Articles for use in aerosol delivery systems and methods for manufacturing such articles

Abstract

We provide articles for use in aerosol delivery systems. [Solution] Article 1 comprises a storage area 2 and a first blocking member 4. The storage area includes an aerosol-generating material 3 configured to be heated within the storage area to generate an aerosol. The first blocking member includes material bodies 6, 7 positioned to resist the aerosol-generating material moving out of the storage area through a first end 2A of the storage area. The disclosure also relates to a method for manufacturing articles for use in an aerosol-delivering system. The disclosure also relates to a kit of parts including the article and an aerosol-delivering device, as well as packaging for the article.

Description

[Technical Field]

[0001] The present disclosure relates to an article for use in an aerosol provision system and to a method of manufacturing an article for use in an aerosol provision system. The present disclosure also relates to a kit of parts comprising an article and an aerosol provision device, and to a package of the article. [Background Art]

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

[0003] According to some embodiments described herein, there is provided an article for use in an aerosol provision system, the article comprising a storage region containing an aerosol-generating material configured to be heated within the storage region to generate an aerosol, and a first blocking member comprising a body of material arranged to prevent movement of the aerosol-generating material out of the storage region through a first end of the storage region.

[0004] In some embodiments, the article further comprises a wall surrounding the storage region.

[0005] In some embodiments, the wall comprises a sheet material, and preferably the sheet material comprises paper and / or foil.

[0006] In some embodiments, the sheet material surrounds the first and / or second blocking member. In some embodiments, the sheet material secures the first and / or second blocking member in place.

[0007] In some embodiments, the first blocking member comprises a first packaging material surrounding the material body of the first blocking member, and preferably the first packaging material comprises paper or cardboard.

[0008] In one such embodiment, the material body of the first blocking member is a cigarette plug, and the packaging material surrounds the cigarette plug.

[0009] In some embodiments, the first blocking member does not contain plastic.

[0010] In some embodiments, the first and / or second blocking members do not contain plastic.

[0011] In some embodiments, the first and / or second blocking member does not contain cellulose acetate.

[0012] In some embodiments, the first and / or second blocking member includes an aerosol modifier.

[0013] In some embodiments, the first and / or second blocking member contains a flavoring agent.

[0014] In some embodiments, the first blocking member is substantially cylindrical.

[0015] In some embodiments, the first blocking member includes the end of the rod of the aerosol-generating material, preferably the end of the rod having a higher density than the rest of the rod.

[0016] In some embodiments, the rod is a cigarette rod.

[0017] In some embodiments, the material body includes a material plug.

[0018] In some embodiments, the material body is positioned adjacent to the first end of the storage area.

[0019] In some embodiments, at least a portion of the material body is received within the open end of the wall of the article.

[0020] In some embodiments, the material body has an axial length in the range of 3 to 20 mm, preferably in the range of 4 to 15 mm, 5 to 12 mm or 7 to 10 mm.

[0021] In some embodiments, the material body comprises an aerosol-generating material.

[0022] In some embodiments, the aerosol-generating material of the material body comprises tobacco material.

[0023] In some embodiments, the tobacco material consists solely of tobacco lamina and not other types of tobacco material, and / or the tobacco material has a nicotine level in the range of 0.5% to 2.5% by weight of tobacco, preferably in the range of 1% to 2.1% by weight of tobacco.

[0024] In some embodiments, the material body comprises an aerosol-forming material.

[0025] In some embodiments, the blocking member comprises an aerosol-generating material consisting of about 10 to about 50 weight percent of aerosol-forming material, about 15 to about 60 weight percent of gelling agent, and optionally a filler, wherein the weight percentage values are calculated on a dry weight basis.

[0026] In some embodiments, the aerosol-generating material of the blocking member comprises a flavourant.

[0027] In some embodiments, the material body comprises sheet material arranged to form the material body, preferably the sheet material is gathered to form the material body.

[0028] In some embodiments, the sheet material is crimped.

[0029] In some embodiments, the sheet material of the material body comprises one or more of paper and / or an aerosol-generating material, preferably comprising tobacco.

[0030] In some embodiments, the first blocking member includes an end that contacts the aerosol-generating material.

[0031] In some embodiments, the first blocking member is located upstream of the storage area. In other embodiments, the blocking member is located downstream of the storage area.

[0032] In some embodiments, the end wall is located upstream of the storage area. In other embodiments, the end wall is located downstream of the storage area.

[0033] In some embodiments, the article further includes a second blocking member positioned to prevent the aerosol-generating material from moving out of the storage area through a second end of the storage area.

[0034] In some embodiments, the second blocking member includes a second material body.

[0035] In some embodiments, the second blocking member has any of the features of the first blocking member described above.

[0036] In some embodiments, the second blocking member is substantially cylindrical.

[0037] In some embodiments, the second blocking member includes the end of the rod of the aerosol-generating material, preferably the end of the rod having a higher density than the rest of the rod.

[0038] In some embodiments, the rod is a cigarette rod.

[0039] In some embodiments, the material body includes a material plug.

[0040] In some embodiments, the material body is positioned adjacent to the second end of the storage area.

[0041] In some embodiments, at least a portion of the material body is received within the open end of the wall of the article.

[0042] In some embodiments, the material body has an axial length in the range of 3 to 20 mm, preferably in the range of 4 to 15 mm, 5 to 12 mm, or 7 to 10 mm.

[0043] In some embodiments, the material body includes an aerosol-generating material.

[0044] In some embodiments, the aerosol-generating material of the material body includes tobacco material.

[0045] In some embodiments, the tobacco material is only tobacco leaf pulp and not other types of tobacco material, and / or the tobacco material has a nicotine level in the range of 0.5% to 2.5%, preferably in the range of 1% to 2.1%, of the weight of the tobacco.

[0046] In some embodiments, the material body includes an aerosol-forming material.

[0047] In some embodiments, the second blocking member comprises an aerosol-generating material consisting of about 10 to about 50% by weight of an aerosol-forming material, about 15 to about 60% by weight of a gelling agent, and optionally a filler, where the weight percentage values ​​are calculated on a dry weight basis.

[0048] In some embodiments, the aerosol-generating material of the second blocking member includes a flavoring agent.

[0049] In some embodiments, the material body includes sheet material arranged to form the material body of a second blocking member, preferably the sheet material is bundled together to form the material body.

[0050] In some embodiments, the sheet material is crimped.

[0051] In some embodiments, the sheet material of the material body comprises one or more of paper and / or aerosol-generating materials, preferably tobacco.

[0052] In some embodiments, the second blocking member includes an end that contacts the aerosol-generating material.

[0053] In some embodiments, the second blocking member is located downstream of the storage area. In other embodiments, the second blocking member is located upstream of the storage area.

[0054] In some embodiments, the second blocking member includes a second packaging material surrounding the material body of the second blocking member, preferably the second packaging material being paper or cardboard.

[0055] In some embodiments, the first and second blocking members each define at least partially the boundary of the storage area.

[0056] In some embodiments, the first and / or second blocking members are separate from and distinct from the wall.

[0057] In some embodiments, the material body of the second blocking member is a cigarette plug, and the second packaging material surrounds the cigarette plug.

[0058] In some embodiments, the first and / or second blocking member is gas permeable.

[0059] In some embodiments, the first blocking member and the second blocking member are the same.

[0060] In some embodiments, the aerosol-generating material in the storage area is a first aerosol-generating material, and the first and / or second blocking member (or the first blocking member in embodiments including a second blocking member) includes a second aerosol-generating material.

[0061] 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. However, in other embodiments, the density of the first aerosol-generating material and the density of the second aerosol-generating material are the same.

[0062] In some embodiments, one of the first and second aerosol-generating materials is approximately 0.4 g / cm³ 3 ~About 2g / cm 3 It has a density of .

[0063] In some embodiments, the other of the first and second aerosol-generating materials is approximately 0.1 g / cm³ 3 ~Approx. 1g / cm 3 It has a density of .

[0064] In some embodiments, heating the article provides a relatively constant release of volatile compounds into an inhalable medium.

[0065] In some embodiments, the first aerosol-generating material includes extruded tobacco.

[0066] In some embodiments, the first aerosol-generating material includes beads.

[0067] In some embodiments, the second aerosol-generating material comprises one or more tobacco materials selected from the group consisting of leaf tissue and reconstituted tobacco materials.

[0068] In some embodiments, at least one of the first and second aerosol-generating materials includes a combination of pulp and reconstituted tobacco material. In some embodiments, the pulp and reconstituted tobacco material are present in the aerosol-generating material in a weight ratio of 1:4 to 4:1.

[0069] In some embodiments, the first and second aerosol-generating materials have the same level of volatile compound. In some embodiments, the volatile compound is nicotine.

[0070] 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.

[0071] 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.

[0072] In some embodiments, the first and second blocking members each include, consist of, or are essentially made of, a cigarette, and preferably each includes a cigarette plug.

[0073] In some embodiments, the first blocking member comprises a first end of the consumable, and the second blocking member comprises a second end of the consumable.

[0074] In some embodiments, the aerosol-generating material in the storage area is a solid material.

[0075] In some embodiments, the aerosol-generating material in the storage area is loose material.

[0076] In some embodiments, the aerosol-generating material in the storage area is in the form of separate particles.

[0077] In some embodiments, the aerosol-generating material in the storage area includes a plurality of compressed or extruded aerosol-generating materials, preferably a plurality of compressed or extruded tobacco materials.

[0078] In some embodiments, the aerosol-generating material in the storage area contains, consists of, or is essentially composed of tobacco material.

[0079] In some embodiments, the tobacco material consists solely of tobacco leaf pulp and not any other type of tobacco material.

[0080] In some embodiments, the tobacco material has a nicotine level in the range of 0.5% to 2.5%, preferably in the range of 1% to 2.1%, of the weight of the tobacco.

[0081] In some embodiments, the article further comprises a cooling section, preferably positioned so that the cooling section is downstream of the aerosol-generating material when the consumable is in use.

[0082] In some embodiments, the cooling section includes an aerosol-generating material, preferably in the form of a plug.

[0083] In some embodiments, the cooling section includes flavorings.

[0084] In some embodiments, the article further comprises a plug of material provided on the other side of the first and / or second blocking member relative to the storage area.

[0085] In some embodiments, the article has an axial length in the range of 10 to 36 mm, preferably in the range of 14 to 32 mm, 20 to 26 mm, or 22 to 24 mm.

[0086] In some embodiments, the article contains an aerosol-generating material along at least 90% of the length of the article, preferably along at least 92%, 94%, 96%, 98%, or 99% of the length of the article, and preferably along the entire length of the article.

[0087] The present disclosure also provides a method for manufacturing articles for use in an aerosol supply system, the method comprising the steps of providing an aerosol generating material and a first blocking member including a material body, wherein the aerosol generating material and the first blocking member are arranged such that the aerosol generating material is housed in a storage area and the first blocking member prevents the aerosol generating material from moving out of the storage area through a first end of the storage area.

[0088] In some embodiments, the first blocking member has any of the features of the first blocking member described above.

[0089] In some embodiments, the method includes the step of wrapping a first packaging material around the material body of the first blocking member.

[0090] In some embodiments, the step of providing the aerosol-generating material and the first blocking member includes the step of placing the aerosol-generating material and the first blocking member on a sheet material, preferably the sheet material being paper and / or foil.

[0091] In some embodiments, the method includes the step of wrapping a sheet material around an aerosol-generating material and a first blocking member.

[0092] In some embodiments, the method further includes the step of providing a second blocking member, the second blocking member being positioned to prevent the aerosol-generating material from moving out of the storage area through a second end of the storage area, preferably the second blocking member including the material body.

[0093] In some embodiments, the second blocking member has any of the features of the first blocking member described above.

[0094] In some embodiments, the first and second blocking members each define at least partially the boundary of the storage area.

[0095] In some embodiments, the first and / or second blocking members are separate from and distinct from the wall.

[0096] In some embodiments, the material body of the second blocking member is a cigarette plug, and the second packaging material surrounds the cigarette plug.

[0097] In some embodiments, the first and / or second blocking member is gas permeable.

[0098] In some embodiments, the first and second blocking members may have the same characteristics and be identical.

[0099] In some embodiments, the first and second blocking members each include a cigarette, preferably each including a cigarette plug.

[0100] In some embodiments, the first blocking member comprises a first end of the consumable, and the second blocking member comprises a second end of the consumable.

[0101] In some embodiments, the method includes the step of forming a sheet material into a wall surrounding a storage area.

[0102] In some embodiments, the method includes the step of wrapping a second packaging material around the material body of the second blocking member.

[0103] In some embodiments, the method includes the steps of arranging first and second blocking members on a sheet material such that a gap is formed between the first blocking member and the second blocking member, and at least partially filling the gap with an aerosol-generating material.

[0104] In some embodiments, a sheet material on which the first and second blocking members are placed is transported along a transport path.

[0105] In some embodiments, when the sheet material with first and second blocking members passes through the filling device, the gaps are at least partially filled with the aerosol-generating material.

[0106] In some embodiments, the method includes the steps of providing a plurality of first and second blocking members arranged in a continuous manner on a web of sheet material, and filling the gaps between adjacent first and second blocking members with an aerosol-generating material.

[0107] In some embodiments, the method includes the steps of wrapping first and second blocking members and aerosol generating material with a sheet material to form a rod, and then cutting the rod to form an article.

[0108] In some embodiments, the step of providing a first blocking member includes the step of providing a first blocking member that is twice as long, and the step of providing a second blocking member includes the step of providing a second blocking member that is twice as long.

[0109] In some embodiments, the aerosol-generating material in the storage area is a solid material.

[0110] In some embodiments, the aerosol-generating material in the storage area is loose material.

[0111] In some embodiments, the aerosol-generating material in the storage area contains, consists of, or is essentially composed of tobacco material.

[0112] In some embodiments, the tobacco material consists solely of tobacco leaf pulp and not any other type of tobacco material.

[0113] In some embodiments, the tobacco material has a nicotine level in the range of 0.5% to 2.5%, preferably in the range of 1% to 2.1%, of the weight of the tobacco.

[0114] In some embodiments, the method includes the steps of providing a cooling section and, preferably, positioning the cooling section downstream of the aerosol-generating material when a consumable is in use.

[0115] In some embodiments, the cooling section includes an aerosol-generating material, preferably a plug of the aerosol-generating material. In some embodiments, the cooling section includes a flavoring.

[0116] In some embodiments, the method further includes the step of providing a plug for the material on the other side of the first and / or second blocking member relative to the storage area.

[0117] According to this disclosure, articles for use in an aerosol delivery system are also provided, the articles comprising an aerosol-generating material along at least 90% of the length of the article.

[0118] In some embodiments, the article includes an aerosol-generating material along at least 92% of the length of the article, preferably at least 94%, 96%, 98%, or 99% of the length of the article.

[0119] In some embodiments, the article includes an aerosol-generating material along substantially the entire length of the article.

[0120] In some embodiments, the article comprises one or more material bodies, and the material bodies of the article or each material body comprises an aerosol-generating material.

[0121] In embodiments in which the article comprises multiple material bodies, all material bodies contain an aerosol-generating material.

[0122] In some embodiments, the aerosol-generating material includes a first and a second aerosol-generating material.

[0123] In some embodiments, the first aerosol-generating material and the second aerosol-generating material are mixed over at least a portion of the axial length of the article, preferably over the entire axial length of the article.

[0124] In some embodiments, the article comprises a first region containing a first aerosol-generating material and a second region containing a second aerosol-generating material, preferably the first region being arranged along a first portion of the axial length of the article and the second region being arranged along a second portion of the axial length of the article.

[0125] In some embodiments, the aerosol-generating material comprises one or more extruded or compressed bodies of the aerosol-generating material, preferably, the extruded or compressed bodies of the aerosol-generating material, or each extruded or compressed body, is a bead of the aerosol-generating material.

[0126] In some embodiments, the first aerosol-generating material comprises one or more extruded or compressed bodies of the aerosol-generating material.

[0127] In some embodiments, the aerosol-generating material comprises a sheet of aerosol-generating material, preferably the sheet is shredded or cut into strips.

[0128] In some embodiments, the aerosol-generating material sheet includes reconstituted tobacco.

[0129] In some embodiments, the aerosol-generating material includes tobacco leaves, preferably shredded tobacco leaves.

[0130] In some embodiments, the second aerosol-generating material comprises a sheet of aerosol-generating material and / or tobacco leaves.

[0131] In some embodiments, the article comprises first and second blocking members, each containing an aerosol-generating material, with a storage area positioned between the first and second blocking members, and the storage area containing the aerosol-generating material.

[0132] In some embodiments, the aerosol-generating material in the storage area is a first aerosol-generating material, and the aerosol-generating material of the first and / or second blocking member is a second aerosol-generating material.

[0133] In some embodiments, the aerosol-generating material includes, consists of, or is essentially composed of tobacco material.

[0134] In some embodiments, the tobacco material is provided along at least 90% of the axial length of the article, preferably at least 92%, 94%, 96%, 98%, or 99% of the length of the article, preferably along the entire axial length of the article.

[0135] In some embodiments, the tobacco material is manufactured solely from tobacco leaf pulp and not from any other type of tobacco material.

[0136] In some embodiments, the tobacco material has a nicotine level in the range of 0.5% to 2.5%, preferably in the range of 1% to 2.1%, of the weight of the tobacco.

[0137] In some embodiments, the aerosol-generating material includes an extruded or compressed body of tobacco material, preferably the extruded or compressed body of tobacco material includes beads of tobacco material.

[0138] In some embodiments, the aerosol-generating material includes reconstituted tobacco, preferably a shredded sheet of reconstituted tobacco.

[0139] In some embodiments, the aerosol-generating material includes tobacco pulp, preferably shredded tobacco pulp.

[0140] In some embodiments, the aerosol-generating material comprises reconstituted tobacco and pulp tobacco, preferably a mixture of reconstituted tobacco and pulp tobacco.

[0141] In some embodiments, the aerosol-generating material includes a sheet of aerosol-generating material bundled together to form a material body, preferably the sheet material being crimped. Preferably, the sheet is a sheet of reconstituted tobacco.

[0142] In some embodiments, the aerosol-generating material includes a sheet of material that is cut into strips. Preferably, the sheet is a sheet of reconstituted tobacco.

[0143] In some embodiments, the aerosol-generating material is in the form of a rod.

[0144] In some embodiments, the article includes first and second ends, at least one of the first and second ends containing an aerosol-generating material, preferably both the first and second ends containing an aerosol-generating material.

[0145] In some embodiments, the article has an axial length in the range of 10 to 36 mm, preferably in the range of 14 to 32 mm, 20 to 26 mm, or 22 to 24 mm.

[0146] According to this disclosure, a kit of components including the articles described herein and an aerosol dispensing device is also provided.

[0147] The present disclosure also provides a package containing a plurality of articles described herein. Preferably, the package is sealed.

[0148] Here, an embodiment will be described as merely an example, with reference to the attached drawings. [Brief explanation of the drawing]

[0149] [Figure 1] This is a side cross-sectional view of one embodiment of an article for use in an aerosol delivery system. [Figure 2] Figure 1 is a top view of the sheet material of the item, with the sheet material laid flat. [Figure 3] This is a perspective view of the first material body of the first blocking member of the article shown in Figure 1. [Figure 4] This is a perspective view of the second material body of the second blocking member of the article shown in Figure 1. [Figure 5] This is a block diagram showing a method for manufacturing articles for use in aerosol delivery systems. [Figure 6A] This is a top view of the first step in a method for manufacturing an article for use in an aerosol dispensing system. [Figure 6B] This is a top view of the second step of a method for manufacturing articles for use in an aerosol delivery system. [Figure 6C]This is a top view of the third step of a method for manufacturing articles for use in an aerosol delivery system. [Figure 7A] This is a top view of the first step of another method for manufacturing an article having an aerosol supply system. [Figure 7B] This is a top view of the second step of the aforementioned alternative method for manufacturing articles for use in an aerosol supply system. [Figure 7C] This is a top view of the third step of the aforementioned alternative method for manufacturing articles for use in an aerosol supply system. [Figure 7D] This is a top view of the fourth step of the aforementioned alternative method for manufacturing articles for use in an aerosol supply system. [Figure 8] This is a side view of the second step of the aforementioned alternative method for manufacturing articles for use in an aerosol supply system. [Figure 9] This is a cross-sectional side view of an alternative blocking member. [Figure 10] This is a cross-sectional side view of another alternative blocking member. [Figure 11] This is a cross-sectional view of one embodiment of a non-combustion type aerosol dispensing device. [Figure 12] Figure 11 is a simplified schematic diagram of the components inside the housing of the aerosol dispensing device shown. [Figure 13] Figure 11 is a cross-sectional view of the non-combustion aerosol dispenser shown in Figure 1, with the articles shown in Figure 1 inserted. [Figure 14] This is a side cross-sectional view of another embodiment of an article for use in an aerosol delivery system. [Figure 15] This is a side cross-sectional view of another embodiment of an article for use in an aerosol delivery system. [Figure 16] This is a side cross-sectional view of another embodiment of an article for use in an aerosol delivery system. [Figure 17] This is a side cross-sectional view of another embodiment of an article for use in an aerosol delivery system. [Modes for carrying out the invention]

[0150] As used herein, the term “delivery system” is intended to encompass a system for delivering at least one substance to a user. Combustion aerosol dispensing systems for pipes, roll-up or roll-up cigarettes, cigarettes, cigars, and tobacco (in any case, based on tobacco, tobacco derivatives, expanded tobacco, recombined tobacco, tobacco substitutes, or other smokeable materials), Non-combustion aerosol-providing systems that release compounds from aerosol-producing materials without burning the materials, such as hybrid systems that generate aerosols using a combination of e-cigarettes, tobacco heating products, and aerosol-generating materials, an aerosol-free delivery system for delivering at least one substance to a user orally, nasally, transdermally, or otherwise without forming an aerosol, and including, but not limited to, articles containing lozenges, gums, patches, inhalable powders, and oral products such as oral tobacco containing snuff or moist snuff, wherein at least one substance may or may not contain nicotine.

[0151] According to this disclosure, a “non-combustible” aerosol delivery system is a system in which the aerosol-generating materials (or their components) that make up the aerosol delivery system are not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0152] In some embodiments, the delivery system is a non-combustible aerosol delivery system, such as a powered non-combustible aerosol delivery system.

[0153] In some embodiments, the non-combustion aerosol delivery system is an e-cigarette, also known as a vaporizer 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.

[0154] 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.

[0155] In some embodiments, the non-combustible aerosol-producing system is a hybrid system that generates an aerosol using a combination of one or more aerosol-generating materials, each of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include plant-based materials, such as tobacco or non-tobacco products.

[0156] Typically, a non-combustible aerosol dispensing system may comprise a non-combustible aerosol dispensing device and consumables for use with the non-combustible aerosol dispensing device.

[0157] In some embodiments, the disclosure relates to consumables comprising aerosol-generating materials and configured for use with non-combustible aerosol-providing devices. These consumables may be referred to as articles throughout the disclosure.

[0158] 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 apparatus in use. A “distal end” refers to the upstream end of the apparatus, and a “proximal end” refers to the downstream end of the apparatus.

[0159] In some embodiments, the non-combustible aerosol supply system, such as the non-combustible aerosol supply device, may include a power supply and a controller. The power supply may be, for example, a power supply or a heat-generating power supply. In some embodiments, the heat-generating power supply includes a carbon substrate that can be energized to distribute power in the form of heat to an aerosol-generating material or heat-transfer material adjacent to the heat-generating power supply.

[0160] In some embodiments, a non-combustible aerosol supply system comprises a region for receiving consumables, an aerosol generator, an aerosol generating region, a housing, a mouthpiece, a filter and / or an aerosol modifier.

[0161] In some embodiments, consumables for use with a non-combustible aerosol dispenser may include aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, packaging material, a filter, a mouthpiece, and / or an aerosol modifier.

[0162] The consumables include the substance to be delivered. The substance to be delivered is an aerosol-generating material. The material may optionally include one or more active ingredients, one or more fragrances, one or more aerosol-forming materials, and / or one or more other functional materials.

[0163] In some embodiments, the delivered substance includes an active substance. The active substance used herein 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 psychostimulants. The active substance may be naturally occurring or obtained synthetically. 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 also include one or more components, derivatives, or extracts of tobacco, cannabis, or another plant. In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0164] As described herein, the active substance may include or be derived from one or more plants or their components, derivatives, or extracts. As used herein, the term “plant-derived” includes, but is not limited to, any material derived from plants, including extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, exoskeletons, shells, etc. Alternatively, the material may include naturally occurring active compounds in synthetically obtained plants. The material may be in the form of a liquid, gas, solid, powder, dust, 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, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. - Lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damian, marjoram, olive, lemon balm, lemon basil, chives, fennel, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha Arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv, and Mentha suaveolens.

[0165] 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.

[0166] 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.

[0167] 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.

[0168] In some embodiments, the delivered substance includes a fragrance.

[0169] As used herein, the terms “flavoring” and “flavoring” refer to materials that may be used in products intended for adult consumers to create a desired taste, aroma, or other somatosensory experience, where permitted by local regulations.These are naturally derived fragrance materials, 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, limes, toro). 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, cascaria, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, Lan-ylang, sage, fennel, wasabi, pimento, ginger, coffee, hemp, peppermint oil from any species of mint, 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, marjoram It may also contain other additives such as olives, lemon balm, lemon basil, chives, fennel, 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 matter, or breath fresheners.They may be imitations, synthetic or natural raw materials, or blends thereof. They may be in any suitable form, such as a liquid like an oil, a solid like a powder, or a gas.

[0170] In some embodiments, the flavoring includes menthol, spearmint, and / or peppermint. In some embodiments, the flavoring includes cucumber, blueberry, citrus, and / or red berry flavoring components. In some embodiments, the flavoring includes eugenol. In some embodiments, the flavoring includes flavoring components extracted from tobacco. In some embodiments, the flavoring includes flavoring components extracted from cannabis.

[0171] In some embodiments, the fragrance 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 suitable thermal agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucoliptol or WS-3.

[0172] The aerosol-generating material 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 may include, for example, about 50% by weight, 60% by weight, or 70% by weight of amorphous solid to about 90% by weight, 95% by weight, or 100% by weight of amorphous solid. The aerosol-generating material may also be called an aerosolizable material.

[0173] Aerosol-generating materials are materials that can generate aerosols when heated, irradiated, or electrically charged, for example, by other means. Aerosol-generating materials may be in the form of a solid, liquid, or gel, and may or may not contain active substances and / or flavorings. Aerosol-generating materials are incorporated into articles for use in aerosol-generating systems.

[0174] As used herein, the term “tobacco material” refers to any material comprising tobacco or its derivatives or substitutes. The tobacco material may be in any suitable form. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, recombined tobacco, or tobacco substitutes. The tobacco material may include one or more of crushed tobacco, tobacco fibers, cut tobacco, extruded tobacco, tobacco stems, tobacco pulp, recombined tobacco, and / or tobacco extracts.

[0175] Consumables are articles containing 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, that releases heat to generate an aerosol in the aerosol-generating material during use. The heater may comprise an electrically conductive material or a susceptor.

[0176] The aerosol-generating material may include one or more active substances and / or fragrances, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0177] The aerosolizable material may be present on a substrate. The substrate may be, for example, paper, cardboard, cardboard, reconstituted aerosolizable material, plastic material, ceramic material, composite material, glass, metal, or metal alloy, or may contain these materials.

[0178] The aerosol-forming material may contain one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming 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, a mixture of diacetins, benzyl benzoate, benzylphenyl acetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0179] One or more other functional materials may include one or more of the following: pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0180] Consumables are articles containing 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 releases heat to generate an aerosol in the aerosol-generating material during use. The heater may comprise, for example, a flammable material, an electrically conductive material, or a susceptor.

[0181] A susceptor is a material that can be heated by penetration due to a fluctuating magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, and consequently, penetration of the conductive material by the fluctuating magnetic field causes inductive heating of the heating material. The heating material may be a magnetic material, and consequently, penetration of the magnetic material by the fluctuating magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, 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.

[0182] Aerosol modifiers are typically substances located downstream of the aerosol generation region and are configured to modify the generated aerosol by altering, for example, the taste, flavor, acidity, or other properties of the aerosol. The aerosol modifier may be provided in an aerosol modifier release component that is operable to selectively release the aerosol modifier.

[0183] 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, colorings, 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 need to contain a filter material.

[0184] An aerosol generator is a device configured to produce 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 in order 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 produce 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.

[0185] The filamentous tow materials described herein may include cellulose acetate fiber tow. The filamentous tow may also be formed using other materials used to form fibers, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1-4-butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers or combinations thereof. The filamentous tow may be plasticized with a tow-suitable plasticizer such as triacetin, where the material is cellulose acetate tow, or the tow may be unplasticized. The tow may have any suitable specifications, such as fibers having other cross-sections, such as "Y" or "X" shapes, and have filamentous denier values ​​of 2.5 to 15 denier per filament, e.g., 8.0 to 11.0 denier per filament, and a total denier value of 5,000 to 50,000, e.g., 10,000 to 40,000.

[0186] In the figures described herein, similar reference numerals are used to indicate equivalent features, articles, or components.

[0187] 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 11 to 13).

[0188] Article 1 has an upstream or distal end "D" and a downstream or proximal end "P". In some embodiments, the proximal end P is located relatively closer to the mouthpiece 207 of the aerosol delivery device 200 in use than the distal end D. In another embodiment (not shown), the proximal end P of Article 1 includes the mouthpiece. In some embodiments (not shown), the proximal end P of Article 1 forms the mouthpiece.

[0189] Article 1 includes a space 2 for containing an aerosol-generating material 3. The space 2 forms a storage area 2 for the aerosol-generating material 3. Article 1 further comprises first and second blocking members 4, 5 at both ends of the space 2.

[0190] The aerosol-generating material 3 is configured to be heated in space 2 in order to generate an aerosol.

[0191] The first blocking member 4 optionally comprises a first material body 6 which is externally enclosed by a first packaging material 8. The first packaging material 8 may include, for example, paper or cardboard.

[0192] The second blocking member 5 optionally comprises a second material body 7 that is externally enclosed by a second packaging material 9. The second packaging material 9 may include, for example, paper or cardboard.

[0193] The first material body 6 is positioned to prevent the aerosol-generating material 3, which may be loose material, from falling from the first end 2A of the space 2. The second material body 7 is positioned to prevent the aerosol-generating material 3 from falling from the second end 2B of the space 2. Thus, the first and second blocking members 4 and 5 help to hold the aerosol-generating material 3 within the space 2. The aerosol-generating material 3 may be in the form of separate particles.

[0194] The first material body 6 and / or the second material body 7 may be substantially cylindrical. However, it should be noted that either or both of the material bodies 6 and 7 may have different shapes.

[0195] Article 1 may have an axial length of at least 10 mm, preferably at least 12, 14, 16, 18, 20, 22, or 23 mm (indicated by the arrow "X" in Figure 1).

[0196] Article 1 may have an axial length of up to 36 mm, preferably up to 34, 32, 30, 28, 26, 24, or 23 mm.

[0197] Article 1 may have an axial length in the range of 10 to 36 mm, preferably in the range of 14 to 32 mm, 20 to 26 mm, or 22 to 24 mm.

[0198] The first material body 6 may have an axial length of at least 3 mm, preferably at least 4, 5, 6, or 7 mm.

[0199] The first material body 6 can have an axial length of up to 20 mm, preferably up to 15, 12, 10, or 8 mm.

[0200] The first material body 6 can have an axial length in the range of 3 to 20 mm, preferably in the range of 4 to 15 mm, 5 to 12 mm, or 7 to 10 mm.

[0201] The second material body 7 may have an axial length of at least 3 mm, preferably at least 4, 5, 6, or 7 mm.

[0202] The second material body 7 can have an axial length of up to 20 mm, preferably up to 15, 12, 10, or 8 mm.

[0203] The second material body 7 may have an axial length in the range of 3 to 20 mm, preferably in the range of 4 to 15 mm, 5 to 12 mm, or 7 to 10 mm.

[0204] The first material body 6 and the second material body 7 may be spaced axially apart by a distance of at least 4 mm, preferably at least 5 or 6 mm.

[0205] The first material body 6 and the second material body 7 may be spaced axially by a distance of up to 22 mm, preferably up to 20, 18, 16, 14, or 12 mm.

[0206] The first material body 6 and the second material body 7 may be spaced axially apart by a distance in the range of 4 to 22 mm, preferably in the range of 6 to 12 mm.

[0207] In some embodiments, the total weight of the aerosol-generating material in the article is in the range of 150 to 350 mg, preferably in the range of 200 to 300 mg, 220 to 280 mg, or 230 to 260 mg.

[0208] In some embodiments, the first body and / or second body contain aerosol-generating material in the range of 7 mg to 13 mg per 1 mm of length of the first body and / or second body, preferably in the range of 8 to 12, 9 to 11.5, 9 to 11, or 9.5 to 10.5 mg per 1 mm of length of the first body and / or second body.

[0209] In some embodiments, the space between the first object and the second object contains an aerosol-generating material in the range of 7 mg to 13 mg per mm of space length, preferably 8 to 12, 9 to 11.5, 9 to 11, or 9.5 to 10.5 mg per mm of space length.

[0210] In some embodiments, article 1 contains an aerosol-generating material in the range of 7 mg / mm to 13 mg per mm length of article 1, preferably in the range of 8 to 12, 9 to 11.5, 9 to 11, or 9.5 to 10.5 mg per mm length of article 1.

[0211] Article 1 includes a sheet material 10 that forms a wrap 10 surrounding the first and second blocking members 4, 5 and the aerosol-generating material 3. The sheet material 10 thus forms a substantially cylindrical peripheral wall 10A surrounding the space 2. That is, the space 2 is formed by the gap between the axially spaced first and second blocking members 4, 5, and the peripheral wall 10A surrounds the space 2. The space 2 is filled, or at least partially filled, with the aerosol-generating material 3.

[0212] The first and second blocking members 4 and 5 and the sheet material 10 may define the boundary of the space 2, or at least partially define it.

[0213] The sheet material 10 may include, for example, paper and / or foil. In some embodiments, the sheet material 10 includes paper without foil. In some embodiments, the sheet material 10 includes a metal foil such as aluminum foil. The sheet material 10 may optionally include a plurality of material layers, such as a paper layer having a foil layer.

[0214] In some embodiments, the sheet material 10 secures the first and second blocking members 4 and 5 in place. The sheet material 10 may be wrapped around the packaging materials 8 and 9 of the first and second blocking members 4 and 5, or the packaging materials 8 and 9 may be omitted, and the sheet material 10 may be wrapped directly around the material bodies 6 and 7.

[0215] In some embodiments, the sheet material 10 is bonded to the first and / or second retaining members 4, 5. However, those skilled in the art will recognize that in other embodiments, the sheet material 10 does not need to be bonded to the first and / or second retaining members 4, 5, and may be held in place by friction, for example.

[0216] In this example, the sheet material 10 is externally tangent to the first and second blocking members 4 and 5. The sheet material 10 may be wrapped around the entire axial length of the first and / or second blocking members 4 and 5. In other embodiments, the sheet material 10 may be wrapped around only a portion of the axial length of the first and / or second blocking members 4 and 5, for example, as a strip of material that overlaps the first blocking member 4 without extending the entire axial length of the first blocking member 4 and / or overlaps the second blocking member 5 without extending the entire axial length of the second blocking member 5.

[0217] In other embodiments (not shown), article 1 may include a cylindrical tube forming a peripheral wall 10A, space 2 provided within the cylindrical tube, and first and second blocking members 4, 5 provided adjacent to both ends of the cylindrical tube to prevent the aerosol-generating material 3 from falling out of the first and second ends of the tube, respectively. The tube may be formed from a sheet material such as paper or foil. The tube may be a cardboard tube or plastic (e.g., injection molded). In some embodiments, the tube may be connected to the first and second blocking members 4, 5 by packaging material surrounding the tube and the first and second blocking members 4, 5.

[0218] In some embodiments, the first and second blocking members 4, 5 are plastic-free. This makes article 1 more environmentally friendly and is also advantageous in embodiments where the entire article 1 is heated by an aerosol delivery device 200 (as described later). In some embodiments, the first and second blocking members 4, 5 are cellulose acetate-free.

[0219] In some embodiments, Article 1 as a whole does not contain plastic. In some embodiments, Article 1 as a whole does not contain cellulose acetate.

[0220] In this example, the material bodies 6 and 7 of the first and second blocking members 4 and 5 are gas permeable. Therefore, in an embodiment where the first blocking member 4 is upstream of the second blocking member 5 during the use of article 1 in the apparatus 200, the gas can pass through the material body 6 of the first blocking member 4, through the aerosol-generating material 3, and then through the material body 7 of the second blocking member 5 for inhalation by the user. Alternatively, in an embodiment where the first blocking member 4 is downstream of the second blocking member 5 during the use of article 1 in the apparatus 200, the gas can pass through the material body 7 of the second blocking member 5, through the aerosol-generating material 3, and then through the material body 6 of the first blocking member 4 for inhalation by the user.

[0221] In this embodiment, the first material body 6 of the first blocking member 4 is a material plug, and the second material body 7 of the second blocking member 5 is a material plug.

[0222] In this embodiment, the first blocking member 4 includes the aerosol-generating material 11, and the second blocking member 5 includes the aerosol-generating material 12. In this example, the first material body 6 of the first blocking member 4 includes the aerosol-generating material 11, and the second material body 7 of the second blocking member 5 includes the aerosol-generating material 12. In this example, the first material body 6 is a plug for the aerosol-generating material 11, and the second material body 7 is a plug for the aerosol-generating material 12. In other embodiments, it should be noted that one or both of the first and second blocking members 4 and 5 do not contain the aerosol-generating material.

[0223] The advantage of the first and / or second blocking members 4 and 5, which include aerosol-generating materials 11 and 12, is that the first and / or second blocking members 4 and 5 can prevent the aerosol-generating material 3 from falling from the space 2, and the first and / or second blocking members 4 and 5 themselves can also generate aerosols, thereby saving space and material compared to arrangements that have separate blocking members and further aerosol-generating regions. In addition, the aerosol-generating materials 11 and 12 of the first and / or second blocking members 4 and 5 can be provided with one or more properties that differ from the aerosol-generating material 3 in the space 2.

[0224] In some embodiments, the aerosol-generating materials 11, 12 of the first and / or second blocking members 4, 5 may contain tobacco material, consist of tobacco material, or consist essentially of tobacco material. As stated above, the term “tobacco material” refers to any material including tobacco or its derivatives or substitutes. The tobacco material may be in any suitable form. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of crushed tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco pulp, reconstituted tobacco, and / or tobacco extracts.

[0225] In some embodiments, the material bodies 6, 7 of the first and / or second blocking members 4, 5 additionally or alternatively include one or more aerosol-forming materials. For example, the first and / or second material bodies 6, 7 may additionally or alternatively include one or more components that can form an aerosol. The aerosol-forming material includes one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzylphenyl acetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The aerosol-forming material may be glycerol or propylene glycol.

[0226] The first material body 6 of the first blocking member 4 includes a first end 6A that faces the space 2 and is in contact with the aerosol-generating material 3 in the space 2. The first material body 6 has a second end 6B that faces outward from the space 2. In this example, the second end 6B constitutes the first end 1A of article 1 (i.e., no components of article 1 are provided on the side of the first material body 6 opposite to the space 2).

[0227] The second material body 7 of the second blocking member 5 includes a first end 7A that faces the space 2 and contacts the aerosol-generating material 3 in the space 2. The second material body 7 has a second end 7B that faces outward from the space 2. In this example, the second end 7B constitutes the second end 1B of article 1 (i.e., no components of article 1 are provided on the side of the second material body 7 opposite to the space 2).

[0228] The first and second ends 1A and 1B of article 1 are located at the outer ends of article 1. One of the first and second ends 1A and 1B is the upstream end P of article 1, and the other of the first and second ends 1A and 1B is the downstream end D of article 1.

[0229] The aerosol-generating material 3 may be provided in space 2 as loose material held in space 2 by first and second blocking members 4, 5. The aerosol-generating material 3 may also be, for example, separate strands or particles of the aerosol-generating material 3. Another example of loose aerosol-generating material 3 is beads / pellets of the aerosol-generating material 3, which include aerosol-generating material that has been extruded and then cut into beads / pellets. Yet another example of the aerosol-generating material 3 is a sheet of aerosol-generating material that has been cut into individual pieces, for example, individual strips of the aerosol-generating material 3. The sheet of aerosol-generating material may also be a sheet of reconstituted tobacco.

[0230] The aerosol-generating material 3 in space 2 may be called the first aerosol-generating material 3. In embodiments where the material body 6 of the first blocking member 4 includes the aerosol-generating material 11, this may be called the second aerosol-generating material 11. In embodiments where the material body 7 of the second blocking member 5 includes the aerosol-generating material 12, this may be called the third aerosol-generating material 12. Note that the first, second, and / or third aerosol-generating materials 3, 11, and 12 may be the same.

[0231] Article 1 may include first, second, and third regions 3A, 11A, and 12A, each containing first, second, and third aerosol-generating materials 3, 11, and 12, respectively. The first, second, and third regions 3A, 11A, and 12A may be discrete regions.

[0232] In some embodiments, the first aerosol-generating material 3 has at least one different property from the second and / or third aerosol-generating materials 11, 12. The different property may be one or more of the forms, sizes, densities, water content, quantities (by weight), one or more materials, or proportions of materials used to produce the first, second, and third aerosol-generating materials 3, 11, 12 (including recipes for aerosol-generating materials 3, 11, 12 when each produces two or more materials). In preferred embodiments, the second and third aerosol-generating materials 11, 12 are the same, and the first aerosol-generating material has the at least one different property from the second and third aerosol-generating materials 11, 12. In other embodiments, the first, second, and third aerosol-generating materials 3, 11, 12 do not have different properties and are instead the same.

[0233] In some embodiments, the first, second, and / or third aerosol-generating materials 3, 11, 12 may include the same material having different properties, such as tobacco. In one such embodiment, the first, second, and / or third aerosol-generating materials 3, 11, 12 may be in different forms, preferably the second and third aerosol-generating materials 11, 12 having different forms from the first aerosol-generating material 3.

[0234] For example, the first aerosol-generating material 3 may be in the form of beads or pellets of the aerosol-generating material (e.g., tobacco or another material), and the second and / or third aerosol-generating materials 11, 12 may be in the form of strands or strips of the aerosol-generating material (e.g., tobacco or another material), sheets of aerosol-generating material bundled into a plug or cut into strips, loose material (e.g., cut rag tobacco), high-density ends of a rod of aerosol-generating material (e.g., tobacco), or tobacco leaf pulp and / or stem material formed within a plug. However, it should be noted that the first, second and / or third aerosol-generating materials 3, 11, 12 may alternatively have the same form (e.g., both being cut coarse tobacco) and have some other different properties (e.g., materials of different densities).

[0235] In some embodiments, the first, second, and / or third aerosol-generating materials 3, 11, 12 can release one or more volatile compounds at different rates when heated. This allows for more consistent delivery of the compounds over the duration of the consumption session of article 1. For example, the second aerosol-generating material 11 can reach a given temperature more quickly than the first aerosol-generating material 3 when heated by a specific heater power. This allows the second aerosol-generating material 11 to initially release volatile compounds at a faster rate than the first aerosol-generating material 3. In such an embodiment, the second aerosol-generating material 11 may provide the release of volatile compounds during a first period of the consumption session, and the first aerosol-generating material 3 may provide the release of volatile compounds during a second period after the consumption session. In such an embodiment, the second aerosol-generating material 11 is heated during the first period, and the first aerosol-generating material 3 is heated during the second period of the consumption session. Alternatively, or additionally, the third aerosol-generating material 12 can reach a given temperature more quickly than the first aerosol-generating material 3 when heated by a specific heater power. This allows the second aerosol-generating material 11 to initially release volatile compounds at a faster rate than the first aerosol-generating material. In some embodiments, the second and third aerosol-generating materials 11, 12 can release volatile compounds at the same or substantially the same rate when heated to a given temperature.

[0236] In some embodiments, the first aerosol-generating material 3 initially releases one or more volatile compounds at a faster rate than the second aerosol-generating material 11 when exposed to a given heating force. In other embodiments, the first aerosol-generating material 3 releases one or more volatile compounds at a slower rate than the second aerosol-generating material 11 when exposed to a given heating force.

[0237] In addition, or alternatively, in some embodiments, the first aerosol-generating material 3 releases one or more volatile compounds at a faster rate than the third aerosol-generating material 12 when exposed to a given heating force. In other embodiments, the first aerosol-generating material 3 releases one or more volatile compounds at a slower rate than the third aerosol-generating material 12 when exposed to a given heating force.

[0238] In one embodiment, the first, second, and / or third aerosol-generating materials 3, 11, 12 may include beads / pellets of aerosol-generating material that are known to release volatile compounds at a relatively slow rate. In some such embodiments, the other of the first, second, and / or third aerosol-generating materials 3, 11, 12 includes one or more of tobacco leaf pulp, tobacco stalks, or reconstituted tobacco. In one such embodiment, the other aerosol-generating material of the first, second, and / or third aerosol-generating materials 3, 11, 12 includes a mixture of tobacco leaf pulp and reconstituted tobacco.

[0239] In this example, the first aerosol-generating material 3 includes tobacco beads, and the second and third aerosol-generating materials 11 and 12 include other tobacco materials, such as tobacco pulp, reconstituted tobacco, or a mixture of tobacco pulp and reconstituted tobacco.

[0240] In other embodiments, the first, second, and third aerosol-generating materials 3, 11, and 12 are the same.

[0241] Advantageously, the material body 6 of the first blocking member 4 is positioned to prevent the aerosol-generating material 3 from falling from the first end 2A of the space 2. This reduces the size and weight of article 1, as well as the amount of material required to manufacture article 1, because article 1 does not require any further components (e.g., separate blocking members) to prevent the aerosol-generating material 3 from falling from the first end 2A of the space 2.

[0242] Furthermore, the first material body 6 can perform additional functions of article 1 in addition to holding the aerosol-generating material 3 in space 2. In this example, the first material body 6 includes an aerosol-generating material 11, and therefore the first material body 6 performs both the function of holding the aerosol-generating material 3 in space 2 and the function of releasing one or more volatile compounds when heated. Similarly, the first material body 6 may optionally or additionally include an aerosol-forming material, and therefore, in addition to holding the aerosol-generating material 3 in space 2, it may perform the function of forming an aerosol. In other embodiments, the first material body 6 may include a filter (e.g., paper bundled on a plug) that, in addition to holding the aerosol-generating material 3 in space 2, performs the function of filtering the gas flow as it passes through article 1.

[0243] Advantageously, the material body 7 of the second blocking member 5 is positioned to prevent the aerosol-generating material 3 from falling from the second end 2B of the space 2. This reduces the size and weight of article 1, as well as the amount of material required to manufacture article 1, because article 1 does not require any further components (e.g., separate blocking members) to prevent the aerosol-generating material 3 from falling from the second end 2B of the space 2.

[0244] Furthermore, the second material body 7 can perform additional functions of article 1 in addition to holding the aerosol-generating material 3 in space 2. In this example, the second material body 7 includes the aerosol-generating material 12, and therefore the second material body 7 performs both the function of holding the aerosol-generating material 3 in space 2 and the function of releasing one or more volatile compounds when heated. Similarly, the second material body 7 may optionally or additionally include an aerosol-forming material, and therefore, in addition to holding the aerosol-generating material 3 in space 2, it also performs the function of forming an aerosol. In other embodiments, the second material body 7 may include a filter (e.g., paper bundled on a plug) that, in addition to holding the aerosol-generating material in space 2, also performs the function of filtering the gas flow passing through article 1.

[0245] In other embodiments (not shown), the second blocking member 5 may not include a second material body 7, and may instead include, for example, a mesh, sheet material, or label applied to the second end of the space 2 to prevent the aerosol-generating material 3 from falling from the second end 2B of the space 2 (e.g., the sheet material / label may include one or more openings to allow gas flow through it). In some embodiments (not shown), the second blocking member 5 may be omitted entirely. However, it has been found that the first and second blocking members 4, 5, each including their respective material bodies 6, 7, can be held in place relative to the space 2 relatively easily by, for example, using a sheet material 10 surrounding the first and second blocking members 4, 5.

[0246] The first, second, and / or third aerosol-generating materials 3, 11, and 12 may comprise multiple strands or strips of aerosol-generating material. For example, the first, second, and / or third aerosol-generating materials 3, 11, and 12 may comprise multiple strands or strips of aerosolizable material and / or multiple strands or strips of amorphous solid.

[0247] The first, second, and / or third aerosol-generating materials 3, 11, and 12 may include plant-based materials such as tobacco material. The first, second, and / or third aerosol-generating materials 3, 11, and 12 may be sheets or shredded sheets of aerosolizable material containing plant-based materials such as tobacco material.

[0248] The plant-based material may be granular or a granular material. 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.

[0249] The tobacco material of the first, second, and / or third aerosol-generating materials 3, 11, 12 may include tobacco obtained from any part of the tobacco plant. In some embodiments, the tobacco material includes tobacco leaves.

[0250] A sheet or shredded sheet can contain 5% to approximately 90% tobacco leaves by weight.

[0251] In some embodiments, all of the first, second, and third aerosol-generating materials 3, 11, and 12 contain, consist of, or are essentially made of tobacco material.

[0252] The aerosol-forming material may be mixed with or otherwise added to the first, second, and / or third aerosol-forming materials 3, 11, and 12. The aerosol-forming material comprises one or more components capable of forming an aerosol. The aerosol-forming 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, diacetin mixture, benzyl benzoate, benzylphenyl acetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The aerosol-forming material may also be glycerol or propylene glycol.

[0253] In some embodiments, the first, second, and / or third aerosol-forming materials 3, 11, 12 comprise a sheet or shredded sheet of an aerosolizable material containing the aerosol-forming material. Optionally, the aerosol-forming material is provided in an amount up to about 50% of the dry weight of the sheet or shredded sheet. In some embodiments, the aerosol-forming material is provided in an amount of about 5% to about 40% of the dry weight of the sheet or shredded sheet, about 10% to about 30% of the dry weight of the sheet or shredded sheet, or about 10% to about 20% of the dry weight of the sheet or shredded sheet.

[0254] The first, second, and / or third aerosol-generating materials 3, 11, 12 may include fillers. In some embodiments, a sheet or shredded sheet includes a filler. The filler is generally a non-tobacco component, i.e., a component that does not contain tobacco-derived components. The filler may include one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and a suitable inorganic adsorbent, such as molecular sieves. The filler may be a non-tobacco fiber such as wood fiber or pulp or wheat fiber. The filler may be a cellulose-containing material or a cellulose derivative. The filler component may also be a non-tobacco cast material or a non-tobacco extruded material.

[0255] The first, second, and / or third aerosol-generating materials 3, 11, and 12 of this specification may include aerosol modifiers such as any of the fragrances described herein. In one embodiment, the first, second, and / or third aerosol-generating materials 3, 11, and 12 include menthol. When the first, second, and / or third aerosol-generating materials 3, 11, and 12 are incorporated into article 1 for use in an aerosol-providing system, the article may be called mentrate article 1. The first, second, and / or third aerosol-generating materials 3, 11, and 12 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.

[0256] In some embodiments, article 1 comprises an aerosol-generating composition comprising an aerosol-generating material. The aerosol-generating material may include first, second, and / or third aerosol-generating materials 3, 11, and 12.

[0257] Aerosol-generating materials are materials that can generate aerosols when heated, irradiated, or electrically charged by other means, for example. The aerosol-generating materials (e.g., the first, second, and / or third aerosol-generating materials 3, 11, 12) 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.

[0258] The aerosol-generating materials (e.g., the first, second, and / or third aerosol-generating materials 3, 11, and 12) may include binders and aerosol-forming agents. Optionally, active substances and / or fillers may also be present. Optionally, a solvent such as water may also be present, and one or more other components of the aerosol-generating materials may or may not be soluble in the solvent. In some embodiments, the aerosol-generating materials (e.g., the first, second, and / or third aerosol-generating materials 3, 11, and 12) are substantially free of plant materials. In particular, in some embodiments, the aerosol-generating materials (e.g., the first, second, and / or third aerosol-generating materials 3, 11, and 12) are substantially free of tobacco.

[0259] The aerosol-generating material (e.g., the first, second, and / or third aerosol-generating materials 3, 11, 12) may include or may be an "amorphous solid". The amorphous solid may 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% by weight, 60% by weight, or 70% by weight of amorphous solid, or about 90% by weight, 95% by weight, or 100% by weight of amorphous solid. The amorphous solid may be substantially non-fibrous.

[0260] The aerosol-generating material (e.g., the first, second, and / or third aerosol-generating material 3, 11, 12) may include an aerosol-generating film. The aerosol-generating film can 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 to form an aerosol-generating film. The slurry may be heated to remove at least about 60% by weight, 70% by weight, 80% by weight, 85% by weight, or 90% by weight of the solvent. The aerosol-generating film may be a continuous film or a discontinuous film, such as by arranging discontinuous portions of the film on a support. The aerosol-generating film may not substantially contain tobacco.

[0261] The aerosol-generating film may include or may contain sheets that can be optionally shredded to form shredded sheets.

[0262] The aerosol-generating material (e.g., the first, second, and / or third aerosol-generating materials 3, 11, 12) may comprise one or more active substances and / or fragrances, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0263] In each embodiment of Article 1 described herein, the Article may include such first, second, and / or third aerosol-generating materials 3, 11, 12, and may also include such aerosol-generating compositions.

[0264] The first, second, and / or third aerosol-forming materials 3, 11, 12 may include tobacco material reconstituted with paper. The composition may, alternatively or additionally, include any of the forms of tobacco described herein. The first, second, and / or third aerosol-forming materials 3, 11, 12 may include a sheet or shredded sheet containing tobacco material comprising 10% to 90% by weight of tobacco leaves, wherein the aerosol-forming material is provided in an amount up to about 20% by weight of the sheet or shredded sheet, and the remainder of the tobacco material comprises tobacco reconstituted with paper.

[0265] If the first, second, and / or third aerosol-generating materials 3, 11, and 12 include an amorphous solid material, the amorphous solid material may be a dry gel containing menthol.

[0266] In some embodiments, the first, second, and / or third aerosol-generating materials 3, 11, 12 include an extruded aerosol-generating material which is then cut into pellet beads.

[0267] In this example, the first aerosol-generating material 3 (i.e., provided within space 2) comprises tobacco beads, the second aerosol-generating material 11 (i.e., of the first material body 6) comprises tobacco pulp and / or a plug of shredded reconstituted tobacco, and the third aerosol-generating material 12 (i.e., of the second material body 7) comprises tobacco pulp and / or a plug of shredded reconstituted tobacco.

[0268] In the embodiments described above, the material bodies 6, 7 of the first and / or second blocking members 4, 5 include plugs of aerosol-generating material 11, 12, such as plugs of tobacco fibers, or strips of reconstituted tobacco, or sheets of reconstituted tobacco bundled into plugs. In one embodiment, the material bodies 6, 7 of the first and / or second blocking members 4, 5 are formed from crimped sheets of aerosol-generating material (e.g., reconstituted tobacco). Apparatus and methods for producing crimped webs for use in aerosol product 1 are known in the art and generally involve feeding a web or sheet between a pair of interleaved rollers that apply a plurality of parallel and equidistant longitudinally extending crimped corrugations to the web or sheet. Once crimped, the sheets or webs are bundled to form a continuous rod.

[0269] In some embodiments, the material bodies 6, 7 of the first and / or second blocking members 4, 5 are formed from material sheets having aerosol-generating material 11, 12 added during the casting of the sheet. For example, the sheet material can be cast from a slurry, and the aerosol-generating material (e.g., tobacco fibers, granules, pellets, beads, or dust, including fibers, granules, pellets, beads, or dust, and / or other plant materials) is added to the slurry during casting. In other embodiments, the aerosol-generating material is added to the sheet material once the sheet material is formed. For example, the aerosol-generating material (e.g., tobacco fibers, granules, pellets, beads, or dust, including fibers, granules, pellets, beads, or dust, and / or other plant materials) is bonded to the sheet material using an adhesive or applied to the sheet material and retained within the sheet material when bundled into a plug. In some embodiments, the sheet material includes paper or a gel sheet, and the aerosol-generating material is incorporated into the sheet or applied to the sheet.

[0270] In other embodiments, it should be noted that the material bodies 6, 7 of the first and / or second blocking members 4, 5 do not contain aerosol-generating material. For example, in an alternative embodiment, the material bodies 6, 7 of the first and / or second blocking members 4, 5 include paper formed on the plug (e.g., crimped or cut into strips and formed on the plug) without aerosol-generating material applied to or incorporated into the sheet material of the plug.

[0271] An example of a blocking member including sheet material is shown in Figure 9. In Figure 9, the first blocking member 4 is shown, but additionally or alternatively, the second blocking member 5 may have the configuration shown in Figure 9.

[0272] In the embodiment shown in Figure 9, the material body 6 of the first blocking member 4 includes a sheet material 11B bundled to form the material body 6. The first blocking member 4 may have any of the features described above. For example, the sheet material 11B may include an aerosol-generating material 11 and / or an aerosol-forming material (the aerosol-generating material and / or aerosol-forming material is formed in the sheet material during the manufacture of the sheet material or subsequently applied to the sheet material). In one embodiment, the sheet material 11B includes an aerosol-generating material. In some embodiments, the sheet material 11B includes a tobacco material and / or a gel. In one embodiment, the sheet material 11B includes paper. The sheet material may be crimped and bundled to form a plug. In other embodiments, the sheet material may be rolled up (e.g., spirally) to form the material body 6. In yet another embodiment, the sheet material 11B may be cut into strips and / or strands and then formed into the material body 6. In some embodiments, the first blocking member 4 further comprises a packaging material 8 surrounding the material body 6.

[0273] The material body 6 prevents the aerosol-generating material 3 in space 2 from falling from the edge of space 2.

[0274] Another example of the blocking member 4 is shown in Figure 10. Although the first blocking member 4 is shown in Figure 10, the second blocking member 5 may have the configuration shown in Figure 10 in addition to or instead of this.

[0275] In the embodiment shown in Figure 10, the first blocking member 4 includes an end portion 17 of the material body 6, which is in the form of a rod 6 of the aerosol-generating material 11. Optionally, the end portion 17 of the rod 6 has a higher density than another portion 18 of the rod 6. For example, the end portion 17 may be at least 10%, preferably at least 20%, denser than the other portion 18 of the rod 16 (and the other portion 18 may be adjacent to the end portion 17).

[0276] In some embodiments, the rod 6 is a cigarette rod. In some embodiments, the other portion 18 of the rod 6 is the remaining length of the rod 6. The end portion 17 may extend a first region along the length of the rod 6, and the other portion 18 may extend a second region along the length of the rod 6, which may be the remaining axial length of the rod 6.

[0277] In some embodiments, article 1 comprises packaging material 8 surrounding a rod 6.

[0278] The increased density of the end portion 17 of the rod 6 helps prevent the aerosol-generating material 3 from falling out of the space 2. Furthermore, the increased density of the end portion 17 of the rod 6 also helps prevent the material of the end portion 17 from detaching from the end portion 17 and mixing with the aerosol-generating material 3 in the space 2.

[0279] In some embodiments, the end portion 17 of the rod 6 comprises a greater amount of material per unit axial length of the rod 6 (for example per mm) than said further portion 18. That is, the end portion of the rod 17 has a greater mass of material per unit axial length (for example per mm) than said further portion 18. For example, the end portion 17 comprises a greater amount of aerosol-generating material 11, aerosol-forming material, filler material and / or other material. Accordingly, when the aerosol-generating material 11 is formed into the rod 6 (for example using a rod-forming apparatus as known to the person skilled in the art), the increased amount of material in the end portion 17 means that the rod 6 has an increased density at the end portion 17 compared to said further portion 18 of the rod 6. In some embodiments, the end portion 17 of the rod 16 comprises at least 10% by weight, preferably at least 20% by weight, more material per mm length of the rod 16 than said further portion 18 of the rod 16.

[0280] According to the present disclosure, there is also provided a method of manufacturing an article 1 for an aerosol provision device 200. The method comprises providing an aerosol-generating material 3 and a first blocking member 4 comprising a material body 6, wherein the aerosol-generating material 3 and the first blocking member 4 are arranged such that the aerosol-generating material 3 is accommodated in the space 2, and the first blocking member 4 prevents movement of the aerosol-generating material 3 out of the first end 2A of the space 2 (for example, prevents falling out from ~).

[0281] The first blocking member 4 may have any of the features described herein.

[0282] The method may further comprise wrapping a first wrapping material 8 around the material body 6 of the first blocking member 4.

[0283] In some embodiments, providing an aerosol-generating material 3 and a first blocking member 4 involves arranging the aerosol-generating material 3 and the first blocking member 4 on a sheet material 10, preferably the sheet material 10 comprising paper and / or foil. In some embodiments, the method involves winding the sheet material 10 around the aerosol-generating material 3 and the first blocking member 4.

[0284] In some embodiments, the method further includes providing a second blocking member 5 positioned to prevent the aerosol-generating material 3 from moving away from the second end 2B of the space 2 (e.g., falling out of it), preferably the second blocking member 5 includes a material body 7.

[0285] In some embodiments, the second blocking member 5 has any of the features described herein, which include any of the features of the first blocking member 4.

[0286] In some embodiments, the first and second blocking members 4 and 5 each define at least partially the boundary of the space 2.

[0287] In some embodiments, the first and / or second blocking members 4, 5 are separate from and distinct from the sheet material 10.

[0288] In some embodiments, the method includes the steps of forming a material body 6 and optionally packaging the material body 6 in a first packaging material 8.

[0289] In some embodiments, the material body 6 of the first blocking member 4 is a cigarette plug 6, and the first packaging material 8 surrounds the cigarette plug 6.

[0290] In some embodiments, the method includes the steps of forming a material body 7 and optionally packaging the material body 7 in a second packaging material 9.

[0291] In some embodiments, the material body 7 of the second blocking member 5 is a cigarette plug 7, and the second packaging material 9 surrounds the cigarette plug 7.

[0292] In some embodiments, the material bodies 6, 7 of the first and / or second blocking members 4, 5 are gas permeable.

[0293] In some embodiments, the first and second blocking members 4, 5 have the same form and / or composition.

[0294] In some embodiments, the first and second blocking members 4 and 5 may have the same characteristics and be identical.

[0295] In some embodiments, the first and second blocking members 4 and 5 each include a cigarette, preferably each including a cigarette plug.

[0296] In some embodiments, the first blocking member 4 includes the first end 1A of the article 1, and the second blocking member 5 includes the second end 1B of the article 1.

[0297] In some embodiments, the method includes wrapping the second packaging material 9 around the material body 7 of the second blocking member 5.

[0298] It should be noted that in other embodiments, the first and / or second packaging materials 8, 9 may be omitted.

[0299] In some embodiments, the method includes arranging first and second blocking members 4 and 5 on a sheet material 10 so that a gap G is formed between them, and at least partially filling the gap G with an aerosol-generating material 3.

[0300] In some embodiments, the sheet material 10 on which the first and second blocking members 4 and 5 are placed is transported along a transport path.

[0301] In some embodiments, when the sheet material 10 carrying the first and second blocking members 4, 5 passes through a filling device, the gap G is at least partially filled with aerosol-generating material 3.

[0302] In some embodiments, the method comprises the steps of: providing a plurality of first blocking members 4 and second blocking members 5 sequentially arranged on a web W of sheet material 10; and filling the gap G between adjacent first blocking members 4 and second blocking members 5 with aerosol-generating material 3.

[0303] In some embodiments, the method comprises the steps of: wrapping the first and second blocking members 4, 5 and the aerosol-generating material 3 with the sheet material 10 to form a rod, and then cutting the rod to form the article 1.

[0304] In some embodiments, the method comprises forming the sheet material 10 into a wall 10A surrounding the space 2 that accommodates the aerosol-generating material 3.

[0305] In some embodiments, the aerosol-generating material 3 in the space is a solid material.

[0306] In some embodiments, the aerosol-generating material 3 in the space is a bulk material.

[0307] In some embodiments, the aerosol-generating material 3 in the space is in the form of discrete particles.

[0308] In some embodiments, the aerosol-generating material 3 is provided in metered amounts using, for example, a dosing wheel that supplies the aerosol-generating material 3 onto the sheet material 10.

[0309] In some embodiments, the aerosol-generating material 3 in the space comprises tobacco material, consists of tobacco material, or consists essentially of tobacco material. In some embodiments, the tobacco material is only tobacco mesophyll, and is not other types of tobacco material.

[0310] In some embodiments, the tobacco material has a nicotine level in the range of 0.6% to 2.5%, preferably in the range of 1% to 2.1%.

[0311] In some embodiments, the method further includes providing a cooling section and, preferably, positioning the cooling section downstream of the aerosol-generating material 3 when the article 1 is in use. In some embodiments, the cooling section includes the aerosol-generating material, preferably including a plug for the aerosol-generating material. In some embodiments, the cooling section includes a flavoring, for example, the aerosol-generating material of the cooling section may include a flavoring. The cooling section may include a gel, for example, a gel plug.

[0312] In some embodiments, the method further includes the step of providing a material plug or other component in the space 2 on the other side of the first and / or second blocking members 4, 5.

[0313] Referring now to Figure 5, a block diagram is shown illustrating an exemplary embodiment of a method 100 for manufacturing article 1 for an aerosol dispensing device.

[0314] Method 100 includes the step (S1) of positioning the first and second blocking members 4 and 5 on the sheet material 10 such that the first and second blocking members 4 and 5 are spaced apart in the axial direction to form a gap G between them. Method 100 includes the step (S2) of providing the aerosol generating material 3 in the gap G between the first and second blocking members 4 and 5. Method 100 includes the step (S3) of wrapping the sheet material 10 around the aerosol generating material 3 and the first and second blocking members 4 and 5 such that the sheet material 10 forms a wall surrounding the aerosol generating material and the first and second blocking members 4 and 5.

[0315] Optionally, method 100 may include manufacturing a plurality of articles 1 according to a continuous process.

[0316] Step (S1) may include providing a plurality of double-length first blocking members 104 and a plurality of double-length second blocking members 105 on the web W of the sheet material 10, thereby the double-length first and second blocking members 104, 105 are alternately arranged on the sheet material 10 with gaps G between adjacent double-length first and second blocking members 104, 105. Step (S1) is shown in Figure 7A. Each gap G forms a space 2 that is filled, or at least partially filled, with the aerosol-generating material 3.

[0317] Step (S2) may include providing aerosol-generating material 3 into a plurality of gaps G. For example, the web W may be conveyed along a transport path P such that each gap G passes through a filling device F, which provides the aerosol-generating material 3 to each gap G as it passes through. The filling device F may include, for example, a hopper, conveyor belt, pneumatic pipe supply system, or filling drum configured to provide the aerosol-generating material 3 to each gap G. In some embodiments, sections of the web W passing through the filling device F may be bundled into a U-shaped tongue or garnish that bends the sheet material 10 to help collect the aerosol-generating material 3 into the gaps G. Step (S2) is shown in Figures 7B and 8.

[0318] Step (S3) may include winding the sheet material 10 of the web W around first and second blocking members 104, 105 that are twice the length of the ends (i.e., the two furthest forwards) after the aerosol generating material 3 has been supplied in between to form the rod 106. For example, the ends of the web W and the first and second blocking members 104, 105 that are twice the length of the ends may be supplied through a packaging device, as is known to those skilled in the art. Step (S3) is shown in Figure 7C.

[0319] A packaging device (not shown) may comprise, for example, a garnisher tongue (not shown), a garnisher belt (not shown), and a belt drive (not shown) for driving the garnisher belt (not shown). The belt drive may comprise, for example, one or more pulleys or wheels driven by an electric motor to drive the garnisher belt. The garnisher belt extends through the garnisher tongue. The web W overlaps the garnisher belt so that the operation of the belt drive feeds the web W through the garnisher tongue. The garnisher tongue comprises a first portion (not shown) shaped to form a U-shape as the web W passes through the garnisher tongue. Optionally, the filling device F is configured to deposit the aerosol-generating material 3 on the U-shaped web W between adjacent double-length plugs 104, 105. In an alternative embodiment, the aerosol-generating material 3 is deposited on the web W at a different location, for example, upstream of the first portion of the garnisher tongue.

[0320] Next, the U-shaped web W passes through a second portion (not shown) of the garnisher tongue, which is formed such that a first longitudinal edge (not shown) of the web W folds over a second longitudinal edge (not shown) on the opposite side, so that the web W exiting the garnisher tongue is formed in a cylindrical shape. In some embodiments, the first portion of the garnisher tongue has a substantially U-shaped cross-section, and the second portion of the garnisher tongue has a substantially O-shaped cross-section.

[0321] In some embodiments, the packaging apparatus further comprises an adhesive applicator (not shown) configured to apply an adhesive line to the web W such that as the web W passes a second portion (not shown) of the garnish tang, the first longitudinal edge folds over the second longitudinal edge on the opposite side of the web W and is bonded in place by the adhesive line. Thus, a continuous rod 106 is formed, comprising first and second length-restricting members 4, 5, with the aerosol-generating material 3 in the gap G between them, surrounded by the web W.

[0322] In alternative embodiments (not shown), the packaging apparatus has a different arrangement, for example, comprising a drum or conveyor belt configured to advance the length-reducing members 104, 105 and the web W along a transport path. In one such embodiment, the length-reducing members 104, 105 are positioned on the packaging material located in grooves of a drum that rotates to move the reducing members and the packaging material along an arc-shaped transport path. The first / second filling material is supplied to the packaging material between the length-reducing members as the drum rotates to move the packaging material and the length-reducing members along the transport path.

[0323] Method 100 may further include the step of cutting a continuous rod 106 to form article 1. First, the continuous rod 106 has a double-length first stopper member 104 and a double-length second stopper member 105, the double-length first stopper member 104 is cut along a first cutting line (shown as dashed line Y1-Y1 in Figure 7C), and the double-length second stopper member 105 is cut along a second cutting line (shown as dashed line Y2-Y2 in Figure 7C). Subsequently, the continuous rod 106 has a single first stopper member 4 or a second stopper member 5 at its end (as shown in Figure 7D), thereby providing a single cut through adjacent double-length first stopper members 104, 105 or second stopper members to form article 1.

[0324] In some embodiments, the rod 106 is formed continuously, and the ends of the rod 106 are repeatedly cut to form multiple articles 1.

[0325] In some embodiments, the rod 106 is cut to form matching first and second blocking members 104, 105 of double length. The matching members are then further cut to form individual articles 1.

[0326] In the example described above, method 100 includes the step of providing double-length first and second blocking members 104, 105 on the sheet material 10. However, it should be noted that in alternative embodiments, method 100 may include the steps of providing single-length blocking members 4, 5 on the sheet material 10 with a gap G between them, and filling the gap G with an aerosol-generating material 3. For example, Figure 6A shows the first and second blocking members 4, 5 positioned on the sheet material 10, Figure 6B shows the aerosol-generating material 3 provided on the sheet material 10 in the space 2 between the first blocking member 4 and the second blocking member 5, and Figure 6C shows the sheet material 10 wrapped around the first and second blocking members 4, 5 to form an article 1.

[0327] In some embodiments, method 100 further includes providing a cooling section and incorporating the cooling section into an article, preferably the cooling section being positioned downstream of the blocking members 4, 5 when the article 1 is in use. In some embodiments, the cooling section includes an aerosol-generating material, preferably a plug of the aerosol-generating material. In some embodiments, the cooling section includes a flavoring, for example, the aerosol-generating material of the cooling section may include a flavoring. The cooling section may include a gel, for example, a gel plug.

[0328] In some embodiments, the first blocking member 4 is located upstream of space 1 when article 1 is being used in the aerosol dispenser 200. In other embodiments, the first blocking member 4 is located downstream of space 1.

[0329] In some embodiments, method 100 further includes providing space 2 with one or more additional plugs of material (not shown) or other components on the other side of the first and / or second blocking members 4, 5. The additional material plugs may include, for example, sections of filtering material or cooling sections and / or fragrance sections.

[0330] Referring to Figures 11 to 13, one embodiment of the aerosol dispensing device 200 is shown.

[0331] Article 1 is configured for use in an aerosol dispensing device 200 (see Figure 11) 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 resistance heated and / or induction heated.

[0332] In other embodiments (not shown), the heating element 203 instead comprises a blade or pin for insertion into article 1, for example, the blade or pin may be inserted into one or both of the first and second blocking members 4, 5, and optimally also into the aerosol-generating material 3 in space 2. In other embodiments (not shown), article 1 may include a heating element that can be embedded, for example, in the aerosol-generating material 3 and / or the first and / or second blocking members 4, 5.

[0333] Figure 11 shows a simplified representation of the components of one embodiment of the aerosol dispensing device 200. In particular, the elements of the aerosol dispensing device 200 are not depicted to scale in Figure 11. Elements not relevant to understanding this embodiment have been omitted in order to simplify Figure 11.

[0334] In the example shown in Figure 11, the aerosol dispenser 200 is a non-combustible aerosol dispenser 200. The non-combustible aerosol dispenser 200 comprises a housing 201 including a region 202 for receiving article 1.

[0335] When article 1 is received within the heating region 202, at least a portion of article 1 is thermally close to the heater 203. Thus, at least a portion of the aerosol-generating material 3 and / or the aerosol-generating material 11, 12 of the first and / or second blocking members 4, 5 in space 2 is thermally close to the heater 203. In some embodiments, the heater 203 is spaced away from article 1, for example, externally tangent to article 1 but having a larger diameter and spaced away from it. In other embodiments, the heater 203 is in direct contact with article 1, for example, in contact with the outer surface of the packaging material 10 of article 1. In yet another embodiment, the heater 203 includes blades or pins that contact the interior of article 1, for example, in contact with the material bodies 6, 7 of the aerosol-generating material 3 and / or the first and / or second blocking members 4, 5 in space 2.

[0336] When article 1 is heated, the aerosol-generating material 3 and / or the aerosol-generating materials 11, 12 of the first and / or second blocking members 4, 5 in space 2 release one or more volatile compounds, and can release volatile compounds in a range of volatile compounds at different temperatures. By controlling the maximum operating temperature of the electrically heated aerosol-generating system 200, the selective release of undesirable compounds can be controlled by preventing the release of selected volatile compounds.

[0337] As shown in Figure 12, the housing 201 contains an electrical energy source 204, such as a rechargeable lithium-ion battery. The controller 205 is connected to the heater 203, the electrical energy source 204, and the user interface 206, such as buttons or a display. The controller 205 controls the power supplied to the heater to adjust its temperature. Typically, the aerosol-forming substrate is heated to a temperature of 250°C to 450°C.

[0338] Figure 13 is a schematic cross-sectional view of a non-combustible aerosol dispenser 200 of the type shown in Figure 11, in which article 1 is housed in a heating region 202 of the device 200 for heating by a heater 203. The non-combustible aerosol dispenser 200 is shown to receive the aerosol product 1 for consumption by a user.

[0339] The housing 201 of the non-combustion aerosol dispenser 200 defines a region 202 in the form of a cavity that opens at the proximal end (or inlet end) to receive the aerosol product 1 for consumption by the user.

[0340] In this example, the aerosol dispenser 200 includes a removable mouthpiece 207 from the rest of the device 200 to allow access to the region so that article 1 is of interest to the region 202 and can be removed from the region 202. Once article 1 is dispensed into the region 202, the mouthpiece 207 can be reattached. In some embodiments, the mouthpiece 207 is removablely attached to the housing 201 of the device 200, for example, by a screw thread or bayonet connection.

[0341] When the user inhales through the mouthpiece 207, air is drawn into the article 1, and volatile substances condense to form an inhalable aerosol. This aerosol passes through the mouthpiece 207 of the device 200 and enters the user's mouth.

[0342] It should be noted that in other embodiments, the mouthpiece 207 of the device 200 may be omitted. In some embodiments, article 1 can form a mouthpiece that can come into contact with the user's mouth.

[0343] In the embodiments described above, the first and second blocking members 4 and 5 form the first and second ends 1A and 1B of article 1 (i.e., the proximal end P or the distal end D). However, it should be noted that in alternative embodiments (not shown), article 1 may include one or more further segments, for example, further segments opposite the first blocking member 4 to space 2 and / or opposite the second blocking member 5 to space 2.

[0344] For example, Figure 14 shows an alternative embodiment of Article 1 further comprising a cooling section 25, also called a cooling element, positioned adjacent to the second blocking member 5 immediately downstream. In this example, the cooling element 25 is adjacent to the second blocking member 5 immediately downstream. In some such embodiments, the cooling element 25 is in contact with the second blocking member 5. Article 1 may additionally or alternatively include a further material body 26 downstream of the cooling element 25. The further material body 26 may include fragrance material and / or filtration material, and / or may be provided to obscure the view of the cooling element 25.

[0345] The cooling element 25 includes 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 include a single hollow channel. In an alternative embodiment, the cooling element 25 may include 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 can provide a space in which aerosols drawn into the cooling element 25 can expand and be cooled. The cooling element 25 may be configured during use to limit the cross-sectional area of ​​the hollow channel, thereby limiting the movement of tobacco into the cooling element 25.

[0346] The cooling element 25 may have a wall thickness in the radial direction. The wall thickness of the cooling element 25 defines the inner diameter of the chamber enclosed by the walls of the cooling element 25 with respect to a given outer diameter of the cooling element 25. The cooling element 25 may have a wall thickness of at least about 1.5 mm to about 2 mm. In this example, the cooling element 25 has a wall thickness of about 2 mm.

[0347] The cooling element 25 may be formed from a filamentous tow. To form the cooling element 25, other structures can be used, such as multiple layers of paper wound parallel to each other at butt joints, or helically wound layers of paper, cardboard tubes, tubes formed using a paper-mache process, or molded or extruded plastic tubes. 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.

[0348] 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 material 3 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 aerosol generating material 3 can pass longitudinally through one or more hollow channels.

[0349] The cooling element 25 can be configured to provide a temperature difference of at least 40°C 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 can be configured to provide a temperature difference of at least 60°C, or at least 80°C, or at least 100°C between the heated volatile 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 material body 26 from the high temperature of the aerosol-generating material 3 when heated.

[0350] The material body 26 defines a substantially cylindrical overall shape and is wrapped 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 a 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 a permeability of, for example, at least 100 cholesta units or at least 200 cholesta units.

[0351] The cooling element 25 and / or material body 26 can form a mouthpiece for article 1 configured to be received in the user's mouth. In some embodiments, the mouthpiece 207 of the device 200 may be omitted.

[0352] In some embodiments, chip paper (not shown) is wrapped around the cooling element 25 and the material body 26, and also surrounds the packaging material 10 surrounding the first and second blocking members 4, 5, and can be connected to these components by adhesive. Thus, the chip paper connects the cooling element 25 and the material body 26 to the blocking members 4, 5. In other embodiments, the chip paper is omitted, and instead, the sheet material 10 extends to surround the cooling element 25 and the material body 26 to connect these components to the first and second blocking members 4, 5.

[0353] In the embodiment of article 1 described above in relation to Figure 1, article 1 includes an aerosol-generating material along its entire axial length (indicated by the arrow "X" in Figure 1). That is, the first aerosol-generating material 3 extends over a first portion of the axial length of article 1, the second aerosol-generating material 11 extends over a first portion of the axial length of article 1, and the third aerosol-generating material 12 extends over a first portion of the axial length of article 1. The first, second, and third portions of the axial length of article 1 comprise the entire axial length of article 1.

[0354] The aerosol-generating materials 3, 11, and 12 extending along the entire length of article 1 have the advantage of increasing the amount of volatile compounds released by article 1 when article 1 is heated for an article 1 of a given size. This means that article 1 can be transported and stored more easily.

[0355] In the embodiment shown in Figure 1, the aerosol-generating materials 3, 11, and 12 extend along the entire axial length of article 1, but it should be noted that in other embodiments, the aerosol-generating material may extend over at least 90% of the article. Such arrangements have still been found to beneficially increase the release of volatile compounds compared to articles having aerosol-generating material provided over less than 90% of the axial length of the article. Preferably, the aerosol-generating material is provided over at least 92%, 94%, 96%, 98%, or 99% of the length of the article, and preferably over substantially the entire length of the article.

[0356] Three further embodiments of Article 1, which includes an aerosol-generating material along its entire length, are described below in reference to Figures 15-17.

[0357] Referring to Figure 15, an embodiment of Article 1 for an aerosol dispenser 200 is shown, comprising an aerosol-generating material 3 along the entire axial length of Article 1 (indicated by the arrow "X" in Figure 15). In particular, Article 1 includes a rod of the aerosol-generating material 3 extending from a first end 1A of Article 1 to a second end 1B of Article 1. In this example, the aerosol-generating material 3 includes tobacco material. In this example, the tobacco material is a mixture of mixed shredded reconstituted tobacco and shredded pulp tobacco. However, in other embodiments, the tobacco material may be one of shredded reconstituted tobacco or shredded pulp tobacco, or may include other tobacco materials substituted or additionally. A sheet material 10 surrounds the aerosol-generating material 3 and includes, for example, paper.

[0358] Referring to Figure 16, another embodiment of Article 1 for an aerosol-providing device 200 is shown, comprising aerosol-generating materials 31, 32 along the entire axial length of Article 1 (indicated by the arrow "X" in Figure 16). In particular, Article 1 includes a rod of first aerosol-generating material 31 extending from a first end 1A of Article 1 to a second end 1B of Article 1. Furthermore, Article 1 includes a second aerosol-generating material comprising compressed or extruded bodies of aerosol-generating material 31 scattered within the rod of first aerosol-generating material 32.

[0359] In this example, the first and / or second aerosol-generating materials 31, 32 include tobacco material.

[0360] In this example, the first aerosol generator 31 is a mixture of mixed shredded reconstituted tobacco and shredded pulp tobacco. However, in other embodiments, the tobacco material of the first aerosol generator material 31 may be either shredded reconstituted tobacco or shredded pulp tobacco, or it may contain other tobacco material.

[0361] In this example, the second aerosol generator 32 is compressed or extruded tobacco. In this example, the second aerosol generating material 32 is tobacco material beads.

[0362] The sheet material 10 surrounds the aerosol generating material 3 and includes, for example, paper.

[0363] Referring to Figure 17, another embodiment of Article 1 for an aerosol-providing device 200 is shown, comprising aerosol-generating materials 41, 42 extending along the entire axial length of Article 1 (indicated by the arrow "X" in Figure 17). In particular, Article 1 comprises a first body or rod of aerosol-generating material 41 extending over a first portion of the axial length of Article 1, and a second body or rod of aerosol-generating material 42 extending over the remaining second portion of the axial length of Article 1.

[0364] The first and second rods of the aerosol-generating materials 41 and 42 may contain the same or different aerosol-generating materials. In this example, the first and second rods of the aerosol-generating materials 41 and 42 each contain tobacco material. For example, the first rod of the aerosol-generating material 41 may contain shredded tobacco pulp, and the second rod of the aerosol-generating material 42 may contain shredded reconstituted tobacco material. However, the first or second rods 41 and 42 may, alternatively, contain different tobacco materials.

[0365] The sheet material 10 surrounds the aerosol generating material 3 and includes, for example, paper.

[0366] It should be noted that in other embodiments (not shown), article 1 may include three, four or more bodies or rods of aerosol-generating material.

[0367] In all of the above examples, the aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42 may include, be composed of, or essentially consist of extruded or compressed tobacco materials, preferably the extruded or compressed tobacco materials may include beads of tobacco material.

[0368] In each of the above examples, article 1 may have an axial length of at least 10 mm, preferably at least 12, 14, 16, 18, 20, 22, or 23 mm (indicated by the arrow "X" in Figure 1).

[0369] In each of the above examples, article 1 may have an axial length of up to 36 mm, preferably up to 34, 32, 30, 28, 26, 24, or 23 mm.

[0370] In each of the above examples, article 1 may have an axial length in the range of 10 to 36 mm, preferably in the range of 14 to 32 mm, 20 to 26 mm, or 22 to 24 mm.

[0371] In each of the above examples, the aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42 may contain, consist of, or essentially consist of, reconstituted tobacco, and preferably contain shredded sheets of reconstituted tobacco.

[0372] In all of the above examples, the aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42 may contain, consist of, or essentially consist of tobacco leaves.

[0373] In all of the above examples, the aerosol-generating materials 3, 11, 12, 31, 32, 41, and 32 may contain, consist of, or essentially consist of reconstituted tobacco and pulp tobacco, preferably a mixture of reconstituted tobacco and pulp tobacco.

[0374] In all of the above examples, the aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42 are bundled together to form a material body and may, may be, or essentially be, a sheet of aerosol-generating material which is crimped. Preferably, the sheet is a sheet of reconstituted tobacco.

[0375] In all of the above examples, the aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42 may include, consist of, or essentially consist of sheets of aerosol-generating material that are cut into strips. Preferably, the sheets are sheets of reconstituted tobacco.

[0376] In all of the above examples, the aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42 may contain tobacco material, and the tobacco material is produced solely from tobacco leaf pulp, and no other types of tobacco material are produced.

[0377] In all of the above examples, the aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42 may include tobacco material having a nicotine level in the range of 0.6% to 2.5%, preferably in the range of 1% to 2.1%.

[0378] In each of the examples of the articles described above (including each of the articles shown in Figures 1 to 14, Figure 16, and Figure 17), the aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42 may have different densities. Otherwise, the aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42 of the articles may be the same or different. In other embodiments, the densities of the various aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42 may be the same.

[0379] In some cases, at least one of the aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42 has a higher density than at least one of the other aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42.

[0380] Providing first and second aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42 of different densities has been found to mean that when both materials are subjected to the same heating, the high-density material heats up more slowly, and therefore the high-density material releases volatile compounds (e.g., nicotine) at a slower rate than the low-density material.

[0381] For example, in article 1 shown in Figure 1, the first aerosol-generating material 3 may have a higher density than the second and third aerosol-generating materials 11, 12 (optionally, the second and third aerosol-generating materials 11, 12 may have the same density), and as a result, the first aerosol-generating material 3 heats more slowly than the second and third aerosol-generating materials 11, 12 when subjected to the same heating, and releases its volatile compounds (e.g., nicotine) at a slower rate than the second and third aerosol-generating materials 11, 12 (however, in other embodiments, the converse may be true, such that the second and / or third aerosol-generating materials 11, 12 have a higher density than the first aerosol-generating material 3). Thus, by combining aerosol-generating materials of different densities, a more consistent and longer-lasting release of volatile compounds is provided. In some embodiments, aerosol-generating materials of different densities are combined with heating these materials separately, sometimes for different times and / or at different temperatures, to provide, for example, a more controlled release of volatile compounds over the lifespan of the article. Alternatively, to provide a greater initial impact on the user through use, it may be desirable to have a more rapid or greater release of volatile substances towards the start of consumption of the item. The ability to control aerosol generation and volatile compound release can be particularly advantageous because it allows the item to be relatively small while still achieving a specific desired release of volatile compounds over the period of consumption.

[0382] In another example, article 1 in Figure 16 or Figure 17 may optionally include first aerosol-generating materials 31, 41 having a density higher than that of the second aerosol-generating material 42.

[0383] In some embodiments, at least one of the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42 has a density at least about 25% higher than the density of at least one of the other aerosol-generating materials 3, 11, 12, 31, 32, 41, 42, and optionally has a density at least about 30%, 35%, 40%, 45%, 50%, 55%, 60%, 65%, 70%, or 75% higher. The at least one of the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42 may have a density at least 200% higher than the density of at least one of the other aerosol-generating materials 3, 11, 12, 31, 32, 41, 42, and optionally has a density at least 150%, 125%, 100%, or 75% higher. In some embodiments, at least one of the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42 has a density about 25% to about 75% higher than the density of at least one other aerosol-generating material 3, 11, 12, 31, 32, 41, 42.

[0384] In some embodiments, at least one of the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42 has a density of at least about 0.4 g / cm³, and 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. At least one of the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42 may have a density of about 2 g / cm³ or less, optionally about 1.9, 1.8, 1.7, 1.6, 1.5, 1.4, 1.3, 1.2, 1.1, 1, 0.9, 0.8, 0.7, 0.6, or 0.5 g / cm³ or less. In some embodiments, the density of at least one of the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42 is approximately 0.4 to 1.99 g / cm³.

[0385] In some embodiments, the at least one other aerosol-generating material 3, 11, 12, 31, 32, 41, 42 has a density of at least about 0.1 g / cm³, and optionally at least about 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, or 0.9 g / cm³. The at least one other aerosol-generating material 3, 11, 12, 31, 32, 41, 42 may have a density of about 1 g / cm³ or less, and optionally about 0.9, 0.8, 0.7, 0.6, 0.5, 0.4, 0.3, or 0.2 g / cm³ or less. In some embodiments, the density of the at least one other aerosol-generating material 3, 11, 12, 31, 32, 41, 42 is about 0.1 to 0.9 g / cm³.

[0386] In some embodiments, aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42 contain the same components. Therefore, when heated, they release very similar aerosols having potentially the same content of active substances and / or fragrances, etc. Their different densities make it possible to generate aerosols from the two materials at different rates and / or different times during heating.

[0387] In other embodiments, the aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42 contain different components (and may have the same or different densities). Therefore, upon heating, they release different aerosols and potentially have different compositions such as active substances and / or fragrances. Their different densities allow for the generation of different aerosols from different materials at different rates and / or different times during heating, potentially providing aerosols that vary over their lifespan.

[0388] In some embodiments, one, two or more, or each of the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42, contains tobacco. The tobacco contains volatile components including nicotine, aromas, and flavors. The tobacco may be any type of tobacco and any part of the tobacco plant, including tobacco leaves, pulp, stems, stalks, ribs, trimmings, and trimmings or mixtures of two or more thereof. Suitable tobacco materials include blends of tobacco materials including the following types: Virginia or yellow tobacco, Burley tobacco, Oriental tobacco, or any of those listed herein by choice. The tobacco may be expanded, such as dry ice expanded tobacco (DIET), or processed by any other means. In some embodiments, the tobacco material may be reconstituted tobacco material. The tobacco may be pre-treated or untreated, 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.

[0389] The aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42 may contain different tobaccos. Alternatively, the tobaccos may be the same but provided in different forms, resulting in at least one of the aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42 having a higher density than at least one of the other aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42.

[0390] In some embodiments, at least one of the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42 has at least one (further) different property from the other at least one aerosol-generating material 3, 11, 12, 31, 32, 41, 42. The different property may be one or more of the form, size, water content, quantity (by weight), one or more materials, or proportions of materials used to produce the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42 (including recipes for the aerosol-generating materials when each is made from two or more materials). In some embodiments, the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42 have no different properties other than their different densities. In other embodiments, the densities of the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42 are the same.

[0391] In some embodiments, the at least one other aerosol-generating material 3, 11, 12, 31, 32, 41, 42 comprises one or more tobaccos in the form of cut rags. This tobacco material may be pulp or reconstituted tobacco material.

[0392] In some embodiments, at least one of the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42 is a blend containing both pulp and reconstituted tobacco. For example, the ratio of pulp to reconstituted tobacco may be about 1:4 to about 4:1.

[0393] In some embodiments, at least one of the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42 has a higher density than the at least one other aerosol-generating material 3, 11, 12, 31, 32, 41, 42. In some embodiments, at least one of these higher-density aerosol-generating materials 3, 11, 12, 31, 32, 41, 42 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 at least one other aerosol-generating material 3, 11, 12, 31, 32, 41, 42 may have a higher density than the at least one of the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42, and may be, for example, in the form of beads or one or more sheets. In some embodiments, each of the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42 may be in the form of beads or one or more sheets, and optionally, at least one of the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42 may be treated to have a higher density than at least one of the other aerosol-generating materials 3, 11, 12, 31, 32, 41, 42.

[0394] As used herein, the term “beads” means beads, pellets, or other individual small units formed by molding, shaping, compressing, or otherwise into a desired shape. Beads may have a smooth and regular shape (e.g., spherical, cylindrical, oval, etc.) and / or an irregular shape.

[0395] In some embodiments, the beads have a diameter of at least about 0.5 mm, and optionally at least about 1, 1.5, 2, 2.5, or 3 mm (as measured, for example, by sieving). The beads may have a diameter of about 5 mm or less, and optionally about 4.5, 4, 3.5, 3, 2.5, 2, or 1.5 mm or less (as measured, for example, by sieving). In some embodiments, the diameter of each bead 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 may refer to their average size, e.g., number or volume average size.

[0396] In some embodiments, the desired density of the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42 is achieved or controlled by the formulation of the materials and / or the method by which the materials are processed. Processes involving agglomeration, particularly agglomeration by the application of some compressive force, tend to increase the density of the materials.

[0397] Therefore, in some embodiments, one or more of the aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42 include aggregated material particles.

[0398] In the case of sheet materials, the sheet may be formed from particles of material that are bonded together and optionally compressed to form a sheet having a desired size and density.

[0399] In some embodiments, the beads or pellets can be formed using a so-called marming process.

[0400] In some embodiments, agglomeration is achieved by pelletization. Pelletization is an agglomeration process that converts fine particles of material, sometimes 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. Calcination may involve the use of equipment such as pans, discs, drums, or mixers to produce pellets. Compression pelletization is a form of pressure agglomeration, in which particles are brought together by mechanical force, sometimes with compounding aids. The compressive force means that the formed pellets have an increased density compared to the starting material.

[0401] In some embodiments, aggregation is performed by extrusion. In some embodiments, pellets formed by pelletization can be extruded to form a higher-density extruded material.

[0402] The extruded particles may have a size selected to produce a denser aerosol-generating material (e.g., a denser first, second, and / or third aerosol-generating material 3, 11, 12, 31, 32, 41, 42) that affects heat transfer and release of volatile components within the material.

[0403] Extrusion involves feeding a composition (also called a precursor composition) through a die to produce an extruded product. This process applies pressure to the composition in combination with shear force.

[0404] Extrusion can be carried out 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.

[0405] In some embodiments, during extrusion, a free-flowing composition containing particles such as tobacco particles is subjected to high pressure and high temperature and extruded 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.

[0406] 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, 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, the precursor composition is exposed to temperatures of approximately 60°C to 80°C in the extruder.

[0407] The composition may be subjected to a pressure 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.

[0408] In some embodiments in which tobacco particles are extruded, the density of the extruded material is relatively high and the surface of the tobacco particles within it is 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 flavorings and nicotine.

[0409] In some embodiments, the extrusion may be a generally dry process, and the composition may contain dry or substantially dry aerosol-forming particles. The composition may optionally contain other granular materials, such as bases, diluents, solid aerosol-forming agents, and solid fragrance modifiers.

[0410] 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.

[0411] 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 manner, the liquid is not only applied to the surface but also impregnates the extruder 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 results in high availability of the aerosol-forming material in the resulting beads and can facilitate the evaporation of volatile components.

[0412] In some embodiments, the amount of aerosol-forming agent material incorporated into the extruded beads may be up to about 30% by weight, or even up to about 40% by weight. Typically, such a large amount of aerosol-forming agent material can make the composition difficult to handle. However, this is not a major issue as the particles are impregnated with the aerosol-forming agent material by extrusion. It may be desirable to include an amount of aerosol-forming agent material such as at least about 10% or at least about 20% by weight, in which the beads will generate an aerosol in addition to releasing volatile components. 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 be sufficient.

[0413] In some embodiments, the aggregates do not contain binders or binding additives. For example, extruded beads may not require binders to maintain their structural integrity. In other embodiments, the aggregates include binders or binding additives. Binding additives may be selected to help form aggregate structures by helping to adhere particles to each other and to other components in the composition. Suitable binding additives include, for example, thermoreversible gelling agents such as gelatin, starch, polysaccharides, pectin, alginates, wood pulp, cellulose, and cellulose derivatives such as carboxymethylcellulose.

[0414] In some embodiments, extrusion processing is sufficient to provide, if desired, a higher density aerosol-generating materials 3, 11, 12, 31, 32, 41, 42. However, in other embodiments, if desired, the extruded material may be further processed to increase the density of the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42.

[0415] For example, in some embodiments, the extruded aerosol-producing material undergoes spheroidization. In spheroidization, the extruded cylindrical particles are broken into uniform lengths and gradually deformed into a spherical shape by plastic deformation. If the extruded material is initially divided into uniform lengths, spheres with uniform diameters are produced by the spheroidization step.

[0416] According to one specific example of the embodiments discussed herein, a sample of the aerosol-generating material is produced as follows (which may be used as the aerosol-generating material of any of the articles described herein):

[0417] Table 1 shows three sample formulations, one with a binder and one without, with their amounts expressed as wet weight percentage (WWB).

[0418] [Table 1]

[0419] Care was taken not to overheat the tobacco, and the tobacco was crushed to produce fine powder. The crushed tobacco particles were sieved to select those with a desired size, for example, less than 250 μm, less than 100 μm, or less than 60 μm.

[0420] 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 for 1 minute at a speed of up to 75 RPM. This was to ensure that the dry components were evenly distributed throughout the mixture.

[0421] 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 pressed into a mass, in order to ensure that a homogeneous mixture was achieved. In this particular example, the additional mixing continued for 3 minutes.

[0422] Next, the mixture was extruded using a Caleva Multilab. The extruder was operated at approximately 1500 rpm to produce extruded material of pasta-like length.

[0423] The extruded material was broken into pieces of varying lengths as it emerged from the extruder. These pieces 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. This spheroidization step separated the extruded tobacco into individual pieces, forming high-density spherical beads.

[0424] In the final step, the spheroidized beads were dried in a 65°C oven for 30 minutes. After each drying period, the beads were weighed, and drying was stopped when the desired moisture weight reduction was achieved. Generally, such drying takes about 1 hour.

[0425] In some embodiments, at least one other aerosol-generating material 3, 11, 12, 31, 32, 41, 42 is in the form of separate particles or aggregates of particles. These particles may share various properties (higher density) with at least one of the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42, such as particle size, but have a lower density. As described above, there are various ways to adjust the density of the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42, e.g., compounding and / or processing the material into particles, beads or pellets.

[0426] In some embodiments, at least one of the aerosol-generating materials 3, 11, 12, 31, 32, 41, 42 comprises a combination of 60% reconstituted tobacco and 40% pulp tobacco, with a density of approximately 0.1 to approximately 0.9 g / cm³. 3 It is within the range of: At least one other aerosol-generating material 3, 11, 12, 31, 32, 41, 42 contains approximately 30-90% tobacco and approximately 0.4-1.99 g / cm³. 3 The density is in the range of . The amount of aerosol-forming material contained in at least one of the aerosol-forming materials 3, 11, 12, 31, 32, 41, 42 may be about 8 to about 15%. At least one of the aerosol-forming materials 3, 11, 12, 31, 32, 41, 42 may contain mostly spherical beads having a particle size of about 0.5 to about 3 mm. In some embodiments, the aerosol-forming material in an article comprises, by weight, about 50% of the first type of aerosol-forming material 3, 31, 41 and about 50% of the second type of aerosol-forming material 11, 12, 32, 42. Thus, for example, an article containing 260 mg of aerosol-forming material may contain 130 mg of the first type of aerosol-forming material 3, 31, 41 and 130 mg of the second type of aerosol-forming material 11, 12, 32, 42.

[0427] In some embodiments, the aerosol-generating material includes tobacco, and the tobacco is present in an amount of about 10% to about 90% of the weight of the aerosol-generating material.

[0428] 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.

[0429] 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%, based on the weight of the aerosol-generating material.

[0430] The tobacco described herein may contain nicotine. In some embodiments, the nicotine content is 0.5–2.5% or 0.5–2% by weight of the tobacco, for example, 0.5–1.75%, 0.8–1.2%, or about 0.8–about 1.75% by weight of the tobacco. In some embodiments, the nicotine content may be 0.8–1% by weight of the tobacco.

[0431] In some embodiments, each of the aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42 has the same nicotine content.

[0432] In some embodiments, the aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42 contain one or more volatile components. In some embodiments, each of the aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42 has the same volatile component content.

[0433] In some embodiments, each of the aerosol-generating materials 3, 11, 12, 31, 32, 41, and 42 contains tobacco. For example, the article may contain about 80 to about 350 mg of tobacco. In some specific embodiments, the aerosol-generating material in the article or consumable has a weight of 260 mg and includes a combination of 130 mg of a first aerosol-generating material 3 containing, for example, high-density tobacco beads, and 130 mg of the remaining aerosol-generating material (e.g., a combined second aerosol-generating material and optionally a third aerosol-generating material) containing, for example, a blend of pulp and reconstituted tobacco.

[0434] 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 may contain about 20 to about 330 mg, or about 50 to about 300 mg, or about 40 to about 125 mg of tobacco, while the other region of the aerosol-generating material may contain about 20 to about 330 mg, or about 30 to about 300 mg, or about 40 to about 125 mg of tobacco.

[0435] According to this disclosure, a kit of components including an article and an aerosol dispensing device, as in any of the examples described herein, is also provided.

[0436] The Disclosure also provides a package (not shown) containing multiple articles, according to one of the examples described herein. In some embodiments, the package is sealed. The package may comprise a container having a body and a lid, with space provided within the container body for receiving multiple articles. The lid may be, for example, a hinged lid connected by threads, a snap-fit ​​lid, or a cap.

[0437] The various embodiments described herein are presented solely to aid in the understanding and teaching of 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 suitably include, consist of, or essentially consist of, appropriate combinations of disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Furthermore, this disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

[Claim 1] The invention described in the specification.

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