Aerosol delivery systems and articles for use in aerosol delivery systems

Abstract

The present disclosure relates to an aerosol delivery system comprising an aerosol delivery device including an article including an aerosol-generating material and a first coupling portion, a second coupling portion, and a zone configured to receive the article. The first and second coupling portions are configured such that the first coupling portion is magnetically attracted to the second coupling portion when the article is received in the zone. The present disclosure also relates to an article for the aerosol delivery device and a package of the article.

Description

[Technical field]

[0001] The present disclosure relates to an article for an aerosol delivery system and an aerosol delivery device. The present disclosure also relates to packaging for the article. [Background technology]

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

[0003] According to some embodiments described herein, an aerosol delivery system is provided, the aerosol delivery system comprising: an aerosol delivery device including an article comprising an aerosol-generating material and a first binding portion; a second binding portion; and a zone configured to receive the article, the first and second binding portions being configured such that when the article is received in the zone, the first binding portion is magnetically attracted to the second binding portion.

[0004] In some embodiments, the zone is an aerosol-generation zone, and may optionally be a heating zone.

[0005] According to some embodiments described herein, an aerosol delivery system is provided, the aerosol delivery system comprising: an aerosol delivery device comprising an article comprising an aerosol generating material and a first bonding portion; a second bonding portion; and a heating zone configured to receive the article and heat the aerosol generating material, the first and second bonding portions being configured such that when the article is received in the heating zone, the first bonding portion is magnetically attracted to the second bonding portion.

[0006] In some embodiments, one of the first and second coupling portions comprises a magnet and the other of the first and second coupling portions comprises a ferromagnetic material and / or a second magnet.

[0007] In some embodiments, the other of the first and second binding portions comprises a ferrous material, which may be, for example, iron or steel.

[0008] In some embodiments, the second coupling portion comprises a second magnet. In some embodiments, the first and / or second magnet are permanent magnets.

[0009] In one embodiment, the second binding portion comprises a ferromagnetic material, optionally an iron-based material.

[0010] In some embodiments, one second bonding portion is provided at the end of a zone (or a heating zone, in some embodiments, including a heating zone).

[0011] In some embodiments, one of the aerosol-providing devices includes a chamber that contains a zone (or a heating zone).

[0012] In some embodiments, one of the articles protrudes from the end of the zone (or heating zone).

[0013] In some embodiments, one of the aerosol providing devices includes a heater at least partially surrounding a zone (or heating zone), preferably the heater including a magnetic field generator configured to generate a varying magnetic field to inductively heat the heating material.

[0014] In some embodiments, the aerosol delivery system is an e-cigarette (also known as a vaporizer or electronic nicotine delivery system (END)).

[0015] In some embodiments, the aerosol provider comprises a mouthpiece, preferably detachable from other parts of the aerosol provider to facilitate access to the zone (or heating zone), such that an article can be inserted or removed from the zone (or heating zone) by removing the mouthpiece.

[0016] In some embodiments, one mouthpiece includes a second binding portion.

[0017] In some embodiments, one of the aerosol providers comprises a body that includes a second binding portion.

[0018] In some embodiments, one of the first and second mating portions is configured such that when the article is received in the zone (or the heated zone), the article is axially urged towards the second mating portion.

[0019] In some embodiments, the first bonding portion contacts the second bonding portion when the article is received into the zone (or heated zone), while in other embodiments, the first bonding portion does not contact the second bonding portion when the article is received into the zone (or heated zone).

[0020] The first and second coupling portions may together form a magnetic coupling of the aerosol delivery system.

[0021] According to the present disclosure, there is also provided an article for use with an aerosol delivery device, the aerosol delivery device having a zone configured to receive the article, the article comprising an aerosol generating material and a first coupling portion configured to be magnetically attracted to a second coupling portion of the aerosol delivery device when the article is received in the zone.

[0022] In some embodiments, the zone is an aerosol-generation zone, and may optionally be a heating zone.

[0023] According to the present disclosure, there is also provided an article for use with an aerosol provision device, the aerosol provision device having a heating zone configured to receive the article, the article comprising an aerosol generating material and a first coupling portion configured to be magnetically attracted to a second coupling portion of the aerosol provision device when the article is received in the heating zone.

[0024] In some embodiments, one of the first coupling portions comprises a magnet.

[0025] In some embodiments, one of the first binding portions comprises a ferromagnetic material.

[0026] In some embodiments, the first binding portion comprises an iron-based material.

[0027] In some embodiments, one first coupling portion is provided over only a portion of the axial length of the article.

[0028] In some embodiments, one first coupling portion is provided along substantially the entire axial length of the article.

[0029] In some embodiments, the first coupling portion is provided at the first and / or second end of the article.

[0030] In some embodiments, one of the first binding moieties is embedded within the article, preferably within the aerosol-forming material of the article.

[0031] In some embodiments, the first attachment portion is integral to the article, hi some embodiments, the first attachment portion is permanently embedded in the article.

[0032] In some embodiments, one of the first bonding portions includes a heating material that is heatable by permeation by a varying magnetic field.

[0033] In some embodiments, one of the article and / or the aerosol-providing device further comprises a heating material in addition to the first binding portion, the heating material being heatable by permeation by a varying magnetic field.

[0034] In some embodiments, the heating material is separate and / or distinct from the first binding portion.

[0035] In some embodiments, one of the aerosol-generating materials at least partially surrounds the first binding moiety, preferably surrounds the first binding moiety.

[0036] In some embodiments, the first coupling portion is located along at least a portion of the central axis of the article.

[0037] In some embodiments, the aerosol forming material comprises nicotine.

[0038] In some embodiments, one of the aerosol-forming materials comprises, consists of, or consists essentially of tobacco.

[0039] In some embodiments, the aerosol-forming material does not include tobacco. The aerosol-forming material may be substantially free of tobacco.

[0040] In some embodiments, the aerosol-forming material is a liquid.

[0041] In some embodiments, the article comprises a reservoir that contains the aerosol-generating material. The article may comprise a cartridge that comprises the reservoir. In one such embodiment, the article comprises a cartridge that contains nicotine (e.g., a liquid or powder containing nicotine) in the reservoir of the cartridge.

[0042] In some embodiments, the aerosol-forming material is non-liquid (e.g., solid) or liquid, hi some embodiments, the aerosol-forming material may be a powder.

[0043] In some embodiments, the article has an axial length of up to 36 mm, preferably up to 34 mm, 32 mm, 30 mm, 28 mm, 26 mm, 24 mm or 23 mm.

[0044] In some embodiments, one of the first coupling portions includes one or more openings to facilitate the flow of gas through the first coupling portion.

[0045] In some embodiments, the article comprises a plurality of first coupling portions and / or the aerosol delivery device comprises a plurality of second coupling portions.

[0046] In some embodiments, the article comprises multiple regions of aerosol-forming material.

[0047] In some embodiments, the article includes a substrate and the regions of aerosol-forming material are attached to the substrate.

[0048] In some embodiments, the substrate is substantially planar.

[0049] In some embodiments, the substrate comprises a metal, such as aluminum.

[0050] In some embodiments, the aerosol delivery system is configured to initiate aerosol generation from at least one of the multiple regions of the aerosol-generating material after initiating aerosol generation from another region of the multiple regions of the aerosol-generating material.

[0051] In some embodiments, the system is configured to initiate heating of at least one of the multiple regions of the aerosol-generating material after initiating heating of another of the multiple regions of the aerosol-generating material.

[0052] In some embodiments, the system includes multiple heaters, each configured to heat a respective one of the regions of the aerosol-generating material.

[0053] In some embodiments, the package is sealed.

[0054] In some embodiments, the aerosol delivery system is a non-combustion aerosol delivery system.

[0055] In some embodiments, the article does not include plastic.

[0056] In some embodiments, the article does not include cellulose acetate.

[0057] In some embodiments, the article comprises an aerosol-forming material.

[0058] According to the present disclosure, there is also provided an aerosol provision device comprising a zone configured to receive an article containing an aerosol generating material and a holder for securing the article within the zone, the holder configured to engage with the article, the holder configured to be removably connected to a component of the aerosol provision device.

[0059] In some embodiments, the zone is an aerosol-generation zone, and may optionally be a heating zone.

[0060] In some embodiments, the holder is configured to be removably connected to a component of the aerosol provider to secure the article within the zone.

[0061] Optionally, in some embodiments, the holder is configured to be removably connected to a component of the aerosol delivery device, and in use, when the holder engages the article, the holder and the article may be removably connected to the component, and the user may remove the holder and the article together from the component. For example, the article may comprise a rod containing an aerosol-generating material (e.g., tobacco), the rod being connected to the component by the holder. In another example, the article may comprise a reservoir of an aerosol-generating material (e.g., a reservoir containing nicotine and glycerol), the reservoir being connected to the component by the holder.

[0062] The holder may engage with the article, for example, by mechanically or magnetically coupling to the article. For example, the holder can be mechanically coupled to the article (which may optionally include, for example, a rod containing an aerosol-generating material or a reservoir containing an aerosol-generating material) by clipping to the article, clamping or gripping the article, having a portion (e.g., a pin) that is inserted into the article, coupling to the article via a bayonet connection, or coupling to the article via threads on the holder and the article. Additionally or alternatively, one or both of the article or the holder may include a magnet to couple the article and the holder to each other. Once the holder is coupled to the article, the holder and the article can be removably coupled to a component of the device to secure the article within a zone (which may be an aerosol-generating zone, such as a heating zone), and a user can detach the holder and the article together from the component (while the article is still coupled to the holder) to remove the article from the zone.

[0063] In some embodiments, the article is a consumable item.

[0064] According to the present disclosure, an aerosol provision device is also provided, the aerosol provision device comprising a zone configured to receive an article containing an aerosol-generating material, and a holder for securing the article within the zone, the holder configured to engage with the article, and wherein, in use, when the holder engages with the article, the holder is configured to be removably connected to a component of the aerosol provision device such that the holder and the article can be removably connected to the component, and a user can remove the holder and the article together from the component.

[0065] In some embodiments, in use, when the holder engages the article, the holder and article can be removably connected to the component such that the article is held in a predetermined position relative to the zone (or heating zone).

[0066] In some embodiments, the user can remove the holder from the component and remove the item from the zone (or heating zone).

[0067] In some embodiments, in use, when the holder engages the article, the holder and article can be removably connected to the component such that the article is held in a predetermined position relative to the zone (or heating zone), and the user can remove the holder and article together from the component.

[0068] In some embodiments, the aerosol delivery device comprises a body containing the components of the aerosol delivery device.

[0069] In some embodiments, the aerosol delivery device comprises a mouthpiece.

[0070] In some embodiments, the mouthpiece comprises a component of the aerosol delivery device.

[0071] In some embodiments, the mouthpiece is removable from the body of the aerosol delivery device, and preferably the mouthpiece is removable from the body to provide access to the holder.

[0072] In some embodiments, the zone (or heating zone) is located at or near the mouth end of the aerosol delivery device.

[0073] In some embodiments, the holder is configured to be magnetically removably connected to a component of the aerosol delivery device.

[0074] In some embodiments, one of the holder and the component comprises a first magnet, and the other of the holder and the component comprises a ferromagnetic material and / or a second magnet configured to be attracted to the first magnet to magnetically removably connect the holder to the component.

[0075] In some embodiments, the other of the holder and the component comprises a ferrous material.

[0076] In some embodiments, the holder comprises an engagement member configured to be inserted into the article.

[0077] In some embodiments, the engagement member comprises a pin, preferably the pin is a solid pin.

[0078] In some embodiments, the holder comprises a base portion and the engagement member extends from the base portion.

[0079] In some embodiments, the engagement member is configured to extend along at least a portion of the length of the article, hi some embodiments, the member is configured to extend along the entire length or substantially the entire length of the article.

[0080] In some embodiments, the engagement members extend substantially linearly.

[0081] In some embodiments, the engagement member is configured to be inserted into the center of the article. In some embodiments, the engagement member is configured to be inserted into the article such that it extends along a central axis of the article.

[0082] In some embodiments, the holder comprises a plurality of engagement members configured to be inserted into the article.

[0083] In some embodiments, the holder comprises a heating material that is heatable by permeation of a varying magnetic field.

[0084] In one embodiment, the engagement member comprises a heating material.

[0085] The present disclosure also provides an aerosol delivery system comprising an aerosol delivery device as disclosed herein and an article including an aerosol-generating material.

[0086] In some embodiments, the aerosol forming material comprises nicotine.

[0087] In some embodiments, the aerosol-forming material comprises, consists of, or consists essentially of tobacco.

[0088] In some embodiments, the aerosol-forming material does not include tobacco. The aerosol-forming material may be substantially free of tobacco.

[0089] In some embodiments, the article comprises a reservoir that contains the aerosol-generating material. The article may comprise a cartridge that comprises the reservoir. In one such embodiment, the article comprises a cartridge that contains nicotine (e.g., a liquid or powder containing nicotine) in the reservoir of the cartridge.

[0090] In some embodiments, the aerosol-forming material is non-liquid (e.g., solid) or liquid, hi some embodiments, the aerosol-forming material may be a powder.

[0091] In some embodiments, the article has an axial length of up to 36 mm, preferably up to 34 mm, 32 mm, 30 mm, 28 mm, 26 mm, 24 mm or 23 mm.

[0092] The present disclosure also provides a package comprising a plurality of the articles described herein. In some embodiments, the package is sealed.

[0093] In some embodiments, the aerosol delivery system is a non-combustion aerosol delivery system.

[0094] In some embodiments, the article does not include plastic.

[0095] In some embodiments, the article does not include cellulose acetate.

[0096] In some embodiments, the article comprises an aerosol-forming material.

[0097] In some embodiments, the article comprises first and second aerosol-forming materials.

[0098] In some embodiments, the density of the second aerosol-generating material is at least about 25% higher than the density of the first aerosol-generating material.

[0099] In some embodiments, the first aerosol-generating material has a density of about 0.1 g / cm 3 ~Approx. 1g / cm 3 has a density of

[0100] In some embodiments, the second aerosol-generating material has a density of about 0.4 g / cm 3 ~About 2g / cm 3 has a density of

[0101] In some embodiments, heating the article provides a relatively constant release of volatile compounds into the inhalable medium.

[0102] In some embodiments, the second aerosol-forming material comprises extruded tobacco.

[0103] In some embodiments, the second aerosol-generating material comprises beads.

[0104] In some embodiments, the first aerosol-generating material comprises one or more tobacco materials selected from the group consisting of lamina and reconstituted tobacco materials.

[0105] In some embodiments, at least one of the first and second aerosol-generating materials comprises a combination of lamina and reconstituted tobacco material. In some embodiments, the lamina and reconstituted tobacco material are present in the aerosol-generating materials in a ratio of 1:4 to 4:1 by weight.

[0106] In some embodiments, the first and second aerosol-generating materials have the same level of a volatile compound, hi some embodiments, the volatile compound is nicotine.

[0107] In some embodiments, the release of volatile compounds from the first and second aerosol-generating materials is at the same rate when the materials reach a given temperature.

[0108] In some embodiments, the first and second aerosol-generating materials are present in the article in a ratio of 1:10 to 10:1 by weight.

[0109] In some embodiments, the article contains in the range of 7 mg / mm to 13 mg of aerosol-forming material per mm length of the article 1, preferably in the range of 8 to 12, 9 to 11.5, 9 to 11, or 9.5 to 10.5 mg of aerosol-forming material per mm length of the article 1.

[0110] The present disclosure also provides a kit of parts including an article according to any of the examples described herein and an aerosol delivery device.

[0111] In some embodiments, the aerosol delivery system is an e-cigarette (also known as a vaporizer or electronic nicotine delivery system (END)).

[0112] Embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0113] [Figure 1] 1 is a cross-sectional side view of one embodiment of an article for use with an aerosol delivery device. [Diagram 2] 2 is a perspective view of a first coupling portion of the article of FIG. 1. FIG. [Diagram 3] FIG. 2 is a perspective view of the article of FIG. [Figure 4] FIG. 1 is a cross-sectional view of one embodiment of a non-combustion aerosol delivery device. [Diagram 5] FIG. 5 is a simplified schematic diagram of components within a housing of the aerosol delivery device shown in FIG. [Figure 6] 5 is a cross-sectional view of a non-combustion aerosol delivery system including the device shown in FIG. 4 with the article shown in FIG. 1 inserted into the device. [Figure 7] 5 is a side cross-sectional view of the device of FIG. 4 taken along dashed line ZZ shown in FIG. [Figure 8] 5 is a cross-sectional side view of another embodiment of a non-combustion aerosol delivery device taken from the same perspective as in FIG. 4. [Figure 9] 5 is a cross-sectional side view of another embodiment of a non-combustion aerosol delivery device taken from the same perspective as in FIG. 4. [Figure 10] FIG. 2 is a cross-sectional view of another embodiment of a non-combustion aerosol delivery system. [Figure 11] FIG. 2 is a cross-sectional side view of another embodiment of an article for use with an aerosol delivery device. [Figure 12] FIG. 2 is a cross-sectional side view of another embodiment of an article for use with an aerosol delivery device. [Figure 13] FIG. 2 is a cross-sectional side view of another embodiment of an article for use with an aerosol delivery device. [Figure 14] FIG. 14 is a perspective view of the article of FIG. [Figure 15] FIG. 2 is a cross-sectional side view of another embodiment of an article for use with an aerosol delivery device. [Figure 16] FIG. 2 is a cross-sectional side view of another embodiment of an aerosol delivery system. [Figure 17] 17 is a perspective view of a holder of the aerosol delivery system of FIG. 16. [Figure 18] 17 is a cross-sectional side view of the holder of FIG. 16 inserted into an item. [Figure 19] FIG. 2 is a top view of an article of another embodiment of an aerosol delivery system. [Figure 20] FIG. 20 is a side view of the article of FIG. 19. [Figure 21] FIG. 20 is a cross-sectional side view of one embodiment of an aerosol delivery system comprising the article of FIG. 19. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0114] As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user, a combustion aerosol delivery system, such as cigarettes for pipes, roll-up or reel-up cigarettes, cigars, and tobacco (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smokable materials); a non-combustion aerosol delivery system that releases a compound from an aerosol-generating material without combusting the aerosol-generating material, such as an e-cigarette, a tobacco heating product, and a hybrid system that generates an aerosol using a combination of aerosol-generating materials; and aerosol-free delivery systems that deliver at least one substance to a user orally, nasally, transdermally, or otherwise without forming an aerosol, including, but not limited to, oral products such as lozenges, gums, patches, articles containing inhalable powders, and oral tobacco, including snuff or moist snuff, where the at least one substance may or may not contain nicotine.

[0115] 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.

[0116] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0117] In some embodiments, the non-combustion aerosol delivery system is an e-cigarette, also known as a vaporizer or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol generating material is not a requirement.

[0118] 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.

[0119] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid or gel, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include a plant-based material, such as tobacco or a non-tobacco product.

[0120] Typically, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable item for use with the non-combustion aerosol delivery device.

[0121] In some embodiments, the present disclosure relates to consumables that include an aerosol-generating material and are configured for use with a non-combustion aerosol provider. These consumables may be referred to as articles throughout this disclosure.

[0122] As used herein, the terms "upstream" and "downstream" are relative terms defined with respect to the direction of mainstream aerosol drawn through an article or device in use. References to the "distal end" refer to the upstream end of the device, and the "proximal end" refers to the downstream end of the device.

[0123] In some embodiments, the non-combustion aerosol delivery system, such as the non-combustion aerosol delivery device, may include a power source and a controller. The power source may be, for example, a power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that can be energized to deliver power in the form of heat to an aerosol generating material or a heat transfer material proximate to the heat generating power source.

[0124] In some embodiments, the non-combustion aerosol delivery system comprises an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0125] In some embodiments, consumables for use with a non-combustion aerosol delivery device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material transport component, an aerosol generator, an aerosol generating area, a housing, a packaging material, a filter, a mouthpiece, and / or an aerosol modifier.

[0126] The consumable contains a substance to be delivered. The substance to be delivered is an aerosol-generating material. Optionally, the material may include one or more active ingredients, one or more flavorings, one or more aerosol-forming materials, and / or one or more other functional materials.

[0127] In some embodiments, the delivered substance comprises an active substance. As used herein, an active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, a dietary supplement, a nootropic, a psychoactive agent. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another plant. In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0128] As described herein, the active material may include or be derived from one or more plants or their components, derivatives or extracts. As used herein, the term "botanical" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc. Alternatively, the material may include active compounds naturally occurring in plants that are synthetically obtained. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, or sheets, etc. Exemplary botanicals include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea, such as green or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. The active ingredient in the composition may be any of the following: lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiane, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Memtha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv and Mentha suaveolens.

[0129] 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.

[0130] 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.

[0131] 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.

[0132] In some embodiments, the substance delivered comprises a fragrance.

[0133] As used herein, the terms "flavor" and "flavoring agent" refer to materials that may be used, where local regulations permit, to create a desired taste, odor, or other somatic sensation in products intended for adult consumers.They may be any naturally derived flavoring material, botanical substance, extract of botanical substance, synthetically derived material, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese peppermint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, toro, citrus fruit ... Pical fruit, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascara, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, i Lang ylang, sage, fennel, wasabi, pimenta, ginger, coffee, hemp, peppermint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, damienne, marjoram , olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), as well as 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.

[0134] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus, and / or red berry flavoring ingredients. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavoring ingredients extracted from tobacco. In some embodiments, the flavoring comprises flavoring ingredients extracted from cannabis.

[0135] In some embodiments, the flavoring may include a sensory elicitor, which is intended to achieve somatic sensations that are usually chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the aroma or taste nerves, and may include agents that produce a heating, cooling, tingling, or numbing effect. A suitable 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, eucoliptol, WS-3.

[0136] The aerosol-generating material may include or be an "amorphous solid." In some embodiments, the aerosol-generating material includes an aerosol-generating film that is an amorphous solid. The amorphous solid may be a "monolithic solid." The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dry gel. The amorphous solid is a solid material that may retain some fluid, such as a liquid, within the amorphous solid. In some embodiments, the amorphous solid may include, for example, about 50%, 60%, or 70% amorphous solid to about 90%, 95%, or 100% amorphous solid by weight. The aerosol-generating material may also be referred to as an aerosolizable material.

[0137] An aerosol-generating material is a material that can generate an aerosol when, for example, heated, irradiated, or energized in other ways. The aerosol-generating material may be in the form of a solid, liquid, or gel that may or may not contain active substances and / or flavorings. The aerosol-generating material is incorporated into an article for use in an aerosol generating system.

[0138] As used herein, the term "tobacco material" refers to any material that contains tobacco or a derivative or substitute thereof. The tobacco material may be in any suitable form. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco lamina, reconstituted tobacco and / or tobacco extract.

[0139] A consumable is an article that includes or consists of an aerosol-generating material, some or all of which are intended to be consumed during use by a user. A consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transport component, an aerosol-generating area, a housing, a packaging material, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, particularly a heating element, that releases heat to cause the aerosol-generating material to generate an aerosol during use. A heater may include a material that can be heated by electrical conduction, or a susceptor.

[0140] The aerosol-generating materials may include one or more active agents and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0141] The aerosolizable material may be present on a substrate, which may be or include, for example, paper, card, paperboard, cardboard, reconstituted aerosolizable material, a plastic material, a ceramic material, a composite material, glass, a metal, or a metal alloy.

[0142] The aerosol-forming material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming material may include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0143] 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.

[0144] A consumable is an article that includes or consists of an aerosol-generating material, some or all of which are intended to be consumed during use by a user. A consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transport component, an aerosol-generating area, a housing, a packaging material, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater that emits heat to cause the aerosol-generating material to generate an aerosol upon use. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0145] The susceptor is a material that can be heated by penetration by a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that penetration of the conductive material by the varying magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, such that penetration of the magnetic material by the varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, such that the susceptor is heatable by both heating mechanisms. An apparatus configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0146] An aerosol modifier is a substance that is typically located downstream of the aerosol-generation region and is configured to modify the generated aerosol, for example by changing the taste, flavor, acidity, or other property of the aerosol. The aerosol modifier may be provided in an aerosol modifier-releasing component that is operable to selectively release the aerosol modifier.

[0147] 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, a liquid, or a gel. The aerosol modifier may be in the form of a powder, a string, or granules. The aerosol modifier may not include a filtration material.

[0148] 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.

[0149] The filamentary tow material described herein can include cellulose acetate fiber tow. The filamentary tow can 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 can be plasticized with a plasticizer suitable for the tow, such as triacetin, where the material is cellulose acetate tow, or the tow can be unplasticized. The tow can have any suitable specifications, such as fibers having other cross sections, such as a "Y" shape or an "X" shape, and have a filamentary denier value of 2.5 to 15 denier per filament, e.g., 8.0 to 11.0 denier per filament, and a total denier value of 5,000 to 50,000, e.g., 10,000 to 40,000.

[0150] In the figures described herein, like reference numbers are used to denote equivalent features, items or components.

[0151] FIG. 1 is a cross-sectional side view of an article 1 for use in an aerosol delivery system 100 that includes an aerosol delivery device 200 (see FIGS. 4-9).

[0152] The aerosol delivery system 100 comprises an article 1 and an aerosol delivery device 200 .

[0153] The aerosol delivery system 100 comprises a magnetic coupling portion 2 configured to hold an article 1 in position relative to an aerosol delivery device 200. The magnetic coupling portion 2 comprises first and second coupling portions 5, 6, as described in more detail below.

[0154] Article 1 has an upstream or distal end "D" and a downstream or proximal end "P". In some embodiments, proximal end P is located relatively closer to the mouthpiece 207 of the aerosol delivery device 200 in use than distal end D. In another embodiment (not shown), proximal end P of article 1 includes a mouthpiece. In some embodiments (not shown), proximal end P of article 1 forms a mouthpiece.

[0155] It should be appreciated that in some embodiments, the article 1 can be used with the aerosol delivery device 200 in either orientation, such that it does not matter which end P, D of the article 1 is upstream and which end is downstream.

[0156] The article 1 includes a body of material 3 that includes an aerosol-forming material 4. In other embodiments, the article 1 includes an aerosol-forming material 4 that is not part of the body of material 3. That is, the body of material 3 may be omitted.

[0157] The article 1 further comprises a first coupling portion 5 of the magnetic coupling part 2 .

[0158] In this example, the body of material 3 of the article 1 is surrounded by a packaging material 7. The packaging material 7 comprises a sheet material, which in this example is paper.

[0159] 4-7, one embodiment of an aerosol delivery device 200 is shown.

[0160] The aerosol delivery device 200 includes a zone 202 configured to receive the item 1. The zone 202 may be an aerosol-generation zone 202 configured to generate an aerosol when the aerosol delivery device 200 is operated, once the item 1 is received in the zone 202. In this example, the aerosol delivery device 200 includes a heating zone 202 configured to receive the item 1 such that the aerosol-generating material 4 of the item 1 is heated when the aerosol delivery device 200 is operated. However, in each of the embodiments described herein, the zone 202 need not be a heating zone that heats the aerosol-generating material to generate an aerosol. In some embodiments, the aerosol delivery device 200 is an e-cigarette.

[0161] In this example, the first connector portion 5 of the article 1 includes a heating material that is heated by the aerosol providing device 200 to heat the aerosol-forming material 4 of the article 1. The aerosol-forming material 4 may be resistively heated and / or inductively heated.

[0162] For example, first binding portion 5 may be resistively and / or inductively heated to heat aerosol-forming material 4 .

[0163] Induction heating is a process in which a conductive object is heated by penetrating a varying magnetic field into the conductive object. The process is described by Faraday's law of induction and Ohm's law. An induction heater may comprise an electromagnet and a device for passing a variable current, such as an alternating current, through the electromagnet. When the electromagnet and the object to be heated are suitably positioned relative to each other such that the resulting varying magnetic field generated by the electromagnet penetrates the object, one or more eddy currents are generated within the object. The object has a resistance to the flow of electric current. Thus, when such eddy currents are generated within the object, the flow of the eddy currents against the electrical resistance of the object causes the object to heat up. This process is called Joule heating, Ohmic heating, or resistive heating. Objects that can be inductively heated are known as susceptors.

[0164] It has been found that when the susceptor is in the form of a closed circuit, the magnetic coupling between the susceptor and the electromagnet during use is enhanced, resulting in greater or improved Joule heating.

[0165] Magnetic hysteresis heating is the process by which an object made of a magnetic material is heated by the penetration of the object with a changing magnetic field. The magnetic material can be thought of as containing many atomic-scale magnets, or magnetic dipoles. When a magnetic field penetrates such a material, the magnetic dipoles become aligned with the magnetic field. Thus, when a changing magnetic field, for example an alternating magnetic field generated by an electromagnet, penetrates a magnetic material, the orientation of the magnetic dipoles changes with the applied changing magnetic field. Such magnetic dipole reorientation causes the generation of heat in the magnetic material.

[0166] When an object is both conductive and magnetic, the penetration of a varying magnetic field into the object can cause both Joule heating and magnetic hysteresis heating in the object. Furthermore, the use of magnetic materials can strengthen the magnetic field, which can enhance Joule heating.

[0167] In each of the above processes, because heat is generated within the object itself, rather than by an external heat source via thermal conduction, rapid temperature rise and more uniform heat distribution in the object can be achieved, particularly by selection of the appropriate object material and geometry, and appropriate magnitude and orientation of the varying magnetic field relative to the object. Furthermore, induction heating and magnetic hysteresis heating do not require a physical connection between the source of the varying magnetic field and the object, allowing greater freedom and control in the design of the heating profile and potentially lower costs.

[0168] In this example, the aerosol delivery device 200 includes an electromagnetic field generator 203 configured to generate an electromagnetic field to inductively heat the heating material of the first binding portion 5. However, it should be appreciated that in other embodiments, the article 1 includes an additional component, the heating material, in addition to the first binding portion 5. In some such embodiments, the heating material is separate and / or distinct from the first binding portion 5.

[0169] As shown in Figure 5, within the housing 201 is an electrical energy source 204, e.g., a rechargeable lithium ion battery. A controller 205 is connected to the heater 203, the electrical energy source 204, and a user interface 206, e.g., a button or display. The controller 205 controls the power supplied to the heater to regulate the temperature of the heater 203. Typically, the aerosol-forming substrate is heated to a temperature between 250°C and 450°C.

[0170] In this example, the magnetic field generator 203 comprises a coil (not shown). The electrical energy supply 204 may be configured to pass a varying electrical current, such as an alternating current, through the coil to inductively heat the heating material.

[0171] The coil may take any suitable form. In this embodiment, the coil is a helical coil of a conductive material such as copper. In some embodiments, the magnetic field generator 203 may comprise a magnetically permeable core around which the coil is wound. Such a magnetically permeable core concentrates the magnetic flux generated by the coil in use, producing a stronger magnetic field. The magnetically permeable core may be made of iron, for example. In some embodiments, the magnetically permeable core may extend only partially along the length of the coil, so as to concentrate the magnetic flux only in certain regions. In some embodiments, the coil may be a flat coil; that is, the coil may be a two-dimensional spiral.

[0172] In this example, the first bonding portion 5 is embedded in the article 1 and comprises a heating material.

[0173] In another embodiment, the aerosol provider includes a heating element (not shown) that at least partially surrounds the heating zone 202, e.g., the heating chamber 202. The heating element 203 may be resistively heated and / or inductively heated. In some embodiments, the article 1 does not include a heating material and instead is heated externally by a heating element.

[0174] In other embodiments (not shown), the heating element instead comprises a blade or pin for insertion into the article 1 , for example the blade or pin may be inserted through the body of material 3 .

[0175] Components of one embodiment of aerosol delivery device 200 are shown in a simplified form in Figure 4. In particular, the elements of aerosol delivery device 200 are not drawn to scale in Figure 4. Elements that are not relevant to an understanding of this embodiment have been omitted to simplify Figure 4.

[0176] 4, the aerosol dispenser 200 is a non-combustion aerosol dispenser 200. The non-combustion aerosol dispenser 200 includes a housing 201 including a heating zone 202 for receiving an article 1.

[0177] When the article 1 is received within the heating zone 202 , the heating material of the first bonding portion 5 is heated by a heater 203 , which in this example is a magnetic field generator 203 .

[0178] In other embodiments (not shown), the heater comprises a heating element surrounding at least a portion of the heating zone, and at least a portion of the article 1 is in thermal proximity to the heating element. Thus, at least a portion of the aerosol-generating material 4 is in thermal proximity to the heating element. In some embodiments, the heating element is spaced apart from the article 1, e.g., circumscribing the article 1 but having a larger diameter and spaced apart therefrom. In other embodiments, the heating element is in direct contact with the article 1, e.g., in contact with the outer surface of the packaging material 7 of the article 1. In another embodiment, the heating element comprises a blade or pin that contacts the inside of the article 1, e.g., in contact with the body of material 3. The heating element of the aerosol-providing device 200 may be resistively heated and / or inductively heated. That is, the heater may comprise a resistive heating element or may comprise a magnetic field generator that inductively heats the heating element.

[0179] The article 1 may be heated internally and / or externally.

[0180] When the article 1 is heated, the aerosol generating material 4 releases one or more volatile compounds and can release a range of volatile compounds at different temperatures. By controlling the maximum operating temperature of the electrically heated aerosol generating system 200, the selective release of undesirable compounds can be controlled by preventing the release of selected volatile compounds.

[0181] Figure 6 is a schematic cross-sectional view of a non-combustion aerosol delivery device 200 of the type shown in Figure 4, in which an item 1 is received in a heating region 202 of the device 200 for heating by a magnetic field generator 203. The non-combustion aerosol delivery device 200 is shown receiving an aerosol product item 1 for consumption of the aerosol product item 1 by a user.

[0182] The housing 201 of the non-combustion aerosol delivery device 200 defines a heating zone 202 in the form of a chamber that opens at the proximal end (or mouth end) for receiving the aerosol product 1 for consumption by a user.

[0183] In this example, the aerosol delivery device 200 includes a mouthpiece 207 that is removable from the remainder of the device 200 to allow access to the heating zone so that the article 1 can be brought into and removed from the heating zone 202. Once the article 1 has been delivered to the heating zone 202, the mouthpiece 207 can be reattached. In some embodiments, the mouthpiece 207 is removably attached to the housing 201 of the device 200, for example by a screw thread or bayonet connection.

[0184] When a user inhales on the mouthpiece 207, air is drawn into the article 1 and the volatile materials condense to form an inhalable aerosol that passes through the mouthpiece 207 of the device 200 and into the user's mouth.

[0185] It should be appreciated that in other embodiments, the mouthpiece 207 of the device 200 may be omitted. In some embodiments, the article 1 may form a mouthpiece and may come into contact with the user's mouth.

[0186] In the embodiment described above, the body of material 3 extends between the ends P, D of the article 1. However, it should be appreciated that in alternative embodiments (not shown), the article 1 may include one or more further segments, for example further segments upstream or downstream of the body of material 3.

[0187] The aerosol provision device 200 includes a second coupling portion 6 of the magnetic coupling unit 2. The first coupling portion 5 of the article 1 and the second coupling portion 6 of the aerosol provision device 200 are configured such that the first coupling portion 5 is magnetically attracted to the second coupling portion 6 when the article 1 is accommodated in the heating zone 202. This helps to hold the article 1 in place within the heating zone 202. Thus, the article 1 can be held in an optimal heating position within the heating zone 202 (e.g., within the center of the heating zone 202) to promote consistent and uniform heating of the article 1. The magnetic coupling unit 2 can also facilitate handling of the article 1 and help prevent the article 1 from falling out of the heating zone 202, which is particularly advantageous when the article 1 is of a small size. Furthermore, the coupling unit 2 can help to prevent the article 1 from coming loose during transportation of the aerosol provision system 100.

[0188] The magnetic coupling 2 is advantageously easy to use as a user can insert the item 1 into the heating zone 202 and the first and second coupling parts 5, 6 are attracted to each other to hold the item 1 in place. To remove the item 1 from the heating zone 202, the user can, for example, pull on an end of the item 1.

[0189] Optionally, the housing 201 may include one or more cutouts or slots (not shown) in the area of ​​the heating zone 202 to facilitate the article 1 being grasped and removed from the heating zone 202 by a user.

[0190] In some embodiments, one of the first and second coupling parts 5, 6 comprises a magnet and the other of the first and second coupling parts 5, 6 comprises a ferromagnetic material and / or a second magnet. In some embodiments, the other of the first and second coupling parts 5, 6 comprises a ferrous material.

[0191] For example, in one embodiment, the first coupling portion 5 of the article 1 comprises a first magnet. The second coupling portion 6 of the aerosol provision device 200 comprises a ferromagnetic material arranged such that the first magnet is attracted to the ferromagnetic material. In another embodiment, the first coupling portion 5 of the article 1 comprises a ferromagnetic material and the second coupling portion 6 of the aerosol provision device 200 comprises a first magnet. One of the first and second coupling portions 5, 6 may comprise iron or steel.

[0192] In another embodiment, the first coupling portion 5 comprises a first magnet and the second coupling portion 6 comprises a second magnet (e.g., a permanent magnet), and the poles of the first and second magnets are arranged such that the first and second magnets are attracted when the article 1 is received in the heating zone 202. The embodiment in which the first coupling portion 5 and the second coupling portion 6 include respective magnets can facilitate a stronger attractive force between the first coupling portion 5 and the second coupling portion 6.

[0193] In some embodiments, the first coupling portion 5 of the article 1 comprises an iron-based material. Thus, the article 1 may be less expensive to manufacture than other embodiments in which the first coupling portion 5 comprises a magnet, which is particularly advantageous when the article 1 is disposable after use. The article 1 can also be inserted into the heating zone 202 in either orientation and still be attracted to the magnet of the second coupling portion 6.

[0194] In some embodiments, the first binding portion 5 acts as a heating material that can be heated by being permeated by a varying magnetic field. Thus, the magnetic field generator 203 of the aerosol-providing device 200 can be activated to heat the heating material of the first binding portion 5. This has the advantage of reducing the size of the article 1 and / or increasing the amount of aerosol-generating material 4 of the article 1 compared to embodiments that also include the first binding portion 5 and a separate heating element. In one embodiment, the first binding portion 5 comprises a ferrous material, such as iron or steel.

[0195] In this example, the second bonding portion 6 is located at an end of the heating zone 202. The heating zone 202 includes an opening 202A through which the article 1 can be inserted into and removed from the heating zone 202. The second bonding portion 6 may be at an opposite end of the heating zone 202 from the opening 202A. It should be appreciated that in other embodiments (not shown), the second bonding portion 6 may be provided radially outward of the heating zone 202, for example at least partially circumscribing the heating zone 202.

[0196] In this example, mouthpiece 207 is removably attached to housing 201 of device 200, for example by a screw thread or bayonet connection. Mouthpiece 207 is removable to provide access to the heating zone 202 so that item 1 can be inserted into and removed from the heating zone 202.

[0197] In one embodiment (not shown), the mouthpiece 207 comprises a second coupling portion 6 such that the first coupling portion 5 of the article 1 is attracted towards the second coupling portion 6 of the mouthpiece 207. An advantage of the mouthpiece 207 comprising the second coupling portion 6 is that the article 1 can be removed from the heating zone 202 by removing the mouthpiece 207.

[0198] In one embodiment in which mouthpiece 207 includes second coupling portion 6, article 1 may be magnetically coupled to mouthpiece 207 via magnetic coupling portion 202, and mouthpiece 207 may then be attached to the remainder of aerosol provision device 200 to secure mouthpiece 207 and article 1 in place such that article 1 is held within heating zone 202. In another embodiment, article 1 is inserted into heating zone 202, and then mouthpiece 207 is attached to the remainder of aerosol provision device 200 to hold article 1 in place within heating zone 202.

[0199] In this example, the aerosol delivery device 200 comprises a body 208 that includes a second coupling portion 6 .

[0200] The second coupling portion 6 may be fixed relative to the body 208 .

[0201] In this example, the first and second coupling portions 5, 6 are configured such that when the article 1 is received in the heating zone 202, the article 1 is urged axially (in the direction of arrow "A" shown in FIG. 6 ) towards the second coupling portion 6. That is, the magnetic attraction between the first coupling portion 5 and the second coupling portion 6 urges the article 1 in the direction of its central axis towards the second coupling portion 6.

[0202] In this example, the first bonding portion 5 contacts the second bonding portion 6 when the article 1 is received in the heated zone. This creates a relatively strong holding force between the first bonding portion 5 and the second bonding portion 6, holding the article 1 in place within the heated zone 202. However, it should be appreciated that in other embodiments, the first bonding portion 5 does not contact the second bonding portion 6 when the article 1 is received in the heated zone 202. For example, the second bonding portion 6 may be spaced from the axial ends P, D of the article 1. In one such embodiment, the ends of the article 1 may include a portion of the aerosol-generating material 4 that is disposed between the first and second bonding portions 5, 6 when the article 1 is received in the heated zone 202.

[0203] The first coupling portion 5 may extend to the first end P and / or the second end D of the article 1. In one embodiment, the first coupling portion 5 may be provided at one of the first end P and the second end D of the article 1, while the other of the first end P and the second end D may not include a coupling portion. The first coupling portion may be provided on only a portion of the axial length of the article 1 (indicated by arrow "X" in FIG. 1).

[0204] In one embodiment, the first bonding portion 5 extends between the first end P and the second end D of the article 1. The first bonding portion 5 may extend over substantially the entire axial length X of the article 1. This is particularly advantageous when the first bonding portion 5 comprises a heating material that is heated during operation of the device 200, since a more uniform heating of the aerosol-generating material 4 may be achieved.

[0205] In this example, the first connecting portion 5 extends along the central axis of the article 1 .

[0206] In some embodiments, the first binding portion 5 is embedded within the article 1, preferably embedded within the body of material 3 of the article 1 and / or embedded within the aerosol-generating material 4 of the article 1. Embedding the first binding portion 5 within the aerosol-generating material 4 of the article 1 is particularly advantageous when the first binding portion 5 comprises a heating material that is heated by the penetration of a magnetic field during operation of the device 200. In some embodiments, the first binding portion 5 is integral with the article 1. In some embodiments, the first binding portion 5 is permanently embedded in the article 1.

[0207] In some embodiments, the aerosol-forming material 4 at least partially surrounds the first binding moiety 5 , and preferably completely surrounds the first binding moiety 5 .

[0208] In some embodiments, the first bonding portion 5 includes a susceptor configured to be inductively heated by the aerosol delivery device 200. In other embodiments, the article 1 includes the first bonding portion 5 and further includes a susceptor configured to be inductively heated by the aerosol delivery device 200.

[0209] In some embodiments, the aerosol-generating material 4 comprises, consists of, or consists essentially of tobacco material. The tobacco material may include, for example, one or more of blade tobacco, stem tobacco, reconstituted tobacco, tobacco beads, or extruded or compressed tobacco.

[0210] Body of material 3 and / or aerosol-generating material 4 may have, for example, any of the characteristics and / or configurations described herein.

[0211] Article 1 may have an axial length (indicated by arrow "X" in Figure 1) of at least 10mm, preferably at least 12, 14, 16, 18, 20, 22 or 23mm.

[0212] The article 1 may have an axial length of up to 36 mm, preferably up to 34, 32, 30, 28, 26, 24 or 23 mm.

[0213] The article 1 may have an axial length in the range of 10 to 36 mm, preferably in the range of 14 to 32 mm, in the range of 20 to 26 mm, or in the range of 22 to 24 mm.

[0214] 7, a side cross-sectional view (taken along dashed line ZZ in FIG. 4) of a portion of the aerosol provision device 200 is shown. The second coupling portion 6 is in the form of a magnet 6, which in this example is generally circular. Those skilled in the art will recognize that in alternative embodiments, the second coupling portion 6 may have alternative shapes, for example, a square, a triangle, or an oval. A plurality of flow holes 210 are disposed around the magnet 6 to facilitate the flow of gas through the aerosol provision device 200. In other embodiments, the flow holes 210 may be omitted. In some embodiments, air can flow around the end of the mouthpiece 207 and the outside of the article 1, then into the first end of the article 1, through the article 1, and into the mouth end of the article 1 for inhalation by the user.

[0215] 8, an alternative embodiment of an aerosol delivery device 200 is shown having the same features as the embodiment described above in connection with FIGS. 1-7, except that the second coupling portion 6 is annular and one or more flow holes 210 are provided in the center of the second coupling portion 6. Optionally, the second coupling portion 6 is magnetic. Again, the flow holes 210 may be omitted.

[0216] 9, another embodiment of an aerosol delivery device 200 is shown having the same features as the embodiment of FIG 8, except that the aerosol delivery device 200 includes a plurality of second coupling portions 6. One or more of the second coupling portions 6 may comprise a magnet.

[0217] It should be appreciated that in alternative embodiments of the above described embodiment, the flow holes 210 may be omitted. In one such alternative embodiment, one or more gaps or vents may be provided in the chamber housing 201 surrounding the heating zone 202 to allow air to be drawn into the heating zone 202.

[0218] Referring now to FIG. 10, another embodiment of the aerosol delivery system 100 is shown. The aerosol delivery system 100 is similar to the aerosol delivery system 100 described above in relation to FIGS. 1-7, and similar features retain the same reference numbers. The difference is that the mouthpiece 207 is omitted. In this example, the article 1 protrudes from the opening 202A of the heating zone 202. The proximal end P of the article 1 may itself form the mouthpiece that contacts the user's mouth. In another embodiment (not shown), the separate mouthpiece 207 is omitted, but the article 1 does not extend beyond the end of the heating zone 202. In yet another embodiment (not shown), the article 1 protrudes from the heating zone 202, and the aerosol delivery device 200 comprises a mouthpiece 207.

[0219] Referring now to FIG. 11, an alternative embodiment of an article 1 for use with an aerosol delivery device 200 (e.g., any of the devices of FIGS. 4-10) is shown. The article 1 is similar to the article 1 of the embodiment described above in relation to FIGS. 1-7, and similar features retain the same reference numbers. The difference is that the article 1 comprises a first coupling portion 5 and further comprises a heating material 8 that can be heated by permeation of a varying magnetic field. In this example, the heating material 8 is in the form of an element 8 extending along a central axis of the article 1. The first coupling portion 5 is provided as an annular element 5 that may include a magnet and / or a ferromagnetic material and / or an iron-based material. Optionally, the first coupling portion 5 surrounds the material body 3, and the heating material 8 is provided in the center of the material body 3. In one such embodiment, the second coupling portion 6 is approximately annular to correspond to the annular shape of the first coupling portion 5.

[0220] In an alternative embodiment (not shown), the first bonding portion 5 extends along a central axis of the article 1 and the heating material 8 is provided as an annular element surrounding the body of material 3 .

[0221] Referring now to FIG. 12, an alternative embodiment of an article 1 for use with an aerosol delivery device 200 (e.g., any of the devices of FIGS. 4-10) is shown. The article 1 is similar to the embodiment of the article 1 described above in relation to FIGS. 1-7, and similar features retain the same reference numerals. The difference is that the article 1 comprises a plurality of first coupling portions 5, one at each end P, D of the article 1. Each first coupling portion 5 may comprise a magnet and / or a ferromagnetic material and / or a ferrous material. In this example, each first coupling member 5 is annular. However, in other embodiments, one or both of the first coupling members 5 may not be annular, and may be located, for example, on the central axis of the article 1.

[0222] The advantage of providing multiple first connector parts 5 is that each first connector part 5 can be a magnet (e.g., a permanent magnet) and the second connector part 6 can be a magnet (e.g., a permanent magnet), while still allowing either end of the article 1 to be inserted into the heating zone 202. For example, the first connector parts 5 can be oriented within the article 1 such that either of the "north" of both "south" extremes of each magnet 5 faces outward at the respective ends P, D of the article. Meanwhile, the magnets 6 of the second connector parts 6 are oriented to attract said outwardly facing poles of the magnets 5 of the first connector parts 5. That is, if the "north" extremes of the magnets 5 of each first connector part 5 face outward from the respective ends P, D of the article 1 (and thus the "south" extremes of the first connector parts 5 face each other), the "south" extremes of the magnets 6 of the second connector parts 6 face towards the article 1 when the article 1 is received in the heating zone 202 to attract the "north" extremes of the closest magnets 5. Thus, regardless of which end P, D of the article 1 is inserted into the heating zone 202 first, the article 1 is attracted towards the second coupling portion 6 of the aerosol provider 200 .

[0223] It should be appreciated that in other embodiments, the coupling portion 2 is configured to be attracted to the second coupling portion 6 only when the article 1 is inserted into the heated zone 202 in the correct orientation, and to be repelled from the second coupling portion 6 when the article 1 is inserted into the heated zone 202 in the other incorrect orientation. This can be achieved, for example, if the second coupling portion 6 comprises a magnet and the article 1 comprises a single magnet having opposing pole ends at opposing ends P, D of the article 1. This can also be achieved, for example, if the second coupling portion 6 comprises a magnet and the article 1 comprises a magnet at each end of the article 1, one of the magnets having its "north" pole at one end P, D of the article 1 and the other of the magnets having its "south" pole at the other end P, D of the article 1. Thus, the article 1 is attracted to the second coupling portion 6 only when the article 1 is oriented such that the end P, D having the pole opposite the closest pole of the second coupling portion 6 is inserted into the heated zone 202 first.

[0224] 13 and 14, another embodiment of an article 1 for use with an aerosol delivery device 200 (e.g., any of the devices of FIGS. 4-10) is shown. The article 1 is similar to the embodiment of the article 1 described above in connection with FIGS. 1-7, and similar features retain the same reference numerals. The difference is that the first coupling portion 5 comprises a plate 9 having a plurality of openings 10 that facilitate gas flow through the first coupling portion 5 into and out of the article 1. The first coupling portion 5 may comprise a magnet and / or a ferromagnetic material and / or a ferrous material. In this example, the first coupling portion 5 is provided at only one of the ends P, D of the article. However, in other embodiments, a first coupling portion 5 is provided at each of the ends P, D of the article 1.

[0225] In this example, article 1 is externally heated, for example, by heating elements surrounding article 1 contained in heating zone 202 and that are resistively and / or inductively heated to heat the aerosol-generating material 4 of article 1. In another embodiment (not shown), article 1 is not externally heated, but instead may include a strip of heating material extending the axial length of body of material 3 and heated by penetration of a varying magnetic field.

[0226] 15, an alternative embodiment of an article 1 for use with an aerosol delivery device 200 (e.g., any of the devices of FIGS. 4-10) is shown. The article 1 is similar to the embodiment of the article 1 described above in relation to FIGS. 1-7, and like features retain the same reference numbers. The difference is that the first coupling portion 5 is provided on the central axis of the article 1 at the distal end D of the article 1. However, the first coupling portion 5 may have any of the configurations of the article 1 described herein.

[0227] The article 1 of Figure 15 further comprises a cooling section 25, also referred to as a cooling element, disposed immediately downstream of the body of material 3. In this example, the cooling element 25 is immediately downstream and adjacent to the body of material 3. In some such embodiments, the cooling element 25 is in an abutting relationship with the body of material 3. The article 1 may additionally or alternatively include a further body of material 26 downstream of the cooling element 25. The further body of material 26 may include a flavoring material and / or a filtering material and / or may be provided to obscure the view of the cooling element 25.

[0228] The cooling element 25 includes a hollow channel having an inner diameter of about 1 mm to about 4 mm, for example about 2 mm to about 4 mm. The hollow channel can have an inner diameter of about 3 mm. The hollow channel extends along the entire length of the cooling element 25. The cooling element 25 can include a single hollow channel. In alternative embodiments, the cooling element 25 can include multiple channels, for example 2, 3 or 4 channels. The single hollow channel can be substantially cylindrical, although in alternative embodiments other channel shapes / cross sections may be used. The hollow channel can provide space in which aerosol drawn into the cooling element 25 can expand and cool. The cooling element 25 can be configured to restrict the cross-sectional area of ​​the hollow channel to restrict the movement of tobacco into the cooling element 25 during use.

[0229] The cooling element 25 can have a wall thickness in the radial direction. The wall thickness of the cooling element 25 defines the inner diameter of the chamber enclosed by the walls of the cooling element 25 for a given outer diameter of the cooling element 25. The cooling element 25 can have a wall thickness of at least about 1.5 mm and up to about 2 mm. In this example, the cooling element 25 has a wall thickness of about 2 mm.

[0230] Cooling element 25 may be formed from filamentary tow. Multiple parallel wound paper layers with butt seams or other structures such as spirally wound layers of paper, cardboard tubes, tubes formed using a paper-mache process, molded or extruded plastic tubes, etc. can be used to form cooling element 25. Cooling element 25 is manufactured to be sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacture and use of article 1.

[0231] The wall material of the cooling element 25 may be relatively non-porous such that at least 90% of the aerosol generated by the aerosol-generating material 3 passes longitudinally through the one or more hollow channels rather than through the wall material of the cooling element 25. For example, at least 92% or at least 95% of the aerosol generated by the first and / or second aerosol-generating materials 4, 5 may pass longitudinally through the one or more hollow channels.

[0232] The cooling element 25 can be configured to provide a temperature difference of at least 40° C. between the heated volatile component entering the first upstream end of the cooling element 25 and the heated volatile component exiting the second downstream end of the cooling element 25. The cooling element 25 can be configured to provide a temperature difference of at least 60° C., or at least 80° C., or at least 100° C., between the heated volatile component entering the first upstream end of the cooling element 25 and the heated volatile component exiting the second downstream end of the cooling element 25. This temperature difference across the length of the cooling element 25 protects the temperature sensitive body of material 26 from the high temperatures of the aerosol generating materials 4, 5 when heated.

[0233] The body of material 26 defines a substantially cylindrical overall outer shape and is encased in a plug wrap 28. The plug wrap 28 may have a basis weight of less than 50 gsm, or between about 20 gsm and 40 gsm. The plug wrap 28 may have a thickness of between 30 μm and 60 μm, or between 35 μm and 45 μm. The plug wrap 28 may be a non-porous plug wrap, for example having a permeability of less than 100 Coresta units, for example less than 50 Coresta units. However, in other embodiments, the plug wrap 28 may be a porous plug wrap, for example having a permeability of greater than 100 Coresta units, preferably greater than 200 Coresta units.

[0234] The cooling element 25 and / or the body of material 26 may form a mouthpiece of the article 1 that is configured to be received in the mouth of a user. In some embodiments, the mouthpiece 207 of the device 200 may be omitted.

[0235] In some embodiments, tipping paper (not shown) is wrapped around cooling element 25 and body of material 26 and may also surround wrapper 7 which surrounds body of material 3 and connects these components to the body of material 3 by adhesive. Thus, the tipping paper connects cooling element 25 and body of material 26 to body of material 3. In other embodiments, tipping paper is omitted and instead wrapper 7 extends around cooling element 25 and body of material 26 to connect these components to body of material 3.

[0236] 16-18, there is shown another embodiment of an aerosol delivery system 100. The aerosol delivery system 100 is similar to the aerosol delivery system 100 described above in relation to Figures 1-7, and like features retain the same reference numbers. The difference is that the aerosol delivery device 200 of the system 100 includes a holder 300.

[0237] The holder 300 is configured to secure the article 1 to the heating zone 202 of the aerosol provider 200. The holder 300 is configured to engage the article 1.

[0238] The holder 300 is configured to be removably connected to a component of the aerosol providing device 200, and the holder 300 and the article 1 can be removably connected to the component such that, in use, when the holder 300 engages the article 1, the article 1 is held in a predetermined position relative to the heating zone 202. A user can remove the holder 300 and the article 1 together from the component. Thus, the holder 300 can make the article 1 easy to handle and hold the article 1 in a predetermined position within the heating zone 202. In an embodiment including the holder 300, the article 1 itself may not include any connecting parts. An advantage of the holder 300 is that the holder 300 can be reused.

[0239] In some embodiments, the aerosol delivery device 200 includes a housing or body 201 (hereinafter referred to as body 201). In this example, the holder 300 is removably connected to the body 201.

[0240] In some embodiments, the aerosol delivery device 200 includes a mouthpiece 207. In some embodiments, the holder 300 is removably connected to the mouthpiece 207.

[0241] In some embodiments, the mouthpiece 207 is removable from the body 201 of the aerosol delivery device 200 , and preferably, the mouthpiece 207 is removable from the body 201 to provide access to the holder 300 .

[0242] In some embodiments, the heating zone 202 is located at or near the mouth end of the aerosol delivery device 200 .

[0243] In this example, the holder 300 comprises an engagement member 301 configured to be inserted into the article 1 such that the engagement member 301 engages the article 1, thus removably connecting the holder 300 to the article 1. The holder 300 may be removed from the article 1 by withdrawing the engagement member 301 from the article 1. In some embodiments, the engagement member 301 may be inserted into the body of material 3 of the article 1.

[0244] In some embodiments, the engagement member 301 comprises a pin 301, preferably a solid pin. The engagement member 301 may comprise a sharp tip (not shown) that facilitates insertion of the engagement member 301 into the article 1.

[0245] In some embodiments, the holder 300 comprises a base portion 302 with the engagement member 301 extending from the base portion 302 .

[0246] Base portion 302 may be shaped to allow the inhalant to pass around or through base portion 302. For example, base portion 302 may include one or more cutouts to allow the inhalant to pass around or through base portion 302. In this example, base portion 302 includes one or more openings 303 that allow the inhalant to pass through base portion 302.

[0247] In some embodiments, the engagement member 301 is configured to extend along at least a portion of the length of the article 1. In some embodiments, the engagement member 301 is configured to extend along the entire length or substantially the entire length of the article 1.

[0248] In some embodiments, the engagement member 301 extends substantially linearly.

[0249] In this example, the engagement member 301 is configured to be inserted into the center of the article 1. The engagement member 301 may be configured to be inserted into the article 1 so as to extend along the central axis 1 of the article 1.

[0250] In some embodiments (not shown), the holder 300 comprises a plurality of engagement members 301 configured to be inserted into the item 1 .

[0251] In some embodiments, the holder 300 is configured to be magnetically removably connected to the component (e.g., the body 201 or the mouthpiece 207) of the aerosol delivery device 200. In other embodiments, the holder 300 may be connected to the component by a mechanical fastener, such as a screw thread, a bayonet connection, or a clip.

[0252] In some embodiments, the system 100 includes a coupling portion 304 including first and second coupling portions 305, 306. The holder 300 includes the first coupling portion 305. The device 200 includes the second coupling portion 306. In some embodiments, the coupling portion 304 is a magnetic coupling portion, and the first and second coupling portions 305, 306 are magnetically attracted to each other. In this example, the base 302 includes the first coupling portion 305. The entire base 302 may form the first coupling portion 305 (e.g., manufactured from a magnetic and / or ferrous material) or the first coupling portion 305 may be attached to the base 302.

[0253] A component of the device 200 (e.g., the mouthpiece 207 or the body 201) may form the second coupling portion 306 (e.g., manufactured from a magnetic and / or ferrous material) or the second coupling portion 306 may be attached to said component.

[0254] In some embodiments, one of the holder 200 and the component comprises a first magnet and the other of the holder 200 and the component comprises a ferromagnetic material and / or a second magnet configured to be attracted to the first magnet to magnetically removably connect the holder 200 to the component. In some embodiments, the other of the holder and the component comprises a ferrous material.

[0255] In some embodiments, the holder 300 comprises a heating material that can be heated by the penetration of a varying magnetic field. For example, the engagement member 301 may comprise such a heating material. The engagement member 301 may thus form a susceptor that heats the material body 3 of the article 1. Alternatively or additionally, the engagement member 301 may comprise a resistive heating element that is powered to heat the article 1 when the holder 300 is attached to the apparatus 200. For example, by attaching the holder 300 to the apparatus 200, the holder 300 may be electrically connected to a circuit of the apparatus 200 to allow power to flow through the holder 300 to power the heater.

[0256] In some embodiments, connecting the holder 300 to components of the aerosol delivery device 200 may result in one or more of: powering a heater (inductive or resistive), activating an indicator so that instructions are provided to a user (e.g., an audible beep or the operation of a light), powering circuitry in the device, and / or operating pre-heat routing so that the heater is pre-heated.

[0257] 16-18 may have any of the features of any of the other articles described herein. In some embodiments, the aerosol-generating material of the article 1 comprises, consists of, or consists essentially of tobacco.

[0258] In some embodiments, article 1 may include a rod containing an aerosol-generating material (e.g., tobacco), which is connected to a component of device 200 by holder 300. In another example, article 1 may include a reservoir of aerosol-generating material (e.g., a reservoir containing nicotine and glycerol), which is connected to a component by holder 300.

[0259] In some embodiments, the holder 300 can engage the article 1, for example, by mechanically or magnetically coupling to the article 1. For example, the holder 300 can mechanically couple to the article 1 (which may optionally include, for example, a rod containing aerosol-forming material or a reservoir containing aerosol-forming material) by clipping onto the article 1, clamping or gripping the article, having a portion (e.g., a pin) that is inserted into the article 1, coupling to the article 1 via a bayonet connection, or coupling to the article 1 via threads on the holder 300 and the article 1. Additionally or alternatively, one or both of the article 1 or the holder 300 may include a magnet for coupling the article 1 and the holder 300 to one another. Once the holder 300 is coupled to the article 1, the holder 300 and article 1 can then be removably coupled to components of the apparatus 200 to secure the article 1 within a zone (which may be an aerosol generation zone such as the heating zone 202), and a user can detach the holder 300 and article 1 from the components of the apparatus 200 (while the article 1 is still engaged with the holder 300) to remove the article 1 from the zone 202.

[0260] In other embodiments, the device 200 may be configured such that the user removes the holder 300 from a component of the device 200 and then removes the item 1 from the zone 202 after the holder 300 is removed.

[0261] 19-21, there is shown another embodiment of an aerosol delivery system 100. The aerosol delivery system 100 is similar to the aerosol delivery system 100 described above in relation to Figures 1-7, and like features retain the same reference numbers. The difference is that item 1 has been omitted and replaced with an alternative item 400.

[0262] The article 400 includes multiple regions 403A, 403B, 403C of an aerosol-forming material 403. In this example, the multiple regions 403A, 403B, 403C of the aerosol-forming material 403 are provided on a substrate 401. The substrate 401 may be substantially planar.

[0263] The aerosol delivery device 200 is configured to selectively heat each of the regions 403A, 403B, 403C. For example, the device 200 can include respective heaters 203A, 203B, 203C for heating each of the regions 403A, 403B, 403C.

[0264] Each heater 203A, 203B, 203C may be a resistive heating element or an electric field generator, as previously described. The device 200 may have the same components as the device 200 described above with reference to Figures 1-7, but are not shown in Figures 19-21 for the sake of brevity. For example, the device 200 of Figures 19-21 may include an electrical energy supply, a controller connected to the heaters 203A, 203B, 302C, the electrical energy supply, and a user interface, such as a button or display. The controller may control the power supplied to the heaters 203A, 203B, 203C to regulate their temperature.

[0265] The heaters 203A, 203B, 203C can be operated sequentially to allow for a more consistent emission of aerosol. For example, the first heater 203A can be operated to heat the first region 403A of the aerosol-generating material until the rate of aerosol emitted therefrom decreases (e.g., by the region 403A being depleted). The second first heater 203B can then be operated to heat the second region 403B of the aerosol-generating material until the rate of aerosol emitted therefrom decreases, and then the third first heater 203C can be operated to heat the third region 403C of the aerosol-generating material until the rate of aerosol emitted therefrom decreases.

[0266] In some embodiments, the system 100 comprises a coupling portion 404 including first and second coupling portions 405, 406. The article 400 comprises a first coupling portion 405. In this embodiment, the article 400 comprises two first coupling portions 405 at opposite ends of the article 400. However, it should be appreciated that in other embodiments, one of the first coupling portions 405 may be omitted or the first coupling portion may be provided in a different location.

[0267] The device 200 includes second coupling portions 406. In this embodiment, the device includes two second coupling portions 406 that correspond to the first coupling portions 405 of the article 400. Again, the number or location of the second coupling portions 406 may vary.

[0268] In some embodiments, the coupling portion 404 is a magnetic coupling portion, and the first and second coupling portions 405, 406 are magnetically attracted to each other. In this example, the substrate 401 includes a first coupling portion 405.

[0269] In this example, the second coupling portion 405 is provided inside the body 201 of the device 200 .

[0270] In some embodiments, the article 400 is slid into the heated zone 202 of the apparatus 200. For example, the mouthpiece 207 can be removed, and then the article 400 can be slid into the heated zone 202 (in the direction of arrow "A" in FIG. 21) until each region 403A, 403B, 403C of aerosol-generating material is aligned with the respective heater 203A, 203B, 203C.

[0271] The first and second coupling portions 405, 406 may become aligned and magnetically attracted when the article 400 is inserted into the heating zone 202. This helps align the article 400 within the heating zone 202, which is particularly advantageous where multiple regions 404A, 404B, 404C are provided as it means that each region 404A, 404B, 404C can be more easily aligned with its respective heater 203A, 203B, 203C. In some embodiments, the coupling portion 404 is such that the article 400 "snaps" into place within the heating zone 202.

[0272] The article 400 can be removed from the heating zone 202 by pulling the article 400 out of the heating zone 202 against the magnetic force of the bonds 404 .

[0273] In all of the above examples, the body of material 3 may be a tobacco rod 3. For example, the body of material 3 may be a rod comprising shredded leaf tobacco and / or shredded reconstituted tobacco (e.g., shredded reconstituted tobacco sheet).

[0274] In another embodiment (not shown), the body of material 3 comprises a sheet material that is gathered to form the body of material 3. The sheet material may comprise an aerosol-forming material 4, which may comprise, consist of, or consist essentially of tobacco material. For example, the sheet material may be reconstituted tobacco that is gathered to form the body of material 3.

[0275] In some embodiments, the sheet materials are crimped to facilitate gathering of a third sheet material to form the body of material 3 .

[0276] In some embodiments, the sheet material is cut into strips which are then formed into the body of material 3 .

[0277] In this example, the body of material 3 extends over a portion of the length of the article 1 (indicated by arrow "X" in Figure 1). In an alternative embodiment, the body of material 3 extends over the entire length X of the article 1.

[0278] In this example, the packaging material 7 has a permeability of at most 100 Coresta units. In other embodiments, the packaging material 7 has a permeability of at least 100 Coresta units.

[0279] In some embodiments, the wrapper 7 has a thickness in the range of 20 to 100 microns. Reducing the thickness of the wrapper 7 has been found to aid in facilitating heat transfer to the aerosol-generating material 4.

[0280] Increasing heat transfer through the wrapper 7 advantageously improves the efficiency of heating the aerosol-forming material 4 .

[0281] In this example, aerosol-forming material 4 comprises an extruded and / or compressed aerosol-forming material, however, it should be appreciated that in other embodiments, aerosol-forming material 4 may have a different form.

[0282] In some embodiments, the aerosol-generating material 4 comprises beads, which may be cylindrical or have alternative shapes, such as spherical, pyramidal, or rectangular shapes.

[0283] In some embodiments, the aerosol-forming material 4 of the article 1 is derived only from tobacco blades and not from other types of tobacco materials.

[0284] In some embodiments, the aerosol-forming material 4 includes tobacco lamina and reconstituted tobacco.

[0285] In some embodiments, the aerosol-forming material 4 of the article 1 has an average nicotine level in the range of 0.6% to 2.5%, preferably in the range of 1% to 2.1%, by weight of the aerosol-forming material 4.

[0286] In some embodiments, aerosol-forming material 4 is a solid material.

[0287] Article 1 may have an axial length (indicated by arrow "X" in Figure 1) of at least 10mm, preferably at least 12, 14, 16, 18, 20, 22 or 23mm.

[0288] The article 1 may have an axial length of up to 36 mm, preferably up to 34, 32, 30, 28, 26, 24 or 23 mm.

[0289] The article 1 may have an axial length in the range of 10 to 36 mm, preferably in the range of 14 to 32 mm, in the range of 20 to 26 mm, or in the range of 22 to 24 mm.

[0290] In some embodiments, the aerosol-forming material does not include tobacco. The aerosol-forming material may be substantially free of tobacco.

[0291] In some embodiments, the aerosol-forming material is a liquid.

[0292] In some embodiments, the article comprises a reservoir that contains the aerosol-generating material. The article may comprise a cartridge (not shown) that comprises the reservoir. The cartridge / reservoir may include, for example, a first coupling portion 5,405, which may optionally be a magnet. When the cartridge / reservoir is received in a zone (or heating zone), the first coupling portion 5,405 is magnetically attracted to the second coupling portion 6,406.

[0293] In one such embodiment, the article includes a cartridge that contains nicotine (eg, a liquid or powder containing nicotine) within a reservoir of the cartridge.

[0294] In some embodiments, the aerosol-forming material is non-liquid (e.g., solid) or liquid, hi some embodiments, the aerosol-forming material may be a powder.

[0295] In some embodiments, the entire article 1 is plastic-free. In some embodiments, the body of material 3 or the entire article 1 is cellulose acetate-free. This makes the article 1 more environmentally friendly, and is also advantageous in embodiments where the entire article 1 is heated by the aerosol delivery device 200 (as described below).

[0296] In some embodiments, the aerosol-generating material 4 may include, consist of, or consist essentially of tobacco material. The term "tobacco material" refers to any material that includes tobacco or a derivative or substitute thereof. The tobacco material may be in any suitable form. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco lamina, reconstituted tobacco, and / or tobacco extract.

[0297] In some embodiments, the aerosol-generating material 4 or another material (not shown) of the article 1, such as another material of the body of material 3, may include one or more aerosol-forming materials. For example, the first and / or second aerosol-generating material 4, 5 or said another material may include one or more components capable of forming an aerosol. The aerosol-forming material includes one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The aerosol-forming material may be glycerol or propylene glycol.

[0298] In some embodiments, article 1 includes first and second aerosol-generating materials. For example, body of material 3 can include shredded lamina and / or reconstituted tobacco mixed with tobacco beads.

[0299] Optionally, the first aerosol generating material has a higher density than the second aerosol generating material. It has been found that this causes the first aerosol generating material to heat up slower than the second aerosol generating material when the heater of the device 200 is activated to heat the article 1. This means that the second aerosol generating material initially releases one or more volatile compounds (e.g., nicotine) at a higher rate than the first aerosol generating material. This also means that the second aerosol generating material relatively depletes said volatile compounds more quickly than the first aerosol generating material. However, once the second aerosol generating material begins to relatively deplete said volatile compounds, the first aerosol generating material begins to reach a temperature at which it begins to release volatile compounds at a higher rate. The effect of this is a more consistent release of volatile compounds over the period of consumption of the article 1, with the second aerosol generating material releasing a greater proportion of volatile compounds towards the start of consumption of the article 1 and the first aerosol generating material releasing a greater proportion of volatile compounds towards the end of consumption of the article 1. This is particularly advantageous because it allows article 1 to be relatively small while still achieving a relatively consistent and / or sufficient release of volatile compounds over the consumption period.

[0300] In some embodiments, the one or more volatile compounds emitted by the first aerosol-generating material are the same as the volatile compounds emitted by the second aerosol-generating material 5.

[0301] In some embodiments, the first aerosol-generating material comprises an aerosol-generating material that has been compressed or extruded (without subsequent expansion or with relatively low / minimal expansion) such that the density of the first aerosol-generating material is higher than the density of the second aerosol-generating material.

[0302] In some embodiments, the second aerosol-generating material comprises one or more of tobacco lamina, tobacco stems, or reconstituted tobacco. In one such embodiment, the second aerosol-generating material comprises a mixture of tobacco lamina and reconstituted tobacco. The second aerosol-generating material may comprise shredded or cut material. However, it should be appreciated that in other embodiments, the second aerosol-generating material comprises a compressed or extruded aerosol-generating material having a lower density than the first aerosol-generating material (e.g., having a lower compression than the first aerosol-generating material 4, which may optionally be extruded or compressed). For example, the body of material 3 may comprise an extruded / compressed body of the second aerosol-generating material.

[0303] In some embodiments, the first and second aerosol-generating materials may comprise the same material, e.g., tobacco, but are processed to have different densities. In one such embodiment, the first and second aerosol-generating materials may be in different forms. For example, the second aerosol-generating material may be a shredded material (e.g., shredded tobacco and / or shredded reconstituted tobacco) formed into the body 3, while the first aerosol-generating material may be compressed or extruded (with minimal expansion) such that the first aerosol-generating material has a higher density than the second aerosol-generating material.

[0304] For example, the first aerosol-generating material may be in the form of an extruded / compressed bead of aerosol-generating material (e.g., tobacco or another material) and the second aerosol-generating material may be in the form of, for example, strands or strips of aerosol-generating material (e.g., tobacco or another material), sheets of aerosol-generating material collected into a plug or cut into strips, rods of aerosol-generating material (e.g., rods formed from cut rag tobacco), or tobacco lamina and / or stem material formed into a plug. However, it should be recognized that the first and / or second aerosol-generating materials may alternatively have the same form (e.g., both being cut rough tobacco).

[0305] It should be appreciated that in alternative embodiments, the density of the first aerosol-generating material is less than the density of the second aerosol-generating material. In yet other embodiments, the densities of the first and second aerosol-generating materials are the same. In other embodiments, article 1 includes a single aerosol-generating material.

[0306] In some embodiments, the first aerosol-generating material has at least one additional different characteristic relative to the second aerosol-generating material. The different characteristic may be one or more of the form, size, moisture content, amount (by weight), one or more materials, or proportions of materials that make up the first and second aerosol-generating materials (including recipes of the aerosol-generating materials when each produces two or more materials). In some embodiments, the first and second aerosol-generating materials do not have different characteristics other than being of different forms.

[0307] The aerosol-generating material may include multiple strands or strips of aerosol-generating material. For example, the aerosol-generating material may include multiple strands or strips of aerosolizable material and / or multiple strands or strips of an amorphous solid.

[0308] The aerosol-forming material may include a plant-based material, such as a tobacco material. The aerosol-forming material may be a sheet or shredded sheet of aerosolizable material that includes a plant-based material, such as a tobacco material.

[0309] The plant-based material may be a granular or particulate material. In some embodiments, the plant-based material is a powder. Alternatively or additionally, the plant-based material may comprise tobacco strips, strands or fibers. For example, where tobacco material is provided, the tobacco material may comprise tobacco particles, granules, fibers, strips and / or strands. In some embodiments, the tobacco material consists of particles or granules of tobacco material.

[0310] The tobacco material may include tobacco obtained from any part of the tobacco plant, hi some embodiments, the tobacco material includes tobacco leaf.

[0311] The sheet or shredded sheet can contain from 5% to about 90% tobacco leaf by weight.

[0312] In some embodiments, the aerosol-generating material comprises a sheet or shredded sheet of aerosolizable material comprising an aerosol-forming material. The aerosol-forming material is provided in an amount of up to about 50% by dry weight of the sheet or shredded sheet. In some embodiments, the aerosol-forming material is provided in an amount of about 5% to about 40% by dry weight of the sheet or shredded sheet, about 10% to about 30% by dry weight of the sheet or shredded sheet, or about 10% to about 20% by dry weight of the sheet or shredded sheet.

[0313] The aerosol-generating material may include a filler. The filler is generally a non-tobacco component, i.e., a component that does not include components derived from tobacco. The filler may include one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents, such as molecular sieves. The filler may be non-tobacco fibers, such as wood fibers or pulp or wheat fibers. The filler may be a material that includes cellulose or a material that includes a derivative of cellulose. The filler component may also be a non-tobacco cast material or a non-tobacco extrusion material. In some embodiments, the aerosol-generating material is in the form of a sheet or shredded sheet that includes the filler.

[0314] The aerosol-generating material may include an aerosol modifier, such as any of the flavorings described herein. In one embodiment, the aerosol-generating material includes menthol. When the aerosol-generating material is incorporated into an article 1 for use in an aerosol delivery system, the article may be referred to as a mentholated consumable or article 1. The aerosol-generating material may include between 0.5 mg and 20 mg of menthol, between 0.7 mg and 20 mg of menthol, between 1 mg and 18 mg, or between 8 mg and 16 mg of menthol.

[0315] In some embodiments, article 1 comprises an aerosol-forming composition that includes an aerosol-forming material 4 .

[0316] An aerosol-forming material is a material that can generate an aerosol when, for example, heated, irradiated, or otherwise energized. The aerosol-forming material may be in the form of, for example, a solid, liquid, or semi-solid (such as a gel), which may or may not contain active substances and / or fragrances.

[0317] The aerosol-generating material may include a binder and an aerosol-forming agent. Optionally, an active agent and / or a filler may also be present. Optionally, a solvent, such as water, is also present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material is substantially free of plant material. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0318] The aerosol-generating material may include or be an "amorphous solid." The amorphous solid may be a "monolithic solid." In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that may retain some fluid, such as a liquid, within the amorphous solid. In some embodiments, the aerosol-generating material may include, for example, about 50%, 60%, or 70% amorphous solid, up to about 90%, 95%, or 100% amorphous solid by weight. The amorphous solid may be substantially non-fibrous.

[0319] The aerosol-generating material may include or be an aerosol-generating film. The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-forming agent, and one or more other ingredients, such as an active agent, to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent to form the aerosol-generating film. The slurry may be heated to remove at least about 60%, 70%, 80%, 85% or 90% of the solvent by weight. The aerosol-generating film may be a continuous film or a discontinuous film, such as an arrangement of discontinuous portions of the film on a substrate. The aerosol-generating film may be substantially free of tobacco.

[0320] The aerosol-generating film may include or be a sheet that can optionally be chopped to form chopped sheets.

[0321] In some instances, the amorphous solid is 1 to 60% by weight of a gelling agent; 0.1 to 50 weight percent of an aerosol forming material; 0.1 to 80% by weight of a fragrance, Here, these weights are calculated on a dry weight basis.

[0322] In some further embodiments, the amorphous solid is 1 to 50% by weight of a gelling agent; 0.1 to 50 weight percent of an aerosol forming material; 30 to 60% by weight of a fragrance, Here, these weights are calculated on a dry weight basis.

[0323] The aerosol-generating material may comprise tobacco material reconstituted with paper. The composition may alternatively or additionally comprise any of the tobacco forms described herein. The aerosol-generating material may comprise a sheet or shredded sheet comprising tobacco material comprising 10%-90% tobacco leaf by weight, the aerosol-forming material being provided in an amount up to about 20% by weight of the sheet or shredded sheet, with the remainder of the tobacco material comprising tobacco reconstituted with paper.

[0324] When the aerosol-forming material comprises an amorphous solid material, the amorphous solid material may be a dry gel comprising menthol.

[0325] In each of the embodiments described herein, article 1 may include first and second aerosol-forming materials.

[0326] The first and second aerosol-generating materials of the article may optionally have different densities. Otherwise, the aerosol-generating materials in the article may be the same or different.

[0327] It has been found that providing a region containing a second aerosol-generating material having a higher density than the first aerosol-generating material causes the second aerosol-generating material to heat more slowly than the first aerosol-generating material when exposed to the same heating, and release its volatile compound (e.g., nicotine) at a slower rate than the first aerosol-generating material. Thus, aerosol-generating materials having different densities, possibly in combination with separately heating these materials at different times and / or temperatures, can provide a more tailored release of the volatile compound over the consumption period of the article, for example, a more consistent and sustained release of the volatile compound. Alternatively, it may be desirable to have a more rapid or greater release of the volatile material toward the beginning of the consumption of the article, in order to give the user a greater initial impact of use. The ability to control aerosol generation and volatile compound release can be particularly advantageous, as the article can be relatively small while still achieving a particular desired release of the volatile compound over the consumption period.

[0328] In some embodiments, the second aerosol-generating material has a density at least about 25% higher than the density of the first aerosol-generating material, and optionally at least about 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, or 75% higher than the density of the first aerosol-generating material. The second aerosol-generating material may have a density not greater than about 200% higher than the density of the first aerosol-generating material, and optionally not greater than about 150%, 125%, 100%, or 75% higher than the density of the first aerosol-generating material. In some embodiments, the second aerosol-generating material has a density between about 25% and about 75% higher than the density of the first aerosol-generating material.

[0329] In some embodiments, the first aerosol-generating material has a density of at least about 0.1 g / cm 3 , optionally at least about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8 or 0.9 g / cm 3The first aerosol-forming material has a density of about 1 g / cm 3 Optionally, about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3 or 0.2 g / cm 3 In some embodiments, the density of the first aerosol-generating material is about 0.1 to 0.9 g / cm. 3 It is.

[0330] In some embodiments, the second aerosol-generating material has a density of at least about 0.4 g / cm 3 , optionally at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9 or 2 g / cm 3 The second aerosol-forming material has a density of about 2 g / cm 3 or less, and optionally about 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6 or 0.5 g / cm 3 In some embodiments, the density of the first aerosol-generating material is between about 0.4 and 1.99 g / cm. 3 It is.

[0331] In some embodiments, the first and second aerosol-generating materials contain the same components. Thus, upon heating, they release very similar aerosols, potentially with the same content of actives and / or flavors, etc. Their different densities allow aerosols to be generated from the two materials at different rates and / or for different times during heating.

[0332] In other embodiments, the first and second aerosol-generating materials contain different components. Thus, when heated, they emit different aerosols, potentially with different compositions of actives and / or fragrances, etc. Their different densities allow different aerosols to be generated from the two materials at different rates and / or times during heating, potentially providing aerosols that vary over the period of use.

[0333] In some embodiments, the first aerosol-forming material and the second aerosol-forming material each comprise tobacco. Tobacco contains volatile components including nicotine, aromas and flavors. Tobacco may be any type of tobacco and any part of the tobacco plant, including tobacco leaf, blade, stem, stalk, rib, stubble and stubble, or a mixture of two or more thereof. Suitable tobacco materials include the following types: Virginia or flue-cured tobacco, Burley tobacco, Oriental tobacco, or blends of tobacco materials, optionally including those listed herein. The tobacco may be expanded, such as dry ice expanded tobacco (DIET), or processed by any other means. In some embodiments, the tobacco material may be a reconstituted tobacco material. The tobacco may be pre-treated or untreated, for example, solid stem (SS), shredded dried stem (SDS), steam treated stem (STS), or any combination thereof. The tobacco material may be fermented, cured, uncured, roasted, or otherwise pre-treated.

[0334] The first and second aerosol-generating materials may comprise different tobacco, or the tobacco may be the same but provided in a different form such that the second aerosol-generating material has a higher density than the first aerosol-generating material.

[0335] In some embodiments, the first aerosol-generating material has at least one additional different characteristic relative to the second aerosol-generating material. The different characteristic may be one or more of the following: form, size, moisture content, amount (by weight), one or more materials, or proportions of materials that make up the first and second aerosol-generating materials (including recipes of the aerosol-generating materials when each is made from two or more materials). In some embodiments, the first and second aerosol-generating materials do not have different characteristics other than their different densities.

[0336] In some embodiments, the first aerosol-generating material includes one or more tobaccos in the form of cut rags. The tobacco material may be lamina or reconstituted tobacco material. In some embodiments, the first aerosol-generating material is a blend that includes both lamina and reconstituted tobacco. For example, the ratio of lamina to reconstituted tobacco may be about 1:4 to about 4:1.

[0337] The second aerosol-generating material has a higher density than the first aerosol-generating material. In some embodiments, this higher density second aerosol-generating material may include particles or be in the form of beads or one or more sheets. Each bead or sheet may be formed from an agglomeration of smaller particles.

[0338] As used herein, the term "bead" is meant to include beads, pellets, or other small discrete units that have been molded, shaped, compressed, or otherwise formed into a desired shape. Beads may have a smooth, regular outline (e.g., spherical, cylindrical, ovoid, etc.) and / or may have an irregular outline.

[0339] In some embodiments, the beads have a diameter of at least about 0.5 mm (e.g., as measured by sieving), optionally at least about 1, 1.5, 2, 2.5, or 3 mm. The beads may have a diameter of about 5 mm or less (e.g., as measured by sieving), optionally no greater than about 4.5, 4, 3.5, 3, 2.5, 2, or 1.5 mm. In some embodiments, the diameter of each bead may range from about 0.5 mm to about 3 mm, or from about 1 mm to about 2 mm. The size of the beads may refer to their average size, e.g., number or volume average size.

[0340] In some embodiments, the desired density of the aerosol-generating material is achieved or controlled by the formulation of the material and / or the way in which the material is processed. Processes involving agglomeration, particularly agglomeration by some application of compressive force, tend to increase the density of the material.

[0341] Thus, in some embodiments, the aerosol-forming material comprises particles of agglomerated material.

[0342] In the case of sheet material, the sheet may be formed from particles of material that are combined and optionally compressed to form a sheet having the desired dimensions and density.

[0343] In some embodiments, the beads or pellets can be formed using a so-called malming process.

[0344] In some embodiments, the agglomeration is by pelleting. Pelletization is an agglomeration process that converts fine particles of material, optionally with excipients, into free-flowing units called pellets. Depending on the type of equipment and process selected, pellet formation and growth can occur in several ways. These pellets may be formed by agitation, where particles are rolled and tumbled in the presence of an appropriate amount of liquid to form agglomerates. Sintering may include the use of equipment such as pans, disks, drums or mixers to produce pellets. Compression pelleting is a form of pressure agglomeration, where particles are brought together by mechanical force, optionally with compounding aids. The compression force means that the pellets formed have an increased density compared to the starting material.

[0345] In some embodiments, the agglomeration is by extrusion. In some embodiments, the pellets formed by pelletization can be extruded to form a denser extrudate.

[0346] The extruded particles may have a size selected to produce a denser aerosol-forming material, which affects heat transfer and release of volatile components within the material.

[0347] Extrusion involves feeding a composition (also called a precursor composition) through a die to produce an extruded product. This process applies pressure to the composition in combination with shear forces.

[0348] Extrusion can be carried out using one of the major types of extruders: screw, sieve and basket, roll, ram and pin barrel extruders. Single or twin screw extruders may be used. Forming tobacco beads by extrusion has the advantage that this process combines compression, mixing, conditioning, homogenization and shaping of the composition.

[0349] In some embodiments, during extrusion, a free-flowing composition including particles, such as tobacco particles, is subjected to high pressure and temperature and forced through an orifice, such as a shaped nozzle or die, to form an extrudate, which in some embodiments has a rod-like form and can be cut into segments of a desired length.

[0350] In some embodiments, the composition is exposed to a temperature in the extruder of about 40° C. to about 150° C., or about 80° C. to about 130° C., or about 60° C. to about 95° C. In some embodiments, including those using dual extrusion, the precursor composition is exposed to a temperature in the extruder of about 70° C. to about 95° C. In some embodiments, including those using single extrusion, the precursor composition is exposed to a temperature in the extruder of about 60° C. to about 80° C.

[0351] The composition may be subjected to pressures (just before the die or nozzle) ranging from about 2 bar to about 100 bar, or from about 5 bar to about 60 bar, depending on the design of the die or nozzle used. Higher pressures tend to produce a denser extrudate. Thus, the extrusion process can be adjusted to provide an extruded aerosol-generating material having a desired density.

[0352] In some embodiments in which tobacco particles are extruded, due to the relatively high density of the extrudate and the relatively open surfaces of the tobacco particles therein, the tobacco beads formed from the extrudate exhibit good heat and mass transfer, which positively impacts the release of tobacco components such as flavors and nicotine.

[0353] In some embodiments, extrusion may be a generally dry process and the composition comprises dry or substantially dry aerosol-generating particles. The composition may optionally include other particulate materials including, for example, bases, diluents, solid aerosol formers, solid flavor modifiers, and the like.

[0354] In some embodiments, liquid can be added to the composition before or during the extrusion process. For example, water can be added as a processing aid, for example, to aid in dissolving or solubilizing the components of the composition, or to aid in binding or cohesion. Alternatively or additionally, a wetting agent can be added to the composition.

[0355] In some embodiments, the liquid may be an aerosol former material, such as glycerol or others discussed herein. When the liquid is added to the composition in this manner, the liquid is not only applied to the surface, but the extrudate is impregnated with the liquid as a result of the vigorous mixing caused by the pressure and high shear forces of the extruder. If the liquid is an aerosol former material, this can result in high availability of the aerosol former material in the resulting beads, facilitating the evaporation of volatile components.

[0356] In some embodiments, the amount of aerosol former material incorporated into the extruded beads may be up to about 30% by weight, or even up to about 40% by weight. Usually, such a large amount of aerosol former material may make the composition difficult to handle. However, this is less of a problem as the particles are impregnated with aerosol former material upon extrusion. It may be desirable to include an amount of aerosol former material, such as at least about 10% by weight or at least about 20% by weight, that will generate an aerosol in addition to releasing volatile components. If the main function of the beads is to release volatile components carried by the beads into an existing aerosol or air stream, a smaller amount of aerosol former material, such as up to about 5% by weight, may be sufficient.

[0357] In some embodiments, the aggregates do not include a binder or binding additive. For example, extruded beads may not require a binder to maintain their structural integrity. In other embodiments, the aggregates include a binder or binding additive. The binding additive may be selected to aid in the formation of the aggregate structure by helping to adhere the particles to each other and to other components in the composition. Suitable binding additives include, for example, thermoreversible gelling agents such as gelatin, starch, polysaccharides, pectin, alginates, wood pulp, cellulose, and cellulose derivatives such as carboxymethylcellulose.

[0358] In some embodiments, processing by extrusion is sufficient to provide the desired high density of the second aerosol-generating material, however, in other embodiments, the extrudate may be further processed to increase the density of the aerosol-generating material.

[0359] For example, in some embodiments, the extruded aerosol-generating material is subjected to spheronization, in which the extruded cylindrical particles are broken into uniform lengths and gradually transformed into spherical shapes by plastic deformation. If the extrudate is first divided into uniform lengths, spheres having uniform diameters are produced by the spheronization step.

[0360] According to one specific example of the embodiments discussed herein, a sample of the second aerosol-forming material was generated as follows.

[0361] Three sample formulations, with and without binder, are shown in Table 1, with the amounts given as wet weight percent (WWB). [Table 1] The tobacco was ground to produce a fine powder, taking care not to overheat the tobacco. The ground tobacco particles were sieved to select those having a desired size, for example, a particle size of less than 250 μm, less than 100 μm, or less than 60 μm.

[0362] Next, all of the dry (non-liquid) ingredients of the formulation were combined and mixed or blended in a mixer. In this particular example, the mixture was mixed for 1 minute at speeds up to 75 RPM. This was to ensure that the dry ingredients were evenly distributed within the mixture.

[0363] Next, half of the glycerol and half of the water were added to the dry mix and mixed. Specifically, the mix was mixed for an additional minute at 75 RPM. The remaining glycerol and water were then added and mixed again for 1 minute at 75 RPM. Mixing was then continued until the mix had a crumbly consistency that could be pressed into a mass to ensure a homogenous mix was achieved. In this particular example, additional mixing continued for 3 minutes.

[0364] The mixture was then extruded using a Caleva Multilab. The extruder was operated at approximately 1500 rpm to produce extrudates of pasta-like length.

[0365] The extrudate was broken into pieces of various lengths as it emerged from the extruder. These pieces were then spheronized. Spheronization was carried out until spherical beads were formed. In this case, the extrudate was first spheronized in a Caleva Multilab operating at 2,500 RPM for 1 minute, and then the beads were checked for defects. Spheronization was then continued for an additional 1-2 minutes. This spheronization step broke the extruded tobacco into individual pieces, forming dense spherical beads.

[0366] In the final step, the spheronized beads were dried in an oven at 65° C. for 30 minutes. After each drying period, the beads were weighed and drying was stopped when the desired moisture weight loss was achieved. Generally, such drying takes about 1 hour.

[0367] In some embodiments, the first aerosol-generating material is in the form of discrete particles or aggregates of particles. These particles may share various properties, such as particle size, with the second aerosol-generating material, but have a lower density than the second aerosol-generating material. As discussed above, there are various ways to adjust the density of the aerosol-generating material, such as compounding and / or processing the material into particles, beads, or pellets.

[0368] In some embodiments, the first aerosol-generating material comprises a combination of 60% reconstituted tobacco and 40% flaxseed tobacco, and the density of this material is from about 0.1 to about 0.9 g / cm. 3 The second aerosol-forming material contains about 30 to about 90% tobacco and has a density of about 0.4 to about 1.99 g / cm 3The second aerosol-generating material may comprise approximately spherical beads having a particle size of about 0.5 to about 3 mm. In some embodiments, the aerosol-generating material in the article comprises, by weight, about 50% of the first aerosol-generating material and about 50% of the second aerosol-generating material. Thus, for example, an article comprising 260 mg of aerosol-generating material may comprise 130 mg of the first aerosol-generating material and 130 mg of the second aerosol-generating material.

[0369] In some embodiments where the aerosol-forming material includes tobacco, the tobacco is present in an amount between about 10% and about 90% by weight of the aerosol-forming material.

[0370] In some embodiments, tobacco may be present in an amount of at least about 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, or at least about 35% tobacco based on the weight of the aerosol-generating material.

[0371] In some embodiments, tobacco may be present in an amount of about 90%, 89%, 88%, 87%, 86%, 85%, 84%, 83%, 82%, 81%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, or about 40% or less tobacco based on the weight of the aerosol-forming material.

[0372] The cigarettes described herein may contain nicotine. In some embodiments, the nicotine content may be between 0.5 and 2% by weight of the cigarette, such as between 0.5 and 1.75% by weight of the cigarette, between 0.8 and 1.2% by weight of the cigarette, or between about 0.8 and about 1.75% by weight of the cigarette. In some embodiments, the nicotine content may be between 0.8 and 1% by weight of the cigarette.

[0373] In some embodiments, the first and second aerosol-forming materials have the same nicotine content.

[0374] In some embodiments, the first and second aerosol-generating materials include one or more volatile components, hi some embodiments, the first and second aerosol-generating materials have the same volatile component content.

[0375] In some embodiments, the first and / or second aerosol generating material comprises tobacco. For example, the first and / or second aerosol generating material may comprise about 80 to about 350 mg of tobacco. In some particular embodiments, the aerosol generating material in the article or consumable has a weight of 260 mg and comprises a combination of 130 mg of a first aerosol generating material, e.g., comprising a blend of lamina and reconstituted tobacco, and 130 mg of a second aerosol generating material, e.g., comprising higher density tobacco beads.

[0376] In some embodiments, each of the regions containing aerosol-generating material contains an equal amount of tobacco. In alternative embodiments, the regions may contain different amounts of tobacco. If the total amount of tobacco is about 80 to about 350 mg, one region of aerosol-generating material contains about 20 to about 330 mg, or about 50 to about 300 mg, or about 40 to about 125 mg of tobacco, and the other region of aerosol-generating material contains about 20 to about 330 mg, or about 30 to about 300 mg, or about 40 to about 125 mg of tobacco.

[0377] The present disclosure also provides a package (not shown) including a plurality of articles according to any of the examples described herein. In some embodiments, the package is sealed. The package can include a container having a body and a lid, with a space provided within the container body to receive the plurality of articles. The lid can be, for example, a hinged lid, a snap-fit ​​lid, or a lid connected by a screw thread.

[0378] The various embodiments described herein are presented only to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limitations on the scope of the invention as defined by the claims or limitations on the equivalents of the claims, and it is understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Furthermore, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. 1. An aerosol delivery system comprising: an article comprising an aerosol-forming material and a first binding moiety; an aerosol provider including a second coupling portion and a zone configured to receive the article; An aerosol delivery system, wherein the first and second coupling portions are configured such that when the article is received in the zone, the first coupling portion is magnetically attracted to the second coupling portion.

2. 1. An aerosol delivery system comprising: an article comprising an aerosol-forming material and a first binding moiety; an aerosol provider comprising a second coupling portion and a heating zone configured to receive the article and heat the aerosol-generating material; The aerosol delivery system, wherein the first and second coupling portions are configured such that when the article is received in the heating zone, the first coupling portion is magnetically attracted to the second coupling portion.

3. 3. The aerosol delivery system of claim 1 or claim 2, wherein one of the first and second coupling portions comprises a magnet and the other of the first and second coupling portions comprises a ferromagnetic material and / or a second magnet.

4. The aerosol delivery system according to any one of claims 1 to 3, wherein the second coupling portion is provided at an end of the zone or the heating zone.

5. The aerosol delivery system according to any one of claims 1 to 4, wherein the aerosol delivery device comprises a chamber containing the zone or the heating zone.

6. The aerosol delivery system of any one of claims 1 to 5, wherein the article protrudes from an end of the zone or the heating zone.

7. The aerosol delivery system of any one of claims 1 to 6, wherein the aerosol delivery device comprises a heater at least partially surrounding the heating zone, preferably the heater comprising a magnetic field generator configured to generate a varying magnetic field to inductively heat the heating material.

8. The aerosol delivery system according to any one of claims 1 to 7, wherein the aerosol delivery device is an electronic cigarette.

9. An aerosol delivery system according to any one of claims 1 to 8, wherein the aerosol delivery device comprises a mouthpiece, preferably the mouthpiece being removable from other parts of the aerosol delivery device to facilitate access to the zone or heating zone.

10. The aerosol delivery system of claim 9 , wherein the mouthpiece comprises the second coupling portion.

11. The aerosol delivery system according to any one of claims 1 to 10, wherein the aerosol delivery device comprises a body comprising the second coupling portion.

12. The aerosol delivery system of any one of claims 1 to 11, wherein the first and second coupling portions are configured such that when the article is received in the zone or the heating zone, the article is axially urged toward the second coupling portion.

13. 1. An article for use with an aerosol delivery device, the aerosol delivery device comprising a zone configured to receive the article, the article comprising: an aerosol-generating material; a first coupling portion configured to be magnetically attracted to a second coupling portion of the aerosol provider when the article is received in the zone.

14. 1. An article for use with an aerosol dispenser, the aerosol dispenser comprising a heating zone configured to receive the article, the article comprising: an aerosol-generating material; a first coupling portion configured to be magnetically attracted to a second coupling portion of the aerosol provider when the article is received in the heating zone.

15. The aerosol delivery system of any one of claims 1 to 12 or the article of claim 13 or claim 14, wherein the first binding portion comprises a magnet.

16. The aerosol delivery system of any one of claims 1 to 12 or 15 or the article of any one of claims 13 to 15, wherein the first binding portion comprises a ferromagnetic material.

17. An aerosol delivery system as claimed in any one of claims 1 to 12, 15 or 16, or an article as claimed in any one of claims 13 to 16, wherein the first coupling portion is provided over only a portion of the axial length of the article.

18. An aerosol delivery system according to any one of claims 1 to 12, 15 or 16, or an article according to any one of claims 13 to 16, wherein the first coupling portion is provided over substantially the entire axial length of the article.

19. An aerosol delivery system according to any one of claims 1 to 12 or 15 to 18, or an article according to any one of claims 13 to 18, wherein the first binding portion is embedded within the article, preferably within the aerosol-generating material of the article.

20. An aerosol delivery system according to any one of claims 1 to 12 or 15 to 19, or an article according to any one of claims 13 to 19, wherein the first binding portion comprises a heating material that can be heated by penetration by a varying magnetic field.

21. An aerosol delivery system as described in any one of claims 1 to 12 or 15 to 20, or an article as described in any one of claims 13 to 20, wherein the article and / or the aerosol delivery device further comprises a heating material in addition to the first binding portion, the heating material being heatable by penetration by a varying magnetic field.

22. An aerosol delivery system according to any one of claims 1 to 12 or 15 to 21, or an article according to any one of claims 13 to 21, wherein the aerosol-generating material at least partially surrounds the first binding portion, preferably surrounds the first binding portion.

23. The aerosol delivery system of any one of claims 1 to 12 or 15 to 22, or the article of any one of claims 13 to 22, wherein the aerosol-forming material comprises nicotine.

24. An aerosol delivery system according to any one of claims 1 to 12 or 15 to 23, or an article according to any one of claims 13 to 23, wherein the aerosol-generating material comprises, consists of, or consists essentially of tobacco.

25. The aerosol delivery system of any one of claims 1 to 12 or 15 to 23, or the article of any one of claims 13 to 23, wherein the aerosol-forming material does not contain tobacco.

26. The aerosol delivery system of any one of claims 1 to 12 or 15 to 25, or the article of any one of claims 13 to 25, wherein the aerosol-generating material is a liquid.

27. An aerosol delivery system according to any one of claims 1 to 12 or 14 to 26, or an article according to any one of claims 13 to 26, wherein the article comprises a reservoir for containing the aerosol-generating material.

28. 28. An aerosol delivery system according to any one of claims 1 to 12 or 15 to 27, or an article according to any one of claims 13 to 27, wherein the article has an axial length of up to 36 mm, preferably up to 34 mm, 32 mm, 30 mm, 28 mm, 26 mm, 24 mm or 23 mm.

29. The aerosol delivery system of any one of claims 1 to 12 or 15 to 28, or the article of any one of claims 13 to 28, wherein the first coupling portion comprises one or more openings for facilitating the flow of gas through the first coupling portion.

30. 30. The aerosol delivery system of any one of claims 1 to 12 or 15 to 29, or the article of any one of claims 13 to 29, wherein the article comprises a plurality of regions of aerosol-generating material.

31. 31. The aerosol delivery system of claim 30 or the article of claim 30, wherein the article comprises a substrate and the regions of the aerosol-forming material are attached to the substrate.

32. 32. The aerosol delivery system of claim 31 or the article of claim 31, wherein the substrate is substantially planar.

33. 33. The aerosol delivery system of claim 30, configured to initiate aerosol generation from at least one of the plurality of regions of the aerosol-generating material after initiating aerosol generation from another of the plurality of regions of the aerosol-generating material.

34. 34. The aerosol delivery system of claim 30, configured to initiate heating of at least one of the plurality of regions of the aerosol generating material after initiating heating of another of the plurality of regions of the aerosol generating material.

35. A package comprising a plurality of articles according to any one of claims 13 to 34, preferably said package being sealed.

36. An aerosol providing device, comprising: a zone configured to receive an article including an aerosol-generating material; a holder for securing the article within the zone, the holder configured to engage the article; The aerosol delivery device, wherein the holder is configured to be removably connected to a component of the aerosol delivery device.

37. 37. The aerosol dispenser of claim 36, wherein the zone is a heating zone.

38. The aerosol provision device of claim 36 or claim 37, wherein the holder is configured to be removably connected to a component of the aerosol provision device, and when in use, when the holder engages with the article, the holder and the article can be removably connected to the component, and a user can remove the holder and the article together from the component.

39. The aerosol dispenser of any one of claims 36 to 38, wherein the aerosol dispenser comprises a body containing the components of the aerosol dispenser.

40. 40. An aerosol provision device according to any one of claims 36 to 39, comprising a mouthpiece.

41. 41. The aerosol delivery device of claim 40, wherein the mouthpiece comprises the component of the aerosol delivery device.

42. 42. An aerosol delivery device according to claim 40 or claim 41, wherein the mouthpiece is removable from the body of the aerosol delivery device, preferably the mouthpiece is removable from the body to provide access to the holder.

43. 43. An aerosol dispenser according to any one of claims 36 to 42, wherein the zone is located at or near the mouth end of the aerosol dispenser.

44. An aerosol provision device according to any one of claims 36 to 43, wherein the holder is configured to be magnetically removably connected to the component of the aerosol provision device.

45. 45. The aerosol delivery device of claim 44, wherein one of the holder and the component comprises a first magnet, and the other of the holder and the component comprises a ferromagnetic material and / or a second magnet configured to be attracted to the first magnet to magnetically detachably connect the holder to the component.

46. An aerosol dispensing device according to any one of claims 36 to 45, wherein the holder comprises an engagement member configured to be inserted into the article.

47. 47. The aerosol dispenser of claim 46, wherein the engagement member comprises a pin, preferably the pin is a solid pin.

48. 48. The aerosol dispensing device of claim 46 or claim 47, wherein the holder comprises a base portion, and the engagement member extends from the base portion.

49. An aerosol dispenser according to any one of claims 36 to 48, wherein the holder comprises a heating material that is heatable by penetration by a varying magnetic field.

50. 50. The aerosol dispensing device of any one of claims 36 to 49, wherein the holder is configured to mechanically couple to the article.

51. 51. The aerosol provision device of any one of claims 36 to 50, wherein the holder is configured to connect to the article by at least one of: clipping to the article, clamping or gripping the article, connecting to the article via a bayonet connection, or connecting to the article via threads on the holder and the article.

52. 52. The aerosol dispenser of any one of claims 36 to 51, wherein one or both of the article and the holder include one or more magnets for coupling the article and the holder to one another.

53. An aerosol delivery system comprising an aerosol delivery device according to any one of claims 36 to 52 and an article containing an aerosol-generating material.

54. 54. The aerosol delivery system of claim 53, wherein the aerosol generating material comprises nicotine.

55. 55. An aerosol delivery system according to claim 53 or claim 54, wherein the aerosol-generating material comprises, consists of, or consists essentially of tobacco.

56. 55. The aerosol delivery system of claim 53 or claim 54, wherein the aerosol-forming material does not include tobacco.

57. 57. The aerosol delivery system of any one of claims 53 to 56, wherein the aerosol-generating material is a liquid.

58. 58. An aerosol delivery system according to any one of claims 53 to 57, wherein the article comprises a reservoir for containing the aerosol-generating material.

59. 59. An aerosol delivery system according to any one of claims 55 to 58, wherein the article has an axial length of up to 36 mm, preferably up to 34 mm, 32 mm, 30 mm, 28 mm, 26 mm, 24 mm or 23 mm.

60. An aerosol delivery system according to claim 1 or any one of claims 3 to 12 or 15 to 34 when dependent on claim 1 or any one of claims 53 to 59, or an article according to claim 13 or any one of claims 15 to 34 when dependent on claim 13, or an aerosol delivery device according to any one of claims 36 to 52, wherein the zone is an aerosol generation zone and optionally a heating zone.

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