Apparatus for producing a rod of aerosol generating material, method of producing a rod of aerosol generating material, and method of producing an article for an aerosol provision system

Abstract

To provide an apparatus for manufacturing an aerosol-generating material rod.SOLUTION: The apparatus 9 comprises a suction belt 11 for transporting an aerosol-generating material, the suction belt comprising suction holes for retaining the aerosol-generating material on the suction belt, the apparatus being arranged such that the suction belt receives a first aerosol-generating material 4 at a first feeding zone 17. The apparatus further comprises a blocking member 19 configured to block some of the suction holes of the suction belt at the first feeding zone, such that the first aerosol generating material is arranged in a profile comprising a plurality of first areas of the first aerosol generating material, with no or a reduced amount of the first aerosol generating material provided between the first areas. The apparatus further comprises a first feeding device 30 configured to feed at least one of beads, pellets or granules of a second aerosol generating material 5 between said first regions.SELECTED DRAWING: Figure 3A

Description

[Technical Field]

[0001] The present disclosure relates to an apparatus for manufacturing aerosol-generating material rods, a method for manufacturing aerosol-generating material rods, and a method for manufacturing an article for an aerosol delivery system. The present disclosure also relates to an article for use in an aerosol delivery system. [Background technology]

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

[0003] According to the present invention, there is provided an apparatus for producing a rod of aerosol-generating material, the apparatus comprising: a suction belt for transporting the aerosol-generating material, the suction belt including suction holes for retaining the aerosol-generating material on the suction belt, the apparatus comprising: a suction belt arranged to receive a first aerosol-generating material at a first supply zone; a blocking member configured to block some of the suction holes of the suction belt in the first supply zone so that the first aerosol-generating material is arranged in a profile including a plurality of first regions of the first aerosol-generating material, and zero or a reduced amount of the first aerosol-generating material is provided between the first regions; and a first supply device configured to supply at least one of beads, pellets, or granules of a second aerosol-generating material between the first regions.

[0004] In some embodiments, the first feeding device is disposed downstream of the first feeding zone.

[0005] In some embodiments, the profiles are arranged such that the first regions are discrete and spaced apart, with substantially no first aerosol-generating material disposed between the first regions.

[0006] In some embodiments, the profiles are arranged such that there are connecting regions between each of the first regions, each connecting region having a reduced amount of first aerosol-forming material than the first regions.

[0007] In some embodiments, the first supply device comprises a drum including a plurality of receiving spaces configured to receive beads, pellets, and / or granules and move the beads, pellets, and / or granules between the first regions.

[0008] In some embodiments, the first supply device is configured to blow and / or suck the beads, pellets, and / or granules out of the receiving space. The first supply device may comprise a flow generator configured to blow and / or suck the beads, pellets, and / or granules out of the receiving space.

[0009] In some embodiments, the drum includes a plurality of mesh portions that define the receiving space.

[0010] In some embodiments, the feeding device is configured to feed beads, pellets, and / or granules to the suction belt.

[0011] In some embodiments, the feeding device is configured to feed beads, pellets, and / or granules downstream of the suction belt.

[0012] In some embodiments, the apparatus further comprises a winding device configured to wind a paper ribbon around the first aerosol-generating material and the beads, pellets, and / or granules to form a continuous aerosol-generating material rod.

[0013] In some embodiments, the feeding device is configured to feed beads, pellets, and / or granules to the winding device.

[0014] The wrapping device may include a garniture positioned to receive the profile of the first aerosol-forming material from the suction belt.

[0015] In some embodiments, the delivery device is configured to deliver beads, pellets, and / or granules to a profile on the garniture.

[0016] In some embodiments, the garniture is configured to wrap a paper ribbon around the first aerosol-generating material and the beads, pellets, and / or granules to form a continuous aerosol-generating material rod.

[0017] In some embodiments, the apparatus further comprises a cutter configured to cut the continuous aerosol-forming material rod.

[0018] In some embodiments, the first supply device is configured to supply at least one of extruded beads, pellets, or granules, preferably at least one of extruded and spheronized beads, pellets, or granules.

[0019] In some embodiments, the first delivery device has a density of at least about 0.4 g / cm 3 , preferably at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2 g / cm 3 The beads, pellets, and / or granules are configured to deliver about 2 g / cm of beads, pellets, and / or granules. 3 the following, optionally about 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6, or 0.5 g / cm3 In some embodiments, the density of the beads, pellets, and / or granules is between about 0.4 and 1.99 g / cm 3 is.

[0020] In some embodiments, the first aerosol-forming material has a density of at least about 0.1 g / cm 3 , optionally at least about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, or 0.9 g / cm 3 The first aerosol-forming material 4 has a density of about 1 g / cm 3 hereinafter, optionally about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, or 0.2 g / cm 3 In some embodiments, the density of the first aerosol-forming material 4 is between about 0.1 and 0.9 g / cm. 3 is.

[0021] In some embodiments, the density of one of the first and second aerosol-generating materials (e.g., beads, pellets, and / or granules) is at least about 25% higher than the density of the other of the first and second aerosol-generating materials, although in other embodiments, the densities of the first and second aerosol-generating materials are the same.

[0022] In some embodiments, the first aerosol-forming material has a density of about 0.1 g / cm 3 ~Approx. 1g / cm 3 It has a density of

[0023] In some embodiments, the beads, pellets, or granules have a density of about 0.4 g / cm 3 ~Approx. 2g / cm 3 It has a density of

[0024] In some embodiments, heating the article results in a relatively constant release of volatile compounds into the inhalable medium.

[0025] In some embodiments, the second aerosol-forming material comprises extruded tobacco.

[0026] In some embodiments, the second aerosol-forming material comprises beads.

[0027] In some embodiments, the first aerosol-forming material comprises one or more tobacco materials selected from the group consisting of lamina and reconstituted tobacco materials.

[0028] In some embodiments, the first and / or second aerosol-forming materials comprise a combination of lamina and reconstituted tobacco material, hi some embodiments, the lamina and reconstituted tobacco material are present in the aerosol-forming materials in a weight ratio of 1:4 to 4:1.

[0029] In some embodiments, the first and second aerosol-forming materials have the same level of a volatile compound, hi some embodiments, the volatile compound is nicotine.

[0030] In some embodiments, the release of volatile compounds from the first and second aerosol-forming materials occurs at the same rate when the materials reach a given temperature.

[0031] In some embodiments, the first and second aerosol-forming materials are present in the article in a weight ratio of 1:10 to 10:1.

[0032] In some embodiments, the first delivery device is configured to deliver beads, pellets, and / or granules having a particle size in the range of 0.5-3 mm, preferably in the range of 1-2 mm.

[0033] In some embodiments, the first and / or second aerosol-forming materials comprise, consist of, or consist essentially of tobacco material.

[0034] In some embodiments, the first aerosol-forming material comprises, consists of, or consists essentially of cut rag tobacco.

[0035] In some embodiments, the suction belt is positioned to hold the first aerosol-forming material on the underside of the suction belt.

[0036] In some embodiments, the apparatus further comprises a second supply device positioned to supply the first aerosol-generating material onto the suction belt in the first supply zone, preferably disposed below the suction belt.

[0037] In some embodiments, the first delivery device is disposed below the suction belt.

[0038] In some embodiments, the occlusion member comprises a profiled belt that may be positioned to overlap the suction belt in the first region and configured to block some of the suction holes of the suction belt such that the first aerosol-generating material is retained on the suction belt at the profile.

[0039] In some embodiments, the apparatus further comprises rollers, and the suction belt is arranged to have an upper run and a lower run by running on the rollers, and preferably a profiled belt is disposed between the upper and lower runs of the suction belt.

[0040] In some embodiments, the apparatus further comprises a first roller, a second roller, and a third roller disposed between the first roller and the second roller, the suction belt being arranged to run over the first roller and the second roller, and the profiled belt being arranged to run over the first roller and the third roller, thereby overlapping the suction belt between the first roller and the third roller.

[0041] In some embodiments, the apparatus further comprises first, second, third, and fourth rollers, the third and fourth rollers being disposed between the first and second rollers, the suction belt being arranged to run over the first and second rollers, and the profile belt being arranged to run over the third and fourth rollers.

[0042] In some embodiments, the profiled belt includes a plurality of suction regions and a plurality of occlusion regions disposed along the length of the profiled belt.

[0043] In some embodiments, each suction region includes a plurality of suction holes.

[0044] In some embodiments, each suction region includes a single opening.

[0045] In some embodiments, the profile belt further includes connecting suction regions disposed between the suction regions, each of the connecting suction regions being smaller than the suction region such that less aerosol-generating material is held at each connecting suction region than is held at each suction region on the suction belt.

[0046] In some embodiments, each connecting suction region includes a plurality of suction holes.

[0047] In some embodiments, each connecting suction region includes a single opening.

[0048] In some embodiments, the profiled belt has a higher porosity in the suction regions than in the occlusion regions.

[0049] In some embodiments, the material of the profiled belt has a higher porosity in the suction areas than in the occlusion areas.

[0050] In some embodiments, the suction belt has a first width and the profiled belt has a second width, the second width being smaller than the first width.

[0051] In some embodiments, the apparatus further includes a trimmer positioned to trim the first and / or second aerosol-generating material on the suction belt, the trimmer being disposed between the first supply zone and the second supply zone (wherein beads, pellets, and / or granules of the second aerosol-generating material are supplied in the second supply zone).

[0052] In some embodiments, the apparatus further comprises a second trimmer positioned to trim the aerosol-forming material on the suction belt downstream of the second feed zone.

[0053] In some embodiments, the trimmer and / or the second trimmer comprises a spacer.

[0054] The present disclosure also provides a method for manufacturing a rod of aerosol-generating material, the method including the steps of: applying suction to a suction belt having suction holes to retain a first aerosol-generating material on the suction belt in a first supply zone; blocking some of the suction holes of the suction belt in the first regions so that the first aerosol-generating material is retained on the suction belt in a profile including a plurality of first regions of the first aerosol-generating material, with zero or reduced amounts of the first aerosol-generating material being provided between the first regions; and supplying at least one of beads, pellets, or granules of a second aerosol-generating material between the first regions.

[0055] In some embodiments, the beads, pellets, and / or granules are fed to a suction belt.

[0056] In some embodiments, beads, pellets, and / or granules are fed downstream of the suction belt.

[0057] In some embodiments, the method further comprises transferring the first aerosol-generating material to a garniture.

[0058] In some embodiments, beads, pellets, and / or granules are provided in the garniture.

[0059] In some embodiments, the method further comprises wrapping the aerosol-forming material with a paper ribbon to form a continuous aerosol-forming material rod.

[0060] In some embodiments, the method further comprises cutting the continuous rod of aerosol-forming material.

[0061] In some embodiments, the first supply device is configured to supply extruded beads, pellets, and / or granules, preferably extruded and spheronized beads, pellets, and / or granules.

[0062] In some embodiments, the first delivery device has a density of at least about 0.4 g / cm 3 , preferably at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2 g / cm 3 The beads, pellets, and / or granules are configured to deliver about 2 g / cm of beads, pellets, and / or granules. 3 the following, optionally about 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6, or 0.5 g / cm 3 In some embodiments, the density of the beads, pellets, and / or granules is between about 0.4 and 1.99 g / cm 3 is.

[0063] In some embodiments, the first aerosol-forming material has a density of at least about 0.1 g / cm 3, optionally at least about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, or 0.9 g / cm 3 The first aerosol-forming material 4 has a density of about 1 g / cm 3 hereinafter, optionally about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, or 0.2 g / cm 3 In some embodiments, the density of the first aerosol-forming material 4 is between about 0.1 and 0.9 g / cm. 3 is.

[0064] In some embodiments, the density of one of the first and second aerosol-generating materials (e.g., beads, pellets, and / or granules) is at least about 25% higher than the density of the other of the first and second aerosol-generating materials, although in other embodiments, the densities of the first and second aerosol-generating materials are the same.

[0065] In some embodiments, the first aerosol-forming material has a density of about 0.1 g / cm 3 ~Approx. 1g / cm 3 It has a density of

[0066] In some embodiments, the beads, pellets, or granules have a density of about 0.4 g / cm 3 ~Approx. 2g / cm 3 It has a density of

[0067] In some embodiments, heating the article results in a relatively constant release of volatile compounds into the inhalable medium.

[0068] In some embodiments, the second aerosol-forming material comprises extruded tobacco.

[0069] In some embodiments, the second aerosol-forming material comprises beads.

[0070] In some embodiments, the first aerosol-forming material comprises one or more tobacco materials selected from the group consisting of lamina and reconstituted tobacco materials.

[0071] In some embodiments, the first and / or second aerosol-forming materials comprise a combination of lamina and reconstituted tobacco material, hi some embodiments, the lamina and reconstituted tobacco material are present in the aerosol-forming materials in a weight ratio of 1:4 to 4:1.

[0072] In some embodiments, the first and second aerosol-forming materials have the same level of a volatile compound, hi some embodiments, the volatile compound is nicotine.

[0073] In some embodiments, the release of volatile compounds from the first and second aerosol-forming materials occurs at the same rate when the materials reach a given temperature.

[0074] In some embodiments, the first and second aerosol-forming materials are present in the article in a weight ratio of 1:10 to 10:1.

[0075] In some embodiments, the first delivery device is configured to deliver beads, pellets, and / or granules having a particle size in the range of 0.5-3 mm, preferably in the range of 1-2 mm.

[0076] In some embodiments, the first aerosol-forming material and / or the beads, pellets, and / or granules comprise, consist of, or consist essentially of tobacco material.

[0077] In some embodiments, the first aerosol-forming material comprises, consists of, or consists essentially of cut rag tobacco.

[0078] The present disclosure also provides a method of manufacturing an article for an aerosol delivery system, the method comprising manufacturing a rod of aerosol-generating material according to the methods disclosed herein, wherein the first end and second end of the rod of aerosol-generating material comprise the first end and second end of the article.

[0079] The present disclosure also provides a method of manufacturing an aerosol-generating material rod, the method including the steps of providing at least one of beads, pellets, or granules of tobacco material; incorporating the beads, pellets, and / or granules into a continuous pressurized fluid stream; and supplying the fluid stream to a first aerosol-generating material.

[0080] In some embodiments, the step of entraining the beads, pellets, and / or granules in the continuous pressurized fluid stream comprises entraining the beads, pellets, and / or granules using a venturi device.

[0081] In some embodiments, the step of entraining the beads, pellets, and / or granules in a continuous pressurized fluid stream comprises propelling the beads, pellets, and / or granules through a high pressure jet.

[0082] In some embodiments, the step of incorporating the beads, pellets, and / or granules into a continuous pressurized fluid stream comprises propelling the beads, pellets, and / or granules using a vacuum pump.

[0083] In some embodiments, supplying the fluid stream to the first aerosol-generating material includes supplying the fluid stream to a body or rod of the first aerosol-generating material.

[0084] In some embodiments, the step of providing a fluid flow includes aligning the fluid flow substantially parallel to a longitudinal axis of the body or rod.

[0085] In some embodiments, the step of providing beads, pellets, and / or granules of tobacco material includes storing the beads, pellets, and / or granules of tobacco material in a storage unit and receiving the beads, pellets, and / or granules from the storage unit.

[0086] In some embodiments, storing the beads, pellets, and / or granules includes storing the beads, pellets, and / or granules in a conical hopper.

[0087] In some embodiments, the beads, pellets, and / or granules are extruded, preferably the beads, pellets, and / or granules are extruded and spheronized.

[0088] In some embodiments, the beads, pellets, and / or granules have a density of at least about 0.4 g / cm 3 , preferably at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2 g / cm 3 It has density.

[0089] Beads, pellets, and / or granules are about 2 g / cm 3 the following, optionally about 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6, or 0.5 g / cm 3 In some embodiments, the density of the beads, pellets, and / or granules is between about 0.4 and 1.99 g / cm 3 is.

[0090] In some embodiments, the first aerosol-forming material has a density of at least about 0.1 g / cm 3 , optionally at least about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, or 0.9 g / cm 3 The first aerosol-forming material 4 has a density of about 1 g / cm 3hereinafter, optionally about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, or 0.2 g / cm 3 In some embodiments, the density of the first aerosol-forming material 4 is between about 0.1 and 0.9 g / cm. 3 is.

[0091] In some embodiments, the density of one of the first and second aerosol-generating materials (e.g., beads, pellets, and / or granules) is at least about 25% higher than the density of the other of the first and second aerosol-generating materials, although in other embodiments, the densities of the first and second aerosol-generating materials are the same.

[0092] In some embodiments, the first aerosol-forming material has a density of about 0.1 g / cm 3 ~Approx. 1g / cm 3 It has a density of

[0093] In some embodiments, the beads, pellets, or granules have a density of about 0.4 g / cm 3 ~Approx. 2g / cm 3 It has a density of

[0094] In some embodiments, heating the article results in a relatively constant release of volatile compounds into the inhalable medium.

[0095] In some embodiments, the second aerosol-forming material comprises extruded tobacco.

[0096] In some embodiments, the second aerosol-forming material comprises beads.

[0097] In some embodiments, the first aerosol-forming material comprises one or more tobacco materials selected from the group consisting of lamina and reconstituted tobacco materials.

[0098] In some embodiments, the first and / or second aerosol-forming materials comprise a combination of lamina and reconstituted tobacco material, hi some embodiments, the lamina and reconstituted tobacco material are present in the aerosol-forming materials in a weight ratio of 1:4 to 4:1.

[0099] In some embodiments, the first and second aerosol-forming materials have the same level of a volatile compound, hi some embodiments, the volatile compound is nicotine.

[0100] In some embodiments, the release of volatile compounds from the first and second aerosol-forming materials occurs at the same rate when the materials reach a given temperature.

[0101] In some embodiments, the first and second aerosol-forming materials are present in the article in a weight ratio of 1:10 to 10:1.

[0102] In some embodiments, the beads, pellets, and / or granules have a particle size in the range of 0.5 to 3 mm, preferably in the range of about 1 to 2 mm.

[0103] In some embodiments, the first aerosol-forming material comprises, consists of, or consists essentially of tobacco material.

[0104] In some embodiments, the first aerosol-forming material comprises, consists of, or consists essentially of cut rag tobacco.

[0105] Also provided in accordance with the present disclosure is a method of manufacturing an article for an aerosol delivery system, the method comprising manufacturing an aerosol-generating material rod according to a method described herein, wherein the first end and second end of the material rod comprise the first end and second end of the article.

[0106] The present disclosure also provides a pack comprising a plurality of articles manufactured according to the methods described herein.

[0107] The present disclosure also provides articles made from the rods of aerosol-forming material made according to the methods described herein.

[0108] The present disclosure also provides an article for an aerosol delivery system including an aerosol-generating material rod, the aerosol-generating material rod including a first region of a first aerosol-generating material and a second region of a second aerosol-generating material including at least one of beads, pellets, and / or granules.

[0109] In some embodiments, the beads, pellets, or granules are inserted into the first aerosol-generating material.

[0110] In some embodiments, the article is made by an apparatus as described herein or a method as described herein.

[0111] In some embodiments, the first and second ends of the rod of aerosol-forming material comprise the first and second ends of the article.

[0112] In some embodiments, the beads, pellets, and / or granules have a density of at least about 0.4 g / cm 3 , preferably at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2 g / cm 3 It has a density of

[0113] Beads, pellets, and / or granules are about 2 g / cm 3 the following, optionally about 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6, or 0.5 g / cm 3In some embodiments, the density of the beads, pellets, and / or granules is between about 0.4 and 1.99 g / cm 3 is.

[0114] In some embodiments, the first aerosol-forming material has a density of at least about 0.1 g / cm 3 , optionally at least about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, or 0.9 g / cm 3 The first aerosol-forming material has a density of about 1 g / cm 3 hereinafter, optionally about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, or 0.2 g / cm 3 In some embodiments, the density of the first aerosol-forming material is about 0.1 to 0.9 g / cm. 3 is.

[0115] In some embodiments, the density of one of the beads, pellets, and / or granules is at least about 25% higher than that of the first aerosol-generating material, although in other embodiments, the densities of the first and second aerosol-generating materials are the same.

[0116] In some embodiments, the first aerosol-forming material has a density of about 0.1 g / cm 3 ~Approx. 1g / cm 3 It has a density of

[0117] In some embodiments, the beads, pellets, or granules have a density of about 0.4 g / cm 3 ~Approx. 2g / cm 3 It has a density of

[0118] In some embodiments, heating the article results in a relatively constant release of volatile compounds into the inhalable medium.

[0119] In some embodiments, the second aerosol-forming material comprises extruded tobacco.

[0120] In some embodiments, the second aerosol-forming material comprises beads.

[0121] In some embodiments, the first aerosol-forming material comprises one or more tobacco materials selected from the group consisting of lamina and reconstituted tobacco materials.

[0122] In some embodiments, the first and / or second aerosol-forming materials comprise a combination of lamina and reconstituted tobacco material, hi some embodiments, the lamina and reconstituted tobacco material are present in the aerosol-forming materials in a weight ratio of 1:4 to 4:1.

[0123] In some embodiments, the first and second aerosol-forming materials have the same level of a volatile compound, hi some embodiments, the volatile compound is nicotine.

[0124] In some embodiments, the release of volatile compounds from the first and second aerosol-forming materials occurs at the same rate when the materials reach a given temperature.

[0125] In some embodiments, the first and second aerosol-forming materials are present in the article in a weight ratio of 1:10 to 10:1.

[0126] In some embodiments, the beads, pellets, and / or granules have a particle size in the range of 0.5 to 3 mm, preferably in the range of about 1 to 2 mm.

[0127] In some embodiments, the first aerosol-forming material comprises, consists of, or consists essentially of tobacco material.

[0128] In some embodiments, the first aerosol-forming material comprises, consists of, or consists essentially of cut rag tobacco.

[0129] Embodiments will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0130] [Figure 1A] FIG. 1 shows an example of an article for an aerosol delivery system that includes two different types of aerosol-generating materials. [Figure 1B] FIG. 1 shows an example of an article for an aerosol delivery system that includes two different types of aerosol-generating materials. [Figure 1C] FIG. 1 shows an example of an article for an aerosol delivery system that includes two different types of aerosol-generating materials. [Figure 1D] FIG. 1 shows an example of an article for an aerosol delivery system that includes two different types of aerosol-generating materials. [Figure 2A] FIG. 1C shows an example of a wrapped aerosol-generating material rod having two different types of aerosol-generating material formed during manufacturing of a consumable for the aerosol delivery system of FIGS. 1A-1D. [Figure 2B] FIG. 1C shows an example of a wrapped aerosol-generating material rod having two different types of aerosol-generating material formed during manufacturing of a consumable for the aerosol delivery system of FIGS. 1A-1D. [Figure 3A] FIG. 2C illustrates a portion of an apparatus for producing the exemplary wrapping aerosol-generating material rod of FIGS. 2A and 2B. [Figure 3B] FIG. 2C illustrates a portion of an alternative apparatus for producing the exemplary wrapping aerosol-generating material rod of FIGS. 2A and 2B. [Figure 4A] FIG. 2C illustrates a portion of an alternative apparatus for producing the exemplary wrapping aerosol-generating material rod of FIGS. 2A and 2B. [Figure 4B] FIG. 2C illustrates a portion of an alternative apparatus for producing the exemplary wrapping aerosol-generating material rod of FIGS. 2A and 2B. [Figure 5A]5A and 5B are diagrams showing an example of a closing member of the device of FIG. 3 or FIG. 4. [Figure 5B] 5A and 5B are diagrams showing an example of a closing member of the device of FIG. 3 or FIG. 4. [Figure 5C] 5A and 5B are diagrams showing an example of a closing member of the device of FIG. 3 or FIG. 4. [Figure 5D] 5A and 5B are diagrams showing an example of a closing member of the device of FIG. 3 or FIG. 4. [Figure 6] FIG. 5 shows a suction belt of the device of FIG. 3 or 4. [Figure 7] FIG. 1 is a three-dimensional perspective view of a rod making machine and a bead insertion unit attached thereto. [Figure 8] FIG. 8 is a cross-sectional view of the bead insertion unit shown in FIG. [Figure 9] FIG. 9 is an exploded cross-sectional view of the bead insertion unit shown in FIG. 8. [Figure 10] 10A-B are partial cross-sectional views illustrating the operation of the Venturi device of FIG. 9. [Figure 11] FIG. 10 is a side cross-sectional view of an alternative embodiment of the present disclosure. [Figure 12] FIG. 1 is a cross-sectional view of a rod of aerosol-forming material. [Figure 13] FIG. 10 is a cross-sectional view of an alternative rod of aerosol-forming material. [Figure 14] FIG. 1 is a cross-sectional view of an aerosol delivery system including a rod of aerosol-generating material. [Figure 15] FIG. 10 is a side view of a bead insertion unit according to an alternative embodiment. [Figure 16] FIG. 1 is a three-dimensional view of a hopper, according to one embodiment. [Figure 17] 1 is a cross-sectional view of one embodiment of a non-flammable aerosol delivery device. [Figure 18] FIG. 18 is a simplified schematic diagram of components within the housing of the aerosol delivery device shown in FIG. 17. [Figure 19] 18 is a cross-sectional view of the non-burning aerosol delivery device shown in FIG. 17 with the article shown in FIGS. 1A-1D and 12-14 inserted therein. DETAILED DESCRIPTION OF THE INVENTION

[0131] [Detailed explanation] 1A-1D show different examples of an article 1 (e.g., a consumable) for an aerosol delivery system. An example of an aerosol delivery system 200 is shown and described with reference to FIGS. 17-19. The article 1 includes an aerosol-generating material rod 3 that, in use, generates an aerosol for delivery to a user.

[0132] As shown in the figures, in these examples, the aerosol-generating material rod 3 includes a first aerosol-generating material 4 and a second aerosol-generating material 5. The first and second aerosol-generating materials 4, 5 are different. In particular, the second aerosol-generating material 5 is provided in the form of beads, pellets, and / or granules 5. Hereinafter, the beads of the second aerosol-generating material 5 will be referred to as "beads" for simplicity. As shown in FIGS. 1A-1D, the first aerosol-generating material 4 and the beads 5 are disposed in different areas of the aerosol-generating material rod 3 such that a boundary between the first aerosol-generating material 4 and the beads 5 is formed in the aerosol-generating material rod 3.

[0133] In the example of FIG. 1A , the first aerosol-generating material 4 extends from the first end 2 of the rod of aerosol-generating material 3. The first aerosol-generating material 4 extends along the beads 5 to the second end 6 of the rod of aerosol-generating material 3. In this example, the first aerosol-generating material 4 extends from the first end 2 to the second end 6 of the rod of aerosol-generating material 3 and overlaps the beads 5 along a portion of the length of the rod of aerosol-generating material 3. In this example, the beads 5 are disposed closer to the first end 2 than to the second end 6. The boundary between the first aerosol-generating material 4 and the beads 5 is angled relative to the axial direction of the article 1 so that at any given point along the article 1, there is an area with a different content of the first aerosol-generating material 4 and the beads 5.

[0134] The example of Figure 1B is similar to the example of Figure 1A, except that the first aerosol-generating material 4 and the second aerosol-generating material 5 are oppositely positioned with respect to the first end 2 and the second end 6 of the aerosol-generating material rod 3. The beads 5 are disposed closer to the second end 6 than to the first end 2 of the aerosol-generating material rod 3.

[0135] 1A and 1B, a first area of ​​first aerosol-generating material 4 extends from first end 2 of rod 3 of aerosol-generating material. A second area of ​​first aerosol-generating material 4 extends from second end 6 of rod 3 of aerosol-generating material. A region of beads 5 is disposed between the first and second areas of first aerosol-generating material 4 disposed at ends 2, 6 of rod 3 of aerosol-generating material.

[0136] The example of FIG. 1D is similar to the examples of FIGS. 1A, 1B, and 1C, except that the beads 5 are positioned adjacent to the first end 2 of the rod 3 of aerosol-generating material, and the first aerosol-generating material 4 extends to the second end 6 of the rod 3 of aerosol-generating material. In this example, the article 1 includes a filter plug 24 and a tube 42 at the first end 2 of the rod 3 of aerosol-generating material. The filter 24 and the tube 42 may include a filtering material (e.g., but not limited to, cellulose acetate) and a wrapper. The article 1 may also include a wrapper, such as, but not limited to, paper or foil. For clarity, these details have been omitted from FIGS. 1A-1D, which schematically illustrate the configuration of the first and second aerosol-generating tobacco materials 4, 5 in the tobacco rod 3.

[0137] It should be understood that any of the illustrated and described articles 1 may include the filter 24 and / or the tube 42, or any other known component of an article 1. Alternatively, the first and second ends 2, 6 of the rod 3 of aerosol-forming material may comprise the first and second portions of the article 1. When the first and second ends 2, 6 of the rod 3 of aerosol-forming material comprise the first and second portions of the article 1, no additional components are added to the ends 2, 6 of the rod 3 of aerosol-forming material prior to use as the article 1 for an aerosol delivery system.

[0138] In another example, the boundary between the first aerosol-forming material 4 and the beads 5 may be a line perpendicular to the longitudinal direction of the article 1 at a location along the length of the rod 3 of aerosol-forming material.

[0139] The first aerosol-generating material 4 is preferably positioned within the rod 3 so that the beads 5 do not fall off the ends 2, 6 of the rod 3. It should be appreciated that many configurations of the first aerosol-generating material 4 and the beads 5 are possible based on Figures 1A-1D, in addition to the configurations shown in the drawings.

[0140] During manufacture of the article 1, a continuous, wrapped rod of aerosol-generating material 7 is formed by wrapping a wrapper around streams of aerosol-generating material 4, 5. The stream of aerosol-generating material is formed of a first aerosol-generating material 4 and beads 5 that are appropriately positioned to form a rod of aerosol-generating material 3. The continuous, wrapped rod of aerosol-generating material 7 is then cut into individual rods of aerosol-generating material 3 for the individual articles 1 shown in FIGS. 1A-1D.

[0141] 2A shows an exemplary continuous wrapping rod of aerosol-forming material, such as continuous aerosol-forming material rod 7. Continuous aerosol-forming material rod 7 is formed during the manufacture of article 1 of FIG. 1C.

[0142] 2B illustrates an exemplary continuous, wrapping rod of aerosol-generating material, such as a continuous aerosol-generating material rod 7. The continuous aerosol-generating material rod 7 is formed during the manufacture of the article 1 of FIGS. 1A, 1B, and 1D, but the cut line 8 is positioned differently for each of the articles 1 illustrated in FIGS. 1A, 1B, and 1D than it is for the article 1 illustrated in FIG. 2B.

[0143] 2A and 2B are schematic diagrams showing the arrangement of the first aerosol-generating material 4 and the beads 5 along the continuous aerosol-generating material rod 7, and the length and width shown are not representative of the actual dimensions of the continuous aerosol-generating material rod 7. In particular, the length dimension has been compressed and the width dimension has been expanded to clearly show the arrangement of the first aerosol-generating material 4 and the beads 5 along the continuous aerosol-generating material rod 7.

[0144] As shown, the first aerosol-generating material 4 and beads 5 are arranged in an alternating pattern along the continuous rod of aerosol-generating material 7. In particular, the first aerosol-generating material 4 and beads 5 are arranged so that the continuous rod of aerosol-generating material 7 can be cut at regular intervals to form the aerosol-generating material rods 3 for the article 1 of FIGS. 1A-1D. The first aerosol-generating material 4 and beads 5 are arranged so that after the continuous rod of aerosol-generating material 7 is cut along lines 8, the individual rods of aerosol-generating material 3 are positioned back-to-back (i.e., mirror images of each other about the cut lines). The individual rods of aerosol-generating material 3 can then be sent for further processing as needed, for example, to attach any required filter plugs 24 and / or tubes 42 using known assembly equipment, as shown in FIG. 1D.

[0145] Apparatus 9 for producing article 1, and in particular rod 3 of aerosol-forming material, is described below, although it will be appreciated that apparatus 9 may be adapted to produce article 1 that includes materials in addition to aerosol-forming material.

[0146] 3, 4A, and 4B are schematic diagrams of an exemplary apparatus 9 for producing a continuous aerosol-forming material rod (eg, continuous aerosol-forming material rod 7 of FIGS. 2A and 2B).

[0147] As shown in Figures 3A, 3B, 4A, and 4B, apparatus 9 includes a suction conveyor 10 that includes a suction belt 11. Suction belt 11 is arranged to have an upper run 14 and a lower run 15 that moves leftward as shown in Figures 3A, 3B, 4A, and 4B by traveling on rollers 12 and 13. With particular reference to Figure 3, lower run 15 of suction belt 11 receives and transports first aerosol-forming material 4 and beads 5.

[0148] The suction belt 11 includes suction holes 16 (shown in FIG. 6) that attract the first aerosol-generating material 4 and beads 5 to the suction belt 11 and hold and transport the first aerosol-generating material 4 and beads 5 on the suction belt 11. Guides (not shown) may also be provided to guide the first aerosol-generating material 4 and beads 5 along the suction conveyor 10 as the suction belt 11 moves.

[0149] The suction belt 11 is shown in Figure 6. As shown, the suction holes 16 are arranged in a continuous pattern along the suction belt 11. In use, as described below, the first aerosol-generating material 4 and optional beads 5 are held on the suction belt 11 by application of suction through the suction holes 16 in the suction belt 11. The suction holes 16 are sized such that the suction applied through the suction holes 16 holds the first aerosol-generating material 4 and optional beads 5 on the underside of the lower run 15 of the suction belt 11.

[0150] 3, the suction belt 11 receives the first aerosol-generating material 4 in a first feed zone 17 and the beads 5 in a second feed zone 18. The second feed zone 18 is downstream of the first feed zone 17. That is, the lower run 15 of the suction belt 11 passes through the first feed zone 17 and then the second feed zone 18. In this manner, the suction belt 11 is supplied with a combination of the first aerosol-generating material 4 and the beads 5.

[0151] In various examples described below, the first aerosol-generating material 4 is formed into a profile on the suction belt 11 before the beads 5 are added to the first aerosol-generating material 4 so that the combined supply of the first aerosol-generating material 4 and the beads 5 is arranged in a profile to produce a continuous aerosol-generating material rod (e.g., the continuous aerosol-generating material rod 7 shown in Figure 2A or 2B).

[0152] The blocking member 19 is positioned to overlap and / or block a portion of the suction belt 11. The blocking member 19 is disposed between the upper and lower runs 14, 15 of the suction belt 11 and has a blocking surface 20 that contacts or is adjacent to a portion of the lower run 15 of the suction belt 11. Specifically, the blocking member 19 is configured to block a portion of the suction holes 16 of the suction belt 11 in the first supply zone 17 so that the first aerosol-generating material 4 is arranged in a profile including a plurality of first regions of the first aerosol-generating material 4, with zero or reduced amounts of the first aerosol-generating material 4 between the first regions.

[0153] In the example of Figure 3A, the closure member 19 is a profiled belt running on rollers 12 and 21. Both the suction belt 11 and the closure member 19 run on roller 12 (with the suction belt 11 being the outermost), and roller 21 is located between the upper and lower runs 14, 15 of the suction belt 11.

[0154] In the example of Fig. 3B, the closure member 19 is a profiled belt running on rollers 12 and 13. Both the suction belt 11 and the closure member 19 run on rollers 12 and 13 (with the suction belt 11 being the outermost). The closure member 19 is guided away from or above the suction belt 11 in a position near the second supply zone 18 so that the suction holes 16 in the second supply zone 18 are not blocked by the closure member 19. The closure member 19 is lifted by rollers 21A and 21B, which are located between the upper and lower runs 14, 15 of the suction belt 11 and between rollers 12 and 13. The closure member 19 travels on roller 21A between the lower run 15 of the suction belt 11 and roller 21A near the start of the second supply zone 18. The blocking member 19 then travels on the roller 21B between the roller 21B and the upper run 14 of the suction belt 11 as the lower run 15 of the suction belt 11 passes through the second feed zone 18.

[0155] 3B may also include another roller 21C (not shown) located between the upper and lower runs 14, 15 of the suction belt 11 and between rollers 12 and 13. After traveling over rollers 21A and 21B, the blocking member 19 travels on roller 21C between roller 21C and the upper run 14 of the suction belt 11 as the lower run 15 of the suction belt 11 passes through the second feed zone 18. Of course, the blocking member 19 may also travel over another roller 21 before being guided towards the suction belt 11 and traveling over roller 13.

[0156] In the example of Figure 4A, the closure member 19 is a profiled belt running on rollers 36 and 37 which are separate from rollers 12 and 13. Rollers 36, 37 are arranged between the upper and lower runs 14, 15 of the suction belt 11. Rollers 36 and 37 have a substantially smaller diameter than rollers 12 and 13, so that the closure member 19 is further away from the upper run 14 of the suction belt 11 than from the lower run 15 of the suction belt 11.

[0157] 4B, the blocking member 19 is a substantially planar element, such as a profile-defining plate, arranged between the upper and lower runs 14, 15 of the suction belt 11. The planar element 19 moves together with the lower run 15 of the suction belt 11 in the vicinity of the first feed zone 17. It is also conceivable that there are two or more planar elements (not shown), one of which is arranged in place of the first in the region of the first feed zone 17 when another planar element moves together with the lower run 15 of the suction belt 11 in the direction towards the second feed zone 18.

[0158] In the examples of Figures 3A, 3B, 4A, and 4B, the blocking member 19 has a blocking surface 20 that is substantially opposite the lower running portion 15 of the suction belt 11, is in contact with or adjacent to the lower running portion 15 of the suction belt 11, and overlaps the suction belt 11 in the first supply zone 17.

[0159] The blocking member 19 has suction regions 22 arranged in a profile along the blocking member 19. Blocking regions 47 are disposed between the suction regions 22. Various examples of the blocking member 19 are shown in Figures 5A to 5D. As will be described later, the suction regions 22 and the blocking regions 47 are arranged to limit the suction provided to the suction holes 16 of the suction belt 11. In particular, the blocking regions 47 of the blocking member 19 block at least some of the suction holes 16, thereby preventing the first aerosol-generating material 4 from being retained by these suction holes 16. However, the suction regions 22 do not block other suction holes 16, allowing the first aerosol-generating material 4 to be retained by these suction holes 16. In this way, the suction belt 11 is provided with a profile of the first aerosol-generating material 4, i.e., multiple first regions, according to the profiles of the suction regions 22 and the blocking regions 47 of the blocking member 19.

[0160] In the example of FIG. 5A , multiple suction regions 22 are spaced apart along the length of the occlusion member 19. Each suction region 22 includes multiple suction holes 23. Suction is provided in the first feed zone 17 through the suction holes 16 of the suction belt 11 that coincide with, or at least partially coincide with, the spaced apart suction regions 22 on the occlusion member 19 during use, while suction is not provided through the suction holes 16 of the suction belt 11 that coincide with the occlusion region 47 because they are blocked during use. Thus, the first aerosol-generating material 4 is retained on the suction belt 11 only by the profile of the suction regions 22 on the occlusion member 19. The profile in this example includes multiple first regions of the first aerosol-generating material 4, with zero or reduced amounts of the first aerosol-generating material 4 between the first regions. The first regions are preferably discrete and spaced apart from one another.

[0161] In the example of FIG. 5B, the occlusion member 19 includes multiple suction regions 22 spaced apart along the length of the occlusion member 19, as in FIG. 5A. Each suction region 22 includes multiple suction holes 23. In this example, the occlusion member 19 includes connecting suction regions 25 formed by one or more suction holes 26 disposed between the suction regions 22 in the occlusion region 47. Thus, the amount of first aerosol-generating material 4 retained on the suction belt 11 is less in the areas corresponding to the connecting suction regions 25 than in the areas corresponding to the suction regions 22 formed by the groups of spaced suction holes 23 in the occlusion member 19. The profile in this example includes multiple first regions of first aerosol-generating material 4, with a reduced amount of first aerosol-generating material 4 between the first regions. Preferably, the profile is arranged so that connecting regions are disposed between each of the first regions, and each connecting region contains a reduced amount of first aerosol-generating material 4 compared to the first region.

[0162] The exemplary occlusion members 19 of Figures 5C and 5D are similar to those of Figures 5A and 5B, respectively, except that each suction region 22 is formed by a single opening 27 in the occlusion member 19 rather than as a group of suction holes 23 as in Figures 5A and 5B. In the example of Figure 5D, the connecting suction regions 28 between each suction region 22 are formed by single openings in the occlusion member 19, but these are smaller than the openings 27 that form the suction regions 22.

[0163] In an alternative embodiment, the closure member 19 may have a width smaller than the width of the suction belt 11. In this embodiment, the closure member 19 may not include a suction region, or may have a suction region as described with reference to Figures 5A-5D. Thus, in the first feed zone 17, the closure member 19 blocks only a portion of the suction holes 16 of the suction belt 11, thereby allowing the unblocked suction holes 16 to hold the first aerosol-generating material 4.

[0164] In an alternative embodiment, occlusion member 19 has areas of high porosity and areas of low porosity. For example, occlusion member 19 may have suction regions corresponding to suction region 22 in FIGS. 5A-5D formed by imparting high porosity to occlusion member 19 in suction region 22 compared to low porosity in regions corresponding to occlusion region 47. Varying the porosity of occlusion member 19 can be achieved by using different materials in different regions of occlusion member 19 or by changing the material of occlusion member 19; for example, thinner materials or looser woven materials result in higher porosity. Alternatively or additionally, occlusion member 19 may be formed from a laminate, with one of the layers of the laminate varying in porosity, thickness, or perforation such that occlusion member 19 has a higher porosity in suction region 22 than in occlusion region 47.

[0165] 3A, 3B, 4A, and 4B, in second feeding zone 18, a first feeding device 30 is positioned to feed beads 5 onto suction belt 11 or garniture 44, and in first feeding zone 17, a second feeding device 49, such as a vertical feeder 29, is positioned to feed first aerosol-generating material 4 onto suction belt 11. First feeding device 30 is disposed downstream of first feeding zone 17 and is configured to feed beads 5 between first regions of the profile of first aerosol-generating material 4.

[0166] The vertical feeder 29 includes a vertical chimney 31 that receives the first aerosol-generating material 4. The aerosol-generating material 4 is fed into the bottom of the vertical chimney 31 and forced upward toward the suction conveyor 10. The vertical feeder 29 is disposed in the first feeding zone 17, directly below the lower run 15 of the suction belt 11. Optionally, an airflow is directed within the vertical chimney 31 to force the aerosol-generating material 4 vertically upward toward the suction belt 11.

[0167] As shown in FIGS. 3A and 4A, the first delivery device 30 comprises a drum or roller in the form of a pocket wheel including a plurality of pockets that define a receiving space 48 configured to receive beads 5 and move the beads 5 between the first regions of the first aerosol-generating material 4. FIG. 4A illustrates a first delivery device 30 with six receiving spaces 48. However, the first delivery device 30 may have more than six receiving spaces or fewer than five receiving spaces. Furthermore, each receiving space 48 can be further divided into smaller sub-receiving spaces. Optionally, the first delivery device 30 includes a plurality of mesh portions defining the receiving spaces 48. The mesh portions allow air to flow through the receiving spaces 48, facilitating blowing and / or sucking of the beads 5 from the receiving spaces 48.

[0168] 3A and 4A, the drum 30 is disposed in a second feed zone 18 downstream of the first feed zone 17 and directly below the lower run 15 of the suction belt 11. In FIG.

[0169] As shown in Figure 3B, the first feeding device 30 comprises a modified carding drum configured to pick up beads 5 in the second feeding zone 18 and transfer them to the suction belt 11. The drum 30 is disposed in the second feeding zone 18 downstream from the first feeding zone 17, directly below the lower run 15 of the suction belt 11.

[0170] 3A, 3B and 4A, the first supply device 30 is configured to supply the beads 5 to the suction belt 11. However, as shown in FIG. 4B, the first supply device 30 can be configured to supply the beads 5 downstream of the suction belt 11.

[0171] 4B, at the end of the suction conveyor 10, the profile of first aerosol-generating material 4 moves to a garniture 44, which will be described in more detail below. In this example, the garniture 44 is positioned to receive the profile of first aerosol-generating material 4 from the suction belt 11.

[0172] As shown in FIG. 4B , the first supply device 30 is disposed above the garniture 44 and downstream of the suction belt 11 and the first supply zone 17. The first supply device 30 is configured to supply beads 5 to a profile of first aerosol-generating material 4 on the garniture 44, after which the first aerosol-generating material 4 and beads 5 are formed into an aerosol-generating material rod 3. The first supply device 30 in this example can include a hopper, as shown, a metering drum (e.g., a pocket wheel as described above), a modified carding drum, a belt conveyor, and / or the beads 5 can be pneumatically fed from above or gravity fed. The first supply device 30 can also include two or more of the above examples (e.g., the first supply device 30 can include a hopper and a pocket wheel).

[0173] As shown in Figure 4B, the apparatus 9 may further comprise a second supply device 49 arranged to supply the first aerosol-forming material 4 onto the suction belt 11 in the first supply zone 17. The second supply device 49 is preferably disposed below the suction belt 11. The second supply device 49 is similar to the first supply device 30 and therefore will not be described again for the sake of brevity.

[0174] The first supply device 30 in any of the above examples may be, but is not limited to, a metering drum (e.g., a pocket wheel (the pockets may or may not include a mesh)), a modified carding drum, a belt conveyor, a pneumatic drive system, or a belt conveyor. Because the beads 5 are denser than the first aerosol-generating material 4, the first supply device 30 is configured to effectively move the dense beads 5.

[0175] The second supply device 49 in any of the above examples may be, but is not limited to, a metering drum (e.g., a pocket wheel (the pockets may or may not have a mesh)), a modified carding drum, a belt conveyor, a pneumatic drive system, or a belt conveyor.

[0176] The configuration and type of first delivery device 30 in any of the above examples may be combined with the configuration and type of second delivery device 49 in any of the above examples.

[0177] In examples including a first supply device 30 and / or a second supply device 49, blowing and / or sucking the first aerosol-generating material 4 and / or beads 5 from the first supply device 30 and / or the second supply device 49 can assist in moving the beads 5 and / or first aerosol-generating material 4 to the suction belt 11 or garniture 44.

[0178] As shown in Figures 3A, 3B, 4A and 4B, suction is applied to the suction belt 11 by at least one suction chamber 32 connected to a vacuum pump via an outlet 33. The suction chamber 32 is located between the upper and lower runs 14, 15 of the suction belt 11.

[0179] 3A and 4A, in some instances, a second suction chamber 34 may be provided near the closure member 19 to apply suction to the suction belt 11 in the first feed zone 17. The second suction chamber 34 may be connected to a vacuum pump via a second outlet 35. However, it will be appreciated that a single suction chamber may be arranged to apply suction to the entire length of the suction belt 11, including the first feed zone 17.

[0180] In the first feeding zone 17, suction acts through the suction holes 16 in the suction belt 11 and the suction area 22 in the closure member 19, attracting the first aerosol-generating material 4 to the underside of the lower run 15 of the suction belt 11 as the suction belt 11 passes over the vertical feeder 29. Then, in some examples, such as those shown in Figures 3A, 3B, and 4A, suction acts through the suction holes 16 in the suction belt 11 to attract the beads 5 to the underside of the lower run 15 of the suction belt 11 as the suction belt 11 passes over the first feeding device 30.

[0181] As briefly described above, the profile of the suction region 22 and the blocking region 47 of the blocking member 19 is configured to block some of the suction holes 16 of the suction belt 11 in the first feed zone 17. In this way, the first aerosol-generating material 4 is retained on the suction belt 11 only if the suction holes 16 are not blocked by the blocking member 19. Therefore, the profile of the suction region 22 on the blocking member 19 determines the profile of the first aerosol-generating material 4, i.e., the plurality of first regions, retained on the suction belt 11.

[0182] As the lower run 15 of the suction belt moves away from the first feed zone 17, all of the suction holes 16 of the suction belt 11 become uncovered. As the suction belt 11 moves over the first feed device 30, the beads 5 are attracted to and retained by the suction belt 11. The beads 5 are retained on the suction belt 11 in areas where the first aerosol-generating material 4 is absent or minimally present. In this way, a combined stream of the first aerosol-generating material 4 and the beads 5 is formed on the suction belt 11.

[0183] The first aerosol-generating material 4 on the suction belt 11 may be trimmed by a first trimmer unit 38. The first trimmer 38 may include a spacer having a pair of counter-rotating blades 39 spaced apart from the suction belt 11 to trim the first aerosol-generating material 4 to an appropriate thickness and / or shape. Alternatively or additionally, the first trimmer 38 may include a paddle wheel that rotates to knock the first aerosol-generating material 4 off the suction belt 11.

[0184] The first trimmer 38 is disposed between the first and second feed zones 17, 18, i.e., downstream of the first feed zone 17 and upstream of the second feed zone 18, so that the first aerosol-generating material 4 is trimmed to an appropriate thickness before the beads 5 are fed between the first regions of the first aerosol-generating material 4. The recycling device 40 may be positioned to collect the first aerosol-generating material 4 trimmed by the first trimmer 38 and recycle it to the vertical feeder 29.

[0185] In another example, the composite profile of the first aerosol-generating material 4 and the beads 5 may be trimmed by a second trimmer 41. The second trimmer 41 is disposed downstream of the first delivery device 30. The second trimmer 41 may include a paddle wheel that rotates to knock the aerosol-generating materials 4, 5 off the profile. Depending on the configuration of the profile of the first aerosol-generating material 4 and the beads 5, either the first aerosol-generating material 4 or the beads 5 or both may be trimmed by the second trimmer 41.

[0186] The second trimmer 41 may include a recycling device 43 arranged to collect the aerosol-generating material 4, 5 trimmed by the second trimmer 41. If only the first aerosol-generating material 4 or the beads 5 are trimmed from the profile, the trimmed aerosol-generating material 4, 5 may be recycled as needed. If the trimmed aerosol-generating material is a mixture of the first aerosol-generating material 4 and the beads 5, it may be recycled for an alternative use (e.g., used in a different item or separated and recycled separately).

[0187] As previously mentioned, at the end of suction conveyor 10, the combined profile of first aerosol-generating material 4 and beads 5 moves to garniture 44. Suction conveyor 10 is angled at a downward slope toward garniture 44. While those skilled in the art will recognize suitable existing garnitures, a brief description of garniture 44 follows.

[0188] The garniture 44 includes a continuous garniture belt 45 that threads a paper ribbon 46 through the garniture 44. The garniture belt 45 is disposed below the paper ribbon 46, and a combined stream or profile of the first and second aerosol-generating materials 4, 5 moves from the suction conveyor 10 onto the paper ribbon 46. In this manner, the first aerosol-generating material 4 and beads 5 are disposed on the paper ribbon 46, which moves through the garniture 44 by the garniture belt 45. At the end of the lower run 15 of the suction belt 11, where the garniture 44 is located, suction is no longer applied to the suction belt 11, and the aerosol-generating material(s) are released from the suction belt 11 and move toward the garniture 44.

[0189] An adhesive applicator (not shown) applies adhesive to the top of the paper ribbon 46 along one side of the paper ribbon 46. The garniture 44 includes a winding unit (not shown) through which the paper ribbon 46, along with the combined stream of first aerosol-generating material 4 and beads 5, is transported. The winding unit wraps the paper ribbon 46 around the first aerosol-generating material 4 and beads 5, and the adhesive bonds the paper ribbon 46 in place to form a continuous aerosol-generating material rod (e.g., continuous aerosol-generating material rod 7 as shown in one of FIGS. 2A and 2B).

[0190] The apparatus 9 further includes a cutter (not shown) configured to cut the continuous rod of aerosol-generating material 7. The continuous rod of aerosol-generating material 7 is then cut to an appropriate length to form a consumable product (e.g., article 1 shown in FIGS. 1A-1D). In various examples, the continuous rod of aerosol-generating material 7 is cut on an aerosol-generating material rod manufacturing machine and / or on a subsequent assembly machine. In various examples, the continuous rod of aerosol-generating material 7 can be cut into double-length rods, quadruple-length rods, etc., and transferred to an assembly machine for further cutting and assembly with filters to form a complete consumable product. By way of example, this may be referred to as a "2-up" or "4-up" manufacturing process.

[0191] Advantageously, the suction conveyor 10, the second feeding device 49, such as the vertical feeder 29, and the first feeding device 30 can be produced by modification of conventional equipment already used in the tobacco product industry. For example, the Hauni Protos cigarette making machine includes a vertical feeder and suction conveyor arrangement commonly known as a "VE." This machine can be used as the apparatus described with reference to the examples by modification. For example, modifications may include replacing the suction belt, modifying the suction chamber and / or adding a trimmer, and providing a feeding device for supplying high-density beads.

[0192] 7 to 16, another embodiment of the aerosol-generating material rod 3 will be described. In the following description, reference will be made to the insertion of objects in the form of beads 5 (specifically, tobacco beads 5), such as beads, pellets, and / or granules of the second aerosol-generating material 5, into the first aerosol-generating material 4.

[0193] Referring now to Figure 7, beads 5 can be inserted or fed into a first aerosol-generating material 4. Figure 7 shows a portion of a rod-making machine 101 that includes a bead insertion unit 102. During operation of the machine 101, the first aerosol-generating material 4 is drawn through a set of transfer rollers (not shown), compressed through a stuffer jet (not shown) and tongue 104 of the garniture 44, wrapped in wrapping 106, and then cut into segments by a cutter (not shown) to form the aerosol-generating material rod 3.

[0194] FIG. 8 shows a cross section of the bead insertion unit 102 engaged with the tongue 104 of the rod-making machine 101 shown in FIG. 7. The bead insertion unit 102 includes a bead feed funnel or hopper 107, a venturi insertion device 108, and an insertion tube 109. The insertion tube 109 may be curved so that it can be longitudinally aligned with the direction of transport of the first aerosol-generating material 4. The position of the insertion tube 109 may be adjusted using an insertion tube adjustment wheel 109A shown in FIG. 7, thereby positioning the stream of beads 5 along the longitudinal axis of the first aerosol-generating material 4 or off-center but parallel to the longitudinal axis. The bead insertion unit 102 also includes air injection inlets 10a-10c, as shown in FIG. 7.

[0195] 8, feed funnel or hopper 107 is configured to receive beads 5 for insertion or feeding into first aerosol-generating material 4. Hopper 107 is preferably conical in shape so that beads 5 can be moved into hopper 7 manually or by use of mechanical or electromechanical delivery means such as a feed conveyor, grooved feed drum, or screw feeder (not shown).

[0196] Figure 9 is an enlarged cross-sectional view of the venturi device 108 shown in Figure 8. The venturi device 108 comprises a generally conical block 111 including an axial bore 112 having an inlet 113 through which the beads 5 are supplied from the hopper 107 and an outlet 115 through which the beads 5 are supplied to the insertion tube 109.

[0197] The conical block 111 is received in a generally cylindrical housing 116 with its conical end spaced from the block 111 and defines a convergent air passage 117 which opens into the insertion tube 109 in the region of the outlet 115 of the bore 112. The air supply passage 117 is supplied with compressed air by three air injection inlets 10a-10c, one of which (110a) is shown in Figure 9. The air injection inlets 110a-110c are coupled to a gas source (not shown), such as compressed air, which supplies each longitudinal bore 118 which leads to the convergent air supply passage 117.

[0198] The injection inlets 110a-110c are supplied with air, although other fluids (for example, helium or nitrogen) can also be employed.

[0199] Beads 5 are received from hopper 107 and directed into axial bore 112. Compressed air from inlet 110a is directed along longitudinal bore 118 towards region 115 where axial bore 112 and longitudinal bore 118 converge.

[0200] During operation of the Venturi device 108, the beads 5 are propelled toward the first aerosol-generating material 4 by utilizing the Venturi effect, forming the aerosol-generating material rod 3. FIG. 10 is a schematic diagram of airflow through the Venturi device 108 during operation of the bead insertion unit 102. As air travels from two of the jet sources 110a, 110b through the longitudinal bores 118a, 118b into the insertion tube 109, a low-pressure area is created in region 115 and the insertion tube 109. The beads 5 initially occupy an area of ​​high pressure relative to this low-pressure region 115. A pressure gradient force acts on the beads 5, propelling them into the insertion tube 109 at a greater velocity than would be possible under gravity alone. This allows the high-density beads 5 to be inserted into the first aerosol-generating material 4.

[0201] An insertion tube 109 feeds the tongue 104 of the rod-making machine 101. The position of the insertion tube 109 can be adjusted relative to the longitudinal axis of the aerosol-generating material rod 7 being produced. While the insertion tube 109 is shown as curved in FIG. 8, in other embodiments, the insertion tube 109 can be straight. The beads 5 can be centered along the longitudinal axis of the aerosol-generating material rod 7, or can be substantially parallel to (but offset from) the longitudinal axis through the use of an insertion tube adjustment wheel 109A, as shown in FIG. 7.

[0202] FIG. 11 illustrates an alternative embodiment. Beads 5 (i.e., second aerosol-generating material 5) are stored in a bead storage unit 119 prior to insertion into the first aerosol-generating material 4. The storage unit 119 includes a pressurized air source 120 operable to inject an air jet 121 into a chamber 122. The direction of the air jet 121 is represented by an arrow in FIG. 11. The pressurized air jet 121 forces a stream of beads 5 into an outlet tube 123. The beads 5 forced into the outlet tube 123 are entrained by the high-pressurized air jet 121 and directed toward the insertion tube 109 of the alternative embodiment of the bead insertion unit 2. The high-pressurized air jet 121 may be a continuous pressurized fluid stream. The beads 5 entrained in the continuous pressurized fluid stream are then fed into the first aerosol-generating material 4. The insertion tube 109 may operate in substantially the same manner as described above with reference to FIGS. 7-10.

[0203] 12 is a cross-sectional view of a rod of aerosol-generating material 7 produced using machine 101. A region 125 containing beads 5 may extend substantially along the longitudinal axis of the rod of aerosol-generating material 7. The diameter of region 125 may be determined largely by the diameter of the insertion tube 109 of the bead insertion unit 102. Alternatively, region 125 containing beads 5 may extend parallel to (but offset from) the longitudinal axis. This flexibility allows for control of the position of region 125. The rod of aerosol-generating material 124 is then wrapped in a suitable wrapper and cut into separate rods of aerosol-generating material 3, as is well known in the art for forming articles 1 for aerosol delivery systems.

[0204] In the embodiments described above with reference to Figures 7-11, the regions 125 may be formed by a single continuous stream of beads 5 inserted into the first aerosol-generating material 4. While this configuration may be desirable, it may also be desirable to provide a series of regions 125 formed by a continuous stream of beads 5, separated by gaps 126. An aerosol-generating material rod 7 conforming to such a configuration is shown in Figure 13. Individual aerosol-generating material rods 3 may then be created by cutting the aerosol-generating material rod 7 along dashed lines 128a-128c, as is well known in the art.

[0205] FIG. 14 shows an article 1 manufactured as described above with reference to FIG. 7 . A filter 24 may be attached to the rod of aerosol-generating material 3 as is well known in the art, such as by using tipping paper (not shown). A region 125 of the rod of aerosol-generating material 3 containing beads 5 may be in contact with the first end 2 of the article 1. A region 126 without beads 5 may be located at the second end 6 of the rod of aerosol-generating material 3. Alternatively, the first and second ends 2, 6 of the rod of aerosol-generating material 3 may comprise the first and second ends of the article 1. If the first and second ends 2, 6 of the rod of aerosol-generating material 3 comprise the first and second portions of the article 1, no additional components are added to the ends 2, 6 of the rod of aerosol-generating material 3 prior to use as the article 1 for an aerosol delivery system.

[0206] Figure 15 shows a granule insertion unit 102 according to another embodiment. The insertion unit 102 shown in Figure 15 is similar to the insertion unit 102 shown in Figure 8. However, the insertion unit 102 shown in Figure 15 includes a high-flow vacuum pump 132 instead of the venturi insertion device 108 shown in Figure 8. The bead insertion unit 102 also includes a bead supply hopper 107 and an outlet pipe 109.

[0207] 15 is a funnel formed by a frusto-conical portion 135 and a tubular portion 136 that are connected to each other. The flow of beads 5 from the hopper 107 to the vacuum pump 132 can be promoted by passing air through the bottom of the hopper 107 to fluidize the stored beads 5.

[0208] The high flow vacuum pump 132 may be of a type well known in the art for material transfer, such as a KVPDF high flow vacuum pump. Compressed air enters the vacuum pump 132 through an air inlet 133 and flows in a cyclone through a central tube 134 of the pump 132. The cyclone flow of the compressed air creates a vacuum that can draw the beads 5 from the hopper 107, through the central tube 134, and into the exit tube 109, where they converge at the tongue 104 of the garniture 44, as shown in FIG. 7.

[0209] It is contemplated that the insertion unit 102, when used to insert beads 5 into the stream of first aerosol-generating material 4, may be attached to a rod-making device of a type well known in the art. The insertion unit 102 may insert beads 5 into the stream of first aerosol-generating material 4 as the stream is transported toward the garniture 44 along a device known in the art as a suction chamber rail or conveyor. Insertion of beads 5 may be further facilitated by modifications to the insertion unit 102, such as the use of a plow (not shown) to create grooves in the stream of first aerosol-generating material 4. However, it is contemplated that the embodiments described above may be adapted for inserting beads 5 into the stream of first aerosol-generating material 4 without substantial modification.

[0210] This insertion technique allows for precise insertion of a specific amount of beads 5, minimizing the amount of beads 5 lost during rod fabrication.

[0211] An alternative hopper 107 is shown in Figure 16. The hopper 107 comprises a frusto-conical section 135 and a tubular section 136. The tubular section 136 is connected to a hopper outlet pipe 137. The hopper outlet pipe 137 may be connected to the Venturi device 108 described above with reference to Figures 7-9 or to the vacuum pump 132 described above with reference to Figure 15.

[0212] In use, beads 5 are placed into the hopper 107 shown in Figure 16 and fall by gravity into the hopper outlet tube 137. From the hopper outlet tube 137, the beads 5 are drawn in by the Venturi device 108 or vacuum pump 132 and fed or inserted into the first aerosol-generating material 4 as described above.

[0213] Alternatively, the beads 5 may fall by gravity from the hopper 107 into a stream of first aerosol-generating material 4 being transported by a suction chamber rail or conveyor as known in the art.

[0214] An article 1 manufactured in accordance with the above description has the advantage of being able to include a large number of beads 5 interspersed with a small amount of a first aerosol-generating material 4. An article manufactured in accordance with the above description also has the advantage of including two different types of aerosol-generating materials without requiring a separate component to hold the beads 5 in place. Because no separate component is required in the article to hold the beads 5 other than the first aerosol-generating material, the article 1 can be made smaller for the same delivery of aerosol-generating material to the user.

[0215] The article described above preferably does not include beads 5 at the ends of the article 1 due to the possibility of them falling off, and preferably includes discrete pockets of beads 5 within the first aerosol-forming material 4.

[0216] 17-19, which illustrate one embodiment of an aerosol delivery device 200. As shown in FIG.

[0217] Article 1 as described above is configured for use in aerosol delivery device 200, which includes an aerosol generator in the form of heating element 203 for heating article 1. In this example, heating element 203 at least partially surrounds heating area 202 (e.g., heating chamber 202). Heating element 203 may be adapted to be resistively and / or inductively heated.

[0218] In other embodiments (not shown), the heating element 203 instead comprises a blade or pin that is inserted into the article 1. In other embodiments (not shown), the article 1 may comprise a heating element that can be embedded in, for example, the aerosol-forming material rod 3.

[0219] Figure 17 shows a simplified view of the components of one embodiment of aerosol delivery device 200. Notably, the elements of aerosol delivery device 200 depicted in Figure 17 are not drawn to scale. To simplify Figure 17, elements that are not relevant to understanding this embodiment have been omitted.

[0220] 17, aerosol delivery device 200 is a non-combustible aerosol delivery device 200. Non-combustible aerosol delivery device 200 comprises a housing 201 including an area 202 for receiving item 1.

[0221] When the article 1 is received in the heating area 202, at least a portion of the article 1 is in thermal proximity to the heater 203. As a result, at least a portion of the first aerosol-generating material 4 and / or beads 5 are in thermal proximity to the heater 203. In some embodiments, the heater 203 is spaced apart from the article 1 (e.g., it defines the boundary of the article 1 but is spaced apart due to its large diameter). In other embodiments, the heater 203 is in direct contact with the article 1 (e.g., it is in contact with the outer surface of the wrapper of the article 1). In another embodiment, the heater 203 comprises a blade or pin that contacts the inside of the article 1 (e.g., it contacts the first aerosol-generating material 4 and / or beads 5).

[0222] As article 1 is heated, first aerosol-generating material 4 and / or beads 5 may release one or more volatile compounds, and may release different volatile compounds at different temperatures. Beads 5 preferably heat more slowly than first aerosol-generating material 4. Controlling the maximum operating temperature of electrically heated aerosol-generating system 200 may allow for selective control of the release of undesirable compounds by preventing the release of certain volatile compounds.

[0223] As shown in Figure 18, an electrical energy source 204 (e.g., a rechargeable lithium-ion battery) is present within the housing 201. A controller 205 is connected to the heater 203, the electrical energy source 204, and a user interface 206 (e.g., buttons or a display). The controller 205 controls the power supplied to the heater 203 to regulate its temperature. Typically, the aerosol-forming substrate is heated to a temperature of 250 to 450°C.

[0224] Figure 19 is a schematic cross-section of a non-combustible aerosol delivery device 200 of the type shown in Figure 17, with an item 1 received in a heated area 202 of the device 200 for heating by a heater 203. The non-combustible aerosol delivery device 200 receives the aerosol product item 1 as shown, for consumption by a user.

[0225] The housing 201 of the non-combustible aerosol delivery device 200 defines an area 202 in the form of a cavity that is open at the proximal end (or mouth end) for receipt of the aerosol product item 1 for consumption by a user.

[0226] In this example, aerosol delivery device 200 includes a mouthpiece 207 that is detachable from the rest of device 200 to allow access to area 202 to insert and remove article 1 from area 202. After article 1 has been delivered to area 202, mouthpiece 207 can be reattached. In some embodiments, mouthpiece 207 is detachably attached to housing 201 of device 200, for example, by a screw thread or bayonet connection.

[0227] When a user inhales on mouthpiece 207, air is drawn into article 1 and the volatile materials condense to form an inhalable aerosol that passes through mouthpiece 207 of device 200 and into the user's mouth.

[0228] It is to be appreciated that in other embodiments, the mouthpiece 207 of the device 200 may be omitted. In some embodiments, the article 1 may form the mouthpiece and be adapted to contact the user's mouth.

[0229] As used herein, the term "aerosol-generating material" includes materials that, upon heating, provide volatile components, typically in the form of a vapor or aerosol. In some instances, the aerosol-generating material includes tobacco material, as described above. In other instances, the aerosol-generating material is comprised of tobacco material or a blend of different tobacco materials. In other instances, the aerosol-generating material does not include tobacco material. The devices described herein may be adapted to produce any rod of aerosol-generating material.

[0230] The first aerosol-generating material 4 and the beads 5 are different materials. The first aerosol-generating material 4 and / or the beads 5 may comprise, consist of, or consist essentially of tobacco material. For example, the first aerosol-generating material 4 may contain different types of tobacco (e.g., Burley, Oriental, Virginia) or different blends of these different types of tobacco. Alternatively or additionally, the first aerosol-generating material 4 may contain tobacco that has been cured, cured, or otherwise processed (e.g., flue-cured, air-cured, etc.). The first aerosol-generating material may include, consist of, or consist essentially of cut rag tobacco. Alternatively or additionally, the first aerosol-generating material 4 may contain different additives. The additives may include, for example, flavorings (e.g., menthol), burn rate modifiers, smoke modifiers, etc., in the form of granules or liquid additives. Alternatively or additionally, the first aerosol-forming material 4 may comprise a tobacco substitute (eg, a reconstituted tobacco material) or a blend of a tobacco substitute with a tobacco material.

[0231] The second aerosol-generating material 5 is provided in the form of beads. The first delivery device 30 is configured to deliver extruded beads 5, optionally extruded and spheronized beads 5. In some embodiments, the first delivery device 30 has a density of at least about 0.4 g / cm. 3 , preferably at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2 g / cm 3 In some embodiments, the first supply device 30 is configured to supply beads 5 having a particle size in the range of 0.5 to 3 mm, preferably in the range of 1 to 2 mm.

[0232] As used herein, the term "delivery system" is intended to include a system that delivers at least one substance to a user; Combustible aerosol delivery systems, such as cigarettes, cigarillos, cigars, and pipe tobacco or tobacco for home-rolled or home-made cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smoking materials); a non-combustible aerosol delivery system that releases compounds from an aerosol-generating material without combustion (such as an e-cigarette, a tobacco heating product, and a hybrid system that generates an aerosol by combining an aerosol-generating material); an aerosol-free delivery system (including, but not limited to, oral products such as lozenges, gums, patches, articles containing inhalable powders, and oral tobacco products including snus or moist snuff) that delivers at least one substance to a user orally, nasally, transdermally, or otherwise without the formation of an aerosol (the at least one substance may or may not contain nicotine); Includes:

[0233] According to the present disclosure, a "non-flammable" aerosol delivery system is one in which the aerosol-generating material (or components thereof) that constitutes the aerosol delivery system is not burned or incinerated to facilitate delivery of at least one substance to a user.

[0234] In some embodiments, the delivery system is a non-flammable aerosol delivery system, such as a powered non-flammable aerosol delivery system.

[0235] In some embodiments, the non-combustible aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although the presence of nicotine in the aerosol-generating material is not a requirement.

[0236] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system.

[0237] In some embodiments, the non-combustible aerosol delivery system is a hybrid system that generates aerosol through a combination of aerosol-forming materials, one or more of which may be heated. Each aerosol-forming material 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-forming material as well as a solid aerosol-forming material. The solid aerosol-forming material may include a plant-based material (e.g., tobacco or a non-tobacco product).

[0238] Generally, a non-flammable aerosol delivery system may include a non-flammable aerosol delivery device and a consumable item for use with the non-flammable aerosol delivery device.

[0239] In some embodiments, the present disclosure relates to consumables, sometimes referred to as articles, that include an aerosol-forming material and are configured for use with a non-flammable aerosol delivery device.

[0240] As used herein, the terms "upstream" and "downstream" are relative terms defined relative to the direction of mainstream aerosol drawn through an article or device in use. References to the "distal end" refer to the upstream end of the device, while the "proximal end" refers to the downstream end of the device.

[0241] In some embodiments, a non-combustible aerosol delivery system (e.g., a non-combustible aerosol delivery device) can include a power source and a controller. The power source can be, for example, an electrical power source or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon substrate that can be energized to provide power in the form of heat to an aerosol-generating material or a heat transfer material proximate the heat-generating power source.

[0242] In some embodiments, the non-flammable aerosol delivery system comprises an area for receiving a consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0243] In some embodiments, consumables for use with non-flammable aerosol delivery devices may include an aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol-generating area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0244] The consumable product includes a substance to be delivered. The substance to be delivered is an aerosol-generating material, which may also optionally include one or more active ingredients, one or more flavoring agents, one or more aerosol-forming materials, and / or one or more other functional materials.

[0245] In some embodiments, the substance to be delivered comprises an active substance. As used herein, an active substance may be a physiologically active material (a material intended to produce or enhance a physiological response). The active substance may be selected from, for example, a dietary supplement, a psychotropic drug, or a psychoactive agent. The active substance may be naturally occurring or synthetically derived. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or constituents, derivatives, or combinations thereof. The active substance may include one or more constituents, derivatives, or extracts of tobacco, cannabis, or another plant. In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0246] As described herein, the active agent may include or be derived from one or more botanical substances or constituents, derivatives, or extracts thereof. As used herein, the term "botanical" may include any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, pods, etc. Alternatively, the material may include active compounds naturally occurring in plants or synthetically obtained. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, chips, strips, sheets, etc. Exemplary plants include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice, matcha, yerba mate, orange skin, 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, Lavender, lemon peel, mint, juniper, elderberry, vanilla, wintergreen, sedge, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, kalbi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint can be selected from the following mint varieties: Mentha arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0247] In some embodiments, the active agent comprises or is derived from one or more plant substances or constituents, derivatives or extracts thereof, and the plant is tobacco.

[0248] In some embodiments, the active agent comprises or is derived from one or more botanical substances or constituents, derivatives or extracts thereof, the plants being selected from eucalyptus, star anise, cocoa, and hemp.

[0249] In some embodiments, the active agent comprises or is derived from one or more botanical substances or constituents, derivatives or extracts thereof, and the plant is selected from rooibos and fennel.

[0250] In some embodiments, the substance to be delivered comprises a fragrance.

[0251] As used herein, the terms "flavor" and "flavorant" refer to materials that can be used, where local regulations permit, to produce a desired flavor, aroma, or other sensory experience in products intended for adult consumers.These include naturally occurring flavoring materials, botanicals, plant extracts, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, peppermint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, etc.). Roots, 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-ylang Orchids, sage, fennel, wasabi, bell peppers, ginger, coriander, coffee, hemp, mint oil of any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, yerba mate, orange skin, rose, tea such as green tea or black tea, thyme, juniper, elderberry, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, Pedunculaceae, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, damia In some embodiments, the additives may include but are not limited to: citric acid, citric acid, citric acid salts, citric acid derivative ...They may be imitation, synthetic or natural ingredients, or a mixture thereof. They may be in any suitable form, for example a liquid such as an oil, a solid such as a powder, or a gel.

[0252] In some embodiments, the flavoring agent comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring agent comprises cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavoring agent comprises eugenol. In some embodiments, the flavoring agent comprises flavor components extracted from tobacco. In some embodiments, the flavoring agent comprises flavor components extracted from cannabis.

[0253] In some embodiments, the fragrance may include sensates intended to produce the sensations typically perceived by chemically induced stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of olfactory or gustatory nerves, including agents that produce heating, cooling, tingling, and numbing effects. Suitable heating agents include, but are not limited to, vanillyl ethyl ether. Suitable cooling agents include, but are not limited to, eucalyptol and WS-3.

[0254] The aerosol-generating material may include or be an "amorphous solid." In some embodiments, the aerosol-generating material includes an aerosol-generating film that is an amorphous solid. The amorphous solid may be a "monolithic solid." The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within it. In some embodiments, the amorphous solid may comprise, for example, about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% amorphous solid. The aerosol-generating material may also be referred to as an aerosolizable material.

[0255] An aerosol-forming material is a material that can generate an aerosol when energized, for example, by heating, irradiation, or any other method. The aerosol-forming material may be in solid, liquid, or gel form and may or may not contain active substances and / or flavorings. The aerosol-forming material is incorporated into an article for use in an aerosol generating system.

[0256] 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. Tobacco materials include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco lamina, reconstituted tobacco, and / or tobacco extract.

[0257] A consumable is an article containing or consisting of an aerosol-generating material, intended to be consumed, in part or in whole, upon use by a user. A consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator (particularly a heating element) that, upon use, releases heat to generate an aerosol from the aerosol-generating material. The heater may include a material or susceptor that can be heated by electrical conduction.

[0258] The aerosol-generating material may include one or more active agents and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0259] The aerosolizable material may be present on a substrate, which may be or include, for example, paper, cardboard, paperboard, cardboard, recycled aerosolizable material, plastic material, ceramic material, composite material, glass, metal, or alloy.

[0260] The aerosol-forming material may include one or more constituents capable of forming an aerosol, such as glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl sulfate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0261] The one or more other functional materials may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0262] A consumable is an article containing or consisting of an aerosol-forming material, intended to be consumed, in part or in whole, upon use by a user. A consumable may include one or more other components, such as an aerosol-forming material storage area, an aerosol-forming material transfer component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater, that releases heat upon use to generate an aerosol from the aerosol-generating material. A heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0263] A susceptor is a material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that the penetration of the varying magnetic field results in induction heating of the heating material. The heating material may be a magnetic material, such that the penetration of the varying magnetic field results in magnetic hysteresis heating of the heating material. The susceptor may be bi-directional, such that it can be heated by both conductive and magnetic heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0264] An aerosol modifier is a substance that is typically located downstream of the aerosol-generation area and configured to modify the generated aerosol, for example by altering the taste, flavor, acidity, or another characteristic of the aerosol. The aerosol modifier may be provided in an aerosol modifier-releasing component that is operable to selectively release the aerosol modifier.

[0265] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavoring, a coloring, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, a string, or a granule. The aerosol modifier may not have a filter material.

[0266] 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 to release one or more volatile substances from the aerosol-generating material and 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 vibrational, high pressure, or electrostatic energy to the aerosol-generating material.

[0267] The filamentary tow materials described herein may include cellulose acetate fiber tow. The filamentary tow can also be formed using other materials used to form fibers, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1-4 butanediol succinate) (PBS), poly(butylene adipate co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers, or combinations thereof. The filamentary tow can be plasticized with a plasticizer suitable for the tow (e.g., triacetin when the material is cellulose acetate tow), or can be unplasticized. The tow may have any suitable specifications, such as fibers having other cross sections such as a "Y" or "X" shape, a filament fineness value per filament of 2.5 to 15 denier (e.g., 8.0 to 11.0 denier), and a total fineness value of 5,000 to 50,000 (e.g., 10,000 to 40,000).

[0268] In the drawings described herein, the same reference numbers are used to denote like features, items or components.

[0269] In some embodiments, article 1 comprises an aerosol-forming composition including aerosol-forming materials, which may include first and / or second aerosol-forming materials 4, 5.

[0270] An aerosol-forming material is a material that can generate an aerosol when energized, for example, by heating, irradiation, or any other method. The aerosol-forming materials (e.g., first and / or second aerosol-forming materials 4, 5) may be in, for example, a solid, liquid, or semi-solid (e.g., gel) form, and may or may not contain an active substance and / or flavoring.

[0271] The aerosol-generating materials (e.g., the first and / or second aerosol-generating materials 4, 5) may include a binder and an aerosol-forming agent. Optionally, an active material and / or a filler may also be present. Optionally, a solvent, such as water, may also be present, in which one or more other components of the aerosol-generating materials may or may not be soluble. In some embodiments, the aerosol-generating materials (e.g., the first and / or second aerosol-generating materials 4, 5) are substantially free of plant material. In particular, in some embodiments, the aerosol-generating materials (e.g., the first and / or second aerosol-generating materials 4, 5) are substantially free of tobacco.

[0272] The aerosol-generating material (e.g., first and / or second aerosol-generating materials 4, 5) may include or be an "amorphous solid." An amorphous solid may be a "monolithic solid." In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material capable of retaining a fluid, such as a liquid, within it. In some embodiments, the aerosol-generating material may contain, for example, about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% amorphous solid. The amorphous solid may be substantially non-fibrous.

[0273] The aerosol-generating materials (e.g., first and / or second aerosol-generating materials 4, 5) may include or be an aerosol-generating film. The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-forming agent, and one or more other ingredients (e.g., an active substance), to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent. The slurry may be heated such that at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent is removed. The aerosol-generating film may be a continuous film or a discontinuous film (e.g., a structure of discrete film portions on a support). The aerosol-generating film may be substantially free of tobacco.

[0274] The aerosol-generating film may comprise or be a sheet, optionally chopped to form a chopped sheet.

[0275] The aerosol-generating materials (e.g., first and / or second aerosol-generating materials 4, 5) may include one or more active substances and / or fragrances, one or more aerosol-forming materials, and, optionally, one or more other functional materials.

[0276] In each of the embodiments of article 1 described herein, the article may include first and / or second aerosol-forming materials 4, 5 as described above, and may also include an aerosol-forming composition as described above.

[0277] The first aerosol-generating material 4 may include reconstituted tobacco paper. Alternatively, or in addition, the composition may include any of the tobacco forms described herein. The first aerosol-generating material 4 may include a sheet or shredded sheet containing tobacco material comprising 10% to 90% by weight of tobacco leaf, with the aerosol-generating material being provided in an amount of up to about 20% by weight of the sheet or shredded sheet, with the remainder of the tobacco material comprising reconstituted tobacco paper.

[0278] When the first and / or second aerosol-forming materials 4, 5 comprise an amorphous solid material, the amorphous solid material may be a dry gel containing menthol.

[0279] In some embodiments, the first and / or second aerosol-forming materials 4, 5 comprise extruded aerosol-forming materials that are cut into pellet beads.

[0280] In each of the example devices, methods, and articles described above (including the devices of FIGS. 3A-11, 15, and 16, respectively, and the articles of FIGS. 1A-1D, 12-14, and 19, respectively), a first aerosol-generating material 4 (which in some embodiments is tobacco material) is provided, and beads, granules, and / or pellets of a second aerosol-generating material 5 (which in some embodiments is tobacco material) are provided. In some embodiments, the second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4. Otherwise, the aerosol-generating materials 4, 5 of the article may be the same or different.

[0281] It has been found that the second aerosol-generating material 5 having a higher density than the first aerosol-generating material 4 means that when both materials are exposed to the same heat, the higher-density material heats up more slowly and therefore releases the volatile compound (e.g., nicotine) at a slower rate than the lower-density material. Thus, the second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4 such that when exposed to the same heat, the second aerosol-generating material 5 heats up more slowly and releases the volatile compound (e.g., nicotine) at a slower rate than the first aerosol-generating material 4. Thus, combining aerosol-generating materials with different densities results in a more consistent and longer-lasting release of the volatile compound(s). In some embodiments, aerosol-generating materials with different densities can be optionally combined with separate heating of different durations and / or temperatures to further tailor the release of the volatile compound(s), for example, over the consumption period of the article. Alternatively, it may be desirable to release the volatile material more quickly or in greater volume towards the beginning of consumption of the article, thereby providing a greater initial effect on the user upon use. The ability to control the generation of aerosol and the release of volatile compounds may be particularly advantageous, as it allows the article to be relatively small while still providing a specific, desired release of volatile compound(s) over the period of consumption.

[0282] In some embodiments, the second aerosol-generating material 5 has a density that is at least about 25%, and optionally at least about 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, or 75% higher than the density of the first aerosol-generating material 4. The second aerosol-generating material 5 may have a density that is up to about 200%, and optionally up to about 150%, 125%, 100%, or 75% higher than the density of the first and second aerosol-generating materials 4. In some embodiments, the second aerosol-generating material 5 has a density that is between about 25% and about 75% higher than the density of the first aerosol-generating material 4.

[0283] In some embodiments, the second aerosol-forming material 5 has a density of at least about 0.4 g / cm 3 , optionally at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2 g / cm 3 The second aerosol-forming material 5 has a density of about 2 g / cm 3 the following, optionally about 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6, or 0.5 g / cm 3 In some embodiments, the density of the second aerosol-forming material 5 is between about 0.4 and 1.99 g / cm. 3 is.

[0284] In some embodiments, the first aerosol-forming material 4 has a density of at least about 0.1 g / cm 3 , optionally at least about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, or 0.9 g / cm 3 The first aerosol-forming material 4 has a density of about 1 g / cm 3 hereinafter, optionally about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, or 0.2 g / cm 3 In some embodiments, the density of the first aerosol-forming material 4 is between about 0.1 and 0.9 g / cm. 3 is.

[0285] In some embodiments, the first and second aerosol-generating materials 4, 5 contain the same ingredients and therefore will emit very similar aerosols upon heating, potentially with the same active and / or flavor content. Due to their different densities, the two materials may generate aerosols at different rates and / or for different periods of time upon heating.

[0286] In other embodiments, the first and / or second aerosol-generating materials 4, 5 contain different components (which may have the same or different densities) and therefore emit different aerosols upon heating, potentially with different active and / or flavor compositions. The different densities may cause the two materials to generate different aerosols at different rates and / or for different periods upon heating, potentially resulting in varying aerosol output over the course of use.

[0287] In some embodiments, the first aerosol-forming material 4 and the second aerosol-forming material 5 each comprise tobacco. Tobacco contains volatile components, including nicotine, aroma, and flavor. The tobacco may be any type of tobacco and any part of the tobacco plant, including tobacco leaf, lamina, stem, stalk, rib, scraps, and shorts, or a mixture of two or more thereof. Suitable tobacco materials include types such as Virginia or flue-cured tobacco, Burley tobacco, Oriental tobacco, or blends of tobacco materials (optionally including those described herein). The tobacco may be expanded, such as dry-ice expanded tobacco (DIET), or processed by any other means. In some embodiments, the tobacco material may be reconstituted tobacco. The tobacco may be pre-treated or untreated, for example, solid stem (SS), shredded dried stem (SDS), steam treated stem (STS), or any combination thereof. The tobacco material may be fermented, cured, uncured, roasted, or pre-treated.

[0288] The first and second aerosol-generating materials 4, 5 may contain different tobaccos, or the tobacco may be the same but provided in a different form such that the second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4.

[0289] In some embodiments, the first aerosol-generating material 4 has at least one different characteristic from the second aerosol-generating material 5. The different characteristic may be one or more of the shape, size, water content, amount (weight), one or more materials, or ratio of materials comprising the first and second aerosol-generating materials 4, 5 (including the manufacturing method of the aerosol-generating materials if each is made from two or more materials). In some embodiments, the first and second aerosol-generating materials 4, 5 have no different characteristics other than their different densities.

[0290] In some embodiments, the first aerosol-generating material 4 includes one or more tobaccos in the form of cut rags. This tobacco material may be lamina or reconstituted tobacco material. In some embodiments, the first aerosol-generating material 4 is a blend containing both lamina and reconstituted tobacco. For example, the ratio of lamina to reconstituted tobacco may be about 1:4 to about 4:1.

[0291] The second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4. In some embodiments, this high-density second aerosol-generating material 5 comprises particles or may be in the form of beads or one or more sheets. Each bead or sheet may be formed from agglomerated small particles. In some embodiments, both the first and second aerosol-generating materials 4, 5 may be in the form of beads or one or more sheets, and optionally, the second aerosol-generating material 5 may be processed to have a higher density than the first aerosol-generating material 4.

[0292] As used herein, the term "bead" is intended to include beads, pellets, or other small discrete units that are formed, molded, compressed, or shaped into a desired shape. Beads may have smooth, regular shapes (e.g., spherical, cylindrical, oval, etc.) and / or irregular shapes.

[0293] In some embodiments, the beads have a diameter of at least about 0.5 mm (e.g., as measured by sieving), optionally at least about 1, 1.5, 2, 2.5, or 3 mm. The beads may have a diameter of no more than about 5 mm (e.g., as measured by sieving), optionally no more than about 4.5, 4, 3.5, 3, 2.5, 2, or 1.5 mm. In some embodiments, the diameter of each bead may range from about 0.5 mm to about 3 mm, or from about 1 mm to about 2 mm. Bead size may refer to an average size, such as an average size by number or volume.

[0294] In some embodiments, the desired density of the aerosol-generating material 4, 5 is achieved or controlled by the method(s) by which the material is formed and / or processed. Processes that involve agglomeration, particularly agglomeration that involves the application of some compressive force, tend to increase the density of the material.

[0295] Thus, in some embodiments, the first and / or second aerosol-forming materials 4, 5 comprise particles of agglomerated material.

[0296] In the case of a sheet material, the sheet may be formed by particles of material that are bonded and optionally compressed to form a sheet having the desired dimensions and density.

[0297] In some embodiments, the beads or pellets may be formed through the use of a so-called marumarising process.

[0298] In some embodiments, agglomeration is by pelletizing. Pelletizing is an agglomeration process that converts fine particles of material, optionally with excipients, into free-flowing units called pellets. Pellets can form and grow in many ways, depending on the type of equipment and process selected. These pellets may be formed by agitation, where particles rotate and tumble in the presence of an appropriate amount of liquid to form a mass. Balling can involve the use of equipment such as pans, disks, drums, or mixers to produce pellets. Compression pelleting is a form of pressure agglomeration, where particles are held together by mechanical force, optionally with the use of forming aids. The compression force means that the density of the formed pellets is higher than that of the starting material.

[0299] In some embodiments, the agglomeration is by extrusion. In some embodiments, pellets formed by pelletization may be extruded to form a denser molded article.

[0300] The extruded particles may have a size selected to produce a denser aerosol-generating material (e.g., denser second aerosol-generating material 5), which will affect heat transfer and release of volatile components within the material.

[0301] In extrusion, the extruded product is produced by feeding a composition (also called a precursor composition) through a die, a process in which pressure is applied to the composition in combination with shear forces.

[0302] Extrusion may be carried out using one of the major classes of extruders: screw, screen and basket, roll, ram, and pin barrel extruders. Single screw or twin screw extruders may be used. Forming tobacco beads by extrusion has the advantage that the process combines compression, mixing, conditioning, homogenization, and shaping of the composition.

[0303] In some embodiments, during extrusion, a free-flowing composition including particles, such as tobacco particles, is subjected to high pressure and temperature and forced through an orifice, such as a forming nozzle or die, to form a shaped article, which in some embodiments may be in the form of a rod, which may be cut into segments of a desired length.

[0304] In some embodiments, the composition is exposed to a temperature of about 40°C to about 150°C, about 80°C to about 130°C, or about 60°C to about 95°C in the extruder. In some embodiments (including those using dual extrusion), the precursor composition is exposed to a temperature of about 70°C to about 95°C in the extruder. In some embodiments (including those using single extrusion), the precursor composition is exposed to a temperature of about 60°C to about 80°C in the extruder.

[0305] The composition may be subjected to a pressure (just before the die or nozzle) ranging from about 2 bar to about 100 bar, or from about 5 bar to about 60 bar, depending on the die or nozzle design used. The higher the pressure, the higher the density of the molded article is likely to be. Thus, the extrusion process may be tailored to provide an extruded aerosol-forming material having a desired density.

[0306] In some embodiments in which tobacco particles are extruded, the relatively high density of the extruded article, in which the surfaces of the tobacco particles are relatively open, allows the tobacco beads formed from the extruded article to exhibit good heat and mass transfer, favorably affecting the release of tobacco constituents such as flavors and nicotine.

[0307] In some embodiments, extrusion may be a generally dry process, such that the composition including the aerosol-forming particles is dry or substantially dry. The composition may optionally include other particulate materials, including, for example, bases, diluents, solid aerosol-forming agents, solid flavor modifiers, etc.

[0308] In some embodiments, a liquid may be added to the composition before or during the extrusion process. For example, water may be added as a processing aid to help dissolve or solubilize the components of the composition or to help bind or cohere them. Alternatively or additionally, a wetting agent may be added to the composition.

[0309] In some embodiments, the liquid may be an aerosol-forming material, such as glycerol, as discussed herein. When a liquid is added to the composition in this manner, not only is the liquid applied to the surface, but the combined high shear, vigorous mixing and extruder pressure results in the liquid impregnating the shaped article. If the liquid is an aerosol-forming material, this increases the likelihood of the aerosol-forming material in the resulting beads and promotes evaporation of volatile components.

[0310] In some embodiments, the amount of aerosol-forming material incorporated into the extruded beads may be up to about 30% by weight, or even up to about 40% by weight. Typically, such a large amount of aerosol-forming material makes the composition difficult to handle. However, this is less of a problem when the particles are impregnated with the aerosol-forming material as a result of extrusion. If the beads generate an aerosol other than by releasing volatile components, it may be desirable to include an amount of aerosol-forming material, such as at least about 10% by weight or at least about 20% by weight. If the primary function of the beads is to release volatile constituents carried by the beads into an existing aerosol or airstream, a smaller amount of aerosol-forming material, such as up to about 5% by weight, may be sufficient.

[0311] In some embodiments, the mass does not include a binder or binding additive. For example, extruded beads may not require a binder to maintain their structural integrity. In other embodiments, the mass includes a binder or binding additive. The binding additive may be selected to aid in the formation of a cohesive structure by aiding in the adhesion of particles to each other and to other components in the composition. Suitable binding additives include thermoreversible gelling agents such as gelatin, starch, polysaccharides, pectin, alginate, wood pulp, cellulose, and cellulose derivatives such as carboxymethylcellulose.

[0312] In some embodiments, extrusion is sufficient to densify the second aerosol-generating material 5, if desired, although in other embodiments, additional processing of the molded article may further densify the second aerosol-generating material 5.

[0313] For example, in some embodiments, the extruded aerosol-forming material is spheronized. In spheronization, extruded cylindrical particles are broken down to uniform lengths and gradually transformed into spherical shapes by plastic deformation. If the shaped article is first broken down to uniform lengths, the spheronization step produces spheres of uniform diameter.

[0314] According to one specific example of the embodiments discussed herein, a sample of second aerosol-generating material 5 was generated as follows (although in some embodiments, a sample may be generated as follows and alternatively used for the first aerosol-generating material):

[0315] Three sample formulations, one with and one without binder, are shown in Table 1, with amounts given as wet weight ratios (WWB).

[0316] [Table 1] The tobacco was ground into a fine powder, taking care not to overheat it. The ground tobacco particles were sieved to select a desired size, for example, less than 250 μm, less than 100 μm, or less than 60 μm.

[0317] All of the dry (non-liquid) ingredients of the formulation were then combined and mixed or blended in a mixer. In this particular case, the mixture was mixed at a speed of 75 RPM for 1 minute. This was to ensure that the dry ingredients were evenly dispersed throughout the mixture.

[0318] Next, half of the glycerol and half of the water were added to the dry mix and mixed. Specifically, the mix was mixed for an additional minute at 75 RPM. The remaining glycerol and water were then added and mixed again for an additional minute at 75 RPM. Mixing was continued until the mix was crumbly enough to squeeze together to achieve a homogeneous mixture. In this specific case, mixing continued for an additional 3 minutes.

[0319] The mixture was then extruded using a Caleva Multilab, which was operated at approximately 1500 rpm to produce spaghetti-like long pieces.

[0320] The extruded product exited the extruder broken into small pieces of varying lengths. These pieces were then spheronized. Spheronization was carried out until spherical beads were formed. In this case, the extruded product was first spheronized for 1 minute in a Caleva Multilab operating at 2,500 RPM, after which the beads were inspected for defects. Spheronization was then continued for an additional 1-2 minutes. This spheronization step broke the extruded tobacco into individual pieces, forming dense spherical beads.

[0321] In the final step, the spheronized beads were dried in an oven at 65°C for 30 minutes. After each drying period, the beads were weighed and drying was stopped when the desired reduction in water weight was achieved. Typically, such drying would require approximately 1 hour.

[0322] In some embodiments, the other of the first and / or second aerosol-generating materials 4, 5 is in the form of discrete particles or particle agglomerates. These particles may share various properties, such as particle size, with the (higher density) second aerosol-generating material 5, but will have a lower density. As noted above, there are various ways to adjust the density of the aerosol-generating materials 4, 5, including forming and / or processing the material as particles, beads, or pellets.

[0323] In some embodiments, the first aerosol-forming material 4 comprises a combination of 60% reconstituted tobacco and 40% laminar tobacco, and the density of this material is between about 0.1 and about 0.9 g / cm. 3 The second aerosol-forming material 5 contains about 30 to about 90% tobacco and has a density in the range of about 0.4 to about 1.99 g / cm. 3 The amount of aerosol-forming material in one of the first and / or second aerosol-generating materials 4, 5 may be about 8 to about 15%. The second aerosol-generating material 5 may comprise large spherical beads having a particle diameter of about 0.5 to about 3 mm. In some embodiments, the aerosol-generating material in the article comprises about 50% by weight of the first aerosol-generating material 4 and about 50% by weight of the second aerosol-generating material 5. Thus, for example, an article containing 260 mg of aerosol-generating material may contain 130 mg of the first aerosol-generating material 4 and 130 mg of the second aerosol-generating material 5.

[0324] In some embodiments in which the aerosol-forming material comprises tobacco, the tobacco is present in an amount of from about 10% to about 90% by weight of the aerosol-forming material.

[0325] In some embodiments, tobacco may be present in an amount of at least about 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, or finally about 35% tobacco, based on the weight of the aerosol-forming material.

[0326] In some embodiments, tobacco may be present in an amount of about 90%, 89%, 88%, 87%, 86%, 85%, 84%, 83%, 82%, 81%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45%, or less, or may be present in an amount of about 40% or less, based on the weight of the aerosol-forming material.

[0327] The tobacco described herein may contain nicotine. In some embodiments, the nicotine content may be 0.5 to 2% by volume of the tobacco, such as 0.5 to 1.75% by volume of the tobacco, 0.8 to 1.2% by volume of the tobacco, or about 0.8 to about 1.75% by volume of the tobacco. In some embodiments, the nicotine content may be 0.8 to 1% by volume of the tobacco.

[0328] In some embodiments, the first and second aerosol-forming materials 4, 5 have the same nicotine content.

[0329] In some embodiments, the first and second aerosol-generating materials 4, 5 contain one or more volatile components. In some embodiments, the first and second aerosol-generating materials 4, 5 have the same content of volatile components.

[0330] In some embodiments, the first and / or second aerosol-generating material 4, 5 comprises tobacco. For example, the first and / or second aerosol-generating material 4, 5 may comprise between about 80 mg and about 350 mg of tobacco. In some specific embodiments, the aerosol-generating material in the article or consumable has a weight of 260 mg, which includes a combination of 130 mg of the first aerosol-generating material 4 (e.g., comprising a blend of lamina and reconstituted tobacco) and 130 mg of the second aerosol-generating material 5 (e.g., comprising higher density tobacco beads).

[0331] In some embodiments, the article may include regions of aerosol-generating material, each region containing an equal amount of tobacco. In alternative embodiments, the regions may contain different amounts of tobacco. For a total tobacco amount of about 80 to about 350 mg, one region of aerosol-generating material may contain about 20 to about 330 mg, about 50 to about 300 mg, or about 40 to about 125 mg of tobacco, and another region of aerosol-generating material may contain about 20 to about 330 mg, about 30 to about 300 mg, or about 40 to about 125 mg of tobacco.

[0332] The present disclosure also provides a kit of parts comprising an article according to any of the examples described herein and an aerosol delivery device.

[0333] Also provided in accordance with the present disclosure is a package (not shown) including a plurality of articles according to any of the examples described herein. In some embodiments, the package is hermetically sealed. The package may include a container including a body and a lid, with the container body defining a space for receiving the plurality of articles. The lid may be, for example, a hinged lid, a snap-fit ​​lid, or a lid connected by a screw thread.

[0334] The various embodiments described herein are presented solely to aid in understanding and teaching the claimed features. These embodiments are provided as a representative sample of embodiments and are not intended to be exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be construed as limitations on the scope of the invention as defined by the claims or limitations on the equivalents of the claims, and it is understood that other embodiments may be utilized and improved upon without departing from the scope of the claimed invention. The various embodiments of the present invention may suitably include, consist of, or essentially consist of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. The present disclosure may also include other inventions not currently claimed but which may be claimed in the future.

Claims

1. 1. An apparatus for producing a rod of aerosol-forming material, comprising: a suction belt for transporting aerosol-forming material, the suction belt including suction holes for retaining the aerosol-forming material on the suction belt, the apparatus being positioned such that the suction belt receives a first aerosol-forming material at a first supply zone; the first aerosol-generating material is arranged in a profile including a plurality of first regions of the first aerosol-generating material, and a blocking member configured to block some of the suction holes of the suction belt in the first supply zone such that zero or a reduced amount of the first aerosol-generating material is provided between the first regions; and a first delivery device configured to deliver at least one of beads, pellets, or granules of a second aerosol-generating material between the first regions; and An apparatus comprising:

2. 2. The device of claim 1, wherein the profile is arranged such that the first regions are discrete and spaced apart from one another with substantially no first aerosol-forming material disposed between the first regions.

3. 2. The device of claim 1, wherein the profile is arranged such that there are connection regions between each of the first regions, and each connection region contains a smaller amount of the first aerosol-forming material than the first regions.

4. 4. The apparatus of claim 1, wherein the first supply device comprises a drum including a plurality of receiving spaces configured to receive the beads, pellets, and / or granules and to move the beads, pellets, and / or granules between the first regions.

5. 5. The device of claim 4, configured to blow and / or suck the beads, pellets, and / or granules out of the receiving space.

6. The device according to claim 4 or 5, comprising a plurality of mesh portions defining the receiving space.

7. The apparatus according to any one of claims 1 to 6, wherein the feeding device is configured to feed the beads, pellets and / or granules to the suction belt.

8. The apparatus according to any one of claims 1 to 6, wherein the feeding device is configured to feed the beads, pellets and / or granules downstream of the suction belt.

9. The apparatus of any one of claims 1 to 8, further comprising a garniture positioned to receive the profile of first aerosol-forming material from the suction belt.

10. 10. The apparatus of claim 9 when dependent on claim 8, wherein the feeding device is configured to feed the beads, pellets, and / or granules to the profile on the garniture.

11. 11. The apparatus of claim 9 or 10, wherein the garniture is configured to wrap a paper ribbon around the first aerosol-forming material and the beads, pellets, and / or granules to form a continuous aerosol-forming material rod.

12. 12. The apparatus of claim 11, further comprising a cutter configured to cut the continuous aerosol-forming material rod.

13. 13. The apparatus according to any one of the preceding claims, wherein the first supply device is configured to supply at least one of extruded beads, pellets or granules, preferably at least one of extruded and spheronized beads, pellets or granules.

14. the first delivery device having a density of at least about 0.4 g / cm ３ , preferably at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2 g / cm ３ 14. The apparatus of any one of claims 1 to 13, configured to deliver beads, pellets and / or granules.

15. 15. Apparatus according to any one of the preceding claims, wherein the first supply device is configured to supply beads, pellets and / or granules having a particle size in the range of 0.5 to 3 mm, preferably in the range of 1 to 2 mm.

16. 16. The device of any one of claims 1 to 15, wherein the first aerosol-forming material and / or the second aerosol-forming material comprises, consists of, or consists essentially of tobacco material.

17. 17. The apparatus of any one of claims 1 to 16, wherein the suction belt is arranged to hold the first aerosol-forming material on an underside of the suction belt.

18. 18. The apparatus of claim 1, further comprising a second supply device arranged to supply the first aerosol-generating material onto the suction belt in the first supply zone, the second supply device preferably being disposed below the suction belt.

19. Apparatus according to any one of the preceding claims, wherein the first supply device is arranged below the suction belt.

20. 20. The apparatus of claim 1, wherein the blocking member comprises a profiled belt arranged to overlap the suction belt in the first region and configured to block some of the suction holes in the suction belt so that the first aerosol-generating material is retained on the suction belt at the profile.

21. 21. The apparatus of claim 20, wherein the profiled belt includes a plurality of suction regions and a plurality of occlusion regions disposed along the length of the profiled belt.

22. 22. The apparatus of claim 21, wherein the profiled belt further includes connecting suction areas disposed between the suction areas, each of the connecting suction areas being smaller than the suction areas such that less aerosol-generating material is held at each connecting suction area than is held at each suction area on the suction belt.

23. 23. Apparatus according to any one of claims 20 to 22, wherein the suction belt has a first width and the profiled belt has a second width, the second width being smaller than the first width.

24. 1. A method of making a rod of aerosol-generating material, comprising: applying suction to a suction belt having suction holes to retain a first aerosol-forming material on the suction belt in a first feed zone; blocking some of the suction holes of the suction belt in the first regions so that the first aerosol-generating material is held on the suction belt in a profile including a plurality of first regions of the first aerosol-generating material, with zero or reduced amounts of the first aerosol-generating material being provided between the first regions; providing at least one of beads, pellets, or granules of a second aerosol-generating material between the first regions; A method comprising:

25. 25. The method of claim 24, wherein the beads, pellets, and / or granules are fed to the suction belt.

26. 25. The method of claim 24, wherein the beads, pellets, and / or granules are fed downstream of the suction belt.

27. The method of any one of claims 24 to 26, further comprising transferring the first aerosol-forming material to a garniture.

28. 28. The method of claim 27 when dependent on claim 26, wherein the beads, pellets, and / or granules are provided in the garniture.

29. 29. The method of claim 27 or 28, further comprising wrapping the aerosol-forming material with a paper ribbon to form a continuous aerosol-forming material rod.

30. 30. The method of claim 29, further comprising cutting the continuous rod of aerosol-forming material.

31. 31. The method according to any one of claims 24 to 30, wherein the first supply device is configured to supply extruded beads, pellets and / or granules, preferably extruded and spheronized beads, pellets and / or granules.

32. the first delivery device having a density of at least about 0.4 g / cm ３ , preferably at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2 g / cm ３ 32. The method of any one of claims 24 to 31, configured to provide beads, pellets and / or granules of

33. 33. The method of any one of claims 24 to 32, wherein the first supply device is configured to supply beads, pellets and / or granules having a particle size in the range of 0.5 to 3 mm, preferably in the range of 1 to 2 mm.

34. 34. The method of any one of claims 24 to 33, wherein the first aerosol-forming material and / or the beads, pellets, and / or granules comprise, consist of, or consist essentially of tobacco material.

35. 35. A method of manufacturing an article for an aerosol delivery system, the method comprising: manufacturing a rod of aerosol-generating material according to the method of any one of claims 24 to 34, wherein a first end and a second end of the rod of aerosol-generating material comprise a first end and a second end of the article.

36. 1. A method of making a rod of aerosol-generating material, comprising: providing at least one of beads, pellets, or granules of tobacco material; entraining the beads, pellets, and / or granules in a continuous pressurized fluid stream; supplying the fluid stream to a first aerosol-forming material; A method comprising:

37. 37. The method of claim 36, wherein entraining the beads, pellets, and / or granules in a continuous pressurized fluid stream comprises entraining the beads, pellets, and / or granules using a venturi device.

38. 37. The method of claim 36, wherein the step of entraining the beads, pellets, and / or granules in a continuous pressurized fluid stream comprises propelling the beads, pellets, and / or granules in a high pressure jet.

39. 37. The method of any of claims 36, wherein the step of entraining the beads, pellets, and / or granules in a continuous pressurized fluid stream comprises propelling the beads, pellets, and / or granules using a vacuum pump.

40. 40. The method of any one of claims 36 to 39, wherein supplying the fluid stream to a first aerosol-generating material comprises supplying the fluid stream to a body or rod of first aerosol-generating material.

41. 31. The method of claim 30, wherein the step of providing the fluid flow includes orienting the fluid flow substantially parallel to a longitudinal axis of the body or rod.

42. 42. The method of any one of claims 36 to 41, wherein the step of providing the beads, pellets, and / or granules of tobacco material comprises storing beads, pellets, and / or granules of tobacco material in a storage unit and receiving the beads, pellets, and / or granules from the storage unit.

43. 43. The method of claim 42, wherein storing the beads, pellets, and / or granules comprises storing the beads, pellets, and / or granules in a conical hopper.

44. 44. The method according to any one of claims 36 to 43, wherein the beads, pellets and / or granules are extruded, preferably the beads, pellets and / or granules are extruded and spheronized.

45. The beads, pellets, and / or granules have a density of at least about 0.4 g / cm ３ Preferably, at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2 g / cm ３ 45. The method of any one of claims 36 to 44, wherein the composition has a density of

46. 46. ​​The method according to any one of claims 36 to 45, wherein the beads, pellets and / or granules have a particle size in the range of 0.5 to 3 mm, preferably in the range of 1 to 2 mm.

47. 47. The method of any one of claims 36 to 46, wherein the first aerosol-forming material comprises, consists of, or consists essentially of tobacco material.

48. 48. A method of manufacturing an article for an aerosol delivery system, the method comprising: manufacturing a rod of aerosol-generating material according to the method of any one of claims 36 to 47, wherein a first end and a second end of the rod of material comprise a first end and a second end of the article.

49. A pack comprising a plurality of articles produced according to the method of any one of claims 24 to 48.

50. An article made from a rod of aerosol-forming material made according to the method of any one of claims 24 to 48.

51. An article for an aerosol delivery system comprising a rod of aerosol-generating material, the rod of aerosol-generating material comprising a first region of a first aerosol-generating material and a second region of a second aerosol-generating material comprising at least one of beads, pellets, and / or granules.

52. 52. The article of claim 51, wherein the beads, pellets, or granules are inserted into the first aerosol-forming material.

53. 52. An article according to claim 51, manufactured according to the apparatus of any one of claims 1 to 23 or the method of any one of claims 24 to 35.

54. 53. An article according to claim 51 or 52, produced according to the method of any one of claims 36 to 48.

55. 55. The article of any one of claims 51-54, wherein the first and second ends of the rod of aerosol-forming material comprise first and second ends of the article.

56. The beads, pellets, and / or granules have a density of at least about 0.4 g / cm ３ Preferably, at least about 0.5, 0.6, 0.7, 0.8, 0.9, 1, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6, 1.7, 1.8, 1.9, or 2 g / cm ３ 56. The article of any one of claims 51 to 55, having a density of

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