusion can be carried out using one of the major types of extruders: screw, screen and basket, roll, ram and pin barrel extruders. Single or twin screw extruders may be used. Forming tobacco beads by extrusion has the advantage that this process combines compression, mixing, conditioning, homogenization and shaping of the composition.

[0408] 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 shaped nozzle or die, to form an extrudate, which in some embodiments has a rod-like form and can be cut into segments of a desired length.

[0409] In some embodiments, the composition is exposed to a temperature in the extruder of from about 40° C. to about 150° C., or from about 80° C. to about 130° C., or from about 60° C. to about 95° C. In some embodiments, including those using dual extrusion, the precursor composition is exposed to a temperature in the extruder of from about 70° C. to about 95° C. In some embodiments, including those using single extrusion, the precursor composition is exposed to a temperature in the extruder of from about 60° C. to about 80° C.

[0410] The composition may be subjected to pressures (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. Higher pressures tend to result in a denser extrudate. Thus, the extrusion process can be adjusted to provide an extruded aerosol-generating material having a desired density.

[0411] In some embodiments in which tobacco particles are extruded, due to the relatively high density of the extrudate and the relatively open surfaces of the tobacco particles therein, the tobacco beads formed from the extrudate exhibit good heat and mass transfer, which positively impacts the release of tobacco components such as flavors and nicotine.

[0412] In some embodiments, extrusion may be a generally dry process and the composition comprises dry or substantially dry aerosol-generating particles. The composition may optionally include other particulate materials including, for example, bases, diluents, solid aerosol formers, solid flavor modifiers, and the like.

[0413] In some embodiments, a liquid can be added to the composition before or during the extrusion process. For example, water can be added as a processing aid, for example, to aid in dissolving or solubilizing the components of the composition, or to aid in binding or cohesion. Alternatively or additionally, a wetting agent can be added to the composition.

[0414] In some embodiments, the liquid may be an aerosol former material, such as glycerol or others discussed herein. Adding a liquid to the composition in this manner not only applies the liquid to the surface, but also impregnates the extrudate with the liquid as a result of the vigorous mixing caused by the pressure and high shear forces of the extruder. If the liquid is an aerosol former material, this can result in high availability of the aerosol former material in the resulting beads, facilitating evaporation of volatile components.

[0415] In some embodiments, the amount of aerosol former 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 former material may make the composition difficult to handle. However, this is less of a problem as the particles are impregnated with aerosol former material upon extrusion. It may be desirable to include an amount of aerosol former material, such as at least about 10% by weight or at least about 20% by weight, that will generate an aerosol in addition to releasing a volatile component. If the primary function of the beads is to release a volatile component carried by the beads into an existing aerosol or air stream, a smaller amount of aerosol former material, such as up to about 5% by weight, may be sufficient.

[0416] In some embodiments, the aggregates do 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 aggregates include a binder or binding additive. The binding additive may be selected to aid in the formation of the aggregate structure by helping to adhere the particles to each other and to other components in the composition. Suitable binding additives include, for example, thermoreversible gelling agents such as gelatin, starch, polysaccharides, pectin, alginates, wood pulp, cellulose, and cellulose derivatives such as carboxymethylcellulose.

[0417] In some embodiments, processing by extrusion is sufficient to provide a higher density, if desired, of the first or second aerosol-generating materials 4, 5. However, in other embodiments, the extrudate may be further processed to increase the density of the first or second aerosol-generating materials 4, 5.

[0418] For example, in some embodiments, the extruded aerosol-generating material is subjected to spheronization, in which the extruded cylindrical particles are broken into uniform lengths and gradually transformed into spherical shapes by plastic deformation. If the extrudate is first divided into uniform lengths, spheres having uniform diameters are produced by the spheronization step.

[0419] According to one specific example of the embodiments discussed herein, a sample of a first aerosol-generating material 4 was generated as follows (although it should be noted that in some embodiments, samples used for a second aerosol-generating material 5 and / or a third aerosol-generating material may instead be generated as follows):

[0420] Three sample formulations, with and without binder, are shown in Table 1, with the amounts given as wet weight percent (WWB). [Table 1]

[0421] The tobacco was ground to produce a fine powder, taking care not to overheat the tobacco. The ground tobacco particles were sieved to select those having a desired size, for example, a particle size of less than 250 μm, less than 100 μm, or less than 60 μm.

[0422] All of the dry (non-liquid) ingredients of the formulation were then combined and mixed or blended in a mixer. In this particular example, the mixture was mixed for 1 minute at speeds up to 75 RPM. This was to ensure that the dry ingredients were evenly distributed within the mixture.

[0423] 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 then continued until the mix had a crumbly consistency that could be pressed into a mass to ensure a homogenous mix was achieved. In this particular example, additional mixing continued for 3 minutes.

[0424] The mixture was then extruded using a Caleva Multilab. The extruder was operated at approximately 1500 rpm to produce extrudates of pasta-like length.

[0425] The extrudate was broken into pieces of various lengths as it emerged from the extruder. These pieces were then spheronized. Spheronization was carried out until spherical beads were formed. In this case, the extrudate was first spheronized in a Caleva Multilab operating at 2,500 RPM for 1 minute, and then the beads were checked for defects. Spheronization was then continued for an additional 1-2 minutes. This spheronization step broke the extruded tobacco into individual pieces, forming dense spherical beads.

[0426] In the 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 drying was stopped when the desired moisture weight loss was achieved. Generally, such drying takes about 1 hour.

[0427] In some embodiments, the other of the first and / or second aerosol-generating materials 4, 5 is in the form of discrete particles or in the form of agglomerates of particles. These particles may share various properties with the (higher density) one of the first and second aerosol-generating materials 4, 5, such as particle size, but have a lower density. As mentioned above, there are various ways to adjust the density of the aerosol-generating materials 4, 5, for example, compounding and / or processing the materials into particles, beads or pellets.

[0428] In some embodiments, the other of the first and second aerosol-forming materials 4, 5 comprises a combination of 60% reconstituted tobacco and 40% leaf tobacco, the density of which is between about 0.1 and about 0.9 g / cm. 3 Other (higher density) aerosol-forming materials 4, 5 include from about 30 to about 90% tobacco and have a density of from about 0.4 to about 1.99 g / cm 3The first and / or second aerosol-generating material 4, 5 may comprise about 8 to about 15% aerosol-forming material. The (higher density) one of the first and second aerosol-generating materials 4, 5 may comprise mostly 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% first aerosol-generating material 4 and about 50% second aerosol-generating material 5 by weight. Thus, for example, an article comprising 260 mg of aerosol-generating material may comprise 130 mg of first aerosol-generating material 4 and 130 mg of second aerosol-generating material 5.

[0429] In some embodiments where 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.

[0430] 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 at least about 35% tobacco, based on the weight of the aerosol-forming material.

[0431] 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 about 40% or less tobacco, based on the weight of the aerosol-forming material.

[0432] The cigarettes described herein may contain nicotine. In some embodiments, the nicotine content may be between 0.5 and 2% by weight of the cigarette, such as between 0.5 and 1.75% by weight of the cigarette, between 0.8 and 1.2% by weight of the cigarette, or between about 0.8 and about 1.75% by weight of the cigarette. In some embodiments, the nicotine content may be between 0.8 and 1% by weight of the cigarette.

[0433] In some embodiments, the first and second aerosol-forming materials 4, 5 have the same nicotine content.

[0434] 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 volatile component content.

[0435] 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 mg 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 and comprises a combination of 130 mg of a second aerosol-generating material 5, e.g., comprising a blend of lamina and reconstituted tobacco, and 130 mg of a first aerosol-generating material 4, e.g., comprising higher density tobacco beads.

[0436] In some embodiments, the article includes regions of aerosol-generating material, each region including an aerosol-generating material that contains 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, or 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, or about 30 to about 300 mg, or about 40 to about 125 mg of tobacco.

[0437] The present disclosure also provides a kit of parts including an article 1 according to any of the examples described herein and an aerosol delivery device 200.

[0438] The present disclosure also provides a package (not shown) including a plurality of articles according to any of the examples described herein. In some embodiments, the package is sealed. The package can include a container having a body and a lid, with a space provided within the container body for receiving the plurality of articles. The lid can be, for example, a hinged lid, a snap-fit ​​lid, or a lid connected by a screw thread.

[0439] The various embodiments described herein are presented only to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, 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 may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Furthermore, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. 1. A method of manufacturing an article for use in an aerosol delivery system, comprising: Providing a first sheet material; providing a substrate comprising a first aerosol-generating material, the substrate being attached to the first sheet material; positioning the first sheet material with the substrate attached such that the first sheet material surrounds the substrate; The method includes:

2. The method of claim 1 , wherein the first sheet material comprises paper or card.

3. The method of claim 1 or 2, wherein the first sheet material comprises a metal.

4. The method of any one of claims 1 to 3, wherein the first sheet material comprises a co-laminate material comprising a paper layer and an aluminium layer.

5. The method of claim 4 , wherein attaching the substrate to the first sheet material comprises attaching the substrate to the aluminum layer.

6. The method of any one of claims 1 to 5, further comprising hollowing out the substrate and / or first sheet of material to provide vent openings.

7. A method according to any preceding claim, wherein the substrate comprises a second sheet material, preferably wherein providing the substrate comprises attaching the second sheet material to the first sheet material.

8. The method of claim 7 wherein the second sheet material is a cast sheet.

9. The method of claim 7 or 8, wherein the second sheet material comprises the first aerosol-forming material.

10. 10. The method of claim 9, wherein the second sheet material is formed from a slurry including the first aerosol-generating material, and preferably the slurry is cast to form the second sheet material.

11. 8. The method of claim 7, wherein the first aerosol-generating material is attached to a surface of the second sheet material, preferably glued to the surface of the second sheet material.

12. 12. The method of claim 11, wherein the first aerosol-forming material is attached to the surface of the second sheet material before or after the second sheet material is attached to the first sheet material.

13. A method according to any one of claims 7 to 12, wherein the second sheet material comprises one or more of paper, card and / or aerosol-forming material.

14. A method according to any preceding claim, wherein the step of providing a first sheet material comprises providing a web of first sheet material.

15. The method of claim 14 , wherein the step of providing a substrate comprises applying the substrate to the first web of sheet material.

16. The method of claim 15 when dependent on any one of claims 2 to 8, wherein applying the substrate to the first web of sheet material comprises applying the second web of sheet material to the first web of sheet material.

17. The method of claim 15 when dependent on any one of claims 2 to 8, wherein applying the substrate to the web of first sheet material comprises applying a plurality of portions of a second sheet material to the web of first sheet material.

18. The method of claim 17 , wherein the portions of the second sheet material are spaced apart from one another on the web of the first sheet material.

19. A method according to any one of the preceding claims, wherein an edge of the substrate is spaced from an edge of the first sheet material such that an area of ​​the first sheet material is not covered by the substrate, preferably the method comprising the step of applying an adhesive to said area.

20. A method according to any one of the preceding claims, wherein the first sheet material has a permeability of at most 100 Coresta units.

21. A method according to any preceding claim, wherein the first sheet material forms an outer surface of the article.

22. The method of any one of claims 1 to 21, wherein the first aerosol-forming material comprises aerosol-forming material dust and / or aerosol-forming material fibers.

23. The method of any one of claims 1 to 22, wherein the first aerosol-forming material comprises an extruded and / or compressed aerosol-forming material.

24. The method of any one of claims 1 to 23, wherein the first aerosol-forming material comprises beads.

25. 25. The method of any one of the preceding claims, wherein the first aerosol-forming material comprises, consists of, or consists essentially of tobacco material.

26. The method of any one of claims 1 to 25, wherein the article further comprises a second aerosol-forming material.

27. 27. The method of claim 26, wherein the second aerosol-forming material has a higher or lower density than the first aerosol-forming material.

28. 28. The method of claim 26 or claim 27, wherein the second aerosol-forming material comprises, consists of, or consists essentially of tobacco material.

29. The method of any one of claims 26 to 28, wherein the substrate comprises the second aerosol-forming material.

30. 30. A method according to any one of the preceding claims, wherein the step of positioning the first sheet material having the substrate attached thereto comprises providing the first sheet material and the substrate around at least a portion of a body of material, preferably wrapping the first sheet material together with the substrate around the body of material.

31. 31. The method of claim 30, wherein the body of material comprises a third sheet material gathered to form the body of material.

32. 32. The method of claim 31 , wherein the third sheet material is crimped and / or cut into strips.

33. A method according to any one of claims 30 to 32 when dependent on any one of claims 21 to 24, wherein the body of material comprises the second aerosol-forming material.

34. 1. An assembly for use in a method of manufacturing an article for use in an aerosol delivery system, comprising: a first sheet material; a patch comprising a first aerosol-generating material and attached to the first sheet material.

35. 1. An article for use in an aerosol delivery system, comprising: a first sheet material; a patch comprising a first aerosol-generating material and attached to the first sheet material; The article, wherein the sheet material and patch are positioned such that the sheet material surrounds the patch.

36. 36. The article of claim 35, wherein the first sheet material comprises paper or card.

37. 37. The article of claim 35 or 36, wherein the first sheet material comprises a metal.

38. The article of any one of claims 35 to 37, wherein the first sheet material comprises a co-laminate material comprising a paper layer and an aluminum layer.

39. 39. The article of claim 38, wherein the patch is attached to the aluminum layer.

40. The article of any one of claims 35 to 39, wherein the first sheet material forms an outer surface of the article.

41. 41. The article of claim 35 or 40, further comprising a second aerosol-forming material.

42. 42. The article of claim 41, wherein the second aerosol-forming material has a higher or lower density than the first aerosol-forming material.

43. 43. The article of claim 41 or 42, wherein the second aerosol-forming material comprises, consists of, or consists essentially of tobacco material.

44. The article of any one of claims 35-43, further comprising a body of material, the first sheet material and patch being disposed about at least a portion of the body of material.

45. 45. The article of claim 44, wherein the body of material comprises a third sheet material gathered to form the body of material.

46. 46. ​​The article of claim 45, wherein the third sheet material is crimped and / or cut into strips.

47. The article of any one of claims 44 to 46 when dependent on any one of claims 32 to 34, wherein the body of material comprises the second aerosol-forming material.

48. The arrangement of claim 34 or the article of any one of claims 35 to 47, wherein the patch comprises a second sheet material, preferably the second sheet material is a cast sheet.

49. 49. The arrangement or the article of claim 48, wherein the second sheet material comprises the first aerosol-forming material.

50. 50. The arrangement of claim 48 or 49 or the article of claim 48 or 49, wherein the second sheet material is formed from a slurry including the first aerosol-generating material, preferably the slurry is cast to form the second sheet material.

51. 50. The arrangement of claim 48 or 49 or the article of claim 48 or 49, wherein the first aerosol-generating material is attached to a surface of the second sheet material, preferably adhered to the surface of the second sheet material.

52. 52. The arrangement of any one of claims 48 to 51 or the article of any one of claims 48 to 51, wherein the second sheet material comprises one or more of paper, card and / or an aerosol-forming material.

53. 53. The arrangement of claim 34 or any one of claims 48-52 or the article of any one of claims 35-52, wherein the patch has a first end spaced from a first end of the first sheet material.

54. 54. The arrangement or article of claim 53, wherein the patch has a second end opposite the first end, the second end being spaced from the second end of the first sheet material.

55. 55. The arrangement of claim 34 or any one of claims 48 to 54 or the article of any one of claims 35 to 54, wherein an edge of the substrate is spaced from an edge of the first sheet material such that an area of ​​the first sheet material is not covered by the substrate, preferably the edge is a longitudinal edge of the substrate and first sheet material.

56. An arrangement according to claim 34 or any one of claims 48 to 55 or an article according to any one of claims 35 to 55, wherein the first sheet material has a permeability of at most 100 Coresta units.

57. The arrangement of claim 34 or any one of claims 48-56 or the article of any one of claims 35-56, wherein the first aerosol-forming material comprises aerosol-forming material dust and / or aerosol-forming material fibers.

58. The arrangement of claim 34 or any one of claims 48-57 or the article of any one of claims 35-57, wherein the first aerosol-generating material comprises an extruded and / or compressed aerosol-generating material.

59. The arrangement of claim 34 or any one of claims 48-57 or the article of any one of claims 35-58, wherein the first aerosol-generating material comprises beads.

60. 60. The arrangement of claim 34 or any one of claims 48 to 59 or the article of any one of claims 35 to 59, wherein the first aerosol-forming material comprises, consists of, or consists essentially of tobacco material.

61. The arrangement of claim 34 or any one of claims 48-60 or the article of any one of claims 35-60, wherein the patch comprises the second aerosol-forming material.

62. An article produced according to the method of any one of claims 1 to 33.

63. A package comprising a plurality of articles according to any one of claims 35 to 62, preferably the package being sealed.

64. A kit of parts comprising the article of any one of claims 35 to 62 and an aerosol delivery device.

65. 65. The kit of parts of claim 64, wherein the aerosol delivery device comprises a heating chamber for receiving the articles and heating the first and second aerosol-generating materials.

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