Articles for use in aerosol supply systems and methods for manufacturing articles for use in aerosol supply systems

Abstract

This disclosure relates to articles for use in aerosol supply systems. [Solution] Article 1 comprises a sheet material 2 containing a first aerosol-generating material, the sheet material being assembled to form a body. The article further comprises a second aerosol-generating material 5, the second aerosol-generating material being engaged by the sheet material such that the second aerosol-generating material is held within the body by the sheet material. The disclosure also relates to a method for manufacturing an article for an aerosol-supplying device, a kit of parts comprising the article and the aerosol-supplying device, and a package for the article.

Description

[Technical Field]

[0001] This disclosure relates to articles for aerosol dispensing devices. This disclosure also relates to methods for manufacturing articles for aerosol dispensing devices, kits of articles and components comprising aerosol dispensing devices, and packaging for articles. [Background technology]

[0002] Aerosol supply systems generate inhalable aerosols or vapors during use by releasing compounds from aerosol-generating materials. These may be called, for example, non-combustible cigarettes, aerosol-generating assemblies, or aerosol supply devices. [Overview of the project]

[0003] According to some embodiments described herein, an article for use in an aerosol supply system is provided, the article comprising: a sheet material containing a first aerosol-generating material, wherein the sheet material is assembled to form a body; and a second aerosol-generating material engaged by the sheet material such that the second aerosol-generating material is held within the body by the sheet material.

[0004] In some embodiments, the second aerosol-generating material is held within the body by friction.

[0005] In some embodiments, the second aerosol-generating material is held between portions of the sheet material, preferably the body comprises multiple layers of the sheet material, and the second aerosol-generating material is held between the layers of the sheet material.

[0006] In some embodiments, the portion of the sheet material is a strip or strand of the sheet material. In other embodiments, the portion is a fold in the sheet material.

[0007] In some embodiments, the sheet material is formed into strips or strands, and a second aerosol-generating material is held between the strips or strands.

[0008] In some embodiments, the sheet material is shredded and / or cut. In some embodiments, the sheet material is cut into strips.

[0009] In some embodiments, the sheet material is formed into strips having a width in the range of 0.5 mm to 3 mm, preferably in the range of 0.5 mm to 1.5 mm.

[0010] In some embodiments, the sheet material is formed into strips having a width of at least 0.5 mm, preferably at least about 0.6, 0.7, 0.8, or 0.9 mm.

[0011] In some embodiments, the sheet material is formed into strips having a maximum width of about 3 mm, preferably a maximum width of about 2.5, 2, 1.8, 1.6, 1.4, 1.2, or 1.1 mm.

[0012] In some embodiments, the sheet material is formed into strips having the same length as the article.

[0013] In some embodiments, the strip or strand extends in a direction from a first end to a second end of the article.

[0014] In some embodiments, the strips or strands extend substantially parallel to the central axis of the article. In other embodiments, the strips or strands do not have to be oriented in a particular direction, but may be oriented randomly, for example.

[0015] In some embodiments, the sheet material is corrugated.

[0016] In some embodiments, the article does not include an additive or binder for retaining the second aerosol - forming material within the body.

[0017] In some embodiments, the body of the material extends from a first end of the article to a second end of the article.

[0018] In some embodiments, the body of the material extends over a portion of the length of the article. In some embodiments, the body of the material extends over the entire length of the article.

[0019] In some embodiments, the first and second aerosol - forming materials form a collation of aerosol - forming materials that extends over at least 90% of the length of the article, preferably at least 92%, 94%, 96%, 98%, or 99% of the length of the article, and preferably over the entire length of the article.

[0020] In some embodiments, the body comprises a single sheet material gathered to form the body. In other embodiments, the body may comprise a plurality of sheets of material gathered to form the body.

[0021] In some embodiments, the first and / or second aerosol - forming material comprises, consists of, or consists essentially of tobacco material.

[0022] In some embodiments, the aerosol - forming material extends over at least 90% of the length of the article, preferably at least 92%, 94%, 96%, 98%, or 99% of the length of the article, and preferably over the entire length of the article.

[0023] In some embodiments, the first aerosol - forming material comprises reconstituted tobacco.

[0024] In some embodiments, the first aerosol - forming material comprises tobacco leaf lamina.

[0025] In some embodiments, the first aerosol-forming material is substantially tobacco-free. In some embodiments, the first aerosol-forming material is tobacco-free.

[0026] In some embodiments, the first aerosol-forming material comprises a filler.

[0027] In some embodiments, the filler is a non-tobacco fiber.

[0028] In some embodiments, the filler is wood fiber or pulp or wheat fiber.

[0029] In some embodiments, the filler comprises cellulose.

[0030] In some embodiments, the filler is a non-tobacco cast material or a non-tobacco extrusion material.

[0031] In some embodiments, the article comprises an aerosol-forming agent material.

[0032] In some embodiments, the first and / or second aerosol-forming material comprises an aerosol-forming agent material.

[0033] In some embodiments, the aerosol-forming agent material comprises one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0034] In some embodiments, the second aerosol-forming material comprises an extruded and / or compressed aerosol-forming material, preferably an extruded and / or compressed tobacco.

[0035] In some embodiments, the tobacco material of the first and / or second aerosol-generating material is derived solely from tobacco leaf blades and not from any other type of tobacco material.

[0036] In some embodiments, the first and / or second aerosol-generating material includes tobacco leaf blades and reconstituted tobacco.

[0037] In some embodiments, both the first and second aerosol-generating materials have an average nicotine level in the range of 0.5% to 2.5% by weight, preferably in the range of 1% to 2.1% by weight, of the aerosol-generating material.

[0038] In some embodiments, the first and / or second aerosol-generating material is a solid material.

[0039] In some embodiments, the article does not contain plastic.

[0040] In some embodiments, the article does not contain cellulose acetate.

[0041] In some embodiments, the first and second aerosol-generating materials are produced from the same aerosol-generating starting material that has been processed to have different forms.

[0042] In some embodiments, the second aerosol-generating material includes beads of the aerosol-generating material.

[0043] In some embodiments, the beads are substantially cylindrical.

[0044] In one embodiment, the beads are extruded beads, preferably extruded tobacco beads.

[0045] In some embodiments, the beads have a particle size ranging from about 0.5 mm to about 3 mm.

[0046] In some embodiments, the first and second aerosol-generating materials have different densities, preferably the density of the second aerosol-generating material is at least 25% higher than the density of the first aerosol-generating material.

[0047] In some embodiments, the second aerosol-generating material is approximately 0.4 g / cm³ 3 ~About 2g / cm 3 It has a density within that range.

[0048] In some embodiments, the first aerosol-generating material is approximately 0.1 g / cm³ 3 ~Approx. 1g / cm 3 It has a density within that range.

[0049] In some embodiments, the second aerosol-generating material includes fibers of the aerosol-generating material.

[0050] In some embodiments, the second aerosol-generating material is distributed throughout the entire body of the material.

[0051] In some embodiments, the second aerosol-generating material is discretely distributed within the material body, forming a plurality of discrete regions of the second aerosol-generating material.

[0052] In some embodiments, the sheet material comprises an aerosol-generating material comprising about 10 to about 50 wt% aerosol-forming agent material, about 15 to about 60 wt% gelling agent, and optionally a filler, where the wt% values ​​are calculated on a dry weight basis.

[0053] In some embodiments, the aerosol-generating material of the sheet includes a flavoring agent.

[0054] In some embodiments, the sheet material is elastically deformable.

[0055] In some embodiments, the first and second aerosol-generating materials are present in the article in a ratio of 1:10 to 10:1 by weight.

[0056] In some embodiments, the density of one of the first and second aerosol-generating materials is at least about 25% higher than the density of the other of the first and second aerosol-generating materials. However, in other embodiments, the densities of the first and second aerosol-generating materials are the same.

[0057] In some embodiments, one of the first and second aerosol-generating materials is approximately 0.1 g / cm³ 3 ~Approx. 1g / cm 3 It has a density of .

[0058] In some embodiments, the other of the first and second aerosol-generating materials is approximately 0.4 g / cm³ 3 ~About 2g / cm 3 It has a density of .

[0059] In some embodiments, heating the article provides a relatively constant release of volatile compounds into an inhalable medium.

[0060] In some embodiments, the second aerosol-generating material includes extruded tobacco.

[0061] In some embodiments, the second aerosol-generating material includes beads.

[0062] In some embodiments, the first aerosol-generating material comprises one or more tobacco materials selected from the group consisting of leaf tobacco materials and reconstituted tobacco materials.

[0063] In some embodiments, at least one of the first and second aerosol-generating materials includes a combination of leaf tobacco material and reconstituted tobacco material. In some embodiments, the leaf tobacco material and reconstituted tobacco material are present in the aerosol-generating material in a weight ratio of 1:4 to 4:1.

[0064] In some embodiments, the first and second aerosol-generating materials have the same level of volatile compounds. In some embodiments, the volatile compound is nicotine.

[0065] In some embodiments, the release of volatile compounds from the first and second aerosol-generating materials is at the same rate when the material reaches a given temperature.

[0066] In some embodiments, the article comprises about 20 to about 330 mg of a first aerosol-generating material, preferably about 50 to about 300 mg, or about 40 to about 125 mg of a first aerosol-generating material.

[0067] In some embodiments, the article comprises about 20 to about 330 mg of a second aerosol-generating material, preferably about 50 to about 300 mg, or about 40 to about 125 mg of a second aerosol-generating material.

[0068] In some embodiments, the main body of the material is surrounded by packaging material.

[0069] In some embodiments, the packaging material forms the outer surface of the article.

[0070] In some embodiments, the packaging material has a degree of air permeability of less than 100 cholesta units, preferably 90, 80, 70, 60, or less than 50 cholesta units.

[0071] In some embodiments, the packaging material has a thickness in the range of 20 to 100 microns.

[0072] In some embodiments, the packaging material has a basis weight in the range of 20 to 50 gsm.

[0073] In some embodiments, the article includes a cooling element immediately downstream of the main body.

[0074] In some embodiments, the cooling element includes a hollow channel.

[0075] In some embodiments, the article comprises a body of further material downstream of the cooling element.

[0076] In some embodiments, the body of the further materials includes flavoring materials and / or filtering materials.

[0077] In some embodiments, the article comprises a segment upstream of the main body.

[0078] The present disclosure provides a method for manufacturing an article for use in an aerosol supply system, the method comprising: providing a sheet material comprising a first aerosol generating material; providing a second aerosol generating material; and assembling the sheet materials to form a body, wherein the sheet materials are engaged by the sheet material such that the second aerosol generating material is held within the body by the sheet material.

[0079] In some embodiments, the method includes combining a sheet material with a second aerosol-generating material, and then assembling the sheet materials to form a body.

[0080] In some embodiments, the method includes assembling sheet materials to form a body, and simultaneously combining the sheet materials with a second aerosol-generating material.

[0081] In some embodiments, the method includes forming a sheet material into strips or stands.

[0082] In some embodiments, the method includes shredding and / or cutting a sheet material.

[0083] In some embodiments, the sheet may be cut into strips using a strip cutter.

[0084] In some embodiments, the strip or strand extends in a direction from a first end to a second end of the article.

[0085] In some embodiments, the method includes making a sheet material corrugated.

[0086] In some embodiments, the sheet material is formed into strips or strands, and a second aerosol-generating material is held between the strips or strands.

[0087] In some embodiments, the second aerosol-generating material is held within the body by friction.

[0088] In some embodiments, assembling the sheet material involves assembling the sheet material such that the body comprises multiple layers of sheet material, preferably so that the second aerosol-generating material is held between the portions of the sheet material, and the second aerosol-generating material is held between the layers of sheet material.

[0089] In some embodiments, the method does not involve using an additive or binder to retain the second aerosol-generating material within the body.

[0090] In some embodiments, the body of the material extends from a first end of the article to a second end of the article.

[0091] In some embodiments, the body of the material extends over a portion of the length of the article. In some embodiments, the body of the material extends over the entire length of the article.

[0092] In some embodiments, the aerosol-generating material extends to at least 90% of the length of the article, preferably at least 92%, 94%, 96%, 98%, or 99% of the length of the article, and preferably extends to the entire length of the article.

[0093] In some embodiments, the first aerosol-generating material extends to at least 90% of the length of the article, preferably at least 92%, 94%, 96%, 98%, or 99% of the length of the article, and preferably extends to the entire length of the article.

[0094] In some embodiments, the body includes a single sheet material that is assembled to form the body.

[0095] In some embodiments, the first and / or second aerosol-generating material includes, consists of, or is essentially made of tobacco material.

[0096] In some embodiments, the first aerosol-generating material includes reconstituted tobacco.

[0097] In some embodiments, the first aerosol-generating material includes tobacco leaf blades.

[0098] In some embodiments, the first aerosol-generating material is substantially free of tobacco.

[0099] In some embodiments, the first aerosol-generating material includes a filler.

[0100] In some embodiments, the filler is a non-tobacco fiber.

[0101] In some embodiments, the filler is wood fiber, pulp, or wheat fiber.

[0102] In some embodiments, the filler includes cellulose.

[0103] In some embodiments, the filler is a non-tobacco cast material or a non-tobacco extruded material.

[0104] In some embodiments, the article includes an aerosol-forming agent material.

[0105] In some embodiments, the first and / or second aerosol-generating material includes an aerosol-forming agent material.

[0106] In some embodiments, the aerosol-forming agent material comprises one or more of the following: glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a mixture of diacetins, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0107] In some embodiments, the second aerosol-generating material includes an extruded and / or compressed aerosol-generating material, preferably including extruded and / or compressed tobacco.

[0108] In some embodiments, the tobacco material of the first and / or second aerosol-generating material is derived solely from tobacco leaf blades and not from any other type of tobacco material.

[0109] In some embodiments, the first and / or second aerosol-generating material includes tobacco leaf blades and reconstituted tobacco.

[0110] In one embodiment, both the first and second aerosol-generating materials have an average nicotine level in the range of 0.5% to 2.5% by weight, preferably 1% to 2.1% by weight, of the first and second aerosol-generating materials.

[0111] In some embodiments, the first and / or second aerosol-generating material is a solid material.

[0112] In some embodiments, the article does not contain plastic.

[0113] In one embodiment, the article does not contain cellulose acetate.

[0114] In some embodiments, the first and second aerosol-generating materials are produced from the same aerosol-generating starting material that has been processed to have different forms.

[0115] In some embodiments, the second aerosol-generating material includes beads of the aerosol-generating material.

[0116] In some embodiments, providing a second aerosol-generating material involves extruding the second aerosol-generating material.

[0117] In some embodiments, the beads are substantially cylindrical.

[0118] In some embodiments, the beads are extruded beads, preferably extruded tobacco beads.

[0119] In some embodiments, the beads have a particle size in the range of 0.5 to 3 mm.

[0120] In some embodiments, the second aerosol-generating material includes fibers of the aerosol-generating material.

[0121] In some embodiments, the second aerosol-generating material is distributed throughout the entire body of the material.

[0122] In some embodiments, the second aerosol-generating material is discretely distributed within the material body, forming a plurality of discrete regions of the second aerosol-generating material.

[0123] In some embodiments, the first and second aerosol-generating materials have different densities, preferably the density of the second aerosol-generating material is at least 25% higher than the density of the first aerosol-generating material.

[0124] In some embodiments, the density of one of the first and second aerosol - forming materials is at least about 25% higher than the density of the other of the first and second aerosol - forming materials. However, in other embodiments, the densities of the first and second aerosol - forming materials are the same.

[0125] In some embodiments, one of the first and second aerosol - forming materials has a density of about 0.1 g / cm 3 to about 1 g / cm 3 .

[0126] In some embodiments, the other of the first and second aerosol - forming materials has a density of about 0.4 g / cm 3 to about 2 g / cm 3 .

[0127] In some embodiments, heating of the article provides a relatively constant release into an inhalable medium of the volatile compounds.

[0128] In some embodiments, the second aerosol - forming material includes an extruded tobacco.

[0129] In some embodiments, the second aerosol - forming material includes beads.

[0130] In some embodiments, the first aerosol - forming material includes one or more tobacco materials selected from the group consisting of cut - filler tobacco materials and reconstituted tobacco materials.

[0131] In some embodiments, at least one of the first and second aerosol - forming materials includes a combination of cut - filler tobacco material and reconstituted tobacco material. In some embodiments, the cut - filler tobacco material and the reconstituted tobacco material are present in the aerosol - forming material in a ratio of 1:4 to 4:1 by weight.

[0132] In some embodiments, the first and second aerosol-generating materials have the same level of volatile compounds. In some embodiments, the volatile compound is nicotine.

[0133] In some embodiments, the release of volatile compounds from the first and second aerosol-generating materials is at the same rate when the material reaches a given temperature.

[0134] In some embodiments, the first and second aerosol-generating materials are present in the article in a ratio of 1:10 to 10:1 by weight.

[0135] In some embodiments, the article comprises first and second aerosol-generating materials in a total amount of 7 mg / mm to 13 mg per mm length of the article, preferably 8 to 12, 9 to 11.5, 9 to 11, or 9.5 to 10.5 mg per mm length of the article.

[0136] In some embodiments, the sheet material comprises an aerosol-generating material comprising about 10 to about 50 wt% aerosol-forming agent material, about 15 to about 60 wt% gelling agent, and optionally a filler, where the wt% values ​​are calculated on a dry weight basis.

[0137] In some embodiments, the aerosol-generating material of the sheet material includes a flavoring agent.

[0138] In some embodiments, the sheet material is elastically deformable, and by bringing the sheet material together, a second aerosol-generating material is held between regions of the sheet material so that the sheet material is elastically deformable.

[0139] In some embodiments, the article includes a cooling element immediately downstream of the main body. The method may include providing a cooling element and positioning the cooking element immediately downstream of the main body.

[0140] In some embodiments, the cooling element includes a hollow channel.

[0141] In some embodiments, the article comprises a body of further material downstream of the cooling element. The method may include providing a body of further material and positioning the body of further material downstream of the cooling element.

[0142] In some embodiments, the body of the further materials includes flavoring materials and / or filtering materials.

[0143] In some embodiments, the article comprises a segment upstream of the body. The method may include providing a segment and providing a segment upstream of the body.

[0144] In some embodiments, the article comprises about 20 to about 330 mg of a first aerosol-generating material, preferably about 50 to about 300 mg, or about 40 to about 125 mg of a first aerosol-generating material.

[0145] In some embodiments, the article comprises about 20 to about 330 mg of a second aerosol-generating material, preferably about 50 to about 300 mg, or about 40 to about 125 mg of a second aerosol-generating material.

[0146] In some embodiments, the article contains aerosol-generating material (including first and second aerosol-generating materials) in the range of 7 mg to 13 mg per mm length of the article, preferably 8 to 12, 9 to 11.5, 9 to 11, or 9.5 to 10.5 mg per mm length of the article.

[0147] In some embodiments, the packaging material has a degree of air permeability of less than 100 cholesta units, preferably 90, 80, 70, 60, or less than 50 cholesta units.

[0148] In some embodiments, the packaging material has a thickness in the range of 20 to 100 microns.

[0149] In some embodiments, the packaging material has a basis weight in the range of 20 to 50 gsm.

[0150] According to this disclosure, articles manufactured in accordance with the methods described herein are also provided.

[0151] The present disclosure also provides a package comprising a plurality of articles described herein. In one embodiment, the package is hermetically sealed.

[0152] According to this disclosure, a kit of components comprising the articles described herein and an aerosol supply device is also provided.

[0153] In some embodiments, the aerosol supply device includes heating zones for receiving articles and heating first and second aerosol-generating materials.

[0154] Here, an embodiment will be described as merely an example, with reference to the attached drawings. [Brief explanation of the drawing]

[0155] [Figure 1] This is a side cross-sectional view of one embodiment of an article for use in an aerosol supply system. [Figure 2] This is a front cross-sectional view of the article in Figure 1, along line ZZ in Figure 1. [Figure 3] Figure 1 is a sheet material of the article, and this is a top view of the sheet material with the sheet material laid flat. [Figure 4] Figure 1 is a top view of a strip of sheet material of the article, with the strip laid flat. [Figure 5] Figure 1 is a perspective view of the beads of the aerosol-generating material in the article. [Figure 6] This is a side cross-sectional view of another embodiment of an article for use in an aerosol supply system. [Figure 7] This is a front cross-sectional view of the article in Figure 6, along line ZZ in Figure 6. [Figure 8] This is a side cross-sectional view of another embodiment of an article for use in an aerosol supply system. [Figure 9] This is a cross-sectional view of one embodiment of a non-combustion aerosol supply device. [Figure 10] Figure 9 is a simplified schematic diagram of the components inside the housing of the aerosol supply device. [Figure 11] Figure 9 is a cross-sectional view of a non-combustible aerosol supply device, in which the article shown in Figure 1 is inserted into the device. [Figure 12] This is a block diagram showing a method for manufacturing articles for use in aerosol supply systems. [Modes for carrying out the invention]

[0156] As used herein, the term “delivery system” is intended to encompass a system for delivering at least one substance to a user. Combustion aerosol supply systems for cigarettes, cigarillos, cigars, and tobacco for pipes, hand-rolled cigarettes, or homemade cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smokeable materials), Non-combustion aerosol supply systems that release compounds from aerosol-generating materials without burning the materials, such as hybrid systems that generate aerosols using a combination of electronic cigarettes, tobacco heating products, and aerosol-generating materials, as well as Aerosol-free delivery system for delivering at least one substance to a user orally, nasally, transdermally, or by another means that does not form an aerosol, including but not limited to oral products such as lozenges, gums, patches, articles containing inhalable powders, and oral tobacco containing snus or moist snuff, wherein at least one substance may or may not contain nicotine. Includes.

[0157] According to this disclosure, a “non-combustible” aerosol supply system is a system in which the constituent aerosol-generating materials (or their components) of the aerosol supply system are not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0158] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0159] In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0160] In some embodiments, the non-combustion aerosol supply system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a cigarette heating system.

[0161] In some embodiments, the non-combustible aerosol supply system is a hybrid system configured to produce an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include plant-based materials, such as tobacco or non-tobacco products.

[0162] Typically, a non-combustible aerosol supply system may comprise a non-combustible aerosol supply device and consumables for use with the non-combustible aerosol supply device.

[0163] In some embodiments, the disclosure relates to consumables comprising an aerosol-generating material and configured for use with a non-combustible aerosol supply device. These consumables may be referred to as articles throughout the disclosure.

[0164] As used herein, the terms “upstream” and “downstream” are relative terms defined with respect to the direction of the mainstream aerosol drawn through the article or device in use. A reference to the “distal end” refers to the upstream end of the device, while a reference to the “proximal end” refers to the downstream end of the device.

[0165] In some embodiments, a non-combustible aerosol supply system, such as a non-combustible aerosol supply device, may include a power source and a controller. The power source may be, for example, a power source or a heat source. In some embodiments, the heat source includes a carbon substrate to which energy can be supplied to distribute power in the form of heat to an aerosol-generating material or heat transfer material adjacent to the heat source.

[0166] In some embodiments, the non-combustion aerosol supply system includes an area for receiving consumables, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0167] In some embodiments, consumables for use with a non-combustible aerosol supply device may include aerosol generating material, aerosol generating material storage area, aerosol generating material transfer component, aerosol generator, aerosol generating area, housing, packaging material, filter, suction nozzle, and / or aerosol modifier.

[0168] The consumables include the delivered substance, which is an aerosol-generating material. If necessary, the material may include one or more active ingredients, one or more flavorings, one or more aerosol-forming materials, and / or one or more other functional materials.

[0169] In some embodiments, the delivered substance includes an active substance. As used herein, the active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, and psychotropic drugs. The active substance may be naturally occurring or obtained by synthesis. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or their components, derivatives, or combinations. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another plant substance. In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0170] As described herein, the active substance may include or be derived from one or more plant substances or their components, derivatives, or extracts. As used herein, the term “plant substance” includes, but is not limited to, any material derived from a plant, including extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, exoskeletons, or shells. Alternatively, the material may include those obtained by synthesizing active compounds naturally present in plant substances. The material may be in the form of a liquid, gas, solid, powder, fine powder, crushed particles, granules, pellets, flakes, strips, or sheets. Examples of plant-based substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay leaf, licorice, matcha, mate, orange peel, papaya, rose, sage, tea (such as green or black tea), thyme, clove, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and rabbi. The herbs are mint, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, perilla, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damian, marjoram, olive, lemon balm, lemon basil, chives, calvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. The mint may be selected from the following mint varieties: peppermint, mint cv, Egyptian mint, European mint, eau de cologne mint, candy mint, curly mint, Kentucky colonel mint, horse mint, pineapple mint, pennyroyal mint, green mint, and apple mint.

[0171] In some embodiments, the active substance comprises or is derived from one or more plant substances or their components, derivatives, or extracts, the plant substance being tobacco.

[0172] In some embodiments, the active substance comprises or is derived from one or more plant substances or their components, derivatives, or extracts, the plant substances being selected from eucalyptus, star anise, cocoa, and hemp.

[0173] In some embodiments, the active substance comprises or is derived from one or more plant substances or their components, derivatives, or extracts, the plant substances being selected from rooibos and fennel.

[0174] In some embodiments, the delivered substance includes flavorings.

[0175] As used herein, the terms “flavoring” and “flavoring agent” refer to materials that may be used to create a desired taste, aroma, or other somatosensory effect in products intended for adult consumers, where permitted by local regulations.These are naturally occurring flavorings, plant substances, plant substance extracts, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, anise, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, rye). Tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, kurt, eggplant, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, illa Ilex crenata, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, peppermint oil from any of the Mentha species, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazelnut, hibiscus, bay leaf, mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, mace, damien, ma It may contain other additives such as joram, olive, lemon balm, lemon basil, chives, calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), as well as charcoal, chlorophyll, minerals, plant-based substances, or breath fresheners.They may be imitations, synthetics, or natural raw materials, or blends thereof. They may be in any suitable form, such as liquids like oils, solids like powders, or gases.

[0176] In some embodiments, the flavor includes menthol, spearmint, and / or peppermint. In some embodiments, the flavor includes cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavor includes eugenol. In some embodiments, the flavor includes flavor components extracted from tobacco. In some embodiments, the flavor includes flavor components extracted from cannabis.

[0177] In some embodiments, the flavor may include a sensory stimulant, which is intended to achieve somatosensations that are normally chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or instead of the aroma or taste nerves, and these may include agents that produce heating, cooling, tingling, or numbing effects. A preferred thermal agent may be, but is not limited to, vanillyl ethyl ether, and a preferred cooling agent may be, but is not limited to, eucalyptol or WS-3.

[0178] Aerosol-generating materials may include, or may be, an amorphous solid. In some embodiments, the aerosol-generating material includes an aerosol-generating film which is an amorphous solid. The amorphous solid may be a monolithic solid. The amorphous solid may be substantially non-fibrous. In some embodiments, the amorphous solid may be a dry gel. The amorphous solid is a solid material that can hold some fluid, such as a liquid, within the amorphous solid. In some embodiments, the amorphous solid includes, for example, about 50 wt%, 60 wt%, or 70 wt% amorphous solid, or about 90 wt%, 95 wt%, or 100 wt% amorphous solid. Aerosol-generating materials may also be called aerosolizable materials.

[0179] Aerosol-generating materials are materials that can generate aerosols when heated, irradiated, or energized by any other means. Aerosol-generating materials may be in the form of solids, liquids, or gels, and may or may not contain active substances and / or flavorings. Aerosol-generating materials are incorporated into articles for use in aerosol-generating systems.

[0180] As used herein, the term “tobacco material” refers to any material including tobacco or its derivatives or substitutes. Tobacco material may be any preferred form. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, extended tobacco, reconstituted tobacco, or tobacco substitutes. Tobacco material may include one or more of ground tobacco, tobacco fibers, cut tobacco, extruded tobacco, tobacco stems, tobacco leaves, reconstituted tobacco, and / or tobacco extracts.

[0181] Consumables are articles comprising or consisting of aerosol-generating material, some or all of which are intended to be consumed during use by the user. Consumables may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, packaging material, a mouthpiece, a filter, and / or an aerosol modifier. Consumables may also comprise an aerosol generator, particularly a heating element, which generates heat during use to cause the aerosol-generating material to produce an aerosol. The heater may comprise an electrically conductive material or a susceptor.

[0182] The aerosol-generating material may comprise one or more active substances and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0183] Aerosolizable materials may be present on a substrate. The substrate may be, for example, paper, cardboard, cardboard, reconstituteable aerosolizable materials, plastic materials, ceramic materials, composite materials, glass, metals, or metal alloys, or may include them.

[0184] The aerosol-forming agent material may contain one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming agent material may contain one or more of the following: glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0185] One or more other functional materials may include one or more of the following: pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0186] Consumables are articles comprising or consisting of aerosol-generating material, some or all of which are intended to be consumed during use by the user. Consumables may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, packaging material, a mouthpiece, a filter, and / or an aerosol modifier. Consumables may also comprise an aerosol generator, such as a heater, which generates heat during use to cause the aerosol-generating material to produce an aerosol. The heater may comprise, for example, a flammable material, an electrically conductive material, or a susceptor.

[0187] A susceptor is a material that can be heated by penetration through a fluctuating magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, and consequently, penetration through the conductive material by the fluctuating magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, and consequently, penetration through the magnetic material by the fluctuating magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, and consequently, the susceptor can be heated by both heating mechanisms. A device configured to generate a fluctuating magnetic field is referred to herein as a magnetic field generator.

[0188] Aerosol modifiers are typically substances located downstream of the aerosol generation area and are configured to modify the generated aerosol by altering, for example, the taste, flavor, acidity, or other properties of the aerosol. Aerosol modifiers may be provided within an aerosol modifier release component that is operable to selectively release the aerosol modifier.

[0189] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may contain, for example, one or more of the following: flavorings, colorants, water, and carbon adsorbents. 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, thread, or granules. The aerosol modifier does not necessarily contain a filter material.

[0190] 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 supply thermal energy to the aerosol-generating material so as to release one or more volatile substances from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from an aerosol-generating material without heating. For example, the aerosol generator may be configured to supply one or more of the aerosol-generating material to vibration, pressure increase, or electrostatic energy.

[0191] The filamentous tow materials described herein may include cellulose acetate fiber tow. Filamentous tow can also be formed using other materials used to form fibers, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1-4-butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers, or combinations thereof. If the material is cellulose acetate tow, the filamentous tow may be plasticized with a tow-suitable plasticizer such as triacetin, or the tow may not be plasticized. The tow may have any preferred specifications, such as having a cross-section that is "Y"-shaped or "X"-shaped, and a filament denier value of 2.5 to 15 denier per filament, for example 8.0 to 11.0 denier per filament, and a total denier value of 5,000 to 50,000, for example 10,000 to 40,000.

[0192] In the figures described herein, similar reference numerals are used to indicate equivalent features, articles, or components.

[0193] Figure 1 is a side cross-sectional view of article 1 for use in an aerosol delivery system including an aerosol delivery device 200 (see Figures 9 to 11).

[0194] Article 1 comprises a sheet material 2 arranged to form a main body 3. The sheet material 2 includes a first aerosol-generating material 4.

[0195] The main body 3 is surrounded by packaging material 6. In this example, the packaging material 7 includes paper.

[0196] Article 1 further comprises a second aerosol-generating material 5. In this example, the second aerosol-generating material 5 includes beads 5 of the aerosol-generating material. However, it should be noted that in other embodiments, the second aerosol-generating material 5 may take a different form. The second aerosol-generating material 5 may be in the form of discrete particles of the aerosol-generating material.

[0197] The second aerosol generating material 5 is engaged with the sheet material 2 such that the second aerosol generating material 5 is held within the main body 3 by the sheet material 2. In this example, the second aerosol generating material 5 is held within the main body 3 by friction. That is, the friction between the second aerosol generating material 5 and the sheet material 2 keeps the second aerosol generating material 5 in a predetermined position within the main body 3.

[0198] The fact that the second aerosol-generating material 5 is held in place within the main body 3 by the sheet material 2 has the advantage of preventing the second aerosol-generating material 5 from falling out of the main body 3 during transport and use of the article 1. This also has the advantage that no binder or additive is required to hold the second aerosol-generating material 5 within the main body 3 (for example, the second aerosol-generating material 5 does not need to be bonded to the sheet material 2), thereby making the article easier, cheaper, and more environmentally friendly to manufacture.

[0199] In this example, the sheet material 2 is formed into strips 7, but for example, the sheet material 2 may be cut or shredded into strips 7. The second aerosol-generating material 5 is then combined with the strips 7, and the strips 7 are then assembled together to form the body 3. The strips 7 may be aligned in a predetermined manner (for example, extending substantially parallel to the central axis of article 1) or oriented in a random manner.

[0200] Additionally or alternatively, the sheet material 2 may be corrugated, for example, before or after cutting or shredding the sheet material 2.

[0201] The second aerosol-generating material 5 is held between the strips 7 as the strips 7 are assembled to form the body 3. The second aerosol-generating material 5 is held between portions of the sheet material 2 to keep the second aerosol-generating material 5 within the body 3. In this example, the portions of the sheet material 2 are adjacent strips 7. However, in other embodiments, the sheet material 2 of the body 3 may be a continuous sheet assembled to form the body 3, and the second aerosol-generating material 5 is held between portions of the same continuous piece of sheet material 2, for example, between folds of sheet material 2. In some embodiments, the body 3 comprises multiple layers of sheet material 2, and the second aerosol-generating material 5 is held between the layers of sheet material 2.

[0202] In this example, the strip 7 of the main body 2 extends from the first end P to the second end D of the article 1. In some embodiments, the strip or strand 7 may extend substantially parallel to the central axis of the article 1 and in the longitudinal direction. The strip or strand 7 may extend from the first end P to the second end D of the article 1 and may extend along the entire or substantially entire axial length of the article 1 (indicated by the arrow "X" in Figure 1). In other embodiments, the strip or strand 7 may extend at an angle to the central axis of the article 1, for example, perpendicular to the central axis. In some embodiments, the strip or strand 7 may be randomly oriented.

[0203] In this example, the main body 3 of the material extends from the first end P of article 1 to the second end D of article 1.

[0204] In this example, the main body 3 of the material extends along the entire length X of the article 1. This increases the amount of aerosol that can be generated for a given axial length of the article 1. In this example, the first and second aerosol-generating materials 4 and 5 extend to at least 90% of the length X of the article 1, preferably at least 92%, 94%, 96%, 98%, or 99% of the length X of the article, and preferably form a collation of aerosol-generating materials that extends along the entire length X of the article 1.

[0205] In other embodiments, the material body 3 extends over a portion of the length X of article 1.

[0206] In some embodiments, the first and / or second aerosol-generating materials 4, 5 include, consist of, or are essentially made of tobacco material.

[0207] In this example, the first aerosol-generating material 4 contains reconstituted tobacco.

[0208] In some embodiments, the first aerosol-generating material 4 includes tobacco leaf blades.

[0209] In some embodiments, the second aerosol generating material 5 includes beads 5 of the second aerosol generating material 5, such as tobacco beads.

[0210] In some embodiments, the bead 5 is substantially cylindrical.

[0211] In some embodiments, the beads 5 have a diameter of at least about 0.5 mm, and optionally at least about 1, 1.5, 2, 2.5, or 3 mm (e.g., measured by sieving). The beads 5 may have a diameter of about 5 mm or less, and optionally at least about 4.5, 4, 3.5, 3, 2.5, 2, or 1.5 mm (e.g., measured by sieving). In some embodiments, the diameter of each bead 5 may be in the range of about 0.5 mm to about 3 mm, or about 1 mm to about 2 mm. The size of the beads 5 may refer to the average size of the beads 5, such as by number or volume average size.

[0212] In some embodiments, the second aerosol-generating material 5 includes an extruded and / or compressed aerosol-generating material, preferably including extruded and / or compressed tobacco.

[0213] In some embodiments, the tobacco material of the first and / or second aerosol-generating materials 4, 5 is derived solely from tobacco leaf blades and not from any other type of tobacco material.

[0214] In some embodiments, the first and / or second aerosol-generating materials 4, 5 include tobacco leaf blades and reconstituted tobacco.

[0215] In one embodiment, both the first and second aerosol-generating materials 4 and 5 have an average nicotine level in the range of 0.5% to 2.5% by weight, preferably 1% to 2.1% by weight, of the first and second aerosol-generating materials.

[0216] In some embodiments, the first and / or second aerosol-generating materials 4, 5 are solid materials.

[0217] In some embodiments, article 1 does not contain plastic. This makes article 1 more environmentally friendly.

[0218] In some embodiments, article 1 does not contain cellulose acetate.

[0219] In some embodiments, the first and second aerosol-generating materials 4 and 5 are manufactured from the same aerosol-generating starting material that has been processed to have different forms.

[0220] In some embodiments, the second aerosol-generating material 5 includes fibers of the aerosol-generating material.

[0221] In some embodiments, the second aerosol-generating material 5 is distributed throughout the entire body 3.

[0222] In some embodiments, the second aerosol-generating material 5 is discretely distributed within the main body 3, forming multiple discrete regions of the second aerosol-generating material 5.

[0223] The second aerosol-generating material 5 may be provided as a loose material. For example, the second aerosol-generating material 5 may be a loose material held in place within the body 3 by engagement with the sheet material 2. The second aerosol-generating material 5 may be, for example, a loose strand or particle of the aerosol-generating material. Another example of a loose aerosol-generating material is aerosol-generating material beads / pellets, which include aerosol-generating material that is extruded and then cut into beads / pellets. Yet another example of an aerosol-generating material is a sheet of aerosol-generating material cut into individual pieces, for example, individual strips of aerosol-generating material. A sheet of aerosol-generating material may be a sheet of reconstituted tobacco.

[0224] In some embodiments, the first and second aerosol-generating materials 4 and 5 have different densities.

[0225] In some embodiments, the sheet material 2 is elastically deformable. This allows the sheet material 2 to deform around the second aerosol-generating material 5, and thus may help to keep the second aerosol-generating material 5 in place within the body 3.

[0226] In some embodiments, the aerosol-generating material in article 1 comprises about 50% by weight of a first aerosol-generating material 4 and about 50% by weight of a second aerosol-generating material 5. Therefore, 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.

[0227] In some embodiments, the main body 3 is surrounded by packaging material 6.

[0228] In some embodiments, the packaging material 6 forms the outer surface 1A of the article 1.

[0229] In some embodiments, the packaging material 6 has a degree of air permeability of less than 100 cholesta units, preferably 90, 80, 70, 60, or less than 50 cholesta units.

[0230] In some embodiments, the packaging material 6 has a thickness in the range of 20 to 100 microns.

[0231] In some embodiments, the packaging material 6 has a basis weight in the range of 20 to 50 gsm.

[0232] In some embodiments, the first and / or second aerosol-generating materials 4, 5 may contain, consist of, or essentially consist of tobacco material. The term “tobacco material” refers to any material containing tobacco or its derivatives or substitutes. The tobacco material may be any preferred form. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, extended tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fibers, cut tobacco, extruded tobacco, tobacco stems, tobacco leaf blades, reconstituted tobacco, and / or tobacco extracts.

[0233] In some embodiments, the first and / or second aerosol-generating materials 4, 5 or another material of Article 1 (not shown), for example another material of Body 3, may comprise one or more aerosol-forming materials. For example, the first and / or second aerosol-generating materials 4, 5 or the other material may comprise one or more components capable of forming an aerosol. The aerosol-forming materials may comprise one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The aerosol-forming materials may be glycerol or propylene glycol.

[0234] In this example, the second aerosol-generating material 5 comprises extruded and / or compressed tobacco. In such embodiments, the second aerosol-generating material 5 may comprise a single body of the aerosol-generating material 5. However, in this example, the second aerosol-generating material 5 comprises multiple bodies of the aerosol-generating material.

[0235] In this example, the second aerosol-generating material 5 includes beads / pellets / granules of the aerosol-generating material (hereinafter referred to as "beads" of the aerosol-generating material). The beads 5 may be extruded and / or compressed beads 5, and may be subjected to a spheroidizing process.

[0236] Optionally, the second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4. This has been found to cause the second aerosol-generating material 5 to heat more slowly than the first aerosol-generating material 4 when the heater of the device 200 is activated to heat the article 1. This means that the first aerosol-generating material 4 will initially release one or more volatile compounds (e.g., nicotine) at a higher rate than the second aerosol-generating material 5. This also means that the first aerosol-generating material 4 will relatively deplete the volatile compounds(s) more quickly than the second aerosol-generating material 5. However, once the first aerosol-generating material 4 begins to relatively deplete the volatile compounds(s), the second aerosol-generating material 5 will begin to reach a temperature at which it begins to release the volatile compounds(s) at a higher rate. This effect is a more consistent release of volatile compounds over the consumption period of article 1, with the first aerosol-generating material 4 releasing a larger proportion of volatile compounds towards the start of consumption of article 1, and the second aerosol-generating material 5 releasing a larger proportion of volatile compounds towards the end of consumption of article 1. This is particularly advantageous because it allows article 1 to be relatively small while still achieving a relatively consistent and / or sufficient release of volatile compounds over the consumption period.

[0237] In some embodiments, the one or more volatile compounds released by the first aerosol-generating material 4 are the same as the volatile compounds released by the second aerosol-generating material 5.

[0238] In some embodiments, the second aerosol-generating material 5 includes an aerosol-generating material that has been compressed or extruded (without subsequent expansion or with relatively low / minimal expansion) such that the density of the second aerosol-generating material 5 is higher than the density of the first aerosol-generating material 4.

[0239] In some embodiments, the first aerosol-generating material 4 comprises one or more of tobacco leaf blades, tobacco stems, or reconstituted tobacco. In one such embodiment, the first aerosol-generating material 4 comprises a mixture of tobacco leaf blades and reconstituted tobacco. The first aerosol-generating material 4 is formed in sheet form.

[0240] In some embodiments, the first and second aerosol-generating materials 4 and 5 may contain the same material, such as tobacco, but are processed to have different densities. In one such embodiment, the first and second aerosol-generating materials 4 and 5 may be in different forms. For example, the first aerosol-generating material 5 is formed in a sheet material 2, while the second aerosol-generating material 5 can be compressed or extruded (without expansion or with minimal expansion) such that the second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4.

[0241] In alternative embodiments, it should be noted that the density of the second aerosol-generating material 5 is lower than that of the first aerosol-generating material 4. In yet another embodiment, the densities of the first and second aerosol-generating materials 4 and 5 are the same.

[0242] In some embodiments, the first aerosol-generating material 4 has at least one further different property compared to the second aerosol-generating material 5. The different property may be one or more of the form, size, water content, quantity (by weight), one or more materials, or proportions of the materials used to make the first and second aerosol-generating materials 4 and 5 (including recipes for aerosol-generating materials 4 and 5 when each is made from two or more materials). In some embodiments, the first and second aerosol-generating materials 4 and 5 do not have different properties other than being in different forms.

[0243] The first aerosol-generating material 4 may include a plurality of strands or strips of aerosol-generating material. For example, the first aerosol-generating material 4 may include a plurality of strands or strips of aerosolizable material and / or a plurality of strands or strips of amorphous solid.

[0244] The first and / or second aerosol-generating materials 4 and 5 may include plant-based materials such as tobacco material. The first and / or second aerosol-generating materials 4 and 5 may be sheets or shredded sheets of aerosolizable material containing plant-based materials such as tobacco material.

[0245] The plant-based material may be particulate or granular. In some embodiments, the plant-based material is a powder. Alternatively or additionally, the plant-based material may include tobacco strips, strands, or fibers. For example, if a tobacco material is provided, the tobacco material may include tobacco particles, granules, fibers, strips, and / or strands. In some embodiments, the tobacco material consists of tobacco particles or granules.

[0246] The tobacco material of the first and / or second aerosol-generating materials 4, 5 may include tobacco obtained from any part of the tobacco plant. In some embodiments, the tobacco material includes tobacco leaves.

[0247] The sheets or shredded sheets may contain 5% to approximately 90% by weight of tobacco leaves.

[0248] In some embodiments, both the first and / or second aerosol-generating materials 4, 5 contain, consist of, or are essentially made of tobacco material.

[0249] In some embodiments, the first aerosol-generating material 4 comprises a sheet or shredded sheet of aerosolizable material containing an aerosol-forming agent material. In some embodiments, the aerosol-forming agent material is provided in an amount of up to about 50% by weight on a dry weight basis of the sheet or shredded sheet. In some embodiments, the aerosol-forming agent material is provided in an amount of about 5% to about 40% by weight, about 10% to about 30% by weight, or about 10% to about 20% by weight on a dry weight basis of the sheet or shredded sheet.

[0250] The first and / or second aerosol-generating materials 4, 5 may include fillers. The fillers are generally non-tobacco components, i.e., components that do not contain raw materials derived from tobacco. The fillers may include one or more inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. The fillers may be non-tobacco fibers such as wood fibers or pulp or wheat fibers. The fillers may be materials containing cellulose or derivatives of cellulose. The filler components may also be non-tobacco cast materials or non-tobacco extruded materials. In some embodiments, the first and / or second aerosol-generating materials 4, 5 are in the form of sheets or shredded sheets containing the fillers.

[0251] The first and / or second aerosol-generating materials 4, 5 may include an aerosol modifier, such as any of the flavors described herein. In one embodiment, the first and / or second aerosol-generating materials 4, 5 include menthol. When the first and / or second aerosol-generating materials 4, 5 are incorporated into an article 1 for use in an aerosol supply system, the article may be referred to as a menthol-containing consumable or article 1. The first and / or second aerosol-generating materials 4, 5 may contain 0.5 mg to 20 mg of menthol, 0.7 mg to 20 mg of menthol, 1 mg to 18 mg, or 8 mg to 16 mg of menthol.

[0252] In some embodiments, article 1 comprises an aerosol-generating composition containing an aerosol-generating material. The aerosol-generating material may include first and / or second aerosol-generating materials 4, 5.

[0253] Aerosol-generating materials are materials that can generate aerosols when heated, irradiated, or given energy in any other way. The aerosol-generating materials (e.g., the first and / or second aerosol-generating materials 4, 5) may be in the form of a solid, liquid, or semi-solid (such as a gel), which may or may not contain active substances and / or flavorings.

[0254] The aerosol-generating material (e.g., the first and / or second aerosol-generating material 4, 5) may include a binder and an aerosol-forming agent. Optionally, an activator and / or filler may also be present. Optionally, a solvent such as water may also be present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent. In some embodiments, the aerosol-generating material (e.g., the first and / or second aerosol-generating material 4, 5) is substantially free of plant material. In particular, in some embodiments, the aerosol-generating material (e.g., the first and / or second aerosol-generating material 4, 5) is substantially free of tobacco.

[0255] The aerosol-generating material (e.g., the first and / or second aerosol-generating materials 4, 5) may include an "amorphous solid," and may also be a "monolithic solid." In some embodiments, the amorphous solid may be a dry gel. The amorphous solid is a solid material capable of holding some fluid, such as a liquid, within the amorphous solid. In some embodiments, the aerosol-generating material may include, for example, about 50 wt%, 60 wt%, or 70 wt% amorphous solid, or about 90 wt%, 95 wt%, or 100 wt% amorphous solid. The amorphous solid may be substantially non-fibrous.

[0256] The aerosol-generating material (e.g., the first and / or second aerosol-generating material 4, 5) may include an aerosol-generating film. The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with one or more other components, such as a solvent, such as water, an aerosol-forming agent, and an active substance, to form a slurry, and then heating the slurry to volatilize at least a portion of the solvent, thereby forming an aerosol-generating film. The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent. The aerosol-generating film may be a continuous film or a discontinuous film in which separate parts of the film are arranged on a support. The aerosol-generating film may not substantially contain tobacco.

[0257] The aerosol-generating film may include a sheet that can be selectively shredded to form shredded sheets, or may be a sheet that can be selectively shredded to form shredded sheets.

[0258] The aerosol-generating material (e.g., the first and / or second aerosol-generating materials 4, 5) may include one or more active substances and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0259] In each embodiment of Article 1 described herein, the Article may include such first and / or second aerosol-generating materials 4, 5 and such aerosol-generating compositions.

[0260] The first and / or second aerosol-generating materials 4, 5 may comprise paper-reconstructed tobacco material. The composition may optionally or additionally comprise any of the forms of tobacco described herein. The first and / or second aerosol-generating materials 4, 5 may comprise a sheet or shredded sheet comprising tobacco material containing 10% to 90% by weight of tobacco leaves, wherein the aerosol-forming material is provided in an amount of up to about 20% by weight of the sheet or shredded sheet, and the remainder of the tobacco material comprises paper-reconstructed tobacco.

[0261] If the first and / or second aerosol-generating materials 4, 5 include an amorphous solid material, the amorphous solid material may be a dry gel containing menthol.

[0262] In some embodiments, the second aerosol-generating material 5 includes an extruded aerosol-generating material which is then cut into pellet beads.

[0263] Referring here to Figures 6 and 7, alternative embodiments of Article 1 for an aerosol supply device 200 are shown. Article 1 has similar features to Article 1 described above in relation to Figures 1 to 5, and similar features have the same reference numerals and may have any of the variations of features described herein. The difference is that the sheet material 2 is not cut into strips 7. Instead, continuous sheet material 2 is assembled to form a body 3 such that a second aerosol-generating material 5 is held within the folds between the sheet material 2. That is, the second aerosol-generating material 5 is held between portions of the same continuous pieces of sheet material 2, for example, between the folds of sheet material 2. In some embodiments, the body 3 comprises multiple layers of sheet material 2, and the second aerosol-generating material 5 is held between the layers of sheet material 2. The sheet material 2 may be assembled in a manner similar to that of assembling paper sheets during the manufacture of a "crepe filter," as is known to those skilled in the art.

[0264] In the embodiment described above, the body 3 extends between the ends P and D of article 1. However, it should be noted that in alternative embodiments (not shown), article 1 may include one or more further segments, for example, further segments upstream or downstream of the body 3.

[0265] For example, an alternative embodiment of Article 1 is shown in Figure 8, further comprising a cooling section 25, also called a cooling element, positioned immediately downstream of the main body 3. In this example, the cooling element 25 is adjacent to the main body 3 immediately downstream. In some such embodiments, the cooling element 25 is in contact with the main body 3. Article 1 may additionally or alternatively include a body 26 of further material downstream of the cooling element 25. The body 26 of further material may include flavoring material and / or filtering material and / or may be provided to obstruct the view of the cooling element 25.

[0266] The cooling element 25 comprises a hollow channel having an inner diameter of approximately 1 mm to approximately 4 mm, for example, approximately 2 mm to approximately 4 mm. The hollow channel may have an inner diameter of approximately 3 mm. The hollow channel extends along the entire length of the cooling element 25. The cooling element 25 may comprise a single hollow channel. In an alternative embodiment, the cooling element 25 may comprise multiple channels, for example, two, three, or four channels. The single hollow channel may be substantially cylindrical, but in an alternative embodiment, other channel shapes / cross-sections may be used. The hollow channel may provide a space in which an aerosol drawn into the cooling element 25 can expand and be cooled. The cooling element 25 may be configured to limit the cross-sectional area of ​​the hollow channel(s) to limit the displacement of the cigarette into the cooling element 25 during use.

[0267] The cooling element 25 may have a wall thickness in the radial direction. The wall thickness of the cooling element 25 relative to a given outer diameter of the cooling element 25 defines the inner diameter of the chamber surrounded by the wall of the cooling element 25. The cooling element 25 may have a wall thickness of at least about 1.5 mm to a maximum of about 2 mm. In this example, the cooling element 25 has a wall thickness of about 2 mm.

[0268] The cooling element 25 may be formed from a filamentous tow. Other structures may also be used to form the cooling element 25, such as multiple layers of paper wound parallel to each other at butt joints, or layers of paper wound in a spiral, a cardboard tube, a tube formed using a papier-mâché type process, or a molded or extruded plastic tube. The cooling element 25 is manufactured to have sufficient rigidity to withstand axial compressive forces and bending moments that may occur during manufacturing and during use of article 1.

[0269] The wall material of the cooling element 25 may be relatively non-porous such that at least 90% of the aerosols generated by the aerosol generating materials 4 and 5 pass longitudinally through one or more hollow channels rather than through the wall material of the cooling element 25. For example, at least 92% or at least 95% of the aerosols generated by the first and / or second aerosol generating materials 4 and 5 may pass longitudinally through one or more hollow channels.

[0270] The cooling element 25 may be configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile components entering the first upstream end of the cooling element 25 and the heated volatile components exiting the second downstream end of the cooling element 25. The cooling element 25 may be configured to provide a temperature difference of at least 60 degrees Celsius, or at least 80 degrees Celsius, or at least 100 degrees Celsius between the heated volatile components entering the first upstream end of the cooling element 25 and the heated volatile components exiting the second downstream end of the cooling element 25. This temperature difference along the length of the cooling element 25 protects the temperature-sensitive body 26 from the higher temperatures of the aerosol-generating materials 4, 5 when heated.

[0271] The material body 26 defines a substantially cylindrical overall shape and is encased in a plug wrap 28. The plug wrap 28 may have a basis weight of less than 50 gsm, or about 20 gsm to 40 gsm. The plug wrap 28 may have a thickness of 30 μm to 60 μm, or 35 μm to 45 μm. The plug wrap 28 may be a non-porous plug wrap having an air permeability of, for example, less than 100 cholesta units, or for example, less than 50 cholesta units. However, in other embodiments, the plug wrap 28 may be a porous plug wrap having an air permeability of, for example, at least 100 cholesta units or at least 200 cholesta units.

[0272] The cooling element 25 and / or the material body 26 may form a mouthpiece for article 1 configured to be received in the user's mouth. In some embodiments, the mouthpiece 207 of device 200 may be omitted.

[0273] In some embodiments, chip paper (not shown) may be wrapped around the cooling element 25 and the material body 26, and may also surround the packaging material 6 that encloses the body 3, and be connected to these components by adhesive. Thus, the chip paper connects the cooling element 25 and the material body 26 to the body 3. In other embodiments, the chip paper is omitted, and instead the packaging material 6 extends to surround the cooling element 25 and the material body 26, connecting these components to the body 3.

[0274] Embodiments in which the aerosol-generating material extends along the entire axial length X of article 1 (or the entire axial length of body 3) offer the advantage of increasing the amount of aerosol-generating material in article 1, and therefore the amount of aerosol that can be generated for a given axial length X of article 1.

[0275] An embodiment of the aerosol-generating material extending only a portion of the axial length X of article 1 offers the advantage that the aerosol-generating material is not visible from the ends P and D of article 1, and also helps reduce the possibility of the aerosol-generating material falling from the ends P and D of article 1.

[0276] Referring now to Figures 9 to 11, one embodiment of the aerosol supply device 200 is shown.

[0277] Article 1 is configured to be used in an aerosol supply device 200 (see Figure 9) which includes an aerosol generator in the form of a heating element 203 for heating Article 1. In this example, the heating element 203 at least partially surrounds a heating area 202, for example, a heating chamber 202. The heating element 203 may be heated by resistance heating and / or induction heating.

[0278] In other embodiments (not shown), the heating element 203 may instead comprise a blade or pin for insertion into the article 1, for example, the blade or pin may be inserted through the body 3 of the material. In other embodiments (not shown), the consumable 1 may comprise a heating element that can be embedded, for example, within the body 3 of the material.

[0279] Figure 9 shows a simplified representation of the components of one embodiment of the aerosol supply device 200. In particular, the elements of the aerosol supply device 200 are not depicted to scale in Figure 9. To simplify Figure 9, elements not relevant to understanding this embodiment have been omitted.

[0280] In the example shown in Figure 9, the aerosol supply device 200 is a non-combustible aerosol supply device 200. The non-combustible aerosol supply device 200 comprises a housing 201 having an area 202 for receiving article 1.

[0281] When article 1 is received within heating area 202, at least a portion of article 1 is thermally proximate to heater 203. Accordingly, at least a portion of aerosol-forming materials 4, 5 is thermally proximate to heater 203. In some embodiments, heater 203 is spaced apart from article 1, for example, surrounds article 1 but has a larger diameter and is spaced therefrom. In other embodiments, heater 203 is in direct contact with article 1, for example, is in contact with the outer surface of the first sheet material 6 of the article. In another embodiment, heater 203 comprises blades or pins that contact the inside of article 1, for example, contact body 3 of the material and / or substrate 2.

[0282] When article 1 is heated, the first and / or second aerosol-forming materials 4, 5 will release one or more volatile compounds and may release a range of volatile compounds at different temperatures. By controlling the maximum operating temperature of the electrically heated aerosol-generating system 200 and by preventing the release of selected volatile compounds, the selective release of undesirable compounds can be controlled.

[0283] As shown in FIG. 10, within housing 201 there is an electrical energy source 204, for example a rechargeable lithium-ion battery. Controller 205 is connected to heater 203, electrical energy source 204, and user interface 206, such as a button or display. Controller 205 controls the power supplied to heater 203 to adjust the temperature of heater 203. Typically, the aerosol-forming substrate is heated to a temperature of between 250 and 450 degrees Celsius.

[0284] FIG. 11 is a schematic cross-sectional view of a non-combustible aerosol supply device 200 of the type shown in FIG. 9, with article 1 received within heating area 202 of device 200 for heating by heater 203. Non-combustible aerosol supply device 200 is shown as receiving aerosol-generating article 1 for consumption by a user.

[0285] The housing 201 of the non-combustion aerosol supply device 200 defines an area 202 in the form of a cavity that opens at the proximal end (or mouth end) to receive the aerosol-generating article 1 for consumption by the user.

[0286] In this example, the aerosol supply device 2 is provided with a suction mouth 207 that is removable from the rest of the device 200 to allow access to the area 202 so that the article 1 can be interested in the area 202 and removed from the area 202. When the article 1 is provided within the area 202, the suction mouth 207 can be reattached. In some embodiments, the suction mouth 207 is removably attached to the housing 201 of the device 200, for example, by a thread or a bayonet connection.

[0287] When the user sucks on the suction mouth 207, air is drawn into the article 1, and the volatile substance condenses to form an inhalable aerosol. This aerosol passes through the suction mouth 207 of the device 200 and enters the user's mouth.

[0288] It should be recognized that in other embodiments, the suction mouth 207 of the device 200 can be omitted. In some embodiments, the article 1 can form a suction mouth and can contact the user's mouth.

[0289] Referring now to FIG. 12, a block diagram depicting an exemplary embodiment of a method 100 for manufacturing an article 1 for an aerosol supply device is shown. [[ID=...]]

[0290] The method 100 includes a step (S1) of providing a sheet material 2 comprising a first aerosol-generating material 4 (e.g., a tobacco sheet). The method 100 also includes a step (S2) of providing a second aerosol-generating material 5. The method 100 also includes a step (S3) of gathering the sheet material 2 so that the second aerosol-generating material 5 is engaged by the sheet material 2 and forming a body 3 such that the second aerosol-generating material 5 is held within the body 3 by the sheet material 2.

[0291] In some embodiments, method 100 includes combining a sheet material 2 and a second aerosol-generating material 5, and then assembling the sheet material 2 to form a body 3.

[0292] In some embodiments, method 100 includes assembling sheet material 2 to form a body 2 while simultaneously combining sheet material 2 with a second aerosol-generating material 5, for example, while sheet material 2 is being supplied through a garnish.

[0293] In some embodiments, method 100 includes forming the sheet material 2 into strips or strands 7.

[0294] In some embodiments, method 100 includes shredding and / or cutting the sheet material 2.

[0295] In some embodiments, the strip or strand 7 extends in a direction from a first end P to a second end D of article 1. In other embodiments, the strip or strand 7 may be randomly oriented.

[0296] In some embodiments, method 100 includes making the sheet material 2 corrugated.

[0297] In some embodiments, the sheet material 2 is formed into strips or strands 7, and the second aerosol-generating material 5 is held between the strips or strands 7.

[0298] In some embodiments, the second aerosol-generating material 5 is held within the main body 3 by friction.

[0299] In some embodiments, the step of gathering the sheet material 2 (S3) includes gathering the sheet material 2 such that the second aerosol-generating material 5 is held between the portions of the sheet material 2.

[0300] In some embodiments, the step of assembling the sheet material 2 (S3) includes assembling the sheet material 2 such that the body 2 comprises a plurality of layers of the sheet material 2 and a second aerosol-generating material 5 held between the layers of the sheet material 2.

[0301] In one embodiment, no additives or binders are applied to the sheet material 2 or the second aerosol-generating material 5 in order to hold the second aerosol-generating material 5 within the main body 3.

[0302] In all of the above examples, the second aerosol-generating material 5 may, may be, or may essentially be an extruded or compressed body of tobacco material, preferably the extruded or compressed body of tobacco material includes beads of tobacco material.

[0303] In each of the above examples, the first and / or second aerosol-generating materials 4, 5 may, may be, or may essentially be, reconstituted tobacco, preferably including shredded sheets of reconstituted tobacco.

[0304] In all of the above examples, the first and / or second aerosol-generating materials 4, 5 may, may be, or may essentially be, tobacco leaves.

[0305] In all of the above examples, the first and / or second aerosol-generating materials 4, 5 may include, consist of, or essentially consist of reconstituted tobacco and leaf tobacco, preferably the reconstituted tobacco and leaf tobacco are mixed together.

[0306] In all of the above examples, the first and / or second aerosol - generating materials 4, 5 may comprise, consist of, or consist essentially of a sheet of aerosol - generating material cut into strips. In some embodiments, the sheet is a sheet of reconstituted tobacco. For example, the first aerosol - generating material 4 may be cut into strips, and then the strips are arranged to form the body 3.

[0307] In all of the above examples, the first and / or second aerosol - generating materials 4, 5 may comprise tobacco material, and the tobacco material is manufactured from only tobacco leaf laminae and is not manufactured from other types of tobacco materials.

[0308] In all of the above examples, the first and second aerosol - generating materials 4, 5 are manufactured from the same aerosol - generating starting material that has been processed to have different forms.

[0309] According to the present disclosure, there is also provided a kit of parts comprising an article 1 according to any of the examples described herein and an aerosol supply device 200.

[0310] According to the present disclosure, there is also provided a package (not shown) comprising a plurality of articles according to any of the examples described herein. In some embodiments, the package is hermetically sealed. The package may comprise a container having a body and a lid, and a space is provided within the container body for receiving the plurality of articles. The lid may be, for example, a hinged lid, a snap - fit lid, or a lid connected by threads.

[0311] In each of the examples of the articles described above (including each of the articles shown in FIGS. 1 to 8), the first and second aerosol - generating materials 4, 5 may have different densities. Otherwise, the aerosol - generating materials of the article may be the same or different. In other embodiments, the densities of the first and second aerosol - generating materials 4, 5 may be the same.

[0312] It has been found that providing first and second aerosol-generating materials 4, 5 with different densities means that when both materials are subjected to the same heating, the higher-density material will heat up more slowly, and therefore the higher-density material will release volatile compounds (e.g., nicotine) at a slower rate than the lower-density material. In some embodiments, the second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4, and as a result, the second aerosol-generating material 5 heats up more slowly than the first aerosol-generating material 4 when subjected to the same heating, and releases volatile compounds (e.g., nicotine) at a slower rate than the first aerosol-generating material 4 (however, in other embodiments, the reverse may be true, such that the first aerosol-generating material 4 has a higher density than the second aerosol-generating material 5). Thus, combining aerosol-generating materials of different densities provides a more consistent and longer-lasting release of volatile compounds(s). In some embodiments, aerosol-generating materials of different densities are combined with the optional heating of these materials separately for different times and / or different temperatures, thereby enabling a more controlled release of volatile compounds over the lifespan of the article, or, for example, it may be desirable to have a more rapid or greater release of volatile substances at the beginning of consumption of the article to provide the user with a greater initial impact from use. The ability to control aerosol generation and volatile compound release can be particularly advantageous because it allows the article to be relatively small while still achieving a specific desired release of volatile compounds over the lifespan.

[0313] In some embodiments, one of the first and second aerosol-generating materials 4, 5 has a density at least about 25% higher than the density of the other of the first and second aerosol-generating materials 4, 5, and optionally has a density at least about 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, or 75% higher. The one of the first and second aerosol-generating materials 4, 5 may have a density about 200% or less higher than the density of the other of the first and second aerosol-generating materials 4, 5, and optionally has a density about 150%, 125%, 100%, or 75% or less higher. In some embodiments, one of the first and second aerosol-generating materials 4, 5 has a density about 25% to about 75% higher than the density of the other of the first and second aerosol-generating materials 4, 5.

[0314] In some embodiments, one of the first and second aerosol-generating materials 4, 5 has a density of at least about 0.4 g / cm³, 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 / cm³. One of the first and second aerosol-generating materials 4, 5 may have a density of about 2 g / cm³ or less, optionally at least 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 one of the first and second aerosol-generating materials 4, 5 is about 0.4 to 1.99 g / cm³.

[0315] In some embodiments, the other of the first and second aerosol-generating materials 4, 5 has a density of at least about 0.1 g / cm³, optionally at least about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, or 0.9 g / cm³. The other of the first and second aerosol-generating materials 4, 5 may have a density of about 1 g / cm³ or less, optionally at least about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, or 0.2 g / cm³. In some embodiments, the density of the other of the first and second aerosol-generating materials 4, 5 is about 0.1 to 0.9 g / cm³.

[0316] In some embodiments, the first and second aerosol-generating materials 4 and 5 contain the same components. Therefore, when heated, they will release very similar aerosols having potentially the same content of active substances and / or flavors, etc. Their different densities make it possible to generate aerosols from the two materials at different rates and / or different times during heating.

[0317] In other embodiments, the first and second aerosol-generating materials 4 and 5 contain different components (they may have the same or different densities). Therefore, upon heating, they will release different aerosols having different compositions of potentially active substances and / or flavors, etc. Their different densities make it possible to generate different aerosols from the two materials at different rates and / or different times during heating, potentially providing aerosols that change over their lifespan.

[0318] In some embodiments, the first aerosol-generating material 4 and the second aerosol-generating material 5 each contain tobacco. The tobacco will contain volatile components including nicotine, aroma, and flavor. The tobacco may be any type of tobacco and any part of the tobacco plant, including tobacco leaves, leaf blades, stems, stalks, veins, trimmings, and pieces, or mixtures of two or more of these. Preferred tobacco materials include, optionally, Virginia or yellow tobacco, Burley tobacco, Oriental tobacco, or blends of tobacco materials, which are listed herein. The tobacco may be expanded, such as dry ice expanded tobacco (DIET), or processed by any other means. In some embodiments, the tobacco material may be a reconstituted tobacco material. The tobacco may be pre-treated or untreated, and may be, for example, solid stems (SS), shredded dried stems (SDS), steam-treated stems (STS), or any combination thereof. The tobacco material may be fermented, hardened, unhardened, roasted, or otherwise pre-treated.

[0319] The first and second aerosol-generating materials 4 and 5 may contain different tobaccos. Alternatively, the tobaccos may be the same, but one of the first and second aerosol-generating materials 4 and 5 may be provided in different forms such that it has a higher density than the other of the first and second aerosol-generating materials 4 and 5.

[0320] In some embodiments, the first aerosol-generating material 4 has at least one (further) different property from the second aerosol-generating material 5. The different property may be one or more of the form, size, water content, quantity (by weight), one or more materials, or proportions of the materials used to make the first and second aerosol-generating materials 4, 5 (including recipes for aerosol-generating materials when each is made from two or more materials). In some embodiments, the first and second aerosol-generating materials 4, 5 have no different properties other than different densities. In other embodiments, the densities of the first and second aerosol-generating materials 4, 5 are the same.

[0321] In some embodiments, the sheet 2 of the first aerosol-generating material 4 may be formed from cut rags. This tobacco material may be foliate tobacco material or reconstituted tobacco material. In some embodiments, the second aerosol-generating material 5 is a blend containing both foliate tobacco and reconstituted tobacco. For example, the ratio of foliate tobacco to reconstituted tobacco may be about 1:4 to about 4:1.

[0322] In some embodiments, the second aerosol-generating material 5 has a higher density than the first aerosol-generating material 4. In some embodiments, this higher-density second aerosol-generating material 5 may contain particles or be in the form of beads or one or more sheets. Each bead or sheet may be formed from aggregated smaller particles. However, it should be noted that in other embodiments, the first aerosol-generating material 4 may be denser than the second aerosol-generating material 5, or the materials may have the same density. In some embodiments, both the first and second aerosol-generating materials 4, 5 may be in the form of one or more sheets, and optionally, one of the first and second aerosol-generating materials 4, 5 may be processed to have a higher density than the other of the first and second aerosol-generating materials 4, 5, and the second aerosol-generating material 5 may be cut into individual pieces and then held between sheets 2 of the first aerosol-generating material 4 in the body 3.

[0323] The second aerosol-generating material 5 may be in the form of beads 5. Optionally, the first aerosol-generating material 4 may include beads incorporated into the sheet 2.

[0324] As used herein, the term “beads” means including beads, pellets, or other individual small units that are molded, compressed, or otherwise made into a desired shape. Beads may have a smooth and regular shape (e.g., spherical, cylindrical, oval, etc.) and / or an irregular shape.

[0325] In some embodiments, the beads have a diameter of at least about 0.5 mm, optionally at least about 1, 1.5, 2, 2.5, or 3 mm (e.g., measured by sieving). The beads may have a diameter of about 5 mm or less, optionally at least about 4.5, 4, 3.5, 3, 2.5, 2, or 1.5 mm (e.g., measured by sieving). In some embodiments, the diameter of each bead may range from about 0.5 mm to about 3 mm, or from about 1 mm to about 2 mm. The bead size may refer to the average size of the beads, such as number or volume average size.

[0326] In some embodiments, the desired density of the aerosol-generating materials 4, 5 is achieved or controlled by the formulation of the materials and / or the method(s) in which the materials are processed. Processes involving aggregation, particularly aggregation by the application of some compressive force, tend to increase the density of the materials.

[0327] Therefore, in some embodiments, the first and / or second aerosol-generating materials 4, 5 include aggregated material particles.

[0328] In the case of sheet materials, the sheet may be formed from particles of the material that are bonded together and optionally compressed to form a sheet having desired dimensions and density.

[0329] In some embodiments, the beads or pellets can be formed using a so-called marmarizing process.

[0330] In some embodiments, agglomeration is achieved by pelletization. Pelletization is an agglomeration process that converts fine particles of a material, optionally with excipients, into free-flowing units called pellets. Depending on the selected equipment and type of process, pellet formation and growth can occur in several ways. These pellets may be formed by agitation, or agglomeration may be formed when particles are rolled and tumbled in the presence of a suitable amount of liquid. Spherical formation may involve the use of equipment such as pans, discs, drums, or mixers to produce pellets. Compression pelletization is a form of pressure agglomeration, where particles are brought together by mechanical force with optionally compounding aids. The compressive force means that the formed pellets have an increased density compared to the starting material.

[0331] In some embodiments, aggregation is achieved by extrusion. In some embodiments, pellets formed by pelletization may be extruded to form a higher-density extruded product.

[0332] The extruded particles may have a size selected to produce a higher-density aerosol-generating material (e.g., a higher-density first or second aerosol-generating material 4, 5), which will affect heat transfer and the release of volatile components within the material.

[0333] Extrusion molding involves feeding a composition (also called a precursor composition) through a die to produce an extruded product. This process applies pressure to the composition in combination with shear force.

[0334] Extrusion can be performed using one of the main types of extruders: screw, sieve 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 this process combines compression, mixing, conditioning, homogenization, and molding of the composition.

[0335] In some embodiments, during extrusion molding, a free-flowing composition containing particles such as tobacco particles is subjected to high pressure and high temperature and passed through an orifice such as a molding nozzle or die to form an extruded product. In some embodiments, the extruded product has a rod-like form and can be cut into segments of a desired length.

[0336] In some embodiments, the composition is exposed to temperatures of approximately 40°C to 150°C, or approximately 80°C to 130°C, or approximately 60°C to 95°C in the extruder. In some embodiments, including those using double extrusion molding, the precursor composition is exposed to temperatures of approximately 70°C to 95°C in the extruder. In some embodiments, including those using single extrusion molding, the precursor composition is exposed to temperatures of approximately 60°C to 80°C in the extruder.

[0337] The composition may be subjected to pressures ranging from approximately 2 bar to approximately 100 bar, or approximately 5 bar to approximately 60 bar (immediately before the die or nozzle), depending on the design of the die or nozzle used. Higher pressures tend to result in higher density of the extruded material. Therefore, the extrusion process can be adjusted to provide an extruded aerosol-producing material with a desired density.

[0338] In some embodiments in which tobacco particles are extruded, the density of the extruded material is relatively high and the surfaces of the tobacco particles within the extruded material are relatively open, so the tobacco beads formed from the extruded material exhibit good heat transfer and mass transfer, which has a positive effect on the release of tobacco components such as flavor and nicotine.

[0339] In some embodiments, the extrusion process may be a generally dry process, and the composition comprises dry or substantially dry aerosol-forming particles. The composition may optionally include other granular materials, such as a base, diluent, solid aerosol-forming agent, solid flavor modifier, etc.

[0340] 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 coagulate them. Alternatively or additionally, a wetting agent may be added to the composition.

[0341] In some embodiments, the liquid may be an aerosol-forming material such as glycerol or others discussed herein. When the liquid is added to the composition in this way, the liquid is not only applied to the surface, but the extruder is impregnated with the liquid as a result of vigorous mixing due to the pressure and high shear force of the extruder. If the liquid is an aerosol-forming material, this can increase the availability of the aerosol-forming material in the resulting beads and enhance the evaporation of volatile components.

[0342] In some embodiments, the amount of aerosol-forming agent material incorporated into the extruded beads can be up to about 30% by weight, or even up to about 40% by weight. Typically, such a large amount of aerosol-forming agent material can make the composition difficult to handle. However, this problem is less pronounced when the aerosol-forming agent material is impregnated into the particles by extrusion. If the beads are intended to generate aerosols in addition to releasing volatile components, it may be desirable to include an amount of aerosol-forming agent 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 components carried by the beads into an existing aerosol or airflow, a smaller amount of aerosol-forming agent material, such as up to about 5% by weight, may suffice.

[0343] In some embodiments, the aggregates do not contain binders or binding additives. For example, extruded beads may not require a binder to maintain the structural integrity of the extruded beads. In other embodiments, the aggregates include binders or binding additives. Binding additives may be selected to assist in the formation of aggregate structures by helping particles adhere to each other and to other components in the composition. Suitable binding additives include, for example, thermoreversible gelling agents such as gelatin, starch, polysaccharides, pectin, alginates, wood pulp, cellulose, and cellulose derivatives such as carboxymethylcellulose.

[0344] In some embodiments, processing by extrusion is sufficient to provide a higher density of the first or second aerosol-generating material 4, 5, if desired. However, in other embodiments, the extruded material may be further processed to increase the density of the first or second aerosol-generating material 4, 5.

[0345] For example, in some embodiments, the extruded aerosol-generating material undergoes spheroidization. In spheroidization, the extruded cylindrical particles are divided into uniform lengths and gradually deformed into a spherical shape by plastic deformation. If the extruded material is initially divided into uniform lengths, the spheroidization step will produce spheres with uniform diameters.

[0346] According to one specific example of the embodiments discussed herein, a sample of beads of the second aerosol-generating material 5 was prepared as follows (however, it should be noted that in some embodiments, the sample may be prepared according to the following, and instead used for the first aerosol-generating material 4, and incorporated into a sheet 2, for example, by being cast into a slurry to form a sheet 2).

[0347] Table 1 shows three sample formulations, one with a binder and one without, with quantities expressed as percentages based on wet weight (WWB).

[0348] [Table 1]

[0349] Care was taken not to overheat the tobacco, and the tobacco was ground to produce a fine powder. The ground tobacco particles were sieved to select those with a desired particle size, for example, less than 250 μm, less than 100 μm, or less than 60 μm.

[0350] Next, all the dry (non-liquid) components of the formulation were combined and mixed or blended in a mixer. In this particular example, the mixture was mixed at a rate of 75 RPM for 1 minute. This was to ensure that the dry components were homogeneously distributed within the mixture.

[0351] Next, half of the glycerol and half of the water were added to the dry mixture and mixed. Specifically, the mixture was mixed for a further minute at 75 RPM. Then, the remaining glycerol and water were added and mixed again for a minute at 75 RPM. Mixing was then continued until the mixture had a crumbly consistency that could be compressed into a mass, in order to ensure that a homogeneous mixture was achieved. In this particular example, the additional mixing continued for 3 minutes.

[0352] Next, the mixture was extruded using a Caleva Multilab. The extruder was operated at approximately 1500 rpm to produce extruded material of spaghetti-like length.

[0353] The extruded material was divided into sections of varying lengths as it emerged from the extruder. These sections were then spheroidized. Spheroidization was carried out until spherical beads were formed. In this case, the extruded material was first spheroidized in a Caleva Multilab operating at 2,500 RPM for 1 minute, and then the beads were checked for defects. Spheroidization was then continued for another 1-2 minutes. During this spheroidization step, the extruded tobacco was divided into individual sections, forming high-density spherical beads.

[0354] In the final step, the spherical beads were dried in a 65°C oven for 30 minutes. After each drying period, the beads were weighed, and drying was terminated when the desired moisture weight reduction was achieved. Generally, such drying takes about one hour.

[0355] In some embodiments, the other of the first and / or second aerosol-generating materials 4, 5 is in the form of discrete particles or aggregated clumps of particles. These particles may share various properties with one of the first and second aerosol-generating materials 4, 5 (the denser one), such as particle size, but will have a lower density. As described above, there are various ways to adjust the density of the aerosol-generating materials 4, 5, such as compounding and / or processing the materials into particles, beads, or pellets.

[0356] In some embodiments, one of the first and second aerosol-generating materials 4, 5 comprises a combination of 60% reconstituted tobacco and 40% leaf tobacco, and the density of this material is approximately 0.1 to approximately 0.9 g / cm³. 3 It falls within this range. Of the first and second aerosol-generating materials 4 and 5, the other contains approximately 30-90% tobacco and has a concentration of approximately 0.4-1.99 g / cm³. 3 It has a density in the range of . The amount of aerosol-forming material contained in one of the first and second aerosol-generating materials 4, 5 may be about 8 to about 15%. One of the first and second aerosol-generating materials 4, 5 may contain substantially spherical beads having a particle size of about 0.5 to about 3 mm. In some embodiments, the aerosol-generating material in an 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.

[0357] In some embodiments, the aerosol-generating material includes tobacco, and the tobacco is present in an amount of about 10% to about 90% by weight of the aerosol-generating material.

[0358] In some embodiments, tobacco may be present in an amount of at least about 10%, 11%, 12%, 13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%, 27%, 28%, 29%, 30%, 31%, 32%, 33%, 34%, or at least about 35% based on the weight of the aerosol-generating material.

[0359] In some embodiments, tobacco may be present in amounts of approximately 90%, 89%, 88%, 87%, 86%, 85%, 84%, 83%, 82%, 81%, 80%, 75%, 70%, 65%, 60%, 55%, 50%, 45% or less, or approximately 40% or less, based on the weight of the aerosol-generating material.

[0360] The tobacco described herein may contain nicotine. In some embodiments, the nicotine content is 0.5 to 2% by weight of the tobacco, for example, 0.5 to 1.75% by weight, 0.8 to 1.2% by weight, or about 0.8 to about 1.75% by weight of the tobacco. In some embodiments, the nicotine content may be 0.8 to 1% by weight of the tobacco.

[0361] In some embodiments, the first and second aerosol-generating materials 4 and 5 have the same nicotine content.

[0362] In some embodiments, the first and second aerosol-generating materials 4 and 5 contain one or more volatile components. In some embodiments, the first and second aerosol-generating materials 4 and 5 have the same volatile component content.

[0363] In some embodiments, the first and / or second aerosol-generating materials 4, 5 include tobacco. For example, the first and / or second aerosol-generating materials 4, 5 may contain about 80 to about 350 mg of tobacco. In some specific embodiments, the aerosol-generating material in an article or consumable includes a combination of 130 mg of a first aerosol-generating material 4 having a weight of 260 mg and including, for example, a blend of leaf tobacco and reconstituted tobacco in sheet form, and 130 mg of a second aerosol-generating material 5 including, for example, higher-density tobacco beads.

[0364] In some embodiments, the article comprises regions of aerosol-generating material, each region comprising aerosol-generating material containing an equal amount of tobacco. In alternative embodiments, the regions may contain different amounts of tobacco. If the total amount of tobacco is about 80 to about 350 mg, one region of the aerosol-generating material comprises about 20 to about 330 mg, or about 50 to about 300 mg, or about 40 to about 125 mg of tobacco, and the other region of the aerosol-generating material comprises about 20 to about 330 mg, or about 30 to about 300 mg, or about 40 to about 125 mg of tobacco.

[0365] The various embodiments described herein are presented solely to aid in understanding and teaching the claimed features. These embodiments are provided only as representative examples of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limitations to the scope of the invention as defined by the claims or to equivalents of the claims, and it should be understood that other embodiments may be utilized and modified without departing from the scope of the claimed invention. Various embodiments of the invention may, may consist of, or may essentially consist of, appropriate combinations of disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. Articles for use in an aerosol supply system, wherein the articles are A sheet material comprising a first aerosol generating material, wherein the sheet material is assembled to form a main body, A second aerosol generating material, wherein the second aerosol generating material is engaged by the sheet material such that the second aerosol generating material is held within the main body by the sheet material, An article that is equipped with [something].

2. The article according to claim 1, wherein the second aerosol generating material is held within the main body by friction.

3. The article according to claim 1 or 2, wherein the second aerosol-generating material is held between portions of the sheet material, and preferably the body comprises a plurality of layers of the sheet material, and the second aerosol-generating material is held between the layers of the sheet material.

4. The article according to any one of claims 1 to 3, wherein the sheet material is formed into strips or strands, and the second aerosol-generating material is held between the strips or strands.

5. The article according to claim 4, wherein the strip or strand extends in a direction from a first end to a second end of the article.

6. The article according to any one of claims 1 to 5, wherein the sheet material is shaped like a corrugation.

7. The article according to any one of claims 1 to 6, wherein the article does not contain any additives or binders for retaining the second aerosol-generating material within the main body.

8. The article according to any one of claims 1 to 7, wherein the main body of the material extends from a first end of the article to a second end of the article.

9. The article according to any one of claims 1 to 8, wherein the first and second aerosol-generating materials extend to at least 90% of the length of the article, preferably at least 92%, 94%, 96%, 98%, or 99% of the length of the article, and preferably form a collation of aerosol-generating materials extending to the entire length of the article.

10. The article according to any one of claims 1 to 9, wherein the first and / or second aerosol-generating material comprises, consists of, or is essentially made of, a tobacco material.

11. The article according to claim 10, wherein the first aerosol generating material comprises reconstituted tobacco.

12. The article according to claim 10 or 11, wherein the first aerosol-generating material comprises a tobacco leaf blade.

13. The article according to any one of claims 1 to 9, wherein the first aerosol-generating material is substantially free of tobacco.

14. The article according to any one of claims 1 to 13, wherein the first aerosol generating material includes a filler.

15. The article according to claim 14, wherein the filler is a non-tobacco fiber.

16. The article according to claim 14 or 15, wherein the filler is wood fiber, pulp, or wheat fiber.

17. The article according to any one of claims 14 to 16, wherein the filler comprises cellulose.

18. The article according to any one of claims 14 to 17, wherein the filler is a non-tobacco cast material or a non-tobacco extruded material.

19. The article according to any one of claims 1 to 18, wherein the article comprises an aerosol-forming agent material.

20. The article according to claim 19, wherein the first and / or second aerosol generating material comprises the aerosol forming agent material.

21. The article according to claim 19 or 20, wherein the aerosol-forming agent material comprises one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a mixture of diacetin, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

22. The article according to any one of claims 1 to 21, wherein the second aerosol-generating material comprises an extruded and / or compressed aerosol-generating material, preferably comprising an extruded and / or compressed tobacco.

23. The article according to any one of claims 1 to 22, wherein the second aerosol generating material comprises beads of the aerosol generating material.

24. The article according to claim 22, wherein the beads have a particle size in the range of about 0.5 mm to about 3 mm.

25. The article according to any one of claims 1 to 24, wherein the first and second aerosol-generating materials have different densities, preferably the density of the second aerosol-generating material is at least 25% higher than the density of the first aerosol-generating material.

26. The second aerosol generating material is approximately 0.4 g / cm³ ３ ~Approx. 2g / cm ３ An article according to any one of claims 1 to 25, having a density in the range of [amount].

27. The first aerosol generating material is present in a concentration of approximately 0.1 g / cm³. ３ ~Approx. 1g / cm ３ An article according to any one of claims 1 to 26, having a density in the range of [amount].

28. The article according to any one of claims 1 to 27, wherein the second aerosol generating material includes fibers of the aerosol generating material.

29. The article according to any one of claims 1 to 28, wherein the sheet material comprises an aerosol generating material comprising about 10 to about 50 wt% of an aerosol forming agent material, about 15 to about 60 wt% of a gelling agent, and optionally a filler, the wt% value being calculated on a dry weight basis.

30. The article according to any one of claims 1 to 29, wherein the aerosol generating material of the sheet contains a flavoring agent.

31. The article according to any one of claims 1 to 30, wherein the sheet material is elastically deformable.

32. The article according to any one of claims 1 to 31, wherein the first and second aerosol-generating materials are present in the article in a ratio of 1:10 to 10:1 by weight.

33. The article according to any one of claims 1 to 32, wherein the article comprises about 20 to about 330 mg of the first aerosol-generating material, preferably about 50 to about 300 mg, or about 40 to about 125 mg of the first aerosol-generating material.

34. The article according to any one of claims 1 to 33, wherein the article comprises about 20 to about 330 mg of the second aerosol-generating material, preferably about 50 to about 300 mg, or about 40 to about 125 mg of the second aerosol-generating material.

35. The article according to any one of claims 1 to 34, further comprising a cooling element immediately downstream of the main body.

36. The article according to claim 35, wherein the cooling element comprises a hollow channel.

37. The article according to claim 35 or 36, further comprising a body of a more advanced material downstream of the cooling element.

38. The article according to claim 37, wherein the main body of the further material comprises a flavoring material and / or a filtering material.

39. The article according to any one of claims 1 to 38, further comprising a segment upstream of the main body.

40. A method for manufacturing articles for use in an aerosol supply system, wherein the method is The steps include providing a sheet material containing a first aerosol generating material, The steps include providing a second aerosol generating material, A step of assembling the sheet material to form a body, wherein the second aerosol generating material is held within the body by the sheet material, and the second aerosol generating material is engaged with the sheet material, Methods that include...

41. The method according to claim 40, comprising the steps of combining the sheet material and the second aerosol generating material, and then assembling the sheet material to form the main body.

42. The method according to claim 40, comprising the step of assembling the sheet material to form the main body, and simultaneously the step of combining the sheet material with the second aerosol generating material.

43. The method according to any one of claims 40 to 42, comprising the step of forming the sheet material into strips or strands.

44. The method according to claim 43, comprising the step of shredding and / or cutting the sheet material.

45. The method according to claim 43 or 44, wherein the strip or strand extends in a direction toward a second end of the article.

46. The method according to any one of claims 40 to 45, comprising the step of making the sheet material corrugated.

47. The method according to any one of claims 40 to 46, wherein the step of gathering the sheet material preferably includes a step of gathering the sheet material such that the body comprises a plurality of layers of the sheet material and the second aerosol generating material is held between the portions of the sheet material.

48. The method according to any one of claims 40 to 47, wherein the method does not include the step of using an additive or binder to retain the second aerosol generating material within the body.

49. The method according to any one of claims 40 to 48, wherein the first and / or second aerosol-generating material includes, consists of, or is essentially made of a tobacco material.

50. The method according to claim 49, wherein the first aerosol generating material includes reconstituted tobacco.

51. The method according to claim 49 or 50, wherein the first aerosol generating material includes a tobacco leaf blade.

52. The method according to any one of claims 40 to 51, wherein the first aerosol generating material is substantially free of tobacco.

53. The method according to any one of claims 40 to 52, wherein the first aerosol generating material includes a filler.

54. The method according to claim 53, wherein the filler is a non-tobacco fiber.

55. The method according to claim 53 or 54, wherein the filler is wood fiber, pulp, or wheat fiber.

56. The method according to any one of claims 53 to 55, wherein the filler comprises cellulose.

57. The method according to any one of claims 53 to 56, wherein the filler is a non-tobacco cast material or a non-tobacco extruded material.

58. The method according to any one of claims 40 to 57, wherein the article comprises an aerosol-forming agent material.

59. The method according to claim 58, wherein the first and / or second aerosol generating material comprises an aerosol forming agent material.

60. The method according to claim 58 or 59, wherein the aerosol-forming agent material comprises one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

61. The method according to any one of claims 40 to 60, wherein the second aerosol-generating material comprises an extruded and / or compressed aerosol-generating material, preferably comprising an extruded and / or compressed tobacco.

62. The method according to any one of claims 40 to 61, wherein the second aerosol generating material comprises beads of the aerosol generating material.

63. The method according to any one of claims 40 to 62, wherein the second aerosol generating material includes fibers of the aerosol generating material.

64. The method according to any one of claims 40 to 63, wherein the first and second aerosol-generating materials have different densities, preferably the density of the second aerosol-generating material is at least 25% higher than the density of the first aerosol-generating material.

65. The method according to any one of claims 40 to 64, wherein the sheet material comprises an aerosol generating material comprising about 10 to about 50 wt% of an aerosol forming agent material, about 15 to about 60 wt% of a gelling agent, and optionally a filler, the wt% value being calculated on a dry weight basis.

66. The method according to claim 65, wherein the aerosol generating material of the sheet material includes a flavoring agent.

67. The method according to any one of claims 40 to 66, wherein the sheet material is elastically deformable, and the step of gathering the sheet material causes the second aerosol generating material to be held between regions of the sheet material so that the sheet material is elastically deformable.

68. The method according to any one of claims 40 to 67, wherein a cooling element is provided immediately downstream of the main body.

69. The method according to claim 68, wherein the cooling element comprises a hollow channel.

70. The method according to claim 68 or 69, further comprising a body of additional material downstream of the cooling element.

71. The method according to claim 70, wherein the main body of the further material includes a flavoring material and / or a filtering material.

72. The method according to any one of claims 40 to 71, wherein a segment is provided upstream of the main body.

73. The method according to any one of claims 40 to 72, wherein the article comprises about 20 to about 330 mg of the second aerosol-generating material, preferably about 50 to about 300 mg, or about 40 to about 125 mg of the second aerosol-generating material.

74. An article manufactured according to the method described in any one of claims 40 to 73.

75. A package comprising a plurality of articles according to any one of claims 1 to 39 or 74, wherein the package is hermetically sealed.

76. A kit of components comprising an article according to any one of claims 1 to 39 or 74, and an aerosol supply device.

77. The kit of components according to claim 76, wherein the aerosol supply device comprises heating zones for receiving the article and heating the first and second aerosol generating materials.

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