Article for use in an aerosol supply system

Abstract

The present disclosure relates to an article (1) for use in an aerosol supply system (100), an aerosol supply system (100) comprising the article (1), and a method for forming the article (1). In an example of the invention, the article (1) comprises an aerosol-forming material (3) and a downstream portion (2) located downstream thereof. The downstream portion (2) comprises separate first and second material bodies (6a, 6b), each of which is formed from respective first and second crimped sheet materials (6A, 6B) gathered towards the material body. The first material body (6a) is downstream of the second material body (6b), and the first material body (6a) is provided with a tubular element (8) disposed within the first material body (6a) so as to be circumferentially surrounded by the first material body (6a). An aerosol-modifying release component (11) is provided within the second material body (6b).

Description

Technical Field

[0001] The present disclosure relates to an article for use in an aerosol supply system, an aerosol supply system comprising the article, and a method for forming the article.

Background Art

[0002] Certain tobacco industry products generate an aerosol during use, which is inhaled by the user. For example, a tobacco heating device forms an aerosol by heating an aerosol-forming substrate such as tobacco, rather than burning the substrate. Such tobacco industry products generally include a mouthpiece, and the aerosol passes through the mouthpiece and reaches the user's mouth.

Summary of the Invention

[0003] According to an embodiment described herein, according to a first aspect, an article for use in an aerosol supply system, the article comprising an aerosol-forming material, and a downstream portion positioned downstream of the aerosol-forming material, the downstream portion comprising separate first and second material bodies, each of the first and second material bodies being formed from respective first and second crimped sheet materials gathered towards the material body, the first material body being downstream of the second material body, the first material body being provided with a tubular element disposed within the first material body so as to be circumferentially surrounded by the first material body, and an aerosol modification release component being provided within the second material body. An article is provided.

[0004] According to an embodiment described herein, according to a second aspect, an article for use in an aerosol supply system, the article comprising an aerosol-forming material, and A downstream portion located downstream of the aerosol - generating material, the downstream portion comprising separate first and second material bodies, each of the first and second material bodies being formed from respective first and second crimped sheet materials gathered towards the material body, the first material body being downstream of the second material body, an aerosol - modifying release component being provided within the second material body, and the closed - pressure drop per millimeter of length of the first material body being greater than the closed - pressure drop per millimeter of length of the second material body. An article is provided.

[0005] According to an embodiment described herein, in accordance with a third aspect, an article for use in an aerosol supply system, the article comprising an aerosol - generating material, and a downstream portion located downstream of the aerosol - generating material, the downstream portion comprising separate first and second material bodies, each of the first and second material bodies being formed from respective first and second crimped sheet materials gathered towards the material body, the first material body being downstream of the second material body, an aerosol - modifying release component being provided within the second material body, the first crimped sheet material including a first level of crimp, and the second crimped sheet material including a second level of crimp lower than the first level of crimp. An article is provided.

[0006] According to an embodiment described herein, in accordance with a fourth aspect, a non - combustible aerosol supply system comprising an article according to the first, second, or third aspect is provided.

[0007] According to an embodiment described herein, in accordance with a fifth aspect, a method for forming an article according to the first, second, or third aspect, the method comprising applying a crimp pattern to a first sheet material, gathering the first sheet material towards a first material body, applying a crimp pattern to a second sheet material, Providing an aerosol release component, Collecting the second sheet material around the second material body of the aerosol modifying release component, Combining the first and second material bodies with an aerosol generating material, A method is provided that includes.

[0008] Next, embodiments of the present invention will be described as merely non-limiting examples with reference to the accompanying drawings.

Brief Description of the Drawings

[0009]

Figure 1

Figure 2

Figure 3

Figure 4

Figure 5

Figure 6

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Figure 8

Figure 9

Figure 10A

Figure 10B

Modes for Carrying Out the Invention

[0010] According to the present disclosure, an "aerosol supply system" includes both a combustion-type aerosol supply system and a non-combustion-type aerosol supply system.

[0011] According to the present disclosure, a "combustion-type" aerosol supply system is a system in which the constituent aerosol-generating material (or its components) of the aerosol supply system is burned or ignited during use to facilitate the delivery of at least one substance to the user.

[0012] In some embodiments, the delivery system is a combustion-type aerosol supply system such as a system selected from the group consisting of cigarettes, cigars, and cigars.

[0013] In some embodiments, the present disclosure relates to components for use in a combustion-type aerosol supply system, such as aerosol modifier release components such as filters, filter rods, filter segments, tobacco rods, spills, capsules, threads, or beads, or papers such as plug wraps, tip papers, or cigarette papers.

[0014] According to the present disclosure, a "non-combustion-type" aerosol supply system is a system in which the constituent aerosol-generating material (or its components) of the aerosol supply system is neither burned nor ignited to facilitate the delivery of at least one substance to the user.

[0015] In some embodiments, the delivery system is a non-combustion-type aerosol supply system such as a powered non-combustion-type aerosol supply system.

[0016] In some embodiments, the non-combustion-type aerosol supply system is an electronic cigarette, also known as a vaping device or an electronic nicotine delivery system (ENDS), but it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0017] In some embodiments, the non-combustion aerosol supply system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a tobacco heating system.

[0018] In some embodiments, the non-combustion aerosol supply system is a hybrid system that generates an aerosol using a combination of aerosol-generating materials that can be heated, one or more of which may be in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or non-tobacco products.

[0019] Typically, the non-combustion aerosol supply system may comprise a non-combustion aerosol supply device and a consumable for use with the non-combustion aerosol supply device.

[0020] In some embodiments, the present disclosure relates to consumables that comprise an aerosol-generating material and are configured to be used with a non-combustion aerosol supply device. These consumables may sometimes be referred to as articles throughout the present disclosure.

[0021] In some embodiments, the non-combustion aerosol supply system, such as its non-combustion aerosol supply device, etc., may comprise a power source and a controller. The power source may be, for example, a power supply or a heat-generating power source. In some embodiments, the heat-generating power source comprises a carbon-based substrate that can be energized to distribute power in the form of heat to an aerosol-generating material or a heat transfer material in proximity to the heat-generating power source.

[0022] In some embodiments, the non-combustion aerosol supply system may comprise an area for receiving the consumable, an aerosol generator, an aerosol generation area, a housing, a downstream portion, a filter, and / or an aerosol modifier.

[0023] In some embodiments, the consumables for use with a non-combustion aerosol supply device may comprise an aerosol-forming material, an aerosol-forming material storage area, an aerosol-forming material transfer component, an aerosol generator, an aerosol generation area, a housing, a packaging material, a filter, a downstream portion, and / or an aerosol modifier.

[0024] In some embodiments, the substance to be delivered comprises an active substance.

[0025] As used herein, the active substance can be a physiologically active material, which is a material intended to effect or enhance a physiological response. The active substance may be selected, for example, from nutraceuticals, nootropics, and psychotropics. The active substance may be of natural origin 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 their constituents, derivatives, or combinations. The active substance may include one or more constituents, derivatives, or extracts of tobacco, cannabis, or another plant-based substance.

[0026] In some embodiments, the active substance comprises nicotine. In some embodiments, the active substance comprises caffeine, melatonin, or vitamin B12.

[0027] As described herein, the active substance may include or be derived from one or more plant substances or their components, derivatives, or extracts. As used herein, the term "plant substance" includes, but is not limited to, any material derived from a plant, including extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, hulls, or shells. Alternatively, the material may include synthetically obtained active compounds that are naturally present in the plant substance. Exemplary plant substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hops, hibiscus, laurel, licorice, matcha, mate, orange peel, papaya, rose, sage, teas such as green tea or black tea, thyme, clove, cinnamon, coffee, anise seed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, bilberry, Japanese butterbur flower, vanilla, wintergreen, perilla, turmeric, gardenia, sandalwood, silantro, bergamot, orange flower, kinkan, blackcurrant, valerian, pimento, mace, damiana, marjoram, olive, lemon balm, lemon basil, chive, calv, vervain, tarragon, geranium, mulberry, burdock, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. Mint may be selected from the following mint varieties: Japanese mint, Mentha canadensis L., Egyptian mint, European mint, Mentha suaveolens Ehrh., Candy mint, Curly mint, Kentucky Colonel mint, Horsemint, Pineapple mint, Pennyroyal mint, Field mint, and Apple mint.

[0028] In some embodiments, the active substance includes or is derived from one or more plant substances or their components, derivatives, or extracts, and the plant substance is tobacco.

[0029] In some embodiments, the active substance comprises or is derived from one or more phytochemicals or their constituents, derivatives, or extracts, and the phytochemicals are selected from eucalyptus, star anise, cocoa, and hemp.

[0030] In some embodiments, the active substance comprises or is derived from one or more phytochemicals or their constituents, derivatives, or extracts, and the phytochemicals are selected from rooibos and fennel.

[0031] In some embodiments, the substance to be delivered comprises a fragrance.

[0032] As used herein, the terms "flavor" and "flavoring" refer to materials that can be used to create a desired taste, aroma, or other somatic sensations in products for adult consumers, when permitted by regional regulations.They may contain naturally occurring flavor materials, plant substances, extracts of plant substances, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, kozo leaves, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spice, Asian spice, herb, wintergreen, strawberry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus, damson, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, cart, nasturtium, kinma, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange flower, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, fennel, wasabi, pepper, ginger, coriander, coffee, hemp, peppermint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hashish, hibiscus, laurel, mate, orange peel, rose, tea such as green tea or black tea, thyme, vaccinium, nasturtium flower, basil, laurel, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, perilla, curcuma, silantro, gingergrass, blackcurrant, buttercup, pimento, mace, damiana, marjoram, olive, lemon balm, lemon basil, chive, calvi, verbena, tarragon, limonene, thymol, camphor), flavor enhancers, bitter receptor site blockers, sensory receptor site activators or stimulants, sugars and / or alternative sugars (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, plant substances, or breath fresheners.They may be imitation, synthetic, or natural raw materials, or blends thereof. They may be in any suitable form, such as a liquid like oil, a solid like powder, or a gas.

[0033] In some embodiments, the flavor includes menthol, spearmint, and / or peppermint. In some embodiments, the flavor includes flavor components of cucumber, blueberry, citrus, and / or redberry. In some embodiments, the flavor includes eugenol. In some embodiments, the flavor includes flavor components extracted from tobacco. In some embodiments, the flavor includes flavor components extracted from cannabis.

[0034] In some embodiments, the flavor may include a sensory agent, which is usually chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the olfactory or gustatory nerves, and is intended to achieve somatosensory sensations, and these may include agents that provide heating, cooling, a stinging sensation, or a numbing effect. Suitable heat-effect agents can be, but are not limited to, vanillyl ethyl ether, and suitable cooling agents can be, but are not limited to, eucalyptol, WS-3.

[0035] The aerosol-forming material is a material that can generate an aerosol when heated, irradiated, or energized by any other method, for example. The aerosol-forming material may be in the form of a solid, liquid, or gel, which may or may not contain, for example, an active substance and / or a flavorant. In some embodiments, the aerosol-forming material may include an "amorphous solid", which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. The amorphous solid is a solid material that can hold some fluid such as a liquid in the amorphous solid. In some embodiments, the aerosol-forming material may include, for example, from about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% of an amorphous solid.

[0036] The aerosol-forming material may comprise one or more active substances and / or fragrances, one or more aerosol-forming agent materials, and optionally one or more other functional materials.

[0037] The aerosol-forming agent material may comprise one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming agent material may comprise one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0038] The one or more other functional materials may comprise one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0039] The material may be present on or within a support to form a substrate. The support may be, for example, paper, card, cardboard, thick paper, reconstituted material, plastic material, ceramic material, composite material, glass, metal, or metal alloy, or may comprise them. In some embodiments, the support comprises a susceptor. In some embodiments, the susceptor is embedded within the material. In some alternative embodiments, the susceptor is on one or both sides of the material.

[0040] A consumable is an article that comprises or consists of an aerosol - generating material, and part or all of which is intended to be consumed during use by a user. The consumable may comprise one or more other components such as an aerosol - generating material storage area, an aerosol - generating material transfer component, an aerosol - generating area, a housing, a packaging material, a downstream portion, a filter, and / or an aerosol modifier. The consumable may also comprise an aerosol generator such as a heater that generates heat during use to generate an aerosol from the aerosol - generating material. The heater may comprise, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0041] A susceptor is a material heatable by penetration by a fluctuating magnetic field such as an alternating magnetic field. The susceptor may be a conductive material, such that penetration of the conductive material by the fluctuating 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 fluctuating magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, such that the susceptor is heatable by both heating mechanisms. A device configured to generate a fluctuating magnetic field is referred to herein as a magnetic field generator.

[0042] An aerosol modifier is a substance configured to modify the generated aerosol, for example, by changing the taste, flavor, acidity, or another property of the aerosol. The aerosol modifier may be provided within an aerosol modifier release component operable to selectively release the aerosol modifier.

[0043] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may comprise, for example, one or more of a flavorant, 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 thread, or a granule. The aerosol modifier may not comprise a filter material.

[0044] An aerosol generator is a device configured to generate an aerosol from an aerosol-forming material. In some embodiments, the aerosol generator is a heater configured to apply thermal energy to the aerosol-forming material to release one or more volatile substances from the aerosol-forming material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-forming material without heating. For example, the aerosol generator may be configured to subject the aerosol-forming material to one or more of vibration, pressure increase, or electrostatic energy.

[0045] Articles, such as rod-shaped articles, are often named "regular" (typically in the range of 68 - 75 mm, e.g., about 68 mm to about 72 mm), "short" or "mini" (less than 68 mm), "king size" (typically in the range of 75 - 91 mm, e.g., about 79 mm to about 88 mm), "long" or "super king" (typically in the range of 91 - 105 mm, e.g., about 94 mm to about 101 mm), and "ultra long" (typically in the range of about 110 mm to about 121 mm) according to the length of the product.

[0046] They are also named "regular" (about 23 - 25 mm), "wide" (more than 25 mm), "slim" (about 22 - 23 mm), "demislim" (about 19 - 22 mm), "super slim" (about 16 - 19 mm), and "micro slim" (less than about 16 mm) according to the circumference of the product.

[0047] Thus, a king size super slim format article will have, for example, a length of about 83 mm and a circumference of about 17 mm.

[0048] Each form may be fabricated using downstream portions of different lengths. The length of the downstream portion is about 30 mm to 50 mm. The chip paper connects the downstream portion to the aerosol-generating material such that the chip paper covers the downstream portion and overlaps, for example, the aerosol-generating material in the form of a rod of base material, connecting the downstream portion to the rod, and typically has a length that is longer than the downstream portion, for example 3 to 10 mm longer.

[0049] The articles and the aerosol-generating materials and downstream portions of the articles described herein may be made in any of the above forms, but are not limited thereto.

[0050] As used herein, the terms "upstream" and "downstream" are relative terms defined with respect to the direction of the main stream aerosol drawn through the article or device during use.

[0051] The filamentous tow material described herein can include cellulose acetate fiber tow. The filamentous 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 filamentous tow may be plasticized with a plasticizer suitable for the tow, such as triacetin, if the material is cellulose acetate tow, or the tow may not be plasticized.

[0052] As used herein, the term "tobacco material" refers to any material that includes tobacco or a derivative or substitute thereof. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fibers, cut tobacco, extruded tobacco, tobacco stems, tobacco leaf blades, reconstituted tobacco, and / or tobacco extracts.

[0053] In the figures described in this specification, like reference numerals are used to indicate like features, articles, or components.

[0054] FIG. 1 is a side cross-sectional view of article 1 for use with a non-combustible aerosol supply system.

[0055] Article 1 comprises a downstream portion 2 and an aerosol-forming material 3 connected to the downstream portion 2, in this case a cylindrical rod of tobacco material. In some embodiments, the downstream portion 2 may extend to the downstream end 2b of article 1. The downstream portion 2 may be a mouthpiece 2. The aerosol-forming material 3 supplies an aerosol when heated, for example, in a non-combustible aerosol supply device as described herein, for example, a non-combustible aerosol supply device comprising a coil that forms part of a system. In other embodiments, article 1 may comprise a heat source of article 1 itself that forms an aerosol supply system without the need for a separate aerosol supply device.

[0056] The aerosol-forming material 3, also referred to herein as the aerosol-forming substrate 3, comprises at least one aerosol-forming agent material. The aerosol-forming agent material is glycerol. Alternatively, the aerosol-forming agent material may be another material or a combination thereof as described herein. It has been found that the sensory performance of the article is improved by the aerosol-forming agent material assisting in transmitting compounds, such as flavor compounds, from the aerosol-forming material to the consumer.

[0057] The downstream portion 2 includes first and second material bodies 6a, 6b. In the illustrated embodiment, the first and second bodies 6a, 6b are in abutting relation directly adjacent to the first body 6a downstream of the second body 6b. The downstream portion 2 includes a tubular portion 4a, also referred to as the cooling element 4a. The tubular portion 4a is disposed between the second body 6b and the rod of the aerosol-forming material 3. In the illustrated embodiment, the tubular portion 4a is in direct abutting contact with both the second material body 6b and the rod 3. In the embodiments described herein, as further described below, an aerosol-modifying emission component 11 is provided within the second material body 6b. The material bodies 6a, 6b and the tubular portion 4a each define a generally cylindrical overall outer shape and share a common longitudinal axis.

[0058] The tubular portion 4a is optional and in embodiments not shown, the tubular portion 4a may be omitted, whereby instead the second body 6b directly abuts the rod of the aerosol-forming material 3 will be understood.

[0059] Figure 2 shows an embodiment in which a tubular element 8 is provided within the first material body 6a. In the illustrated embodiment, the tubular element 8 extends partially through the first material body 6a from the downstream end 2b of the article 1 and forms a cavity within the first material body 6a. The tubular element 8 is positioned substantially radially centrally within the first material body 6a such that it is circumferentially surrounded by the first material body 6a. The terms "tubular element 8" and "hollow tubular element 8" are used interchangeably herein.

[0060] Except for the tubular element 8, Figures 1 and 2 show the same features continuing with the same reference numerals.

[0061] The first and second material bodies 6a, 6b are each enclosed within first and second plug wraps 7a, 7b. The tubular portion 4a and both material bodies 6a, 6b are combined using a third plug wrap 9 wrapped around all three sections 4a, 6a, 6b. The tip paper 5 is wrapped around the entire length of the downstream portion 2 and a part of the rod of the aerosol-forming material 3, and has an adhesive on the inner surface of the tip paper 5 to connect the downstream portion 2 and the rod 3.

[0062] The tubular portion 4a is formed from a plurality of paper layers whose seams are butted and wound in parallel to form a hollow tube. For example, the first and second paper layers are provided in a two-ply tube. In other examples, three, four, or more paper layers can be used to form three, four, or more ply tubes. Other configurations can be used, such as a spirally wound paper layer, a cardboard tube, a tube formed using a tatami-type process, or a plastic tube that has been molded or extruded.

[0063] In some embodiments, the tubular portion preferably has a wall thickness of at least about 325 μm to a maximum of about 2 mm, preferably 500 μm to 1.5 mm, more preferably 750 μm to 1 mm. The tubular portion may have a wall thickness of about 1 mm. The "wall thickness" of the tubular portion corresponds to the radial thickness of the wall of the tubular portion. This may be measured, for example, using calipers.

[0064] In some embodiments, the thickness of the wall of the tubular portion is at least 325 microns, preferably at least 400, 500, 600, 700, 800, 900, or 1000 microns. In some embodiments, the thickness of the wall of the tubular portion is at least 1250 or 1500 microns.

[0065] In some embodiments, the thickness of the wall of the tubular portion is less than 2000 microns, preferably less than 1500 microns.

[0066] An increase in the wall thickness of the tubular portion means that the tubular portion has a greater heat mass, which has been found to help lower the temperature of the aerosol passing through the tubular portion and the surface temperature of the downstream portion at a location downstream of the tubular portion. This is thought to be because the greater the heat mass of the tubular portion, the more heat the tubular portion can absorb from the aerosol compared to a tubular portion with a thinner wall thickness. By increasing the thickness of the tubular portion, the aerosol is guided to the center within the downstream portion so that less heat from the aerosol is transferred to the outer portion of the downstream portion such as the outer portion of the material body.

[0067] In some embodiments, the air permeability of the material of the wall of the tubular portion 4a is at least 100 Gurley units, preferably at least 500 or 1000 Gurley units.

[0068] A relatively high air permeability of the tubular portion has been found to increase the amount of heat transferred from the aerosol to the tubular portion and thus lower the temperature of the aerosol. The air permeability of the tubular portion has also been found to increase the amount of moisture transferred from the aerosol to the tubular portion, which has been found to improve the feel of the aerosol in the user's mouth. The high air permeability of the tubular portion 4a also makes it easier to cut the ventilation holes 12 using a laser, which means that a lower power laser can be used.

[0069] Article 1 has a ventilation level at which approximately 75% of the aerosol is drawn through the article. In an alternative embodiment, the article may have a ventilation level at which 50% - 80%, such as 65% - 75%, of the aerosol is drawn through the article. Ventilation at these levels helps to slow down the flow of aerosol drawn through downstream portion 2, thereby allowing the aerosol to be sufficiently cooled before it reaches the downstream end 2b of downstream portion 2. The ventilation is provided directly within downstream portion 2 of article 1. The ventilation may be provided within tubular portion 4a, which has been found to be particularly beneficial in assisting the aerosol generation process. The ventilation may be provided by first and second parallel rows of ventilation holes 12 formed as laser perforations at positions 17.925 mm and 18.625 mm respectively from the suction port end 2b downstream of downstream portion 2. These ventilation holes 12 penetrate through chip paper 5, third plug wrap 9, and tubular portion 4a. In an alternative embodiment, the ventilation can be provided at other locations within the downstream portion. For example, the ventilation may be provided within either of material bodies 6a, 6b. In such an example, the ventilation is provided at least 1 mm from the end of the material body 6a, 6b within which the ventilation is provided, when measured along the length of the article.

[0070] Alternatively, the ventilation may be provided by a single row of ventilation holes, such as by laser perforation, within a portion of the article where the tubular body 4a is located. It has been found that this results in improved aerosol formation, which is thought to be due to the air flow through the ventilation holes being more uniform than that through multiple rows of ventilation holes for a given ventilation level.

[0071] The aerosol temperature has generally been found to increase with a decrease in the ventilation level. However, the relationship between the aerosol temperature and the ventilation level does not appear to be linear, for example, there are variations in ventilation due to manufacturing tolerances, and the impact is less at lower target ventilation levels. For example, with a ±15% ventilation tolerance and a target ventilation level of 75%, the aerosol temperature can increase by approximately 6 °C at the ventilation lower limit (60% ventilation). However, at a target ventilation level of 60%, the aerosol temperature may only increase by approximately 3.5 °C at the ventilation lower limit (45% ventilation). Therefore, the target ventilation level of the article can be in the range of 40% to 70%, for example, 45% to 65%. The average ventilation level of at least 20 articles can be 40% to 70%, for example, 45% to 70%, or 51% to 59%.

[0072] In some examples, the aerosol - generating material 3 described herein is a first aerosol - generating material, and the tubular portion 4a may include a second aerosol - generating material. In one example, the wall 4b of the tubular portion 4a comprises a second aerosol - generating material. For example, the second aerosol - generating material may be disposed on the inner surface of the wall 4b of the tubular portion 4a.

[0073] The second aerosol - generating material includes at least one aerosol - forming agent material and may also include at least one aerosol - modifying agent or other sensory material. The aerosol - forming agent material and / or the aerosol - modifying agent can be any aerosol - forming agent material or aerosol - modifying agent described herein, or a combination thereof.

[0074] When the aerosol generated from the aerosol - generating material 3, which is called the first aerosol herein, is drawn through the downstream tubular portion 4a, the heat from the first aerosol can aerosolize the aerosol - forming material of the second aerosol - generating material to form a second aerosol. The second aerosol may include a flavorant that can be additional or complementary to the flavor of the first aerosol.

[0075] By providing a second aerosol - generating material on the tubular body 4a, it can result in generating a second aerosol that enhances or complements the flavor or visual appearance of the first aerosol.

[0076] The article 1 may have an outer circumference of about 21 mm (i.e., the article is in a demi - slim format). Preferably, the article 1 has a rod of aerosol - generating material having a circumference greater than 19 mm. It has been found that this provides a circumference sufficient to generate an improved and sustained aerosol over a normal aerosol - generating session that is preferred by consumers. When the article is heated, heat is transferred through the rod of the aerosol - generating material 3, causing the components of the rod to volatilize, and a circumference greater than 19 mm has been found to be particularly effective in generating an aerosol in this way. Since the article is to be heated to release an aerosol, improved heating efficiency can be achieved by using an article having a circumference of less than about 25 mm. To achieve an improved aerosol by heating while maintaining a suitable product length, a rod circumference greater than 19 mm and less than 25 mm is preferred. In some examples, the rod circumference can be from 20 mm to 25 mm, which has been found to provide a good balance between providing effective aerosol delivery and enabling efficient heating on the one hand.

[0077] The outer circumference of the downstream portion 2 is substantially the same so that the transition between these components and the outer circumference of the rod of the aerosol - generating material 3 is smooth. In some embodiments, the outer circumference of the downstream portion 2 is about 20.4 mm or about 24.2 mm.

[0078] In some examples, the tip paper 5 contains a citrate such as sodium citrate or potassium citrate. In such examples, the tip paper 5 may have a citrate content of 2 wt% or less, or 1 wt% or less. Reducing the citrate content of the tip paper 5 is thought to help reduce the charring effect that can occur during use.

[0079] In some embodiments, the tip paper 5 extends 5 mm over the rod of the aerosol - generating material 3. Alternatively, in order to provide a secure attachment between the downstream portion 2 and the rod 3, it can extend 3 mm to 10 mm, or more preferably 4 mm to 6 mm over the rod 3. The tip paper 5 can have a basis weight of 40 gsm to 80 gsm, more preferably 50 gsm to 70 gsm, and in some embodiments 58 gsm. It has been found that basis weights in these ranges result in a tip paper that has an acceptable tensile strength while at the same time wrapping around the article 1 and having sufficient flexibility to adhere to itself along the longitudinal lap joint of the paper.

[0080] In some embodiments, the first plug wrap 7a has a basis weight of less than 110 gsm, more preferably about 40 gsm to 100 gsm. In some embodiments, the second plug wrap 7b has a basis weight of less than 60 gsm, more preferably about 26 gsm to 50 gsm. It should be appreciated that the basis weight of the plug wrap affects the hardness of the downstream portion 2. In some embodiments, the basis weight of the first plug wrap 7a is different from the basis weight of the second plug wrap 7b. In some embodiments, the basis weight of the first plug wrap 7a is greater than the basis weight of the second plug wrap 7b. In such embodiments, the hardness of the downstream portion 2 in the region of the first material body 6a may be greater than the hardness of the downstream portion 2 in the region of the second material body 6b. Alternatively, if the tubular element 8 is incorporated into the first material body 6a, increasing the basis weight of the first plug wrap 7a compensates for the tubular element 8, which otherwise could result in a hardness of the downstream portion 2 in the region of the first body 6a that is lower than the desired hardness.

[0081] Preferably, the first and second plug raps 7a, 7b are non-porous plug raps having a porosity of, for example, less than 100 cholesterol units, for example less than 50 cholesterol units. However, in other embodiments, the first and second plug raps 7a, 7b can be porous plug raps having a porosity of, for example, 100 cholesterol units to 5000 cholesterol units. For example, the second plug rap 7b may be a porous PWP plug rap having a porosity exceeding 100 cholesterol units. Preferably, either the first or the second plug rap 7a, 7b has a porosity of about 1500 cholesterol units.

[0082] Preferably, the first material body 6a has an axial length of about 6 mm to about 8 mm.

[0083] Preferably, the second material body 6b has an axial length of about 10 mm to about 12 mm.

[0084] The first material body 6a may have an axial length of about 6 mm, or about 8 mm, or about 10 mm. The second material body 6b may have an axial length of about 10 mm or about 12 mm.

[0085] Each of the first and second material bodies 6a, 6b is formed from respective sheet materials 6A, 6B disposed within the material bodies 6a, 6b. The sheet material 6A of the first material body 6a may be the same as or different from the sheet material 6B of the second material body 6b. The sheet material 6A of the first material body 6a is shown in the cross-section of FIG. 3 as an example of how the sheet materials 6A, 6B of the first and second bodies 6a, 6b are folded, or crimped, and gathered to form the first and second bodies 6a, 6b. Each material body 6a, 6b may be formed from a continuous web of sheet materials 6A, 6B that are crimped and gathered as shown in FIG. 3. The sheet materials 6A, 6B may be gathered using a CU-20 filter manufacturing machine made by Decoufle (trademark) to manufacture the respective bodies 6a, 6b. However, those skilled in the art will understand that other machines may be used to manufacture the material bodies 6a, 6b.

[0086] When viewing the article 1 from the downstream end 2b, it is desirable that the aerosol modification release component 11 is not visible through the sheet material 6A of the first material body 6a. To achieve this, the average density of at least a portion of the first material body 6a needs to be sufficient to hide the aerosol modification release component 11. However, manufacturing the downstream portion using both the first and second material bodies 6a, 6b having an average density sufficient to hide the aerosol modification release component 11 through the sheet material 6A of the first material body 6a may result in an undesirably high pressure drop across the downstream portion 2 or an unacceptable hardness of the second material body 6a. Thus, in some embodiments, the first material body 6a is configured to have a higher average density than the second material body 6b. In some embodiments, the first material body 6a is configured such that at least a portion of the first material body 6a has a higher average density than the second material body 6b.

[0087] As used herein, the "average density" is defined as the mass of the material bodies 6a, 6b formed by the sheet materials 6A, 6B divided by the volume of the material bodies 6a, 6b formed by the sheet materials 6A, 6B. Therefore, it will be understood that the addition of further components within the material bodies 6a, 6b, such as the tubular element 8 within the first body 6a or the aerosol modification release component 11 of the second body 6b, does not affect the "average density" of the material bodies 6a, 6b because the volume occupied by the further components does not contribute to the volume of the material bodies 6a, 6b formed by the sheet materials 6A, 6B.

[0088] In some embodiments, the average density of the first and second material bodies 6a, 6b is from about 0.1 to about 0.25 mg / mm3.

[0089] In some embodiments, the average density of the first material body 6a is greater than about 0.18 mg / mm3 and the average density of the second material body is less than about 0.18 mg / mm3.

[0090] In some embodiments, the average density of the first material body is from about 0.2 to about 0.25 mg / mm3 and the average density of the second material body is from about 0.1 to about 0.15 mg / mm3.

[0091] The continuous web of sheet material is a continuous web of crimped sheet materials 6A, 6B. "Crimped sheet material" means having a series of folds pressed into the material that form a corrugated pattern of ridges and grooves, as further described below. In some embodiments, the crimped sheet materials 6A, 6B can have an extended width of from about 80 mm to about 250 mm. "Extended width" means the width of the sheet material before it is crimped, because the width of the sheet material decreases as a result of the concertina effect of introducing a series of ridges and grooves by crimping.

[0092] As described above, the continuous web of sheet material 6A used to form the first material body 6a may be different from the continuous web of sheet material 6B used to form the second material body 6b. The continuous web of sheet material 6A used to form the first body 6a is alternatively referred to herein as the first sheet material 6A, while the continuous web of sheet material 6B used to form the second body 6b is alternatively referred to as the second sheet material 6B.

[0093] In some embodiments, the first sheet material 6A has a stretch width that is greater than the stretch width of the second sheet material 6B. For example, the first sheet material 6A may have a stretch width greater than about 160 mm, and the second sheet material 6B may have a stretch width less than about 160 mm.

[0094] In some embodiments, the first sheet material 6A has a stretch width of about 180 to about 200 mm, and the second sheet material 6B has a stretch width of about 120 to about 140 mm.

[0095] It will be appreciated that the stretch width of the sheets of material 6A, 6B gathered towards their respective material bodies 6a, 6b affects the average density of their respective material bodies 6a, 6b. The greater the stretch width of the sheets of material 6A, 6B gathered towards their respective material bodies 6a, 6b, the greater the average density of their respective material bodies 6a, 6b.

[0096] Thus, by using the first sheet material 6A having a greater stretch width to form the first body 6a than the second sheet material 6B used to form the second body 6b, the average density of the first body 6a is greater than the average density of the second body 6b. When the tubular element 8 is provided within the first material body 6a, the available volume of the sheet material 6A is reduced, and thus the stretch width of the sheet material can be reduced to achieve an equivalent average density. In embodiments having the tubular element 8, the stretch width of the first sheet material 6A may be from 80 mm to 160 mm.

[0097] The sheet materials 6A and 6B may contain cellulose. In some embodiments, the sheet materials 6A and 6B are paper. However, the sheet materials 6A and 6B may alternatively or additionally contain different materials. For example, in some embodiments, the sheet materials 6A and 6B contain reconstituted tobacco formed on the sheet materials 6A and 6B. The reconstituted tobacco contains cellulose. The reconstituted tobacco may optionally be paper reconstituted tobacco.

[0098] In one embodiment, the sheet materials 6A and 6B include paper having a basis weight in the range of 20 to 65 gsm, preferably in the range of 20 to 50 gsm.

[0099] In some embodiments, the basis weight of the first sheet material 6A is greater than the basis weight of the second sheet material 6B. In some embodiments, the basis weight of the first crimped sheet material 6A is 24 to 62 gsm, and the basis weight of the second crimped sheet material is 26 to 50 gsm.

[0100] It will be appreciated that the greater the basis weight of the sheet materials 6A and 6B gathered towards the respective material bodies 6a and 6b, the greater the average density of the respective material bodies 6a and 6b. Thus, by using a sheet material 6A with a greater basis weight to form the first body 6a than the sheet material 6B used to form the second body 6b, the average density of the first body 6a is greater than the average density of the second body 6b.

[0101] In some embodiments, the first and second crimped sheet materials 6A and 6B contain fibers having an average length in the range of 2 mm to 6 mm, 2 mm to 5 mm, 2 mm to 4 mm, or 2 mm to 3 mm.

[0102] In some embodiments, the first and second sheet materials 6A and 6B have a thickness of about 50 to about 2500 μm, or about 60 to about 90 μm.

[0103] In some embodiments, the width W1 of the first and second material bodies 6a, 6b (which corresponds to the diameter of the material bodies 6a, 6b) is at least 6.5 mm, or at least 7.5 mm. In one embodiment, the diameters of the first and second material bodies 6a, 6b are 6.5 mm. In another embodiment, the diameters of the first and second material bodies 6a, 6b are 7.7 mm.

[0104] The first material body 6a has an axial length of from about 6 mm to about 8 mm. For example, the axial length of the first material body 6a can be about 6 mm, or about 8 mm, or about 10 mm.

[0105] The second material body 6b has an axial length of from about 10 mm to about 12 mm. For example, the axial length of the second material body 6b can be about 10 mm or about 12 mm.

[0106] In some embodiments, the first and / or second material bodies 6a, 6b have a volume of at least 115 mm 3 "And / or" means that the first and second material bodies 6a, 6b may have the total volume of the recited amount, or they may have the volume of the individually recited amounts. The material bodies 6a, 6b are substantially cylindrical and thus have a substantially cylindrical volume. In other embodiments, it should be recognized that the first and / or second material bodies 6a, 6b may have a volume smaller than 115 mm 3 In other embodiments, the first and / or second material bodies 6a, 6b have a volume of at least 100 mm3, at least 115 mm3, at least 150 mm3, at least 200 mm3, at least 300 mm3, at least 400 mm3, at least 500 mm3, at least 600 mm3, at least 700 mm3, at least 800 mm3, at least 900 mm3, or at least 1000 mm3.

[0107] contain cellulose and have a volume of at least 115 mm 3The material body having a volume has been found to be useful for removing moisture from the aerosol generated by the aerosol-generating material 3 when the aerosol passes through the material body of the suction port 2. That is, the cellulose-containing sheet material absorbs water from the aerosol. By removing moisture from the aerosol, the aerosol is felt colder in the user's mouth.

[0108] In some embodiments, each material body 6a, 6b has at least 19 mm 3 per millimeter of the axial length of the material bodies 6a, 6b, preferably at least 25 mm 3 per millimeter of the axial length, or at least 30 mm 3 per millimeter of the axial length. For example, if the material bodies 6a, 6b have a volume of 19 mm 3 per millimeter of the axial length and a length L1 of 10 mm, the volume of the material body can be 190 mm 3 .

[0109] In some embodiments, the sheet materials 6A, 6B are crimped before being disposed within their respective material bodies 6a, 6b. For example, each sheet material 6A, 6B may be passed through a pair of crimpling rollers. Crimping can make it easier to gather each sheet material 6A, 6B to form their respective material bodies 6a, 6b. Also, crimping can increase the length of each sheet material 6A, 6B that can be used to form a respective material body 6a, 6b of a specific volume. By increasing the amount of each sheet material 6A, 6B within their respective material bodies 6a, 6b, the surface area of each sheet material 6A, 6B that contacts the aerosol passing through their respective material bodies 6a, 6b is increased, and thus the amount of moisture absorbed from the aerosol by the sheet materials 6A, 6B can be increased.

[0110] In some embodiments, the first crimped sheet material 6A includes a first level of crimping, and the second crimped sheet material 6B includes a second level of crimping that is lower than the first level of crimping.

[0111] The level of the crimp may refer to the amplitude A and / or the average pitch P of the crimp, as shown in FIG. 4. FIG. 4 shows a cross-section through an exemplary sheet of crimped material, the sheet representing the crimps of the first and second material sheets 6A, 6B. As illustrated and described above, the continuous web of crimped sheets 6A, 6B discussed herein includes a waveform pattern of ridges and grooves. The ridges and grooves are substantially parallel and extend along the longitudinal direction of the first and second sheets 6A, 6B, i.e., along the length of each of the first and second sheets 6A, 6B. The "crimp amplitude A" means the distance between a plane P1 spanning the apex of a ridge and a plane P2 spanning the bottom of a groove. The "average pitch P" means the distance between the apexes of adjacent grooves.

[0112] An increase in the level of the crimp refers to an increase in the crimp amplitude A and / or a decrease in the average pitch P. Thus, "a second level of crimp less than a first level of crimp" means that the crimp amplitude A of the first sheet 6A is greater than the crimp amplitude A of the second sheet 6B and / or the average pitch P of the first sheet 6A is less than the average pitch P of the second sheet 6B.

[0113] In some embodiments, the average pitch P of the first and second sheets 6A, 6B is greater than about 0.3 mm.

[0114] In some embodiments, the average pitch P of the first sheet material 6A is less than the average pitch of the crimp of the second sheet material 6B.

[0115] In some embodiments, the average pitch P of the crimp of the first sheet material 6A is less than about 0.5 mm and the average pitch P of the crimp of the second sheet material 6B is greater than about 0.5 mm or greater than about 0.6 mm.

[0116] In some embodiments, the crimp amplitude A of the first and second sheet materials 6A, 6B is less than about 1.1 mm.

[0117] In some embodiments, the crimp amplitude A of the first sheet material 6A is smaller than the crimp amplitude A of the second sheet material 6B.

[0118] In some embodiments, the crimp amplitude A of the first sheet material 6A is less than about 1 mm.

[0119] In some embodiments, the crimp amplitude A of the first sheet material 6A is from about 0.1 mm to about 0.7 mm, and the crimp amplitude A of the second sheet material 6B is from about 0.5 mm to about 1 mm.

[0120] It will be appreciated that the level of crimp of the sheets of materials 6A, 6B gathered towards their respective material bodies 6a, 6b affects the average density of their respective material bodies 6a, 6b. The greater the level of crimp of the sheets of materials 6A, 6B gathered towards their respective material bodies 6a, 6b, the greater the average density of their respective material bodies 6a, 6b.

[0121] Thus, by using a first sheet material 6A having a higher level of crimp for forming the first body 6a than the level of crimp used for the second sheet material 6B for forming the second body 6b, the average density of the first body 6a is greater than the average density of the second body 6b.

[0122] In some embodiments, the closed pressure drop per 1 mm of length of the first material body 6a is greater than the closed pressure drop per 1 mm of length of the second material body 6b. "Closed pressure drop per 1 mm of length" means the closed pressure drop per 1 mm of at least a portion of the material bodies 6a, 6b in the longitudinal direction of the article 1, i.e., the direction extending between the upstream end and the downstream end 2a, 2b of the downstream portion 2. It should be understood that the addition of further components within the material bodies 6a, 6b, such as the tubular element 8 within the first body 6a or the aerosol modifying release component 11 of the second body 6b, does not affect the closed pressure drop per 1 mm of length of the material bodies 6a, 6b.

[0123] In some embodiments, the closed pressure drop across the first and second material bodies 6a, 6b is from about 1.0 mmHg2O per 1 mm length to about 3 mmHg2O per 1 mm length.

[0124] In some embodiments, the closed pressure drop across the first material body 6a is greater than 2.0 mmHg2O per 1 mm length, and the closed pressure drop across the second material body is less than 2.0 mmHg2O per 1 mm length.

[0125] In some embodiments, the closed pressure drop across the first material body is 2.5 - 3.0 mmHg2O per 1 mm longitudinal length, and the closed pressure drop across the second material body is 1.0 - 1.5 mmHg2O per 1 mm longitudinal length.

[0126] In some of the embodiments, the combined or individual mass of each of the material bodies 6a, 6b is at least 20 mg, preferably at least 30 mg, at least 40 mg, at least 50 mg, at least 55 mg, or at least 60 mg. It has been preferably found that increasing the mass of the material bodies 6a, 6b to a higher mass increases the amount of moisture absorbed from the aerosol. In some embodiments, the mass of the material body is about 44 mg.

[0127] In some of the embodiments, the combined or individual mass of each of the material bodies 6a, 6b is less than 150 mg, preferably less than 100 mg, less than 75 mg, less than 55 mg, less than 50 mg, or less than 45 mg.

[0128] In some embodiments, the mass of each of the material bodies 6a, 6b is at least 2 mg per 1 mm of the axial length of the material body, preferably at least 3 mg per 1 mm of the axial length, or at least 4 mg per 1 mm of the axial length.

[0129] In some embodiments, the mass of each material body 6a, 6b is about 4.4 mg per mm. That is, as in some embodiments, when the material bodies 6a, 6b have an axial length L1 of 10 mm, the mass can be about 44 mg.

[0130] In some embodiments, each of the material bodies 6a, 6b is a solid cylindrical material body.

[0131] In some embodiments, the downstream portion 2 has a hardness in the range of about 80% - 95%, preferably in the range of about 80% - 95%. The hardness of the downstream portion 2 can be at least 80%, preferably at least 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, or 91% - 92%.

[0132] The hardness of the downstream portion 2 can be measured according to the following protocol. When referring to the hardness of a cross-section in this specification, the hardness is determined by the following measurement process. Any suitable device such as a Borgwaldt Hardness Tester H10 may be used to perform the measurement.

[0133] Hardness is defined as the ratio of the height h0 of the body to the height h1 of the body under a defined load and is expressed as a percentage of h0. Hardness can be expressed as follows. Hardness = (h1 / h0) × 100

[0134] For an individual body or a body included in a multi-section rod, the hardness measurement is performed at the longitudinal center point of the body.

[0135] A load bar is used to apply the defined load to the body. The length of the load bar must be significantly longer than the length of the sample being measured. Before the hardness measurement, the body to be measured is conditioned for at least 48 hours according to ISO 3402 and maintained under the environmental conditions according to ISO 3402 during the measurement.

[0136] To perform the hardness measurement, place the body in Hardness Tester H10, apply a preload of 2 g to the body, and after 1 second, record the initial height h0 of the body under the 2 g preload. Then, remove the preload, lower the load bar supporting a 150 g load onto the sample at a speed of 0.6 mm / s, and measure the height h1 of the body under the 150 g load after 5 seconds.

[0137] The hardness of the downstream part is determined as the average hardness of at least 20 downstream parts measured according to this protocol.

[0138] The hardness of either the first or second material body 6a, 6b (hereinafter collectively referred to as "component" for the purpose of determining hardness) surrounded by each plug wrap 7a, 7b can also be determined by carefully cutting the article and removing one or the other of the material bodies 6a, 6b surrounded by the respective first plug wraps 7a, 7b using the above protocol. The hardness of the component can be at least 80%, preferably at least 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%, or 91%92%.

[0139] The expression "circularity" refers to the percentage by which the cross-sectional shape of the article / component matches a perfect circle. Circularity is calculated according to Equation 1 below.

Equation

[0140] To determine the circularity of article 1, the maximum outer diameter "X" of the component is measured using calipers, and the minimum outer diameter "Y" of the article is measured using calipers (the diameter is perpendicular to the central axis of article 1). The smaller the deviation between the maximum outer diameter X and the minimum outer diameter Y of article 1, the higher the circularity, indicating that the cross-sectional shape of article 1 is closer to a perfect circle.

[0141] In some embodiments, the roundness of the article 1 is at least 90%, preferably at least 91%, 92%, 93%, 94%, or 95%.

[0142] To determine the roundness of the first or second material body 6a, 6b (hereinafter collectively referred to as "components" for the purpose of determining roundness) surrounded by each plug wrap 7a, 7b, the maximum outer diameter "X" of the component is measured using a caliper, and the minimum outer diameter "Y" of the component is measured using a caliper (the diameter is perpendicular to the central axis of the component). The smaller the deviation between the maximum outer diameter X and the minimum outer diameter Y of the component, the higher the roundness, indicating that the cross-sectional shape of the component is closer to a perfect circle.

[0143] In some embodiments, the roundness of the component is at least 90%, preferably at least 91%, 92%, 93%, 94%, or 95%.

[0144] An increase in the roundness of the article / component helps to ensure that the downstream portion can be processed because the downstream portion, which would otherwise be too elliptical, may become clogged or misaligned within the manufacturing machine.

[0145] Preferably, the length of the tubular portion 4a is less than about 50 mm. More preferably, the length of the tubular portion 4a is less than about 40 mm. Even more preferably, the length of the tubular portion 4a is less than about 35 mm. Additionally, or alternatively, the length of the tubular portion 4a is preferably at least about 10 mm. Preferably, the length of the tubular portion 4a is at least about 15 mm.

[0146] In some preferred embodiments, the length of the tubular portion 4a is from about 15 mm to about 35 mm, more preferably from about 20 mm to about 30 mm, even more preferably from about 23 to about 27 mm, and most preferably about 25 mm. In some embodiments, the length of the tubular portion 4a is 25 mm.

[0147] Preferably, the third plug wrap 9 has a basis weight of less than 50 gsm, more preferably about 20 gsm to 45 gsm. However, it should be recognized that the basis weight of the third plug wrap 9 may be higher in order to increase the hardness of the downstream portion. For example, the basis weight of the third plug wrap 9 can be at least 50, 60, 70, 80, 90, or 100 gsm. In some embodiments, the basis weight of the third plug wrap 9 is within the range of 50 to 110 gsm, or within the range of 60 to 100 gsm.

[0148] In some embodiments, the third plug wrap 9 has a basis weight of at least 10 gsm, or at least 15 gsm, or at least 20 gsm, or at least 25 gsm.

[0149] In some embodiments, the third plug wrap 9 has a basis weight of less than 40 gsm, less than 35 gsm, or less than 30 gsm.

[0150] In some embodiments, the third plug wrap 9 has a basis weight within the range of 10 to 40 gsm, preferably within the range of 15 to 35 gsm, or within the range of 20 to 30 gsm, or within the range of 25 to 30 gsm. In some embodiments, the basis weight of the third plug wrap 9 is about 27 gsm.

[0151] Preferably, the third plug wrap 9 has a thickness of 30 μm to 60 μm, more preferably 35 μm to 45 μm. However, it should be recognized that the thickness of the third plug wrap 9 may be greater in order to increase the hardness of the downstream portion. In some embodiments, for example, the thickness of the third plug wrap 9 can be at least 40, 50, 60, 70, 80, 90, or 100 microns. In some embodiments, the thickness of the third plug wrap 9 is within the range of 40 to 120 microns, or within the range of 50 to 100 microns.

[0152] The third plug wrap 9 is preferably a non-porous plug wrap having an air permeability of less than 100 cholesterol units, for example less than 50 cholesterol units. However, in an alternative embodiment, the third plug wrap 9 can be a porous plug wrap having an air permeability of, for example, more than 200 cholesterol units.

[0153] The tubular portion 4a is positioned around the downstream portion 2 and defines an air gap within the downstream portion 2, which acts as a cooling segment. The air gap provides a chamber through which the heated volatile components generated by the aerosol-forming material 3 flow. The tubular portion 4a is hollow to provide a chamber for aerosol accumulation, but is rigid enough to withstand the axial compressive forces and bending moments that can occur during manufacture and while the article 1 is in use. The tubular portion 4a provides a physical displacement between the aerosol-forming material 3 and the second material body 6b. The physical displacement provided by the tubular portion 4a provides a thermal gradient along the length of the tubular portion 4a.

[0154] Preferably, the downstream portion 2 comprises a cavity having an internal volume of more than 450 mm 3 It has been found that by providing at least this volume of cavity, improved aerosol formation is possible. Such a cavity size provides sufficient space within the downstream portion 2 to allow the heated volatile components to cool, and thus allows the aerosol-forming material 3 to be exposed to a higher temperature than might otherwise be possible, as the volatile components could otherwise result in an overly warm aerosol. In some embodiments, the cavity is formed by the tubular portion 4a, but in alternative configurations, the cavity can be formed within different portions of the downstream portion 2. More preferably, the downstream portion 2 comprises a cavity formed, for example, within the tubular portion 4a and having an internal volume of more than 500 mm 3 and even more preferably more than 550 mm 3 to allow further improvement of the aerosol. In some examples, the internal cavity is from about 550 mm 3 to about 850 mm3 and preferably about 600 mm 3 to about 800 mm 3 has a volume of 7. In some embodiments, the internal cavity of the tubular portion 4a is about 762 mm 3 has a volume of.

[0155] The tubular portion 4a can be configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile component entering the first upstream end of the tubular portion 4a and the heated volatile component exiting the second downstream end of the tubular portion 4a. The tubular portion 4a is preferably configured to provide a temperature difference of at least 60 degrees Celsius, preferably at least 80 degrees Celsius, more preferably at least 100 degrees Celsius between the heated volatile component entering the first upstream end of the tubular portion 4a and the heated volatile component exiting the second downstream end of the tubular portion 4a. This temperature difference across the length of the tubular portion 4a protects the temperature-sensitive material bodies 6a, 6b from the high temperature of the aerosol-forming material 3 when heated.

[0156] In an alternative article, the tubular portion 4a can be replaced with an alternative cooling element, for example, an element formed from a material body that allows the aerosol to pass longitudinally through the alternative cooling element and also serves the function of cooling the aerosol.

[0157] The downstream portion 2 of the article 1 comprises an upstream end 3a adjacent to the aerosol-forming substrate 3 and a downstream end 2b distal from the aerosol-forming substrate 3.

[0158] The pressure drop or pressure difference (also referred to as draw resistance) across the downstream portion, for example the portion of the article 1 downstream of the aerosol-forming material 3, is preferably less than about 40 mmH2O. Such a pressure drop has been found to allow a sufficient aerosol containing desirable compounds such as flavor compounds to pass through the downstream portion 2 and reach the consumer. More preferably, the pressure drop across the downstream portion 2 is less than about 20 mmH2O. In some embodiments, a downstream portion 2 having a pressure drop of less than 15 mmH2O, such as about 6 mmH2O, about 10 mmH2O, or about 14 mmH2O, is used to achieve a particularly improved aerosol. Alternatively or additionally, the pressure drop across the downstream portion can be at least 3 mmH2O, preferably at least 4 mmH2O, more preferably at least 5 mmH2O. In some embodiments, the pressure drop across the downstream portion can be from about 5 mmH2O to 20 mmH2O, preferably from 5 mmH2O to 15 mmH2O. These values allow the downstream portion 2 to decelerate the aerosol as it passes through the downstream portion 2 such that the aerosol has time for its temperature to decrease before reaching the downstream end 2b of the downstream portion 2.

[0159] In some embodiments, the aerosol-forming material 3 is enclosed within a wrapper 10. The wrapper 10 can be, for example, a paper or a foil wrapper lined with paper. In some embodiments, the wrapper 10 is substantially impermeable to air. In alternative embodiments, the wrapper 10 preferably has an air permeability of less than 100 Gurley units, more preferably less than 60 Gurley units. For example, a low air permeability wrapper having an air permeability of less than 100 Gurley units, more preferably less than 60 Gurley units, has been found to result in an improvement in aerosol formation in the aerosol-forming material 3. Without wishing to be bound by theory, this is assumed to be due to a reduced loss of aerosol compounds through the wrapper 10. The air permeability of the wrapper 10 can be measured according to ISO 2965:2009 regarding the determination of the air permeability of materials used as cigarette paper, filter plug wrap, and filter tipping paper.

[0160] In some embodiments, the wrapper 10 includes an aluminum foil. The aluminum foil has been found to be particularly effective in promoting the formation of an aerosol within the aerosol generating material 3. In some embodiments, the aluminum foil has a metal layer with a thickness of about 6 μm. In some embodiments, the aluminum foil has a paper backing. However, in alternative configurations, the aluminum foil can be of other thicknesses, such as a thickness of 4 μm to 16 μm. The aluminum foil may also not have a paper backing, but may have a backing formed from other materials, or may not have a backing material, for example to help provide appropriate tensile strength to the foil. Metal layers or foils other than aluminum can also be used. The total thickness of the wrapper is preferably 20 μm to 60 μm, more preferably 30 μm to 50 μm, thereby providing a wrapper with appropriate structural integrity and heat transfer properties. The tension that can be applied to the wrapper before it breaks can be a force exceeding 3,000 grams, such as a force of 3,000 to 10,000 grams, or a force of 3,000 to 4,500 grams.

[0161] In some examples, the wrapper 10 surrounding the aerosol generating material 3 has a high level of air permeability, such as more than about 1000 Gurley units, or more than about 1500 Gurley units, or more than about 2000 Gurley units. The air permeability of the wrapper 10 can be measured in accordance with ISO 2965:2009 regarding the determination of the air permeability of materials used as cigarette paper, filter plug wrap, and filter joining paper.

[0162] The packaging material 10 may be formed from a material having a high inherent level of air permeability, an inherent porous material, or a material having an arbitrary level of inherent air permeability such that the final level of air permeability is achieved by providing an air-permeable zone or area in the packaging material 10. By providing the air-permeable packaging material 10, a path for air to enter the article is provided. The packaging material 10 may be provided with an air permeability such that the amount of air entering through the rod of the aerosol-generating material is relatively greater than the amount of air entering the article through the air holes 12 in the downstream portion. An article having this configuration can generate a more flavorful aerosol, which can be more satisfactory for the user.

[0163] In some embodiments, the aerosol-forming agent material added to the aerosol-generating substrate 3 constitutes 14% by weight of the aerosol-generating substrate 3. Preferably, the aerosol-forming agent material constitutes at least 5% by weight, more preferably at least 10% by weight, of the aerosol-generating substrate. Preferably, the aerosol-forming agent material constitutes less than 25% by weight, more preferably less than 20% by weight, of the aerosol-generating substrate, such as 10% - 20% by weight, 12% - 18% by weight, or 13% - 16% by weight.

[0164] Preferably, the aerosol-generating material 3 is provided as a cylindrical rod of the aerosol-generating material. Regardless of the form of the aerosol-generating material, the aerosol-generating material preferably has a length of about 10 mm to 100 mm. In some embodiments, the length of the aerosol-generating material is preferably in the range of about 25 mm to 50 mm, more preferably in the range of about 30 mm to 45 mm, and even more preferably about 30 mm to 40 mm.

[0165] In some examples, the article 1 may be configured such that there is a separation (i.e., a minimum distance) between the heater of the non-combustible aerosol supply device 100 and the tubular body 4a. This prevents the material forming the tubular body 4a from being damaged by the heat from the heater.

[0166] The minimum distance between the heater of the non-combustion aerosol supply device 100 and the tubular body 4a can be 3 mm or more. In some examples, the minimum distance between the heater of the non-combustion aerosol supply device 100 and the tubular body 4a can be in the range of 3 mm to 10 mm, such as 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm.

[0167] The separation between the heater of the non-combustion aerosol supply device 100 and the tubular body 4a can be achieved, for example, by adjusting the length of the rod of the aerosol-generating material 3.

[0168] The volume of the aerosol-generating material 3 provided is about 200 mm 3 ~ about 4300 mm 3 Preferably about 500 mm 3 ~ 1500 mm 3 More preferably about 1000 mm 3 ~ about 1300 mm 3 Can vary. For example, about 1000 mm 3 ~ about 1300 mm 3 By providing the aerosol-generating material in these volumes, it is preferably shown that an excellent aerosol with better visibility and sensory performance is achieved compared to that achieved with a volume selected from the lower end of the range.

[0169] The mass of the aerosol-generating material 3 provided can be more than 200 mg, for example about 200 mg to 400 mg, preferably about 230 mg to 360 mg, more preferably about 250 mg to 360 mg. It has been preferably found that providing a higher mass of the aerosol-generating material results in improved sensory performance compared to an aerosol generated from a lower mass tobacco material.

[0170] Preferably, the aerosol-generating material or the substrate is formed from the tobacco material described herein that contains tobacco components.

[0171] In the tobacco material described herein, the tobacco component preferably contains reconstituted tobacco. The tobacco component may also contain leaf tobacco, extruded tobacco, and / or band cast tobacco.

[0172] The aerosol-generating material 3 may include a reconstituted tobacco material having a density of less than about 700 milligrams per cubic centimeter (mg / cc). Such tobacco materials have been found to be particularly effective in providing an aerosol-generating material that can be rapidly heated to release an aerosol as compared to higher density materials. For example, the inventors have tested the properties of various aerosol-generating materials such as band cast reconstituted tobacco materials and paper reconstituted tobacco materials when heated. For each given aerosol-generating material, there is a specific zero heat flux temperature, and while heat is being applied to the material, if the temperature is below that temperature, the net heat flux is endothermic, in other words, more heat enters the material than exits the material, and if the temperature is above that temperature, the net heat flux is exothermic, in other words, more heat exits the material than enters the material. Materials having a density of less than 700 mg / cc had a lower zero heat flux temperature. Since most of the heat flux out of the material is due to aerosol formation, having a lower zero heat flux temperature has a beneficial effect on the time it takes for the aerosol to be first released from the aerosol-generating material. For example, it has been found that an aerosol-generating material having a density of less than 700 mg / cc has a zero heat flux temperature of less than 164°C as compared to a material having a density of more than 700 mg / cc having a zero heat flux temperature above 164°C.

[0173] The density of the aerosol-generating material also affects the rate at which heat conducts through the material, and at lower densities, for example less than 700 mg / cc, heat conducts more slowly through the material, thus allowing for a more sustained release of the aerosol.

[0174] Preferably, the aerosol - generating material 3 comprises a reconstituted tobacco material having a density of less than about 700 mg / cc, such as a paper - reconstituted tobacco material. More preferably, the aerosol - generating material 3 comprises a reconstituted tobacco material having a density of less than about 600 mg / cc. Alternatively or additionally, the aerosol - generating material 3 preferably comprises a reconstituted tobacco material having a density of at least 350 mg / cc, which is considered to allow sufficient heat conduction through the material.

[0175] The tobacco material may be provided in the form of cut - rag tobacco. The cut - rag tobacco may have a cut width of at least 15 cuts per inch (corresponding to about 5.9 cuts / cm with a cut width of about 1.7 mm). Preferably, the cut - rag tobacco has a cut width of at least 18 cuts per inch (corresponding to about 7.1 cuts / cm with a cut width of about 1.4 mm), more preferably at least 20 cuts per inch (corresponding to about 7.9 cuts / cm with a cut width of about 1.27 mm). In one example, the cut - rag tobacco has a cut width of 22 cuts per inch (corresponding to about 8.7 cuts / cm with a cut width of about 1.15 mm). Preferably, the cut - rag tobacco has a cut width of 40 cuts per inch (corresponding to about 15.7 cuts / cm with a cut width of about 0.64 mm) or less. A cut width of 0.5 mm to 2.0 mm, such as 0.6 mm to 1.5 mm, or 0.6 mm to 1.7 mm, has been found to be a preferred tobacco material with respect to the surface - area - to - volume ratio when heated, as well as the overall density and pressure drop of the substrate 3. The cut - rag tobacco may be formed from a mixture of forms of tobacco material, such as one or more mixtures of paper - reconstituted tobacco, leaf tobacco, extruded tobacco, and band - cast tobacco. Preferably, the tobacco material comprises paper - reconstituted tobacco, or a mixture of paper - reconstituted tobacco and leaf tobacco.

[0176] In the tobacco material described in this specification, the tobacco material may contain a filler component. The filler component is generally a non-tobacco component, that is, a component that does not contain raw materials derived from tobacco. The filler component can be non-tobacco fibers such as wood fibers, pulp, or wheat fibers. The filler component can also be an inorganic material such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, or magnesium carbonate. The filler component can also be a non-tobacco cast material or a non-tobacco extrusion material. The filler component can be present in an amount of 0% to 20% by weight of the tobacco material, or in an amount of 1% to 10% by weight of the composition. In some embodiments, the filler component is absent.

[0177] In the tobacco materials described herein, the tobacco material contains an aerosol-forming agent material. In this context, an "aerosol-forming agent material" is an agent that promotes the generation of an aerosol. The aerosol-forming agent material can promote the generation of an aerosol by facilitating the initial vaporization and / or condensation of a gas into an inhalable solid and / or liquid aerosol. In some embodiments, the aerosol-forming agent material can improve the delivery of flavors from the aerosol-generating material. Generally, any suitable aerosol-forming agent material, including those described herein, can be included in the aerosol-generating material of the present invention. Other suitable aerosol-forming agent materials include polyols such as sorbitol, glycerol, and glycols such as propylene glycol or triethylene glycol, non-polyols such as monohydric alcohols, high-boiling hydrocarbons, acids such as lactic acid, glycerol derivatives, diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, or esters such as myristic acid including ethyl myristate and isopropyl myristate, and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate, and dimethyl tetradecanedioate, but are not limited thereto. In some embodiments, the aerosol-forming agent material can be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. Glycerol can be present in an amount of 10% to 20% by weight of the tobacco material, such as 13% to 16% by weight of the composition, or about 14% or 15% by weight of the composition. Propylene glycol, if present, can be present in an amount of 0.1% to 0.3% by weight of the composition.

[0178] The aerosol-forming agent material can be included in any component of the tobacco material, such as in any tobacco component, and / or, if present, in the filler component. Alternatively or additionally, the aerosol-forming agent material can be added separately to the tobacco material. In either case, the total amount of the aerosol-forming agent material in the tobacco material can be as defined herein.

[0179] The tobacco material may contain from 10 wt% to 90 wt% of tobacco leaves, and the aerosol forming agent material is provided in an amount of up to about 10 wt% of the tobacco leaves. To achieve an overall level of aerosol forming agent material of from 10 wt% to 20 wt% of the tobacco material, it has been preferably found that this can be added at a higher weight percentage relative to another component of the tobacco material, such as a reconstituted tobacco material.

[0180] The tobacco material described herein contains nicotine. The nicotine content is from 0.5 wt% to 1.75 wt% relative to the tobacco material, and can be, for example, from 0.8 wt% to 1.5 wt% relative to the tobacco material. Additionally or alternatively, the tobacco material contains from 10 wt% to 90 wt% of tobacco leaves having a nicotine content of more than 1.5 wt% of the tobacco leaves. Using tobacco leaves having a nicotine content of more than 1.5% in combination with a lower nicotine substrate such as paper reconstituted tobacco provides a tobacco material having an appropriate nicotine level but superior sensory performance compared to the use of paper reconstituted tobacco alone. Tobacco leaves, such as shredded tobacco, can have, for example, a nicotine content of from 1.5 wt% to 5 wt% of the tobacco leaves.

[0181] The tobacco material described in this specification may contain an aerosol modifier such as any of the flavors described in this specification. In one embodiment, the tobacco material contains menthol and forms an article containing menthol. The tobacco material may contain 3 mg to 20 mg of menthol, preferably 5 mg to 18 mg, more preferably 8 mg to 16 mg of menthol. In some embodiments, the tobacco material contains 16 mg of menthol. The tobacco material may contain 2 wt% to 8 wt% of menthol, preferably 3 wt% to 7 wt% of menthol, more preferably 4 wt% to 5.5 wt% of menthol. In one embodiment, the tobacco material contains 4.7 wt% of menthol. Such a high level of menthol filling can be achieved, for example, using a high percentage of reconstituted tobacco material exceeding 50 wt% of the tobacco material. Alternatively or additionally, the menthol filling level can be increased by using a large amount of aerosol-forming material, such as tobacco material, which is, for example, about 500 mm 3 or preferably about 1000 mm 3 or more of aerosol-forming material such as tobacco material.

[0182] In the compositions described herein, when amounts are given in weight %, this refers to a dry weight basis, unless otherwise indicated, to avoid confusion. Thus, water that may be present in the tobacco material or any of its components is completely ignored for the purpose of determining weight %. The water content of the tobacco materials described herein can vary, for example, from 5 wt% to 15 wt%. The water content of the tobacco materials described herein can vary, for example, according to the temperature, pressure, and humidity conditions under which the composition is maintained. The water content can be determined by Karl Fischer analysis, as is known to those skilled in the art. On the other hand, to avoid confusion, any component other than water is included in the weight of the tobacco material, even if the aerosol-forming agent material is a component in the liquid phase, such as glycerol or propylene glycol. However, if the aerosol-forming agent material is provided in the tobacco component of the tobacco material or in the filler component (if present) of the tobacco material, instead of or in addition to being added separately to the tobacco material, the aerosol-forming agent material is not included in the weight of the tobacco component or filler component and is included in the weight of the "aerosol-forming agent material" at the weight % as defined herein. All other raw materials present in the tobacco component are included in the weight of the tobacco component, even if they are non-tobacco-derived (e.g., non-tobacco fibers in the case of reconstituted tobacco paper).

[0183] In one embodiment, the tobacco material comprises a tobacco component as defined herein and an aerosol-forming agent material as defined herein. In one embodiment, the tobacco material consists essentially of a tobacco component as defined herein and an aerosol-forming agent material as defined herein. In one embodiment, the tobacco material consists of a tobacco component as defined herein and an aerosol-forming agent material as defined herein.

[0184] The reconstituted tobacco paper is present in the tobacco component of the tobacco material described herein in an amount of 10% to 100% by weight of the tobacco component. In embodiments, the reconstituted tobacco paper is present in an amount of 10% to 80% by weight, or 20% to 70% by weight, of the tobacco component. In further embodiments, the tobacco component consists essentially of or consists of the reconstituted tobacco paper. In a preferred embodiment, the leaf tobacco is present in the tobacco component of the tobacco material in an amount of at least 10% by weight of the tobacco component. For example, the leaf tobacco can be present in an amount of at least 10% by weight of the tobacco component, while the remainder of the tobacco component includes the reconstituted tobacco paper, the bandcast reconstituted tobacco, or a combination of the bandcast reconstituted tobacco and another form of tobacco such as tobacco granules.

[0185] The reconstituted tobacco paper refers to a tobacco material formed by a process in which tobacco raw materials are extracted with a solvent to obtain an extract of soluble substances and a residue containing fibrous material, and then the extract (usually after concentration and optionally after further treatment) is recombined with the fibrous material from the residue by deposition of the extract onto the fibrous material (usually after purifying the fibrous material and optionally adding a portion of non-tobacco fibers). The process of recombination is similar to the process of making paper.

[0186] The reconstituted tobacco paper can be any type of reconstituted tobacco paper known in the art. In certain embodiments, the reconstituted tobacco paper is made from a raw material comprising one or more of tobacco strips, tobacco stems, and whole leaf tobacco. In further embodiments, the reconstituted tobacco paper is made from a raw material comprising tobacco strips and / or whole leaf tobacco, and tobacco stems. However, in other embodiments, scraps, fines, and husks can be alternatively or additionally employed as raw materials.

[0187] The reconstituted tobacco paper for use in the tobacco material described herein can be prepared by methods known to those skilled in the art for preparing reconstituted tobacco paper.

[0188] The portion of the downstream part that contacts the consumer's lips is typically either hollow or a paper tube surrounding the cylindrical body of the filter material. By providing the hollow tubular element 8, it has been preferably found that the temperature of the outer surface of the downstream part 2' at the downstream end 2b of the downstream part that contacts the consumer's mouth when the article 1' is in use is significantly reduced. Additionally, by using the tubular portion 4a, it has also been found that the temperature of the outer surface of the downstream part 2' is significantly reduced even upstream of the tubular portion 4a. Without wishing to be bound by theory, this is presumably due to the tubular portion 4a guiding the aerosol closer to the center of the downstream part 2', and thus reducing the heat transfer from the aerosol to the outer surface of the downstream part 2'. Additionally, the first and second material bodies 6a, 6b have been found to remove moisture from the aerosol generated by the aerosol generating material 3 when the aerosol passes through the material bodies 6a, 6b of the downstream part 2, whereby the aerosol is felt colder in the user's mouth.

[0189] In some embodiments, the tubular element 8 has a length of at least 3 mm, preferably about 4 mm. Thus, the tubular element 8 extends within the region that is placed between the user's lips during use.

[0190] In some embodiments, the hollow tubular element 8 is formed from a filamentary tow or from a cellulosic material such as paper. If paper is used, the hollow tubular element may be formed from wood pulp. In an alternative embodiment, the hollow tubular element may be formed using any configuration as described herein for the tubular portion 4a.

[0191] The "wall thickness" of the hollow tubular element 8 corresponds to the thickness of the wall of the tube 8 in the radial direction. This may be measured in the same manner as the tubular portion. The wall thickness is preferably greater than 0.9 mm, more preferably 1.0 mm or more. Preferably, the wall thickness is substantially constant around the entire wall of the hollow tubular element 8. However, if the wall thickness is not substantially constant, the wall thickness is preferably greater than 0.9 mm at any point around the hollow tubular element 8, and more preferably 1.0 mm or more.

[0192] Preferably, the density of the hollow tubular element 8 is at least about 0.25 grams per cubic centimeter (g / cc), more preferably at least about 0.3 g / cc. Preferably, the density of the hollow tubular element 8 is less than about 0.75 grams per cubic centimeter (g / cc), more preferably less than 0.6 g / cc. In some embodiments, the density of the hollow tubular element 8 is from 0.25 to 0.75 g / cc, more preferably from 0.3 to 0.6 g / cc, even more preferably from 0.4 g / cc to 0.6 g / cc or about 0.5 g / cc. These densities have been found to provide a good balance between the improved hardness provided by the higher density materials and the lower heat transfer properties of the lower density materials. For the purposes of the present invention, the "density" of the hollow tubular element 8 refers to the density of the filamentous tow or cellulose material forming the element with any plasticizer incorporated. The density may be determined by dividing the total weight of the hollow tubular element 8 by the total volume of the hollow tubular element 8, and the total volume may be calculated using appropriate measurements of the hollow tubular element 8 obtained, for example, using calipers. If necessary, appropriate dimensions may be measured using a microscope.

[0193] The hollow tubular element 8 preferably has an inner diameter greater than 3.0 mm. A smaller diameter than this can result in increasing the speed of the aerosol passing through the downstream portion 2' and reaching the consumer's mouth to a speed greater than the desired speed such that the aerosol becomes overly warm, e.g., reaches a temperature above 40 °C or above 45 °C. More preferably, the hollow tubular element 8 has an inner diameter greater than 3.1 mm, even more preferably greater than 3.5 mm or 3.6 mm. In one embodiment, the inner diameter of the hollow tubular element 8 is about 3.9 mm.

[0194] In some embodiments, the tubular portion 4a is the first hollow tubular element and the hollow tubular element 8 is the second hollow tubular element.

[0195] In some embodiments, as described above, ventilation is provided within the tubular portion 4a. In alternative embodiments, ventilation can be provided at other locations within the downstream portion, e.g., in any of the material bodies 6a, 6b or the hollow tubular element 8.

[0196] In some embodiments, the aerosol modifier release component 11 can be, for example, a capsule, a thread, or beads. In some embodiments, a plurality of aerosol modifier release components 11 are provided and may include a plurality of charcoal particles filled with an aerosol modifier.

[0197] In some embodiments, the aerosol modifier release component 11 includes a thread filled with an additive. The thread may be made of, for example, cellulose acetate or cotton fibers.

[0198] In some embodiments, the aerosol modifier release component has an aerosol modifier in the range of 1 mg to 20 mg, preferably in the range of 2 mg to 15 mg.

[0199] In some embodiments, the aerosol modifying release component 11 is a capsule 11. The aerosol modifying release component 11 may be adhered to, for example, the sheet material 6B and combined with the sheet material 6B before the sheet material 6B is formed on the material body 6b.

[0200] The capsule 11 includes an outer shell and a liquid core of the aerosol modifying agent.

[0201] The shell of the capsule 11 can be solid at room temperature. The shell can contain, consist of, or essentially consist of alginate. However, it should be recognized that in alternative embodiments, the shell is formed from a different material. For example, the shell can alternatively contain, consist of, or essentially consist of gelatin, carrageenan, or pectin. The shell can contain, consist of, or essentially consist of one or more of alginate, gelatin, carrageenan, or pectin.

[0202] The shell of the capsule 11 may be impermeable or substantially impermeable to the core aerosol modifying agent drug. Thus, the shell initially prevents the core drug from leaking out of the capsule 11. When the user desires to modify the aerosol, the shell of the capsule 11 is ruptured so that the drug is released.

[0203] In some embodiments (not shown), the capsule 11 further includes a carrier material. The carrier material can include, for example, gelatin.

[0204] In some embodiments, the capsule 11 has a diameter in the range of 1 to 5 mm, preferably in the range of 2 to 4 mm. In some embodiments, the diameter of the capsule or each capsule is about 3 mm. The capsule or each capsule can be substantially spherical. In other examples, other shapes and sizes of the capsule can be used.

[0205] The total weight of the capsule 11 can be in the range of about 5 mg to about 50 mg, preferably in the range of about 10 to 30 mg. In some embodiments, the capsule 11 has a weight of about 14 mg.

[0206] In some embodiments, the capsule 11 is centered on the longitudinal axis of the downstream portion 2.

[0207] As described above, the capsule 11 can have a core - shell structure. That is, the encapsulating material or barrier material creates a shell around a core that includes an aerosol modifier. The shell structure prevents the movement of the aerosol modifier during storage of the article, but allows for a controlled release of the aerosol modifying agent (also referred to as an aerosol modifier) during use.

[0208] In some cases, the barrier material (also referred to herein as the encapsulating material) is fragile. The capsule 11 is crushed, broken, or destroyed by the user in order to release the encapsulated aerosol modifier. Typically, the capsule 11 is destroyed immediately before heating is initiated, but the user can choose when to release the aerosol modifier of the capsule 11. Thereafter, the user can choose to destroy the capsule later, for example, after heating has been initiated.

[0209] The term "destructible capsule" refers to a capsule in which the shell can be broken by pressure to release the core. More specifically, the shell can be ruptured under the pressure applied by the user's finger when the user wants to release the core of the capsule.

[0210] In some cases, the barrier material is heat-resistant. That is, in some cases, the barrier will not rupture, melt, or otherwise break at the temperature that reaches the capsule site during the operation of the aerosol supply device. Exemplarily, the capsule positioned within the downstream portion 2 may be exposed to a temperature within the range of, for example, 30°C to 100°C, and the barrier material can continue to hold the liquid core up to at least about 50°C to 120°C at most.

[0211] In other cases, the capsule 11 releases the core composition upon heating, for example, by melting of the barrier material or by swelling of the capsule that causes rupture of the barrier material.

[0212] The total weight of the capsule 11 can be in the range of about 1 mg to about 100 mg, preferably about 5 mg to about 60 mg, about 8 mg to about 50 mg, about 10 mg to about 20 mg, or about 12 mg to about 18 mg.

[0213] The total weight of the core formulation can be in the range of about 2 mg to about 90 mg, preferably 3 mg to about 70 mg, about 5 mg to about 25 mg, about 8 mg to about 20 mg, or about 10 mg to about 15 mg.

[0214] In some embodiments, the capsule 11 comprises the core and the shell as described above. The capsule 11 can exhibit a crushing strength of about 4.5 N to about 40 N, more preferably about 5 N to about 30 N or about 28 N (for example, about 9.8 N to about 24.5 N). The capsule rupture strength can be measured using a force gauge to measure the force at which the capsule ruptures when the capsule is removed from the material body 6b and pressed between two flat metal plates. A suitable measuring device is the Sauter FK 50 force gauge with an attachment having a flat head, using which the capsule can be crushed against a flat and hard surface having a surface similar to that of the attachment.

[0215] The capsule 11 may be substantially spherical and may have a diameter of at least about 0.4 mm, 0.6 mm, 0.8 mm, 1.0 mm, 2.0 mm, 2.5 mm, 2.8 mm, or 3.0 mm. The diameter of the capsule 11 may be less than about 10.0 mm, 8.0 mm, 7.0 mm, 6.0 mm, 5.5 mm, 5.0 mm, 4.5 mm, 4.0 mm, 3.5 mm, or 3.2 mm. Exemplarily, the capsule diameter may be in the range of about 0.4 mm to about 10.0 mm, about 0.8 mm to about 6.0 mm, about 2.5 mm to about 5.5 mm, or about 2.8 mm to about 3.2 mm. In some cases, the capsule 11 may have a diameter of about 3.0 mm. These sizes are particularly suitable for the incorporation of the capsule 11 into the article 1 described herein.

[0216] In some embodiments, the cross-sectional area of the capsule 11 at the maximum cross-sectional area is less than 28%, more preferably less than 27%, and even more preferably less than 25% of the cross-sectional area of the portion of the downstream portion 2 in which the capsule 11 is provided. A capsule having a maximum cross-sectional area less than 28% of the cross-sectional area of the portion of the downstream portion 2 in which the capsule is provided has the advantage that the pressure drop across the downstream portion 2 is reduced compared to a capsule having a larger cross-sectional area, and there is sufficient space remaining around the capsule for the aerosol to pass through without the material body 6b removing a significant amount of aerosol mass as the aerosol passes through the downstream portion 2. In some embodiments, first and second capsules are provided, which may be of the same size or different sizes.

[0217] Each of the material bodies 6a, 6b may be manufactured from a plurality of elongate rods 22. FIG. 5 shows an exemplary plurality of elongate rods for forming a first material body 6a having a tubular element 8. In the illustrated example, the plurality of elongate rods 22 are four elongate rods. The rods are cut along line C-C to form individual material bodies 6a each comprising a tubular element 8.

[0218] To heat the aerosol-forming material 3 of the article 1 described in this specification, a non-combustion aerosol supply device is used. The non-combustion aerosol supply device preferably comprises a coil, because it has been found that this can improve heat transfer to the article 1 compared to other configurations.

[0219] In some examples, the coil is configured to cause heating of at least one conductive heating element during use, whereby thermal energy is conducted from the at least one conductive heating element to the aerosol-forming material, thereby causing heating of the aerosol-forming material.

[0220] In some examples, the coil is configured to generate a varying magnetic field that passes through at least one heating element during use, thereby causing inductive heating and / or magnetic hysteresis heating of the at least one heating element. In such a configuration, the heating element or each heating element may be referred to as a "susceptor" as defined herein. A coil configured to generate a varying magnetic field that passes through at least one conductive heating element during use, thereby causing inductive heating of the at least one conductive heating element, may be referred to as an "induction coil" or "inductor coil".

[0221] The device may comprise a heating element(s), such as a conductive heating element(s), and the heating element(s) can be suitably positioned or positionable relative to the coil to enable such heating of the heating element(s). The heating element(s) may be in a fixed position relative to the coil. Alternatively, at least one heating element, such as at least one conductive heating element, may be included in article 1 for insertion into the heating zone of the device, which article 1 also comprises an aerosol-forming material 3 and is removable from the heating zone after use. Alternatively, both the device and such an article 1 may comprise at least one respective heating element, such as at least one conductive heating element, and the coil can cause heating of each heating element(s) of the device and the article when the article is within the heating zone.

[0222] In some examples, the coil is helical. In some examples, the coil surrounds at least a portion of the heating zone of a device configured to receive an aerosol-forming material. In some examples, the coil is a helical coil that surrounds at least a portion of the heating zone.

[0223] In some examples, the device comprises a conductive heating element that at least partially surrounds the heating zone, and the coil is a helical coil that surrounds at least a portion of the conductive heating element. In some examples, the conductive heating element is tubular. In some examples, the coil is an inductor coil.

[0224] In some examples, the use of the coil enables a non-combustion aerosol supply device to reach its operating temperature more quickly than a non-coil aerosol supply device. For example, a non-combustion aerosol supply device comprising a coil as described above can reach its operating temperature such that it can provide its first puff in less than 30 seconds, more preferably less than 25 seconds, from the start of the device heating program. In some examples, the device can reach its operating temperature in about 20 seconds from the start of the device heating program.

[0225] It has been found that the use of the coils described herein in a device for causing heating of an aerosol-generating material promotes the generation of the aerosol. For example, consumers have reported that an aerosol generated by a device comprising a coil such as those described herein is more sensory similar to an aerosol generated by a factory-made cigarette (FMC) product than an aerosol generated by other non-combustion aerosol supply systems. Without wishing to be bound by theory, this is presumably a result of the shorter time to reach the required heating temperature when the coil is used, the higher heating temperature achievable when the coil is used, and / or the fact that the coil allows such a system to heat a relatively large amount of aerosol-generating material simultaneously, resulting in an aerosol temperature similar to that of the FMC aerosol. In an FMC product, a high-temperature aerosol is generated by burning charcoal, and as the aerosol is drawn through a rod, the tobacco in the tobacco rod behind the charcoal is heated. This high-temperature aerosol is understood to release flavor compounds from the tobacco in the rod behind the burning charcoal. Devices comprising a coil as described herein can also heat an aerosol-generating material such as the tobacco material described herein to release flavor compounds, resulting in an aerosol that is reported to be even more similar to the FMC aerosol. Certain improvements to the aerosol can be achieved by the use of a device comprising a coil for heating an article comprising a rod of aerosol-generating material having a circumference greater than 19 mm, such as a circumference of from about 19 mm to about 23 mm.

[0226] By using an aerosol supply system that includes a coil as described herein, for example, an induction coil that heats at least a portion of an aerosol-forming material to at least 200 °C, more preferably to at least 220 °C, it may be possible to generate an aerosol from an aerosol-forming material having certain properties that are thought to more closely resemble the properties of an FMC product. For example, when using an induction heater heated to at least 250 °C to heat an aerosol-forming material containing nicotine for 2 seconds under an air flow of at least 1.50 L / m for the period, the following, at least 10 μg of nicotine is aerosolized from the aerosol-forming material, the weight ratio of aerosol-forming agent material to nicotine in the generated aerosol is at least about 2.5:1, preferably at least 8.5:1, at least 100 μg of aerosol-forming agent material can be aerosolized from the aerosol-forming material, the average particle or droplet size in the generated aerosol is less than about 1000 nm, and the aerosol density is at least 0.1 μg / cc one or more of the following characteristics were observed.

[0227] In some cases, at least 10 μg of nicotine, preferably at least 30 μg or 40 μg of nicotine, is aerosolized from the aerosol-forming material under an air flow of at least 1.50 L / m for the period. In some cases, less than about 200 μg, preferably less than about 150 μg or less than about 125 μg of nicotine is aerosolized from the aerosol-forming material under an air flow of at least 1.50 L / m for the period.

[0228] In some cases, the aerosol contains at least 100 μg of aerosol-forming agent material, preferably at least 200 μg, 500 μg, or 1 mg of aerosol-forming agent material is aerosolized from the aerosol-forming material under an air flow of at least 1.50 L / m for the period. Preferably, the aerosol-forming agent material can include or consist of glycerol.

[0229] As defined herein, the term "average particle or droplet size" refers to the average size of the solid or liquid components of the aerosol (i.e., the components suspended in the gas). When the aerosol contains suspended droplets and suspended solid particles, this term refers to the average size of all components combined.

[0230] In some cases, the average particle or droplet size in the generated aerosol can be less than about 900 nm, 800 nm, 700 nm, 600 nm, 500 nm, 450 nm, or 400 nm. In some cases, the average particle or droplet size can be greater than about 25 nm, 50 nm, or 100 nm.

[0231] In some cases, the aerosol density generated during the period is at least 0.1 μg / cc. In some cases, the aerosol density is at least 0.2 μg / cc, 0.3 μg / cc, or 0.4 μg / cc. In some cases, the aerosol density is less than about 2.5 μg / cc, 2.0 μg / cc, 1.5 μg / cc, or 1.0 μg / cc.

[0232] The non-combustion aerosol supply device is preferably configured to heat the aerosol generating material 3 of article 1 to a maximum temperature of at least 160°C. Preferably, the non-combustion aerosol supply device heats the aerosol forming agent material 3 of article 1 to a maximum temperature of at least about 200°C, or at least about 220°C, or at least about 240°C, more preferably at least about 270°C, at least once during the heating process, and then the non-combustion aerosol supply device is configured to continue.

[0233] Using an aerosol supply system described herein that includes a coil, such as an induction coil that heats at least a portion of the aerosol generating material to at least 200°C, more preferably at least 220°C.

[0234] In some embodiments, the temperature of the aerosol exiting the suction port end of the downstream portion 2 is less than 50 degrees Celsius, preferably less than 45 degrees Celsius.

[0235] Figure 6 shows an example of a non-combustible aerosol supply device 100 for generating an aerosol from an aerosol-generating medium / material such as the aerosol-generating material 3 of the article 1 described herein. Generally, the device 100 includes a replaceable article 110 comprising an aerosol-generating medium, which can be used, for example, to heat the article described herein to generate an aerosol or other inhalable medium inhaled by the user of the device 100. The device 100 and the replaceable article 110 together form a system.

[0236] The device 100 includes a housing 102 (in the form of an outer cover) that surrounds and houses various components of the device 100. The device 100 has an opening 104 in one end, through which the article 110 can be inserted for heating by a heating assembly. In use, the article 110 can be fully or partially inserted into the heating assembly, where the article 110 can be heated by one or more components of the heater assembly.

[0237] When the article 110 is inserted into the device 100, the minimum distance between one or more components of the heater assembly and the tubular body 4a of the article 110 can be in the range of 3 mm to 10 mm, such as 3 mm, 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm.

[0238] The device 100 of this example includes a first end member 106, and the first end member 106 includes a lid 108 that is movable relative to the first end member 106 to close the opening 104 when the article 110 is not in a predetermined position. In Figure 7, the lid 108 is shown in an open configuration, but the lid 108 can move to a closed configuration. For example, the user can slide the lid 108 in the direction of arrow "B".

[0239] Device 100 may also include a user-operable control element 112, such as a button or switch that activates the device 100 when pressed. For example, the user may turn on device 100 by operating switch 112.

[0240] Device 100 may also include electrical components, such as socket / port 114 that can receive a cable for charging the battery of device 100. For example, socket 114 may be a charging port, such as a USB charging port.

[0241] FIG. 7 depicts device 100 of FIG. 6 with outer cover 102 removed and article 110 absent. Device 100 defines a longitudinal axis 134.

[0242] As shown in FIG. 7, first end member 106 is disposed at one end of device 100, and second end member 116 is disposed at the opposite end of device 100. First and second end members 106, 116 together at least partially define the end faces of device 100. For example, the bottom surface of second end member 116 at least partially defines the bottom surface of device 100. The edge of outer cover 102 may also define a portion of the end face. In this example, lid 108 also defines a portion of the top surface of device 100.

[0243] The end of the device closest to opening 104 is sometimes referred to as the proximal end (or mouth end) of device 100 because it is closest to the user's mouth during use. During use, the user inserts article 110 into opening 104, operates user control 112 to initiate heating of the aerosol-generating material, and inhales the aerosol generated within the device. Thereby, the aerosol flows through device 100 along a flow path towards the proximal end of device 100.

[0244] The other end of the device that is farthest from the opening 104 is, during use, the end that is farthest from the user's mouth and may thus be known as the distal end of device 100. When the user inhales the aerosol generated within the device, the aerosol flows from the distal end of device 100.

[0245] Device 100 further comprises a power source 118. The power source 118 can be a battery, such as a rechargeable battery or a non-rechargeable battery, for example. Examples of suitable batteries include, for example, lithium batteries (such as lithium-ion batteries), nickel batteries (such as nickel-cadmium batteries), and alkaline batteries. The battery is electrically coupled to the heating assembly to supply power, under the control of a controller (not shown) if necessary, to heat the aerosol-generating material. In this example, the battery is connected to a central support 120 that holds the battery 118 in a predetermined position.

[0246] The device further comprises at least one electronic module 122. The electronic module 122 can comprise, for example, a printed circuit board (PCB). The PCB 122 can support at least one controller, such as a processor, and memory. The PCB 122 can also comprise one or more electrical tracks for electrically connecting the various electronic components of device 100 together. For example, the battery terminals can be electrically connected to the PCB 122 so as to distribute power throughout device 100. The socket 114 can also be electrically coupled to the battery via an electrical track.

[0247] In the exemplary device 100, the heating assembly is an induction heating assembly and includes various components for heating the aerosol-forming material of the article 110 via an induction heating process. Induction heating is a process of heating a conductive object (such as a susceptor) by electromagnetic induction. The induction heating assembly may include an induction element, such as one or more inductor coils, and a device for passing a variable current, such as an alternating current, through the induction element. The variable current in the induction element generates a varying magnetic field. The varying magnetic field penetrates a susceptor suitably positioned relative to the induction element and generates eddy currents inside the susceptor. The susceptor has an electrical resistance to the eddy currents, and thus the flow of the eddy currents against this resistance heats the susceptor by Joule heating. If the susceptor includes a ferromagnetic material such as iron, nickel, or cobalt, heat can also be generated by magnetic hysteresis losses in the susceptor, i.e., as a result of a change in the orientation of magnetic dipoles in the magnetic material as a result of alignment with the varying magnetic field. In induction heating, heat is generated inside the susceptor, enabling rapid heating, for example as compared to heating by conduction. Furthermore, it is possible to increase the degrees of freedom in construction and application without requiring any physical contact between the induction heater and the susceptor.

[0248] The induction heating assembly of the exemplary device 100 includes a susceptor construct 132 (referred to herein as the "susceptor"), a first inductor coil 124, and a second inductor coil 126. The first and second inductor coils 124, 126 are made of a conductive material. In this example, the first and second inductor coils 124, 126 are made of a Litz wire / cable that is wound in a spiral to provide the spiral inductor coils 124, 126. A Litz wire includes a plurality of individual wires that are individually insulated and twisted together to form a single wire. The Litz wire is designed to reduce skin effect losses in the conductor. In the exemplary device 100, the first and second inductor coils 124, 126 are made of a copper Litz wire having a rectangular cross-section. In other examples, the Litz wire may have a cross-section of other shapes, such as circular.

[0249] The first inductor coil 124 is configured to generate a first alternating magnetic field for heating a first section of the susceptor 132, and the second inductor coil 126 is configured to generate a second alternating magnetic field for heating a second section of the susceptor 132. In this example, the first inductor coil 124 is adjacent to the second inductor coil 126 in a direction along the longitudinal axis 134 of the device 100 (i.e., the first and second inductor coils 124, 126 do not overlap). The susceptor structure 132 may comprise a single susceptor or two or more separate susceptors. The ends 130 of the first and second inductor coils 124, 126 may be connected to the PCB 122.

[0250] It will be appreciated that the first and second inductor coils 124, 126 may have at least one characteristic that is different from each other in some examples. For example, the first inductor coil 124 may have at least one characteristic that is different from the second inductor coil 126. More specifically, in one example, the first inductor coil 124 may have an inductance value that is different from the second inductor coil 126. In FIG. 7, the first and second inductor coils 124, 126 are of different lengths such that the first inductor coil 124 is wound over a section of the susceptor 132 that is smaller than the second inductor coil 126. Thus, the first inductor coil 124 may include a different number of turns than the second inductor coil 126 (assuming that the spacing between individual turns is substantially the same). In yet another example, the first inductor coil 124 may be made of a different material than the second inductor coil 126. In some examples, the first and second inductor coils 124, 126 may be substantially identical.

[0251] In this example, the first inductor coil 124 and the second inductor coil 126 are wound in opposite directions. This can be useful when the inductor coils are active at different times. For example, initially, the first inductor coil 124 may operate to heat a first section / portion of the article 110, and later, the second inductor coil 126 may operate to heat a second section / portion of the article 110. Winding the coils in opposite directions helps reduce the current induced in the non-active coil when used with a particular type of control circuit. In FIG. 7, the first inductor coil 124 is a right-handed helix, and the second inductor coil 126 is a left-handed helix. However, in another embodiment, the inductor coils 124, 126 may be wound in the same direction, or the first inductor coil 124 may be a left-handed helix and the second inductor coil 126 may be a right-handed helix.

[0252] The susceptor 132 of this example is hollow and thus defines a receptacle in which an aerosol-forming material is received. For example, the article 110 can be inserted into the susceptor 132. In this example, the susceptor 120 is tubular with a circular cross-section.

[0253] The susceptor 132 can be made from one or more materials. Preferably, the susceptor 132 comprises carbon steel having a coating of nickel or cobalt.

[0254] In some examples, susceptor 132 can include at least two materials that can be heated at two different frequencies for selective aerosolization of the at least two materials. For example, a first section of susceptor 132 (heated by first inductor coil 124) can include a first material, and a second section of susceptor 132 heated by second inductor coil 126 can include a second, different material. In another example, the first section can include the first and second materials, and the first and second materials can be heated differently based on the operation of first inductor coil 124. The first and second materials can be adjacent along an axis defined by susceptor 132, or can form different layers within susceptor 132. Similarly, the second section can include third and fourth materials, and the third and fourth materials can be heated differently based on the operation of second inductor coil 126. The third and fourth materials can be adjacent along an axis defined by susceptor 132, or can form different layers within susceptor 132. The third material can be, for example, the same as the first material, and the fourth material can be the same as the second material. Alternatively, each of the materials can be different. The susceptor can include, for example, carbon steel or aluminum.

[0255] Device 100 of FIG. 7 can further include an insulating member 128 that can generally be tubular and can at least partially surround susceptor 132. Insulating member 128 can be constructed from any insulating material, such as, for example, plastic. In this particular example, the insulating member is constructed from polyetheretherketone (PEEK). Insulating member 128 can serve to insulate various components of device 100 from heat generated within susceptor 132.

[0256] The insulating member 128 can also fully or partially support the first and second inductor coils 124, 126. For example, as shown in FIG. 8, the first and second inductor coils 124, 126 are positioned around the insulating member 128 and are in contact with the radially outer surface of the insulating member 128. In some examples, the insulating member 128 does not abut against the first and second inductor coils 124, 126. For example, there may be a small gap between the outer surface of the insulating member 128 and the inner surfaces of the first and second inductor coils 124, 126.

[0257] In a specific example, the susceptor 132, the insulating member 128, and the first and second inductor coils 124, 126 are coaxial about the central longitudinal axis of the susceptor 132.

[0258] FIG. 8 shows a side view of the device 100 in partial cross-section. In this example, there is an outer cover 102. The rectangular cross-sectional shapes of the first and second inductor coils 124, 126 can be more clearly visualized.

[0259] The device 100 further includes a support 136 that engages one end of the susceptor 132 to hold the susceptor 132 in a predetermined position. The support 136 is connected to the second end member 116.

[0260] The device may also include a second printed circuit board 138 associated within the control element 112.

[0261] The device 100 further includes a second lid / cap 140 and a spring 142 disposed toward the distal end of the device 100. The spring 142 enables the second lid 140 to be opened to provide access to the susceptor 132. The user may open the second lid 140 to clean the susceptor 132 and / or the support 136.

[0262] Device 100 further includes an expansion chamber 144 that extends toward the opening 104 of the device away from the proximal end of susceptor 132. A retaining clip 146 for contacting and holding article 110 when article 110 is received within device 100 is at least partially positioned within expansion chamber 144. Expansion chamber 144 is connected to end member 106.

[0263] FIG. 9 is an exploded view of device 100 of FIG. 8 with outer cover 102 omitted.

[0264] FIG. 10A depicts a cross-section of a portion of device 100 of FIG. 8. FIG. 10B depicts an enlarged view of an area of FIG. 10A. FIGS. 10A and 10B show article 110 received within susceptor 132, and article 110 is dimensioned such that the outer surface of article 110 abuts the inner surface of susceptor 132. This ensures that heating is performed most efficiently. Article 110 in this example comprises an aerosol-generating material 110a. Aerosol-generating material 110a is positioned within susceptor 132. Article 110 may also comprise other components such as filters, packaging materials, and / or cooling structures.

[0265] FIG. 10B shows that the outer surface of susceptor 132 is spaced from the inner surfaces of inductor coils 124, 126 by a distance 150 measured in a direction perpendicular to the longitudinal axis 158 of susceptor 132. In one particular example, distance 150 is about 3 mm to 4 mm, about 3 - 3.5 mm, or about 3.25 mm.

[0266] FIG. 10B further shows that the outer surface of insulating member 128 is spaced from the inner surfaces of inductor coils 124, 126 by a distance 152 measured in a direction perpendicular to the longitudinal axis 158 of susceptor 132. In one particular example, distance 152 is about 0.05 mm. In another example, distance 152 is substantially 0 mm such that inductor coils 124, 126 abut and contact insulating member 128.

[0267] In one example, susceptor 132 has a wall thickness 154 of from about 0.025 mm to 1 mm, or about 0.05 mm.

[0268] In one example, susceptor 132 has a length of from about 40 mm to 60 mm, from about 40 mm to 45 mm, or about 44.5 mm.

[0269] In one example, insulating member 128 has a wall thickness 156 of from about 0.25 mm to 2 mm, from 0.25 mm to 1 mm, or about 0.5 mm.

[0270] In use, article 1 described herein can be inserted into a non-combustible aerosol supply device such as device 100 described with reference to FIGS. 6 to 10B. At least a portion of the downstream portion 2 of article 1 can protrude from the non-combustible aerosol supply device 100 and be placed in the user's mouth. By heating the aerosol-generating material 3 using device 100, an aerosol is generated. The aerosol generated by the aerosol-generating material 3 passes through the downstream portion 2 and reaches the user's mouth.

[0271] The various embodiments described herein are presented only to assist in the understanding and teaching of the claimed features. These embodiments are provided only as representative samples of the 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 to the scope of the invention defined by the claims or to the equivalents of the claims, and it should be understood that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. The various embodiments of the present invention may preferably include, consist of, or consist essentially of suitable combinations of disclosed elements, components, features, parts, steps, means, etc. other than those specifically described herein. Additionally, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. Articles for use in an aerosol supply system, wherein the articles are Aerosol generating materials and The aerosol generating material comprises a downstream portion located downstream of the aerosol generating material, the downstream portion comprising separate first and second material bodies, each of the first and second material bodies being formed from respective first and second crimped sheet materials assembled into the material body, the first material body being downstream of the second material body, the first material body being provided with a tubular element disposed within the first material body so as to be circumferentially surrounded by the first material body, and the aerosol modifying release component being provided within the second material body. Goods.

2. The article according to claim 1, wherein the closing pressure drop per 1 mm of length of the first material body is greater than the closing pressure drop per 1 mm of length of the second material body.

3. The article according to claim 1, wherein the first crimped sheet material comprises a first level of crimp, and the second crimped sheet material comprises a second level of crimp smaller than the first level of crimp.

4. The article according to claim 1, wherein the tubular element extends to the downstream end of the article.

5. The article according to claim 1, wherein the tubular element has a length of at least 3 mm, preferably about 4 mm.

6. The article according to claim 1, wherein the tubular element extends only partially through the first material body to form a cavity within the first material body.

7. The article according to claim 2, wherein the closing pressure drop across the first and second material bodies is approximately 1.0 mmH2O to approximately 5 mmH2O per mm of length.

8. The article according to claim 3, wherein the level of crimp varies based on the crimp amplitude and / or average interval of the crimp.

9. The article according to claim 1, wherein the average density of the first material body is greater than the average density of the second material body.

10. The article according to claim 1, wherein the first and second crimped sheet materials have a basis weight of about 20 to about 65 g / m2.

11. The article according to claim 1, wherein the basis weight of the first crimped sheet material is greater than the basis weight of the second crimped sheet material.

12. The article according to claim 1, wherein the first crimped sheet material has a stretch width greater than the stretch width of the second crimped sheet material.

13. The article according to any one of claims 1 to 12, wherein the first and second crimped sheet materials include paper.

14. The article according to claim 1, wherein the first and second material bodies are surrounded by the first and second plug wraps, respectively, and the basis weight of the first plug wrap is greater than the basis weight of the second plug wrap.

15. The article according to claim 14, wherein the basis weight of the first plug wrap is about 40 g / m² to about 100 g / m², and the basis weight of the second plug wrap is about 26 g / m² to about 50 g / m².

16. The article according to claim 1, wherein the first and second material bodies are directly adjacent to each other.

17. The article according to claim 1, wherein the article is for use in a non-combustible aerosol supply system.

18. An aerosol supply system comprising the article described in claim 17.

19. The aerosol supply system according to claim 18, wherein the non-combustion aerosol supply system is an aerosol generating material heating system, and optionally the non-combustion aerosol supply system is a tobacco heating system.

20. A method for forming an article according to claim 1, wherein the method is The first step is to add a crimp pattern to the sheet material, The steps include gathering the first sheet material onto the first material body, The second step involves adding a crimp pattern to the sheet material, The steps include providing an aerosol release component, The steps include gathering the second sheet material around the second material body surrounding the aerosol modification release component, The steps include combining the first and second material bodies with an aerosol generating material, Methods that include...

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