Articles for use in aerosol delivery systems and methods for making articles for use in aerosol delivery systems - Patents.com

Abstract

The present disclosure relates to an article for use in an aerosol delivery system. The article comprises a sheet material including a first aerosol generating material, the sheet material being gathered together to form a body. The article further comprises a second aerosol generating material engaged by the sheet material such that the second aerosol generating material is held within the body by the sheet material. The present disclosure also relates to a method of manufacturing the article for 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 articles for aerosol delivery devices. The present disclosure also relates to methods of manufacturing articles for aerosol delivery devices, kits of parts including the articles and aerosol delivery devices, and packages of the articles. [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-combustible smoking article, an aerosol-generating assembly, or an aerosol delivery device. Summary of the Invention

[0003] According to some embodiments described herein, an article is provided for use in an aerosol delivery system, the article comprising: a sheet material including a first aerosol generating material, the sheet material being gathered together to form a body; and a second aerosol generating material engaged by the sheet material such that the second aerosol generating material is held within the body by the sheet material.

[0004] In some embodiments, the second aerosol-generating material is held within the body by friction.

[0005] In some embodiments, the second aerosol generating material is held between portions of the sheet material, preferably the body comprises multiple layers of sheet material and the second aerosol generating material is held between the layers of the sheet material.

[0006] In some embodiments, the portion of sheet material is a strip or strand of sheet material, hi other embodiments, the portion is a fold of the sheet material.

[0007] In some embodiments, the sheet material is formed into strips or strands and the second aerosol-generating material is held between the strips or strands.

[0008] In some embodiments, the sheet material is chopped and / or cut, hi some embodiments, the sheet material is cut into strips.

[0009] In some embodiments, the sheet material is formed into strips having widths in the range of 0.5 mm to 3 mm, preferably in the range of 0.5 to 1.5 mm.

[0010] In some embodiments, the sheet material is formed into strips having a width of at least 0.5 mm, preferably at least about 0.6, 0.7, 0.8, or 0.91 mm.

[0011] In some embodiments, the sheet material is formed into strips having a width of at most about 3 mm, preferably at most about 2.5, 2, 1.8, 1.6, 1.4, 1.2, or 1.1 mm.

[0012] In some embodiments, the sheet material is formed into a strip having a length the same as the length of the article.

[0013] In some embodiments, the strips or strands extend in a direction from a first end toward a second end of the article.

[0014] In some embodiments, the strips or strands extend generally parallel to the central axis of the article, while in other embodiments, the strips or strands may not be oriented in a particular direction, for example, they may be randomly oriented.

[0015] In some embodiments, the sheet material is crimped.

[0016] In some embodiments, the article does not include an additive or binder to keep the second aerosol-generating material within the body.

[0017] In some embodiments, the body of material extends from a first end of the article to a second end of the article.

[0018] In some embodiments, the body of material extends over a portion of the length of the article, hi some embodiments, the body of material extends over the entire length of the article.

[0019] In some embodiments, the first and second aerosol-generating materials form a collation of aerosol-generating materials that extends along at least 90% of the length of the article, preferably at least 92%, 94%, 96%, 98%, or 99% of the length of the article, and preferably extends along the entire length of the article.

[0020] In some embodiments, the body comprises a single sheet of material that is brought together to form the body, hi other embodiments, the body may comprise multiple sheets of material that are brought together to form the body.

[0021] In some embodiments, the first and / or second aerosol-forming materials comprise, consist of, or consist essentially of tobacco material.

[0022] In some embodiments, the aerosol-forming material extends along at least 90% of the length of the article, preferably at least 92%, 94%, 96%, 98%, or 99% of the length of the article, preferably the entire length of the article.

[0023] In some embodiments, the first aerosol-forming material comprises reconstituted tobacco.

[0024] In some embodiments, the first aerosol-generating material includes tobacco blade.

[0025] In some embodiments, the first aerosol-generating material is substantially free of tobacco.In some embodiments, the first aerosol-generating material is substantially free of tobacco.

[0026] In some embodiments, the first aerosol-generating material includes a bulking agent.

[0027] In some embodiments, the filler is a non-tobacco fiber.

[0028] In some embodiments, the filler is wood fiber or pulp or wheat fiber.

[0029] In some embodiments, the filler comprises cellulose.

[0030] In some embodiments, the filler is a non-tobacco cast material or a non-tobacco extrusion material.

[0031] In some embodiments, the article comprises an aerosol former material.

[0032] In some embodiments, the first and / or second aerosol-generating materials comprise an aerosol former material.

[0033] In some embodiments, the aerosol former material comprises one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0034] In some embodiments, the second aerosol-forming material comprises an extruded and / or compressed aerosol-forming material, preferably extruded and / or compressed tobacco.

[0035] In some embodiments, the tobacco material of the first and / or second aerosol-generating 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-generating materials include tobacco lamina and reconstituted tobacco.

[0037] In some embodiments, the first and second aerosol-forming materials both have average nicotine levels in the range of 0.5% to 2.5% by weight of the aerosol-forming materials, preferably in the range of 1% to 2.1% by weight.

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

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

[0040] In some embodiments, the article does not include cellulose acetate.

[0041] 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.

[0042] In some embodiments, the second aerosol-generating material comprises beads of aerosol-generating material.

[0043] In some embodiments, the beads are generally cylindrical.

[0044] In one embodiment, the beads are extruded beads, preferably extruded tobacco beads.

[0045] In some embodiments, the beads have a particle size ranging from about 0.5 mm to about 3 mm.

[0046] In some embodiments, the first and second aerosol-generating materials have different densities, and preferably the density of the second aerosol-generating material is at least 25% higher than the density of the first aerosol-generating material.

[0047] In some embodiments, the second aerosol-generating material has a density of about 0.4 g / cm 3 ~About 2g / cm 3 It has a density in the range of

[0048] In some embodiments, the first aerosol-generating material has a density of about 0.1 g / cm 3 ~Approx. 1g / cm 3 It has a density in the range of

[0049] In some embodiments, the second aerosol-generating material comprises fibers of an aerosol-generating material.

[0050] In some embodiments, the second aerosol-generating material is distributed throughout the body of the material.

[0051] In some embodiments, the second aerosol-generating material is discretely distributed within the body of material to form a plurality of discrete regions of the second aerosol-generating material.

[0052] In some embodiments, the sheet material comprises an aerosol-generating material, including about 10 to about 50 wt.% aerosol former material, about 15 to about 60 wt.% gelling agent, and optionally a filler, the wt.% values ​​being calculated on a dry weight basis.

[0053] In some embodiments, the aerosol-generating material of the sheet includes a flavoring.

[0054] In some embodiments, the sheet material is elastically deformable.

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

[0056] 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.

[0057] 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

[0058] In some embodiments, the other of the first and second aerosol-forming materials has a density of about 0.4 g / cm 3 ~About 2g / cm 3 has a density of

[0059] In some embodiments, heating the article provides a relatively constant release of volatile compounds into the inhalable medium.

[0060] In some embodiments, the second aerosol-forming material includes extruded tobacco.

[0061] In some embodiments, the second aerosol-generating material comprises beads.

[0062] In some embodiments, the first aerosol-forming material comprises one or more tobacco materials selected from the group consisting of blade tobacco materials and reconstituted tobacco materials.

[0063] In some embodiments, at least one of the first and second aerosol-forming materials comprises a combination of leaf tobacco material and reconstituted tobacco material, hi some embodiments, the leaf tobacco material and the reconstituted tobacco material are present in the aerosol-forming material in a ratio of 1:4 to 4:1 by weight.

[0064] 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.

[0065] In some embodiments, the release of volatile compounds from the first and second aerosol-generating materials is at the same rate when the materials reach a given temperature.

[0066] In some embodiments, the article comprises from about 20 to about 330 mg of the first aerosol-generating material, preferably from about 50 to about 300 mg, or from about 40 to about 125 mg of the first aerosol-generating material.

[0067] In some embodiments, the article comprises from about 20 to about 330 mg of the second aerosol-generating material, preferably from about 50 to about 300 mg, or from about 40 to about 125 mg of the second aerosol-generating material.

[0068] In some embodiments, the body of material is surrounded by a wrapper.

[0069] In some embodiments, the wrapper forms an outer surface of the article.

[0070] In some embodiments, the wrapping material has an air permeability of less than 100 Coresta units, preferably less than 90, 80, 70, 60, or 50 Coresta units.

[0071] In some embodiments, the wrapping material has a thickness in the range of 20 to 100 microns.

[0072] In some embodiments, the wrapping material has a basis weight in the range of 20 to 50 gsm.

[0073] In some embodiments, the article comprises a cooling element immediately downstream of the body.

[0074] In some embodiments, the cooling element comprises a hollow channel.

[0075] In some embodiments, the article comprises a further body of material downstream of the cooling element.

[0076] In some embodiments, the body of additional material comprises a flavor material and / or a filtering material.

[0077] In some embodiments, the article comprises a segment upstream of the body.

[0078] According to the present disclosure, there is provided a method of manufacturing an article for use in an aerosol delivery system, the method including: providing a sheet material including a first aerosol generating material; providing a second aerosol generating material; and gathering the sheet material to form a body, the sheet material being engaged by the sheet material such that the second aerosol generating material is retained within the body by the sheet material.

[0079] In some embodiments, the method includes combining the sheet material with a second aerosol-generating material and then bringing the sheet material together to form a body.

[0080] In some embodiments, the method includes combining the sheet material with a second aerosol-generating material simultaneously with gathering the sheet material to form the body.

[0081] In some embodiments, the method includes forming the sheet material into a strip or stand.

[0082] In some embodiments, the method includes shredding and / or cutting the sheet material.

[0083] In some embodiments, the sheet may be cut into strips using a strip cut maker.

[0084] In some embodiments, the strips or strands extend in a direction from a first end toward a second end of the article.

[0085] In some embodiments, the method includes crimping the sheet material.

[0086] In some embodiments, the sheet material is formed into strips or strands and the second aerosol-generating material is held between the strips or strands.

[0087] In some embodiments, the second aerosol-generating material is held within the body by friction.

[0088] In some embodiments, gathering the sheet material includes gathering the sheet material such that the second aerosol generating material is retained between portions of the sheet material, preferably such that the body comprises multiple layers of sheet material and the second aerosol generating material is retained between the layers of the sheet material.

[0089] In some embodiments, the method does not include using an additive or binder to hold the second aerosol-generating material within the body.

[0090] In some embodiments, the body of material extends from a first end of the article to a second end of the article.

[0091] In some embodiments, the body of material extends over a portion of the length of the article, hi some embodiments, the body of material extends over the entire length of the article.

[0092] In some embodiments, the aerosol-forming material extends along at least 90% of the length of the article, preferably at least 92%, 94%, 96%, 98%, or 99% of the length of the article, preferably the entire length of the article.

[0093] In some embodiments, the first aerosol-generating material extends over at least 90% of the length of the article, preferably at least 92%, 94%, 96%, 98%, or 99% of the length of the article, and preferably extends the entire length of the article.

[0094] In some embodiments, the body comprises a single sheet of material that is gathered together to form the body.

[0095] In some embodiments, the first and / or second aerosol-forming materials comprise, consist of, or consist essentially of tobacco material.

[0096] In some embodiments, the first aerosol-forming material comprises reconstituted tobacco.

[0097] In some embodiments, the first aerosol-generating material includes tobacco blade.

[0098] In some embodiments, the first aerosol-generating material is substantially free of tobacco.In some embodiments, the first aerosol-generating material is substantially free of tobacco.

[0099] In some embodiments, the first aerosol-generating material includes a bulking agent.

[0100] In some embodiments, the filler is a non-tobacco fiber.

[0101] In some embodiments, the filler is wood fiber or pulp or wheat fiber.

[0102] In some embodiments, the filler comprises cellulose.

[0103] In some embodiments, the filler is a non-tobacco cast material or a non-tobacco extrusion material.

[0104] In some embodiments, the article comprises an aerosol former material.

[0105] In some embodiments, the first and / or second aerosol-generating materials comprise an aerosol former material.

[0106] In some embodiments, the aerosol former material comprises one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

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

[0108] In some embodiments, the tobacco material of the first and / or second aerosol-generating materials is derived only from tobacco lamina and not from other types of tobacco material.

[0109] In some embodiments, the first and / or second aerosol-generating materials include tobacco lamina and reconstituted tobacco.

[0110] In some embodiments, the first and second aerosol-generating materials together have an average nicotine level in the range of 0.5% to 2.5% by weight of the first and second aerosol-generating materials, preferably in the range of 1% to 2.1% by weight.

[0111] In some embodiments, the first and / or second aerosol-generating materials are solid materials.

[0112] In some embodiments, the article does not include plastic.

[0113] In some embodiments, the article does not include cellulose acetate.

[0114] 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.

[0115] In some embodiments, the second aerosol-generating material comprises beads of aerosol-generating material.

[0116] In some embodiments, providing the second aerosol-generating material comprises extruding the second aerosol-generating material.

[0117] In some embodiments, the beads are approximately cylindrical.

[0118] In some embodiments, the beads are extruded beads, preferably extruded tobacco beads.

[0119] In some embodiments, the beads have a particle size in the range of 0.5 to 3 mm.

[0120] In some embodiments, the second aerosol-generating material comprises fibers of an aerosol-generating material.

[0121] In some embodiments, the second aerosol-generating material is distributed throughout the body of the material.

[0122] In some embodiments, the second aerosol-generating material is discretely distributed within the body of material to form a plurality of discrete regions of the second aerosol-generating material.

[0123] In some embodiments, the first and second aerosol-generating materials have different densities, and preferably the density of the second aerosol-generating material is at least 25% higher than the density of the first aerosol-generating material.

[0124] 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.

[0125] 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

[0126] In some embodiments, the other of the first and second aerosol-forming materials has a density of about 0.4 g / cm 3 ~About 2g / cm 3 has a density of

[0127] In some embodiments, heating the article provides a relatively constant release of volatile compounds into the inhalable medium.

[0128] In some embodiments, the second aerosol-forming material includes extruded tobacco.

[0129] In some embodiments, the second aerosol-generating material comprises beads.

[0130] In some embodiments, the first aerosol-forming material comprises one or more tobacco materials selected from the group consisting of blade tobacco materials and reconstituted tobacco materials.

[0131] In some embodiments, at least one of the first and second aerosol-forming materials comprises a combination of leaf tobacco material and reconstituted tobacco material, hi some embodiments, the leaf tobacco material and the reconstituted tobacco material are present in the aerosol-forming material in a ratio of 1:4 to 4:1 by weight.

[0132] 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.

[0133] In some embodiments, the release of volatile compounds from the first and second aerosol-generating materials is at the same rate when the materials reach a given temperature.

[0134] In some embodiments, the first and second aerosol-generating materials are present in the article in a ratio of 1:10 to 10:1 by weight.

[0135] In some embodiments, the article comprises a total of between 7 mg / mm and 13 mg of first and second aerosol-generating material per mm length of the article, preferably between 8 to 12, 9 to 11.5, 9 to 11, or 9.5 to 10.5 mg of aerosol-generating material per mm length of the article.

[0136] In some embodiments, the sheet material comprises an aerosol-generating material, including about 10 to about 50 wt.% aerosol former material, about 15 to about 60 wt.% gelling agent, and optionally a filler, the wt.% values ​​being calculated on a dry weight basis.

[0137] In some embodiments, the aerosol-forming material of the sheet material includes a flavoring.

[0138] In some embodiments, the sheet material is elastically deformable and by bringing the sheet material together, the second aerosol-generating material is held between areas of the sheet material such that the sheet material is elastically deformed.

[0139] In some embodiments, the article includes a cooling element immediately downstream of the body. The method may include providing a cooling element and positioning a cooking element immediately downstream of the body.

[0140] In some embodiments, the cooling element comprises a hollow channel.

[0141] In some embodiments, the article comprises a body of additional material downstream of the cooling element. The method may include providing a body of additional material and positioning the body of additional material downstream of the cooling element.

[0142] In some embodiments, the body of additional material comprises a flavor material and / or a filtering material.

[0143] In some embodiments, the article comprises a segment upstream of the body. The method may include providing a segment and providing a segment upstream of the body.

[0144] In some embodiments, the article comprises from about 20 to about 330 mg of the first aerosol-generating material, preferably from about 50 to about 300 mg, or from about 40 to about 125 mg of the first aerosol-generating material.

[0145] In some embodiments, the article comprises from about 20 to about 330 mg of the second aerosol-generating material, preferably from about 50 to about 300 mg, or from about 40 to about 125 mg of the second aerosol-generating material.

[0146] In some embodiments, the article contains in the range of 7 mg / mm to 13 mg of aerosol-generating material (including the first and second aerosol-generating materials) per mm length of the article, preferably 8 to 12, 9 to 11.5, 9 to 11, or 9.5 to 10.5 mg of aerosol-generating material per mm length of the article.

[0147] In some embodiments, the wrapping material has an air permeability of less than 100 Coresta units, preferably less than 90, 80, 70, 60, or 50 Coresta units.

[0148] In some embodiments, the packaging material has a thickness in the range of 20 to 100 microns.

[0149] In some embodiments, the wrapping material has a basis weight in the range of 20 to 50 gsm.

[0150] The present disclosure also provides articles made according to the methods described herein.

[0151] The present disclosure also provides a package comprising a plurality of the articles described herein. In some embodiments, the package is hermetically sealed.

[0152] The present disclosure also provides a kit of parts comprising an article described herein and an aerosol delivery device.

[0153] In some embodiments, the aerosol delivery device includes a heating zone for receiving the articles and heating the first and second aerosol-generating materials.

[0154] Embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0155] [Figure 1] 1 is a side cross-sectional view of one embodiment of an article for use in an aerosol delivery system. [Diagram 2] 2 is a front cross-sectional view of the article of FIG. 1 taken along line ZZ in FIG. 1. [Diagram 3] 2 is a top view of the sheet material of the article of FIG. 1, the sheet material lying flat. [Figure 4] 2 is a top view of the strip of sheet material of the article of FIG. 1, the strip lying flat. FIG. [Diagram 5] 2 is a perspective view of a bead of aerosol-forming material of the article of FIG. 1. [Figure 6] 1 is a side cross-sectional view of another embodiment of an article for use in an aerosol delivery system. [Figure 7] 7 is a front cross-sectional view of the article of FIG. 6 taken along line ZZ in FIG. 6. [Figure 8] 1 is a side cross-sectional view of another embodiment of an article for use in an aerosol delivery system. [Figure 9] FIG. 1 is a cross-sectional view of an embodiment of a non-combustion aerosol delivery device. [Figure 10] FIG. 10 is a simplified schematic diagram of components within a housing of the aerosol delivery device shown in FIG. [Figure 11] 10 is a cross-sectional view of the non-combustion aerosol delivery device shown in FIG. 9, with the article shown in FIG. 1 inserted into the device. [Figure 12] FIG. 1 is a block diagram illustrating a method of manufacturing an article for use in an aerosol delivery system. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0156] As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user, Combustion aerosol delivery systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for rolled or hand-made cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smokable materials); non-combustion aerosol delivery systems that release compounds from an aerosol-forming material without burning the aerosol-forming material, such as electronic cigarettes, tobacco heating products, and hybrid systems that generate aerosols using a combination of aerosol-forming materials; and An aerosol-free delivery system that delivers 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 snus or moist snuff, where the at least one substance may or may not contain nicotine. Includes.

[0157] 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.

[0158] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0159] In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0160] 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.

[0161] In some embodiments, the non-combustion aerosol delivery system is a hybrid system configured to generate 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 comprises 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.

[0162] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device.

[0163] 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.

[0164] As used herein, the terms "upstream" and "downstream" are relative terms defined with respect to the direction of mainstream aerosol drawn through an article or device in use. References to the "distal end" refer to the upstream end of the device, while the "proximal end" refers to the downstream end of the device.

[0165] In some embodiments, a non-combustion aerosol delivery system, such as a non-combustion aerosol delivery device, can include a power source and a controller. The power source can be, for example, a power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that can be energized to deliver power in the form of heat to an aerosol-generating material or a heat transfer material proximate to the heat generating power source.

[0166] In some embodiments, the non-combustion aerosol delivery system includes an area for receiving a consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0167] 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 transport components, aerosol generators, aerosol generating areas, housings, packaging materials, filters, mouthpieces, and / or aerosol modifiers.

[0168] 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 flavors, one or more aerosol former materials, and / or one or more other functional materials.

[0169] In some embodiments, the delivered substance comprises an active substance. As used herein, an active substance can be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance can be selected from, for example, dietary supplements, nootropics, psychotropic drugs. The active substance can be naturally occurring or synthetically obtained. The active substance can 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 can include one or more components, derivatives, or extracts of tobacco, cannabis, or another botanical substance. In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0170] As described herein, the active material may include or be derived from one or more botanical materials or components, derivatives, or extracts thereof. As used herein, the term "botanical material" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, or shells. Alternatively, the material may include a synthetic version of an active compound naturally present in the botanical material. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, or sheets, or the like. 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, rabe The mint may be selected from the following mint varieties: peppermint, 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, calvi, 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: peppermint, mentha cv, Egyptian mint, peppermint, cologne mint, candy mint, curly mint, Kentucky kernel mint, horse mint, pineapple mint, pennyroyal mint, green peppermint, and apple mint.

[0171] 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.

[0172] 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.

[0173] 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.

[0174] In some embodiments, the substance to be delivered comprises a flavor.

[0175] 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 occurring 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 mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherries, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, ryes, and the like). citrus fruits, tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, eggplant, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, isopropyl alcohol, sorbet, sorbet, sorbet juice ... Nile ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, 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, maize In some embodiments, the additives may include oleaginous compounds such as oleic acid, joram, olive, lemon balm, lemon basil, chives, calvi, 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 other additives such 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.

[0176] In some embodiments, the flavor comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavor comprises cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavor comprises eugenol. In some embodiments, the flavor comprises flavor components extracted from tobacco. In some embodiments, the flavor comprises flavor components extracted from cannabis.

[0177] In some embodiments, the flavor 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 scent or taste nerves, and may include agents that produce a heating, cooling, tingling, or numbing effect. A suitable heat effect agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol, WS-3.

[0178] An aerosol-generating material may include or be an "amorphous solid." In some embodiments, an aerosol-generating material includes an aerosol-generating film that is an amorphous solid. An amorphous solid may be a "monolithic solid." An amorphous solid may be substantially non-fibrous. In some embodiments, an amorphous solid may be a dry gel. An amorphous solid is a solid material that may retain some fluid, such as a liquid, within the amorphous solid. In some embodiments, an amorphous solid includes, for example, about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid. An aerosol-generating material may also be referred to as an aerosolizable material.

[0179] An aerosol-generating material is a material that can generate an aerosol when, for example, heated, irradiated, or energized in any other manner. The aerosol-generating material can 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.

[0180] 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.

[0181] A consumable is an article that comprises 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 comprise 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 comprise an aerosol generator, particularly a heating element, that generates heat upon use to cause the aerosol-generating material to generate an aerosol. A heater may comprise a material that can be heated by electrical conduction, or a susceptor.

[0182] The aerosol-generating materials may include one or more active agents and / or flavors, one or more aerosol former materials, and optionally one or more other functional materials.

[0183] The aerosolizable material may be 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.

[0184] The aerosol former material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol former 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 phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0185] 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.

[0186] A consumable is an article that comprises 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 comprise 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 comprise an aerosol generator, such as a heater that generates heat upon use to cause the aerosol-generating material to generate an aerosol. The heater may comprise, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0187] 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. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0188] An aerosol modifier is a substance, typically located downstream of the aerosol-generation area, that is configured to modify the generated aerosol, for example by changing the taste, flavor, acidity, or another property of the aerosol. The aerosol modifier may be provided within an aerosol modifier-emitting component that is operable to selectively emit the aerosol modifier.

[0189] 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 a granule. The aerosol modifier may not include a filtering material.

[0190] 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.

[0191] 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, if the material is cellulose acetate tow, or the tow may be unplasticized. The tows may have other cross sections, such as "Y" or "X" shaped, and may have any suitable specifications, such as fibers with filamentary denier values ​​of 2.5 to 15 denier per filament, e.g., 8.0 to 11.0 denier per filament, and total denier values ​​of 5,000 to 50,000, e.g., 10,000 to 40,000.

[0192] In the figures described herein, like reference numbers are used to denote equivalent features, items or components.

[0193] FIG. 1 is a side cross-sectional view of an article 1 for use in an aerosol delivery system that includes an aerosol delivery device 200 (see FIGS. 9 to 11).

[0194] Article 1 comprises a sheet of material 2 arranged to form a body 3. Sheet of material 2 includes a first aerosol-forming material 4.

[0195] The body 3 is surrounded by a wrapping material 6. In this example, the wrapping material 7 comprises paper.

[0196] The article 1 further comprises a second aerosol-generating material 5. In this example, the second aerosol-generating material 5 comprises beads 5 of an aerosol-generating material. However, it should be appreciated that in other embodiments, the second aerosol-generating material 5 may take a different form. The second aerosol-generating material 5 may be in the form of discrete particles of an aerosol-generating material.

[0197] The second aerosol generating material 5 is engaged by the sheet of material 2 such that the second aerosol generating material 5 is held within the body 3 by the sheet of material 2. In this example, the second aerosol generating material 5 is held within the body 3 by friction; that is, friction between the second aerosol generating material 5 and the sheet of material 2 keeps the second aerosol generating material 5 in place within the body 3.

[0198] Having the second aerosol-generating material 5 held in place within the body 3 by the sheet material 2 has the advantage of preventing the second aerosol-generating material 5 from falling out of the body 3 during transportation and use of the article 1. This also provides the advantage that no binders or additives are required to hold the second aerosol-generating material 5 within the body 3 (e.g., the second aerosol-generating material 5 does not have to be adhered to the sheet material 2), thereby making the article easier, cheaper and more environmentally friendly to manufacture.

[0199] In this example, the sheet material 2 is formed into strips 7; for example, the sheet material 2 is cut or chopped into strips 7. A second aerosol-generating material 5 is then combined with the strips 7, and the strips 7 are then gathered together to form the body 3. The strips 7 may be aligned in a predetermined manner (e.g., extending substantially parallel to a central axis of the article 1) or may be oriented in a random manner.

[0200] Additionally or alternatively, the sheet material 2 may be crimped, for example, before or after cutting or shredding the sheet material 2.

[0201] The second aerosol-generating material 5 is held between the strips 7 as they are brought together to form the body 3. The second aerosol-generating material 5 is held between portions of the sheet material 2 to keep the second aerosol-generating material 5 within the body 3. In this example, the portions of the sheet material 2 are adjacent strips 7. However, in other embodiments, the sheet material 2 of the body 3 may be a continuous sheet that is brought together to form the body 3, and the second aerosol-generating material 5 is held between portions of the same continuous piece of sheet material 2, for example, between folds in the sheet material 2. In some embodiments, the body 3 comprises multiple layers of sheet material 2, and the second aerosol-generating material 5 is held between the layers of the sheet material 2.

[0202] In this example, the strips 7 of the body 2 extend in a direction from the first end P to the second end D of the article 1. In some embodiments, the strips or strands 7 may extend generally parallel to the central axis of the article 1 and may extend longitudinally. The strips or strands 7 may extend from the first end P to the second end D of the article 1, and may extend the entire or substantially the entire axial length of the article 1 (indicated by the arrow "X" in FIG. 1). In other embodiments, the strips or strands 7 may extend at an angle to the central axis of the article 1, for example, perpendicular to the central axis. In some embodiments, the strips or strands 7 may be randomly oriented.

[0203] In this example, the body of material 3 extends from a first end P of the article 1 to a second end D of the article 1 .

[0204] In this example, the body of material 3 extends over the entire length X of the article 1. This increases the amount of aerosol that can be generated for a given axial length of the article 1. In this example, the first and second aerosol-generating materials 4, 5 extend over at least 90% of the length X of the article 1, preferably at least 92%, 94%, 96%, 98%, or 99% of the length X of the article, and preferably form a collation of aerosol-generating material that extends over the entire length X of the article 1.

[0205] In other embodiments, the body of material 3 extends over a portion of the length X of the article 1 .

[0206] In some embodiments, the first and / or second aerosol-forming materials 4, 5 comprise, consist of, or consist essentially of tobacco material.

[0207] In this example, the first aerosol-forming material 4 includes reconstituted tobacco.

[0208] In some embodiments, first aerosol-generating material 4 includes tobacco blade.

[0209] In some embodiments, the second aerosol-forming material 5 comprises beads 5 of the second aerosol-forming material 5, such as tobacco beads.

[0210] In some embodiments, the bead 5 is generally cylindrical.

[0211] In some embodiments, the beads 5 have a diameter (e.g., as measured by sieving) of at least about 0.5 mm, and optionally at least about 1, 1.5, 2, 2.5, or 3 mm. The beads 5 may have a diameter (e.g., as measured by sieving) of about 5 mm or less, and optionally about 4.5, 4, 3.5, 3, 2.5, 2, or 1.5 mm or less. In some embodiments, the diameter of each bead 5 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 5 may refer to the average size of the beads 5, such as a number or a volume average size.

[0212] In some embodiments, the second aerosol-forming material 5 comprises an extruded and / or compressed aerosol-forming material, preferably extruded and / or compressed tobacco.

[0213] In some embodiments, the tobacco material of the first and / or second aerosol-generating materials 4, 5 is derived only from tobacco lamina and not from other types of tobacco material.

[0214] In some embodiments, the first and / or second aerosol-generating materials 4, 5 include tobacco lamina and reconstituted tobacco.

[0215] In one embodiment, the first and second aerosol-generating materials 4, 5 together have an average nicotine level in the range of 0.5% to 2.5% by weight of the first and second aerosol-generating materials, preferably in the range of 1% to 2.1% by weight.

[0216] In some embodiments, the first and / or second aerosol-generating materials 4, 5 are solid materials.

[0217] In some embodiments, the article 1 does not contain plastic, which makes the article 1 more environmentally friendly.

[0218] In some embodiments, Article 1 does not include cellulose acetate.

[0219] 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.

[0220] In some embodiments, the second aerosol-generating material 5 comprises fibers of an aerosol-generating material.

[0221] In some embodiments, the second aerosol-generating material 5 is distributed throughout the body 3 .

[0222] In some embodiments, the second aerosol-generating material 5 is discretely distributed within the body 3 to form a plurality of discrete regions of the second aerosol-generating material 5 .

[0223] The second aerosol-generating material 5 may be provided as a loose material. For example, the second aerosol-generating material 5 may be a loose material held in place within the body 3 by engagement with the sheet material 2. The second aerosol-generating material 5 may be, for example, loose 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 strips of aerosol-generating material. The sheet of aerosol-generating material may be a sheet of reconstituted tobacco.

[0224] In some embodiments, the first and second aerosol-generating materials 4, 5 have different densities.

[0225] In some embodiments, the sheet material 2 is elastically deformable, which may allow the sheet material 2 to deform around the second aerosol-generating material 5 and thus help keep the second aerosol-generating material 5 in place within the body 3.

[0226] In some embodiments, the aerosol-generating material in article 1 comprises about 50% by weight of the first aerosol-generating material 4 and about 50% by weight of the second aerosol-generating material 5. Thus, for example, an article 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.

[0227] In some embodiments, the body 3 is surrounded by a wrapper 6 .

[0228] In some embodiments, the packaging material 6 forms the outer surface 1A of the article 1.

[0229] In some embodiments, the wrapper 6 has an air permeability of less than 100 Coresta units, preferably less than 90, 80, 70, 60, or 50 Coresta units.

[0230] In some embodiments, the wrapper 6 has a thickness in the range of 20 to 100 microns.

[0231] In some embodiments, the wrapper 6 has a basis weight in the range of 20 to 50 gsm.

[0232] In some embodiments, the first and / or second aerosol-generating materials 4, 5 may include, consist of, or consist essentially of tobacco material. The term "tobacco material" refers to any material that includes tobacco or a derivative or substitute thereof. The tobacco material may be in any suitable form. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. 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.

[0233] In some embodiments, the first and / or second aerosol-generating material 4, 5 or another material of the article 1 (not shown), such as another material of the body 3, may include one or more aerosol former 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 former 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 phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The aerosol former material may be glycerol or propylene glycol.

[0234] In this example, the second aerosol-generating material 5 includes extruded and / or compressed tobacco. In such embodiments, the second aerosol-generating material 5 may include a single body of aerosol-generating material 5. However, in this example, the second aerosol-generating material 5 includes multiple bodies of aerosol-generating material.

[0235] In this example, the second aerosol-generating material 5 comprises beads / pellets / granules of aerosol-generating material (hereinafter referred to as "beads" of aerosol-generating material). The beads 5 may be extruded and / or compressed beads 5 and may be subjected to a spheronization process.

[0236] Optionally, the second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4. It has been found that this causes the second aerosol-generating material 5 to heat up more slowly than the first aerosol-generating material 4 when the heater of the device 200 is operated to heat the article 1. This means that the first aerosol-generating material 4 will initially release one or more volatile compounds (e.g., nicotine) at a higher rate than the second aerosol-generating material 5. This also means that the first aerosol-generating material 4 will relatively deplete the volatile compound(s) more quickly than the second aerosol-generating material 5. However, once the first aerosol-generating material 4 begins to relatively deplete the volatile compound(s), the second aerosol-generating material 5 will begin to reach a temperature at which it begins to release the volatile compound(s) at a higher rate. The effect is a more consistent release of the volatile compound(s) over the period of consumption of article 1, with first aerosol-generating material 4 releasing a greater proportion of the volatile compound(s) toward the beginning of consumption of article 1 and second aerosol-generating material 5 releasing a greater proportion of the volatile compound(s) toward 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 the volatile compound(s) over the period of consumption.

[0237] In some embodiments, the one or more volatile compound(s) emitted by the first aerosol-generating material 4 are the same as the volatile compound(s) emitted by the second aerosol-generating material 5.

[0238] In some embodiments, the second aerosol-generating material 5 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 second aerosol-generating material 5 is higher than the density of the first aerosol-generating material 4.

[0239] In some embodiments, the first aerosol-generating material 4 comprises one or more of tobacco lamina, tobacco stems, or reconstituted tobacco. In one such embodiment, the first aerosol-generating material 4 comprises a mixture of tobacco lamina and reconstituted tobacco. The first aerosol-generating material 4 is formed into a sheet.

[0240] In some embodiments, the first and second aerosol-generating materials 4, 5 may comprise the same material, e.g., tobacco, but are processed to have different densities. In one such embodiment, the first and second aerosol-generating materials 4, 5 may be in different forms. For example, the first aerosol-generating material 5 may be formed into a sheet material 2, while the second aerosol-generating material 5 may be compressed or extruded (with no or minimal expansion) such that the second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4.

[0241] It should be appreciated that in alternative embodiments, the density of the second aerosol-generating material 5 is less than the density of the first aerosol-generating material 4. In yet other embodiments, the densities of the first and second aerosol-generating materials 4, 5 are the same.

[0242] In some embodiments, the first aerosol-generating material 4 has at least one additional different property relative to the second aerosol-generating material 5. The different property can be one or more of the form, size, moisture content, amount (by weight), material(s), or proportions of materials making up the first and second aerosol-generating materials 4, 5 (including recipes of the aerosol-generating materials 4, 5 when each is made from two or more materials). In some embodiments, the first and second aerosol-generating materials 4, 5 do not have different properties other than being of different forms.

[0243] The first aerosol-generating material 4 may include multiple strands or strips of an aerosol-generating material. For example, the first aerosol-generating material 4 may include multiple strands or strips of an aerosolizable material and / or multiple strands or strips of an amorphous solid.

[0244] The first and / or second aerosol-generating materials 4, 5 may comprise plant-based material, such as tobacco material. The first and / or second aerosol-generating materials 4, 5 may be sheets or shredded sheets of aerosolizable material comprising plant-based material, such as tobacco material.

[0245] The plant-based material may be a particulate or granular material. In some embodiments, the plant-based material is a powder. Alternatively or additionally, the plant-based material may include tobacco strips, strands, or fibers. For example, when tobacco material is provided, the tobacco material may include tobacco particles, granules, fibers, strips, and / or strands. In some embodiments, the tobacco material consists of particles or granules of tobacco material.

[0246] The tobacco material of the first and / or second aerosol-generating materials 4, 5 may include tobacco obtained from any part of the tobacco plant, hi some embodiments, the tobacco material includes tobacco leaf.

[0247] The sheet or shredded sheet may contain from 5% to about 90% tobacco leaf by weight.

[0248] In some embodiments, both the first and / or second aerosol-forming materials 4, 5 comprise, consist of, or consist essentially of tobacco material.

[0249] In some embodiments, the first aerosol-generating material 4 comprises a sheet or chopped sheet of aerosolizable material that includes an aerosol former material. In some embodiments, the aerosol former material is provided in an amount of up to about 50% by weight based on the dry weight of the sheet or chopped sheet. In some embodiments, the aerosol former material is provided in an amount of about 5% to about 40% by weight based on the dry weight of the sheet or chopped sheet, about 10% to about 30% by weight based on the dry weight of the sheet or chopped sheet, or about 10% to about 20% by weight based on the dry weight of the sheet or chopped sheet.

[0250] 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 raw materials 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 a non-tobacco fiber, such as wood fiber or pulp or wheat fiber. 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.

[0251] The first and / or second aerosol generating materials 4, 5 may include an aerosol modifier, such as any of the flavors 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 consumable product or article 1 that includes menthol. The first and / or second aerosol generating materials 4, 5 may include 0.5 mg to 20 mg of menthol, 0.7 mg to 20 mg of menthol, 1 mg to 18 mg, or 8 mg to 16 mg of menthol.

[0252] In some embodiments, the 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.

[0253] An aerosol-generating material is, for example, a material that can generate an aerosol when heated, irradiated, or energized in any other manner. The aerosol-generating materials (e.g., the first and / or second aerosol-generating materials 4, 5) can 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 flavorings.

[0254] 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.

[0255] The aerosol-generating material (e.g., first and / or second aerosol-generating materials 4, 5) may include or be an "amorphous solid." The amorphous solid may be a "monolithic solid." In some embodiments, the amorphous solid may be a dry gel. 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 include, for example, about 50 wt%, 60 wt%, or 70 wt% amorphous solid, up to about 90 wt%, 95 wt%, or 100 wt% amorphous solid. The amorphous solid may be substantially non-fibrous.

[0256] 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 a solvent, such as water, an aerosol-forming agent, and one or more other ingredients, such as an active agent, to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent, thereby forming an aerosol-generating film. The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent. The aerosol-generating film may be a continuous film or a discontinuous film with individual portions of the film disposed on a substrate. The aerosol-generating film may be substantially free of tobacco.

[0257] The aerosol-generating film may include a sheet that may optionally be chopped to form a chopped sheet or may be a sheet that may optionally be chopped to form a chopped sheet.

[0258] The aerosol-generating materials (e.g., first and / or second aerosol-generating materials 4, 5) may include one or more active agents and / or flavors, one or more aerosol former materials, and optionally one or more other functional materials.

[0259] In each of the embodiments of article 1 described herein, the article may include such first and / or second aerosol-forming materials 4, 5, and may include such an aerosol-forming composition.

[0260] The first and / or second aerosol-generating material 4, 5 may comprise a paper reconstituted tobacco material. The composition may alternatively or additionally comprise any of the tobacco forms described herein. The first and / or second aerosol-generating material 4, 5 may comprise a sheet or shredded sheet comprising tobacco material comprising 10% to 90% by weight of tobacco leaf, the aerosol former material being provided in an amount of up to about 20% by weight of the sheet or shredded sheet, and the remainder of the tobacco material comprising paper reconstituted tobacco.

[0261] 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.

[0262] In some embodiments, the second aerosol-generating material 5 comprises an extruded aerosol-generating material that is then cut into pellet beads.

[0263] 6 and 7, an alternative embodiment of an article 1 for an aerosol delivery device 200 is shown. The article 1 has similar features to the article 1 described above in connection with FIGS. 1 to 5, and similar features bear the same reference numbers and may have any of the feature variations described herein. The difference is that the sheet material 2 is not cut into strips 7. Instead, a continuous sheet material 2 is gathered to form the body 3 such that the second aerosol-generating material 5 is held within the folds between the sheet material 2. That is, the second aerosol-generating material 5 is held between portions of the same continuous piece of sheet material 2, e.g., between the folds of the sheet material 2. In some embodiments, the body 3 comprises multiple layers of sheet material 2, with the second aerosol-generating material 5 being held between the layers of the sheet material 2. The sheet material 2 may be gathered in a manner similar to gathering paper sheets during the manufacture of "crepe filters," as known to those skilled in the art.

[0264] In the embodiment described above, the body 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 3.

[0265] For example, an alternative embodiment of article 1 is shown in FIG. 8 further comprising a cooling section 25, also referred to as a cooling element, positioned immediately downstream of body 3. In this example, cooling element 25 is immediately downstream and adjacent to body 3. In some such embodiments, cooling element 25 is in an abutting relationship with body 3. Article 1 may additionally or alternatively include a body 26 of further material downstream of cooling element 25. Body 26 of further material may include flavoring material and / or filtering material and / or may be provided to block the view of cooling element 25.

[0266] The cooling element 25 comprises 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 comprise a single hollow channel. In alternative embodiments, the cooling element 25 may comprise multiple channels, for example two, three, or four channels. The single hollow channel may be generally 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 be cooled. The cooling element 25 may be configured to restrict the cross-sectional area of ​​the hollow channel(s) to restrict the displacement of tobacco into the cooling element 25 during use.

[0267] The cooling element 25 may have a wall thickness in the radial direction. The wall thickness of the cooling element 25 for a given outer diameter of the cooling element 25 defines the inner diameter of the chamber enclosed by the walls of the cooling element 25. The cooling element 25 may 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.

[0268] Cooling element 25 may be formed from filamentary tow. Other constructions may also be used, such as multiple parallel or spirally wound layers of paper with butt seams to form cooling element 25, a cardboard tube, a tube formed using a paper mache type process, or a molded or extruded plastic tube. 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.

[0269] 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 materials 4, 5 passes longitudinally through the one or more hollow channels rather than passing 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.

[0270] The cooling element 25 may be configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatilized components entering the first upstream end of the cooling element 25 and the heated volatilized components exiting the second downstream end of the cooling element 25. The cooling element 25 may be configured to provide a temperature difference of at least 60 degrees Celsius, or at least 80 degrees Celsius, or at least 100 degrees Celsius between the heated volatilized components entering the first upstream end of the cooling element 25 and the heated volatilized components exiting the second downstream end of the cooling element 25. This temperature difference across the length of the cooling element 25 protects the temperature sensitive body 26 from the higher temperatures of the aerosol generating materials 4, 5 when heated.

[0271] The body of material 26 defines a generally cylindrical overall outline and is encased within 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 an air 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 an air permeability of at least 100 Coresta units or at least 200 Coresta units.

[0272] The cooling element 25 and / or the body of material 26 may form a mouth tip of the article 1 configured to be received in a user's mouth. In some embodiments, the mouth tip 207 of the device 200 may be omitted.

[0273] In some embodiments, tipping paper (not shown) may be wrapped around the cooling element 25 and body of material 26 and also surrounds the wrapper 6 which surrounds the body 3 and is connected to these components by adhesive. Thus, the tipping paper connects the cooling element 25 and body of material 26 to the body 3. In other embodiments, the tipping paper is omitted and instead the wrapper 6 extends around the cooling element 25 and body of material 26 to connect these components to the body 3.

[0274] Embodiments in which the aerosol-generating material extends along the entire axial length X of the article 1 (or along the entire axial length of the body 3) provide the advantage of increasing the amount of aerosol-generating material within the article 1 and, therefore, the amount of aerosol that can be generated for a given axial length X of the article 1.

[0275] The embodiment of the aerosol-generating material spanning only a portion of the overall axial length X of the article 1 provides the advantage that the aerosol-generating material is not visible from the ends P, D of the article 1 and also helps reduce the likelihood of the aerosol-generating material falling from the ends P, D of the article 1.

[0276] 9-11, one embodiment of an aerosol delivery device 200 is shown.

[0277] The article 1 is configured for use in an aerosol delivery device 200 (see FIG. 9 ) 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 area 202, e.g., a heating chamber 202. The heating element 203 may be resistively heated and / or inductively heated.

[0278] In other embodiments (not shown), the heating element 203 instead comprises a blade or pin for insertion into the article 1, e.g., the blade or pin may be inserted through the body of material 3. In other embodiments (not shown), the consumable 1 may comprise a heating element that may be embedded within the body of material 3, for example.

[0279] Components of one embodiment of aerosol delivery device 200 are shown in a simplified manner in Figure 9. In particular, the elements of aerosol delivery device 200 are not drawn to scale in Figure 9. To simplify Figure 9, elements that are not relevant to an understanding of the present embodiment have been omitted.

[0280] 9, aerosol delivery device 200 is a non-combustion aerosol delivery device 200. Non-combustion aerosol delivery device 200 comprises a housing 201 having an area 202 for receiving an item 1.

[0281] When the article 1 is received within the heating area 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., surrounding 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 the outer surface of the first sheet material 6 of the article. In another embodiment, the heater 203 comprises blades or pins that contact the inside of the article 1, e.g., in contact with the body of material 3 and / or the substrate 2.

[0282] When the article 1 is heated, the first and / or second aerosol generating materials 4, 5 will 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.

[0283] As shown in Figure 10, within the housing 201 is an electrical energy source 204, e.g., a rechargeable lithium ion battery. A controller 205 is connected to the heater 203, the electrical energy source 204, and a user interface 206, e.g., a button or 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 250-450 degrees Celsius.

[0284] Figure 11 is a schematic cross-sectional view of a non-combustion aerosol delivery device 200 of the type shown in Figure 9, with an item 1 received within a heating area 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.

[0285] 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 a proximal end (or mouth end) for receiving the aerosol product 1 for consumption by a user.

[0286] 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 taken into and removed from the area 202. Once the article 1 has been provided within 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.

[0287] When a user inhales on mouth opening 207, air is drawn into article 1 and volatile materials condense to form an inhalable aerosol that passes through mouth opening 207 of device 200 and into the user's mouth.

[0288] 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 the mouthpiece and may contact the user's mouth.

[0289] Referring now to FIG. 12, a block diagram is shown depicting an exemplary embodiment of a method 100 of manufacturing an article 1 for an aerosol delivery device.

[0290] Method 100 includes the step of providing (S1) a sheet material 2 comprising a first aerosol-generating material 4 (e.g., a tobacco sheet). Method 100 also includes the step of providing (S2) a second aerosol-generating material 5. Method 100 also includes the step of gathering sheet material 2 to form body 3 such that second aerosol-generating material 5 is engaged by sheet material 2 such that second aerosol-generating material 5 is retained within body 3 by sheet material 2.

[0291] In some embodiments, method 100 includes combining sheet material 2 with a second aerosol-generating material 5 and then gathering sheet material 2 together to form body 3 .

[0292] In some embodiments, method 100 includes combining sheet material 2 with second aerosol-generating material 5 simultaneously with gathering sheet material 2 to form body 2, for example, while sheet material 2 is being fed through the garniture.

[0293] In some embodiments, the method 100 includes forming the sheet material 2 into strips or strands 7 .

[0294] In some embodiments, the method 100 includes shredding and / or cutting the sheet material 2 .

[0295] In some embodiments, the strips or strands 7 extend in a direction from the first end P towards the second end D of the article 1. In other embodiments, the strips or strands 7 may be randomly oriented.

[0296] In some embodiments, the method 100 includes crimping the sheet material 2 .

[0297] In some embodiments, the sheet material 2 is formed into strips or strands 7 and the second aerosol-generating material 5 is held between the strips or strands 7 .

[0298] In some embodiments, the second aerosol-generating material 5 is held within the body 3 by friction.

[0299] In some embodiments, the step (S3) of gathering the sheet material 2 comprises gathering the sheet material 2 such that the second aerosol-generating material 5 is retained between portions of the sheet material 2.

[0300] In some embodiments, the step (S3) of gathering the sheet material 2 includes gathering the sheet material 2 such that the body 2 comprises multiple layers of the sheet material 2 and a second aerosol-generating material 5 held between the layers of the sheet material 2.

[0301] In some embodiments, no additives or binders are applied to the sheet material 2 or the second aerosol-forming material 5 to hold the second aerosol-forming material 5 within the body 3 .

[0302] In all of the above examples, the second aerosol-forming material 5 may comprise, consist of, or consist essentially of an extruded or compressed body of tobacco material, preferably the extruded or compressed body of tobacco material comprises beads of tobacco material.

[0303] 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.

[0304] In all of the above examples, the first and / or second aerosol-forming materials 4, 5 may comprise, consist of, or consist essentially of tobacco blade.

[0305] 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 flaxseed tobacco, preferably the reconstituted tobacco and flaxseed tobacco are mixed together.

[0306] 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. In some embodiments, the sheet is a sheet of reconstituted tobacco. For example, the first aerosol-generating material 4 may be cut into strips and the strips then arranged to form the body 3.

[0307] In all of the above examples, the first and / or second aerosol-forming materials 4, 5 may comprise tobacco material that is made only from tobacco blade and not from other types of tobacco material.

[0308] In all of the above examples, 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.

[0309] According to the present disclosure, there is also provided a kit of parts comprising an article 1 according to any of the examples described herein and an aerosol delivery device 200.

[0310] Also provided in accordance with the present disclosure is a package (not shown) comprising a plurality of articles according to any of the examples described herein. In some embodiments, the package is hermetically sealed. The package may comprise a container comprising a body and a lid, with a space provided within the container body to receive the plurality of articles. The lid may be, for example, a hinged lid, a snap-fit ​​lid, or a lid connected by a screw thread.

[0311] In each of the example articles described above (including each of the articles shown in Figures 1 through 8), the first and second aerosol-generating materials 4, 5 can have different densities. Otherwise, the aerosol-generating materials of the articles can be the same or different. In other embodiments, the densities of the first and second aerosol-generating materials 4, 5 can be the same.

[0312] It has been found that providing first and second aerosol-generating materials 4, 5 of different densities means that the higher density material will heat up slower when both materials are exposed to the same heat, and therefore will release the volatile compound of the material (e.g., nicotine) at a slower rate than the lower density material. In some embodiments, the second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4, such that the second aerosol-generating material 5 will heat up slower than the first aerosol-generating material 4 when exposed to the same heat, and will release the volatile compound of the material (e.g., nicotine) at a slower rate than the first aerosol-generating material 4 (however, in other embodiments, the reverse may be true, such that the first aerosol-generating material 4 has a higher density than the second aerosol-generating material 5). Thus, combining aerosol-generating materials of different densities provides a more consistent and longer-lasting release of the volatile compound(s). In some embodiments, aerosol-generating materials of different densities, optionally combined with separately heating these materials for different times and / or different temperatures, can provide a more regulated release of the volatile compound(s) over the consumption period of the article, or it may be desirable to have a more rapid or greater release of volatile material near the beginning of consumption of the article, for example, to provide the user with 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(s) over the consumption period.

[0313] 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 about 25% to about 75% higher than the density of the other of the first and second aerosol-generating materials 4, 5.

[0314] 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, 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, 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.

[0315] 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 / cm3, optionally at least about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, or 0.9 g / cm3. The other of the first and second aerosol-generating materials 4, 5 may have a density of about 1 g / cm3 or less, optionally about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, or 0.2 g / cm3 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 / cm3.

[0316] In some embodiments, the first and second aerosol-generating materials 4, 5 contain the same components. Thus, upon heating, they will 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.

[0317] In other embodiments, the first and second aerosol-generating materials 4, 5 comprise different components (which may have the same or different densities). Thus, upon heating, they will release different aerosols, potentially with different compositions of active substances and / or flavors, etc. Their different densities allow different aerosols to be generated from the two materials at different rates and / or times during heating, potentially providing an aerosol that changes over the period of use.

[0318] In some embodiments, the first aerosol-generating material 4 and the second aerosol-generating material 5 each comprise tobacco. The tobacco will contain volatile components, including nicotine, aroma, and flavor. The tobacco can be any type of tobacco and any part of the tobacco plant, including tobacco leaves, blades, stems, stalks, veins, scraps, and bits, 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.

[0319] The first and second aerosol-generating materials 4, 5 may comprise different tobaccos, 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.

[0320] 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 can be one or more of the form, size, moisture content, amount (by weight), material or materials, or proportions of materials making up the first and second aerosol-generating materials 4, 5 (including recipes of 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 property other than the different densities of the first and second aerosol-generating materials 4, 5. In other embodiments, the densities of the first and second aerosol-generating materials 4, 5 are the same.

[0321] In some embodiments, the sheet 2 of the first aerosol-generating material 4 may be formed from cut rags. The tobacco material may be a flax tobacco material or a reconstituted tobacco material. In some embodiments, the second aerosol-generating material 5 is a blend that includes both flax tobacco and reconstituted tobacco. For example, the ratio of flax tobacco to reconstituted tobacco may be about 1:4 to about 4:1.

[0322] In some embodiments, the second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4. In some embodiments, this higher density second aerosol-generating material 5 may comprise particles or 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 recognized that in other embodiments, the first aerosol-generating material 4 may be denser than the second aerosol-generating material 5, or the materials may have the same density. In some embodiments, both the first and second aerosol-generating materials 4, 5 may be in the form of one or more sheets, optionally processed 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, and the second aerosol-generating material 5 is cut into individual portions and then held between the sheets 2 of the first aerosol-generating material 4 within the body 3.

[0323] The second aerosol-generating material 5 may be in the form of beads 5. Optionally, the first aerosol-generating material 4 may include beads incorporated into the sheet 2.

[0324] As used herein, the term "bead" is meant to include beads, pellets, or other small discrete units that are shaped, molded, compressed, or otherwise fabricated into a desired shape. Beads may have a smooth, regular outline (e.g., spherical, cylindrical, ovoid, etc.) and / or may have an irregular outline.

[0325] In some embodiments, the beads have a diameter (e.g., as measured by sieving) of at least about 0.5 mm, optionally at least about 1, 1.5, 2. 2.5, or 3 mm. The beads may have a diameter (e.g., as measured by sieving) of about 5 mm or less, optionally about 4.5, 4, 3.5, 3, 2.5, 2, or 1.5 mm or less. In some embodiments, the diameter of each bead may range from about 0.5 mm to about 3 mm, or from about 1 mm to about 2 mm. The size of the beads may refer to the average size of the beads, such as a number or volume average size.

[0326] 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 method(s) by which the material is processed. Processes that involve agglomeration, particularly agglomeration by application of some compressive force, will tend to increase the density of the material.

[0327] Thus, in some embodiments, the first and / or second aerosol-generating materials 4, 5 comprise particles of agglomerated material.

[0328] In the case of sheet materials, the sheets may be formed from particles of material that are bonded and optionally compressed to form a sheet having the desired dimensions and density.

[0329] In some embodiments, the beads or pellets can be formed using the so-called marmarizing process.

[0330] 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 aggregates are formed when particles are rolled and tumbled in the presence of an appropriate amount of liquid. Spheronization can involve the use of equipment such as pans, disks, drums, or mixers to fabricate 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.

[0331] In some embodiments, the agglomeration is by extrusion. In some embodiments, the pellets formed by pelletization may be extruded to form a denser extrudate.

[0332] The extruded particles may have a size selected to produce a denser aerosol-generating material (e.g., a denser first or second aerosol-generating material 4, 5), which will affect heat transfer and release of volatile components within the material.

[0333] 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.

[0334] Extrusion may be carried out using one of the major types of extruders: screw, sieve 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.

[0335] In some embodiments, during extrusion, a free-flowing composition including particles, such as tobacco particles, is subjected to high pressure and temperature and forced through an orifice, such as a forming nozzle or die, to form an extrudate, which in some embodiments has a rod-like form and can be cut into segments of a desired length.

[0336] In some embodiments, the composition is exposed to a temperature in the extruder of about 40° C. to about 150° C., or about 80° C. to about 130° C., or about 60° C. to about 95° C. In some embodiments, including those using dual extrusion, the precursor composition is exposed to a temperature in the extruder of 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 about 60° C. to about 80° C.

[0337] 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 may be adjusted to provide an extruded aerosol-generating material having a desired density.

[0338] 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 within the extrudate, the tobacco beads formed from the extrudate exhibit good heat and mass transfer, which positively impacts the release of tobacco components such as flavor and nicotine.

[0339] 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.

[0340] In some embodiments, 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 assist 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.

[0341] In some embodiments, the liquid may be an aerosol former material, such as glycerol or others discussed herein. When the liquid is added to the composition in this manner, the liquid is not only applied onto the surface, but the extrudate is impregnated with the liquid as a result of the combination of the extruder pressure and the vigorous mixing caused by the high shear forces. If the liquid is an aerosol former material, this may increase the availability of the aerosol former material in the resulting beads and enhance the evaporation of volatile components.

[0342] In some embodiments, the amount of aerosol former material incorporated into the extruded beads can be up to about 30% by weight, or even up to about 40% by weight. Usually, such a large amount of aerosol former material can make the composition difficult to handle. However, this problem is less likely to occur when the particles are impregnated with the aerosol former material by extrusion. If the beads are to generate aerosol in addition to releasing volatile components, 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. If the main function of the beads is to release volatile components 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.

[0343] In some embodiments, the aggregates do not include a binder or binding additive. For example, extruded beads may not require a binder to maintain the structural integrity of the extruded beads. 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 the particles adhere 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.

[0344] In some embodiments, processing by extrusion is sufficient to provide a higher density, if desired, of the first or second aerosol-generating material 4, 5. However, in other embodiments, the extrudate may be further processed to increase the density of the first or second aerosol-generating material 4, 5.

[0345] For example, in some embodiments, the extruded aerosol-generating material is subjected to spheronization, in which the extruded cylindrical particles are divided into uniform lengths and gradually transformed into spherical shapes by plastic deformation, If the extrudate is initially divided into uniform lengths, spheres having uniform diameters will be produced by the spheronization step.

[0346] According to one specific example of the embodiments discussed herein, a sample of beads of second aerosol-generating material 5 was fabricated as follows (note, however, that in some embodiments, a sample may be fabricated as follows and instead be used for a first aerosol-generating material 4 and incorporated into sheet 2, e.g., cast into a slurry to form sheet 2).

[0347] Three sample formulations with and without binder are shown in Table 1, with amounts given as percent wet weight basis (WWB).

[0348] [Table 1]

[0349] 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.

[0350] Next, all of the dry (non-liquid) ingredients of the formulation were combined and mixed or blended in a mixer. In this particular example, the mixture was mixed at a speed of 75 RPM for 1 minute. This was to ensure that the dry ingredients were homogenously distributed within the mixture.

[0351] Next, half the glycerol and half 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 squeezed into clumps to ensure a homogenous mix was achieved. In this particular example, additional mixing continued for 3 minutes.

[0352] The mixture was then extruded using a Caleva Multilab. The extruder was operated at approximately 1500 rpm to produce spaghetti-like lengths of extrudate.

[0353] The extrudate was divided into sections of various lengths as it emerged from the extruder. These sections 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 another 1-2 minutes. In this spheronization step, the extruded tobacco was divided into individual sections, forming dense spherical beads.

[0354] 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 the drying was terminated when the desired moisture weight loss was achieved. Generally, such drying will take about 1 hour.

[0355] In some embodiments, the other of the first and / or second aerosol-generating materials 4, 5 is in the form of discrete particles or an aggregated mass 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 will have a lower density. As mentioned above, there are various ways to adjust the density of the aerosol-generating materials 4, 5, such as by compounding and / or processing the materials into particles, beads, or pellets.

[0356] In some embodiments, the one 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 The other of the first and second aerosol-forming materials 4, 5 comprises about 30 to about 90% tobacco and has a density of about 0.4 to about 1.99 g / cm 3 The aerosol-generating material in the one of the first and second aerosol-generating materials 4, 5 may comprise approximately spherical beads having a particle size of about 0.5 to about 3 mm. In some embodiments, the aerosol-generating material in the article comprises about 50% by weight of the first aerosol-generating material 4 and about 50% by weight of the second aerosol-generating material 5. Thus, for example, an article 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.

[0357] In some embodiments in which the aerosol-forming material includes tobacco, the tobacco is present in an amount between about 10% and about 90% by weight of the aerosol-forming material.

[0358] 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-generating material.

[0359] 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 about 40% or less tobacco based on the weight of the aerosol-generating material.

[0360] The cigarettes described herein may contain nicotine. In some embodiments, the nicotine content may be 0.5-2% by weight of the tobacco, e.g., 0.5-1.75% by weight of the tobacco, 0.8-1.2% by weight of the tobacco, or about 0.8 to about 1.75% by weight of the tobacco. In some embodiments, the nicotine content may be 0.8-1% by weight of the tobacco.

[0361] In some embodiments, the first and second aerosol-forming materials 4, 5 have the same nicotine content.

[0362] 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.

[0363] In some embodiments, the first and / or second aerosol-generating material 4, 5 comprises tobacco. For example, the first and / or second aerosol-generating material 4, 5 may comprise from about 80 to about 350 mg of tobacco. In some particular embodiments, the aerosol-generating material in the article or consumable has a weight of 260 mg and comprises a combination of 130 mg of a first aerosol-generating material 4, e.g., comprising a blend of leaf tobacco and reconstituted tobacco in sheet form, and 130 mg of a second aerosol-generating material 5, e.g., comprising higher density tobacco beads.

[0364] In some embodiments, the article includes regions of aerosol-generating material, each region comprising aerosol-generating material containing an equal amount of tobacco. In alternative embodiments, the regions may contain different amounts of tobacco. For a total amount of tobacco of about 80 to about 350 mg, one region of aerosol-generating material may comprise 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 comprise about 20 to about 330 mg, or about 30 to about 300 mg, or about 40 to about 125 mg of tobacco.

[0365] 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 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 include, 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. In addition, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. 1. An article for use in an aerosol delivery system, said article comprising: a corrugated sheet material comprising a first aerosol-generating material, the sheet material being gathered to form a body; a second aerosol-generating material engaged by the sheet of material such that the second aerosol-generating material is retained within the body by the sheet of material; and An article comprising:

2. The article of claim 1 , wherein the second aerosol-forming material is held within the body by friction.

3. The article of claim 1 or 2, wherein the second aerosol-forming material is held between portions of the sheet material.

4. An article as described in claim 1 or 2, wherein the body comprises multiple layers of the sheet material, and the second aerosol-generating material is held between the layers of the sheet material.

5. The article of any one of claims 1 to 4, wherein the sheet material is formed into strips or strands, and the second aerosol-forming material is held between the strips or strands.

6. 6. The article of claim 5, wherein the strips or strands extend in a direction from a first end toward a second end of the article.

7. The article of any one of claims 1 to 6, wherein the article does not include an additive or binder to keep the second aerosol-forming material within the body.

8. An article described in any one of claims 1 to 7, comprising a cooling element immediately downstream of the main body.

9. The article described in claim 8, wherein the cooling element has a hollow channel.

10. An article as described in claim 8 or 9, comprising a further body of material downstream of the cooling element.

11. An article as described in claim 10, wherein the body of further material comprises a flavoring material and / or a filtering material.

12. The article of any one of claims 1 to 7, wherein the body of material extends from a first end of the article to a second end of the article.

13. The article of any one of claims 1 to 7, wherein the first and second aerosol-forming materials form a collation of aerosol-forming materials that extends along at least 90% of the length of the article.

14. An article described in any one of claims 1 to 7, wherein the first and second aerosol-generating materials form a collation of aerosol-generating material extending over at least 92%, 94%, 96%, 98%, or 99% of the length of the article, or form a collation of aerosol-generating material extending over the entire length of the article.

15. 15. The article of any one of claims 1 to 14, wherein the first and / or second aerosol-forming materials comprise, consist of, or consist essentially of tobacco material.

16. 16. The article of claim 15, wherein the first aerosol-forming material comprises reconstituted tobacco.

17. 17. The article of claim 15 or 16, wherein the first aerosol-forming material comprises tobacco lamina.

18. The article of any one of claims 1 to 14, wherein the first aerosol-forming material is substantially tobacco-free.

19. The article of any one of claims 1 to 18, wherein the first aerosol-forming material comprises a filler.

20. 20. The article of claim 19, wherein the filler is a non-tobacco fiber.

21. 21. An article according to claim 19 or 20, wherein the filler is wood fibre or pulp or wheat fibre.

22. The article of any one of claims 19 to 21, wherein the filler comprises cellulose.

23. 23. The article of any one of claims 19 to 22, wherein the filler is a non-tobacco cast or non-tobacco extruded material.

24. The article of any one of claims 1 to 23, wherein the article comprises an aerosol former material.

25. 25. The article of claim 24, wherein the first and / or second aerosol-generating material comprises the aerosol former material.

26. 26. The article of claim 24 or 25, wherein the aerosol former material comprises one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

27. The article of any one of claims 1 to 26, wherein the second aerosol-forming material comprises an extruded and / or compressed aerosol-forming material.

28. An article described in any one of claims 1 to 26, wherein the second aerosol-generating material comprises extruded and / or compressed tobacco.

29. The article of any one of claims 1 to 28, wherein the second aerosol-forming material comprises beads of aerosol-forming material.

30. 30. The article of claim 29, wherein the beads have a particle size ranging from about 0.5 mm to about 3 mm.

31. The article of any one of claims 1 to 30, wherein the first and second aerosol-forming materials have different densities.

32. An article described in any one of claims 1 to 30, wherein the density of the second aerosol-generating material is at least 25% higher than the density of the first aerosol-generating material.

33. the second aerosol-forming material having a density of about 0.4 g / cm ３ ~Approx. 2g / cm ３ 33. The article of any one of claims 1 to 32, having a density in the range of

34. The first aerosol-forming material has a density of about 0.1 g / cm ３ ~Approx. 1g / cm ３ The article of any one of claims 1 to 33, having a density in the range of

35. The article of any one of claims 1 to 34, wherein the second aerosol-forming material comprises fibers of an aerosol-forming material.

36. 36. The article of any one of claims 1 to 35, wherein the sheet material comprises an aerosol-generating material comprising about 10 to about 50 wt % aerosol former material, about 15 to about 60 wt % gelling agent, and optionally a filler, wt % values ​​calculated on a dry weight basis.

37. The article of any one of claims 1 to 36, wherein the first aerosol-forming material of the sheet comprises a flavorant.

38. The article of any one of claims 1 to 37, wherein the sheet material is elastically deformable.

39. The article of any one of claims 1 to 38, wherein the first and second aerosol-forming materials are present in the article in a ratio of 1:10 to 10:1 by weight.

40. The article of any one of claims 1 to 39, wherein the article comprises from about 20 to about 330 mg of the first aerosol-forming material.

41. An article described in any one of claims 1 to 39, wherein the article comprises about 50 to about 300 mg of the first aerosol-generating material.

42. An article described in any one of claims 1 to 39, wherein the article comprises about 40 to about 125 mg of the first aerosol-generating material.

43. The article of any one of claims 1 to 42, wherein the article comprises from about 20 to about 330 mg of the second aerosol-forming material.

44. An article described in any one of claims 1 to 42, wherein the article comprises about 50 to about 300 mg of the second aerosol-generating material.

45. An article described in any one of claims 1 to 42, wherein the article comprises about 40 to about 125 mg of the second aerosol-generating material.

46. The article of any one of claims 1 to 45, comprising a segment upstream of the body.

47. 1. A method of manufacturing an article for use in an aerosol delivery system, said method comprising: providing a corrugated sheet material including a first aerosol-generating material; providing a second aerosol-forming material; and gathering the sheet material to form a body such that the second aerosol-generating material is engaged by the sheet material such that the second aerosol-generating material is held within the body by the sheet material.

48. 48. The method of claim 47, comprising combining the sheet material with the second aerosol-generating material and then gathering the sheet material together to form the body.

49. 48. The method of claim 47, comprising combining the sheet material with the second aerosol-forming material simultaneously with gathering the sheet material to form the body.

50. A method as claimed in any one of claims 47 to 49, including forming the sheet material into strips or strands.

51. 51. The method of claim 50, including the step of shredding and / or cutting the sheet material.

52. 52. The method of claim 50 or 51, wherein the strips or strands extend in a direction from a first end toward a second end of the article.

53. 53. The method of any one of claims 47 to 52, wherein gathering the sheet material comprises gathering the sheet material such that the second aerosol-generating material is retained between portions of the sheet material.

54. A method as described in any one of claims 47 to 52, wherein the step of gathering the sheet material includes gathering the sheet material so that the body comprises multiple layers of the sheet material and the second aerosol-generating material is held between the layers of the sheet material.

55. 55. The method of any one of claims 47 to 54, wherein the method does not include using an additive or binder to hold the second aerosol-forming material within the body.

56. 56. The method of any one of claims 47 to 55, wherein the first and / or second aerosol-forming materials comprise, consist of, or consist essentially of tobacco material.

57. 57. The method of claim 56, wherein the first aerosol-forming material comprises reconstituted tobacco.

58. 58. The method of claim 56 or 57, wherein the first aerosol-forming material comprises tobacco lamina.

59. 59. The method of any one of claims 47 to 58, wherein the first aerosol-forming material is substantially tobacco-free.

60. 60. The method of any one of claims 47 to 59, wherein the first aerosol-forming material comprises a bulking agent.

61. 61. The method of claim 60, wherein the filler is a non-tobacco fiber.

62. 62. The method of claim 60 or 61, wherein the filler is wood fiber or pulp or wheat fiber.

63. 63. The method of any one of claims 60 to 62, wherein the filler comprises cellulose.

64. 64. The method of any one of claims 60 to 63, wherein the filler is a non-tobacco cast material or a non-tobacco extrusion material.

65. The method of any one of claims 47 to 64, wherein the article comprises an aerosol former material.

66. 66. The method of claim 65, wherein the first and / or second aerosol-generating materials comprise an aerosol former material.

67. 67. The method of claim 65 or 66, wherein the aerosol former material comprises one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

68. 68. The method of any one of claims 47 to 67, wherein the second aerosol-forming material comprises an extruded and / or compressed aerosol-forming material.

69. A method described in any one of claims 47 to 67, wherein the second aerosol-generating material comprises extruded and / or compressed tobacco.

70. 70. The method of any one of claims 47 to 69, wherein the second aerosol-forming material comprises beads of aerosol-forming material.

71. 71. The method of any one of claims 47 to 70, wherein the second aerosol-forming material comprises fibers of an aerosol-forming material.

72. 72. The method of any one of claims 47 to 71, wherein the first and second aerosol-forming materials have different densities.

73. A method described in any one of claims 47 to 71, wherein the density of the second aerosol-generating material is at least 25% higher than the density of the first aerosol-generating material.

74. 74. The method of any one of claims 47 to 73, wherein the sheet material comprises an aerosol-generating material comprising about 10 to about 50 wt % aerosol former material, about 15 to about 60 wt % gelling agent, and optionally a filler, the wt % values ​​being calculated on a dry weight basis.

75. 75. The method of claim 74, wherein the first aerosol-forming material of the sheet material comprises a flavoring agent.

76. 76. The method of any one of claims 47 to 75, wherein the sheet material is elastically deformable and the step of gathering the sheet material causes the second aerosol-generating material to be held between regions of the sheet material such that the sheet material is elastically deformed.

77. A method according to any one of claims 47 to 76, comprising providing a cooling element immediately downstream of the body.

78. 78. The method of claim 77, wherein the cooling element comprises a hollow channel.

79. 79. A method according to claim 77 or 78, comprising providing a further body of material downstream of the cooling element.

80. 80. The method of claim 79, wherein the body of additional material comprises a flavor material and / or a filtering material.

81. A method according to any one of claims 47 to 80, comprising providing a segment upstream of the main body.

82. 82. The method of any one of claims 47 to 81, wherein the article comprises from about 20 to about 330 mg of the second aerosol-forming material.

83. A method described in any one of claims 47 to 81, wherein the article comprises about 50 to about 300 mg of the second aerosol-generating material.

84. A method described in any one of claims 47 to 81, wherein the article comprises about 40 to about 125 mg of the second aerosol-generating material.

85. An article produced according to the method of any one of claims 47 to 84.

86. A package comprising a plurality of the articles of any one of claims 1 to 46 or 85.

87. A package comprising a plurality of items according to any one of claims 1 to 46 or 85, wherein the package is hermetically sealed.

88. 86. A kit of parts comprising the article of any one of claims 1 to 46 or 85 and an aerosol delivery device.

89. 90. The kit of parts of claim 88, wherein the aerosol delivery device comprises a heating zone for receiving the articles and heating the first and second aerosol-generating materials.

Images