Components for delivery systems and methods and apparatus for manufacturing components for delivery systems - Patents.com

Abstract

A component for an article for use in or as an aerosol delivery system is provided, the component comprising a tubular body of cellulosic material sandwiched between inner and outer sheet materials, the inner sheet material having an air permeability of at least 200 CU. Also described are articles for use in or as an aerosol delivery system, methods of making the component, and apparatus configured to make the component.

Description

[Technical field]

[0001] The present disclosure relates to components for use in or as an aerosol delivery system. The present disclosure also relates to articles for use in or as an aerosol delivery system, and methods and apparatus for manufacturing components for an aerosol delivery system. [Background technology]

[0002] Certain tobacco industry products generate an aerosol during use, which is inhaled by the user. For example, tobacco heating devices heat an aerosol-generating substrate, such as tobacco, to form an aerosol by heating the substrate rather than burning it. Such tobacco industry products typically include a mouthpiece through which the aerosol passes to reach the user's mouth. Summary of the Invention

[0003] According to a first aspect of embodiments described herein, there is provided a component for an article for use in or as an aerosol delivery system, the component comprising a tubular body of cellulosic material sandwiched between inner and outer sheet materials, the inner sheet material comprising a porous sheet material having an air permeability of at least 200 CU.

[0004] According to a second aspect in accordance with embodiments described herein, there is provided an article for use in or as an aerosol delivery system, the article comprising a component according to the first aspect.

[0005] According to a third aspect in accordance with embodiments described herein, there is provided a method of manufacturing a component for an article for use in an aerosol delivery system, the method comprising the steps of: providing a supply of a first sheet material having a porosity of at least 200 CU; forming an inner tubular element from the first sheet material; providing a supply of cellulosic material and a supply of a second sheet material; gathering the cellulosic material around the inner tubular element; and wrapping the gathered cellulosic material with the second sheet material to form a tubular body of cellulosic material sandwiched between the inner and outer sheet materials.

[0006] According to a fourth aspect in accordance with embodiments described herein, there is provided an apparatus configured to manufacture the component according to the first aspect, the apparatus comprising: a first feeding mechanism for a first sheet material; a first garniture assembly for forming an inner tubular element from the first sheet material; a second feeding mechanism for feeding cellulosic material; a third feeding mechanism for the second sheet material; and a second garniture assembly for gathering the cellulosic material around the inner tubular element and wrapping the gathered cellulosic material with the second sheet material to form a tubular body of cellulosic material sandwiched between the inner and outer sheet materials.

[0007] Embodiments of the invention will now be described, by way of non-limiting example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0008] [Figure 1] 1 is a side cross-sectional view of an article for use as or with a non-combustion aerosol delivery device, the article including a mouthpiece. [Figure 1B] 2 is a side view of a sheet of material forming a first body of material of the article of FIG. 1. FIG. [Diagram 2]2 is a cross-sectional side view of another embodiment of an article for use as or with a non-combustion aerosol delivery device. FIG. [Diagram 3] 2 is a cross-sectional side view of another embodiment of an article for use as or with a non-combustion aerosol delivery device. FIG. [Figure 4] 2 is a cross-sectional side view of another embodiment of an article for use as or with a non-combustion aerosol delivery device. FIG. [Diagram 5] FIG. 5 is a perspective view of a non-combustion aerosol delivery device for generating aerosol from the aerosol-forming materials of the articles of FIGS. 1-4. [Figure 6] 6 shows the device of FIG. 5 with the outer cover removed and no items present. [Figure 7] FIG. 7 is a side view of the device of FIG. 6 in partial cross-section. [Figure 8] FIG. 8 is an exploded view of the device of FIG. 7 with the outer cover omitted. [Figure 9A] FIG. 7 is a cross-sectional view of a portion of the device of FIG. 6. [Figure 9B] FIG. 9B is an enlarged view of a region of the device of FIG. 9A. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] In the figures described herein, like reference numerals are used to denote equivalent features, items or components.

[0010] FIG. 1 is a cross-sectional side view of an article 1 for use with a non-combustion aerosol delivery system.

[0011] Article 1 comprises a tipping member 2 and an aerosol-generating material 3, in this case a cylindrical rod of tobacco material, connected to tipping member 2. The aerosol-generating material 3 delivers an aerosol when heated, for example, in a non-combustion aerosol delivery device, for example, a non-combustion aerosol delivery device comprising a coil, forming a system, as described herein. In other embodiments, article 1 may comprise its own heat source, forming an aerosol delivery system without the need for a separate aerosol delivery device.

[0012] The mouthpiece 2 of the article 1 has an upstream end 2 a adjacent the aerosol-forming material 3 and a downstream end 2 b distal to the aerosol-forming material 3 .

[0013] The aerosol-generating material 3, also referred to herein as aerosol-generating substrate 3, includes at least one aerosol former material. In this example, the aerosol former material is glycerol. In alternative examples, the aerosol former material may be another material or combination thereof described herein. It has been found that the aerosol former material improves the sensory performance of the article by aiding in the transfer of compounds, such as flavor compounds, from the aerosol-generating material to the consumer. However, a problem with adding such an aerosol former material to the aerosol-generating material in an article for use in a non-combustion aerosol delivery system is that the aerosol former material, when aerosolized upon heating, may increase the mass of the aerosol delivered by the article, and this increased mass may sustain a higher temperature as the aerosol passes through the mouthpiece. As the aerosol passes through the mouthpiece, it transfers heat to the mouthpiece, which warms the exterior surface of the mouthpiece, including the area that contacts the consumer's lips during use. The mouthpiece temperature may be significantly higher than the temperature a consumer may be accustomed to when smoking, such as a conventional cigarette, which may be an undesirable effect caused by the use of such aerosol former materials.

[0014] In this example, the tipping comprises a body 4 of a first material. Embedded within the body 4 of first material are a hollow tubular element 8 and a capsule 15. The hollow tubular element 8 and the capsule 14 are each embedded within the body 4 of material and are circumferentially surrounded by the material forming the body 4. The body of first material is wrapped in a first plug wrap 7.

[0015] In this embodiment, the body 4 is a filter, however, it should be appreciated that in other embodiments, the body 4 may be provided to act simply as a carrier or support for the embedded matter, without substantially filtering the inhalant of the article 1.

[0016] The first body of material 4 is formed from a fibrous material. In this example, the first body of material 4 is formed from a sheet material 14. The sheet material 14 may be folded to form the body of material 4. The body of material 4 may be formed from a continuous web of sheet material 14. In this example, the sheet material 14 is gathered to form the body of material 4 in a manner similar to a "crepe filter." The hollow tubular elements 8 and capsules 15 are embedded within and circumferentially surrounded by the gathered sheet material 14 to form the first body of material 4.

[0017] In this example, the hollow tubular element 8 is positioned at the longitudinal end of the body of material 4 and extends to said longitudinal end of the body. The capsule 15 is positioned downstream of the hollow tubular element 8, the body of material 4 extending beyond the position of the capsule 14 such that the capsule 14 is surrounded both circumferentially and longitudinally by the body of first material 4. Advantageously, such an arrangement can result in a simplified manufacturing process, since it is possible to provide a single component comprising both a cavity for aerosol cooling and an aerosol modifier releasing component.

[0018] In this example, the hollow tubular element 8 is formed from multiple layers of paper wound in parallel with seams butted together to form a hollow tube. In this example, the first and second paper layers are provided in a two-ply tube, but in other examples, three, four, or more paper layers can be used to form a three, four, or more ply tube. Other constructions can be used, such as spirally wound paper layers, cardboard tubes, tubes formed using a paper-mache type process, or molded or extruded plastic tubes.

[0019] In some embodiments, the air permeability of the wall material of hollow tubular element 8 is at least 100 Coresta Units, preferably at least 200, 500, or 1000 Coresta Units.

[0020] In some examples, the walls of the hollow tubular element 8 are formed from paper having a basis weight in the range of 40 gsm to 100 gsm, for example, paper having a basis weight of 60 gsm to 80 gsm.

[0021] In some examples, the air permeability level of the hollow tubular element 8 as measured on the outside of the body 4 of material may be between 0.1% and 1%, for example 0.1%.

[0022] It has been found that the relatively high air permeability of the hollow tubular element 8 increases the amount of heat transferred from the aerosol to the tubular portion, thus reducing the temperature of the aerosol. It has also been found that the air permeability of the hollow tubular element 8 increases the amount of moisture transferred from the aerosol to the tubular portion, which improves the feel of the aerosol in the user's mouth. The high air permeability of the hollow tubular element 8 also means that air entering the body 4 portion of material surrounding the tubular portion can pass through the wall of the hollow tubular element 8 into the aerosol stream without having to cut and pass air holes through all of the outer plug wrap(s) and tipping paper, the material of the body 4, and the tubular element forming the tubular portion, thereby reducing manufacturing complexity.

[0023] In some examples, the sheet material 14 may be provided with cut-out portions, e.g. punched areas, to reduce the density of the body of material 4. In some examples, the cut-out portions may be provided in the portion of the sheet material that forms the portion of the body of material 4 that surrounds the hollow tubular element 8. Suitably, by providing cut-out portions in the sheet material 14 that forms this portion of the body, the amount of material that is perforated to provide ventilation within the hollow tubular element 8 may be reduced.

[0024] In some embodiments, to further enhance the ease of providing ventilation within the hollow tubular element 8, perforations may be provided in the hollow tubular element 8 before it is embedded within the body 4 of material.

[0025] In some embodiments, the air permeability of the material of the wall of the hollow tubular element 8 is provided by perforations formed in said material. In some examples, the material is a non-porous paper and the air permeability is provided by perforations formed in the material. In other examples, the material is a porous paper, which may or may not include perforations. If perforations are provided, they may be provided, for example, as a line of one or more perforations extending through the wall of the hollow tubular element. The perforations may be provided as a band or ring of perforations through the wall of the hollow tubular element. In this case, the perforations may be provided towards the upstream end of the hollow tubular element, for example, at a location from about 8 mm to about 2 mm, or from about 5 mm to about 2 mm from the upstream end of the hollow tubular element.

[0026] The article 1 has a ventilation level where about 75% of the aerosol is drawn through the article. In alternative embodiments, the article may have a ventilation level where 20%-80%, or 30%-75%, or 50%-80%, such as 65%-75%, of the aerosol is drawn through the article. Ventilation at these levels helps to slow down the flow of aerosol drawn through the mouthpiece 2, thereby allowing the aerosol to cool sufficiently before it reaches the downstream end 2b of the mouthpiece 2. Ventilation is provided directly within the mouthpiece 2 of the article 1. In this example, ventilation is provided within the tubular portion, which has been found to be particularly beneficial in aiding the aerosol generation process. Ventilation is provided by first and second parallel rows of ventilation holes 12, in this case formed as laser drillings, located 17.925 mm and 18.625 mm from the downstream mouth end 2b of the mouthpiece 2, respectively. In this example, these vent holes 12 extend through the tipping paper 5, the plug wrap 7, and the hollow tubular element 8. In alternative embodiments, ventilation may be provided at other locations within the mouthpiece.

[0027] Alternatively, ventilation can be provided by a single row of vent holes, e.g., laser drilling, in the portion of the article in which the tubular portion is located. This has been found to result in improved aerosol formation, believed to be due to the airflow through the vent holes being more uniform than multiple rows of vent holes, for a given ventilation level.

[0028] Aerosol temperature was found to generally increase with decreasing ventilation level. However, the relationship between aerosol temperature and ventilation level does not appear to be linear, e.g., there are variations in ventilation due to manufacturing tolerances, which have less impact at lower target ventilation levels. For example, with a ventilation tolerance of ±15%, for a target ventilation level of 75%, the aerosol temperature may increase by about 6°C at the lower ventilation limit (60% ventilation). However, at a target ventilation level of 60%, the aerosol temperature may only increase by about 3.5°C at the lower ventilation limit (45% ventilation). Thus, the target ventilation level of an article may be in the range of 40% to 70%, e.g., 45% to 65%. The average ventilation level of at least 20 articles may be 40% to 70%, e.g., 45% to 70%, or 51% to 59%.

[0029] In some embodiments, the first plug wrap 7 has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. However, it should be appreciated that the basis weight of the first plug wrap 7 may be higher to provide increased mouthpiece hardness. For example, the basis weight of the first plug wrap 7 may be at least 50, 60, 70, 80, 90, or 100 gsm. In some embodiments, the basis weight of the first plug wrap 7 is in the range of 50 to 110 gsm, or in the range of 60 to 100 gsm.

[0030] In some embodiments, the first plugwrap 7 has a basis weight of at least 20 gsm or at least 30 gsm.

[0031] In some embodiments, the first plugwrap 7 has a basis weight of at most 120, 110, or 100 gsm.

[0032] In some embodiments, the first plugwrap 7 has a basis weight in the range of 20 to 120 gsm, preferably in the range of 30 to 100 gsm.

[0033] Preferably, the first plug wrap 7 has a thickness of 30 μm to 60 μm, more preferably 35 μm to 45 μm. However, it should be appreciated that the thickness of the first plug wrap 7 may be greater to provide increased mouthpiece hardness. In some embodiments, for example, the thickness of the first plug wrap 7 may be at least 40, 50, 60, 70, 80, 90, or 100 microns. In some embodiments, the thickness of the first plug wrap 7 is in the range of 40 to 120 microns, or in the range of 50 to 100 microns.

[0034] Preferably, the first plug wrap 7 is 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 first plug wrap 7 may be a porous plug wrap, for example having an air permeability of more than 200 Coresta units.

[0035] In this example, the hollow tubular element 8 defines an air gap within the mouthpiece that acts as a cooling segment. The air gap provides a chamber through which the heated volatile components generated by the aerosol-generating material 3 flow. The hollow tubular element 8 is hollow to provide a chamber for aerosol accumulation, but is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacture and while the article 1 is in use. The hollow tubular element 8 provides a physical displacement between the aerosol-generating material 3 and the downstream portion of the mouthpiece 2. The physical displacement provided by the hollow tubular element 8 provides a thermal gradient across the length of the body 4 of the first material.

[0036] Preferably, the internal volume of the hollow tubular element 8 is 100 mm 3It has been found that providing a cavity of at least this volume allows for improved aerosol formation. Such a cavity size provides sufficient space within the mouthpiece 2 to allow heated volatile components to cool, and thus expose the aerosol-generating material 3 to higher temperatures than the volatile components might otherwise be able to do which could result in an overly warm aerosol. More preferably, the mouthpiece 2 is at least 120 mm. 3 greater than 150 mm, and even more preferably 3 In some examples, the internal cavity has a volume greater than about 110 mm, allowing for further improvement of the aerosol. 3 ~ approx. 600mm 3 , preferably about 120 mm 3 ~ approx. 500mm 3 In this example, the internal cavity formed by the tubular element 8 has a volume of about 250 mm 3 Alternatively, if a single one of the tubular elements is arranged to provide a cooling segment, that tubular element preferably has an internal volume as described above.

[0037] The cavity may be configured to provide a temperature differential of at least 40 degrees Celsius between the heated volatile components entering the first upstream end of the cavity and the heated volatile components exiting the second downstream end of the cavity. The cavity may preferably be configured to provide a temperature differential of at least 60 degrees Celsius, preferably at least 80 degrees Celsius, and more preferably at least 100 degrees Celsius, between the heated volatile components entering the first upstream end of the cavity and the heated volatile components exiting the second downstream end of the cavity. This temperature differential across the length of the cavity may protect temperature sensitive elements of the mouthpiece downstream of the cavity from the high temperatures of the aerosol-generating material 3 as it heats up.

[0038] Preferably, the length of the hollow tubular element 8 is less than about 50 mm. More preferably, the length of the hollow tubular element 8 is less than about 40 mm. Even more preferably, the length of the hollow tubular element 8 is less than about 35 mm. Additionally or alternatively, the length of the hollow tubular element 8 is preferably at least about 10 mm. Preferably, the length of the hollow tubular element 8 is at least about 15 mm.

[0039] In some preferred embodiments, the length of the hollow tubular element 8 is about 15 mm to about 35 mm, more preferably about 16 mm to about 30 mm, even more preferably about 18 mm to about 25 mm, and most preferably about 23 mm. In this example, the length of the hollow tubular element 8 is 23 mm.

[0040] In some embodiments, the hollow tubular element 8 preferably has a wall thickness of at least about 50 μm up to about 1 mm, preferably 50 μm to 500 μm, more preferably 60 μm to 130 μm. In the present example, the wall thickness of the hollow tubular element 8 is about 130 μm. The "wall thickness" of the tubular element corresponds to the radial thickness of the wall of the tubular element, not including the surrounding material in which the tubular element is embedded. This can be measured, for example, using a caliper.

[0041] In some embodiments, the wall thickness of the hollow tubular element 8 is at least 50 microns, preferably at least 75, 80, 85, 90, 95, 100, or 105 microns. In some embodiments, the wall thickness of the tubular element is at least 100 or 110 microns.

[0042] In some embodiments, the wall thickness of the hollow tubular element 8 is less than 1000 microns, preferably less than 500 microns.

[0043] The portion of the body of material 4 surrounding the hollow tubular element 8 may have a diameter of from 1 mm to 4 mm. The portion of the body of material 4 surrounding the hollow tubular element 8 and surrounded by the first plug wrap 7 effectively forms a tubular portion having a wall thickness of from about 1 mm to about 4 mm.

[0044] It has been found that the combined thickness of the hollow tubular element 8 and the surrounding body of material 4 means that the tubular section formed by the hollow tubular element 8 embedded within the body of material 4 has a greater thermal mass, which helps to reduce the temperature of the aerosol passing through the tubular section and to reduce the surface temperature of the tip at locations downstream of the tubular section. This is believed to be because the greater thermal mass of the tubular section allows the tubular section to absorb more heat from the aerosol compared to a tubular section with a thinner wall thickness. Increasing the thickness of the tubular section directs the aerosol centrally within the tip so that less heat from the aerosol is transferred to the outer parts of the tip, such as the outer parts of the body of material.

[0045] The capsule 15 may include a breakable capsule, for example a capsule having a solid frangible shell surrounding a liquid payload. In this example, a single capsule 15 is used. The capsule 15 is fully embedded within the body of material 4. In other words, the capsule 15 is fully surrounded by the material forming the body 4. In other examples, multiple breakable capsules may be disposed within the body of material 4, for example two, three, or more breakable capsules. The length of the body of material 4 may be increased to accommodate the number of capsules required. In examples where multiple capsules are used, the individual capsules may be identical to one another or may differ from one another in terms of size and / or capsule payload.

[0046] Capsule 15 has a core-shell structure. In other words, capsule 15 includes a shell that encapsulates a liquid agent, for example, a flavorant or other agent, which may be any one of the flavorants or aerosol modifiers described herein. The capsule shell can be broken by a user to release the flavorant or other agent into the body of material 4. The first plug wrap 7 can include a barrier coating to render the plug wrap material substantially impermeable to the liquid payload of capsule 15.

[0047] In this example, capsule 15 is spherical and has a diameter of about 3 mm. In other examples, other shapes and sizes of capsules may be used. For example, the capsule may have a diameter of less than 4 mm, or less than 3.5 mm, or less than 3.25 mm. In alternative embodiments, the capsule may have a diameter of more than about 3.25 mm, such as more than 3.5 mm, or more than 4 mm. The total weight of capsule 15 may range from about 10 mg to about 50 mg.

[0048] In this example, the capsule 15 is located within the body of material 4 at a location downstream of the hollow tubular element 8. In this example, the capsule 15 is positioned such that the centre of the capsule 15 is 5 mm from the proximal end of the hollow tubular element 8. Alternatively, the capsule may be positioned such that the hollow tubular element 8 and the capsule 15 are separated by a gap of 1 mm to 30 mm, or 1.5 mm to 20 mm, or 2 mm to 15 mm, or 3 mm to 10 mm. In this example, the centre of the capsule is positioned 12 mm from the downstream end of the mouthpiece 2b. Providing the capsule in this location improves the volatility of the capsule contents due to the proximity of the capsule to the aerosol generating section of the article which is heated in use, while at the same time being sufficiently far from the aerosol generating section which is inserted into the aerosol delivery system in use to allow easy access to the capsule by the user and for the capsule to be burst with the user's fingers.

[0049] Preferably, the mouthpiece 2' is configured such that the capsule 15 and the vent hole 12 are longitudinally offset from one another within the mouthpiece 2'.

[0050] The body of material 4 may be manufactured using a Decoufle™ CU-20 filter making machine, however, those skilled in the art will appreciate that other machines may be used to manufacture the first body of material 4.

[0051] In some embodiments, the sheet material 14 has a width of at least 60 mm, preferably at least 70, 80, 90, 100, 110, or 120 mm.

[0052] In some embodiments, the sheet material 14 has a width of at most 240 mm, preferably at most 230, 220, 210, 200, 190, 180, 170, 160, or 150 mm.

[0053] In some embodiments, the sheet material 14 has a width of less than 180 mm, preferably less than 170, 160, 150, 140, or 130 mm.

[0054] In some embodiments, the sheet material 14 has a width in the range of 60-240 mm, preferably in the range of 80-240 mm, in the range of 90-200 mm, or in the range of 100-170 mm.

[0055] In this example, the sheet material 14 comprises cellulose. In this example, the sheet material 14 is paper. However, the sheet material 14 may additionally or alternatively comprise different materials. For example, in some embodiments, the sheet material 14 comprises reconstituted tobacco formed in the sheet material 14 arranged to form a body 4 of material. The reconstituted tobacco comprises cellulose. The reconstituted tobacco may optionally be paper reconstituted tobacco. In other embodiments, the sheet material 14 comprises different materials, such as cotton, tobacco, lyocell, polyvinyl alcohol (PVOH), polylactic acid (PLA), poly(ε-caprolactone) (PCL), poly(1-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate) (PBAT), starch-based materials, aliphatic polyester materials, polysaccharide polymers, and / or woven or nonwoven materials. The sheet material 14 may be biodegradable. In one embodiment, the sheet material 14 may be non-plastic or plastic. In some embodiments, the sheet material 14 does not include cellulose acetate.

[0056] Biodegradability can be measured according to the procedure described in ISO 14855.

[0057] The tubular elements 8, 11, 4a, and 4b, and body of material 4 described herein are capable of achieving greater than 50% biodegradation in 30 days when exposed to either fresh water or salt water.

[0058] In one embodiment, the sheet material 14 comprises paper having a basis weight in the range of 15 to 80 gsm, preferably in the range of 20 to 50 gsm.

[0059] In some embodiments, the sheet material 14 has a basis weight of at least 15 gsm, preferably at least 20 gsm, 25 gsm, 30 gsm, 35 gsm, 40 gsm, 45 gsm, 50 gsm, 55 gsm, or 60 gsm.

[0060] In some embodiments, the sheet material 14 has a basis weight of 100 gsm or less, preferably 90 gsm or less, 80 gsm or less, 70 gsm or less, 60 gsm or less, 50 gsm or less, or 40 gsm or less, or 30 gsm or less. In some embodiments, the basis weight of the sheet material 14 is 20 gsm or less.

[0061] In some embodiments, the sheet material 14 has a basis weight in the range of 20 to 100 gsm, preferably in the range of 25 to 80 gsm or in the range of 30 to 65 gsm.

[0062] In this example, the sheet material 14 is crimped before being placed within the body of material 4. For example, the sheet material 14 may be passed through a pair of crimping rollers. In this example, the first body of material 4 includes a crimped sheet material 14 formed with a crimp pattern comprising a series of substantially parallel ridges and grooves. Crimping may make it easier to bring the sheet material 14 together to form the body of material 4. Crimping may also increase the length of the sheet material 14 that can be used to form a particular volume of the body of material 4. Increasing the amount of sheet material 14 within the body of material 4 may increase the surface area of ​​the sheet material in contact with an aerosol passing through the body of material 4, and therefore may increase the amount of moisture absorbed from the aerosol by the sheet material 14.

[0063] It may be desirable to form different portions of the body of material 4 from different amounts of sheet material, which can be achieved by applying different levels of crimping to the sheet material 14 from which the portions are formed. For example, it may be desirable to form the longitudinal ends of the body 4 from a longer length of sheet material, whereby the sheet material is more densely arranged and the longitudinal ends of the body 4 appear to the consumer more similar to a conventional filter element when viewed from the longitudinal ends, and additionally or alternatively have a higher stiffness. It may therefore be advantageous to apply a greater amount of crimping to the sheet material 14 forming the longitudinal ends of the body than to the longitudinal central portion of the body. Similarly, it may be advantageous to form a portion of the body 4 from a shorter length of sheet material if a less densely packed configuration of the sheet material is desired. For example, if an object is embedded within the body 4, it may be desirable to apply less crimping to the sheet material 14 forming the longitudinal portion of the body in which the object is embedded, in order to provide a less dense sheet material 14 around the embedded object. Such an arrangement may advantageously prevent undesirably high pressure drops across the longitudinal portions of the body.

[0064] The level of crimping applied to the sheet material may contribute to the hardness of the body formed from said sheet material. Preferably, the hardness of the body of material may be varied along the length of the body of material by varying the crimp factor applied to the sheet material 14 from which the body of material is formed. For example, a portion of the body of material formed from a sheet material having a higher level of crimping may have a hardness of about 88%-92%. A portion of the body of material having a hardness of 88%-92% may be preferably formed at a distal end of the body to improve the appearance of the body when viewed from that end as well as provide improved stability of the longitudinal end portions of the component. Similarly, other portions of the body may be formed from a sheet material having a lower level of crimping and may have a hardness of at least 80%.

[0065] In this example, the average spacing between adjacent ridges on the sheet material 14 is greater than about 0.3 mm, and in this example, the crimp amplitude is less than about 0.7 mm.

[0066] Crimp amplitude (also known as "crimping factor") refers to the depth of the crimped grooves in the sheet material 14 forming the body. That is, as shown in FIG. 1B, crimping the sheet material 14 creates a plurality of peaks and valleys in the sheet material 14 when viewed from a first side of the sheet material 14, and the crimp amplitude "A" is the depth of the valleys measured from the peaks. The crimping may form a "zigzag" form or another shape. In some examples, adjacent grooves in the crimped sheet material 14 are separated by a distance or pitch "P" in the range of 0.3 to 2 mm, preferably in the range of 0.4 to 1 mm. In some embodiments, adjacent grooves in the crimped sheet material 10 are separated by a distance of at least 0.1 mm, preferably at least 0.2, 0.5, 0.7, 1, 1.5, 2, 2.5, or 3 mm. In some embodiments, adjacent grooves in the crimped sheet material are separated by a distance of at most 3 mm, preferably at most 2.5, 2, 1, 1.5, 0.7, 0.5, 0.2, or 0.1 mm.

[0067] For example, the sheet material 14 may have crimps with a crimp amplitude of less than 500 μm and spacing between peaks (or valleys) of at least 300 μm, at least 400 μm, or at least 500 μm.

[0068] In some embodiments, the sheet material 14 is heated as it is crimped. For example, the sheet material 14 may be passed between crimping rollers, one or both of which are heated. For example, one or both of the rollers may be heated to a temperature of up to 100 degrees Celsius, such as 50 degrees Celsius or 60 degrees Celsius. The amount of pressure applied to the sheet material passing between the rollers may also be varied, for example between X and Y. Heating the roller(s) or applying a higher level of pressure to the sheet material can result in a higher level of crimping.

[0069] Advantageously, sheet materials 14, e.g., paper, having the above crimp pitch and / or amplitude have been found to exhibit improved performance when used in components of an aerosol delivery system. In particular, these relatively low levels of crimp pitch and amplitude surprisingly result in a body of material, or a portion of a body of material, having a lower pressure drop compared to a body or a portion of a body formed from a sheet material 14 having a higher level of crimping.

[0070] In any of these examples, the average density of the body of the material is from about 0.1 to about 0.25 mg / mm 3 The density of the body of material can be measured by separating said body from the article and surrounding plug wrap and / or tipping paper and removing embedded objects, but including any additives added to sheet material 14. The density can be calculated as a tightness based on the weight of sheet material 14 and any additives added to sheet material 14, and the total volume occupied by sheet material 14. For example, the total volume of the body of material 4 measured inside plug wrap 7.

[0071] In this example, the density of the body of material 4 is about 0.19 mg / mm 3 In some embodiments, the body 4 has a molecular weight of at least 0.1 mg / mm3, 0.12 mg / mm3, or 0.15 mg / mm3. 3 Alternatively or additionally, the body 4 of material has a density of about 0.3 mg / mm 3 Less than 0.25 mg / mm 3 Less than or about 0.22 mg / mm 3 Preferably, the body of material has a density of less than about 0.15 mg / mm 3 ~about 0.25mg / mm 3As noted above, different portions of the body of material 4 may have different densities depending on the level of crimping and gathering applied to the sheet material 14 forming the portions. These values ​​include any additives contained in the body of material 4. Before being crimped and formed into the body of material, the sheet material 14 may have a density of about 0.2 to 0.5 mg / mm 3 , for example about 0.25, 0.30, or 0.35 mg / mm 3 The density of the sintered body may be 0.01 to 0.01.

[0072] A given dimension of sheet material 14 refers to the size of the sheet material before it is crimped or gathered to form a body of material. The dimensions of sheet material 14 may be measured by stretching sheet material 14 to the extent that no visible crimps remain.

[0073] In this example, the sheet material 14 forming the portion of the body of material 4 in which the tubular element 8 is embedded is subjected to a lower level of crimping, and the sheet material 14 forming the distal end of the body 4 is subjected to a higher level of crimping.

[0074] In some embodiments, the sheet material 14 is crimped to a crimp amplitude of at least 0.1 mm, preferably at least 0.3 mm, 0.4 mm, or 0.5 mm.

[0075] In some embodiments, the sheet material 14 is crimped to a crimp amplitude of at most 1 mm, preferably at most 0.8 mm, 0.6 mm, or 0.5 mm.

[0076] In some embodiments, the sheet material 14 comprises at least one slit extending in a direction substantially perpendicular to the longitudinal axis of the body 4. The at least one slit is positioned to allow the sheet material 14 on a first side (e.g., downstream side) of an object embedded within the body, such as the hollow tubular element 8, to be brought together such that when the sheet material 14 is assembled to the body 4, the slit forms an inner edge within the body 4 that at least partially defines a boundary of a space containing the embedded object. For example, the sheet material 14 may comprise three slits, such that one slit is positioned at the downstream end of the hollow tubular element 8 and another slit is positioned on either side of the capsule 15.

[0077] The inner edge formed by the slits allows the sheet material 14 to be gathered together on one side of the embedded object to at least partially or completely demarcate it, thereby preventing the object from migrating out of the first end of the space in which it is embedded. This improves the positioning of the embedded object within the body 4. In addition, because the sheet material 14 is gathered together, it helps to hide the embedded object when viewed from the longitudinal end of the body 4, which may improve the aesthetics of the mouthpiece 2. Preferably, the slits achieve these benefits without the need for a separate component, such as a cellulose acetate plug, downstream of the embedded object or downstream of the body 4.

[0078] In some examples, the aerosol-generating material 3 described herein is a first aerosol-generating material, and the hollow tubular element 8 can include a second aerosol-generating material. In one example, the inner wall of the tubular element 8 includes the second aerosol-generating material. For example, the second aerosol-generating material can be disposed on the inner surface of the hollow tubular element 8.

[0079] The second aerosol-generating material includes at least one aerosol former material and may also include at least one aerosol modifier or other sensory material. The aerosol former material and / or aerosol modifier may be any aerosol former material or aerosol modifier described herein, or a combination thereof.

[0080] As the aerosol generated from the aerosol-generating material 3, referred to herein as the first aerosol, is drawn through the mouthpiece's hollow tubular element 8, heat from the first aerosol may aerosolize the aerosol-forming material of the second aerosol-generating material to form a second aerosol. The second aerosol may include flavorants that may be additional or complementary to the flavor of the first aerosol.

[0081] Providing a second aerosol-forming material on the tubular element 8 may result in the production of a second aerosol that enhances or complements the flavor or visual appearance of the first aerosol.

[0082] In this example, the article 1 has a circumference of about 21 mm (i.e., the article is in a demi-slim format). Preferably, the article 1 has a rod of aerosol-generating material with a circumference greater than 19 mm. This has been found to provide a sufficient circumference to generate improved sustained aerosol over a typical aerosol generating session that is favorable to the consumer. When the article is heated, heat is transferred through the rod of aerosol-generating material 3 to volatilize the rod's components, and a circumference greater than 19 mm has been found to be particularly effective in generating aerosol in this manner. Because the article is heated to release an aerosol, improved heating efficiency can be achieved by using an article with a circumference of less than about 23 mm. To achieve improved aerosol upon heating while maintaining a suitable product length, a rod circumference greater than 19 mm and less than 23 mm is preferred. In some examples, the rod circumference can be between 20 mm and 22 mm, which has been found to provide a good balance between providing effective aerosol delivery on the one hand and allowing efficient heating on the other.

[0083] The circumference of the tipping tip 2 is substantially the same as the circumference of the rod of aerosol-forming material 3 so that there is a smooth transition between these components. In this example, the circumference of the tipping tip 2 is about 20.8 mm.

[0084] In some examples, the tipping paper 5 includes a citrate, such as sodium citrate or potassium citrate. In such examples, the tipping paper 5 may have a citrate content of 2% by weight or less, or 1% by weight or less. It is believed that reducing the citrate content of the tipping paper 5 helps to reduce charring effects that may occur during use.

[0085] In this example, the tipping paper 5 extends 5 mm over the rod of aerosol-generating material 3, but may alternatively extend 3 mm to 10 mm, or more preferably 4 mm to 6 mm, over the rod 3 to provide a secure attachment between the tipping tip 2 and the rod 3. The tipping paper 5 may have a higher basis weight than that of the plug wrap used in the article 1, for example a basis weight of 40 gsm to 80 gsm, more preferably 50 gsm to 70 gsm, in this example 58 gsm. These ranges of basis weight have been found to result in tipping paper having acceptable tensile strength whilst being flexible enough to wrap around the article 1 and adhere to itself along the longitudinal lap seam of the paper. The circumference of the tipping paper 5, when wrapped around the tipping tip 2, is approximately 21 mm.

[0086] The pressure drop or pressure difference (also called resistance to draw) across the tip, e.g., the portion of the article 1 downstream of the aerosol-generating material 3, is preferably less than about 40 mmH2O. Such a pressure drop has been found to allow sufficient aerosol containing desirable compounds, such as flavor compounds, to pass through the tip 2 and reach the consumer. More preferably, the pressure drop across the tip 2 is less than about 20 mmH2O. In some embodiments, particularly improved aerosols have been achieved using a tip 2 having a pressure drop of less than 15 mmH2O, e.g., about 6 mmH2O, about 10 mmH2O, or about 14 mmH2O. Alternatively or additionally, the pressure drop across the tip may be at least 3 mmH2O, preferably at least 4 mmH2O, more preferably at least 5 mmH2O. In some embodiments, the pressure drop across the tip may be between about 5 mmH2O and 20 mmH2O, preferably between 5 mmH2O and 15 mmH2O. These values ​​make it possible to decelerate the aerosol as it passes through the mouthpiece 2 so that its temperature has time to drop before reaching the downstream end 2b of the mouthpiece 2.

[0087] In this example, the aerosol-generating material 3 is wrapped in a wrapping material 10. The wrapping material 10 may be, for example, a paper or paper-backed foil wrapping material. In this example, the wrapping material 10 is substantially non-breathable to air. In an alternative embodiment, the wrapping material 10 has an air permeability of preferably less than 100 Coresta units, more preferably less than 60 Coresta units. It has been found that low air permeability wrapping materials, for example having an air permeability of less than 100 Coresta units, more preferably less than 60 Coresta units, result in improved aerosol formation in the aerosol-generating material 3. Without wishing to be bound by theory, it is hypothesized that this is due to reduced loss of aerosol compounds through the wrapping material 10. The air permeability of the wrapping material 10 may be measured according to ISO 2965:2009 for the determination of air permeability of materials used as cigarette paper, filter plug wrap, and filter bonding paper.

[0088] In this embodiment, the packaging material 10 comprises an aluminum foil. Aluminum foil has been found to be particularly effective in promoting the formation of an aerosol within the aerosol-generating material 3. In this example, the aluminum foil has a metal layer having a thickness of about 6 μm. In this example, the aluminum foil has a paper backing. However, in alternative configurations, the aluminum foil may be of other thicknesses, for example between 4 μm and 16 μm thick. The aluminum foil may also have no paper backing, but may have a backing formed from another material, for example to help provide the foil with suitable tensile strength, or may have no backing. Metal layers or foils other than aluminum may also be used. The total thickness of the packaging material is preferably between 20 μm and 60 μm, more preferably between 30 μm and 50 μm, which allows for the provision of a packaging material with suitable structural integrity and heat transfer properties. The tension that can be applied to the wrapper before it breaks can be greater than 3,000 grams of force, such as between 3,000 and 10,000 grams of force, or between 3,000 and 4,500 grams of force.

[0089] In some examples, the wrapping material 10 surrounding the aerosol-generating material 3 has a high level of air permeability, for example, greater than about 1000 Coresta units, or greater than about 1500 Coresta units, or greater than about 2000 Coresta units. The air permeability of the wrapping material 10 can be measured according to ISO 2965:2009 for determination of air permeability of materials used as cigarette papers, filter plug wraps, and filter bonding papers.

[0090] The wrapper 10 may be formed from a material with a high inherent level of air permeability, an inherently porous material, or may be formed from a material with any level of inherent air permeability where the final level of air permeability is achieved by providing breathable zones or areas in the wrapper 10. Providing a breathable wrapper 10 provides a path for air to enter the article. The wrapper 10 may be provided with an air permeability such that the amount of air entering through the rod of aerosol-forming material is relatively greater than the amount of air entering the article through the vent 12 in the mouthpiece. An article having this configuration may generate a more flavorful aerosol that may be more satisfying to the user.

[0091] In this example, the aerosol former material added to the aerosol-generating substrate 3 comprises 14% by weight of the aerosol-generating substrate 3. Preferably, the aerosol former material comprises at least 5% by weight of the aerosol-generating substrate, more preferably at least 10% by weight. Preferably, the aerosol former material comprises less than 25% by weight, more preferably less than 20% by weight, for example between 10% and 20% by weight, between 12% and 18% by weight, or between 13% and 16% by weight of the aerosol-generating substrate.

[0092] Preferably, the aerosol-generating material 3 is provided as a cylindrical rod of aerosol-generating material. Regardless of the form of the aerosol-generating material, the aerosol-generating material preferably has a length of about 10 mm to 100 mm. In some embodiments, the length of the aerosol-generating material is preferably in the range of about 25 mm to 50 mm, more preferably in the range of about 30 mm to 45 mm, and even more preferably about 30 mm to 40 mm.

[0093] In some examples, the article 1 can be configured such that there is a separation (i.e., a minimum distance) between the heater and the hollow tubular element 8 of the non-combustion aerosol delivery device 100. This prevents heat from the heater from damaging the material forming the hollow tubular element 8.

[0094] The minimum distance between the heater and the hollow tubular element 8 of the non-combustion aerosol delivery device 100 can be 3 mm or more. In some examples, the minimum distance between the heater and the hollow tubular element 8 of the non-combustion aerosol delivery device 100 can be in the range of 3 mm to 10 mm, such as 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm.

[0095] The separation between the heater and the hollow tubular element 8 of the non-combustion aerosol delivery device 100 can be achieved, for example, by adjusting the length of the rod of aerosol-generating material 3.

[0096] The volume of the aerosol-generating material 3 provided is approximately 200 mm 3 ~ approx. 4300mm 3 , preferably about 500 mm 3 ~1500mm 3 , more preferably about 1000 mm 3 ~ approx. 1300mm 3 For example, the length of the 3 ~ approx. 1300mm 3 Providing these volumes of aerosol-generating material has been shown to advantageously achieve superior aerosols with superior visual and sensory performance compared to those achieved with volumes selected from the lower end of the range.

[0097] The mass of the aerosol-forming material 3 provided may be greater than 200 mg, for example between about 200 mg and 400 mg, preferably between about 230 mg and 360 mg, more preferably between about 250 mg and 360 mg. It has been suitably found that providing a higher mass of aerosol-forming material results in improved sensory performance compared to aerosols generated from lower masses of tobacco material.

[0098] Preferably, the aerosol-forming material or substrate is formed from a tobacco material as described herein that includes a tobacco component.

[0099] In the tobacco materials described herein, the tobacco component preferably contains reconstituted tobacco. The tobacco component may also contain leaf tobacco, extruded tobacco, and / or band-cast tobacco.

[0100] The aerosol-generating material 3 may include a reconstituted tobacco material having a density of less than about 700 milligrams cubic centimeters (mg / cc). Such tobacco materials have been found to be particularly effective in providing an aerosol-generating material that can be heated quickly to release an aerosol, as compared to materials with higher densities. For example, the inventors have tested the properties of various aerosol-generating materials, such as band-cast reconstituted tobacco materials and paper reconstituted tobacco materials, when heated. It has been found that for each given aerosol-generating material, there is a particular zero heat flow temperature below which, while heat is being applied to the material, the net heat flow is endothermic, i.e., more heat enters the material than leaves it, and above which, the net heat flow is exothermic, i.e., more heat leaves the material than enters it. Materials with densities less than 700 mg / cc had lower zero heat flow temperatures. Because the majority of the heat flow leaving the material is through the formation of an aerosol, having a lower zero heat flow temperature has a beneficial effect on the time it takes to initially release an aerosol from the aerosol-generating material. For example, aerosol-forming materials having a density less than 700 mg / cc have been found to have a zero heat flow temperature less than 164° C., compared to materials having a density greater than 700 mg / cc that have a zero heat flow temperature greater than 164° C.

[0101] The density of the aerosol-generating material also affects the rate at which heat is conducted through the material, with lower densities, for example densities below 700 mg / cc, conducting heat more slowly through the material and thus allowing for a more sustained release of the aerosol.

[0102] Preferably, the aerosol-forming material 3 comprises a reconstituted tobacco material, such as a paper reconstituted tobacco material, having a density of less than about 700 mg / cc. More preferably, the aerosol-forming material 3 comprises a reconstituted tobacco material having a density of less than about 600 mg / cc. Alternatively or additionally, the aerosol-forming material 3 preferably comprises a reconstituted tobacco material having a density of at least 350 mg / cc, which is believed to allow for a sufficient amount of heat transfer through the material.

[0103] The tobacco material may be provided in the form of cut rag tobacco. The cut rag tobacco may have a cut width of at least 15 cuts / inch (about 5.9 cuts / cm, which corresponds to a cut width of about 1.7 mm). Preferably, the cut rag tobacco has a cut width of at least 18 cuts / inch (about 7.1 cuts / cm, which corresponds to a cut width of about 1.4 mm), more preferably at least 20 cuts / inch (about 7.9 cuts / cm, which corresponds to a cut width of about 1.27 mm). In one example, the cut rag tobacco has a cut width of 22 cuts / inch (about 8.7 cuts / cm, which corresponds to a cut width of about 1.15 mm). Preferably, the cut rag tobacco has a cut width of no more than 40 cuts / inch (about 15.7 cuts / cm, which corresponds to a cut width of about 0.64 mm). A cut width of 0.5 mm to 2.0 mm, for example 0.6 mm to 1.5 mm, or 0.6 mm to 1.7 mm, has been found to provide a preferred tobacco material, particularly with respect to surface area to volume ratio when heated, and overall density and pressure drop of the substrate 3. The cut rag tobacco may be formed from a mixture of tobacco material forms, such as a mixture of one or more of paper reconstituted tobacco, leaf tobacco, extruded tobacco, and band cast tobacco. Preferably, the tobacco material comprises paper reconstituted tobacco, or a mixture of paper reconstituted tobacco and leaf tobacco.

[0104] In the tobacco materials described herein, the tobacco material may contain a filler component. The filler component is generally a non-tobacco component, i.e. a component that does not contain raw materials derived from tobacco. The filler component may be a non-tobacco fiber, such as wood fiber or pulp or wheat fiber. The filler component may also be an inorganic material, such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, etc. The filler component may also be a non-tobacco cast material or a non-tobacco extrusion material. The filler component may be present in an amount of 0-20% by weight of the tobacco material, or in an amount of 1-10% by weight of the composition. In some embodiments, no filler component is present.

[0105] In the tobacco materials described herein, the tobacco material contains an aerosol former material. In this context, an "aerosol former material" is an agent that promotes the generation of an aerosol. The aerosol former material may promote the generation of an aerosol by promoting the initial vaporization and / or condensation of a gas into an inhalable solid and / or liquid aerosol. In some embodiments, the aerosol former material may improve the delivery of flavor from the aerosol-generating material. In general, any suitable aerosol former material, including those described herein, may be included in the aerosol-generating material of the present invention. Other suitable aerosol former materials include, but are not limited to, polyols such as sorbitol, glycerol, and glycols such as propylene glycol or triethylene glycol, non-polyols such as monohydric alcohols, high boiling point hydrocarbons, acids such as lactic acid, glycerol derivatives, esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, or myristic acid, including ethyl myristate and isopropyl myristate, and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate, and dimethyl tetradecanedioate. In some embodiments, the aerosol former material may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. Glycerol may be present in an amount of 10-20% by weight of the tobacco material, such as 13-16% by weight of the composition, or about 14% or 15% by weight of the composition. Propylene glycol, when present, may be present in an amount of 0.1-0.3% by weight of the composition.

[0106] The aerosol former material may be included in any component of the tobacco material, such as any tobacco component and / or in the filler component, if present. Alternatively or additionally, the aerosol former material may be added separately to the tobacco material. In either case, the total amount of aerosol former material in the tobacco material may be as defined herein.

[0107] The tobacco material may contain 10% to 90% by weight of tobacco leaf, with the aerosol former material being provided in an amount of up to about 10% by weight of the tobacco leaf. It has been found that this may suitably be added at a higher weight percentage relative to another component of the tobacco material, such as a reconstituted tobacco material, to achieve an overall level of aerosol former material of 10% to 20% by weight of the tobacco material.

[0108] The tobacco material described herein contains nicotine. The nicotine content may be 0.5-1.75% by weight of the tobacco material, for example 0.8-1.5% by weight of the tobacco material. Additionally or alternatively, the tobacco material contains 10%-90% by weight of tobacco leaf having a nicotine content of more than 1.5% by weight of the tobacco leaf. It has been suitably found that using tobacco leaf having a nicotine content of more than 1.5% in combination with a lower nicotine base material, such as paper reconstituted tobacco, provides a tobacco material with a suitable nicotine level but superior sensory performance than using paper reconstituted tobacco alone. Tobacco leaf, for example cut rag tobacco, may have a nicotine content of, for example, 1.5%-5% by weight of the tobacco leaf.

[0109] The tobacco material described herein may contain an aerosol modifier, such as any of the flavors described herein. In one embodiment, the tobacco material contains menthol to form a menthol-containing article. The tobacco material may contain 3 mg to 20 mg of menthol, preferably 5 mg to 18 mg, more preferably 8 mg to 16 mg of menthol. In this example, the tobacco material contains 16 mg of menthol. The tobacco material may contain 2% to 8% by weight of menthol, preferably 3% to 7% by weight of menthol, more preferably 4% to 5.5% by weight of menthol. In one embodiment, the tobacco material contains 4.7% by weight of menthol. Such high levels of menthol loading can be achieved using a high percentage of reconstituted tobacco material, for example greater than 50% by weight of the tobacco material. Alternatively or additionally, menthol loading levels can be increased by using a large amount of aerosol-forming material, such as tobacco material, which can be achieved, for example, when an aerosol-forming material, such as tobacco material, of more than about 500 mm3 or suitably more than about 1000 mm3 is used.

[0110] In the compositions described herein, where amounts are given in weight %, for the avoidance of doubt, this refers to a dry weight basis, unless specifically indicated to the contrary. Thus, any water that may be present in the tobacco material or any of its components is completely ignored for purposes of determining the weight %. The moisture content of the tobacco material described herein may vary, for example, from 5 to 15% by weight. The moisture content of the tobacco material described herein may vary, for example, according to the temperature, pressure, and humidity conditions in which the composition is maintained. The moisture content may be determined by Karl Fischer analysis, as known to those skilled in the art. Meanwhile, for the avoidance of doubt, any component other than water is included in the weight of the tobacco material, even if the aerosol former material is a component of a liquid phase, such as glycerol or propylene glycol. However, if the aerosol former material is provided in the tobacco component of the tobacco material or in the filler component of the tobacco material (if present), instead of or in addition to being added separately to the tobacco material, the aerosol former material is not included in the weight of the tobacco component or filler component, but is included in the weight of the "aerosol former material" in weight % as defined herein. All other components present in the tobacco component are included in the weight of the tobacco component, even if they are of non-tobacco origin (eg, non-tobacco fibers in the case of reconstituted tobacco).

[0111] In one embodiment, the tobacco material comprises a tobacco component as defined herein and an aerosol former material as defined herein. In one embodiment, the tobacco material consists essentially of a tobacco component as defined herein and an aerosol former material as defined herein. In one embodiment, the tobacco material consists of a tobacco component as defined herein and an aerosol former material as defined herein.

[0112] The paper reconstituted tobacco is present in the tobacco component of the tobacco material described herein in an amount between 10% and 100% by weight of the tobacco component. In an embodiment, the paper reconstituted tobacco is present in an amount between 10% and 80% by weight, or between 20% and 70% by weight of the tobacco component. In a further embodiment, the tobacco component consists essentially of paper reconstituted tobacco or consists of paper reconstituted tobacco. In a preferred embodiment, leaf tobacco is present in the tobacco component of the tobacco material in an amount of at least 10% by weight of the tobacco component. For example, leaf tobacco may be present in an amount of at least 10% by weight of the tobacco component, while the remainder of the tobacco component comprises paper reconstituted tobacco, banded cast reconstituted tobacco, or a combination of banded cast reconstituted tobacco and another form of tobacco, such as tobacco granules.

[0113] Paper reconstituted tobacco refers to tobacco material formed by a process of extracting tobacco feedstock with a solvent to obtain an extract of soluble substances and a residue containing fibrous material, and then recombining the extract (usually after concentration, and optionally after further processing) with fibrous material from the residue (usually after refining the fibrous material, and optionally with the addition of a portion of non-tobacco fiber) by deposition of the extract onto the fibrous material. The recombination process is similar to the process of making paper.

[0114] The paper reconstituted tobacco can be any type of paper reconstituted tobacco known in the art.In certain embodiments, the paper reconstituted tobacco is made from a raw material comprising one or more of tobacco strip, tobacco stem, and whole leaf tobacco.In further embodiments, the paper reconstituted tobacco is made from a raw material consisting of tobacco strip and / or whole leaf tobacco, and tobacco stem.However, in other embodiments, waste, fines, and wineing can be alternatively or additionally adopted as raw material.

[0115] Paper reconstituted tobacco for use in the tobacco materials described herein may be prepared by methods known to those skilled in the art for preparing paper reconstituted tobacco.

[0116] 2 is a cross-sectional side view of an article 1' for use with a non-combustion aerosol delivery system. The article 1' comprises a tip 2' that is substantially similar to tip 2 except that the body of material 4' is replaced by a body of material 4' further comprising a second tubular element 11 at a downstream end of the body 4'. The second tubular element 11 extends to the mouth end of the body of material 4'.

[0117] In this example, the hollow tubular element 8 and the second hollow tubular element 11 are separated by a gap of 10 mm. Alternatively, the first and second hollow tubular elements 8, 11 are separated by other distances, for example a gap of 5 mm to 15 mm, or 6 mm to 12 mm, or about 6 mm, about 7 mm, about 8 mm, or about 9 mm. A body of material 4' extends within and across the gap. In this example, the capsule 15 is embedded within the body of material 4' in the gap between the first and second hollow tubular elements 8, 11.

[0118] In this example, the sheet material 14 forming the body 4' comprises two slits positioned at the downstream and upstream ends, respectively, of the first and second hollow tubular elements 8, 11. The slits are positioned such that when the sheet material 14 is assembled into the body 4', the slits cause the sheet material 14 to be released between the slits and extend into the gap between the first and second hollow tubular elements 8, 11. Additionally or alternatively, the sheet material 14 may comprise one slit or multiple slits positioned on either or both sides of the embedded capsules 15.

[0119] In this example, the first hollow tubular element 8 provides a cavity for aerosol cooling, as described above.

[0120] The second hollow tubular element 11 is embedded in the body of material 4' at its downstream end and extends to the longitudinal end of the body 4'. It has been found that providing the tubular element in this position significantly reduces the temperature of the outer surface of the mouthpiece 2', preferably at the downstream end 2b of the mouthpiece that is in contact with the consumer's mouth when the article 1' is in use. In addition, it has been found that the use of the tubular portion also significantly reduces the temperature of the outer surface of the mouthpiece 2', even upstream of the tubular portion. Without wishing to be bound by theory, it is hypothesized that this is due to the tubular portion directing the aerosol closer to the center of the mouthpiece 2', thus reducing the heat transfer from the aerosol to the outer surface of the mouthpiece 2'. In addition, it has been found that the body of material 4' filling the gap between the first tubular element 4a' and the second hollow tubular element 11 removes moisture from the aerosol generated by the aerosol-generating material 3 as the aerosol passes through the body of material 4' of the mouthpiece 2, causing the aerosol to feel cooler in the user's mouth.

[0121] The second hollow tubular element 11 preferably has an internal diameter greater than 3.0 mm. A smaller diameter may result in the velocity of the aerosol passing through the mouthpiece 2''' and reaching the consumer's mouth being increased more than desired such that the aerosol becomes too warm, for example reaching a temperature of more than 40° C. or even more than 45° C. More preferably, the second hollow tubular element 11 has an internal diameter greater than 3.1 mm, even more preferably greater than 3.5 mm or 3.6 mm. In one embodiment, the internal diameter of the second hollow tubular element 11 is about 3.9 mm.

[0122] By forming a tip comprising a body of material 4' with first and second hollow tubular elements 8, 11 embedded in opposing ends of the body of material 4', a tip is preferably obtained having a concave mouth end surrounded by a plug wrap of less thickness than would typically be required for such a structure, and a cavity for aerosol cooling at the upstream end of the tip, since both cavities are provided by the tubular elements embedded in the same body of material, eliminating the need for separate plug wraps and tie wraps for the different components. Not only does the reduction in the number of components simplify the manufacture of the tip, but it may be easier to form ventilation apertures in the body of material 4' at desired locations, since there is less thickness of plug wrap to pierce. A body of material 4' comprising both first and second hollow tubular elements 8, 11 and a capsule 15 embedded in the body of material 4' between the first and second hollow tubular elements 8, 11 preferably results in a component having the advantage of simplified manufacture, as described above in connection with FIG. 1.

[0123] In this example, the second hollow tubular element 11 has a thicker wall thickness than the first hollow tubular element 8 and is shorter than the first hollow tubular element 8, such that the cavity at the mouth end 2b of the mouthpiece provided by the second tubular element 11 is smaller than the cavity formed by the first tubular element 8. In other examples, the wall thickness of the hollow tubular element 8 may be thicker than the wall thickness of the second hollow tubular element 11. Advantageously, by selecting different wall thicknesses, inner diameters and / or lengths for the first and second hollow tubular elements 8, 11, respectively, it is possible to optimize the cavities provided at both ends of the body of material 4' for cooling and / or directing the aerosol through the mouthpiece as desired, based on the position of the first and second hollow tubular elements 8, 11 in the mouthpiece.

[0124] Preferably, the length of the second hollow tubular element 11 is less than about 20 mm. More preferably, the length of the second hollow tubular element 11 is less than about 15 mm. Even more preferably, the length of the second hollow tubular element 11 is less than about 10 mm. Additionally or alternatively, the length of the second hollow tubular element 11 is at least about 5 mm. Preferably, the length of the second hollow tubular element 11 is at least about 6 mm. In some preferred embodiments, the length of the second hollow tubular element 11 is about 5 mm to about 20 mm, more preferably about 6 mm to about 10 mm, even more preferably about 6 mm to about 8 mm, and most preferably about 6 mm, 7 mm, or about 8 mm. In this example, the length of the second hollow tubular element 11 is 6 mm.

[0125] In this example, the first and second hollow tubular elements 8, 11 each have the same outer diameter and are surrounded by a body 4' of material of the same thickness.

[0126] As mentioned above, different levels of crimping can be applied to the sheet material 14 forming different portions of the body of material 4'. In this example, a higher level of crimping is applied to the sheet material forming the mouth end portion of the body 4' in which the second hollow tubular element 11 is embedded, compared to the level of crimping applied to the sheet material 14 forming the portion of the body 4' in which the first hollow tubular element 8 and capsule 15 are embedded. Advantageously, the higher level of crimping of the sheet material 14 around the second hollow tubular element 11 can provide a more desirable stiffness of the tip at the mouth end 2b and an improved appearance when viewed from the mouth end of the tip.

[0127] The plug wrap 7 and / or tipping paper 5 may include a barrier coating to render the plug wrap and / or tipping paper material substantially impermeable to the liquid payload of the capsule 15.

[0128] 3 is a side cross-sectional view of an article 1'' for use with a non-combustion aerosol delivery system. Article 1'' comprises a mouthpiece 2'' that includes a body of material 4''. The body of material 4'' is substantially similar to the body of material 4', except that the body of material 4'' does not comprise a first hollow tubular element 8 upstream of the capsule 15. Instead, in this example, a cooling section 13 is provided upstream of the body of material 4'' to provide a cavity for aerosol cooling.

[0129] In this example, the body of material 4'' extends about 3.5 mm upstream of the capsule 15. Alternatively, the body of material 4'' may extend about 1 mm upstream of the capsule 15, or about 2 mm, about 3 mm, about 5 mm, about 6 mm, about 7 mm, about 8 mm, or about 10 mm upstream of the capsule 15.

[0130] In this example, the capsule 15 is spaced from the mouth end second hollow tubular element 11 by a gap of about 4.5 mm. Alternatively, the capsule 15 may be spaced from the second hollow tubular element 11 by a gap of 0.5 mm to 30 mm, or 1 mm to 20 mm, or 1.5 mm to 15 mm, or 2 mm to 10 mm. For example, the capsule 15 may be spaced from the second hollow tubular element 11 by a gap of about 3 mm, about 4 mm, about 5 mm, about 6 mm, about 7 mm, or about 8 mm. The separation of the capsule 15 from the second hollow tubular element 11 may be selected to balance the desired length and pressure drop of the components with providing a suitable amount of material within the body of material 4'' to absorb the liquid load of the capsule 15.

[0131] As described in relation to FIG. 2, various levels of crimping may be applied to the sheet material 14 forming the body of material 4″. In this example, a higher level of crimping is applied to the sheet material forming the section of the body of material 4″ at the mouth end. The body of material 4″ may have a higher density in a portion closer to the downstream end of the body of material 4″ than a portion closer to the upstream end. For example, a portion of the body of material 4″ within 3 mm of a longitudinal end of the body 4″ may have a higher density than a portion upstream of the 3 mm portion. A portion of the body formed from a sheet material having a higher level of crimping and a higher density than another portion of the body may have a more attractive appearance to consumers. Preferably, such a section may be provided at the longitudinal end of the body 4″ to give the body 4″ an attractive longitudinal end appearance to consumers, while the upstream portion of the component may have a lower density to limit the amount of sheet material 14 required to form the body of material 4″ and to prevent the body 4″ from having an undesirably high pressure drop. The density of a particular section of body 4'' can be measured by separating said section from the remainder of the body and the surrounding plug wrap and / or tipping paper (e.g., by cutting the body) and removing any embedded objects, but including any additives added to the sheet material 14.

[0132] In this example, the cooling section 13 defines an air gap within the mouthpiece that acts as a cooling segment, as described with respect to the hollow tubular element 8. The air gap provides a chamber through which the heated volatile components generated by the aerosol-generating material 3 flow. The cooling section 13 is hollow to provide a chamber for aerosol accumulation, but is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacture and while the article 1 is in use. The cooling section 13 provides a physical displacement between the aerosol-generating material 3 and a downstream portion of the mouthpiece 2.

[0133] Preferably, the internal volume of the cooling section 13 is 100 mm 3It has been found that providing a cavity of at least this volume allows for improved aerosol formation. Such a cavity size provides sufficient space within the mouthpiece 2 to allow heated volatile components to cool, and thus expose the aerosol-generating material 3 to higher temperatures than the volatile components might otherwise be able to do which could result in an overly warm aerosol. More preferably, the mouthpiece 2'' is greater than 120 mm. 3 greater than 150 mm, and even more preferably 3 In some examples, the internal cavity has a volume greater than about 110 mm, allowing for further improvement of the aerosol. 3 ~ approx. 600mm 3 , preferably about 120 mm 3 ~ approx. 500mm 3 It has a volume of.

[0134] The cavity may be configured to provide a temperature differential of at least 40 degrees Celsius between the heated volatile components entering the first upstream end of the cavity and the heated volatile components exiting the second downstream end of the cavity. The cavity may preferably be configured to provide a temperature differential of at least 60 degrees Celsius, preferably at least 80 degrees Celsius, and more preferably at least 100 degrees Celsius, between the heated volatile components entering the first upstream end of the cavity and the heated volatile components exiting the second downstream end of the cavity. This temperature differential across the length of the cavity may protect temperature sensitive elements of the mouthpiece downstream of the cavity from the high temperatures of the aerosol-generating material 3 as it heats up.

[0135] Preferably, the length of the cooling section 13 is less than about 50 mm. More preferably, the length of the cooling section 13 is less than about 40 mm. Even more preferably, the length of the cooling section 13 is less than about 35 mm. Additionally or alternatively, the length of the cooling section 13 is preferably at least about 10 mm. Preferably, the length of the cooling section 13 is at least about 15 mm.

[0136] In some preferred embodiments, the length of cooling section 13 is about 15 mm to about 35 mm, more preferably about 20 mm to about 30 mm, even more preferably about 23 mm to about 27 mm, and most preferably about 25 mm. In this example, the length of cooling section 13 is 25 mm.

[0137] In this example, the cooling section 13 is formed from multiple layers of paper that are parallel wrapped with seams butted together to form a hollow tube. In this example, the first and second paper layers are provided in a two-ply tube, but in other examples, three, four, or more paper layers can be used to form a three, four, or more ply tube. Other constructions can be used, such as spirally wrapped layers of paper, cardboard tubes, tubes formed using a paper-mache type process, or molded or extruded plastic tubes.

[0138] In some embodiments, the cooling section 13 preferably has a wall thickness of at least about 50 μm up to about 1 mm, preferably 100 μm to 500 μm, more preferably 100 μm to 150 μm. In the present example, the cooling section 13 has a wall thickness of about 150 μm. The "wall thickness" of the tubular element corresponds to the thickness of the wall of the tubular element in the radial direction, not including the surrounding material in which the tubular element is embedded. This can be measured, for example, using a caliper.

[0139] In some embodiments, the wall thickness of the cooling section 13 is at least 50 microns, preferably at least 75, 80, 85, 90, 95, 100, or 105 microns. In some embodiments, the wall thickness of the tubular elements is at least 100 or 110 microns.

[0140] In some embodiments, the wall thickness of the cooling section 13 is less than 1000 microns, preferably less than 500 microns.

[0141] In some embodiments, the air permeability of the wall material of the cooling section 13 is at least 100 Coresta units, preferably at least 500 or 1000 Coresta units.

[0142] It has been found that the relatively high air permeability of the cooling section 13 increases the amount of heat transferred from the aerosol to the tubular portion, thus reducing the temperature of the aerosol. It has also been found that the air permeability of the cooling section 13 increases the amount of moisture transferred from the aerosol to the tubular portion, thereby improving the feel of the aerosol in the user's mouth. The high air permeability of the cooling section 13 also means that air entering the body 4 portion of material surrounding the tubular portion can pass through the walls of the cooling section 13 into the aerosol stream without having to cut and pass air holes through the outer plug wrap(s) and tipping paper, the material of the body 4, and all of the tubular elements forming the tubular portion, thereby reducing manufacturing complexity.

[0143] The cooling section 13 and the body of material 4 ″ are connected by a second plug wrap 9 .

[0144] According to this disclosure, "aerosol delivery system" includes both combustion and non-combustion aerosol delivery systems.

[0145] FIG. 4 is a cross-sectional side view of a further article 1''' for use with a non-combustion aerosol delivery system. Article 1''' comprises a tip 2''', which is substantially the same as tip 2, except in this example hollow tubular element 8 is replaced by tubular elements 4a, 4b. In this example, tubular elements 4a, 4b form a cavity for aerosol cooling, as described for hollow tubular element 8. Tubular elements 4a, 4b are embedded within a body of material 4''' and are circumferentially surrounded by the material forming body 4'''. Tubular elements 4a, 4b may have any suitable specifications, as described for the first and second hollow tubular elements 8, 11. In this example, tubular elements 4a, 4b have the same specifications. Alternatively, the specifications of tubular element 4a may differ from those of tubular element 4b, for example to provide a cavity with regions of different internal diameters or porosity.

[0146] In the examples of Figures 2 and 4, the provision of a capsule 15 within the body of material 4, 4''' may be optional.

[0147] In this example, the first tubular element 4a is positioned at a longitudinal end of the body of material 4''' and extends to said longitudinal end of the body. The second tubular element 4b is positioned downstream of the first tubular element 4a and the body of material 4''' extends beyond the second tubular element 4b such that the second tubular element is surrounded both circumferentially and longitudinally by the first body of material 4.

[0148] In this example, the first and second tubular elements 4a, 4b are separated by a gap of about 1 mm so as to form an effectively continuous tubular section. In embodiments in which the first and second tubular elements 4a, 4b are intended to form an effectively continuous tubular section, the tubular elements may be suitably separated by a gap of 0.5 mm to 6 mm, for example 1 mm to 3 mm, or 2 mm to 5 mm. In this example, the tubular section formed by the first and second tubular elements 4a, 4b defines an air gap in the mouthpiece that acts as a cooling segment. In this example, the tubular section comprises first and second tubular elements 4a, 4b, each having a length of 11 mm and separated by a gap of 1 mm.

[0149] In another example, the hollow tubular element 11 may be similarly formed by a first and a second tubular element (not shown).

[0150] According to the present disclosure, a "combustion-based" aerosol delivery system is a system in which, during use, a constituent aerosol-generating material (or a component thereof) of the aerosol delivery system is combusted or burned to facilitate delivery of at least one substance to a user.

[0151] In some embodiments, the delivery system is a combustion aerosol delivery system, such as a system selected from the group consisting of a cigarette, a cigarillo, and a cigar.

[0152] In some embodiments, the present disclosure relates to components for use in combustion aerosol delivery systems, such as aerosol modifier-releasing components, such as filters, filter rods, filter segments, tobacco rods, spills, capsules, threads, or beads, or papers, such as plug wrap, tipping paper, or cigarette paper.

[0153] 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.

[0154] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0155] 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.

[0156] 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.

[0157] 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 in the form of, for example, a solid, liquid, or gel, 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, for example, tobacco or a non-tobacco product.

[0158] 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.

[0159] 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.

[0160] 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.

[0161] In some embodiments, the non-combustion aerosol delivery system may include an area for receiving a consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0162] 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.

[0163] In some embodiments, the substance to be delivered comprises an active agent.

[0164] As used herein, an active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. An active substance may be selected from, for example, dietary supplements, nootropics, psychotropic drugs. An active substance may be naturally occurring or synthetically obtained. An active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. An active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another botanical substance.

[0165] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12. As described herein, the active material may include or be derived from one or more botanical materials or their components, derivatives, or extracts. As used herein, the term "botanical material" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, or shells. Alternatively, the material may include synthetically derived active compounds that occur naturally in the botanical material. 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.

[0166] 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.

[0167] 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.

[0168] 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.

[0169] In some embodiments, the substance to be delivered comprises a flavor.

[0170] 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.

[0171] 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.

[0172] 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.

[0173] An aerosol-generating material is a material that can generate an aerosol when, for example, heated, irradiated, or energized in any other way. An aerosol-generating material can be in the form of, for example, a solid, liquid, or gel, which may or may not contain actives and / or flavorings. In some embodiments, an aerosol-generating material can include an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, an amorphous solid can be a dry gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within the amorphous solid. In some embodiments, an aerosol-generating material can 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.

[0174] 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.

[0175] 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.

[0176] 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.

[0177] The material may be on or in a support to form a substrate. The support may be or comprise, for example, paper, card, paperboard, cardboard, reconstituted material, plastic material, ceramic material, composite material, glass, metal, or metal alloy. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded in the material. In some alternative embodiments, the susceptor is on one or both sides of the material.

[0178] 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.

[0179] 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.

[0180] An aerosol modifier is a substance 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-releasing component operable to selectively release the aerosol modifier.

[0181] 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.

[0182] 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.

[0183] Articles, for example rod-shaped articles, are often designated according to the length of the product as "regular" (typically in the range of 68-75 mm, e.g., about 68 mm to about 72 mm), "short" or "mini" (68 mm or less), "king size" (typically in the range of 75-91 mm, e.g., about 79 mm to about 88 mm), "long" or "super king" (typically in the range of 91-105 mm, e.g., about 94 mm to about 101 mm), and "ultra long" (typically in the range of about 110 mm to about 121 mm).

[0184] They are also named according to the circumference of the product: "Regular" (approximately 23-25mm), "Wide" (over 25mm), "Slim" (approximately 22-23mm), "Demi-Slim" (approximately 19-22mm), "Super Slim" (approximately 16-19mm), and "Micro Slim" (less than approximately 16mm).

[0185] Thus, a king size super slim format article, for example, would have a length of about 83 mm and a circumference of about 17 mm.

[0186] Each format may be produced with a different length of tip. The length of the tip will be about 30mm to 50mm. The tipping paper will connect the tip to the aerosol-generating material such that the tipping paper covers the tip and overlaps the aerosol-generating material, for example in the form of a rod of substrate material, connecting the tip to the rod, and will usually have a length longer than the tip, for example 3 to 10mm longer.

[0187] The articles described herein, as well as the aerosol-forming materials and mouthpieces of the articles, can be made in any of the formats described above, but are not limited to these.

[0188] As used herein, the terms "upstream" and "downstream" are relative terms defined with respect to the direction of the mainstream aerosol being drawn through an article or device in use.

[0189] 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.

[0190] As used herein, the term "tobacco material" refers to any material that contains tobacco or a derivative or substitute thereof. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. 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.

[0191] FIG. 5 shows an example of a non-combustion aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium / material, such as an aerosol-generating material 3 of any of the articles 1, 1', 1'', 1''', 1'''' described herein. Generally, the device 100 can be used to heat a replaceable article 110 comprising an aerosol-generating medium, such as any of the articles 1, 1', 1'', 1''', 1'''' described herein, to generate an aerosol or other inhalable medium that is inhaled by a user of the device 100. The device 100 and the replaceable article 110 together form a system.

[0192] The device 100 comprises a housing 102 (in the form of an outer cover) that surrounds and contains the various components of the device 100. The device 100 has an opening 104 in one end through which an item 110 can be inserted for heating by a heating assembly. In use, the item 110 can be fully or partially inserted into the heating assembly where it can be heated by one or more components of the heater assembly.

[0193] When article 110 is inserted into device 100, the minimum distance between one or more components of the heater assembly and tubular body 4a of article 110 may be in the range of 3 mm to 10 mm, for example 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm.

[0194] The device 100 in this example includes a first end member 106 that includes a lid 108 that is movable relative to the first end member 106 to close the opening 104 when the article 110 is not in place. In Figure 5, the lid 108 is shown in an open configuration, but the lid 108 may be moved to a closed configuration. For example, a user may slide the lid 108 in the direction of arrow "B."

[0195] Device 100 may also include user-operable controls 112, such as buttons or switches that, when pressed, operate device 100. For example, a user may turn device 100 on by operating switch 112.

[0196] The device 100 may also include an electrical component, such as a socket / port 114 that can accept a cable for charging a battery of the device 100. For example, the socket 114 may be a charging port, such as a USB charging port.

[0197] Figure 6 depicts the device 100 of Figure 5 with the outer cover 102 removed and without the article 110 present. The device 100 defines a longitudinal axis 134.

[0198] As shown in FIG. 6, the first end member 106 is disposed at one end of the device 100 and the second end member 116 is disposed at an opposite end of the device 100. The first and second end members 106, 116 together at least partially define an end surface of the device 100. For example, the bottom surface of the second end member 116 at least partially defines the bottom surface of the device 100. An edge of the outer cover 102 may also define a portion of the end surface. In this example, the lid 108 also defines a portion of the top surface of the device 100.

[0199] The end of the device closest to the opening 104 may be known as the proximal end (or mouth end) of the device 100, as it is closest to the user's mouth during use. During use, a user inserts an article 110 into the opening 104 and operates a user control 112 to initiate heating of the aerosol-generating material and inhale the aerosol generated within the device. This causes the aerosol to flow through the device 100 along a flow path toward the proximal end of the device 100.

[0200] The other end of the device furthest from opening 104 may be known as the distal end of device 100 because, in use, it is the end farthest from a user's mouth. When a user inhales the aerosol generated within the device, the aerosol flows from the distal end of device 100.

[0201] The device 100 further comprises a power source 118. The power source 118 can be, for example, a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (such as lithium ion batteries), nickel batteries (such as nickel cadmium batteries), and alkaline batteries. The battery is electrically coupled to the heating assembly to provide power to heat the aerosol-generating material as needed under the control of a controller (not shown). In this example, the battery is connected to a central support 120 that holds the battery 118 in place.

[0202] The device further comprises at least one electronic module 122. The electronic module 122 may comprise, for example, a printed circuit board (PCB). The PCB 122 may support at least one controller, such as a processor, and a memory. The PCB 122 may also comprise one or more electrical tracks for electrically connecting various electronic components of the device 100 together. For example, a battery terminal may be electrically connected to the PCB 122 so that power can be distributed throughout the device 100. The socket 114 may also be electrically coupled to a battery via the electrical tracks.

[0203] In the exemplary device 100, the heating assembly is an induction heating assembly, comprising various components for heating the aerosol-generating material of the article 110 via an induction heating process. Induction heating is a process of heating an electrically conductive object (such as a susceptor) by electromagnetic induction. The induction heating assembly may comprise an induction element, e.g., one or more inductor coils, and a device for passing a variable current, such as an alternating current, through the induction element. The variable current in the induction element generates a varying magnetic field. The varying magnetic field penetrates a susceptor suitably positioned relative to the induction element, generating eddy currents inside the susceptor. The susceptor has an electrical resistance to the eddy currents, and thus the flow of eddy currents against this resistance causes the susceptor to heat by Joule heating. If the susceptor comprises a ferromagnetic material, such as iron, nickel, or cobalt, heat may also be generated by magnetic hysteresis losses in the susceptor, i.e., by the change in orientation of magnetic dipoles in the magnetic material as a result of alignment with the varying magnetic field. Induction heating generates heat inside the susceptor, allowing for rapid heating compared to, for example, heating by conduction, and does not require any physical contact between the induction heater and the susceptor, allowing for greater flexibility in design and application.

[0204] The induction heating assembly of the exemplary device 100 includes a susceptor structure 132 (referred to herein as a "susceptor"), a first inductor coil 124, and a second inductor coil 126. The first and second inductor coils 124, 126 are made from a conductive material. In this example, the first and second inductor coils 124, 126 are made from a Litz wire / cable that is helically wound to provide the helical inductor coils 124, 126. The Litz wire includes multiple individual wires that are individually insulated and twisted together to form a single wire. The Litz wire is designed to reduce skin effect losses in the conductor. In the exemplary device 100, the first and second inductor coils 124, 126 are made from copper Litz wire with a rectangular cross section. In other examples, the Litz wire can have other shaped cross sections, such as circular.

[0205] The first inductor coil 124 is configured to generate a first varying magnetic field for heating a first section of the susceptor 132, and the second inductor coil 126 is configured to generate a second varying magnetic field for heating a second section of the susceptor 132. In this example, the first inductor coil 124 is adjacent to the second inductor coil 126 in a direction along a longitudinal axis 134 of the device 100 (i.e., the first and second inductor coils 124, 126 do not overlap). The susceptor structure 132 may comprise a single susceptor, or two or more separate susceptors. Ends 130 of the first and second inductor coils 124, 126 may be connected to the PCB 122.

[0206] It will be appreciated that the first and second inductor coils 124, 126 may have at least one characteristic that differs from one another in some examples. For example, the first inductor coil 124 may have at least one characteristic that differs from the second inductor coil 126. More specifically, in one example, the first inductor coil 124 may have a different inductance value than the second inductor coil 126. In FIG. 7, the first and second inductor coils 124, 126 are of different lengths such that the first inductor coil 124 is wound over a smaller section of the susceptor 132 than the second inductor coil 126. Thus, the first inductor coil 124 may include a different number of turns than the second inductor coil 126 (assuming that the spacing between the individual turns is substantially the same). In yet another example, the first inductor coil 124 may be made of a different material than the second inductor coil 126. In some examples, the first and second inductor coils 124, 126 may be substantially identical.

[0207] In this example, the first inductor coil 124 and the second inductor coil 126 are wound in opposite directions. This can be useful when the inductor coils are active at different times. For example, first, the first inductor coil 124 can operate to heat a first section / portion of the article 110, and later, the second inductor coil 126 can operate to heat a second section / portion of the article 110. Winding the coils in opposite directions helps to reduce current induced in inactive coils when used with certain types of control circuits. In FIG. 6, the first inductor coil 124 is a right-handed helical spiral and the second inductor coil 126 is a left-handed helical spiral. However, in another embodiment, the inductor coils 124, 126 can be wound in the same direction, or the first inductor coil 124 can be a left-handed helical spiral and the second inductor coil 126 can be a right-handed helical spiral.

[0208] The susceptor 132 in this example is hollow and thus defines a receptacle in which the aerosol-generating material is received. For example, the article 110 can be inserted into the susceptor 132. In this example, the susceptor 120 is tubular with a circular cross-section.

[0209] The susceptor 132 may be made from one or more materials. Preferably, the susceptor 132 comprises carbon steel with a coating of nickel or cobalt.

[0210] In some examples, the susceptor 132 may include at least two materials that can be heated at two different frequencies for selective aerosolization of at least two materials. For example, a first section of the susceptor 132 (heated by the first inductor coil 124) may include a first material, and a second section of the susceptor 132 (heated by the second inductor coil 126) may include a second, different material. In another example, the first section may include a first and a second material, and the first and second materials may be heated differently based on the operation of the first inductor coil 124. The first and second materials may be adjacent along an axis defined by the susceptor 132 and may form different layers within the susceptor 132. Similarly, the second section may include a third and a fourth material, and the third and fourth materials may be heated differently based on the operation of the second inductor coil 126. The third and fourth materials may be adjacent along an axis defined by the susceptor 132 and may form different layers within the susceptor 132. The third material may be, for example, the same as the first material and the fourth material may be the same as the second material. Alternatively, each of the materials may be different. The susceptor may include, for example, carbon steel or aluminum.

[0211] 6 further comprises an insulating member 128, which may be generally tubular and may at least partially surround the susceptor 132. The insulating member 128 may be constructed from any insulating material, such as, for example, plastic. In this particular example, the insulating member is constructed from polyetheretherketone (PEEK). The insulating member 128 serves to insulate the various components of the device 100 from heat generated within the susceptor 132.

[0212] The insulating member 128 can also fully or partially support the first and second inductor coils 124, 126. For example, as shown in FIG. 7, the first and second inductor coils 124, 126 are positioned about the insulating member 128 and are in contact with a radially outer surface of the insulating member 128. In some examples, the insulating member 128 does not abut the first and second inductor coils 124, 126. For example, there may be a small gap between the outer surface of the insulating member 128 and the inner surfaces of the first and second inductor coils 124, 126.

[0213] In a particular example, the susceptor 132 , the insulating member 128 , and the first and second inductor coils 124 , 126 are coaxial about a central longitudinal axis of the susceptor 132 .

[0214] 7 shows a side view of device 100 in partial cross-section, in this example with outer cover 102 present. The rectangular cross-sectional shapes of first and second inductor coils 124, 126 are more clearly visible.

[0215] The device 100 further includes a support 136 that engages one end of the susceptor 132 to hold the susceptor 132 in place. The support 136 is connected to the second end member 116.

[0216] The device may also include a second printed circuit board 138 associated with the control element 112 .

[0217] The device 100 further includes a second lid / cap 140 and a spring 142 disposed toward a distal end of the device 100. The spring 142 allows the second lid 140 to be opened to provide access to the susceptor 132. A user can open the second lid 140 to clean the susceptor 132 and / or the support 136.

[0218] The device 100 further comprises an expansion chamber 144 extending away from the proximal end of the susceptor 132 towards the opening 104 of the device. Located at least partially within the expansion chamber 144 is a retaining clip 146 for abutting and retaining the article 110 when the article 110 is received within the device 100. The expansion chamber 144 is connected to the end member 106.

[0219] FIG. 8 is an exploded view of the device 100 of FIG. 7 with the outer cover 102 omitted.

[0220] FIG. 9A depicts a cross-section of a portion of the device 100 of FIG. 8. FIG. 9B depicts an enlarged view of a region of FIG. 9A. FIGS. 10A and 10B show an article 110 received within a susceptor 132, with the article 110 sized so that an outer surface of the article 110 abuts an inner surface of the susceptor 132. This ensures that heating occurs most efficiently. The article 110 in this example comprises an aerosol-generating material 110a. The aerosol-generating material 110a is positioned within the susceptor 132. The article 110 may also comprise other components, such as a filter, packaging material, and / or cooling structures.

[0221] 9B shows that the outer surface of the susceptor 132 is spaced from the inner surfaces of the inductor coils 124, 126 by a distance 150 measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 150 is about 3 mm to 4 mm, about 3 to 3.5 mm, or about 3.25 mm.

[0222] 9B further shows that the outer surface of the insulating member 128 is spaced from the inner surfaces of the inductor coils 124, 126 by a distance 152 measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 152 is about 0.05 mm. In another example, the distance 152 is substantially 0 mm such that the inductor coils 124, 126 abut and contact the insulating member 128.

[0223] In one example, the susceptor 132 has a wall thickness 154 of about 0.025 mm to 1 mm, or about 0.05 mm.

[0224] In one example, the susceptor 132 has a length of about 40 mm to 60 mm, about 40 mm to 45 mm, or about 44.5 mm.

[0225] In one example, the insulating member 128 has a wall thickness 156 of about 0.25 mm to 2 mm, 0.25 mm to 1 mm, or about 0.5 mm.

[0226] A method of manufacturing a component for an article for use in an aerosol delivery system may include providing a supply of a first sheet material having a porosity of at least 200 CU; forming an inner tubular element from the first sheet material; providing a supply of cellulosic material and a supply of a second sheet material; gathering the cellulosic material around the inner tubular element; and wrapping the gathered cellulosic material with the second sheet material to form a tubular body of cellulosic material sandwiched between the inner and outer sheet materials.

[0227] An apparatus configured to manufacture the components described herein may include a first feeding mechanism for a first sheet material, a first garniture assembly for forming an inner tubular element from the first sheet material, a second feeding mechanism for feeding cellulosic material, a third feeding mechanism for the second sheet material, and a second garniture assembly for gathering the cellulosic material around the inner tubular element and wrapping the gathered cellulosic material with the second sheet material to form a tubular body of cellulosic material sandwiched between the inner and outer sheet materials.

Claims

1. 1. A component for use in an aerosol delivery system or for an article for use as an aerosol delivery system, the component comprising a tubular body of cellulosic material sandwiched between inner and outer sheet materials, the inner sheet material having an air permeability of at least 200 CU.

2. The component of claim 1 , wherein the inner sheet material is a porous sheet material.

3. The component of claim 2 , wherein the inner sheet material is provided with perforations.

4. 2. The component of claim 1, wherein said inner sheet material is a non-porous sheet material and said air permeability is provided by perforations formed in said material.

5. 5. The component according to any one of the preceding claims, wherein the air permeability of the inner sheet material is greater than 500 CU or greater than 1000 CU.

6. A component according to any one of the preceding claims, wherein the inner and / or outer sheet material is formed from paper.

7. The component according to any one of the preceding claims, wherein the tubular body has a wall thickness of between 1 mm and 4 mm.

8. The component according to any one of the preceding claims, wherein the inner sheet material has a basis weight of from 40gsm to 100gsm.

9. The component of any one of the preceding claims, wherein the outer sheet material has a basis weight of from 20 gsm to 100 gsm, or from 20 gsm to 80 gsm, or from 30 gsm to 70 gsm.

10. The component according to any one of the preceding claims, wherein the outer sheet material is provided with perforations.

11. The component of any one of claims 1 to 10, further comprising a cylindrical body of cellulosic material.

12. The component of any one of claims 1 to 11, wherein the cellulosic material is paper, optionally the paper being formed from wood pulp.

13. 13. The component of claim 11 or 12, wherein at least one object is embedded within a cylindrical body of material.

14. The component of claim 13 , wherein the at least one object comprises a tubular element and / or an aerosol modifier-releasing component.

15. The component of claim 14 , wherein the at least one object comprises first and second tubular elements.

16. 16. The component of claim 15, wherein the first and second tubular elements are separated by a gap of between 0.5 mm and 6 mm, or between 1 mm and 3 mm, or between 2 mm and 5 mm.

17. 16. The component of claim 15, wherein the first and second tubular elements are separated by a gap of 5 mm to 15 mm, or 6 mm to 12 mm, or about 6 mm, about 7 mm, about 8 mm, or about 9 mm.

18. The component of claim 17 , wherein the body extends into the gap.

19. 19. The component of any one of claims 1 to 18, wherein the tubular body of cellulosic material comprises gathered sheet material, the gathered sheet material comprising a notched portion.

20. An article for use in or as an aerosol delivery system, said article comprising a component according to any one of claims 1 to 19.

21. 1. A method of manufacturing a component for an article for use in an aerosol delivery system, the method comprising: providing a supply of a first sheet material having a porosity of at least 200 CU; forming an inner tubular element from the first sheet material; providing a supply of cellulosic material and a supply of a second sheet material; gathering the cellulosic material around the inner tubular element; wrapping the gathered cellulosic material with the second sheet material to form a tubular body of cellulosic material sandwiched between inner and outer sheet materials; A method comprising:

22. An apparatus configured to manufacture a component according to any one of claims 1 to 19, comprising: a first feed mechanism for a first sheet material; a first garniture assembly for forming an inner tubular element from the first sheet material; a second feed mechanism for feeding the cellulosic material; and a third feed mechanism for the second sheet material; and a second garniture assembly for gathering the cellulosic material around the inner tubular element and wrapping the gathered cellulosic material with the second sheet material to form a tubular body of cellulosic material sandwiched between the inner and outer sheet materials; An apparatus comprising:

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