Consumables

Abstract

Consumables for use in non-combustible aerosol supply systems. The consumables contain approximately 100 to 500 mg of aerosol-generating material, which is in the form of a pleated sheet, an elongated strip, or a shredded sheet, and the consumables are tobacco-free or contain less than 2% tobacco. A non-combustible aerosol supply system is also provided, comprising such consumables and a non-combustible aerosol supply device which, when used together with the consumables, comprises an aerosol-generating device that generates an aerosol from the consumables. An aerosol supply device is also provided, comprising an aerosol supply device which comprises a device housing defining a device chamber, a receptacle defining a heating chamber configured to removably receive at least a portion of the consumables, and a heater assembly which comprises a heating element for heating at least a portion of an article containing the aerosol-generating material received in the heating chamber. Methods for generating an aerosol from such consumables and methods for forming such consumables are also provided.

Description

[Technical Field]

[0001] The present invention relates to consumables for use in a non-combustible aerosol supply system, a non-combustible aerosol supply system, and a method for generating aerosols. [Background technology]

[0002] Smoking consumables such as cigarettes and cigars produce tobacco smoke by burning tobacco during use. Alternatives to these types of consumables release inhalable aerosols or vapors by releasing compounds from a base material through non-combustion heating. These alternatives may be called non-combustion smoking consumables or aerosol-generating assemblies.

[0003] An example of such a product is a heating device that releases compounds by heating a solid aerosol-generating material rather than burning it. This solid aerosol-generating material may, in some cases, contain plant-based materials. Heating volatilizes at least one component of the material, typically forming an inhalable aerosol. These products may be called non-combustion heating devices, cigarette heating devices, or cigarette heating products. Various different configurations are known for volatilizing at least one component of the solid aerosol-generating material.

[0004] Another example is a hybrid device. A hybrid device contains a liquid source (which may or may not contain nicotine) that vaporizes upon heating to produce an inhalable vapor or aerosol. The device further contains a solid aerosol-generating material (which may or may not contain tobacco material), the components of which are entrained in the inhalable vapor or aerosol to form an inhalation medium. [Overview of the project]

[0005] According to a first aspect of the present invention, a consumable for use in a non-combustible aerosol supply system is provided, wherein the consumable comprises about 100 to about 500 mg of aerosol generating material, the aerosol generating material is in the form of a pleated sheet, an elongated strip, or a shredded sheet, and the consumable is tobacco-free or contains less than 2% tobacco.

[0006] The present invention also provides a method for generating an aerosol from a consumable, comprising the step of heating a portion of the aerosol-generating material in the consumable to a temperature of at least 120°C.

[0007] Furthermore, the present invention provides a non-combustible aerosol supply system comprising the consumables described herein and a non-combustible aerosol supply device, wherein the non-combustible aerosol supply device comprises an aerosol generating device that generates an aerosol from the consumables when the consumables are used together with the non-combustible aerosol supply device.

[0008] The present invention also provides a use of the consumables described herein in a non-combustible aerosol supply device, wherein the non-combustible aerosol supply device comprises an aerosol generating device that generates an aerosol from the consumables when the consumables are used together with the non-combustible aerosol supply device.

[0009] The present invention also provides a method for forming a consumable product of the present invention, (a) A step of supplying a slurry containing components of an aerosol-generating material or its precursor, (b) The step of forming a slurry layer, (c) The step of drying the slurry to form an aerosol generating material, (d) A step of forming a consumable containing approximately 100 to 500 mg of aerosol generating material, The method provides a consumable that does not contain tobacco or contains less than 2% tobacco.

[0010] In another aspect, the present invention relates to a method for forming a consumable product of the present invention, (a) A step of supplying a slurry containing components of an aerosol-generating material or its precursor, (b) The step of forming a slurry layer, (c) A step of drying the slurry to form an aerosol generating material, (d) For example, a step of applying one or more flavors to an aerosol generating material by spraying the aerosol generating material with flavors (or a composition containing flavors (or flavors)), (e) A step of forming a consumable containing approximately 100 to 500 mg of aerosol generating material, The method provides a consumable that does not contain tobacco or contains less than 2% tobacco.

[0011] The slurry may contain a solvent, a binder, an aerosol-forming material, a filler, and one or more flavorings and / or active substances.

[0012] The consumables formed by the method described above are consumables as defined herein and therefore do not contain tobacco or contain less than 2% tobacco. Similarly, the aerosol-generating material is included in the consumables in the form of pleated sheets, elongated strips, or shredded sheets.

[0013] Further features and advantages of the present invention will become apparent from the following description of preferred embodiments of the invention, which are given merely as examples with reference to the accompanying drawings. [Brief explanation of the drawing]

[0014] [Figure 1] This is a cross-sectional view of an example of a consumable item. [Figure 2] Figure 1 is a perspective view of the consumables. [Figure 3] This is a side cross-sectional view of an example of a consumable item. [Figure 4] Figure 3 is a perspective view of the consumables. [Figure 5] It is a perspective view of an example of a non-combustion aerosol supply system. [Figure 6] It is a front sectional view of the aerosol supply device of FIG. 5. [Figure 7] It is an enlarged view of a part of FIG. 6. [Figure 8] An article for use with a non-combustion aerosol supply device, which is a side sectional view of the article including a suction port. [Figure 9] It is a view showing an exemplary non-combustion aerosol supply device. [Figure 10] It is a schematic sectional view of a non-combustion aerosol supply device of the type shown in FIG. 9.

Mode for Carrying Out the Invention

[0015] The aerosol generating material described in this specification is, for example, a material that can generate an aerosol when energy is supplied by heating, irradiation, or any other method. The aerosol generating material may be in the form of a solid or gel that may or may not contain nicotine, for example. In some embodiments, the aerosol generating material is a homogeneous solid.

[0016] The aerosol generating material may be an "amorphous solid". In some embodiments, the amorphous solid is a "monolithic solid". The aerosol generating material may be non-fibrous or fibrous. In some embodiments, the aerosol generating material may be a dry gel. The aerosol generating material may be a solid material that can hold some fluid such as a liquid therein. In some embodiments, the held fluid may be water (such as water absorbed from around the aerosol generating material), or the held fluid may be a solvent (such as when the aerosol generating material is formed from a slurry). In some embodiments, the solvent may be water.

[0017] The aerosol-generating material may have any suitable water content, such as 1% to 20% by weight or 1% to 15% by weight. Preferably, the water content of the aerosol-generating material may be about 5% by weight, 7% by weight, or 9% to about 20% by weight, 15% by weight, 13% by weight, or 11% by weight (based on wet weight) (WWB). The water content of the aerosol-generating material may be determined, for example, by Karl Fischer titration or gas chromatography with a thermal conductivity detector (GC-TCD).

[0018] consumables The present invention provides consumables that can be used in aerosol supply systems, such as non-combustion aerosol supply systems. The consumables may be referred to as “articles” or “aerosol products” throughout this disclosure.

[0019] The article is sized to be at least partially received within the heater assembly described herein. The heater assembly comprises a receptacle defining a heating chamber configured to removably receive at least a portion of an article containing an aerosol-generating material, and a heating element for heating at least a portion of the article containing the aerosol-generating material received within the heating chamber. The heater assembly comprises a heating element for heating the article during use. In one embodiment, the heating element is a susceptor structure (referred to herein as “susceptor”). The heating element may be a blade-shaped heating element. The article may be inserted on or around the heating element. Any other preferred shape or form of heating element may be used. For example, the heating element may be, for example, a pin shape having a constant circular cross-section along the axial length of the heating element, tapering toward a pin tip, or a rod shape (e.g., a cylindrical rod or a square rod) having a constant or varying cross-section along the axial length of the heating element, omitting the tip or tapered portion.

[0020] As described above, the present invention relates to a consumable for use in a non-combustible aerosol supply system, wherein the consumable comprises about 100 to about 500 mg of aerosol generating material, and the aerosol generating material is in the form of a pleated sheet, an elongated strip, or a shredded sheet. The consumables do not contain tobacco, or the consumables contain less than 2% tobacco. We provide consumables.

[0021] In some embodiments, the consumables may contain less than 1% tobacco. In some embodiments, the consumables may be substantially free of tobacco.

[0022] In some embodiments, the consumables may include tobacco in the form of tobacco powder.

[0023] The aerosol-generating material may include a binder, an aerosol-forming agent, a filler, and / or one or more flavorings and / or active substances.

[0024] In one embodiment, the aerosol-generating material comprises an aerosol-forming agent material, a binder, optionally a filler, and optionally one or more flavorings and / or active substances.

[0025] In one embodiment, the aerosol-generating material comprises a binder, an aerosol-forming agent material, a filler, and one or more flavorings and / or active substances.

[0026] The inventors have found that the consumables of the present invention can be used in a non-combustible aerosol supply device to form an aerosol even if they do not contain tobacco or contain less than 2% tobacco. Furthermore, since neither the consumables nor the aerosol-generating material contain tobacco or contain less than 2% tobacco, the weight of the consumables is not limited for tax reasons. Therefore, a greater weight of aerosol-generating material can be included in the consumables than in the case of consumables or aerosol-generating materials containing a higher percentage of tobacco. This means that each consumable can last longer during use.

[0027] Therefore, the consumables may contain approximately 100 to 500 mg of aerosol-generating material, for example, approximately 200 to 500 mg, 250 to 500 mg, 300 to 500 mg, 350 to 500 mg, or 400 to 500 mg.

[0028] In one embodiment, the aerosol-generating material contains one or more flavorings but does not contain any active substances.

[0029] In another embodiment, the aerosol-generating material contains one or more active substances but does not contain flavorings.

[0030] In another embodiment, the aerosol-generating material comprises one or more active substances and one or more flavorings.

[0031] In one embodiment, the aerosol-generating material has a GSM of less than about 350 gsm, for example, less than about 300 gsm or less than about 250 gsm. In some embodiments, the aerosol-generating material has a GSM of about 50 gsm to about 300 gsm, for example, about 70 gsm to about 250 gsm.

[0032] In one embodiment, the aerosol-generating material has a specific heat capacity of less than about 6 JK / g, for example, less than about 5 JK / g.

[0033] 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 also comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, packaging material, a mouthpiece, a filter, and / or an aerosol modifier. Consumables may also comprise an aerosol generator, such as a heater, which generates heat during use to produce an aerosol in the aerosol-generating material. The heater may comprise, for example, a flammable material, an electrically conductive material, or a susceptor.

[0034] 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 as a result, inductive heating of the heating material occurs as the fluctuating magnetic field penetrates the susceptor. The heating material may be a magnetic material, and as a result, magnetic hysteresis heating of the heating material occurs as the fluctuating magnetic field penetrates the heating material. The susceptor may be both conductive and magnetic, and as a result, the susceptor can be heated by both heating mechanisms.

[0035] Aerosol modifiers are typically substances located downstream of the aerosol generation region and are configured to modify the generated aerosol, for example, by altering the taste, flavor, acidity, or other properties of the aerosol. The aerosol modifier may be contained within an aerosol modifier release component that is operable to selectively release the aerosol modifier.

[0036] 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, threads, or granules. The aerosol modifier does not need to contain a filter material.

[0037] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to supply thermal energy to the aerosol-generating material so as to release one or more volatile substances from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from an aerosol-generating material without heating. For example, the aerosol generator may be configured to supply one or more of the aerosol-generating material to vibration, pressure increase, or electrostatic energy.

[0038] Carrier The aerosol-generating material may be present on or within a carrier support (or carrier component). The carrier may function as a support on which the aerosol-generating material is formed, thereby facilitating manufacturing. The carrier may also provide rigidity to the aerosol-generating material, facilitating handling.

[0039] The carrier may be any suitable material that can be used to support the aerosol-generating material. In some cases, the carrier may be formed from a material selected from metal foil, paper, carbon paper, oil-resistant paper, ceramics, carbon allotropes such as graphite and graphene, plastics, cardboard, wood, or a combination thereof. In some cases, the carrier may be formed from a material selected from metal foil, paper, cardboard, wood, or a combination thereof. In some cases, the carrier includes paper. In some cases, the carrier itself may be a laminated structure comprising layers of materials selected from the above list. In some cases, the carrier may also function as a flavor support. For example, the carrier may be impregnated with a flavoring agent.

[0040] In some cases, the carrier may be magnetic. This feature may be used to secure the carrier to the assembly during use, or to generate a specific aerosol-generating material shape. In some cases, the consumable may include one or more magnets that can be used to secure the consumable to the induction heater during use.

[0041] In some cases, the carrier may be substantially or entirely impermeable to gases and / or aerosols. This prevents aerosols or gases from passing through the carrier layer, thereby controlling the flow and ensuring that the flow is delivered to the user. This can also be used, for example, to prevent condensation or other deposition of gases / aerosols during use on the surface of a heater located within an aerosol generation assembly. This can, in some cases, improve consumption efficiency and hygiene.

[0042] In some cases, the surface of the carrier in contact with the aerosol-generating material may be porous. For example, in one case, the carrier includes paper. Porous carriers such as paper are particularly suitable for the present invention. The porous (e.g., paper) layer is in contact with the aerosol-generating layer and forms a strong bond. The aerosol-generating material is formed by drying a gel, and is not limited by theory, but it is thought that when the slurry formed from the gel partially impregnates the porous carrier (e.g., paper), and as a result the gel solidifies and crosslinks, the carrier is partially bonded to the gel. This results in a strong bond between the gel and the carrier (and between the dried gel and the carrier).

[0043] Additionally, surface roughness can contribute to the strength of the bond between the aerosol-generating material and the support. The paper roughness (of the surface in contact with the support) may preferably be within the range of 50 to 1000 Beck seconds, preferably 50 to 150 Beck seconds, or preferably 100 Beck seconds (measured at an air pressure interval of 50.66 to 48.00 kPa). (A Beck smoothness tester is an instrument used to determine the smoothness of a paper surface; "Beck smoothness" is the time (in seconds) it takes for a certain amount of air to seep between a smooth glass surface and a paper sample when air at a specific pressure is introduced.)

[0044] Conversely, the surface of the carrier facing outward from the aerosol-generating material may be positioned in contact with the heater, and a smoother surface may provide more efficient heat transfer. Therefore, in some cases, the carrier may be positioned to have a rougher side in contact with the aerosol-generating material and a smoother side facing outward from the aerosol-generating material.

[0045] In one particular case, the carrier may be foil backed with paper. The paper layer is in contact with the aerosol-generating material layer, and the properties discussed in the previous paragraph are brought about by this contact. Foil backing is substantially impermeable and provides control over the aerosol channels. Metal foil backing can also help conduct heat to the aerosol-generating material.

[0046] In another case, the foil layer of a paper-backed foil comes into contact with the aerosol-generating material. The foil is substantially impermeable, thereby preventing water supplied to the aerosol-generating material from being absorbed by the paper, which could weaken the structural integrity of the paper.

[0047] In some cases, the support is formed from or includes a metal foil, such as aluminum foil. The metal support may allow for better conduction of thermal energy to the aerosol-generating material. Additionally or alternatively, the metal foil may function as a susceptor in the induction heating system. In certain embodiments, the support includes a metal foil layer and a support layer, such as cardboard. In these embodiments, the metal foil layer may have a thickness of less than 20 μm, for example, about 1 μm to about 10 μm, preferably about 5 μm.

[0048] In some cases, the carrier may have a thickness of approximately 0.017 mm to approximately 2.0 mm, preferably approximately 0.02 mm, 0.05 mm, or 0.1 mm to approximately 1.5 mm, 1.0 mm, or 0.5 mm.

[0049] Aerosol-forming agent materials The aerosol-generating material may include an aerosol-forming material. The aerosol-generating material may include about 1% by weight, 5% by weight, 10% by weight, 12% by weight, or 13% to about 18% by weight, 20% by weight, 25% by weight, 30% by weight, 35% by weight, 45% by weight, 55% by weight, 65% by weight, 75% by weight, or 80% by weight of the aerosol-forming agent material (all calculated on a dry weight basis). In exemplary embodiments, the aerosol-generating material includes about 1 to about 80% by weight, about 1 to about 50% by weight, about 5 to about 35% by weight, about 10 to about 25% by weight, about 12 to about 20% by weight, or about 13 to about 18% by weight of the aerosol-forming agent material (all calculated on a dry weight basis).

[0050] In some embodiments, the aerosol-generating material includes about 1 to about 60% by weight, about 20 to about 55% by weight, about 30 to about 50% by weight, or about 40 to about 50% by weight of the aerosol-forming agent material (all calculated on a dry weight basis).

[0051] The aerosol-forming agent material may contain one or more of the following: glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0052] In some embodiments, the aerosol-forming agent material includes one or more polyhydric alcohols such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin, esters of polyhydric alcohols such as glycerol mono-, di-, or triacetate, and / or aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanediate and dimethyl tetradecanediate.

[0053] In some embodiments, the aerosol-forming agent material may include glycerol and / or propylene glycol.

[0054] Binder The aerosol-generating material may contain a binder. In some embodiments, the aerosol-generating material contains about 0.5% to about 60% by weight of a binder, for example, about 5% to about 50% by weight, about 10% to about 35% by weight, about 15% to about 30% by weight, or about 15% to about 25% by weight.

[0055] In some embodiments, the binder includes (or is) a hydrophilic colloid. In some embodiments, the binder includes (or is) one or more compounds selected from the group consisting of alginate, pectin, starch (and derivatives), cellulose (and derivatives such as methylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC)), gum, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the binder includes (or is) one or more of alginate, pectin, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol.

[0056] In some embodiments, the binder is a cellulosic binder that can be selected from the group consisting of hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof.

[0057] In some embodiments, the binder includes (or is) a non-cellulose binder selected from the group consisting of agar, xanthan gum, gum arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginate, and combinations thereof. In some embodiments, the non-cellulose binder is alginate.

[0058] In some embodiments, the binder comprises (or is) one or more of hydroxyethylcellulose, hydroxypropylcellulose, hydroxypropylmethylcellulose (HPMC), carboxymethylcellulose, alginate, pectin, guar gum, and acacia gum.

[0059] In some embodiments, the binder includes alginate and / or pectin.

[0060] In some embodiments, the binder includes, essentially consists of, or comprises alginate and pectin.

[0061] In some embodiments, the binder comprises, essentially consists of, or comprises one or more carboxymethylcelluloses, alginates, and pectins.

[0062] Filler The aerosol-generating material may further contain fillers. The use of fillers can help reduce the tackiness of the aerosol-generating material, for example, when a high level of aerosol-forming material is present.

[0063] In some embodiments, the aerosol-generating material includes less than about 50% by weight of a filler, for example, about 1% to 50% by weight, or 5% to 40% by weight, or 5% to 30% by weight, or 10% to 20% by weight.

[0064] In other embodiments, the aerosol-generating material contains less than 20% by weight, preferably less than 10% by weight or less than 5% by weight of filler. In some cases, the aerosol-generating material contains less than 1% by weight of filler, and in some cases, the aerosol-generating material contains no filler.

[0065] In some embodiments, the aerosol-generating material contains about 1% by weight, 5% by weight, 10% by weight, 18% by weight, or 20% to about 50% by weight, 45% by weight, 40% by weight, 35% by weight, or 30% by weight of filler (all calculated on a dry weight basis). For example, the aerosol-generating material may contain about 5% to about 45% by weight, about 10% to about 40% by weight, about 18% to about 35% by weight, or about 20% to about 30% by weight of filler (all calculated on a dry weight basis). These amounts represent the total amount of filler(s) in the aerosol-generating material.

[0066] The filler, if present, may include one or more inorganic filler materials such as calcium carbonate, chitosan, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, and magnesium carbonate, as well as suitable inorganic adsorbents such as molecular sieves. The filler may also include one or more organic filler materials such as wood pulp, hemp fibers, starch and starch derivatives, e.g., maltodextrin, and cellulose and cellulose derivatives, e.g., pulverized cellulose, microcrystalline cellulose, and nanocrystalline cellulose. In certain cases, the aerosol-generating material does not contain calcium carbonate such as chalk.

[0067] In some embodiments, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fiber, cellulose or cellulose derivatives, for example, microcrystalline cellulose (MCC) and / or nanocrystalline cellulose.

[0068] In some cases, the filler may contain maltodextrin or microcrystalline cellulose (MCC).

[0069] As those skilled in the art will understand, microcrystalline cellulose may be formed by depolymerizing cellulose through a chemical process (e.g., using an acid or enzyme). One exemplary method for forming microcrystalline cellulose involves acid hydrolysis of cellulose using an acid such as HCl. The cellulose produced after this treatment is crystalline (i.e., no amorphous regions remain). Preferred methods and conditions for forming microcrystalline cellulose are well known in the art.

[0070] In some cases, the filler may include, essentially consist of, or be composed of wood pulp, calcium carbonate, and combinations thereof.

[0071] In some cases, the filler contains, is essentially composed of, or consists of wood pulp and calcium carbonate.

[0072] In some cases, the filler contains, is essentially, or consists of wood pulp. In some cases, the aerosol-generating material does not contain inorganic fillers such as calcium carbonate.

[0073] The aerosol-generating material may contain approximately 1% by weight, 5% by weight, 10% by weight, 12% by weight, or 13% by weight to approximately 15% by weight, 17% by weight, or 20% by weight, 25% by weight, 30% by weight, 35% by weight, 40% by weight, 45% by weight, 50% by weight, 55% by weight, or 60% by weight of wood pulp (all calculated on a dry weight basis).

[0074] The aerosol-generating material may contain approximately 10% by weight, 20% by weight, 30% by weight, 35% by weight, 40% by weight, or 45% by weight to approximately 55% by weight, 60% by weight, 65% by weight, or 70% by weight of calcium carbonate (all calculated on a dry weight basis).

[0075] acid The aerosol-generating material may contain an acid. The acid may be an organic acid. In some embodiments, the acid may be at least one of a monoprotonic acid, a diprotonic acid, and a triprotonic acid. In some such embodiments, the acid may contain at least one carboxyl functional group. In some such embodiments, the acid may be at least one of an α-hydroxy acid, a carboxylic acid, a dicarboxylic acid, a tricarboxylic acid, and a keto acid. In some such embodiments, the acid may be an α-keto acid.

[0076] In some embodiments, the acid may be at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propionic acid, and pyruvic acid.

[0077] Preferably, the acid is lactic acid. In other embodiments, the acid is benzoic acid. In other embodiments, the acid may be an inorganic acid. In some of these embodiments, the acid may be a mineral acid. In some such embodiments, the acid may be at least one of sulfuric acid, hydrochloric acid, boric acid, and phosphoric acid. In some embodiments, the acid is levulinic acid.

[0078] In embodiments where the aerosol-generating material contains nicotine, it is particularly preferable that it contains an acid. In such embodiments, the presence of the acid can stabilize the dissolved species in the slurry formed therefrom. The presence of the acid can reduce or substantially prevent the evaporation of nicotine during the drying of the slurry, thereby reducing the loss of nicotine during production.

[0079] Flavor In some embodiments, the aerosol-generating material may further contain flavorings.

[0080] The aerosol-generating material may contain about 0.1% by weight, 0.5% by weight, 1% by weight, 5% by weight, 10% by weight, 15% by weight, 20% by weight, 25% by weight, 30% by weight, or 35% to about 45% by weight, 50% by weight, or 60% by weight of flavor (all calculated on a dry weight basis). In exemplary embodiments, the aerosol-generating material contains about 1% by weight, 5% by weight, 10% by weight, 20% by weight, 30% by weight, or 35% to about 42% by weight, 45% by weight, or 47% by weight of flavor. For example, the aerosol-generating material may contain about 1% to about 60% by weight, about 1% to about 45% by weight, about 10% to about 45% by weight, about 20% to about 50% by weight, about 30% to about 50% by weight, about 30% to about 45% by weight, or about 35% to about 45% by weight of flavor.

[0081] In some embodiments, the aerosol-generating material may contain about 1 to about 15% by weight, about 1 to about 10% by weight, about 2 to about 9% by weight, or about 3 to about 8% by weight of flavoring.

[0082] As used herein, the terms “flavoring” and “flavoring agent” refer to materials that may be used to create a desired taste, aroma, or other somatosensory effect in products intended for adult consumers, where permitted by local regulations.These ingredients include naturally occurring flavorings, plant substances, plant substance extracts, synthetically obtained materials, or combinations thereof (e.g., cannabis, licorice, hydrangea, eugenol, magnolia leaves, 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, tropical fruits). Rhubarb, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, kurt, eggplant, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage Ginger, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, peppermint oil from any of the Mentha species, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazelnut, hibiscus, bay leaf, mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, mace, damien, majolica 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-derived substances, or breath fresheners.These may be imitation ingredients, synthetic ingredients, or natural ingredients, or blends thereof. They may be in any suitable form, such as a liquid such as an oil, a solid such as a powder, or a gas.

[0083] In some embodiments, the flavor includes menthol, spearmint, and / or peppermint. In some embodiments, the flavor includes flavor components of cucumber, blueberry, citrus, and / or red berry. In some embodiments, the flavor includes eugenol. In some embodiments, the flavor includes flavor components extracted from tobacco.

[0084] In some embodiments, the flavor may include a sensory stimulant, which is intended to achieve somatosensations that are normally chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to, or instead of, the aroma or taste nerves, and these may include agents that produce heating, cooling, tingling, or numbing effects. Preferred thermal agents may be, but are not limited to, vanillyl ethyl ether, and preferred cooling agents may be, but are not limited to, eucalyptol or WS-3 (N-ethyl-2-isopropyl-5-methylcyclohexanecarboxamide).

[0085] In some embodiments, the flavor may include eucalyptus, star anise, rooibos, fennel, jasmine, and / or lavender.

[0086] Coloring agents The aerosol-generating material may contain a colorant. The addition of a colorant can alter the visual appearance of the aerosol-generating material. The presence of a colorant in the aerosol-generating material can improve its visual appearance. By adding a colorant to the aerosol-generating material, the aerosol-generating material can match the color of other components of the article containing the aerosol-generating material. Alternatively, the colorant may simply give the aerosol-generating material a desired color.

[0087] Depending on the desired color of the aerosol-generating material, various colorants may be used. The color of the aerosol-generating material may be, for example, white, green, red, purple, blue, brown, or black. Other colors are also conceivable. Natural or synthetic colorants, such as natural or synthetic dyes, food-grade colorants, and pharmaceutical-grade colorants may be used. In certain embodiments, the colorant is caramel, which can impart a brown appearance to the aerosol-generating material.

[0088] The coloring agent may be incorporated during the formation of the aerosol-generating material (for example, when forming a slurry containing the material that will form the aerosol-generating material), or the coloring agent may be applied to the aerosol-generating material after its formation (for example, by spraying it onto the aerosol-generating material).

[0089] active substance In some embodiments, the aerosol-generating material comprises one or more active substances. However, the aerosol-generating material is tobacco-free, i.e., does not contain tobacco, or contains less than 2% tobacco.

[0090] The active substances used herein may be physiologically active materials, which are materials intended to achieve or enhance physiological responses. Active substances may be selected from, for example, dietary supplements, nootropics, and psychostimulants. Active substances may be naturally occurring or obtained synthetically. Active substances may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, or components, derivatives, or combinations thereof.

[0091] In one embodiment, the active substance is a legally permissible recreational drug.

[0092] In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0093] In some embodiments, the active substance may include or be derived from one or more plant substances, or components, derivatives, or extracts thereof. As used herein, the term “plant substance” includes, but is not limited to, any material derived from a plant, including extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, exoskeletons, shells, etc. Alternatively, the material may include synthetically obtained active compounds that are naturally present in plant substances. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, flakes, strips, sheets, etc. Examples of plant-based substances include 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 (green or black), thyme, clove, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. Lemon peel, mint, juniper, elderflower, vanilla, wintergreen, perilla, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damian, marjoram, olive, lemon balm, lemon basil, chives, 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.

[0094] In some embodiments, the active substance comprises or is derived from one or more plant substances, or components, derivatives, or extracts thereof, the plant substances being selected from eucalyptus, star anise, cocoa, and hemp.

[0095] In some embodiments, the active substance comprises or is derived from one or more plant substances, or components, derivatives, or extracts thereof, the plant substances being selected from eucalyptus, star anise, rooibos, fennel, jasmine, and lavender.

[0096] In some embodiments, the active substance comprises or is derived from one or more plant substances, or components, derivatives, or extracts thereof, the plant substances being selected from eucalyptus and rooibos.

[0097] In some embodiments, the active substance comprises one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclol (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabiclomevalin (CBCV), cannabigerovalin (CBGV), cannabigerol monomethyl ether (CBGM), and cannabiersoin (CBE) and cannabicitran (CBT).

[0098] The active substance may include one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).

[0099] The active substance may include cannabidiol (CBD).

[0100] The active ingredients may include nicotine and cannabidiol (CBD).

[0101] The active substances may include nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

[0102] In some embodiments, the aerosol-generating material contains about 1% by weight, 2% by weight, 3% by weight, or 4% by weight to about 20% by weight, 18% by weight, 15% by weight, or 12% by weight (calculated on a dry weight basis) of nicotine. For example, the aerosol-generating material may contain about 1% to about 20% by weight, about 2% to about 18% by weight, or about 3% to about 12% by weight of nicotine.

[0103] In some cases, the aerosol-generating material contains at least about 0.1% by weight, 1% by weight, 5% by weight, 10% by weight, 20% by weight, 25% by weight, or 30% by weight of active substances and / or flavorings. In some cases, the aerosol-generating material contains less than about 90% by weight, 80% by weight, 70% by weight, 60% by weight, 50% by weight, or 40% by weight of active substances and / or flavorings (all calculated on a dry weight basis).

[0104] In some cases, the aerosol-generating material contains at least about 0.1% by weight, 1% by weight, 5% by weight, 10% by weight, 20% by weight, 25% by weight, or 30% by weight of plant-based materials, nicotine, and flavorings in total. In some cases, the total content of the active substance and / or flavorings may be less than about 90% by weight, 80% by weight, 70% by weight, 60% by weight, 50% by weight, or 40% by weight (all calculated on a dry weight basis).

[0105] The consumables either do not contain tobacco containing tobacco fibers and tobacco extracts, or the consumables contain less than 2% tobacco.

[0106] In some embodiments, the aerosol-generating material is formed as a sheet. In some cases, the aerosol-generating material may be incorporated into a consumable in sheet form. The aerosol-generating material sheet may be incorporated as a flat sheet, a pleated or bundled sheet, a crimped sheet, or a rolled sheet (i.e., in the form of a tube). For example, the aerosol-generating material sheet may be formed on packaging that surrounds further aerosol-generating material, which may be the same or different aerosol-generating material. In other cases, the sheet may be shredded and then incorporated into a consumable.

[0107] method A further aspect of the present invention provides a method for producing a consumable of the present invention. This method includes producing an aerosol-generating material and incorporating the aerosol-generating material into a consumable.

[0108] This method may include the steps of (a) supplying a slurry containing components or precursors of an aerosol-generating material; (b) forming a layer of slurry; (c) drying the slurry to form an aerosol-generating material; and (d) incorporating the aerosol-generating material into a consumable. The consumable contains the amount of aerosol-generating material described herein and is tobacco-free or contains less than 2% tobacco.

[0109] The slurry may contain a solvent, a binder, an aerosol-forming agent, a filler, and one or more flavorings and / or active substances.

[0110] Therefore, the step of forming the aerosol-generating material is (a) (i) A binder can be optionally selected, (ii) Aerosol-forming agent material, (iii) optionally a filler and (iv) Selectively one or more flavorings and / or active substances, (v) Solvent and A step of supplying a slurry containing, (b) A step of forming a slurry layer, (c) A step to dry the slurry, Includes.

[0111] By drying the slurry, an aerosol-generating material is formed.

[0112] In one embodiment, the step of forming an aerosol-generating material is: (a) (i) A binder and (ii) Aerosol-forming agent material, (iii) Filler and (iv) One or more flavorings and / or active substances, (v) Solvent and A step of supplying a slurry containing, (b) A step of forming a slurry layer, (c) A step to dry the slurry, Includes.

[0113] In another embodiment, any flavoring is added to the slurry after the slurry has been formed and dried. In this case, after step (c), the method includes adding one or more flavorings to the aerosol-generating material, for example, by spraying the aerosol-generating material with flavoring(s) (or a composition containing flavoring(s)).

[0114] Therefore, the step of forming the aerosol-generating material is (a) (i) A binder and (ii) Aerosol-forming agent material, (iii) Filler and (iv) Selectively one or more active substances, (v) Solvent and A step of supplying a slurry containing, (b) A step of forming a slurry layer, (c) A step of drying the slurry to form an aerosol generating material, (d) For example, a step of adding one or more flavorings to an aerosol generating material by spraying the aerosol generating material with flavorings (or a composition containing flavorings), It may include.

[0115] The aerosol-generating material formed as described above may then be incorporated into or formed into a consumable in any of the amounts described herein.

[0116] Step (b) of forming a slurry layer may include spraying, casting, or extruding the slurry. In some cases, the slurry layer is formed by casting the slurry.

[0117] In some cases, a solidifying agent (such as a calcium source) may be added to the slurry before or during step (b). This is appropriate when gelation occurs relatively slowly, and therefore the slurry may be cast, for example, after the solidifying agent has been added.

[0118] In other cases, the step (c) of drying the slurry as a gel may include adding a solidifying agent to the slurry layer. The solidifying agent may, for example, be sprayed onto the gel or preloaded onto the surface of the laminated slurry.

[0119] For example, a solidifying agent containing a calcium source may be added to a slurry containing alginate and / or pectin to form a calcium-crosslinked alginate / pectin gel. In some cases where gelation occurs rapidly (such as when an alginate or pectin gelling agent is used), calcium should be added after casting (because the gel would be too viscous to cast).

[0120] In some examples, the solidifying agent includes or consists of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or a combination thereof. In some examples, the solidifying agent includes or consists of calcium formate and / or calcium lactate. In certain examples, the solidifying agent includes or consists of calcium formate.

[0121] The total amount of solidifying agent, such as a calcium source, may be about 0.5 to about 5% by weight (calculated on a dry weight basis). Preferably, the total amount may be about 1% by weight, 2.5% by weight, or 4% to about 4.8% by weight or 4.5% by weight. If too little solidifying agent is added, the flavoring will not be stabilized, and a gel may be formed that causes the flavoring to fall out of the gel. Conversely, if too much solidifying agent is added, a gel may be formed that is very viscous and difficult to cast.

[0122] If present, step (d) includes adding one or more flavorings to the slurry layer. The flavorings may be sprayed onto the slurry. The flavorings may be applied as is, i.e., in pure form, or as part of a composition. For example, one or more flavorings may be dissolved in a solvent (e.g., ethanol) before the solution is applied to a dried slurry or aerosol-generating material. The solvent (e.g., ethanol) may then be removed by evaporation, such as flash evaporation. If multiple flavorings are present, they may be added simultaneously (optionally, as part of a composition including a solvent such as ethanol) or sequentially (optionally, each as part of a composition including a solvent such as ethanol).

[0123] Alginates are derivatives of alginic acid and are typically high molecular weight polymers (10-600 kDa). Alginic acid is a copolymer of β-D-mannuronic acid (M) units and α-L-guluronic acid (G) units (blocks) that are linked to each other by (1,4)-glycosidic bonds to form a polysaccharide. Upon addition of calcium cations, alginates crosslink to form a gel. Alginates with a high G monomer content form gels more readily upon addition of a calcium source. Therefore, in some cases, gel precursors may contain alginates in which at least about 40%, 45%, 50%, 55%, 60%, or 70% of the monomer units in the alginate copolymer are α-L-guluronic acid (G) units.

[0124] In some cases, the slurry may be heated before and during casting. This can delay gelation, improve handling, and facilitate the casting process. Furthermore, heating the slurry may melt flavoring components (e.g., menthol) to improve handling.

[0125] In some cases, the slurry may be cast as a band-cast sheet. The sheet may be filled with a release agent such as lecithin, which can help separate the band cast from the amorphous solid. In other examples, the band may be covered with a film of a release agent such as lecithin to aid in separation.

[0126] When the solvent consists of water, the dry weight content of the slurry is the same as the dry weight content of the amorphous solid. Therefore, the description herein relating to solid materials is expressly disclosed in combination with any embodiment of the slurry of the present invention.

[0127] The consumables described herein may be used in a combustion-type aerosol supply system or a non-combustion-type aerosol supply system.

[0128] Combustion-type aerosol supply system One aspect of the present invention provides a combustion-type aerosol supply system in which the aerosol-generating material (or its components) constituting the aerosol supply system is burned or incinerated during use in order to facilitate the delivery of at least one substance to the user.

[0129] In some embodiments, the delivery system is a combustion-type aerosol delivery system, such as a system selected from the group consisting of cigarettes, cigarillos, and cigars.

[0130] Non-combustion aerosol supply device One aspect of the present invention provides a non-combustible aerosol supply system comprising consumables (also called articles) described herein and a non-combustible aerosol supply device having a heater configured to heat the consumables without combustion. The non-combustible aerosol supply system may also be called an aerosol generation assembly. The non-combustible aerosol supply device may also be called an aerosol generation device.

[0131] In one embodiment, the present invention provides an aerosol supply device comprising: a device housing defining a device chamber; a receptacle defining a heating chamber configured to removably receive at least a portion of an article described herein; and a heater assembly having a heating element for heating at least a portion of the article containing an aerosol-generating material received in the heating chamber. The heating element and the article are configured such that the article can be inserted on or around the heating element.

[0132] In some cases, during use, the heater may heat the aerosol-generating material to a temperature of 350°C or less, for example, 120°C to 350°C, without burning the material. In some cases, the heater may heat the aerosol-generating material to 140°C to 250°C or 220°C to 280°C during use without burning the material. In some cases, substantially all of the aerosol-generating material may be less than about 4 mm, 3 mm, 2 mm, or 1 mm from the heater during use. In some cases, the material is positioned about 0.010 mm to 2.0 mm, preferably about 0.02 mm to 1.0 mm, preferably 0.1 mm to 0.5 mm from the heater. These minimum distances may, in some cases, reflect the thickness of the support that supports the aerosol-generating material. In some cases, the surface of the aerosol-generating material may be in direct contact with the heater.

[0133] The heater is configured to heat the aerosol product, and therefore the aerosol-generating material, without combustion. The heater may, in some cases, be a thin-film electrical resistive heater. In other cases, the heater may be an induction heater or the like. The heater may be a combustion heat source or a chemical heat source that generates heat through an exothermic reaction during use. The aerosol-generating assembly may comprise multiple heaters. The heater(s) may be powered by a battery.

[0134] The aerosol product may further comprise a cooling element and / or a filter. If present, the cooling element may act or function to cool the gaseous or aerosol components. In some cases, the cooling element may act to cool the gaseous components so that they condense to form an aerosol. Alternatively, the cooling element may act to keep the very hot parts of the non-combustible aerosol supply device away from the user. If present, the filter may include any suitable filter known in the art, such as a cellulose acetate plug.

[0135] In some cases, the aerosol generation assembly may be a non-combustion heating device. That is, the aerosol generation assembly may contain a solid aerosol generation material (but may not contain a liquid aerosol generation material). A non-combustion heating device is disclosed in whole by reference in International Publication No. 2015 / 062983.

[0136] Aerosol products (which may be referred to herein as articles, cartridges, or consumables) may be adapted for use in a THP or another aerosol generating device. In some cases, the articles may further comprise a filter and / or cooling element (as described above). In some cases, the aerosol products may be enclosed in packaging material such as paper.

[0137] The aerosol product may further include a ventilation aperture. The ventilation aperture may be provided on the side wall of the article. In some cases, the ventilation aperture may be provided on a filter and / or cooling element. These apertures may allow cold air to be drawn into the article during use, which can mix with the heated volatile components and thereby cool the aerosol.

[0138] Aeration enhances the generation of visible heated volatile components from the article when the article is heated during use. The heated volatile components are made visible by a cooling process that causes supersaturation of the heated volatile components. The heated volatile components then undergo droplet formation, also known as nucleation, and finally, the size of the aerosol particles of the heated volatile components increases due to further condensation of the heated volatile components and aggregation of newly formed droplets from the heated volatile components.

[0139] In some cases, the ratio of cold air to the total of heated volatile components and cold air is known as the permeability and is at least 15%. A permeability of 15% makes it possible to visualize the heated volatile components using the method described above. The visibility of the heated volatile components allows the user to identify that volatile components have been generated, adding to the sensory experience of smoking.

[0140] In another example, the permeability is 50% to 85% to provide further cooling of the heated volatile components. In some cases, the permeability may be at least 60% or 65%.

[0141] In some cases, the aerosol-generating material may be included in the article / assembly in sheet form. In some cases, the aerosol-generating material may be included as a flat sheet. In some cases, the aerosol-generating material may be included as a flat sheet, a bundled sheet or a crimped sheet, a crimped sheet, or a rolled sheet (i.e., in tube form). In some cases, the aerosol-generating material may be formed as a sheet and then shredded and incorporated into the article.

[0142] In some embodiments, the aerosol-generating material is crimped to form at least a portion of a consumable. The aerosol-generating material may be crimped before crimping. Thus, in some embodiments, the aerosol-generating material may be crimped and then crimped. For example, the aerosol-generating material may be crimped by passing the material through a pair of crimping rollers. Crimping can make it easier to crimp the aerosol-generating material.

[0143] In some embodiments, the aerosol-generating material is crimped to a crimp depth of at least 0.1 mm, and in some examples, at least 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 1.5 mm, or 2 mm. In some embodiments, the aerosol-generating material is crimped to a crimp depth of up to 2 mm. In some embodiments, the aerosol-generating material is crimped to a crimp depth in the range of 0.1 mm to 2 mm, and in some examples, in the range of 0.1 mm to 1 mm, or in the range of 0.2 mm to 0.7 mm.

[0144] The crimp depth (also known as the "crimping coefficient") refers to the depth of the grooves formed by crimping in the aerosol-generating material. That is, crimping the aerosol-generating material creates multiple troughs in the material when viewed from a first side, and the crimp depth is the depth of these troughs. The crimping can form a zigzag shape or another shape. In some embodiments, adjacent grooves in the crimped aerosol-generating material are spaced apart at distances ranging from 0.1 to 3 mm, and in some examples, from 0.2 to 2 mm. In some embodiments, the aerosol-generating material is heated when crimping. For example, the aerosol-generating material may be passed between crimping rollers, with one or both of the crimping rollers being heated.

[0145] In some embodiments, the aerosol-generating material is formed as a foam on a support. The aerosol-generating foam may be a continuous foam or a discontinuous foam, such as a constituent of individual parts of the foam on the support.

[0146] Referring to Figures 1 and 2, a partial cut section and perspective view of an example of an aerosol product 101 are shown. Article 101 is adapted for use with a device having a power supply and a heater. Article 101 of this embodiment is particularly suitable for use with the device 1 shown in Figures 5 to 7, which are described below. When in use, article 101 can be removably inserted into the device shown in Figure 5 at the insertion point 20 of device 1.

[0147] An example article 101 is in the form of a substantially cylindrical rod, comprising a body of aerosol-generating material 103 and a filter assembly 105 in the form of a rod. The aerosol-generating material may be included in sheet form. In some embodiments, the aerosol-generating material may be included in the form of shredded sheets. In some embodiments, the aerosol-generating material described herein may be incorporated in sheet form and shredded form.

[0148] The filter assembly 105 includes three segments: a cooling segment 107, a filter segment 109, and a mouthpiece end segment 111. Article 101 has a first end 113, also known as the mouthpiece end or proximal end, and a second end 115, also known as the distal end. The body of the aerosol-generating material 103 is positioned toward the distal end 115 of article 101. In one example, the cooling segment 107 is positioned adjacent to the body of the aerosol-generating material 103 between the body of the aerosol-generating material 103 and the filter segment 103, such that the cooling segment 107 is in contact with the aerosol-generating material 103 and the filter segment 103. In other examples, there may be separations between the body of the aerosol-generating material 103 and the cooling segment 107, and between the body of the aerosol-generating material 103 and the filter segment 109. The filter segment 109 is positioned between the cooling segment 107 and the mouthpiece end segment 111. The mouthpiece end segment 111 is positioned adjacent to the filter segment 109 and toward the proximal end 113 of the article 101. In one example, the filter segment 109 is in contact with the mouthpiece end segment 111. In one embodiment, the total length of the filter assembly 105 is 37 mm to 45 mm, and more preferably, the total length of the filter assembly 105 is 41 mm.

[0149] In one example, the rod of the aerosol generating material 103 has a length of 34 mm to 50 mm, preferably 38 mm to 46 mm, and preferably 42 mm.

[0150] In one example, the total length of article 101 is 71mm to 95mm, preferably 79mm to 87mm, and preferably 83mm.

[0151] The axial end of the body of the aerosol-generating material 103 can be seen at the distal end 115 of article 101. However, in other embodiments, the distal end 115 of article 101 may include an end member (not shown) that covers the axial end of the body of the aerosol-generating material 103.

[0152] The body of the aerosol generating material 103 is positioned around the filter assembly 105, approximately its circumference, and is joined to the filter assembly 105 by an annular piece of chip paper (not shown) that partially extends along the length of the body of the aerosol generating material 103. In one example, the chip paper is made from 58GSM standard chip paper. In one example, the chip paper has a length of 42mm to 50mm, preferably 46mm.

[0153] In one example, the cooling segment 107 is an annular tube positioned around a void within the cooling segment, defining the void. The void provides a chamber for heated volatile components generated from the body of the aerosol-generating material 103 to flow. The cooling segment 107 is hollow to provide a chamber for aerosol accumulation, but is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and while the article 101 is in use during insertion into the device 1. In one example, the wall thickness of the cooling segment 107 is approximately 0.29 mm.

[0154] The cooling segment 107 provides a physical displacement between the aerosol-generating material 103 and the filter segment 109. The physical displacement provided by the cooling segment 107 provides a thermal gradient over the length of the cooling segment 107. In one example, the cooling segment 107 is configured to provide a temperature difference of at least 40 degrees Celsius between heated volatile components entering the first end of the cooling segment 107 and heated volatile components exiting the second end of the cooling segment 107. In another example, the cooling segment 107 is configured to provide a temperature difference of at least 60 degrees Celsius between heated volatile components entering the first end of the cooling segment 107 and heated volatile components exiting the second end of the cooling segment 107. This temperature difference over the length of the cooling element 107 protects the temperature-sensitive filter segment 109 from the high temperature of the aerosol-generating material 103 when heated by the device 1. If no physical displacement is provided between the filter segment 109 and the body of the aerosol-generating material 103 and the heating element of the device 1, the temperature-sensitive filter segment 109 may be damaged during use and therefore will not effectively perform the required function.

[0155] In one example, the length of the cooling segment 107 is at least 15 mm. In another example, the length of the cooling segment 107 is 20 mm to 30 mm, more specifically 23 mm to 27 mm, more specifically 25 mm to 27 mm, preferably 25 mm.

[0156] The cooling segment 107 is made of paper, which means that the cooling segment 107 is made of a material that does not produce compounds of concern, such as toxic compounds, when used adjacent to the heater of device 1. In one example, the cooling segment 107 is manufactured from a spirally wound paper tube that provides a hollow internal chamber while maintaining mechanical rigidity. The spirally wound paper tube can meet the stringent dimensional accuracy requirements of a high-speed manufacturing process with respect to the length, outer diameter, roundness, and straightness of the tube.

[0157] In another example, the cooling segment 107 is a recess created from rigid plug wrap or tip paper. The rigid plug wrap or tip paper is manufactured to be rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and while the article 101 is being used in insertion into the device 1.

[0158] The filter segment 109 may be formed from any filter material sufficient to remove one or more volatile compounds from heated volatile components from the aerosol-generating material. In one example, the filter segment 109 is made from a monoacetate material such as cellulose acetate. The filter segment 109 provides cooling and irritation reduction from heated volatile components without depleting the amount of heated volatile components to a level unsatisfactory to the user.

[0159] In some embodiments, capsules (not shown) may be provided within the filter segment 109. The capsules may be positioned substantially in the center of the filter segment 109, across the diameter of the filter segment 109 and along the length of the filter segment 109. In other cases, they may be off-center in one or more dimensions. The capsules may optionally contain volatile components, such as flavorings or aerosol-forming materials, if present.

[0160] The density of the cellulose acetate tow material in the filter segment 109 controls the pressure drop across the filter segment 109 and also controls the pull resistance of article 101. Therefore, the selection of the material for the filter segment 109 is important in controlling the pull resistance of article 101. In addition, the filter segment performs a filtration function within article 101.

[0161] In one example, the filter segment 109 is made of 8Y15 grade filter tow material, thereby providing a filtering effect on heated volatile materials while also reducing the size of condensed aerosol droplets generated from the heated volatile materials.

[0162] The presence of the filter segment 109 provides an insulating effect by providing further cooling to the heated volatile components exiting the cooling segment 107. This further cooling effect lowers the contact temperature of the user's lips on the surface of the filter segment 109.

[0163] In one example, the filter segment 109 has a length of 6 mm to 10 mm, preferably 8 mm.

[0164] The mouthpiece end segment 111 is an annular tube positioned around a void within the mouthpiece end segment 111, defining the void within the mouthpiece end segment 111. The void provides a chamber for heated volatile components flowing from the filter segment 109. The mouthpiece end segment 111 is hollow to provide a chamber for aerosol accumulation, but is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and while the article is being used during insertion into device 1. In one example, the wall thickness of the mouthpiece end segment 111 is about 0.29 mm. In one example, the length of the mouthpiece end segment 111 is 6 mm to 10 mm, preferably 8 mm.

[0165] The suction end segment 111 may be manufactured from a helically wound paper tube that provides a hollow internal chamber while maintaining the required mechanical rigidity. The helically wound paper tube can meet the stringent dimensional accuracy requirements of high-speed manufacturing processes with respect to tube length, outer diameter, roundness, and straightness.

[0166] The inlet end segment 111 provides a function to prevent liquid condensation accumulating at the outlet of the filter segment 109 from coming into direct contact with the user.

[0167] In one example, the intake end segment 111 and the cooling segment 107 may be formed from a single tube, and the filter segment 109 is positioned inside that tube to separate the intake end segment 111 and the cooling segment 107.

[0168] Referring to Figures 3 and 4, a partial cross-sectional view and a perspective view of an example of article 301 are shown. The reference numerals shown in Figures 3 and 4 are equivalent to those shown in Figures 1 and 2, but are increased by 200 in each case.

[0169] In the example of article 301 shown in Figures 3 and 4, a ventilation region 317 is provided in article 301 that allows air to flow from the outside of article 301 into the inside of article 301. In one example, the ventilation region 317 takes the form of one or more ventilation holes 317 formed through the outer layer of article 301. The ventilation holes may be located within a cooling segment 307 to help cool article 301. In one example, the ventilation region 317 comprises one or more rows of holes, preferably each row of holes arranged circumferentially around article 301 in a cross section substantially perpendicular to the longitudinal axis of article 301.

[0170] In one example, there are 1 to 4 rows of vents to provide ventilation to the article 301. Each row of vents may have 12 to 36 vents 317. The vents 317 may have, for example, a diameter of 100 to 500 μm. In one example, the axial spacing between rows of vents 317 is 0.25 mm to 0.75 mm, preferably 0.5 mm.

[0171] In one example, the vents 317 are of uniform size. In another example, the vents 317 are of varying sizes. The vents can be fabricated using one or more of any preferred techniques, such as laser technology, mechanical perforation of the cooling segments 307, or pre-perforation of the cooling segments 307 before they are formed in the article 301. The vents 317 are positioned to provide effective cooling to the article 301.

[0172] In one example, the row of vents 317 is positioned at least 11 mm from the proximal end 313 of the article, preferably 17 mm to 20 mm from the proximal end 313 of the article 301. The position of the vents 317 is determined so that the user does not block the vents 317 when using the article 301.

[0173] By providing a row of vents 17mm to 20mm from the proximal end 313 of article 301, as can be seen in Figures 6 and 7, it becomes possible to position the vents 317 on the outside of device 1 when article 301 is fully inserted into device 1. Positioning the vents on the outside of device allows unheated air to enter article 301 from the outside of device 1 through the vents to help cool article 301.

[0174] The length of the cooling segment 307 is such that when the article 301 is fully inserted into the device 1, the cooling segment 307 is partially inserted into the device 1. The length of the cooling segment 307 provides a first function: to provide a physical gap between the heater component and the temperature-sensitive filter component 309 of the device 1 when the article 301 is fully inserted into the device 1; and a second function: to allow the ventilation holes 317 to be located both inside the cooling segment and outside the device 1. As can be seen from Figures 6 and 7, the majority of the cooling element 307 is located inside the device 1. However, there is a portion of the cooling element 307 that extends from the device 1. This portion of the cooling element 307, in which the ventilation holes 317 are located, extends from the device 1.

[0175] Referring more closely to Figures 5 to 7, an example of device 100 is shown, configured to heat an aerosol-generating material to volatilize at least one component of the aerosol-generating material, thereby typically forming an inhalable aerosol. Device 100 is a heating device that releases compounds by heating but not burning the aerosol-generating material.

[0176] Figure 5 shows an example of an aerosol supply device 100 for generating an aerosol from an aerosol-generating medium / material. Schematically, the device 100 may be used to heat a consumable or replaceable article 110 described herein, the consumable comprising an aerosol-generating material that generates an aerosol or other inhalable medium to be inhaled by the user of the device 100.

[0177] Device 100 comprises a housing 102 (including an outer cover 108) that surrounds and houses various components of device 100. Device 100 has an opening 104 in one end, through which an article 110 can be inserted for heating by the heater assembly 200 (see Figure 6). In use, the article 110 may be fully or partially inserted into the heater assembly 200, where it may be heated by one or more components of the heater assembly 200.

[0178] Device 100 may also include a user-operable control element 112, such as a button or switch, which operates device 100 when pressed. For example, a user may turn on device 100 by operating the switch 112.

[0179] Device 100 defines a longitudinal axis 101.

[0180] Figure 6 shows a schematic cross-sectional front view of the device 100 of Figure 5. The device 100 comprises an outer cover 108, a first end member 106, and a second end member 116. The device 100 comprises a chassis 109, a power supply 118, and an aerosol generation assembly 111 including a heater assembly 200. The device 100 further comprises at least one electronic module 122. The outer cover 108 forms part of the device shell. The first end member 106 is located at one end of the device 100, and the second end member 116 is located at the opposite end of the device 100. The first and second end members 106, 116 close the outer cover 108. The first and second end members 106, 116 form part of the shell. In the embodiment, the device 100 includes a lid (not shown) that is movable relative to the first end member 106 to close the opening 104 when the article 110 is not in a predetermined position.

[0181] Device 100 may also include electrical components such as a connector / port 120 that can receive a cable for charging the device 100's battery. For example, the connector may be a charging port, such as a USB charging port. In some examples, the connector may be used additionally or alternatively to transfer data between device 100 and another device, such as a computing device.

[0182] The device 100 includes a chassis 109, which is received by an outer cover 108. The aerosol generation assembly 111 includes a heater assembly 200 into which, when in use, an article 110 can be fully or partially inserted, and where the article 110 can be heated by one or more components of the heater assembly 200. The aerosol generation assembly 111 and the power supply 118 are mounted on the chassis 109, which is a single integrated component.

[0183] An integrated component refers to a component of device 100 that cannot be separated into two or more components after the assembly of device 100. "Integratedly formed" refers to two or more features formed on the integrated component during the manufacturing stage of the component.

[0184] The first and second end members 106 and 116 together define at least partially the end face of the device 100. For example, the bottom surface of the second end member 116 defines at least partially the bottom surface of the device 100. The edges of the outer cover 108 may also define part of the end face. The first and second end members 116 close the open end of the outer cover 108. The second end member 116 is located at one end of the chassis 109.

[0185] The end of the device 100 closest to the opening 104 may be known as the proximal end (or mouthpiece end) of the device 100, as it is closest to the user's mouth during use. During use, the user inserts an article 110 into the opening 104 and operates the user control unit 112 to start heating the aerosol-generating material and aspirates the aerosol generated in the device. This causes the aerosol to flow through the device 100 along a channel toward the proximal end of the device 100.

[0186] The other end of the device furthest from the opening 104 may be known as the distal end of the device 100, as it is the end furthest from the user's mouth during use. When the user inhales the aerosol generated within the device, the aerosol flows toward the proximal end of the device 100. The terms proximal and distal, applied to the features of the device 100, are explained by referring to the relative positions of such features toward each other in the proximal-distal direction along the axis 101.

[0187] The power source 118 is a battery, such as a rechargeable or non-rechargeable battery. Suitable battery examples include, for example, lithium batteries (such as lithium-ion batteries), nickel batteries (such as nickel-cadmium batteries), and alkaline batteries. The battery is electrically coupled to the aerosol generation assembly 111 and supplies power under the control of the controller 121 when needed to heat the aerosol generation material.

[0188] The power supply 118 and the aerosol generation assembly 111 are arranged axially, with the power supply 118 at the distal end of the device 100 and the aerosol generation assembly 111 at the proximal end of the device 100. Other configurations are also possible.

[0189] The electronic device module 122 may include, for example, a printed circuit board (PCB) 123. The PCB 123 may support at least one controller 121, such as a processor, and memory. The PCB 123 may also include one or more electrical tracks for electrically connecting various electronic components of the device 100 together. For example, battery terminals 119a, 119b may be electrically connected to the PCB 123 so that power can be distributed throughout the device 100. The connector 120 may also be electrically coupled to the battery 118 via the electrical tracks.

[0190] The illustrated aerosol-generating assembly 111 is an induction heating assembly comprising various components for heating the aerosol-generating material of article 110 via an induction heating process. Induction heating is the process of heating a conductive object (such as a susceptor) by electromagnetic induction. The induction heating assembly may comprise an inductive element, for example, one or more inductor coils, and a device for passing a variable current, such as an alternating current, through the inductive element. The variable current in the inductive element generates a fluctuating magnetic field. The fluctuating magnetic field penetrates a susceptor suitably positioned relative to the inductive element, generating eddy currents inside the susceptor. The susceptor has electrical resistance to eddy currents, and therefore the flow of eddy currents against this resistance heats the susceptor by Joule heating. If the susceptor contains a ferromagnetic material such as iron, nickel, or cobalt, heat may also be generated by magnetic hysteresis losses within the susceptor, i.e., by a change in the orientation of magnetic dipoles in the magnetic material as a result of alignment with the fluctuating magnetic field. In induction heating, compared to, for example, conduction heating, heat is generated inside the susceptor, enabling rapid heating. Furthermore, it allows for greater flexibility in configuration and application because no physical contact is required between the induction heater and the susceptor.

[0191] A temperature sensor in the form of a thermocouple 150 is thermally connected to a susceptor and connected to an electronics module 122. In the illustrated embodiment, a thermal conductive plate 140 is placed between the thermocouple 150 and the susceptor to facilitate thermal communication between the thermocouple 150 and the susceptor (as will be described in more detail below in relation to Figure 7). In other examples, the plate 140 may be omitted.

[0192] The thermocouple 150 monitors the susceptor temperature during the use of device 100 and supplies this information to the electronics module 122. This allows the electronics module 122 and the controller 121 to monitor and adjust the susceptor temperature as needed during the use of device 100, for example, by adjusting the amount of power supplied by the power supply 118. The thermocouple 150 can be any suitable thermocouple, such as a platinum-rhodium thermocouple (i.e., type B).

[0193] Compared to other devices for sensing temperature, the thermocouple 150 is more robust, durable, power-efficient, and can facilitate accurate temperature measurement. Nevertheless, in other examples within the scope of this disclosure, the temperature sensor can be any other suitable temperature sensor, such as a resistance temperature detector, a thermistor, or an infrared sensor. Figure 7 shows an enlarged view of a portion of the aerosol generation assembly 111 in cross-section, including the heater assembly 200 and the inductor coil assembly 127.

[0194] The aerosol generation assembly 111 includes an inductor coil assembly 127 and a heater assembly 200. The inductor coil assembly 127 extends around the heater assembly 200. The inductor coil assembly 127 comprises a coil support 126. The inductor coil assembly 127 comprises an inductor coil 124 wound around (i.e., around) the heater assembly 200, which is located in a groove 129 defined in the support 126. The inductor coil assembly 127 is fixedly mounted within the device housing 102. The coil support 126 may form part of the device housing 102.

[0195] The heater assembly 200 comprises a heating element 210 for heating the article 110 during use. In the exemplary embodiment shown in Figure 7, the heating element is a susceptor structure 210 (hereinafter referred to as the “susceptor”). The susceptor 210 in this example is a blade-shaped susceptor 210. The article 110 can be inserted on or around the susceptor 210. The blade-shaped susceptor 210 has a constant rectangular cross-section along most of its axial length and then may taper to a blade tip 212. In other examples, the axial cross-section may vary along the axial length of the susceptor 210 up to the blade tip 212.

[0196] While a blade-shaped susceptor 210 is shown, it should be understood that any other suitable shape or form of susceptor 210 may be used within the scope of this disclosure. For example, the susceptor 210 may be a pin shape having a constant circular cross-section along the axial length of the susceptor 210, tapering toward a pin tip, or a rod shape (e.g., a cylindrical rod or a square rod) having a constant or varying cross-section along the axial length of the susceptor 210, omitting the tip or tapered portion. In a further example, the susceptor 210 may be a tubular member that receives the article 110 / aerosol-generating material. Such a susceptor is an external susceptor. In such an example, the susceptor may define a peripheral wall (e.g., an annular wall) that defines at least a portion of a heating chamber that can receive and heat the article 110. In such an example, the susceptor surrounds the article 110, rather than the article 110 surrounding the susceptor as in the blade-shaped embodiment described above. It will be understood that the cross-sectional profile of the outer susceptor may be formed into various profile shapes. In further examples, multiple susceptors (e.g., two or more separate susceptors) may be provided, and may have different or similar configurations (e.g., pin shape, blade shape, rod shape, or tubular type) as needed.

[0197] The susceptor 210 is formed from a conductive material suitable for heating by electromagnetic induction. In this example, the susceptor is made of carbon steel. It will be understood that other suitable materials, such as ferromagnetic materials like iron, nickel, or cobalt, may also be used.

[0198] In other embodiments, the feature functioning as a heating element is not limited to being induction heated. Therefore, the feature functioning as a heating element may be heatable by electrical resistance. Accordingly, the heater assembly 200 may have electrical contacts for electrically connecting to a device for electrically operating the heating element by passing a flow of electrical energy through it. In such embodiments, the induction coil assembly 127 may be omitted if necessary.

[0199] The inductor coil 124 is fabricated from a conductive material. In this example, the inductor coil 124 is fabricated from Litz wire / cable, which is wound spirally to provide a helical inductor coil 124. Litz wire consists of multiple individual wires that are individually insulated and twisted together to form a single wire. Litz wire is designed to reduce skin effect losses in the conductor. In the exemplary device 100, the inductor coil 124 is fabricated from copper Litz wire having a circular cross-section. In other examples, Litz wire may have other shaped cross-sections, such as rectangular. The inductor coil 124 can be connected to the PCB 123 so that the activation of induction heating from there can be controlled using the electronics module 122 and switch 112.

[0200] The number of inductor coils used may also vary. For example, the heater assembly 200 shown in Figure 7 includes an inductor coil assembly 127 having only a single coil 124, but it should be understood that the inductor coil assembly 127 may feature any number of suitable coils. Additional coils may be used to provide different heating zones with different heating characteristics of the susceptor 210 (for example, to provide different heating conditions to different regions along the axial length of the susceptor 210 and / or to provide different heating conditions to the susceptor 210 at different times or in different use cases). Additional coils may also be provided to generate heating in additional susceptors that may be located within the heater assembly 200 (not shown). The heater assembly 200 may also include a receptacle 230, which defines a heating chamber 220 into which an article 110 is received during use. In the illustrated embodiment, the receptacle 230 is an annular body surrounding the susceptor 210, providing an annular space between the susceptor 210 and the receptacle, in which the article 110 can be received and heated during use.

[0201] The coil support 126 and the opening 104 define a device chamber 105 within the device housing 102 that receives and interacts with the receptacle 230 to secure the heater assembly 200 in place. In this embodiment, the device chamber 105 is defined by another feature other than the coil support 126. The coil support 105 forms an inner wall, which is cup-shaped.

[0202] The receptacle 230 may be detachably positioned within the chamber 105 so that it can be removed from the chamber 105 and replaced within it during use. This feature facilitates cleaning of the receptacle 230 (and other heater assembly components) and replacement of the receptacle 230 (and other heater assembly components) in case of damage or failure.

[0203] In the illustrated example, the receptacle 230 is entirely located inside the chamber 105. In other examples, once the receptacle 230 is received inside the chamber 105, a portion of the receptacle 230 (e.g., a lip or flange at its proximal end) may still extend outside the device chamber 105. Thus, in such examples, the receptacle 230 may be "partially removable" within the chamber 105. This disclosure covers all such examples.

[0204] Figure 8 is a side cross-sectional view of an article or consumable 1 for use in an aerosol delivery system.

[0205] Article 1 comprises a mouthpiece 2 and an aerosol generating section connected to the mouthpiece 2. In this example, the aerosol generating section comprises a source of aerosol generating material in the form of a cylindrical rod of aerosol generating material 3. In other examples, the aerosol generating section may comprise a cavity for receiving the source of aerosol generating material. The aerosol generating material may comprise a plurality of strands or strips of aerosol generating material.

[0206] The aerosol-generating material may or may not be crimped.

[0207] In this example, a cylindrical rod of aerosol-generating material 3 comprises multiple strands and / or strips of aerosol-generating material and is enclosed by packaging material 10. In this example, packaging material 10 is a non-permeable packaging material. The multiple strands or strips of aerosol-generating material may be aligned within the aerosol-generating section such that the longitudinal dimensions of the multiple strands or strips of aerosol-generating material are aligned parallel to the longitudinal axis X-X' of article 1. Alternatively, the strands or strips may generally be arranged such that the longitudinal dimensions of the aligned strands or strips cross the longitudinal axis of the article. At least about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, or 95% of the multiple strands or strips may be arranged so that the longitudinal dimensions of the multiple strands or strips are aligned parallel to the longitudinal axis of the article. The majority of the strands or strips may be arranged such that the longitudinal dimensions of the majority of the strands or strips are aligned parallel to the longitudinal axis of the article. In some embodiments, about 95% to about 100% of the strands or strips are arranged such that the longitudinal dimensions of the strands or strips are aligned parallel to the longitudinal axis of the article. In some embodiments, substantially all of the strands or strips are arranged within the aerosol-generating section such that the longitudinal dimensions of the strands or strips are aligned parallel to the longitudinal axis of the aerosol-generating section of the article.

[0208] If the majority of the strands or strips are positioned within the aerosol-generating section such that the longitudinal axis of the strands or strips is parallel to the longitudinal axis of the aerosol-generating section of the article, the force required to insert the aerosol generator into the aerosol-generating material can be relatively low. This can result in an article that is easier to use.

[0209] In this example, the rod of the aerosol-generating material 3 has a circumference of approximately 22.7 mm. In alternative embodiments, the rod of the aerosol-generating material 3 may have any preferred circumference, for example, a circumference of approximately 20 mm to approximately 26 mm.

[0210] Article 1 is configured for use in a non-combustible aerosol supply device that includes an aerosol generator for insertion into an aerosol generation section. In this example, the aerosol generator is a heater, and the article is configured to receive the aerosol generator within a rod of aerosol generation material.

[0211] The mouthpiece 2 includes a cooling section 8, also called a cooling element, positioned adjacent to the source of the aerosol-generating material 3 immediately downstream. In this example, the cooling section 8 is in contact with the source of the aerosol-generating material. The mouthpiece 2 also includes, in this example, a body 6 of the material downstream of the cooling section 8 and a hollow tubular element 4 downstream of the body 6 of the material at the mouthpiece end of the article 1. The cooling section 8 includes a hollow channel having an inner diameter of about 1 mm to about 4 mm, for example, about 2 mm to about 4 mm. In this example, the hollow channel has an inner diameter of about 3 mm. The hollow channel extends along the entire length of the cooling section 8. In this example, the cooling section 8 includes a single hollow channel. In alternative embodiments, the cooling section may include multiple channels, for example, two, three, or four channels. In this example, the single hollow channel is substantially cylindrical, but in alternative embodiments, other channel shapes / cross-sections may be used. The hollow channel can provide a space in which aerosols drawn into the cooling section 8 can expand and be cooled. In all embodiments, the cooling section is configured to limit the cross-sectional area of ​​the hollow channel(s) to restrict the displacement of the cigarette into the cooling section during use.

[0212] The non-permeable packaging material 10 may have lower friction with the aerosol-generating material, and as a result, when the aerosol generator is inserted into the rod of the aerosol-generating material, the strands and / or strips of the aerosol-generating material can be more easily displaced longitudinally within the cooling section. The inventors have found that by providing a cooling section 8 that is directly adjacent to the source of the aerosol-generating material and has an inner channel having a diameter within this range, the longitudinal displacement of the strands and / or strips of the aerosol-generating material is suitably reduced when the aerosol generator is inserted into the rod of the aerosol-generating material. It has been found that by reducing the displacement of the aerosol-generating material during use, a more consistent packing density of the aerosol-generating material can be suitably obtained along the length of the rod and / or within the cavity, thereby resulting in more consistent and improved aerosol generation.

[0213] The rod and cooling section 8 of the aerosol-generating material 3 each have a cross-sectional area measured perpendicular to the longitudinal axis of article 1, as indicated by the line X-X' in Figure 8. The cooling section is configured such that the maximum percentage of the cooling section's cross-sectional area is occupied by one or more hollow channels, for example, less than about 45%, less than about 32%, or less than about 25% of the cross-sectional area. In this example, about 18% of the cooling section's cross-sectional area is occupied by hollow channels. Additionally or alternatively, at least about 4%, or at least about 6%, or at least about 8% of the cooling section's cross-sectional area may be occupied by hollow channels. In some examples, 4% to 32% of the cooling section's cross-sectional area is occupied by hollow channels. Table 1 shows exemplary percentages of the cooling section's cross-sectional area occupied by hollow channels with an inner diameter of either 3 or 3.9 mm for a range of cooling section diameters. For the purposes of this calculation, the cross-sectional area of ​​the cooling section is calculated based on the diameter of the cooling section without applying the chip paper, and the measurement is based on the dimensions of the cooling section that are in direct contact with the aerosol generating section.

[0214] [Table 1]

[0215] The cooling section 8 preferably has a radial wall thickness that can be measured, for example, using a caliper. The wall thickness of the cooling section 8 defines the inner diameter of the cavity enclosed by the wall of the cooling section 8 with respect to a given outer diameter of the cooling section. The cooling section 8 may have a wall thickness of at least about 1.5 mm to about 2 mm. In this example, the cooling section 8 has a wall thickness of about 2 mm. The inventors have found that by providing a cooling section 8 preferably having a wall thickness within this range, the retention of the aerosol-generating material source within the aerosol-generating section is improved by reducing the longitudinal displacement of the strands and / or strips of the aerosol-generating material when the aerosol generator is inserted into the article during use.

[0216] The cooling section 8 is formed from a filamentous tow. To form the cooling section 8, other configurations 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 papier-mulch process, or molded or extruded plastic tubes. The cooling section 8 is manufactured to have sufficient rigidity to withstand axial compressive forces and bending moments that may occur during manufacturing and while article 1 is in use.

[0217] The wall material of the cooling section 8 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 section 8. 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.

[0218] The filamentous tow forming the cooling section 8 preferably has a total denier of less than 45,000, more preferably less than 42,000. This total denier has been found to allow for the formation of a cooling section 8 that is not excessively dense. Preferably, the total denier is at least 20,000, more preferably at least 25,000. In a preferred embodiment, the filamentous tow forming the cooling section 8 has a total denier of 25,000 to 45,000, more preferably 35,000 to 45,000.

[0219] Preferably, the density of the material forming the cooling section 8 is at least about 0.20 grams (g / cc) per cubic centimeter, more preferably at least about 0.25 g / cc.

[0220] Preferably, the density of the material forming the cooling section 8 is less than about 0.80 grams (g / cc) per cubic centimeter, more preferably less than 0.6 g / cc. In some embodiments, the density of the material forming the cooling section 8 is 0.20 to 0.8 g / cc, more preferably 0.3 to 0.6 g / cc, or 0.4 g / cc to 0.6 g / cc, or about 0.5 g / cc. These densities have been found to achieve a good balance between the improved hardness provided by the higher density material and the minimization of the total weight of the article. For the purposes of the present invention, the "density" of the material forming the cooling section 8 refers to the density of any filamentous tow forming the element into which any plasticizer is incorporated. The density may also be determined by dividing the total weight of the material forming the cooling section 8 by the total volume of the material forming the cooling section 8, the total volume of which can be calculated using appropriate measurements of the material forming the cooling section 8, for example, using a caliper. If necessary, appropriate dimensions may be measured using a microscope. Preferably, the length of the cooling section 8 is less than about 30 mm. More preferably, the length of the cooling section 8 is less than about 25 mm. Even more preferably, the length of the cooling section 8 is less than about 20 mm. In addition, or alternatively, the length of the cooling section 8 is preferably at least about 10 mm. Preferably, the length of the cooling section 8 is at least about 15 mm. In some preferred embodiments, the length of the cooling section 8 is about 15 mm to about 20 mm, more preferably about 16 mm to about 19 mm. In this example, the length of the cooling section 8 is 19 mm.

[0221] The cooling section 8 is positioned around the intake port 2 and defines a void within the intake port 2, which functions as a cooling section. The void provides a chamber through which heated volatile components generated by the rod of the aerosol-generating material 3 flow. The cooling section 8 is hollow to provide a chamber for aerosol accumulation, but is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and while the article 1 is in use. The cooling section 8 provides physical displacement between the aerosol-generating material 3 and the body 6 of the material. The physical displacement provided by the cooling section 8 can provide a thermal gradient over the length of the cooling section 8.

[0222] Preferably, the mouthpiece 2 is 110 mm 3 It is provided with a cavity having a larger internal volume. It has been found that by providing a cavity of at least this volume, improved aerosol formation is possible. More preferably, the inlet 2 is formed, for example, within the cooling section 8, and 110 mm 3 Larger, even more preferably 130 mm 3 It features a cavity with a larger internal volume, allowing for further improvement of the aerosol. In some examples, the internal cavity is approximately 130 mm 3 ~approx. 230mm 3 For example, approximately 134mm 3 or 227mm 3 The cooling section 8 has a volume of . The cooling section 8 may be configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile components entering the first upstream end of the cooling section 8 and the heated volatile components exiting the second downstream end of the cooling section 8. Preferably, the cooling section 8 is configured to provide a temperature difference of at least 60 degrees Celsius, preferably at least 80 degrees Celsius, and more preferably at least 100 degrees Celsius between the heated volatile components entering the first upstream end of the cooling section 8 and the heated volatile components exiting the second downstream end of the cooling section 8. This temperature difference along the length of the cooling section 8 protects the body 6 of the temperature-sensitive material from the high temperature of the aerosol-generating material 3 when heated.

[0223] In use, the aerosol generation section may exhibit a pressure drop of about 15 to about 40 mmH2O. In some embodiments, the aerosol generation section exhibits a pressure drop across the aerosol generation section of about 15 to about 30 mmH2O.

[0224] The aerosol-generating material may have a packing density of about 400 mg / cm 3 to about 900 mg / cm 3 . A packing density higher than this may make it difficult to insert the aerosol generator of the aerosol supply device into the aerosol-generating material and may increase the pressure drop. If the packing density is less than 400 mg / cm 3 , the rigidity of the article may decrease. Further, if the packing density is too low, the aerosol-generating material may not effectively grip the aerosol generator of the aerosol supply.

[0225] At least about 70% of the volume of the aerosol generation section is filled with the aerosol-generating material. In some embodiments, about 75% to about 85% of the volume of the cavity is filled with the aerosol-generating material.

[0226] In this embodiment, the non-permeable packaging material 10 surrounding the rod of aerosol-generating material includes aluminum foil. In other embodiments, the packaging material 10 includes paper packaging material optionally comprising a barrier coating to make the material of the packaging material substantially non-permeable. Aluminum foil has been found to be particularly effective in promoting aerosol formation within the aerosol-generating material 3. In this example, the aluminum foil has a metal layer having a thickness of about 6 μm. In this example, the aluminum foil has a paper backing. However, in alternative configurations, the aluminum foil may have other thicknesses, e.g., 4 μm to 16 μm. The aluminum foil does not necessarily have a paper backing, but may have a backing formed from another material, or may not have a backing material at all, for example, to help provide the foil with adequate tensile strength. Metal layers or foils other than aluminum may also be used. The total thickness of the packaging material is preferably 20 μm to 60 μm, more preferably 30 μm to 50 μm, which allows for the provision of packaging material with appropriate structural integrity and heat transfer properties. The tension that can be applied to the packaging material before it breaks may be greater than 3,000 grams, for example, 3,000 to 10,000 grams, or 3,000 to 4,500 grams. If the packaging material includes paper or paper backing, i.e., cellulose-based material, the packaging material may have a basis weight greater than about 30 gsm. For example, the packaging material may have a basis weight in the range of about 40 gsm to about 70 gsm. The inventors have preferably found that such a basis weight provides improved rigidity to the rod of the aerosol-generating material. The improved rigidity provided by the packaging material having a basis weight in this range can make the rod of the aerosol-generating material 3 more resistant to creasing or other deformation under forces that the article experiences during use, for example, when the article is inserted into a device and / or when the heat generator is inserted into the article.Providing a rod of aerosol-generating material with increased rigidity may be beneficial when multiple strands or strips of aerosol-generating material are aligned within an aerosol-generating section such that the longitudinal dimensions of the multiple strands or strips are aligned parallel to the longitudinal axis, because longitudinally aligned strands or strips of the aerosol-generating material may provide lower rigidity to the rod of the aerosol-generating material than when the strands or strips are not aligned. The improved rigidity of the rod of the aerosol-generating material allows the article to withstand increased forces experienced by the article during use. In this example, the non-permeable packaging material 10 is also substantially impermeable to air. In alternative embodiments, the packaging material 10 has a degree of permeability of preferably less than 100 cholesta units, more preferably less than 60 cholesta units. For example, a low-permeability packaging material having a degree of permeability of less than 100 cholesta units, more preferably less than 60 cholesta units, has been found to result in improved aerosol formation in the aerosol-generating material 3. While we do not wish to be bound by theory, this is assumed to be due to reduced loss of aerosol compounds through the packaging material 10. The air permeability of the packaging material 10 can be measured in accordance with ISO 2965:2009, which relates to the determination of air permeability of materials used as cigarette paper, filter plug wraps, and filter bonding paper.

[0227] The material body 6 and the hollow tubular elements 4 each define a substantially cylindrical overall shape and share a common longitudinal axis. The material body 6 is wrapped in a first plug wrap 7. Preferably, the first plug wrap 7 has a basis weight of less than 50 gsm, more preferably about 20 gsm to 40 gsm. Preferably, the first plug wrap 7 has a thickness of 30 μm to 60 μm, more preferably 35 μm to 45 μm. Preferably, the first plug wrap 7 is a non-porous plug wrap having an air permeability of, for example, less than 100 cholesta units, for example less than 50 cholesta units. However, in other embodiments, the first plug wrap 7 may be a porous plug wrap having an air permeability of, for example, more than 200 cholesta units.

[0228] Preferably, the length of the material body 6 is less than about 15 mm. More preferably, the length of the material body 6 is less than about 12 mm. In addition, or alternatively, the length of the material body 6 is at least about 5 mm.

[0229] Preferably, the length of the material body 6 is at least about 8 mm. In some preferred embodiments, the length of the material body 6 is about 5 mm to about 15 mm, more preferably about 6 mm to about 12 mm, even more preferably about 6 mm to about 12 mm, and most preferably about 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. In this example, the length of the material body 6 is 10 mm.

[0230] In this example, the main body 6 of the material is formed from a filamentous tow. In this example, the tow used for the main body 6 of the material has a denier (dpf) of 5 per filament and a total denier of 25,000. In this example, the tow contains plasticized cellulose acetate tow. The plasticizer used in the tow constitutes approximately 9% by weight of the tow. In this example, the plasticizer is triacetin. In other examples, different materials can be used to form the main body 6 of the material. For example, instead of tow, the main body 6 may be formed from paper in a similar manner to paper filters known to be used in cigarettes, for example. For example, paper or other cellulosic material may be provided as one or more parts of a sheet material that is folded and / or crimped to form the main body 6. The sheet material may have a basis weight of 0.5 gsm to 6 gsm, for example, 20 to 50 gsm. The sheet material may have a basis weight in any of the following ranges: 15-25 gsm, 25-30 gsm, 30-40 gsm, 40-45 gsm, and 45-50 gsm. Additionally or alternatively, the sheet material may have a width of 50 mm to 200 mm, for example, 60 mm to 150 mm, or 80 mm to 150 mm. For example, the sheet material may have a basis weight of 20-50 gsm and a width of 80 mm to 150 mm. This allows, for example, the cellulosic body to have a suitable pressure drop for articles having the dimensions described herein. Alternatively, the body 6 may be formed from a tow other than cellulose acetate, for example, polylactic acid (PLA), other materials described herein for filamentous tow, or similar materials. The tow is preferably formed from cellulose acetate. Whether or not the tow is formed from cellulose acetate or other materials, it preferably has a dpf of at least 5. Preferably, in order to achieve a sufficiently uniform material body 6, the tow has a denier per filament of 12 d.pf or less, preferably 11 d.pf or less, and more preferably 10 d.pf or less.

[0231] The total denier of the tow forming the body 6 of the material is preferably up to 30,000, more preferably up to 28,000, and even more preferably up to 25,000. These total denier values ​​provide a tow with a reduced proportion of the cross-sectional area of ​​the mouthpiece 2, resulting in a lower pressure drop across the mouthpiece 2 than tows with higher total denier values. For adequate hardness of the body 6 of the material, the tow preferably has a total denier of at least 8,000, more preferably at least 10,000. Preferably, the denier per filament is 5 to 12, while the total denier is 10,000 to 25,000. Preferably, the cross-sectional shape of the tow filaments is "Y" shaped, but in other embodiments, other shapes such as "X" shaped filaments having the same dpf and total denier values ​​as provided herein may be used. Regardless of the material used to form the body 6, the pressure drop across the body 6 may be, for example, 0.3 to s mmWG per 1 mm of length of the body 6, or 0.s mmWG to 2 mmWG per 1 mm of length of the body 6. The pressure drop may be, for example, 0.5 to 1 mmWG / mm length, 1 to 1.5 mmWG / mm length, or 1.5 to 2 mmWG / mm length. The total pressure drop across the body 6 may be, for example, 3 mmWG to 8 mWG, or 4 mmWG or more / mmWG. The total pressure drop across the body 6 may be about 5, 6, or 7 mmWG.

[0232] As shown in Figure 8, the mouthpiece 2 of article 1 comprises an upstream end 2a adjacent to the rod of the aerosol-generating material 3 and a downstream end 2b distal to the rod of the aerosol-generating material 3. At the downstream end 2b, the mouthpiece 2 has a hollow tubular element 4 formed from a filamentous tow. This has been found to preferably significantly reduce the temperature of the outer surface of the mouthpiece 2 at the downstream end 2b of the mouthpiece, which comes into contact with the consumer's mouth when article 1 is being used. In addition, the use of the tubular element 4 has also been found to significantly reduce the temperature of the outer surface of the mouthpiece 2, even upstream of the tubular element 4. While we do not wish to be bound by theory, it is hypothesized that this is due to the tubular element 4 guiding the aerosol closer to the center of the mouthpiece 2, and thus reducing heat transfer from the aerosol to the outer surface of the mouthpiece 2.

[0233] The "wall thickness" of the hollow tubular element 4 corresponds to the thickness of the wall of the tube 4 in the radial direction. This may be measured, for example, using a caliper. The wall thickness is preferably greater than 0.9 mm, and more preferably 1.0 mm or more. Preferably, the wall thickness is substantially constant around the entire wall of the hollow tubular element 4. However, if the wall thickness is not substantially constant, it is preferably greater than 0.9 mm, and more preferably 1.0 mm or more, at any point around the hollow tubular element 4. In this example, the wall thickness of the hollow tubular element 4 is about 1.3 mm.

[0234] Preferably, the length of the hollow tubular element 4 is less than about 20 mm. More preferably, the length of the hollow tubular element 4 is less than about 15 mm. Even more preferably, the length of the hollow tubular element 4 is less than about 10 mm. In addition, or alternatively, the length of the hollow tubular element 4 is at least about 5 mm. Preferably, the length of the hollow tubular element 4 is at least about 6 mm. In some preferred embodiments, the length of the hollow tubular element 4 is about 5 mm to about 20 mm, more preferably about 6 mm to about 10 mm, even more preferably about 6 mm to about 8 mm, most preferably about 6 mm, 7 mm, or about 8 mm. In this example, the length of the hollow tubular element 4 is 7 mm.

[0235] Preferably, the density of the hollow tubular element 4 is at least about 0.25 grams / cm³ (g / cc), more preferably at least about 0.3 g / cc. Preferably, the density of the hollow tubular element 4 is less than about 0.75 grams / cm³ (g / cc), more preferably less than 0.6 g / cc. In some embodiments, the density of the hollow tubular element 4 is 0.25 to 0.75 g / cc, more preferably 0.3 to 0.6 g / cc, more preferably 0.4 g / cc to 0.6 g / cc or about 0.5 g / cc. These densities have been found to achieve a good balance between the improved hardness given by the higher density material and the lower heat transfer properties of the lower density material. For the purposes of the present invention, the "density" of the hollow tubular element 4 refers to the density of the filamentous tow forming the element into which any plasticizer is incorporated. The density may also be determined by dividing the total weight of the hollow tubular element 4 by the total volume of the hollow tubular element 4, the total volume of which can be calculated, for example, using appropriate measurements of the hollow tubular element 4 obtained using a caliper. If necessary, appropriate dimensions may be measured using a microscope.

[0236] The filamentous tow forming the hollow tubular element 4 preferably has a total denier of less than 45,000, more preferably less than 42,000. This total denier has been found to allow for the formation of tubular elements 4 that are not excessively dense. Preferably, the total denier is at least 20,000, more preferably at least 25,000. In a preferred embodiment, the filamentous tow forming the hollow tubular element 4 has a total denier of 25,000 to 45,000, more preferably 35,000 to 45,000. Preferably, the cross-sectional shape of the tow filaments is "Y" shaped, but in other embodiments, other shapes such as "X" shaped filaments can be used.

[0237] The filamentous tow forming the hollow tubular element 4 preferably has a denier per filament greater than 3. This denier per filament has been found to allow for the formation of tubular elements 4 that are not excessively dense. Preferably, the denier per filament is at least 4, more preferably at least 5. In a preferred embodiment, the filamentous tow forming the hollow tubular element 4 has a denier per filament of 4 to 10, more preferably 4 to 9.

[0238] The hollow tubular element 4 preferably contains 15% to 22% by weight of a plasticizer. In the case of cellulose acetate tow, the plasticizer is preferably triacetin, but other plasticizers such as polyethylene glycol (PEG) may also be used. More preferably, the hollow tubular element 4 contains 16% to 20% by weight of a plasticizer, for example, about 17% by weight, about 18% by weight, or about 19% by weight of a plasticizer.

[0239] In this example, the first hollow tubular element 4, the material body 6, and the cooling section 8 are joined using a second plug wrap 9 that is wrapped around all three sections. Preferably, the second plug wrap 9 has a basis weight of less than 50 gsm, more preferably about 20 gsm to 45 gsm. Preferably, the second plug wrap 9 has a thickness of 30 μm to 60 μm, more preferably 35 μm to 45 μm. The second plug wrap 9 is preferably a non-porous plug wrap with an air permeability of less than 100 cholesta units, for example less than 50 cholesta units. However, in an alternative embodiment, the second plug wrap 9 may be a porous plug wrap with an air permeability of, for example, greater than 200 cholesta units.

[0240] In this example, article 1 has a circumference of approximately 23 mm. In other examples, articles may be provided in any of the forms described herein, for example, having a circumference of 20 mm to 26 mm. Since the articles will be heated and release aerosols, improved heating efficiency can be achieved by using articles with a lower circumference within this range, for example, less than 23 mm. Article circumferences greater than 19 mm have been found to be particularly effective in achieving improved aerosolization by heating while maintaining a suitable product length. Articles with a circumference of 20 mm to 24 mm, more preferably 20 mm to 23 mm, have been found to achieve a good balance between providing effective aerosol delivery and enabling efficient heating on the one hand.

[0241] The tip paper 5 is wrapped around a portion of the rod of the aerosol-generating material 3 along the entire length of the mouthpiece 2, and has adhesive on its inner surface to connect the mouthpiece 2 and the rod 3. In this example, the rod of the aerosol-generating material 3 is enclosed within a packaging material 10 that forms a first packaging material, and the tip paper 5 forms an outer packaging material that extends at least partially over the rod of the aerosol-generating material 3 to connect the mouthpiece 2 and the rod 3. In some examples, the tip paper may extend only partially over the rod of the aerosol-generating material.

[0242] In this example, the chip paper 5 extends 5 mm over the rod of the aerosol generating material 3, but alternatively, it may extend 3 mm to 10 mm, or more preferably 4 mm to 6 mm, over the rod 3 to ensure secure attachment between the mouthpiece 2 and the rod 3. The chip paper may have a basis weight greater than 20 gsm, for example greater than 25 gsm, or preferably greater than 30 gsm, for example greater than 37 gsm. It has been found that basis weights in this range provide a chip paper that has acceptable tensile strength while also being flexible enough to wrap around the article 1 and adhere to the chip paper itself along the longitudinal overlap seams of the paper. The outer circumference of the chip paper 5 is approximately 23 mm when wrapped around the mouthpiece 2.

[0243] The article has a permeability level in which approximately 10% of the aerosol is drawn through the article. In an alternative embodiment, the article may have a permeability level in which 1% to 20%, for example 1% to 12%, of the aerosol is drawn through the article.

[0244] These levels of ventilation help to improve the consistency of the aerosol inhaled by the user at the mouthpiece end 2b while assisting the aerosol cooling process. The ventilation is provided directly within the mouthpiece 2 of the article 1. In this example, the ventilation is provided within the cooling section 8, which has been found to be particularly beneficial in assisting the aerosol generation process. The ventilation is provided through perforations 12, which are located 13 mm from the mouthpiece end 2b downstream of the mouthpiece 2 and are formed in this case as a single row of laser perforations. In an alternative embodiment, two or more rows of ventilation perforations may be provided. These perforations pass through the tip paper 5, the second plug wrap 9, and the cooling section 8. In an alternative embodiment, the ventilation can be provided at other locations within the mouthpiece, for example, in the body of the material 6 or the first tubular element 4. Preferably, the article is configured such that the perforations are located about 28 mm or less from the upstream end of the article 1, preferably 20 mm to 28 mm from the upstream end of the article 1. In this example, the aperture is located about 25 mm from the upstream end of the article.

[0245] The first dimension or cutting width of the strand or strip of aerosol-generating material may be 0.9 mm to 1.5 mm. If a strand or strip of aerosol-generating material having a cutting width of less than 0.9 mm is incorporated into an article for use in a non-combustible aerosol supply system, the pressure drop across the article may increase to a level that makes the article unsuitable for use in a non-combustible aerosol supply device. However, if the strand or strip has a cutting width greater than 2 mm (e.g., greater than 2 mm), it may be difficult to insert the strand or strip of aerosol-generating material into the article during manufacturing. In a preferred embodiment, the cutting width of the strand or strip of aerosol-generating material is about 1 mm to 1.5 mm.

[0246] Strands or strips of material may be formed by shredding a sheet of aerosol-generating material. The sheet of aerosol-generating material may be cut in the width direction, for example by a cross-cut shredding method, to define the cutting width as well as the cutting length of the strands or strips of aerosol-generating material. The cutting length of the shredded aerosol-generating material may be at least 5 mm, for example, at least 10 mm, or at least 20 mm. The cutting length of the shredded aerosol-generating material may be less than 60 mm, less than 50 mm, or less than 40 mm. In some embodiments, a plurality of strands or strips of aerosol-generating material are provided, and at least one of the plurality of strands or strips of aerosol-generating material has a length greater than about 10 mm. At least one of the plurality of strands or strips of aerosol-generating material may, alternatively or additionally, have a length of about 10 mm to about 60 mm, or about 20 mm to about 50 mm. Each of the plurality of strands or strips of aerosol-generating material may have a length of about 10 mm to about 60 mm, or about 20 mm to about 50 mm.

[0247] The sheet or shredded sheet of the aerosol-generating material may have a thickness of at least about 100 μm. The sheet or shredded sheet may have a thickness of at least about 120 μm, 140 μm, 160 μm, 180 μm, or 200 μm. In some embodiments, the sheet or shredded sheet has a thickness of about 150 μm to about 300 μm, about 151 μm to about 299 μm, about 152 μm to about 298 μm, about 153 μm to about 297 μm, about 154 μm to about 296 μm, about 155 μm to about 295 μm, about 156 μm to about 294 μm, about 157 μm to about 293 μm, about 158 ​​μm to about 292 μm, about 159 μm to about 291 μm, or about 160 μm to about 290 μm. In some embodiments, the sheet or shredded sheet has a thickness of approximately 170 μm to approximately 280 μm, approximately 180 to approximately 270 μm, approximately 190 to approximately 260 μm, approximately 200 μm to approximately 250 μm, or approximately 210 μm to approximately 240 μm.

[0248] The thickness of the sheet or shredded sheet may differ between the first and second surfaces. In some embodiments, individual strips or pieces of the aerosol-generating material have a minimum thickness of about 100 μm across the area of ​​the strip or piece. In some cases, individual strips or pieces of the aerosol-generating material have a minimum thickness of about 0.05 mm or about 0.1 mm across the area of ​​the strip or piece. In some cases, individual strips, strands, or pieces of the aerosol-generating material have a maximum thickness of about 1.0 mm across the area of ​​the strip, strand, or piece. In some cases, individual strips or pieces of the aerosol-generating material have a maximum thickness of about 0.5 mm or about 0.3 mm across the area of ​​the strip or piece.

[0249] The sheet thickness can be determined using ISO 534:2011 "Paper and cardboard - Measurement of thickness".

[0250] If the sheet or shredded sheet of aerosol-generating material is too thick, heating efficiency may be impaired. This can negatively affect power consumption during use, for example, power consumption for flavor release from the aerosol-generating material. Conversely, if the aerosol-generating material is too thin, it is difficult to manufacture and handle, and very thin materials are difficult to cast and brittle, which can impair aerosol formation during use. If the sheet or shredded sheet of aerosol-generating material is too thin (e.g., less than 100 μm), it may be necessary to increase the cutting width of the shredded sheet to achieve sufficient filling of the aerosol-generating material when incorporated into an article. As mentioned above, increasing the cutting width of the shredded sheet may increase the pressure drop, which is undesirable.

[0251] Approximately 100g / m 2 ~about 250g / m 2 Along with the area density, a sheet or shredded sheet having a thickness of at least about 100 μm is assumed to be less likely to tear, break, or otherwise deform during the manufacturing of the sheet or shredded sheet. A thickness of at least about 100 μm may have a positive effect on the overall structural integrity and strength of the sheet or shredded sheet. For example, a sheet or shredded sheet having a thickness of at least about 100 μm may have good tensile strength and therefore be relatively easy to process.

[0252] The thickness of the sheet or shredded sheet is also thought to affect the area density of the sheet or shredded sheet. In other words, increasing the thickness of the sheet or shredded sheet may increase the area density of the sheet or shredded sheet.

[0253] Conversely, reducing the thickness of a sheet or shredded sheet may decrease the area density of the sheet or shredded sheet. To avoid misunderstanding, when area density is referred to herein, it refers to the average area density calculated for a given strip, strand, piece, or sheet of aerosol-generating material, which is calculated by measuring the surface area and weight of a given strip, strand, piece, or sheet of aerosol-generating material.

[0254] The aerosol-generating material sheet or shredded sheet may have a tensile strength in the range of approximately 2 N / 15 mm to approximately 300 N / 15 mm. The tensile strength may be greater than approximately 2 N / 15 mm, for example, greater than approximately 3 N / 15 mm, or greater than approximately 4 N / 15 mm, or greater than approximately 5 N / 15 mm, or greater than approximately 6 N / 15 mm. The tensile strength may also be in the range of approximately 6 N / 15 mm to approximately 100 N / 15 mm.

[0255] Articles containing shredded sheets of aerosol-generating material having an area density of approximately 180 gsm and a minimum thickness of 220-230 μm can be filled in such a way that the aerosol-generating material remains in place within the article, while maintaining a desired weight of the aerosol-generating material within the article and delivering acceptable sensory stimuli (e.g., taste and smell) when heated in a non-combustible aerosol supply device. The flexibility of the sheet or shredded sheet is considered to depend, at least in part, on the thickness and area density of the sheet or shredded sheet. Thicker sheets or shredded sheets may be less flexible than thinner sheets or shredded sheets. Also, the higher the area density of the sheet, the lower the flexibility of the sheet or shredded sheet. The combinations of thickness and area density of the aerosol-generating material described herein are considered to provide relatively flexible sheets or shredded sheets.

[0256] When aerosol-generating materials are incorporated into articles for use in non-combustible aerosol supply devices, this flexibility can offer various advantages. For example, strands or strips can be easily deformed and bent when a heater or aerosol generator is inserted into the aerosol-generating material, thus facilitating the insertion of the aerosol generator (e.g., a heater) into the material and improving the retention of the aerosol generator by the aerosol-generating material.

[0257] As shown in Figure 9, the non-combustible aerosol supply device 100 may include a housing 101 having a region 102 for receiving an article 1. The region 102 is configured to receive the article 1. When the article 1 is received within the region 102, at least a portion of the aerosol-generating material is thermally close to the heater 103. When the article 1 is fully received within the region 102, at least a portion of the aerosol-generating material may be in direct contact with the heater 103. The aerosol-forming substrate releases a range of volatile compounds at different temperatures. By controlling the maximum operating temperature of the electrically heated aerosol generation system 100, the selective release of undesirable compounds can be controlled by preventing the release of selected volatile compounds.

[0258] Figure 10 is a schematic cross-sectional view of a non-combustible aerosol supply device of the type shown in Figure 9, in which a heater 103 is inserted into the aerosol-generating material 3 of article 1. The non-combustible aerosol supply device is shown engaged with the aerosol product 1 for consumption by a user. The housing 101 of the non-combustible aerosol supply device defines a region 102 in the form of a cavity that opens at its proximal end (or suction end) to receive the aerosol product 1 for consumption. The distal end of the cavity is covered by a heating assembly comprising a heater 103. The heater 103 is held by a heater mount (not shown) such that the active heating region of the heater is located within the cavity. The active heating region of the heater 103 is located within the aerosol-generating section of the aerosol product 1 once the aerosol product 1 is fully received within the cavity. The heater 103 is configured to be inserted into the aerosol-generating material 3.

[0259] In Figures 9 and 10, the heater 103 is formed in the form of a blade terminating at a single point. That is, the heater has a length dimension greater than its width dimension, and a width dimension greater than its thickness dimension. The first and second surfaces of the heater are defined by the width and length of the heater. However, other shapes of heaters are also possible. For example, the heater may be a pin shape having a constant circular cross-section along the axial length of the heater, tapering towards the pin tip, or a rod shape (e.g., a cylindrical rod or a square rod) having a constant or varying cross-section along the axial length of the heater, omitting the tip or tapered portion.

[0260] When article 1 is pushed into the cavity, the tapered point of the heater engages with the aerosol-generating material 3. The heater is molded for easy insertion into and removal from the aerosol-generating material 3. By applying force to article 1, the heater penetrates the aerosol-generating material 3. When article 1 is properly engaged with the non-combustible aerosol supply device, the heater 103 is inserted into the aerosol-generating material 3. When the heater is activated, the aerosol-generating material 3 is heated, and volatile substances are generated or released. When the user inhales over the mouthpiece 2, air is drawn into article 1, and the volatile substances condense to form an inhalable aerosol. This aerosol passes through the mouthpiece 2 of article 1 and enters the user's mouth.

[0261] It was found that the aerosol generator can be inserted into the aerosol-generating material relatively easily. Furthermore, once the aerosol generator is inserted into the aerosol-generating material, the article is held securely. This makes the article and device easier and safer to use, as it reduces the likelihood of the article being displaced from the aerosol generator during use.

Claims

1. A consumable for use in a non-combustible aerosol supply system, wherein the consumable comprises about 100 to about 500 mg of aerosol generating material, the aerosol generating material is in the form of a pleated sheet, an elongated strip, or a shredded sheet, and the consumable is tobacco-free or contains less than 2% tobacco.

2. The consumable according to claim 1, wherein the consumable comprises approximately 200 to approximately 500 mg, for example, approximately 250 to approximately 500 mg or approximately 300 to approximately 500 mg of aerosol generating material.

3. The consumable according to claim 1, wherein the consumable comprises approximately 350 to approximately 500 mg, for example, approximately 400 to approximately 500 mg of aerosol generating material.

4. The consumable product according to any one of claims 1 to 3, wherein the aerosol generating material comprises a binder, an aerosol forming agent material, a filler, and / or one or more flavorings and / or an active substance.

5. The consumable product according to any one of claims 1 to 4, wherein the aerosol generating material contains one or more flavorings but does not contain an active substance.

6. The consumable product according to any one of claims 1 to 4, wherein the aerosol generating material contains one or more active substances but does not contain flavorings.

7. The consumable product according to any one of claims 1 to 4, wherein the aerosol generating material comprises one or more active substances and one or more flavorings.

8. The consumable product according to any one of claims 1 to 7, wherein the aerosol generating material comprises about 1 to about 80% by weight of an aerosol forming agent material.

9. The consumable product according to claim 4 or 8, wherein the aerosol-forming agent material comprises one or more of the following: glycerol, propylene glycol, 1,3-propanediol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

10. The consumable product according to any one of claims 1 to 9, wherein the aerosol generating material contains about 0.5% to about 60% by weight of a binder.

11. The consumable product according to claim 4 or 10, wherein the binder comprises one or more compounds selected from the group consisting of alginate, pectin, starch, starch derivatives, cellulose, cellulose derivatives, gum, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof.

12. The consumable product according to claim 11, wherein the binder comprises one or more of hydroxyethylcellulose, hydroxypropylcellulose, hydroxypropylmethylcellulose, carboxymethylcellulose, alginate, pectin, guar gum, and acacia gum.

13. The consumable product according to claim 11, wherein the binder comprises alginate and / or pectin.

14. The consumable product according to any one of claims 1 to 13, wherein the aerosol generating material contains about 1 to about 15% by weight, for example, about 1 to about 10% by weight of a flavoring agent.

15. The consumable product according to claim 14, wherein the aerosol generating material contains about 2 to about 9% by weight, for example, about 3 to about 8% by weight of a flavoring agent.

16. The consumable product according to any one of claims 1 to 15, wherein the aerosol generating material comprises nicotine, for example, about 1 to about 20% by weight of nicotine, about 2 to about 18% by weight of nicotine, or about 3 to about 12% by weight of nicotine.

17. The consumable product according to any one of claims 1 to 16, wherein the aerosol generating material comprises an active substance, the active substance comprises or is derived from one or more plant substances, or components, derivatives, or extracts thereof, and the plant substance is selected from eucalyptus and rooibos.

18. The consumable according to any one of claims 1 to 17, wherein the consumable contains less than 1% tobacco.

19. The consumables according to any one of claims 1 to 18, wherein the consumables substantially do not contain tobacco.

20. The consumable product according to any one of claims 1 to 18, wherein the tobacco is tobacco powder.

21. A method for generating an aerosol from a consumable according to any one of claims 1 to 20, comprising the step of heating a portion of the aerosol generating material in the consumable to a temperature of at least 120°C.

22. A non-combustible aerosol supply system comprising a consumable product according to any one of claims 1 to 20 and a non-combustible aerosol supply device, wherein the non-combustible aerosol supply device comprises an aerosol generating device that generates an aerosol from the consumable product when the consumable product is used together with the non-combustible aerosol supply device.

23. Aerosol supply device comprising: a device housing defining a device chamber; a receptacle defining a heating chamber configured to removably receive at least a portion of a consumable according to any one of claims 1 to 20; and a heater assembly having a heating element for heating at least a portion of an article containing an aerosol-generating material received in the heating chamber.

24. Use of a consumable according to any one of claims 1 to 20 in a non-combustible aerosol supply device, wherein the non-combustible aerosol supply device comprises an aerosol generating device that generates an aerosol from the consumable when the consumable is used together with the non-combustible aerosol supply device.

25. A method for forming a consumable product according to any one of claims 1 to 20, (a) A step of supplying a slurry containing the components of the aerosol generating material or its precursors, (b) The step of forming a layer of the slurry, (c) The step of drying the slurry to form an aerosol generating material, (d) A step of forming a consumable product containing the aerosol generating material, Methods that include...

26. The method according to claim 25, wherein the slurry comprises a solvent, a binder, an aerosol-forming material, a filler, and one or more flavorings and / or active substances.

27. The method according to claim 25 or 26, further comprising the step of applying one or more flavorings to the aerosol-generating material before step (d).

28. The method according to claim 27, wherein the step of applying the one or more flavorings includes the step of spraying the flavorings onto the aerosol generating material.

Images