Aerosol-Generating Materials

Abstract

An article is provided that includes an aerosol-forming material for use in a non-combustible aerosol delivery system. The present application provides a sheet or chopped sheet of aerosolizable material comprising a tobacco material, an aerosol-forming material, and a binder, the sheet or chopped sheet having a thickness of at least about 100 μm and a density of at least about 100 g / m 2 ~about 250g / m 2 The aerosol-forming material 3 has a surface density of 1000 .mu.m.sup.- ...

Description

Detailed Description of the Invention

[0001] [Technical field] The present disclosure relates to aerosol-forming materials, methods for making aerosol-forming materials, and articles including aerosol-forming materials for use in non-combustion aerosol delivery devices.

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

[0003] [overview] According to a first aspect of the present disclosure, there is provided a sheet or shredded sheet of aerosolizable material comprising a tobacco material, an aerosol-forming material, and a binder, the sheet or shredded sheet having a thickness of at least about 100 μm and a weight of about 100 g / m 2 ~about 250g / m 2 An aerosol-forming material is provided having a surface density of

[0004] In some embodiments, the sheet or chopped sheet of aerosolizable material has an average thickness of about 160 μm to about 290 μm.

[0005] The sheet or chopped sheet of aerosolizable material may have a tensile strength of at least about 4N / 15mm.

[0006] The sheet or shredded sheet of aerosolizable material can have a burst strength of at least about 75 g.

[0007] The sheet or chopped sheet of aerosolizable material can comprise a plurality of strands or strips of aerosolizable material. The strands or strips of aerosolizable material can have a width of about 0.9 mm to about 2 mm.

[0008] In some embodiments, the sheet or shredded sheet of aerosolizable material comprises water and aerosol-forming material in a total amount of less than about 30% by weight of the aerosolizable material.

[0009] In some embodiments, the tobacco material comprises laminar tobacco in an amount of about 50% to about 100% by weight of the aerosolizable material.

[0010] In some embodiments, the tobacco material comprises stem tobacco in an amount of up to about 15% by weight of the aerosolizable material.

[0011] The aerosol-forming material may be present in an amount of about 10% to about 25% by weight of the aerosolizable material.

[0012] In some embodiments, the tobacco material comprises particulate tobacco, the population of particulate tobacco having a particle size distribution (D90) of at least about 100 μm.

[0013] The aerosolizable material can include a filler, hi some embodiments, the filler comprises a fibrous material, hi some embodiments, the fibrous material comprises wood fibers.

[0014] According to a second aspect of the present disclosure, a sheet or shredded sheet is provided that comprises a tobacco material, an aerosol-forming material, and a binder, the sheet or shredded sheet having a thickness of at least about 100 μm and a weight of about 100 g / m 2 ~about 250g / m 2 An aerosolizable material is provided having a surface density of

[0015] According to any aspect of the present disclosure, the aerosolizable material may be uncompressed.

[0016] According to a third aspect of the present disclosure, there is provided a method for producing a slab of tobacco material, an aerosol-forming material, water, and a binder by mixing the material to form a slurry, the aerosol-forming material having a thickness of at least about 100 μm and a density of about 100 g / m 2 ~about 250g / m 2and treating the slurry to form a sheet of aerosolizable material having an areal density of 0.1 to 0.5.

[0017] In some embodiments, the process includes shredding the sheet to form a shredded sheet comprising a plurality of strips of aerosolizable material.

[0018] In some embodiments, processing the slurry includes casting a sheet or extruding the slurry to form a sheet of aerosolizable material.

[0019] In some embodiments, processing the slurry includes casting a sheet in a band casting machine.

[0020] According to a fourth aspect of the present disclosure, there is provided an aerosol-forming material produced by the process of the third aspect.

[0021] According to a fifth aspect of the present disclosure, there is provided the use of an aerosol-forming material according to the first or fourth aspect in a non-combustible aerosol delivery system.

[0022] According to a sixth aspect of the present disclosure, there is provided an article comprising the aerosol-forming material of the first or fourth aspect for use in a non-combustible aerosol delivery system.

[0023] The article may include an aerosol-forming portion that includes an aerosol-forming material.

[0024] In some embodiments, the aerosol-generating portion comprises a wrapper surrounding the aerosol-generating material.

[0025] In some embodiments, at least about 70% of the volume of the aerosol-generating portion comprises aerosol-forming material.

[0026] In some embodiments, the article is configured so that, during use, the pressure drop across the aerosol-generating portion is from about 15 to about 40 mmH2O.

[0027] In some embodiments, the aerosol-forming material is present in an amount of about 400 mg / cm in the aerosol-forming portion. 3 ~about 900mg / cm 3 has a packing density of

[0028] In some embodiments, the article is for use in a non-combustible aerosol delivery device that includes an aerosol generator that is inserted into the aerosol generation portion.

[0029] In some embodiments, the aerosol-generating portion is configured to receive at least a portion of the aerosol generator.

[0030] In some embodiments, the article is configured such that, during use, the aerosol generator directly contacts at least a portion of the aerosol-forming material when the aerosol generator is received by the article.

[0031] In some embodiments, the article is configured such that, during use, insertion of an aerosol generator into the aerosol-generating portion results in a high packing density of the aerosol-generating material.

[0032] In some embodiments, the article is configured such that, during use, inserting the aerosol generator into the aerosol-generating portion of the article requires a force of less than about 100 N.

[0033] In some embodiments, the wrapper comprises a wrapper material comprising a cellulosic material, wherein the cellulosic material has a basis weight of greater than about 40 grams per square meter.

[0034] According to a seventh aspect of the present disclosure, there is provided a non-combustible aerosol delivery system comprising the article of the sixth aspect and a non-combustible aerosol delivery device.

[0035] In some embodiments, the non-combustible aerosol delivery device comprises an aerosol generator configured for insertion into the aerosol generation portion.

[0036] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0037] [Figure 1] FIG. 1 illustrates steps in a process used to manufacture an article including an aerosol-generating material. [Figure 2] FIG. 1 is a cross-sectional side view of an article including a mouthpiece for use with a non-combustible aerosol delivery device. [Figure 2a] 10 is a cross-sectional side view of a further article comprising a capsule-containing mouthpiece for use with a non-combustible aerosol delivery device. [Figure 2b] 2b is a cross-sectional view of the capsule-containing mouthpiece shown in FIG. 2a. [Figure 3] FIG. 1 is a cross-sectional view of a non-combustion aerosol delivery device including an aerosol generator. [Figure 4] FIG. 4 is a schematic diagram of the non-combustion aerosol delivery device shown in FIG. 3. [Figure 5] 4 is a cross-sectional view of the non-combustible aerosol delivery device shown in FIG. 3 engaged with the article shown in FIG. 2.

[0038] [Detailed explanation] As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user, including: Combustible aerosol delivery systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or hand-rolled or handmade cigarettes, whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smoking materials; a non-combustion aerosol delivery system that releases a compound from an aerosol-forming material without burning the aerosol-forming material, such as an electronic cigarette, a tobacco heating product, and a hybrid system for generating an aerosol using a combination of aerosol-forming materials; and aerosol-free delivery systems that deliver at least one substance, which may or may not contain nicotine, to a user orally, nasally, transdermally, or otherwise without forming an aerosol, including, but not limited to, lozenges, gums, patches, articles containing inhalable powders, and oral products such as oral tobacco, including snus or moist snuff.

[0039] According to the present disclosure, a "non-combustible" aerosol delivery system is one in which the aerosol-generating materials (or components thereof) that are components of the aerosol delivery system do not burn or combust to facilitate delivery of at least one substance to a user.

[0040] In some embodiments, the delivery system is a non-combustible aerosol delivery system, such as a powered non-combustible aerosol delivery system.

[0041] In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not required.

[0042] In some embodiments, the non-combustion aerosol delivery 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.

[0043] In some embodiments, the non-combustion aerosol delivery system is a hybrid system for generating aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0044] Generally, a non-combustible aerosol delivery system can include a non-combustible aerosol delivery device and a consumable item for use with the non-combustible aerosol delivery device.

[0045] In some embodiments, the present disclosure relates to consumables that include aerosol-generating materials and are configured for use with non-combustible aerosol delivery devices. These consumables may be referred to as articles throughout this disclosure.

[0046] As used herein, the terms "upstream" and "downstream" are relative terms defined with respect to the direction in which mainstream aerosol is drawn through an article or device during use.

[0047] In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, can include a power source and a controller. The power source can be, for example, an electrical source or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon substrate that can be activated to dissipate power in the form of heat to an aerosol-generating material or a heat transfer material in proximity to the heat-generating power source.

[0048] In some embodiments, the non-combustible aerosol delivery system comprises an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0049] In some embodiments, consumables for use with non-combustible aerosol delivery devices can include aerosol-generating materials, aerosol-generating material storage areas, aerosol-generating material transfer components, aerosol generators, aerosol-generating areas, housings, wrappers, filters, mouthpieces, and / or aerosol modifiers.

[0050] In some embodiments, the consumable product includes a substance to be delivered. The substance to be delivered may be an aerosol-generating material or a material not intended to be aerosolized. Optionally, either material may include one or more active ingredients, one or more flavorings, one or more aerosol-forming materials, and / or one or more other functional materials.

[0051] In some embodiments, the substance to be delivered can include an active agent.

[0052] As used herein, an active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, known drugs, and psychoactive substances. The active substance may be naturally derived or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another botanical substance.

[0053] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0054] As described herein, the active substance may comprise or be derived from one or more botanical substances, or components, derivatives, or extracts thereof. As used herein, the term "botanical substance" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc. Alternatively, the material may comprise active compounds naturally occurring in synthetically obtained botanical substances. The material may be in the form of a liquid, gas, solid, powder, fine powder, ground particles, granules, pellets, fragments, strips, sheets, etc. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, bay leaf, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. , lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, bell pepper, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, kavi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: common mint (Mentha arvensis), grapefruit mint (Mentha cv), Egyptian mint (Mentha niliaca), peppermint (Mentha piperita), lime mint (Mentha piperita citrata cv), chocolate mint (Mentha piperita cv), curly mint (Mentha spicata crispa), wild mint (Mentha cordifolia), horse mint (Mentha longifolia), pineapple mint (Mentha suaveolens variegata), pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata cv), and apple mint (Mentha suaveolens).

[0055] In some embodiments, the active substance comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substance is tobacco.

[0056] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substances are selected from eucalyptus, star anise, cocoa, and hemp.

[0057] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0058] In some embodiments, the substance delivered comprises a fragrance.

[0059] As used herein, the terms "flavor" and "flavoring" refer to materials that may be used, where local regulations permit, to create a desired taste, aroma, or other somatosensory sensation in products intended for adult consumers.These ingredients may be naturally derived flavoring materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (aniseed), cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit). , papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang ila Sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil of any species of Mentha genus, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, yerba mate, orange peel, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, bell pepper, mace, damian marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.The materials may be imitation, synthetic or natural ingredients, or mixtures thereof. The materials may be in any suitable form, for example, a liquid such as an oil, a solid such as a powder, or a gas.

[0060] In some embodiments, the flavoring includes menthol, spearmint, and / or peppermint. In some embodiments, the flavoring includes cucumber, blueberry, citrus, and / or red berry flavoring ingredients. In some embodiments, the flavoring includes eugenol. In some embodiments, the flavoring includes flavoring ingredients extracted from tobacco. In some embodiments, the flavoring includes flavoring ingredients extracted from cannabis.

[0061] In some embodiments, the flavoring agent may include a sensate intended to achieve a somatosensory sensation typically perceived chemically induced by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the scent or taste nerves, and may include agents that provide a heating, cooling, tingling, or anesthetic effect. A suitable heating agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol WS-3.

[0062] An aerosol-generating material is a material that can generate an aerosol when activated, for example, by heating, irradiation, or in any other way. The aerosol-generating material may be in solid, liquid, or gel form and may or may not contain active substances and / or flavorings. The aerosol-generating material may also be incorporated into an article for use in an aerosol generating system.

[0063] As used herein, the term "tobacco material" refers to any material containing tobacco or its derivatives or substitutes. The tobacco material may be in any suitable form. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco lamina, reconstituted tobacco, and / or tobacco extract.

[0064] According to an aspect of the present disclosure, an aerosol-generating material is provided, the aerosol-generating material comprising a sheet or shredded sheet of aerosolizable material, the aerosolizable material being arranged to generate an aerosol upon heating.

[0065] The sheet or shredded sheet has a first side and a second side opposite the first side. The first and second sides are of matching dimensions. The first and second sides of the sheet or shredded sheet can have any shape. For example, the first and second sides can be square, rectangular, oval, or circular. Irregular shapes are also contemplated.

[0066] The first and / or second sides of the sheet or shredded sheet may be relatively uniform (e.g., relatively smooth), or may be uneven or irregular. For example, the first and / or second sides of the sheet may be textured or patterned to define a relatively rough surface. In some embodiments, the first and / or second sides are relatively rough.

[0067] The smoothness of the first and second surfaces can be affected by several factors, such as the surface density of the sheet or shredded sheet, the nature of the components that make up the aerosolizable material, or whether the surface of the material has been treated, e.g., embossed, engraved, or otherwise modified, to impart a pattern or texture.

[0068] The areas of the first and second sides are each defined by a first dimension (e.g., width) and a second dimension (e.g., length). The measurements of the first and second dimensions can have a ratio of 1:1 or greater than 1:1, and thus the sheet or shredded sheet can have an "aspect ratio" of 1:1 or greater than 1:1. As used herein, the term "aspect ratio" is the ratio of the measurement of the first dimension of the first or second side to the measurement of the second dimension of the first or second side. A "1:1 aspect ratio" means that the measurement of the first dimension (e.g., width) and the measurement of the second dimension (e.g., length) are identical. An "aspect ratio greater than 1:1" means that the measurement of the first dimension (e.g., width) and the measurement of the second dimension (e.g., length) are different. In some embodiments, the first and second sides of the sheet or shredded sheet have an aspect ratio of greater than 1:1, such as 1:2, 1:3, 1:4, 1.5, 1:6, 1:7, or more.

[0069] The shredded sheet can comprise one or more strands or strips of aerosolizable material. In some embodiments, the shredded sheet comprises multiple (e.g., two or more) strands or strips of aerosolizable material. The strands or strips of aerosolizable material can have an aspect ratio of 1:1. In embodiments, the strands or strips of aerosolizable material have an aspect ratio of greater than 1:1. In some embodiments, the strands or strips of aerosolizable material have an aspect ratio of about 1.5 to about 1:16, i.e., about 1.5, 1:6, 1:7, 1:8, 1:9, 1:10, 1:11, or 1:12. When the aspect ratio of a strand or strip is greater than 1:1, the strand or strip comprises a longitudinal dimension or length extending between a first end of the strand or strip and a second end of the strand or strip.

[0070] When a shredded sheet comprises multiple strands or strips of material, the dimensions of each strand or strip can vary among different strands or strips. For example, the shredded sheet can include a first population of strands or strips and a second population of strands or strips, where the dimensions of the strands or strips in the first population are different from the dimensions of the strands or strips in the second population. In other words, the multiple strands or strips can include a first population of strands or strips having a first aspect ratio and a second population of strands or strips having a second aspect ratio that is different from the first aspect ratio.

[0071] The first dimension, i.e., cut width, of the strands or strips of aerosolizable material is between 0.9 mm and 1.5 mm. The inventors have found that incorporating strands or strips of aerosolizable material having a cut width of less than 0.9 mm into an article for use in a non-combustion aerosol delivery system can increase the pressure drop across the article to a level that makes the article unsuitable for use in a non-combustion aerosol delivery device. However, if the strands or strips have a cut width greater than 2 mm (e.g., greater than 2 mm), it can be difficult to insert the strands or strips of aerosolizable material into the article during manufacturing. In a preferred embodiment, the cut width of the strands or strips of aerosolizable material is between about 1 mm and 1.5 mm.

[0072] The strands or strips of material are formed by shredding a sheet of aerosolizable material. The sheet of aerosolizable material may be cut transversely, e.g., in a cross-cut shredding process, to define a cut length of the strands or strips of aerosolizable material in addition to a cut width. Preferably, the cut length of the shredded aerosolizable material is at least 5 mm, e.g., at least 10 mm, or at least 20 mm. The cut length of the shredded aerosolizable material may be less than 60 mm, less than 50 mm, or less than 40 mm.

[0073] In some embodiments, multiple strands or strips of aerosolizable material are provided, and at least one of the multiple strands or strips of aerosolizable material has a length greater than about 10 mm. Alternatively or additionally, at least one of the multiple strands or strips of aerosolizable material can have a length of about 10 mm to about 60 mm, or about 20 mm to about 50 mm. Each of the multiple strands or strips of aerosolizable material can have a length of about 10 mm to about 60 mm, or about 20 mm to about 50 mm.

[0074] The sheet or chopped sheet of aerosolizable material has a thickness of at least about 100 μm. The sheet or chopped sheet can have a thickness of at least about 120 μm, 140 μm, 160 μm, 180 μm, or 200 μm. In some embodiments, the sheet or chopped sheet has a thickness of about 150 μm to about 300 μm, about 151 μm to about 299 μm, about 152 μm to about 298 μm, about 153 μm to about 297 μm, about 154 μm to about 296 μm, about 155 μm to about 295 μm, about 156 μm to about 294 μm, about 157 μm to about 293 μm, about 158 ​​μm to about 292 μm, about 159 μm to about 291 μm, or about 160 μm to about 290 μm. In some embodiments, the sheet or shredded sheet has a thickness of about 170 μm to about 280 μm, about 180 to about 270 μm, about 190 to about 260 μm, about 200 μm to about 250 μm, or about 210 μm to about 240 μm.

[0075] The thickness of the sheet or chopped sheet can vary between the first and second sides. In some embodiments, the individual strips or sections of aerosolizable material have a minimum thickness of about 100 μm across their area. In some cases, the individual strips or sections of aerosolizable material have a minimum thickness of about 0.05 mm or about 0.1 mm across their area. In some cases, the individual strips, strands, or sections of aerosolizable material have a maximum thickness of about 1.0 mm across their area. In some cases, the individual strips or sections of aerosolizable material have a maximum thickness of about 0.5 mm or about 0.3 mm across their area.

[0076] The thickness of the sheet may be determined using ISO 534:2011 "Paper and paperboard - Measurement of thickness".

[0077] The inventors have determined that if the sheet or shredded sheet of aerosolizable material is too thick, heating efficiency may be reduced. This may adversely affect power consumption during use, for example, the power consumption required to release a fragrance from the aerosolizable material. Conversely, if the aerosolizable material is too thin, it may be difficult to manufacture and handle. Very thin materials are more difficult to cast and may be prone to breaking, which may interfere with aerosol formation during use.

[0078] It is hypothesized that if the sheet or chopped sheet of aerosolizable material is too thin (e.g., less than 100 μm), the chopped sheet may need to be cut to a larger width to achieve sufficient loading of the aerosolizable material when the aerosolizable material is incorporated into an article. As previously mentioned, increasing the chopped sheet cut width can increase the pressure drop, which is undesirable.

[0079] Approximately 100g / m 2 ~about 250g / m 2 It is hypothesized that sheets or shredded sheets having a thickness of at least about 100 μm along with an areal density of at least about 100 μm will be less likely to tear, crack, or otherwise deform during manufacturing. A thickness of at least about 100 μm can have a favorable effect on the overall structural integrity and strength of the sheet or shredded sheet. For example, this thickness can have good tensile strength and therefore be relatively easy to process.

[0080] The thickness of the sheet or shredded sheet may also be related to its areal density, i.e., increasing the thickness of the sheet or shredded sheet may increase the areal density of the sheet or shredded sheet.

[0081] Conversely, reducing the thickness of the sheet or chopped sheet may reduce the areal density of the sheet or chopped sheet. For the avoidance of doubt, when areal density is referred to herein, it refers to the average areal density calculated for a given strip, strand, section, or sheet of aerosolizable material, which is calculated by measuring the surface area and weight of the given strip, strand, section, or sheet of aerosolizable material.

[0082] The sheet or shredded sheet of aerosol-forming material has a mass of about 100 g / m 2 ~about 250g / m 2 The sheet or shredded sheet has an areal density of about 110 g / m 2 ~about 240g / m 2 , about 120g / m 2 ~about 230g / m 2 , about 130g / m 2 ~about 220g / m 2 , or about 140 g / m 2 ~about 210g / m 2 In some embodiments, the sheet or shredded sheet may have an areal density of about 130 g / m 2 ~Approx. 190g / m 2 , about 140g / m 2 ~Approx. 180g / m 2 , about 150g / m 2 ~Approx. 170g / m 2 In some embodiments, the sheet or shredded sheet has an areal density of about 160 g / m 2 , 170g / m 2 , 180g / m 2 , 190g / m 2 , or 200 g / m 2 In a preferred embodiment, the sheet or shredded sheet has an areal density of about 160 g / m 2 It has an areal density of

[0083] Approximately 100g / m 2 ~about 250g / m 2The areal density of about 180 gsm is believed to contribute to the strength and flexibility of the sheet or shredded sheet. Furthermore, the inventors have found that a rod comprising a shredded sheet of aerosolizable material having an areal density of about 180 gsm and a minimum thickness of 220-230 μm can be loaded such that the aerosolizable material stays in place within the rod, maintains a desired weight of tobacco material (e.g., about 300 mg) within the rod, and delivers acceptable organoleptic characteristics (e.g., taste and odor) when heated in a non-combustible aerosol delivery device.

[0084] In some embodiments, the aerosolizable material is 160 g / m 2 ~200g / m 2 areal density and a minimum thickness of 200-250 μm, or 160 g / m 2 ~200g / m 2 and a minimum thickness of 210 to 240 μm.

[0085] The flexibility of the sheet or shredded sheet is believed to depend, at least in part, on the thickness and areal density of the sheet or shredded sheet. Thicker sheets or shredded sheets may be less flexible than thinner sheets or shredded sheets. Also, the greater the areal density of the sheet, the less flexible the sheet or shredded sheet. The combination of thickness and areal density of the aerosolizable material described herein is believed to provide a relatively flexible sheet or shredded sheet. This flexibility can provide various advantages when the aerosolizable material is incorporated into an article for use in a non-combustible aerosol delivery device. For example, when inserting an aerosol generator into the aerosol-generating material, the strands or strips can easily deform and bend, facilitating insertion of the aerosol generator (e.g., a heater) into the material and improving retention of the aerosol generator by the aerosolizable material.

[0086] Preferably, the strands or strips or aerosolizable material are not crimped to further enhance the ease with which an aerosol generator can be inserted into the aerosol-generating material. Without wishing to be bound by theory, it is believed that this is because uncrimped strands or strips of aerosolizable material offer less resistance to insertion of the aerosol generator.

[0087] The inventors have found that the areal density of the sheet or chopped sheet of aerosol-generating material affects the roughness of the first and second sides of the sheet or chopped sheet. By varying the areal density, the roughness of the first and / or second sides can be adjusted.

[0088] The average volume density of a sheet or shredded sheet of aerosol-forming material can be calculated from the thickness of the sheet and the areal density of the sheet. The average volume density is about 0.2 g / cm 3 Super, about 0.3g / cm 3 or about 0.4 g / cm 3 In some embodiments, the average bulk density is about 0.2 g / cm 3 ~Approx. 1g / cm 3 , about 0.3g / cm 3 ~Approx. 0.9g / cm 3 , approximately 0.4 g / cm 3 ~Approx. 0.9g / cm 3 , about 0.5g / cm 3 ~Approx. 0.9g / cm 3 , or about 0.6 g / cm 3 ~Approx. 0.9g / cm 3 may be.

[0089] According to an aspect of the present disclosure, a method for producing an aerosolizable composition includes providing a sheet or shredded sheet of aerosolizable material comprising a tobacco material, an aerosol-forming material, and a binder, the sheet or shredded sheet having a density of about 0.4 g / cm 3 In some embodiments, the density is greater than about 0.4 g / cm. 3 ~Approx. 2.9g / cm 3 , approximately 0.4 g / cm 3 ~Approx. 1g / cm 3 , about 0.6 cm3 ~approx. 1.6cm 3 , or about 1.6 cm 3 ~Approx. 2.9cm 3 is.

[0090] The sheet or shredded sheet may have a tensile strength of at least 4 N / 15 mm. In some embodiments, the sheet or shredded sheet has a tensile strength of up to about 30 N / 15 mm, up to about 20 N / 15 mm, or up to about 1.5 N / 15 mm.

[0091] The inventors have found that if the sheet or shredded sheet has a tensile strength of less than 4 N / 15 mm, the sheet or shredded sheet is prone to tearing, breaking, or otherwise deforming during manufacture and / or subsequent incorporation into an article for use in a non-combustible aerosol delivery system. Tensile strength may be measured using ISO 1924:2008.

[0092] The aerosol-forming material comprises tobacco material. The sheet or shredded sheet of aerosolizable material comprises tobacco material.

[0093] The tobacco material may be a particulate or granular material. In some embodiments, the tobacco material is a powder. Alternatively or additionally, the tobacco material may comprise tobacco flakes, strands, or fibers. For example, the tobacco material may comprise tobacco particles, granules, fibers, flakes, and / or strands. In some embodiments, the tobacco material is comprised of particles or granules of tobacco material.

[0094] The density of the tobacco material affects the rate at which heat is conducted through the material; lower densities, for example densities below 900 mg / cc, allow for a more sustained aerosol release because heat is conducted more slowly through the material.

[0095] The tobacco material can include a reconstituted tobacco material, such as a paper reconstituted tobacco material, having a density of less than about 900 mg / cc. For example, the aerosol-forming material can include a reconstituted tobacco material having a density of less than about 800 mg / cc. Alternatively or additionally, the aerosol-forming material can include a reconstituted tobacco material having a density of at least 350 mg / cc.

[0096] The reconstituted tobacco material may be provided in the form of a shredded sheet. The sheet of reconstituted tobacco material may have any suitable thickness. The reconstituted tobacco material may have a thickness of at least about 0.145 mm, e.g., at least about 0.15 mm or at least about 0.16 mm. The reconstituted tobacco material may have a maximum thickness of about 0.30 mm or 0.25 mm; for example, the reconstituted tobacco material may have a thickness of less than about 0.22 mm or less than about 0.2 mm. In some embodiments, the reconstituted tobacco material may have an average thickness in the range of 0.175 mm to 0.195 mm.

[0097] In some embodiments, the tobacco is a particulate tobacco material. Each particle of the particulate tobacco material can have a maximum dimension. As used herein, the term "maximum dimension" refers to the longest linear distance from any point on the surface or face of a particle of tobacco to any other point on the surface or face of the same particle of tobacco. The maximum dimension of a particle of a particulate tobacco material can be measured using scanning electron microscopy (SEM).

[0098] The maximum dimension of each particle of the tobacco material may be up to about 200 μm. In some embodiments, the maximum dimension of each particle of the tobacco material is up to about 150 μm.

[0099] The population of particles of the tobacco material may have a particle size distribution (D90) of at least about 100 μm. In some embodiments, the population of particles of the tobacco material has a particle size distribution (D90) of about 110 μm, at least about 120 μm, at least about 130 μm, at least about 140 μm, or at least about μm. In embodiments, the population of particles of the tobacco material has a particle size distribution (D90) of about 150 μm. Sieve analysis may be used to determine the particle size distribution of the particles of the tobacco material.

[0100] A particle size distribution (D90) of at least about 100 μm is believed to contribute to the tensile strength of a sheet or shredded sheet of aerosolizable material.

[0101] The inventors have found that a particle size distribution (D90) of less than 100 μm provides a sheet or shredded sheet of aerosolizable material with good tensile strength. However, including such fine tobacco material particles in the sheet or shredded sheet can increase the density of the sheet or shredded sheet. When the sheet or shredded sheet is incorporated into an article for use in a non-combustion aerosol delivery system, this higher density can reduce the loading value of the tobacco material. The inventors have found that a particle size distribution (D90) of at least about 100 μm advantageously achieves a balance between sufficient tensile strength and appropriate density (and therefore loading value).

[0102] The particle size of the particulate tobacco material can also affect the roughness of the sheet or shredded sheet of aerosol-forming material. It is hypothesized that forming a sheet or shredded sheet of aerosol-forming material by incorporating larger particles of tobacco material reduces the density of the sheet or shredded sheet of aerosol-forming material.

[0103] The tobacco material can include tobacco obtained from any part of the tobacco plant. In some embodiments, the tobacco material includes tobacco leaf. The sheet or shredded sheet can include from 5% to about 90% by weight of tobacco leaf.

[0104] The tobacco material can include laminar tobacco and / or tobacco stems, such as midrib stems. The laminar tobacco can be present in an amount of 0% to about 100%, about 20% to about 100%, about 40% to about 100%, about 40% to about 95%, about 45% to about 90%, about 50% to about 85%, or about 55% to about 80% by weight of the sheet or shredded sheet and / or tobacco material. In some embodiments, the tobacco material consists of, or consists essentially of, laminar tobacco material.

[0105] The tobacco material may contain tobacco stems in an amount of from 0% to about 100% by weight, from about 0% to about 50% by weight, from about 0 to about 25% by weight, from about 0 to about 20% by weight, or from about 5 to about 15% by weight of the sheet or shredded sheet.

[0106] In some embodiments, the tobacco material comprises a combination of lamina and tobacco stems. In some embodiments, the tobacco material may comprise about 40% to about 95% lamina and about 5% to about 60% stems, or about 60% to about 95% lamina and about 5% to about 40% stems, or about 80% to about 95% lamina and about 5% to about 20% stems, by weight of the sheet or shredded sheet of aerosolizable material.

[0107] The inventors have found that incorporating stems can reduce the stickiness of the aerosolizable material. The inventors have also found that incorporating tobacco materials, including stem tobacco, into the aerosolizable material unexpectedly increases its burst strength.

[0108] The sheet or shredded sheet of aerosolizable material can have a burst strength of at least about 75 g, at least about 100 g, or at least about 200 g.

[0109] If the burst strength is too low, the sheet or shredded sheet may be relatively brittle. As a result, fracture of the sheet or shredded sheet may occur during the manufacturing process of the aerosolizable material. For example, when the sheet is shredded to form shredded sheets by a cutting process, the sheet may crumble or break into pieces or fragments upon cutting.

[0110] The tobacco material described herein contains nicotine. The nicotine content may be 0.1 to 3% by weight of the tobacco material, for example, 0.5 to 2.5% by weight of the tobacco material. Additionally or alternatively, the tobacco material comprises 10% to 90% by weight of tobacco leaf, with a nicotine content of greater than about 1% or greater than about 1.5% by weight of the tobacco leaf. Tobacco leaf, for example, cut rag tobacco, has a nicotine content of, for example, 1% to 5% by weight of the tobacco leaf.

[0111] The sheet or shredded sheet of aerosolizable material may include nicotine in an amount of about 0.1% to about 3% by weight of the sheet or shredded sheet.

[0112] Reconstituted tobacco paper may be present in the aerosol-forming materials described herein. Reconstituted tobacco paper refers to tobacco material formed by a process in which tobacco raw material is extracted with a solvent to obtain a residue containing a soluble extract and fibrous material, and then (usually after concentration, and optionally after further processing) the extract is recombined with fibrous material from the residue by depositing the extract on the fibrous material (usually after purification of the fibrous material, and optionally with the addition of a portion of non-tobacco fiber). The recombination process is similar to the papermaking process.

[0113] The reconstituted tobacco may be any type of reconstituted tobacco known in the art. In certain embodiments, the reconstituted tobacco is made from raw materials including one or more of tobacco shreds, tobacco stems, and whole leaf tobacco. In further embodiments, the reconstituted tobacco is made from raw materials consisting of tobacco shreds and / or whole leaf tobacco and tobacco stems. However, in other embodiments, chips, fines, and rice husks may be used instead or in addition to the raw materials.

[0114] Reconstituted tobacco for use in the tobacco materials described herein may be prepared by methods known to those skilled in the art for preparing reconstituted tobacco.

[0115] In embodiments, the reconstituted tobacco is present in an amount of from 5% to 90%, from 10% to 80%, or from 20% to 70% by weight of the aerosol-forming material.

[0116] The aerosol-generating material includes an aerosol-forming material. The aerosol-forming material includes one or more components capable of forming an aerosol. The aerosol-forming material includes one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. Preferably, the aerosol-forming material is glycerol or propylene glycol.

[0117] The sheet or shredded sheet of aerosolizable material includes an aerosol-forming material. The aerosol-forming material is provided in an amount of up to about 50% by weight of the sheet or shredded sheet on a dry weight basis. In some embodiments, the aerosol-forming material is provided in an amount of about 5% to about 40% by weight of the sheet or shredded sheet on a dry weight basis, about 10% to about 30% by weight of the sheet or shredded sheet on a dry weight basis, or about 10% to about 20% by weight of the sheet or shredded sheet on a dry weight basis.

[0118] The sheet or shredded sheet can also include water. The sheet or shredded sheet of aerosolizable material can include water in an amount less than about 15%, less than about 10%, or less than about 5% by weight of the aerosolizable material. In some embodiments, the aerosolizable material includes water in an amount between about 0% and about 15%, or between about 5% and about 15% by weight of the aerosolizable material.

[0119] The sheet or shredded sheet of aerosolizable material can include water and aerosol-forming material in a total amount of less than about 30% by weight of the sheet or shredded sheet of aerosolizable material, or less than about 25% by weight of the sheet or shredded sheet of aerosolizable material. Incorporating water and aerosol-forming material into the sheet or shredded sheet of aerosolizable material in an amount less than about 30% by weight of the sheet or shredded sheet of aerosolizable material can advantageously reduce the stickiness of the sheet. This can improve the ease with which the aerosolizable material can be handled during processing. For example, it can be easier to roll a sheet of aerosolizable material to form a bobbin of material and then unwind the bobbin without the layers of the sheet sticking to each other. Reducing stickiness also reduces the tendency of strands or pieces of shredded material to clump together or stick to each other, further improving processing efficiency and final product quality.

[0120] The sheet or shredded sheet includes a binder. The binder is arranged to bind the components of the aerosol-forming material together to form the sheet or shredded sheet. The binder can at least partially coat the surface of the tobacco material. If the tobacco material is in particulate form, the binder can at least partially coat the surface of the tobacco particles to bind the particles together.

[0121] The binder may be selected from one or more compounds selected from the group consisting of alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the binder comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, gum arabic, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the binder comprises alginate and / or pectin or carrageenan. In a preferred embodiment, the binder comprises guar gum.

[0122] The binder may be present in an amount of about 1 to about 20% by weight of the sheet or chopped sheet, or 1 to about 10% by weight of the sheet or chopped sheet of aerosolizable material. For example, the binder may be present in an amount of about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, or 10% by weight of the sheet or chopped sheet of aerosolizable material.

[0123] The aerosol-forming material can include a filler. In some embodiments, the sheet or shredded sheet includes a filler. The filler is typically a non-tobacco component, i.e., a component that does not contain tobacco-derived materials. The filler can include one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents, such as molecular sieves. The filler can also be a non-tobacco fiber, such as wood fiber or wood pulp or wheat fiber. The filler can also be a material containing cellulose or a material containing a derivative of cellulose. The filler component can also be a non-tobacco cast material or a non-tobacco extruded material.

[0124] In certain embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material, such as wood, wood pulp, hemp fiber, cellulose, or a cellulose derivative. Without wishing to be bound by theory, it is believed that the inclusion of a fibrous filler can increase the tensile strength of the material.

[0125] Fillers can also contribute to the texture of the sheet or shredded sheet of aerosolizable material. For example, a fibrous filler, such as wood or wood pulp, can provide a sheet or shredded sheet of aerosolizable material with relatively rough first and second sides. Conversely, a non-fibrous particulate filler, such as powdered chalk, can provide a sheet or shredded sheet of aerosolizable material with relatively smooth first and second sides. In some embodiments, the aerosolizable material comprises a combination of different filler materials.

[0126] The filler component may be present in an amount of 0 to 20% by weight of the sheet or shredded sheet, or in an amount of 1 to 10% by weight of the sheet or shredded sheet, hi some embodiments, no filler component is present.

[0127] Fillers can help improve the general structural properties of the aerosolizable material, such as tensile strength and burst strength.

[0128] For the avoidance of doubt, when amounts are expressed in terms of weight percent in the compositions described herein, they refer to a dry weight basis unless otherwise specified. Therefore, any water that may be present in the aerosol-forming material, or any of its components, is completely ignored for purposes of determining weight percent. The water content of the aerosol-forming materials described herein may vary, for example, from 5 to 15 weight percent. The water content of the aerosol-forming materials described herein may vary depending on, for example, the temperature, pressure, and humidity conditions under which the composition is maintained. The water content can be determined by Karl Fischer analysis, as known to those skilled in the art. However, for the avoidance of doubt, even if the aerosol-forming material is a liquid-phase component such as glycerol or propylene glycol, any components other than water are included in the weight of the aerosol-forming material. However, when an aerosol-forming material is provided to the tobacco component of the aerosol-forming material or to a filler component (if present) of the aerosol-forming material instead of or in addition to being added separately to the aerosol-forming material, the aerosol-forming material is not included in the weight of the tobacco component or filler component, but is included in the weight of the "aerosol-forming material" in terms of weight percent as defined herein. Any other materials present in the tobacco component are included in the weight of the tobacco component, even if they are of non-tobacco origin (eg, non-tobacco fiber in the case of reconstituted tobacco).

[0129] The aerosol-forming material herein can include an aerosol modifier, such as any of the flavorings described herein. In one embodiment, the aerosol-forming material includes menthol. When the aerosol-forming material is incorporated into an article for use in an aerosol delivery system, the article can be referred to as a mentholated article. The aerosol-forming material can include 0.5 mg to 20 mg of menthol, 0.7 mg to 20 mg of menthol, 1 mg to 18 mg, or 8 mg to 16 mg of menthol. In this example, the aerosol-forming material includes 16 mg of menthol. The aerosol-forming material can include 1% to 8% by weight of menthol, preferably 3% to 7% by weight of menthol, and more preferably 4% to 5.5% by weight of menthol. In one embodiment, the aerosol-forming material includes 4.7% by weight of menthol. Such high levels of menthol loading can be achieved by using a high percentage of reconstituted tobacco material, for example, greater than 50% by weight of the tobacco material. Alternatively or additionally, for example, using a larger amount of tobacco material can allow for a higher level of menthol loading to be achieved, for example, about 500 mm 3 More than, or preferably about 1000 mm 3 An aerosol-forming material such as tobacco material is used.

[0130] In some embodiments, the composition comprises an aerosol-forming "amorphous solid," which may also be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may comprise a dry gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within it.

[0131] In some instances, the amorphous solid is 1 to 60 wt % of a gelling agent; 0.1 to 50 wt % of an aerosol-forming material; and 0.1 to 80 wt% of a fragrance, These weights are calculated on a dry weight basis.

[0132] In some further embodiments, the amorphous solid is 1 to 50 wt % of a gelling agent; 0.1 to 50 wt % of an aerosol-forming material; Contains 30 to 60 wt% of fragrance, These weights are calculated on a dry weight basis.

[0133] The amorphous solid material may be provided in the form of a sheet or chopped sheet. The amorphous solid material may take the same form as the sheets or chopped sheets as described above with respect to the aerosolizable material.

[0134] The amorphous solid can suitably comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, or 35 wt% of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid can comprise 1-50 wt%, 5-45 wt%, 10-40 wt%, or 20-35 wt% of a gelling agent. In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group including alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohols, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, gum arabic, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some embodiments, the gelling agent comprises alginate and / or pectin and may be mixed with a hardening agent (such as a calcium source) during formation of the amorphous solid. In some embodiments, the amorphous solid may comprise calcium-crosslinked alginate and / or calcium-crosslinked pectin.

[0135] In some embodiments, the gelling agent comprises alginate, and the alginate is present in the amorphous solid in an amount of 10-30 wt% (calculated on a dry weight basis) of the amorphous solid. In some embodiments, the alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginate and at least one additional gelling agent, such as pectin.

[0136] In some embodiments, the amorphous solid may include a gelling agent including carrageenan.

[0137] Preferably, the amorphous solid can comprise from about 0.1 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt%, or 10% to about 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt% of the aerosol-forming material (all calculated on a dry weight basis). The aerosol-forming material can act as a plasticizer. For example, the amorphous solid can comprise from 0.5 to 40 wt%, from 3 to 35 wt%, or from 10 to 25 wt% of the aerosol-forming material. In some cases, the aerosol-forming material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some cases, the aerosol-forming material comprises, consists essentially of, or consists of glycerol.

[0138] The amorphous solid comprises a flavoring agent. Suitably, the amorphous solid can comprise up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% flavoring agent.

[0139] In some cases, the amorphous solid can include at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% flavoring (all calculated on a dry weight basis).

[0140] For example, the amorphous solid can include 1-80 wt%, 10-80 wt%, 20-70 wt%, 30-60 wt%, 35-55 wt%, or 30-45 wt% flavoring. In some cases, the flavoring includes, consists essentially of, or consists of menthol.

[0141] In some cases, the amorphous solid may further comprise an emulsifier that emulsifies the molten flavor during manufacture. For example, the amorphous solid may comprise about 5 wt% to about 15 wt%, preferably about 10 wt%, of an emulsifier (calculated on a dry weight basis). The emulsifier may include gum arabic.

[0142] In some embodiments, the amorphous solid is a hydrogel and contains less than about 20 wt% water, calculated on a wet weight basis. In some cases, the hydrogel can contain less than about 15 wt%, 12 wt%, or 10 wt% water, calculated on a wet weight basis. In some cases, the hydrogel can contain at least about 1 wt%, 2 wt%, or at least about 5 wt% water (wet weight basis).

[0143] In some embodiments, the amorphous solid further comprises an active substance. For example, in some cases, the amorphous solid further comprises tobacco material and / or nicotine. In some cases, the amorphous solid can comprise 5 to 60 wt% (calculated on a dry weight basis) of tobacco material and / or nicotine. In some cases, the amorphous solid can comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of the active substance. In some cases, the amorphous solid can comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of tobacco material. For example, the amorphous solid can comprise from 10 to 50 wt%, 15 to 40 wt%, or 20 to 35 wt% of tobacco material. In some cases, the amorphous solid can comprise from about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% of nicotine (calculated on a dry weight basis). For example, the amorphous solid can comprise from 1 to 20 wt%, 2 to 18 wt%, or 3 to 12 wt% of nicotine.

[0144] In some cases, the amorphous solid includes an active substance such as tobacco extract. In some cases, the amorphous solid can include 5-60 wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the amorphous solid can include about 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of tobacco extract. For example, the amorphous solid can include 10-50 wt%, 15-40 wt%, or 20-35 wt% of tobacco extract. The tobacco extract can contain nicotine in a concentration such that the amorphous solid contains from 1 wt%, 1.5 wt%, 2 wt%, or 2.5 wt% to about 6 wt%, 5 wt%, 4.5 wt%, or 4 wt% nicotine (calculated on a dry weight basis).

[0145] In some cases, no nicotine other than that obtained from the tobacco extract may be present in the amorphous solid.

[0146] In some embodiments, the amorphous solid does not contain tobacco material but does contain nicotine. In some such cases, the amorphous solid can contain from about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% nicotine (calculated on a dry weight basis). For example, the amorphous solid can contain from 1 to 20 wt%, 2 to 18 wt%, or 3 to 12 wt% nicotine.

[0147] In some cases, the total content of actives and / or fragrances may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of actives and / or fragrances may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0148] In some cases, the total content of tobacco material, nicotine, and flavorings may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of actives and / or flavorings may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0149] The amorphous solid may be made from a gel, which may further contain a solvent present at 0.1 to 50 wt %. However, the present inventors have found that the inclusion of a solvent in which the fragrance dissolves may reduce the stability of the gel and cause the fragrance to crystallize from the gel. Therefore, in some cases, the gel does not contain a solvent in which the fragrance dissolves.

[0150] In some embodiments, the amorphous solid comprises less than 60 wt% of filler, for example, between 1 wt% and 60 wt%, or between 5 wt% and 50 wt%, or between 5 wt% and 30 wt%, or between 10 wt% and 20 wt%.

[0151] In other embodiments, the amorphous solid contains less than 20 wt%, preferably less than 10 wt%, or less than 5 wt% filler. In some cases, the amorphous solid contains less than 1 wt% filler, and in some cases, no filler.

[0152] When present, the filler may comprise one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. The filler may comprise one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives. In certain cases, the amorphous solid does not comprise calcium carbonate, such as chalk.

[0153] In certain embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material, such as wood pulp, hemp fiber, cellulose, or a cellulose derivative. Without wishing to be bound by theory, it is believed that the inclusion of a fibrous filler in an amorphous solid can increase the tensile strength of the material.

[0154] In some embodiments, the amorphous solid does not include tobacco fiber.

[0155] In some cases, the amorphous solid in the form of a sheet can have a tensile strength of about 200 N / m to about 1500 N / m. In some cases, such as when the amorphous solid does not include a filler, the amorphous solid can have a tensile strength of 200 N / m to 400 N / m, or 200 N / m to 300 N / m, or about 250 N / m. Such tensile strengths may be particularly suitable for embodiments in which the amorphous solid material is formed into a sheet and then shredded and incorporated into an aerosol product.

[0156] In some instances, such as when the amorphous solid includes a filler, the amorphous solid may have a tensile strength of 600 N / m to 1500 N / m, or 700 N / m to 900 N / m, or about 800 N / m. Such tensile strengths may be particularly suitable for embodiments in which the amorphous solid material is included in the aerosol product article as a rolled sheet, preferably in the form of a tube.

[0157] In some cases, the amorphous solid may consist essentially of or consist of a gelling agent, water, an aerosol-forming material, a flavoring agent, and optionally an active agent.

[0158] In some cases, the amorphous solid may consist essentially of or consist of a gelling agent, water, an aerosol-forming material, flavorings, and optionally a tobacco material and / or a nicotine source.

[0159] The amorphous solid can include one or more active agents and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0160] The aerosol-forming material can include reconstituted tobacco paper. The composition can alternatively or additionally include any of the tobacco forms described herein. The aerosol-forming material can comprise a sheet or shredded sheet containing tobacco material comprising 10% to 90% by weight of tobacco leaf, with the aerosol-forming material being present in an amount of up to about 20% by weight of the sheet or shredded sheet, and the remainder of the tobacco material comprising reconstituted tobacco paper.

[0161] When the aerosol-forming material comprises an amorphous solid material, the amorphous solid material may be a dry gel comprising menthol. In alternative embodiments, the amorphous solid may have any of the compositions described herein.

[0162] The inventors have discovered that improved articles can be advantageously produced that include an aerosol-generating material that includes a first component that includes a sheet or shredded sheet of aerosolizable material and a second component that includes an amorphous solid, and that have material properties (e.g., density) and specifications (e.g., thickness, length, and cut width) that fall within the ranges described herein.

[0163] In some cases, the amorphous solid can have a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness can range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm. The inventors have found that materials having a thickness of about 0.09 mm can be used. The amorphous solid can include two or more layers, and the thicknesses described herein refer to the combined thickness of these layers.

[0164] The thickness of the amorphous solid material can be measured using calipers or a microscope, such as a scanning electron microscope (SEM), as known to those skilled in the art, or any other suitable technique known to those skilled in the art.

[0165] The inventors have found that if the amorphous solid is too thick, heating efficiency may decrease. This may adversely affect power consumption during use, for example, the power consumption required to release a fragrance from the amorphous solid. Conversely, if the amorphous solid for aerosol formation is too thin, it may be difficult to manufacture and handle. Very thin materials are more difficult to cast, are more prone to breakage, and may interfere with aerosol formation during use. In some cases, individual strips or slices of the amorphous solid have a minimum thickness of about 0.015 mm across their area. In some cases, individual strips or slices of the amorphous solid have a minimum thickness of about 0.05 mm or about 0.1 mm across their area. In some cases, individual strips or slices of the amorphous solid have a maximum thickness of about 1.0 mm across their area. In some cases, individual strips or slices of the amorphous solid have a maximum thickness of about 0.5 mm or about 0.3 mm across their area.

[0166] In some cases, the thickness of the amorphous solid may vary by no more than 25%, 20%, 15%, 10%, 5%, or 1% over its area.

[0167] The inventors have discovered that by providing sheets or shredded sheets of amorphous solid material and aerosolizable material having areal density values ​​that differ from each other by less than a given percentage, the mixture of these materials is less likely to separate. In some instances, the areal density of the amorphous solid material may be between 50% and 150% of the areal density of the aerosolizable material. For example, the areal density of the amorphous solid material may be between 60% and 140% of the areal density of the aerosolizable material, or between 70% and 110% of the areal density of the aerosolizable material, or between 80% and 120% of the areal density of the aerosolizable material.

[0168] In embodiments described herein, the amorphous solid material can be incorporated into the article in the form of a sheet. Suitably, the amorphous solid material in sheet form can be shredded before being incorporated into the article and mixed with an aerosolizable material, such as a sheet or shredded sheet of aerosolizable material described herein.

[0169] In further embodiments, the sheet of amorphous solid can further be incorporated as a flat sheet, as a collected or bundled sheet, as a pressed sheet, or as a rolled sheet (i.e., in the form of a tube). In some such cases, the amorphous solid of these embodiments can be included in the aerosol product as a sheet, such as a sheet surrounding a rod containing an aerosolizable material. For example, the sheet of amorphous solid can be formed into a wrapping paper that surrounds an aerosolizable material such as tobacco.

[0170] The amorphous solid in the form of a sheet has a density of about 30 g / m 2 ~about 150g / m 2 In some cases, the sheet may have a density of about 55 g / m 2 ~Approx. 135g / m 2 , or about 80 to about 120 g / m 2, or about 70 to about 110 g / m 2 , or particularly about 90 to about 110 g / m 2 , or preferably about 100 g / m 2 These ranges can provide a density similar to that of cut rag tobacco, thereby providing a mixture of these materials that is less likely to separate. Such areal densities can be particularly suitable when the amorphous solid material is included in the aerosol product as a shredded sheet (as further described herein). In some cases, the sheet can have a mass per unit area of ​​about 30-70 g / m. 2 , 40~60g / m 2 , or 25 to 60 g / m 2 and the sheet can be used to encase an aerosolizable material, such as the aerosolizable materials described herein.

[0171] The aerosol-forming material can include a mixture of the aerosolizable material described herein and an amorphous solid material. Such aerosol-forming materials can provide a desirable flavor profile for the aerosol during use because additional flavorings can be incorporated into the aerosol-forming material by including them in the amorphous solid material component. The flavorings provided in the amorphous solid material can be more stably retained within the amorphous solid material compared to flavorings added directly to the tobacco material, resulting in a more consistent flavor profile among articles manufactured according to the present disclosure.

[0172] As previously mentioned, tobacco materials having a density of at least 350 mg / cc to less than about 900 mg / cc, preferably about 600 mg / cc to about 900 mg / cc, have been found to be advantageous in providing a more sustained aerosol release. To provide an aerosol with a consistent flavor profile, the amorphous solid material components of the aerosol-forming material should be uniformly dispersed throughout the rod. The inventors have found that this can be advantageously achieved by casting the amorphous solid material to provide an amorphous solid material having a thickness as described herein and an areal density similar to that of the tobacco material, and by processing the amorphous solid material as described herein to ensure uniform dispersion throughout the aerosol-forming material.

[0173] According to an aspect of the present disclosure, there is provided a process for producing the aerosol-forming materials described herein.

[0174] The process includes mixing a tobacco material, an aerosol-forming material, water, and a binder to form a slurry. The slurry is then processed to form a sheet of aerosolizable material comprising the tobacco material, the aerosol-forming material, and the binder. The slurry can be processed by forming a layer of the slurry on a surface and then drying the slurry to remove at least a portion of the water and form the sheet of aerosolizable material.

[0175] Water can be removed by evaporating it from the slurry at ambient temperature and pressure (e.g., 25°C and 101 kPa). Alternatively, water can be removed by applying heat to the slurry (e.g., by heating the slurry to about 25°C) and / or by reducing the air pressure surrounding the slurry (e.g., to less than 101 kPa).

[0176] In some embodiments, the slurry is processed by band casting.

[0177] After drying, the sheet of aerosolizable material can be cut into strips or strands of aerosolizable material. The strips or strands of aerosolizable material can be collected and formed into articles for use in non-combustible aerosol delivery systems. A suitable process for cutting a sheet of aerosolizable material and collecting it into articles can be found in WO 2019 / 057796. Optionally, the aerosolizable material can be crimped and then collected to form an article.

[0178] FIG. 1 illustrates a method by which an article containing aerosol-generating material for use in a non-combustion aerosol delivery system can be manufactured. In step S101, a slurry is formed containing tobacco material, aerosol-forming material, water, and a binder. Optionally, fibrous material (e.g., wood pulp / wood fiber) is added at this point. In step S102, a layer of the slurry is formed on a surface. In step S103, the layer of the slurry layer is allowed to dry on the surface to form a sheet or aerosolizable material. In step S104, a single-thickness sheet of aerosolizable material is fed to a shredder. This can be achieved, for example, by providing a roll of sheet material that can be continuously fed to the shredder. Alternatively, individual portions of the aerosolizable material in sheet form, such as sheets known to those skilled in the art as flags, can be fed to the shredder.

[0179] The inventors have surprisingly found that aerosol-generating material in sheet form has advantages when shredded at a single sheet thickness, as opposed to conventional tobacco shredding processes in which several sheets of laminar material are fed simultaneously into a shredder. When multiple thicknesses of aerosol-generating material are fed through a shredder in only one pass, the multiple thicknesses of sheet material tend to adhere to each other and form clumps, resulting in uneven distribution of the material in the final aerosol-generating material.

[0180] In step S105, the sheet of aerosolizable material is chopped to form strands or strips of aerosolizable material. Optionally, the aerosolizable material can be subjected to a second cutting step (not shown), such as a cross-cut chopping process, to obtain a defined cut length.

[0181] In step S106, the strands or strips of aerosolizable material are collected to form the aerosol-generating portion of the article.

[0182] By varying the thickness of the initial slurry layer in step S102 and the amount of tobacco material, aerosol-forming material, and binder in the material, the thickness, volume, and areal density of the sheet or shredded sheet of aerosolizable material can be adjusted.

[0183] According to an aspect of the present disclosure, there is provided an article for use in a non-combustible aerosol delivery system, the article comprising an aerosol-forming material as described herein.

[0184] In the drawings described herein, the same reference numerals are used to denote like features, items or components.

[0185] FIG. 2 is a cross-sectional side view of an article 1 for use in an aerosol delivery system.

[0186] Article 1 comprises a mouthpiece 2 and an aerosol-generating portion connected to mouthpiece 2. In this example, the aerosol-generating portion comprises a source of aerosol-generating material in the form of a cylindrical rod of aerosol-generating material 3. In other examples, the aerosol-generating portion may comprise a cavity that receives the source of aerosol-generating material.

[0187] The aerosol-generating material comprises strands or strips of an aerosol-generating material as described herein. For example, the aerosol-generating material can comprise strands or strips of an aerosolizable material and, optionally, strands or strips of an amorphous solid as described herein. In some embodiments, the aerosol-generating material is comprised of strands or strips of an aerosolizable material.

[0188] In this example, a cylindrical rod of aerosol-forming material 3 comprises multiple strands and / or strips of aerosol-forming material and is surrounded by a wrapper 10. The wrapper 10 may be a moisture-impermeable wrapper.

[0189] In this example, the rod of aerosol-forming material 3 has a circumference of about 22.7 mm. In alternative embodiments, the rod of aerosol-forming material 3 can have any suitable circumference, for example, from about 20 mm to about 26 mm.

[0190] Article 1 is configured for use in a non-combustible aerosol delivery device that includes an aerosol generator for insertion into the aerosol-generating portion. In this example, the aerosol generator is a heater, and the article is configured to receive the aerosol generator in a rod of aerosol-generating material.

[0191] The wrapper 10 surrounding the rod of aerosol-forming material can include a cellulosic material having a basis weight of greater than about 40 grams per square meter (gsm), e.g., greater than about 30 gsm, preferably greater than about 40 gsm, and more preferably greater than about 50 gsm. The inventors have found that such a basis weight advantageously provides increased stiffness to the rod of aerosol-forming material. In this example, the wrapper 10 includes a paper wrapper.

[0192] The increased stiffness provided by a wrapper having a basis weight greater than about 30 gsm, greater than about 40 gsm, or greater than about 50 gsm makes the rod of aerosol-generating material 3 more resistant to wrinkling or other deformation due to forces the article experiences during use, for example, when inserting the article into a device and / or inserting a heat generator into the article. Providing a rod of aerosol-generating material with increased stiffness can be advantageous when multiple strands or strips of aerosol-generating material 3 are aligned within the aerosol-generating portion with their longitudinal dimensions aligned parallel to the longitudinal axis. This is because the longitudinally aligned strands or strips of aerosol-generating material can impart less stiffness to the rod of aerosol-generating material than when the strands or strips are not aligned. The increased stiffness of the rod of aerosol-generating material allows the article to withstand the increased forces the article experiences during use.

[0193] In other embodiments, the wrapper 10 optionally includes a barrier coating that renders the wrapper material substantially moisture-impermeable. For example, a layer of aluminum foil on the wrapper 10 has been found to be particularly effective in enhancing aerosol formation within the aerosol-forming material 3. For example, the wrapper can be provided with a layer of aluminum foil having a thickness of about 4 μm to 16 μm, e.g., about 6 μm. Metal layers or foils other than aluminum can also be used. The total thickness of the wrapper is preferably 20 μm to 90 μm, more preferably 30 μm to 60 μm, to provide the wrapper with adequate structural integrity and heat transfer properties. The tensile force that can be applied to the wrapper before it breaks can be greater than 3,000 grams of force, e.g., 3,000 to 10,000 grams of force, or 3,000 to 4,500 grams of force.

[0194] In this example, the wrapper 10 is also substantially non-breathable. In an alternative embodiment, the wrapper 10 preferably has a breathability of less than 100 Coresta units, more preferably less than 60 Coresta units. It has been found that wrappers with low breathability, for example, having a breathability of less than 100 Coresta units, more preferably less than 60 Coresta units, enhance aerosol formation in the aerosol-generating material 3. Without wishing to be bound by theory, it is hypothesized that this is due to less loss of aerosol compounds through the wrapper 10. The breathability of the wrapper 10 can be measured in accordance with ISO 2965:2009 for measurement of breathability of materials used as cigarette paper, filter plug wrap, and filter bonding paper.

[0195] Tipping paper 5 is wrapped around the entire length of mouthpiece 2 and a portion of the rod of aerosol-generating material 3, and has adhesive on its inner surface to connect mouthpiece 2 to rod 3. In this example, tipping paper 5 extends 5 mm over the rod of aerosol-generating material 3; however, it may alternatively extend 3 mm to 10 mm, or more preferably 4 mm to 6 mm, over rod 3 to securely attach mouthpiece 2 to rod 3. The tipping paper may have a basis weight of greater than 20 gsm, e.g., greater than 25 gsm, or preferably greater than 30 gsm, e.g., 37 gsm. Basis weights in these ranges have been found to provide tipping paper with acceptable tensile strength yet sufficient flexibility to wrap around article 1 and adhere to itself along the paper's longitudinal lap seam. In this example, the circumference of tipping paper 5 after wrapping around the mouthpiece is approximately 23 mm.

[0196] Mouthpiece 2 includes a cooling portion 8, also referred to as a cooling element, located immediately downstream of and adjacent to a source of aerosol-forming material 3. In this example, cooling portion 8 abuts the source of aerosol-forming material. Mouthpiece 2 also includes, in this example, a body of material 6 downstream of cooling portion 8 and a hollow tubular element 4 at the mouth end of article 1 downstream of body of material 6.

[0197] The cooling portion 8 comprises a hollow channel having an inner diameter of about 1 mm to about 4 mm, for example, about 2 mm to about 4 mm. In this example, the hollow channel has an inner diameter of about 3 mm. The hollow channel extends along the entire length of the cooling portion 8. In this example, the cooling portion 8 comprises a single hollow channel. In alternative embodiments, the cooling portion can comprise multiple channels, for example, two, three, or four channels. In this example, the single hollow channel is generally cylindrical, although other channel shapes / cross-sections may be used in alternative embodiments. The hollow channel can provide space in which aerosol drawn into the cooling portion 8 can expand and cool. In all embodiments, the cooling portion is configured to limit the cross-sectional area of ​​the hollow channel or channels and to limit the displacement of tobacco into the cooling portion during use.

[0198] The non-vapor-permeable wrapper 10 has low friction with the aerosol-generating material, which allows strands and / or strips of aerosol-generating material to be more easily displaced longitudinally into the cooling section when the aerosol generator is inserted into the rod of aerosol-generating material. The inventors have found that by providing the cooling section 8 directly adjacent to the source of aerosol-generating material and by providing an internal channel having a diameter in this range, longitudinal displacement of the strands and / or strips of aerosol-generating material is advantageously reduced when the aerosol generator is inserted into the rod of aerosol-generating material. The inventors have found that reducing displacement of the aerosol-generating material during use advantageously results in a more consistent packing density of the aerosol-generating material along the length of the rod and / or within the cavity, resulting in more consistent and easily controllable aerosol generation.

[0199] When the aerosol generator is inserted into the rod of aerosol-generating material 3, strands and / or strips of the aerosol-generating material may be longitudinally displaced into the cooling portion. The inventors have found that by providing the cooling portion 8 directly adjacent to the source of aerosol-generating material and by providing an internal channel having a diameter in this range, longitudinal displacement of the strands and / or strips of aerosol-generating material is advantageously reduced when the aerosol generator is inserted into the rod of aerosol-generating material. The inventors have found that reducing displacement of the aerosol-generating material during use advantageously results in a more consistent packing density of the aerosol-generating material along the length of the rod and / or within the cavity, resulting in more consistent and improved aerosol generation.

[0200] The rod of aerosol-generating material 3 and the cooling section 8 each have a cross-sectional area measured perpendicular to the longitudinal axis of the article 1, as shown by line X-X' in Figure 2. The cooling section is configured so that a maximum percentage of the cross-sectional area of ​​the cooling section is comprised of hollow interior channels, e.g., less than about 45% of the cross-sectional area, preferably less than 30% of the cross-sectional area, and more preferably less than 25% of the cross-sectional area. In this example, about 18% of the cross-sectional area of ​​the cooling section is comprised of hollow channels.

[0201] Additionally or alternatively, the hollow interior channels may occupy at least about 4%, or at least about 6%, or at least about 8% of the cross-sectional area of ​​the cooling portion. In some instances, the hollow interior channels occupy between 4% and 32% of the cross-sectional area of ​​the cooling portion.

[0202] The cooling portion 8 preferably has a radial wall thickness, which can be measured, for example, using calipers. The wall thickness of the cooling portion 8 for a given outer diameter of the cooling portion defines the inner diameter of the cavity enclosed by the walls of the cooling portion 8. The cooling portion 8 preferably has a wall thickness of at least about 1.5 mm and up to about 2 mm. In this example, the cooling portion 8 has a wall thickness of about 1.5 mm. The inventors have found that providing a cooling portion 8 with a wall thickness within this range advantageously improves retention of the supply of aerosol-generating material in the aerosol-generating portion during use by reducing longitudinal displacement of strands and / or strips of aerosol-generating material when the aerosol generator is inserted into an article.

[0203] Cooling portion 8 is formed from filament tow. Other configurations may be used, such as multiple layers of paper wound in parallel and abutting at a seam to form tubular element 8, spirally wound layers of paper, cardboard tubes, tubes formed using a cohesive paper type process, molded or extruded plastic tubes, etc. Cooling portion 8 is manufactured to be sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacturing and use of article 1.

[0204] The filament tow materials described herein can include cellulose acetate fiber tow. The filament tow can 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-cotterephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers, or combinations thereof. The filament tow can be plasticized using an appropriate plasticizer for the tow, such as triacetin, where the material can be cellulose acetate tow or the tow can be unplasticized. The tow can have any suitable specifications, for example, the fibers have other cross sections such as "Y" or "X" shapes, with a single fineness value of 2.5 to 15 denier per filament, for example, 8.0 to 11.0 denier per filament, and a total fineness value of 5,000 to 50,000, for example, 10,000 to 40,000.

[0205] The filament tow forming the cooling portion 8 preferably has a denier per filament greater than 3. This denier per filament has been found to allow for the formation of a tubular element 4 that is not too dense. The denier per filament is preferably at least 4, more preferably at least 5. In a preferred embodiment, the filament tow forming the hollow tubular element 4 has a denier per filament between 4 and 10, more preferably between 4 and 9. In one example, the filament tow forming the cooling portion 8 is formed from cellulose acetate and has an 8Y40,000 tow containing 18% plasticizer, such as triacetin.

[0206] The wall material of the cooling portion 8 may be relatively non-porous, such that at least 90% of the aerosol generated by the aerosol-generating material 3 passes longitudinally through the one or more hollow channels rather than through the wall material of the cooling portion 8. For example, at least 92% or at least 95% of the aerosol generated by the aerosol-generating material 3 may pass longitudinally through the one or more hollow channels.

[0207] Preferably, the length of the cooling portion 8 is less than about 30 mm. More preferably, the length of the cooling portion 8 is less than about 25 mm. Even more preferably, the length of the cooling portion 8 is less than about 20 mm. Additionally or alternatively, the length of the cooling portion 8 is preferably at least about 10 mm. Preferably, the length of the cooling portion 8 is at least about 15 mm. In some preferred embodiments, the length of the cooling portion 8 is between about 15 mm and about 20 mm, more preferably between about 16 mm and about 19 mm. In this example, the length of the cooling portion 8 is 19 mm.

[0208] The cooling portion 8 is disposed around and defines a cavity within the mouthpiece 2 that acts as the cooling portion. The cavity provides a chamber through which heated volatile components generated by the aerosol-generating material 3 flow. The cooling portion 8 is hollow to provide a chamber for aerosol accumulation, yet is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and use of the article 1. The cooling portion 8 provides a physical displacement between the aerosol-generating material 3 and the body of material 6. The physical displacement provided by the cooling portion 8 provides a temperature gradient across the length of the cooling portion 8.

[0209] Mouthpiece 2 is 110mm 3 Preferably, the mouthpiece 2 has a cavity with an internal volume of at least 110 mm. It has been found that providing a cavity of at least this volume allows for improved aerosol formation. The mouthpiece 2 is formed within the cooling section 8, for example, and has an internal volume of 110 mm. 3 More than 130mm, preferably 3 More preferably, the internal cavity has an internal volume of about 130 mm or more, allowing for further improvement of the aerosol. 3 ~about 230mm 3 , for example, about 134 mm 3 or 227 mm 3 It has a volume of

[0210] The cooling section 8 may be configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile components entering the first upstream end of the cooling section 8 and the heated volatile components exiting the second downstream end of the cooling section 8. Preferably, the cooling section 8 is configured to provide a temperature difference of at least 60 degrees Celsius, preferably at least 80 degrees Celsius, and more preferably at least 100 degrees Celsius between the heated volatile components entering the first upstream end of the cooling section 8 and the heated volatile components exiting the second downstream end of the cooling section 8. This temperature difference across the length of the cooling section 8 protects the temperature-sensitive body 6 from the high temperatures of the aerosol-generating material 3 when heated.

[0211] The body of material 6 and the hollow tubular element 4 each define a generally cylindrical overall outer shape and share a common longitudinal axis. The body of material 6 is wrapped in a first plug wrap 7. The first plug wrap 7 preferably has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. The first plug wrap 7 preferably has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The first plug wrap 7 is preferably a non-porous plug wrap having an air permeability of, for example, less than 100 Coresta units, for example, less than 50 Coresta units. However, in other embodiments, the first plug wrap 7 may be a porous plug wrap having an air permeability of, for example, greater than 200 Coresta units.

[0212] Preferably, the length of the body of material 6 is less than about 15 mm. More preferably, the length of the body of material 6 is less than about 12 mm. Additionally or alternatively, the length of the body of material 6 is at least about 5 mm. Preferably, the length of the body of material 6 is at least about 8 mm. In some preferred embodiments, the length of the body of material 6 is between about 5 mm and about 15 mm, more preferably between about 6 mm and about 12 mm, even more preferably between about 6 mm and about 12 mm, and most preferably about 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. In this example, the length of the body of material 6 is 10 mm.

[0213] In this example, the body 6 is formed from filament tow. In this example, the tow used in the body 6 has a denier per filament (dpf) of 5 and a total fineness of 25,000. In this example, the tow comprises plasticized cellulose acetate tow. The plasticizer used in the tow comprises approximately 7% by weight of the tow. In this example, the plasticizer is triacetin. In other examples, different materials may be used to form the body 6. For example, the body 6 may be formed from paper rather than tow, similar to the paper filters known for use in cigarettes. Alternatively, the body 6 may be formed from tow other than cellulose acetate, such as polylactic acid (PLA), other materials described herein for filament tow, or similar materials. Preferably, the tow is formed from cellulose acetate. Whether formed from cellulose acetate or another material, the tow preferably has a denier per filament (dpf) of at least 5. To obtain a sufficiently uniform mass 6, the tow preferably has a denier per filament of 12 d.pf or less, preferably 11 d.pf or less, more preferably 10 d.pf or less.

[0214] The total fineness of the tow forming the body of material 6 is preferably at most 30,000, more preferably at most 28,000, and even more preferably at most 25,000. These total fineness values ​​provide tows that occupy a smaller percentage of the cross-sectional area of ​​the mouthpiece 2, thereby resulting in a lower pressure drop across the mouthpiece 2 than tows having higher total fineness values. For appropriate hardness of the body of material 6, the tows preferably have a total fineness of at least 8,000, more preferably at least 10,000. The denier per filament is preferably 5 to 12, and the total fineness is preferably 10,000 to 25,000. The cross-sectional shape of the filaments of the tow is preferably "Y" shaped, although other shapes, such as "X" shaped filaments, may be used in other embodiments, with the same dpf and total fineness values ​​provided herein.

[0215] Regardless of the material used to form the body of material 6, the pressure drop across the body of material 6 may be, for example, 0.3 to 5 mmWG per mm of length of the body of material 6, such as 0.5 to 2 mmWG per mm of length of the body of material 6. The pressure drop may be, for example, 0.5 to 1 mmWG per mm of length, 1 to 1.5 mmWG per mm of length, or 1.5 to 2 mmWG per mm of length. The total pressure drop across the body of material 6 may be, for example, 3 to 8 mmWG, or 4 to 7 mmWG. The total pressure drop across the body of material 6 may be about 5, 6, or 7 mmWG.

[0216] As shown in FIG. 2 , the mouthpiece 2 of the article 1 has an upstream end 2a adjacent the rod of aerosol-forming material 3 and a downstream end 2b remote from the rod of aerosol-forming material 3. At the downstream end 2b, the mouthpiece 2 has a hollow tubular element 4 formed from filament tow. This has been found to advantageously significantly reduce the temperature of the exterior surface of the mouthpiece 2 at the downstream end 2b of the mouthpiece, which contacts the consumer's mouth during use of the article 1. Additionally, the use of the tubular element 4 has also been found to significantly reduce the temperature of the exterior surface of the mouthpiece 2 upstream of the tubular element 4. While not wishing to be bound by theory, it is hypothesized that this is because the tubular element 4 passes the aerosol near the center of the mouthpiece 2, thereby reducing the transfer of heat from the aerosol to the exterior surface of the mouthpiece 2.

[0217] The "wall thickness" of the hollow tubular element 4 corresponds to the thickness of the wall of the tube 4 in the radial direction. This can be measured, for example, using calipers. Advantageously, the wall thickness is greater than 0.9 mm, more preferably greater than 1.0 mm. Preferably, the wall thickness is substantially constant around the entire wall of the hollow tubular element 4. However, if the wall thickness is not substantially constant, the wall thickness is preferably greater than 0.9 mm, more preferably greater than 1.0 mm, at any point around the hollow tubular element 4. In the present example, the wall thickness of the hollow tubular element 4 is approximately 1.15 mm.

[0218] Preferably, the length of the hollow tubular element 4 is less than about 20 mm. More preferably, the length of the hollow tubular element 4 is less than about 15 mm. Even more preferably, the length of the hollow tubular element 4 is less than about 10 mm. Additionally or alternatively, the length of the hollow tubular element 4 is at least about 5 mm. Preferably, the length of the hollow tubular element 4 is at least about 6 mm. In some preferred embodiments, the length of the hollow tubular element 4 is between about 5 mm and about 20 mm, more preferably between about 6 mm and about 10 mm, even more preferably between about 6 mm and about 8 mm, and most preferably about 6 mm, 7 mm, or about 8 mm. In this example, the length of the hollow tubular element 4 is 7 mm.

[0219] The density of the hollow tubular element 4 is preferably at least about 0.25 grams per cubic centimeter (g / cc), more preferably at least about 0.3 g / cc. The density of the hollow tubular element 4 is preferably 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 4 is 0.25-0.75 g / cc, more preferably 0.3-0.6 g / cc, more preferably 0.4 g / cc-0.6 g / cc, or about 0.5 g / cc. These densities have been found to provide a good balance between the high hardness imparted by higher density materials and the lower heat transfer characteristics of lower density materials. For purposes of the present invention, the "density" of the hollow tubular element 4 refers to the density of the filament tow forming the element, including any plasticizers incorporated therein. The density can be determined by dividing the total weight of the hollow tubular element 4 by the total volume of the hollow tubular element 4, which can be calculated using appropriate measurements of the hollow tubular element 4, for example obtained with calipers. If necessary, appropriate dimensions can be measured using a microscope.

[0220] The filament tow forming the hollow tubular element 4 preferably has a total fineness of less than 45,000, more preferably less than 42,000. This total fineness has been found to allow the formation of a tubular element 4 that is not too dense. The total fineness is preferably at least 20,000, more preferably at least 25,000. In a preferred embodiment, the filament tow forming the hollow tubular element 4 has a total fineness of 25,000 to 45,000, more preferably 35,000 to 45,000. The cross-sectional shape of the filaments in the tow is preferably "Y" shaped, although other shapes, such as "X" shaped filaments, may be used in other embodiments.

[0221] The filament tow forming the hollow tubular element 4 preferably has a denier per filament greater than 3. This denier per filament has been found to allow for the formation of a tubular element 4 that is not too dense. The denier per filament is preferably at least 4, more preferably at least 5. In a preferred embodiment, the filament tow forming the hollow tubular element 4 has a denier per filament between 4 and 10, more preferably between 4 and 9. In one example, the filament tow forming the hollow tubular element 4 is formed from cellulose acetate and has a 7.3Y36,000 tow containing 18% plasticizer, such as triacetin.

[0222] Preferably, the hollow tubular element 4 has an inner diameter greater than 3.0 mm. A smaller inner diameter would result in the aerosol passing through the mouthpiece 2 and reaching the consumer's mouth at a faster rate than desired, causing the aerosol to become too warm, for example reaching temperatures greater than 40°C or 45°C. More preferably, the hollow tubular element 4 has an inner diameter greater than 3.1 mm, and even more preferably greater than 3.5 mm or 3.6 mm. In one embodiment, the hollow tubular element 4 has an inner diameter of about 3.9 mm.

[0223] Preferably, the hollow tubular element 4 comprises 15% to 22% by weight of plasticizer. In the case of cellulose acetate tow, the plasticizer is preferably triacetin, although other plasticizers such as polyethylene glycol (PEG) may also be used. More preferably, the tubular element 4 comprises 16% to 20% by weight of plasticizer, for example, about 17%, about 18%, or about 19%.

[0224] In this example, the first hollow tubular element 4, the body of material 6, and the second hollow tubular element 8 are combined using a second plug wrap 9, which is wrapped around all three sections. The second plug wrap 9 preferably has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 45 gsm. The second plug wrap 9 preferably has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The second plug wrap 9 is preferably a non-porous plug wrap having an air permeability of less than 100 Coresta units, for example, less than 50 Coresta units. However, in alternative embodiments, the second plug wrap 9 may be a porous plug wrap having an air permeability of, for example, greater than 200 Coresta units.

[0225] In this example, Article 1 has a circumference of approximately 23 mm. In other examples, the article may be provided in any of the formats described herein, for example, having a circumference of 15 mm to 25 mm. Because the article is heated to release the aerosol, improved heating efficiency can be achieved using an article having a smaller circumference within this range, for example, a circumference of less than 23 mm. It has also been found that article circumferences greater than 19 mm are particularly effective for achieving improved aerosol upon heating while maintaining an adequate product length. Articles having circumferences of 19 mm to 23 mm, more preferably 20 mm to 22 mm, have been found to provide a good balance between effective aerosol delivery and allowing efficient heating.

[0226] The article has a ventilation level of approximately 10% of the aerosol drawn through the article. In alternative embodiments, the article can have a ventilation level of 1% to 20%, for example 1% to 12%, of the aerosol drawn through the article. These levels of ventilation help to increase the concentration of aerosol inhaled by the user at the mouth end 2b and aid in the aerosol cooling process. The ventilation is provided directly in the mouthpiece 2 of the article 1. In this example, the ventilation is provided in the cooling section 8, which has been found to be particularly advantageous in aiding the aerosol generation process. The ventilation is provided by perforations 12, in this case formed as a single row of laser perforations located 13 mm from the mouth end 2b downstream of the mouthpiece 2. In alternative embodiments, two or more rows of ventilation perforations may be provided. These perforations pass through the tipping paper 5, the second plug wrap 9, and the cooling section 8. In alternative embodiments, the ventilation may be provided elsewhere in the mouthpiece, for example in the body of material 6 or the first tubular element 4. The article is preferably configured so that the perforations are located approximately 28 mm or less from the upstream end of the article 1, preferably 20 mm to 28 mm from the upstream end of the article 1. In this example, the opening is located approximately 25 mm from the upstream end of the article.

[0227] Figure 2a is a side cross-sectional view of a further article 1' comprising a capsule-containing mouthpiece 2'. Figure 2b is a cross-sectional view of the capsule-containing mouthpiece shown in Figure 2a through line A-A'. Article 1' and capsule-containing mouthpiece 2' are the same as article 1 and mouthpiece 2 shown in Figure 2, except that the aerosol modifier, in this example in the form of capsules 11, is provided within body of material 6, and an oil-resistant first plug wrap 7' surrounds body of material 6. In other examples, the aerosol modifier can be provided in other forms, such as a material infused into body of material 6, or in threads that can also be disposed within body of material 6, such as threads carrying flavorings or other aerosol modifiers.

[0228] The capsule 11 may include a breakable capsule, for example, a capsule having a solid, frangible shell surrounding a liquid payload. In this example, a single capsule 11 is used. The capsule 11 is fully embedded within the body of material 6. In other words, the capsule 11 is completely surrounded by the material forming the body of material 6. In other examples, multiple breakable capsules, for example, two, three, or more breakable capsules, may be disposed within the body of material 6. The length of the body of material 6 may be increased to accommodate the required number of capsules. In examples using multiple capsules, the individual capsules may be identical to one another or may differ from one another in terms of size and / or capsule payload. In other examples, multiple bodies of material 6 may be provided, each containing one or more capsules.

[0229] Capsule 11 has a core-shell structure. In other words, capsule 11 includes a shell that encapsulates a liquid agent, such as a flavorant or other adjuvant, which may be, for example, any one of the flavorants or aerosol modifiers described herein. The capsule shell can be ruptured by a user to release the flavorant or other adjuvant into body 6. First plug wrap 7′ can include a barrier coating that renders the plug wrap material substantially impermeable to the liquid payload of capsule 11. Alternatively or additionally, second plug wrap 9 and / or tipping paper 5 can include a barrier coating that renders the plug wrap and / or tipping paper material substantially impermeable to the liquid payload of capsule 11.

[0230] In this example, capsule 11 is spherical and has a diameter of about 3 mm. In other examples, other capsule shapes and sizes may be used. For example, the capsule may have a diameter of less than 4 mm, or less than 3.5 mm, or less than 3.25 mm. In alternative embodiments, the capsule may have a diameter greater than about 3.25 mm, e.g., greater than 3.5 mm, or greater than 4 mm. The total weight of capsule 11 may range from about 10 mg to about 50 mg.

[0231] In this example, capsule 11 is located at a longitudinally central position within body 6. That is, capsule 11 is located with its center 5 mm from each end of body 6. In this example, the center of the capsule is located 36 mm from the upstream end of article 1. Preferably, the capsule is located 28 mm to 38 mm from the upstream end of article 1, more preferably 34 mm to 38 mm from the upstream end of article 1. In this example, the capsule is located 12 mm from the downstream end of mouthpiece 2b. This location of the capsule enhances volatilization of the capsule contents by its proximity to the aerosol-generating portion of the article that is heated during use, and is far enough away from the aerosol-generating portion that is inserted into the aerosol delivery system during use that the user can easily reach the capsule and pop it with their fingers.

[0232] In another example, the capsule 11 may be located at a position other than the longitudinal center of the material body 6, i.e., closer to the downstream end than the upstream end of the material body 6, or closer to the upstream end than the downstream end of the material body 6. The mouthpiece 2' is preferably configured so that the capsule 11 and the vent hole 12 are offset from each other in the longitudinal direction of the mouthpiece 2'. For example, the vent hole 12 may be located immediately upstream of the capsule position, i.e., about 1 mm to about 10 mm upstream of the capsule position.

[0233] In this embodiment, the moisture-impermeable wrapper 10 surrounding the rod of aerosol-forming material comprises aluminum foil. In another embodiment, the wrapper 10 comprises a paper wrapper, which optionally includes a barrier coating that renders the wrapper material substantially moisture-impermeable. Aluminum foil has been found to be particularly effective in enhancing aerosol formation within the aerosol-forming material 3. In this example, the aluminum foil has a metal layer approximately 6 μm thick. In this example, the aluminum foil has a paper backing. However, in alternative configurations, the aluminum foil may have other thicknesses, for example, a thickness of 4 μm to 16 μm. The aluminum foil need not have a paper backing; for example, it may have a backing formed from another material that helps to provide the foil with adequate tensile strength, or it may have no backing material at all. Metal layers or foils other than aluminum may also be used. The total thickness of the wrapper is preferably 20 μm to 60 μm, more preferably 30 μm to 50 μm, to provide a wrapper with adequate structural integrity and heat transfer properties. The pulling force that can be applied to the wrapper before it breaks can be greater than 3,000 grams, e.g., 3,000 to 10,000 grams, or 3,000 to 4,500 grams. When the wrapper comprises paper or a paper backing, i.e., a cellulosic material, the wrapper can have a basis weight of greater than about 30 gsm, preferably greater than about 40 gsm, and more preferably greater than about 50 gsm. The inventors have found that such basis weights advantageously impart high stiffness to the rod of aerosol-generating material. The high stiffness imparted by a wrapper having a basis weight of greater than about 30 gsm, greater than about 40 gsm, or greater than about 50 gsm makes the rod of aerosol-generating material 3 more resistant to wrinkling or other deformation due to forces experienced by the article during use, e.g., when inserting the article into a device and / or inserting a heat generator into the article.

[0234] Providing a rod of aerosol-generating material with high stiffness can be advantageous when cooling portion 8 is included in article 1 because, as described herein, when cooling portion 8 has an inner diameter of less than about 4 mm, the insertion force required to insert the article into a device and / or insert an aerosol generator into the article can be increased. The high stiffness of the rod of aerosol-generating material allows the article to withstand the high forces to which it is subjected during use.

[0235] In this example, the non-breathable wrapper 10 is also substantially non-breathable. In an alternative embodiment, the wrapper 10 preferably has a breathability of less than 100 Coresta units, more preferably less than 60 Coresta units. It has been found that low-breathability wrappers, for example, having a breathability of less than 100 Coresta units, more preferably less than 60 Coresta units, enhance aerosol formation in the aerosol-forming material 3. Without wishing to be bound by theory, it is hypothesized that this is due to reduced loss of aerosol compounds through the wrapper 10. The breathability of the wrapper 10 can be measured in accordance with ISO 2965:2009, which relates to the measurement of breathability of materials used as cigarette paper, filter plug wrap, and filter bonding paper.

[0236] The aerosol-generating portion includes an aerosol-generating material as described herein. The aerosol-generating material can comprise multiple strands or strips of aerosol-generating material. For example, the aerosol-generating material can comprise multiple strands or strips of aerosolizable material and / or multiple strands or strips of an amorphous solid. In some embodiments, the aerosol-generating material is comprised of multiple strands or strips of aerosolizable material.

[0237] Multiple strands or strips of aerosol-generating material may be aligned within the aerosol-generating portion such that their longitudinal dimensions are aligned parallel to the longitudinal axis X-X' of the article 1. Alternatively, the strands or strips may be generally arranged with their aligned longitudinal dimensions transverse to the longitudinal axis of the article.

[0238] At least about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, or 95% of the plurality of strands or strips may be arranged such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the article. A majority of the strands or strips may be arranged such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the article. In some embodiments, between about 95% and about 100% of the plurality of strands or strips are arranged such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the article. In some embodiments, substantially all of the strands or strips are arranged in the aerosol-generation portion of the article such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the aerosol-generation portion.

[0239] The inventors have found that if the majority of the strands or strips are arranged in the aerosol-generating portion so that their longitudinal axes are parallel to the longitudinal axis of the aerosol-generating portion of the article, the force required to insert the aerosol generator into the aerosol-generating material may be relatively small, which may mean that the article is easier to use.

[0240] The longitudinal dimension of the plurality of strands or strips may be approximately the same as the length of the aerosol-generating portion. The plurality of strands and / or strips may have a length of at least about 5 mm.

[0241] As previously mentioned, optionally, the aerosol-generating material comprises a plurality of strips of amorphous solid material. When the aerosol-generating portion comprises a plurality of strands and / or strips of a sheet of aerosolizable material and a plurality of strips of amorphous solid material, the material properties and / or dimensions of these at least two components may be appropriately selected to ensure relatively uniform mixing of the components and in other ways to reduce separation or unmixing of the components during or after manufacture of the rod of aerosol-generating material.

[0242] In use, the aerosol-generating portion may exhibit a pressure drop of about 15 to about 40 mmH 2 O. In some embodiments, the aerosol-generating portion exhibits a pressure drop across the aerosol-generating portion of about 15 to about 30 mmH 2 O.

[0243] The aerosol-forming material has a density of about 400 mg / cm within the aerosol-generating region. 3 ~about 900mg / cm 3 The aerosol-generating material may have a packing density of 400 mg / cm. Packing densities greater than this may make it difficult to insert the aerosol generator of the aerosol delivery device into the aerosol-generating material, resulting in an increased pressure drop. 3 A packing density less than 0.05 can reduce the stiffness of the article. Additionally, if the packing density is too low, the aerosol-generating material cannot effectively grip the aerosol generator of the aerosol supply.

[0244] At least about 70% of the volume of the aerosol-generating portion is filled with the aerosol-generating material. In some embodiments, between about 75% and about 85% of the volume of the cavity is filled with the aerosol-generating material.

[0245] The article may be for use in a non-combustible aerosol delivery device that includes an aerosol generator that inserts into the aerosol-generating material / consumable.

[0246] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to apply thermal energy to the aerosol-generating material, causing one or more volatile substances to be released from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to apply one or more of vibration, high pressure, or electrostatic energy to the aerosol-generating material.

[0247] Figure 3 shows a simplified view of the components of an embodiment of non-combustion aerosol delivery device 100. Notably, in Figure 3, the elements of non-combustion aerosol delivery device 100 are not drawn to scale. To simplify Figure 3, elements not relevant to understanding the present embodiment have been omitted.

[0248] As shown in FIG. 3, non-combustion aerosol delivery device 100 is a non-combustion aerosol delivery device having housing 101 with area 102 for receiving item 1.

[0249] Region 102 is positioned to receive item 1. When item 1 is received in region 102, at least a portion of the aerosol-generating material is in thermal proximity to heater 103. When item 1 is fully received in region 102, at least a portion of the aerosol-generating material can be in direct contact with heater 103. The aerosol-generating material can emit various volatile compounds at different temperatures. By controlling the maximum operating temperature of electrically heated aerosol-generating system 100, the selective emission of undesirable compounds can be controlled by preventing the emission of selected volatile compounds.

[0250] As shown in Figure 4, within housing 101 is an electrical energy source 104, such as a rechargeable lithium-ion battery. A controller 105 is connected to heater 103, electrical energy source 104, and a user interface 106, such as a button or display. Controller 105 controls the power supplied to heater 103 to regulate the temperature of heater 103. Typically, the aerosol-forming substrate is heated to a temperature of 250-450 degrees Celsius.

[0251] 5 is a schematic cross-sectional view of a non-combustion aerosol delivery device of the type shown in FIG. 3, in which a heater 103 is inserted into the aerosol-generating material 3 of the article 1. The non-combustion aerosol delivery device is shown engaged with the aerosol product 1 by a user for consumption of the aerosol product 1.

[0252] The non-combustible aerosol delivery device housing 101 defines a region 102 in the form of a cavity open at its proximal end (or mouth end) for receiving the aerosol product article 1 for consumption. A heating assembly including a heater 103 is suspended at the distal end of the cavity. The heater 103 is held by a heater mount (not shown) such that the active heating area of ​​the heater is located within the cavity. When the aerosol product article 1 is fully received within the cavity, the active heating area of ​​the heater 103 is located within the aerosol-generating portion of the aerosol product article 1.

[0253] The heater 103 is configured to be inserted into the aerosol-generating material 3. The heater 103 is formed in the form of a blade that terminates in a tip. That is, the length dimension of the heater is greater than its width dimension, which is greater than its thickness dimension. A first side and a second side of the heater are defined by the width and length of the heater.

[0254] When the article 1 is pressed into the cavity, the tapered tip of the heater engages the aerosol-generating material 3. The blades are shaped to easily insert into and remove from the aerosol-generating material 3. By applying force to the article 1, the heater penetrates the aerosol-generating material 3. When the article 1 is properly engaged with the non-combustible aerosol delivery device, the heater 103 is inserted into the aerosol-generating material 3. When the heater is activated, the aerosol-generating material 3 is heated and volatile substances are generated or released. When the user draws on the mouthpiece 2, air is drawn into the article 1, and the volatile substances condense to form an inhalable aerosol. This aerosol passes through the mouthpiece 2 of the article 1 and into the user's mouth.

[0255] The inventors have found that the aerosol generator can be inserted into the aerosolizable material relatively easily. Furthermore, after the aerosol generator is inserted into the aerosolizable material, the article is held securely in place. This makes the article and device easier to use and safer, as the article may be less likely to become dislodged from the aerosol generator during use. For example, in some embodiments, insertion of the aerosol generator into the aerosol-generating portion of the article requires a force of less than about 100 N, less than about 90 N, less than about 80 N, less than about 70 N, or less than about 60 N. The amount of force required to remove the article from the device may be at least about 1.9 N, at least about 2 N, at least about 2.1 N, at least about 2.2 N, at least about 2.3 N, at least about 2.4 N, at least about 2.5 N, at least about 2.6 N, at least about 2.7 N, at least about 2.8 N, at least about 2.9 N, or at least about 3 N. In some embodiments, the amount of force required to remove the article from the device may be less than 1 N. For example, the amount of force required to remove the article from the device may be between about 0.1 N and 0.8 N. [Example]

[0256] Example 1 The effect of including stems in sheets of aerosolizable material on the burst strength of the sheets was investigated using a calibrated texture analyzer (load cell 50 kg, probe height calibration 20 mm, contact force 1 g) and index software manufactured by Stable Micro Systems. The burst strength was measured at 3 cm 2 The results are shown in Table 1.

[0257] [Table 1]

[0258] As can be seen, the inclusion of stems increased the burst strength of the sheet of aerosolizable material.

[0259] Example 2 Ten articles (Articles 1-10) for use in non-combustible aerosol delivery devices were manufactured using either Shredded Aerosolizable Sheet 1, "Composition 1," or Shredded Aerosolizable Sheet 2, "Composition 2" (from Example 1). The sheets were formed into the aerosol-generating portions of ten rod-shaped articles. Each article had a total length of 48 mm and a circularity of at least 98%.

[0260] The force required to insert and withdraw each article from a Philip Morris IQOS device was then analyzed using a calibrated texture analyzer and index software manufactured by (Stable Micro Systems). The results are shown in Table 2.

[0261] [Table 2]

[0262] The results showed that the force required to insert the aerosol generator into the tobacco material was greater for Articles 1-10 than for the Comparative Article. However, the amount of force required to remove Articles 1-10 was greater than for the Comparative Article.

[0263] Example 3 The effect of the presence and amount of binder and filler on the tensile strength of the sheets was investigated. Two sheets of aerosolizable material were prepared with different levels of binder (guar gum) and filler (wood pulp, non-sulfur treated). The results are shown in Table 3.

[0264] The tensile strength of each sheet was analyzed using a calibrated texture analyzer and index software (Stable Micro Systems). The analyzer was calibrated with a return distance of 40 mm, a return speed of 5 mm / s, and a contact force of 0.1 g. The sheets were 15 mm wide and 140 mm long. 25 mm of each sheet was folded over at each end. After this folding, the total length of the sheet was 90 mm, with a 40 mm single-thickness section in the middle.

[0265] [Table 3]

[0266] As can be seen, increasing the amount of binder and filler in the sheet increases the tensile strength of the sheet.

[0267] The various embodiments described herein are presented merely to aid in the understanding and teaching of the claimed features. These embodiments are presented as merely representative examples of embodiments and are not intended to be comprehensive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be construed as limiting the scope of the invention as defined in the claims or to the equivalents of the claims, and it should be understood that other embodiments may be used and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those explicitly set forth herein. Additionally, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. The invention comprises a sheet or shredded sheet of an aerosolizable material containing tobacco material, an aerosol-forming material, and a binder, wherein the sheet or shredded sheet has a thickness of at least 100 μm and a density of 100 g / m². ２ ~250g / m ２ It has a surface density, An aerosol-generating material wherein the tobacco material comprises tobacco stems and tobacco laminae, wherein the tobacco stems are present in an amount of 5% to 60% by weight of the aerosolizable material, and the tobacco laminae are present in an amount of 40% to 95% by weight of the aerosolizable material.

2. The aerosol-generating material according to claim 1, wherein the sheet or shredded sheet of the aerosolizable material has an average thickness of 160 μm to 290 μm.

3. The aerosol-generating material according to claim 1 or 2, wherein the sheet or shredded sheet of the aerosolizable material has a tensile strength of at least 4 N / 15 mm.

4. The aerosol-generating material according to any one of claims 1 to 3, wherein the sheet or shredded sheet of the aerosolizable material has a burst strength of at least 75 g.

5. The aerosol-generating material according to any one of claims 1 to 4, wherein the shredded sheet of the aerosolizable material comprises a plurality of strands or fragments of the aerosolizable material.

6. The aerosol-generating material according to claim 5, wherein the strand or fragment of the aerosolizable material has a width of 0.9 mm to 2 mm.

7. The aerosol-generating material according to any one of claims 1 to 6, wherein the sheet or shredded sheet of the aerosolizable material contains water and the aerosol-forming material in a total amount of less than 30% by weight of the aerosolizable material.

8. The aerosol generating material according to any one of claims 1 to 7, wherein the aerosol-forming material is present in an amount of 10% to 25% by weight of the aerosolizable material.

9. The aerosol generating material according to any one of claims 1 to 8, wherein the tobacco material comprises tobacco particles, and the collection of tobacco particles has a particle size distribution (D90) of at least 100 μm.

10. The aerosol-generating material according to any one of claims 1 to 9, wherein the aerosolizable material includes a filler.

11. The aerosol generating material according to claim 10, wherein the filler includes a fibrous material.

12. The aerosol generating material according to claim 11, wherein the fibrous material includes wood fibers.

13. The material comprises tobacco material, aerosol-forming material, and binder, and the sheet or shredded sheet has a thickness of at least 100 μm and a density of 100 g / m². ２ ~250g / m ２ It has a surface density, An aerosolizable material comprising tobacco stems and tobacco laminae, wherein the tobacco stems constitute 5% to 60% by weight of the aerosolizable material, and the tobacco laminae constitutes 40% to 95% by weight of the aerosolizable material.

14. An aerosolizable material according to claim 13, which is not crimped.

15. The process involves mixing tobacco material, aerosol-forming material, water, and a binder to form a slurry, A thickness of at least 100 μm and 100 g / m² ２ ~250g / m ２ The steps include processing the slurry to form a sheet of aerosolizable material having a surface density and Includes, A process for producing an aerosol-generating material, wherein the tobacco material comprises stem tobacco and lamina tobacco, the stem tobacco is present in an amount of 5% to 60% by weight of the aerosolizable material, and the lamina tobacco is present in an amount of 40% to 95% by weight of the aerosolizable material.

16. The process according to claim 15, further comprising the step of shredding the sheet to form a shredded sheet comprising a plurality of fine pieces of the aerosolizable material.

17. The process according to claim 15 or 16, wherein the step of processing the slurry includes the step of casting the sheet or extruding the slurry to form a sheet of the aerosolizable material.

18. The process according to claim 17, wherein the step of processing the slurry includes the step of casting the sheet with a band casting machine.

19. Use of an aerosol generating material according to any one of claims 1 to 6 in a non-flammable aerosol supply system.

20. An article comprising an aerosol generating material according to any one of claims 1 to 12, for use in a non-flammable aerosol supply system.

21. The article according to claim 20, comprising an aerosol generating portion containing the aerosol generating material.

22. The article according to claim 21, wherein the aerosol generating portion comprises a wrapper surrounding the aerosol generating material.

23. The article according to claim 22, wherein at least 70% of the volume of the aerosol generating portion contains the aerosol generating material.

24. During use, the pressure drop across the aerosol generation section is 15-40 mmH ２ An article according to any one of claims 21 to 23, configured to be O.

25. The aerosol generating material has a filling density of 400 mg / cm ３ to 900 mg / cm ３ in the aerosol generating part, and the article according to any one of claims 21 to 24.

26. The article according to any one of claims 21 to 25, for use in a non-flammable aerosol supply device that includes an aerosol generator inserted into the aerosol generating portion.

27. The article according to claim 26, wherein the aerosol generating portion is configured to receive at least a portion of the aerosol generator.

28. The article according to claim 26 or 27, wherein, during use, the aerosol generator is configured to come into direct contact with at least a portion of the aerosol generating material when the aerosol generator is received by the aerosol generating portion of the article.

29. The article according to claim 27, wherein the aerosol generator is configured to increase the packing density of the aerosol generating material by inserting the aerosol generator into the aerosol generating portion during use.

30. The article according to claim 27, wherein, during use, inserting the aerosol generator into the aerosol generating portion of the article requires a force of less than 100 N.

31. The article according to claim 23, wherein the wrapper comprises a wrapper material containing a cellulose-based material, and the cellulose-based material has a basis weight of more than 40 grams per square meter.

32. An article according to any one of claims 20 to 31, Non-flammable aerosol supply device and A non-flammable aerosol supply system equipped with the following features.

33. The non-combustible aerosol supply system according to claim 32, wherein the non-combustible aerosol supply device comprises an aerosol generator configured to be inserted into an aerosol generation portion.

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