Articles for use with non-combustible aerosol supply devices

Abstract

This disclosure relates to an article (1) for use with a non-combustible aerosol supply device (100), the article (1) comprising a first end (2b) having a suction port (2), and a second end (2a) distal to the first end (2b), the second end (2a) comprising an extrusion plug (4) comprising a first aerosol-generating material. A non-combustible aerosol supply system comprising the article (1), a method for manufacturing an extrusion plug (4) for use with the article (1), and an extrusion plug (4) manufactured by a process are also disclosed.

Description

[Technical Field]

[0001] An article for use with a non-combustible aerosol supply device, wherein the article comprises an aerosol generating material. [Background technology]

[0002] Aerosol supply products generate an aerosol during use, which is inhaled by the user. For example, a cigarette heating device heats an aerosol-generating material, such as a cigarette, to form an aerosol by heating rather than burning the base material. Such aerosol supply products generally include an aerosol-generating section or region that generates an aerosol during use, and a mouthpiece through which the aerosol passes and reaches the user's mouth.

[0003] However, such aerosol-generating materials need to be improved, for example, in terms of their flavor delivery, ease of manufacture, and their format within delivery devices. [Overview of the project]

[0004] In a first aspect of the present invention, an article is provided for use with a non-combustible aerosol supply device, the article comprising a first end having a mouthpiece, and a second end distal to the first end, the second end comprising an extrusion plug comprising a first aerosol-generating material.

[0005] In some embodiments, the article comprises a second aerosol-generating material between the plug and the first end.

[0006] In some embodiments, the second aerosol-generating material is in the form of a rod.

[0007] In some embodiments, the extrusion plug is configured to receive an aerosol generator of a non-combustion aerosol supply device.

[0008] In some embodiments, the extrusion plug includes a receiving portion configured to receive an aerosol generator.

[0009] In some embodiments, the plug is configured such that when the aerosol generator is received by the plug, the aerosol generator extends within the plug and into the second aerosol-generating material.

[0010] In some embodiments, the aerosol generator is a pin.

[0011] In some embodiments, the first aerosol-generating material and / or the second aerosol-generating material includes a plant-based material.

[0012] In some embodiments, the plug contains approximately 5 to approximately 75% by weight of plant-based material.

[0013] In some embodiments, the plug includes a channel or recess.

[0014] In some embodiments, the channel is aligned with the longitudinal axis of the article.

[0015] In some embodiments, the channel is configured to allow fluid to pass through the plug.

[0016] In some embodiments, the channel is located on the surface of the plug.

[0017] In some embodiments, the recess or channel has a depth of about 5 to about 300 μm.

[0018] In some embodiments, the plug has a length of less than 6 mm and / or the width of the plug is about 15 to about 35 mm.

[0019] In some embodiments, the plug is substantially made of a first aerosol-generating material.

[0020] In some embodiments, the plug contains water.

[0021] In some embodiments, the plug contains a water content of from about 0 to about 15 wt%.

[0022] In a third aspect, a method of manufacturing an article is provided. The method can include extruding a plug and incorporating the plug into the article.

[0023] In a fourth aspect, a non-combustible aerosol supply system is provided that includes an article and a non-combustible aerosol supply device.

[0024] In a fifth aspect, a method of manufacturing an extrusion plug for use with an article is provided.

[0025] In some embodiments, the process includes extrusion.

[0026] In a fifth aspect, an extrusion plug produced by the process is provided.

[0027] Next, embodiments of the present invention will be described by way of example with reference to the accompanying drawings.

Brief Description of the Drawings

[0028] [Figure 1] A perspective view of an article for use with a non-combustible aerosol supply device. [Figure 2] A side cross-sectional view of the article shown in FIG. 1. [Figure 3] A perspective view of an article for use with a non-combustible aerosol supply device. [Figure 4] A schematic cross-sectional view of an aerosol generation section of an article for use with a non-combustible aerosol supply device. [Figure 5] Exemplary steps of a process used to manufacture an exemplary aerosol-generating composition are shown. [Figure 6]Figure 1 is a perspective view of a non-combustion aerosol supply system for generating aerosols from the articles shown. [Figure 7] This is a schematic side cross-sectional view of the plug described herein. [Modes for carrying out the invention]

[0029] As used herein, the term “delivery system” is intended to encompass a system for delivering at least one substance to a user. Combustion aerosol supply systems for cigarettes, cigarillos, cigars, and tobacco for pipes, hand-rolled cigarettes, or homemade cigarettes (whether based on tobacco, tobacco derivatives, puffed tobacco, recombined tobacco, tobacco substitutes, or other smoky materials), Non-combustion aerosol supply systems that release compounds from aerosol-generating materials without burning the materials, such as hybrid systems that generate aerosols using a combination of electronic cigarettes, tobacco heating products, and aerosol-generating materials, as well as Aerosol-free delivery system for delivering at least one substance to a user orally, nasally, transdermally, or by another non-aerosol-forming method, including but not limited to articles containing lozenges, gums, patches, inhalable powders, and oral products such as oral tobacco containing snus or moist snuff, wherein at least one substance may or may not contain nicotine.

[0030] According to this disclosure, a “non-combustible” aerosol supply system is a system in which the aerosol-generating materials (or their components) that make up the aerosol supply system are not burned or incinerated in order to facilitate the delivery of at least one substance to the user.

[0031] In some embodiments, the delivery system is a non-combustible aerosol supply system, such as a powered non-combustible aerosol supply system.

[0032] In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), but it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0033] In some embodiments, the non-combustion aerosol supply system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a cigarette heating system.

[0034] In some embodiments, the non-combustible aerosol supply system is a hybrid system that generates an aerosol using a combination of one or more aerosol-generating materials, each of which may be heated. Each of the aerosol-generating materials may be, for example, in the form of a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system comprises a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may, for example, include tobacco or a non-tobacco product.

[0035] Typically, a non-combustible aerosol supply system may comprise a non-combustible aerosol supply device and articles for use with the non-combustible aerosol supply device.

[0036] In some embodiments, the disclosure relates to articles comprising an aerosol-generating material and configured for use with a non-combustible aerosol supply device. These articles may be referred to as articles throughout the disclosure.

[0037] An article or consumable is an article comprising or consisting of an aerosol-generating material, some or all of which is intended to be consumed during use by the user. The article may comprise one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, packaging material, a mouthpiece, a filter, and / or an aerosol modifier. The article may also comprise an aerosol generator, such as a heater, which generates heat during use to cause the aerosol-generating material to produce an aerosol. The heater may comprise, for example, a flammable material, a material that can be heated by electrical conductivity, or a susceptor.

[0038] As used herein, the terms “upstream” and “downstream” are relative terms defined with respect to the direction of the mainstream aerosol drawn through the article or device during use.

[0039] In some embodiments, a non-combustible aerosol supply system, such as a non-combustible aerosol supply device, may include a power source and a controller. The power source may be, for example, a power source or a heat source. In some embodiments, the heat source includes a carbon substrate to which energy can be supplied to distribute power in the form of heat to an aerosol-generating material or heat transfer material adjacent to the heat source.

[0040] In some embodiments, a non-combustible aerosol supply system may comprise an area for receiving articles, an aerosol generator, an aerosol generation area, a housing, a suction port, a filter, and / or an aerosol modifier.

[0041] According to a first aspect of the present invention, an article for use with a non-combustible aerosol supply device is provided, the article comprising a first end having a mouthpiece, and a second end distal to the first end, the second end comprising an extrusion plug comprising a first aerosol-generating material.

[0042] In the figures described herein, similar reference numerals are used to indicate equivalent features, articles, or components.

[0043] Referring to Figure 1, article 1 comprises a first downstream end 2b and a second end 2a located upstream and distal to the downstream end 2b.

[0044] Referring to Figure 2, the first end 2b of article 1 comprises a first end 2a having a mouthpiece 2 and a second end 2b distal to the first end. The second end 2a may include an extrusion plug 4 comprising the first aerosol-generating material. The article further comprises an optional second aerosol-generating material 3.

[0045] Aerosol-generating materials are materials that can generate aerosols when energy is supplied, for example, by heating, irradiation, or any other method. Aerosol-generating materials may be in the form of a solid, liquid, or semi-solid (such as a gel), which may or may not contain delivered substances such as active substances and / or flavorings.

[0046] In some embodiments, the delivered substance may be an aerosol-generating material or a material not intended to be aerosolized. Depending on the context, either material may comprise one or more active ingredients, one or more flavorings, one or more aerosol-forming materials, and / or one or more other functional materials.

[0047] In some embodiments, the delivered substance includes an active substance. In some embodiments, the first and / or second aerosol-generating material includes at least one active substance.

[0048] As used herein, the active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, and psychotropic drugs. The active substance may be of natural origin or obtained synthetically. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or their components, derivatives, or combinations. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or other plant substances.

[0049] In one embodiment, the active substance is a legally permissible recreational drug.

[0050] In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0051] As described herein, the active substance may include one or more components, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0052] The active substance may be CBD or a derivative thereof.

[0053] In some embodiments, the delivered substance includes flavorings.

[0054] As used herein, the terms “flavoring” and “flavoring agent” refer to materials that may be used to create a desired taste, aroma, or other somatosensory effect in products intended for adult consumers, where permitted by local regulations.These are naturally derived flavorings, plant-based substances, extracts of plant-based substances, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, anise, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, limes, etc.) Tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, eggplant, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang Iran, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, peppermint oil from any of the Mentha species, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazelnut, hibiscus, bay leaf, mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, blackcurrant, valerian, pimento, mace, damien, ma It may contain other additives such as joram, olive, lemon balm, lemon basil, chives, calvi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), as well as charcoal, chlorophyll, minerals, plant-based substances, or breath fresheners.They may be imitations, synthetics, or natural raw materials, or blends thereof. They may be in any suitable form, such as a liquid like an oil, a solid like a powder, or a gas.

[0055] In some embodiments, the flavor includes menthol, spearmint, and / or peppermint. In some embodiments, the flavor includes cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavor includes eugenol. In some embodiments, the flavor includes flavor components extracted from tobacco. In some embodiments, the flavor includes flavor components extracted from cannabis.

[0056] In some embodiments, the flavor may include a sensory stimulant, which is intended to achieve somatosensory effects that are normally chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or instead of the aroma or taste nerves, and these may include agents that produce heating, cooling, tingling, or numbing effects. A preferred thermal agent may be, but is not limited to, vanillyl ethyl ether, and a preferred cooling agent may be, but is not limited to, eucalyptol or WS-3.

[0057] As described above, plug 4 comprises a first aerosol-generating material. This provides the advantage that the plug may provide an aerosol to the user when heated. The aerosol may contain flavorings and / or active substances that enhance the sensory (e.g., sensory stimulation) properties of the aerosol. In addition, the enhanced sensory properties of the aerosol produced when the plug is heated may help to mask or reduce the perception of flavors that exhibit "off-odors" or negative sensory attributes. Overall, the aerosol-generating material may provide the user with an improved-tasting aerosol.

[0058] In some embodiments and in this example, the plug 4 is positioned adjacent to the second aerosol-generating material 3. The second aerosol-generating material 3 may be located between the plug 4 and the first end 2a. The plug can therefore offer the advantage of preventing the movement of the second aerosol-generating material 3, which might otherwise move during use or storage. For example, the plug prevents the second aerosol-generating material 3 or other components of the article from falling off the end 2a.

[0059] The incorporation of the plug 4, which is equipped with an aerosol-generating material, also allows for greater flexibility in the design and manufacture of the article. Various plugs can be manufactured with different aerosol-generating materials, and as a result, the flavor profile of the aerosol produced by the plug 4 can be adjusted. The second aerosol-generating material 3 can also be adjusted. Furthermore, in this embodiment, since the plug 4 is a separate component that contacts the second aerosol-generating material 3, there is no mixing of the plug 4 and the second aerosol-generating material 3. Thus, by selecting the first and second aerosol-generating materials, it is possible to carefully control (or "adjust") the sensory characteristics of the aerosol produced by the first and second aerosol-generating materials.

[0060] Referring again to Figure 2, the extrusion plug 4 is adjacent to the second aerosol-generating material 3. In this example, the aerosol-generating section 3a (between points 2a and 2c in Figure 2) comprises the cylindrical rod and plug 4 of the second aerosol-generating material 3.

[0061] The mouthpiece 2 includes a cooling section 6, also called a cooling element, positioned adjacent to the second aerosol-generating material 3 immediately downstream. In this example, the cooling section 6 is in contact with the second aerosol-generating material 3. The aerosol-generating section 3a comprises a plug 4 and the second aerosol-generating material 3. The mouthpiece 2 also, in this example, includes at the mouthpiece end of article 1 a body 7 of the material downstream of the cooling section 6 and a hollow tubular element 8 downstream of the body 7 of the material.

[0062] In this example, the extrusion plug 4 is in the form of a cylindrical rod. In some embodiments, the plug may be any preferred shape. For example, the plug may be ball-shaped, triangular, wedge-shaped, or "T-shaped," with the first section of the plug having a smaller diameter than the second section of the plug.

[0063] The plug 4 comprises an upstream end 4a, a downstream end 4b, and a longitudinal axis parallel to and / or aligned with the longitudinal axis X-X' of the article 1. In a cross section that intersects or is perpendicular to the longitudinal axis X-X' of the article 1, the plug 4 may have any preferred cross-sectional shape. The cross section of the plug 4 may be round, elliptical, circular, square, rectangular, or any other preferred shape. This offers the advantage that the cross section of the plug can be adjusted to match the cross section of the mouthpiece, which can be shaped to be ergonomic for handling or use.

[0064] The plug has a length and a width. The length of the plug is the distance between the upstream end 4a of the plug and the downstream end 4b of the plug 4. The width is the dimension of the plug 4 across the length.

[0065] The width of the plug may be approximately 15 to 35 mm. In some embodiments, the width of the plug is approximately 15 to 35 mm, approximately 18 to 30 mm, approximately 20 to 25 mm, or approximately 22 to 23 mm. The width of the plug may be selected or configured to suitably fit the article. The plug 4 may have substantially the same width as the width of the aerosol generating section 3a.

[0066] The plug length can be up to approximately 6mm, 5mm, 3mm, or 2mm.

[0067] The incorporation of a plug into an article may, for example, serve to hold another (e.g., a second) aerosol-generating material within the aerosol-generating section of the article. However, the plug typically occupies space within the aerosol-generating section that would otherwise be occupied by other aerosol-generating materials.

[0068] The extrusion process allows for the production of plugs having relatively short lengths. Extruded plugs may also require less material. In addition, shorter plugs can leave more space within the article for a second aerosol-generating material, yet still offer the benefit of incorporating the plug into the article as described herein.

[0069] When extruded plugs have a relatively short length, they may offer a more delicate flavor profile due to their lower material mass and smaller surface area-to-volume ratio. This can be beneficial for certain flavors and flavor profiles.

[0070] In some embodiments, the plug is substantially made of a first aerosol-generating material.

[0071] In some embodiments and in this example, the article comprises a second aerosol-generating material 3. The second aerosol-generating material 3 is located between the plug 4 and the mouthpiece 2. In some embodiments, the second aerosol-generating material 3 may be in the form of a rod. The rod form is desirable because it provides a shape suitable for an aerosol delivery system, which may be an ergonomic shape held by the user.

[0072] Preferably, the second aerosol-generating material may have a different composition and / or may be manufactured in a different manner than the first aerosol-generating composition. This provides the material with different properties. For example, the flavors in the material may be different. This allows for the delivery of flavor combinations to the user, and the resulting aerosol may have a complex and desirable flavor profile.

[0073] For example, the first aerosol-generating material may be produced by extrusion, which yields an extruded plug having the advantages described herein. The second aerosol-generating material may be produced by band casting, or by forming a slurry and then drying it to form a solid.

[0074] In some embodiments, the plug 4 and / or the second aerosol-generating material 3 are enclosed by a packaging material 5. In this example, the packaging material 5 is a non-permeable packaging material. In some embodiments, the packaging material 5 also encloses the plug 4.

[0075] In some embodiments, at least about 70% of the volume of the aerosol-generating section 3a is filled with the second aerosol-generating material 3. In some embodiments, about 75% to about 85% of the volume of the cavity is filled with the second aerosol-generating material 3.

[0076] The packing density and packing volume of the aerosol generation section 3a may be selected to provide a suitable pressure drop throughout the section. This is to provide a suitable delivery of the aerosol or vapor to the user while providing a suitable pressure drop.

[0077] During use, the aerosol-generating section may exhibit a pressure drop of approximately 15 to 90 mmH2O. In some embodiments, the aerosol-generating section exhibits a pressure drop of approximately 15 to 90, 15 to 40, 30 to 90, or 60 to 90 mmH2O across the entire section.

[0078] The first and / or second aerosol-generating material is approximately 400 mg / cm³. 3 ~about 900mg / cm 3 It may have a packing density of this magnitude. A higher packing density may increase the pressure drop.

[0079] The first and second aerosol-generating materials and / or the second aerosol-generating material may comprise one or more active substances and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0080] In some embodiments, the first aerosol-generating material and / or the second aerosol-generating material comprises a plant material. In some embodiments, the plant material comprises or consists of one or more plant substances, or their components, derivatives, or extracts. In some embodiments, the second aerosol-generating material may be a plant material. As used herein, the term “plant substance” includes, but is not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, exoskeleton, or shells.

[0081] In some embodiments, the plant material is a plant-derived material or plant material cut into smaller fragments, for example, the plant-derived material or plant material may be milled, pulverized, diced, sliced, or otherwise divided to reduce the size of the fragments. In some embodiments, the plant material is a plant-derived material or plant material in the form of particles, as described herein.

[0082] In some embodiments, the plant material comprises or is derived from one or more plant substances, their components, derivatives, or extracts, the plant substances being selected from eucalyptus, star anise, cocoa, and hemp. In some embodiments, the plant substances are selected from rooibos and fennel. Rooibos and tobacco may be preferred plant materials.

[0083] Alternatively, the material may include naturally occurring active compounds in plant substances obtained by synthesis. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, flakes, strips, or sheets. Exemplary plant substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazelnut, hibiscus, bay leaf, licorice, matcha, mate, orange peel, papaya, rose, sage, tea such as green or black tea, thyme, clove, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, and saffron. , 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, calvi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. Mint may be selected from the following mint varieties: American mint, mint cv, Egyptian mint, European mint, eau de cologne mint, candy mint, curly mint, Kentucky colonel mint, horse mint, pineapple mint, pennyroyal mint, green mint, and apple mint.

[0084] In some embodiments, the active substance comprises or is derived from one or more plant substances, or their components, derivatives, or extracts, the plant substance being tobacco.

[0085] In some embodiments, the active substance comprises or is derived from one or more plant substances, or their components, derivatives, or extracts, the plant substances being selected from eucalyptus, star anise, cocoa, and hemp.

[0086] In some embodiments, the active substance comprises or is derived from one or more plant substances, or their components, derivatives, or extracts, the plant substances being selected from rooibos and fennel.

[0087] In some embodiments, the first aerosol-generating material and / or the second aerosol-generating material may comprise different plant substances, or their constituents, derivatives, or extracts. This provides consumers with the advantage of tasting different plant materials. In some embodiments, the proximity of the plug to the mouthpiece end ensures that different flavors are delivered to the user at different times.

[0088] In some embodiments, the first aerosol-generating material and / or the second aerosol-generating material comprises at least about 10 wt% of a plant substance(s), its components(s), derivatives(s), or extract(s). In some embodiments, the first aerosol-generating material and / or the second aerosol-generating material comprises at least 10 wt%, at least about 25 wt%, at least about 50 wt%, at least about 75 wt%, at least about 95 wt%, or at least about 99 wt% of a plant substance(s), its components(s), derivatives(s), or extract(s). In some embodiments, the first aerosol-generating material and / or the second aerosol-generating material is substantially composed of a plant substance(s), its components(s), derivatives(s), or extract(s).

[0089] In some embodiments, the first and / or second aerosol-generating material comprises up to about 10 wt% of plant-derived material(s), its components(s), derivatives(s), or extracts(s). In some embodiments, the first and / or second aerosol-generating material comprises up to 10 wt%, at least up to 25 wt%, up to about 50 wt%, up to about 75 wt%, up to about 95 wt%, or up to about 99 wt% of plant-derived material(s), its components(s), derivatives(s), or extracts(s). In some embodiments, the first and / or second aerosol-generating material is substantially composed of plant-derived material(s), its components(s), derivatives(s), or extracts(s).

[0090] In some embodiments, the plant material is tobacco. Therefore, in some embodiments, the first and / or second aerosol-generating material includes tobacco. In alternative embodiments, the plant material is not tobacco. Therefore, in some embodiments, the first and / or second aerosol-generating material does not include tobacco.

[0091] In some embodiments, the aerosol-generating material is substantially free of plant-based materials. In particular, in some embodiments, the aerosol-generating material is substantially free of tobacco.

[0092] As used herein, the term “tobacco material” refers to material derived from the Nicotiana species of plant. The selection of Nicotiana species of plant is not limited, and the one or more types of tobacco used may vary. The term “tobacco material” may include one or more of tobacco, tobacco derivatives, puffed tobacco, recombined tobacco, or tobacco substitutes. Tobacco material may include one or more of ground tobacco, tobacco fiber, shredded tobacco, extruded tobacco, tobacco leaves, tobacco stems, recombined tobacco, and / or tobacco extracts. As used herein, “tobacco leaves” means shredded lamina tobacco.

[0093] In some embodiments, the tobacco material is selected from pipe-dried or Virginia tobacco, Burley tobacco, sun-dried tobacco, Maryland tobacco, dark-fired tobacco, dark-air-dried tobacco, light-air-dried tobacco, Indian air-dried tobacco, Red Russian tobacco, and Rustica tobacco, as well as mixtures thereof, and various other rare or specialty tobaccos, raw leaf tobacco or dried tobacco. Tobacco material produced by any other type of tobacco processing that can alter the taste of tobacco, such as fermented tobacco or genetic modification or crossbreeding techniques, is also within the scope of this disclosure. For example, it is assumed that tobacco plants may have been genetically engineered or crossbred to increase or decrease the production of components, properties, or attributes.

[0094] In some embodiments, the tobacco material is sun-dried tobacco selected from Indian Kurunur tobacco and Oriental tobacco, including Izmir tobacco, Basma tobacco, Samsun tobacco, Katerini tobacco, Prelip tobacco, Komotini tobacco, Xanchi tobacco, and Yambol tobacco. In some embodiments, the tobacco material is dark-colored air-dried tobacco selected from Pasanda tobacco, Cubano tobacco, Jatin tobacco, and Besqui tobacco. In some embodiments, the tobacco material is light-colored air-dried tobacco selected from North Wisconsin tobacco and Galpao tobacco.

[0095] In some embodiments, the tobacco material is selected from Brazilian tobaccos, including Matafina tobacco and Bahia tobacco. In some embodiments, the tobacco material is selected from Criollo tobacco, Pilotocubano tobacco, Aurore tobacco, Green River tobacco, Isabella DAC tobacco, White Pata tobacco, Elulu tobacco, Jatim tobacco, Madura tobacco, Kastri tobacco, Connecticut Seed tobacco, Broadleaf tobacco, Connecticut tobacco, Pennsylvania tobacco, Italian dry-air-dried tobacco, Paraguay dry-air-dried tobacco, and Wansucker tobacco.

[0096] Tobacco materials may include, or consist of, reconstituted tobacco, tobacco lamina, paper reconstituted tobacco, extruded tobacco, bandcast reconstituted tobacco, or a combination of reconstituted tobacco and another form of tobacco such as tobacco lamina or granules.

[0097] In some embodiments, the first and / or second aerosol-generating material contains tobacco plant material content of about 5 to about 75 wt%, about 10 to about 30 wt%, about 30 to about 50 wt%, about 50 to about 70 wt%, or about 70 to about 75 wt%. The plant material content may be selected to provide a meaningful flavor to the user and a suitable texture for the aerosol-generating material. The plant material content affects the elastic and tensile strength of the plug, the first and / or second aerosol-generating material.

[0098] The plant material may be particulate or granular. In some embodiments, the plant material may be a powder or pulverized. Alternatively or additionally, the plant material may include strips, strands, or fibers of the plant material. For example, the plant material may include particles, granules, fibers, strips, and / or strands of the plant material. In some embodiments, the plant material consists of particles or granules of the plant material. Plant material particles offer the advantage that the particle size distribution and resulting properties described herein can be more easily controlled.

[0099] In embodiments where the plant material is a particulate plant material, each particle of the particulate tobacco material may have a maximum dimension. As used herein, the term “maximum dimension” refers to the longest straight-line distance from the surface of a particle of the plant material or any point on the particle surface to the same particle of tobacco or any other point on the particle surface. The maximum dimension of the particles of the particulate tobacco material may be measured using scanning electron microscopy (SEM).

[0100] In some embodiments, the maximum size of each particle of the plant material is up to about 800 μm. In some embodiments, the maximum size of each particle of the plant material is up to about 2000 μm, up to about 1000 μm, up to about 500 μm, up to about 350 μm, up to about 320 μm, or up to about 300 μm. In some embodiments, the maximum size of each particle of the plant material is from about 200 μm to about 800 μm.

[0101] A collection of plant material particles may have a particle size distribution (D90) of at least about 70 μm. In some embodiments, a collection of plant material particles may have a particle size distribution (D90) of at least about 50 μm, at least about 60, at least about 70 μm, at least about 80 μm, at least about 90, at least about 100 μm, at least about 110 μm, at least about 120 μm, at least about 130 μm, at least about 200 μm, at least about 250, at least about 300 μm, or at least about 320 μm. In some embodiments, the particle population of the plant material has a particle size distribution (D90) of up to approximately 500 μm, up to approximately 450 μm, up to approximately 400 μm, up to approximately 350 μm, up to approximately 720 μm, up to approximately 740 μm, up to approximately 760 μm, up to approximately 780 μm, up to approximately 800 μm, up to approximately 820 μm, up to approximately 840 μm, and up to approximately 860 μm. In some embodiments, the particle population of the plant material has a particle size distribution (D90) of approximately 600 μm. In some embodiments, the particles have a D90 of approximately 320 to approximately 350 μm. The particle size distribution may be measured using a particle size and shape analyzer such as a camsizer, or the particle size distribution of the plant material may be determined by sieve analysis.

[0102] The inventors have found that the particle size of plant-based materials affects their tensile strength. A smaller particle size distribution (D90) is associated with higher tensile strength and higher density in aerosol-generating materials or plugs. Lower density reduces the amount of material required to manufacture the plug, resulting in a lighter plug, which is desirable as it is suitable for transport. Plugs can be optimized to balance these properties.

[0103] The inventors have found that by controlling the particle size distribution (D90), the desired areal density of the aerosol-forming material, and the sheets, shredded sheets, or products manufactured therefrom can be achieved. The areal density of the material can be measured in GSM (grams per square meter, i.e., g / m 2 ²). For example, a lower particle size distribution (D90) is associated with a greater areal density. When the aerosol-forming material is incorporated into an article for use in a non-combustion aerosol supply system, this greater areal density can result in a reduced fill value of the vegetal material. A specific example of this is that a particle size distribution (D90) of 300 is predicted to result in an areal density of 246.6 g / m 2 ².

[0104] In some embodiments, the aerosol-forming material has a density of about 400 g / cm 3 ³. In some embodiments, the aerosol-forming material has a density of at least about 400 g / cm 3 ³, at least about 450 g / cm 3 ³, at least about 500 g / cm 3 ³, at least about 550 g / cm 3 ³, or at least about 600 g / cm 3 ³. In some embodiments, the aerosol-forming material has a density of up to about 700 g / cm 3 ³, up to about 750 g / cm 3 ³, up to about 800 g / cm 3 ³, up to about 820 g / cm 3 ³, or up to about 850 g / cm 3 ³.

[0105] 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. The density can be determined by dividing the total weight of the plug by the total volume of the plug, and the total volume can be calculated using appropriate measurements of the material forming the cooling section 6 obtained, for example, using a caliper. If necessary, appropriate dimensions may be measured using a microscope.

[0106] The articles described herein are suitable for use in non-combustible aerosol supply devices. In some embodiments, the non-combustible aerosol supply device comprises an aerosol generator.

[0107] 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 rise, or electrostatic energy. The aerosol generator may be configured to be inserted into the aerosol-generating section of an article for use with a non-combustible aerosol supply device. In some embodiments, the aerosol generator may be a blade or a pin.

[0108] In some embodiments, the aerosol generator may be in contact with the plug, which offers the advantage of allowing for easy movement and modification of the plug or the aerosol generator.

[0109] In some embodiments, the aerosol generator is configured to extend within the plug. In some embodiments, the extrusion plug is configured to receive the aerosol generator of a non-combustible aerosol supply device. In such embodiments, the plug may have a receiving portion. For example, the receiving portion may be a cavity configured to receive the aerosol generator of a non-combustible aerosol supply device. When the aerosol generator is received within the receiving portion of the plug, the aerosol generator is in direct contact with the plug. This facilitates heat transfer from the aerosol generator to the plug.

[0110] Referring to Figure 7, the exemplary plug 4 has a receiving portion 15 configured to receive an aerosol generator of a non-combustible aerosol supply device, which is in the form of a pin 16. In this embodiment, the extrusion plug does not have a recess or channel.

[0111] The receiving portion of the plug can be fabricated during the extrusion process. Forming the plug and cavity using extrusion means that the dimensions of the receiving portion can be fabricated with relatively tight tolerances, and that the dimensions of the receiving portion can be relatively consistent between different plugs. As a result, when the aerosol generator is received by the receiving portion of the plug, a larger surface area of ​​the aerosol generator can be in direct contact with the plug.

[0112] Furthermore, since the aerosol generator can come into direct contact with the plug when received by the plug's receiving portion, a certain amount of force is required to insert the aerosol generator into the receiving portion. Because the extrusion process consistently produces plugs with precise dimensions, the force required to insert the aerosol generator into and remove the aerosol generator from the plug can be consistent across different plugs, thereby improving the usability of the product.

[0113] In some embodiments, the receiving portion may be 100% of the length of the plug so that the entire length of the plug can receive the aerosol generator. In some embodiments, the receiving portion may be up to about 10%, up to about 25%, up to about 50%, up to about 75%, up to about 80%, up to about 90%, or up to about 99% of the length of the plug.

[0114] The receiving portion offers the advantage that the aerosol generator can directly heat the plug and can be positioned closer to the plug for more efficient heating. A larger surface area of ​​the aerosol generator can contact the plug, thus improving heating efficiency. As described herein, the plug comprises an aerosol-generating material, which can also be heated and thus generate an aerosol. This provides the user with an improved flavor.

[0115] The receiving portion may be in the form of a cavity within a plug into which an aerosol generator can be extended. The cavity may have a cylindrical shape or may be molded to fit the aerosol generator. An exemplary embodiment of the cavity is shown in Figure 3.

[0116] Figure 3 shows a perspective view of article 1. In this embodiment, the second aerosol-generating material 13 is in contact with the plug 4. The plug 4 comprises the cavity 14 and channel 15 described herein.

[0117] In this embodiment, the cavity 14 has a diameter of approximately 2 mm. The aerosol generator may have the shape of a pin with a diameter of approximately 2 mm. Thus, the cavity receives the aerosol generator, providing improved contact and a shortened distance between the aerosol generator and the plug. This provides the advantage of improved (e.g., faster) heating, which in turn improves the rate of flavor release to the user.

[0118] In some embodiments, the receiving portion is in the form of a cavity within the plug, the cavity having a diameter of up to about 1, up to about 2, up to about 3, or up to about 5 mm.

[0119] In some embodiments, the aerosol generator extends within the plug and into the second aerosol-generating material. In such embodiments, the receiving portion of the plug extends along the entire length of the plug, from the first end to the second end. This offers the advantage that the aerosol generator can directly heat the second aerosol-generating material and can be positioned closer to the plug to heat the second aerosol-generating material more efficiently. In some embodiments, the aerosol generator extends into the second aerosol-generating material. The aerosol generator may extend to about 100, about 80, about 50, about 20, or about 10% of the length of the second aerosol-generating material. The aerosol generator may extend to about 2 mm or about 3 mm of the length of the plug.

[0120] The receptacle may be manufactured during the extrusion process in which the plug is formed. An advantage of extruded plugs is that they are malleable after extrusion, so that the receptacle can be integrally formed within the plug. The plug with the receptacle may then be dried to increase its rigidity. This offers the advantage that the shape of the plug and any optional recess or channel is not affected or distorted by the introduction of the receptacle. This means that the plug has a consistent shape and is better suited to fitting into an article. If the plug is manufactured by a different method, the receptacle may be introduced by perforation or other methods, which can alter the shape of the rest of the plug.

[0121] In some embodiments, the first aerosol-generating material and / or the second aerosol-generating material may contain a flavor content of about 0 to about 20% by weight. In some embodiments, the mixture, aerosol-generating material, and / or aerosol-generating composition may contain a flavor content of about 0 to about 20%, about 5 to about 20%, about 5 to about 15%, and about 8 to about 12%.

[0122] The flavor content can be adjusted, for example, to suit flavoring in both the first and second aerosol-generating materials.

[0123] In some embodiments, the first aerosol-generating material and / or the second aerosol-generating material includes an aerosol-forming agent material.

[0124] The aerosol-forming agent material may contain one or more components capable of forming an aerosol. In some embodiments, the aerosol-forming agent material may contain one or more of the following: glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, a mixture of diacetins, benzyl benzoate, benzyl phenylacetate, tributyline, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0125] In some embodiments, the first aerosol-generating material and / or the second aerosol-generating material contains an aerosol-forming agent content of about 5 to about 50% by weight. In some embodiments, the first aerosol-generating material and / or the second aerosol-generating material contains an aerosol-forming agent content of about 10 to about 30% by weight, or about 15 to about 25% by weight.

[0126] Aerosol-forming materials can act as plasticizers. In some cases, the aerosol-forming material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some cases, the aerosol-forming material contains glycerol, is essentially made from glycerol, or consists of glycerol.

[0127] Aerosol-forming agents can enhance the mouthfeel and, in general, the sensory stimulating properties of the aerosol produced by the aerosol-forming material when heated and inhaled by the user, especially when the aerosol-forming material contains a relatively large amount of aerosol-forming agent (e.g., >40 wt%). The ability of the aerosol-forming material to hold a large amount of aerosol-forming agent can reduce the need to fill other components of the aerosol-forming material, such as expanded plant-based materials, with large amounts of aerosol-forming agent. This can improve manufacturing efficiency.

[0128] In some embodiments, the first aerosol-generating material and / or the second aerosol-generating material may contain one or more functional materials. The one or more other functional materials may include one or more of the following: pH adjusters, colorants, preservatives, binders, fillers, stabilizers, and / or antioxidants.

[0129] The binder is configured to bind components of the first aerosol-generating material and / or the second aerosol-generating material. The first aerosol-generating material and / or the second aerosol-generating material may contain two or more binders. In such embodiments, the binders may be the same or different.

[0130] In some embodiments, the binder includes or is a gelling agent. The binder may be selected from one or more compounds selected from the group including alginates, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the binder includes one or more of alginates, pectin, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the binder includes alginates and / or pectin or carrageenan. In some embodiments, the binder includes CMC.

[0131] In some embodiments, the first aerosol-generating material and / or the second aerosol-generating material may contain a binder content of about 5 to about 40% by weight. In some embodiments, the first aerosol-generating material and / or the second aerosol-generating material may contain a binder content of about 5 to about 30% by weight, about 5 to about 20% by weight, about 5 to about 15% by weight, or about 5 to about 10% by weight.

[0132] In some embodiments, the first aerosol-generating material and / or the second aerosol-generating material includes a filler. The filler is generally a non-tobacco component, i.e., a component that does not contain raw materials or components derived from tobacco. The filler may include one or more inorganic fillers such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and a suitable inorganic adsorbent such as molecular sieves. The filler may also be a non-tobacco fiber such as wood fiber or pulp or wheat fiber. The filler may be a cellulose-containing material or a material containing a derivative of cellulose. The filler component may also be a non-tobacco cast material or a non-tobacco extruded material. In some embodiments, the filler is a cellulosic material, cellulose, or CMC. In some embodiments, the filler is essentially composed of cellulose or consists of cellulose.

[0133] In certain embodiments including a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood, wood pulp, hemp fiber, cellulose, or a cellulose derivative. While we do not wish to be bound by theory, it is thought that including a fibrous filler may increase the tensile strength of the aerosol-generating material formed. The use of cellulose as a filler has been found to have a particularly favorable effect on the burst strength of the plug or aerosol-generating material.

[0134] The filler can also contribute to the texture of the plug or aerosol-generating material. For example, fibrous fillers such as cellulose can result in an aerosol-generating material with relatively rough first and second surfaces. Conversely, non-fibrous particulate fillers such as powdered chalk can result in an aerosol-generating material with relatively smooth first and second surfaces. In some embodiments, the plug or aerosol-generating material includes a combination of different filler materials. The filler can help improve the general structural properties of the aerosol-generating material, such as its tensile strength and burst strength.

[0135] In some embodiments, the first aerosol-generating material and / or the second aerosol-generating material may contain a filler content of about 0 to about 20% by weight. In some embodiments, the mixture, aerosol-generating material, and / or aerosol-generating composition may contain a filler content of about 1 to about 15% by weight, about 3 to about 10% by weight, or about 4 to about 6% by weight.

[0136] The plug has an outer surface, i.e., the outer surface of the plug. In some embodiments, this surface may have a recess. The recess is a depression within the surface of the plug. Such a recess may be formed using the extrusion process in which the plug is manufactured. Alternatively, the recess may be formed by machining after the extrusion process. For example, the recess may be formed by stamping, perforating, cutting, or otherwise creating a depression within the surface of the plug.

[0137] The recesses may be of any preferred size or shape and may form a pattern on the surface. For example, the sections may form a “striped” pattern on the surface of the plug, in which case sections without recesses may be adjacent to sections with recesses. This offers the advantage that the pattern of the recesses can be controlled and may affect airflow, pressure drop, and flavor delivery to the user, as described herein.

[0138] The recess may be any preferred volume, but may be selected to provide the advantages described herein. In some embodiments, the recess has length and width. The length may be measured as the longest distance across the recess. In some embodiments, the length and width have ratios of about 1:0.25 to about 1:10, about 1:0.5 to about 1:5, about 1:0.75 to about 1:2, or about 1:1.

[0139] The recess may be in the form of a channel so that the channel is provided on the outer surface of the plug. In some embodiments, the plug has a plurality of recesses on its outer surface in the form of channels.

[0140] Alternatively, the recess may be a shape other than a channel, such as a circle, semicircle, rectangle, triangle, or star shape.

[0141] In some embodiments, the length of the recess is approximately 0.01 to 6 mm, approximately 0.1 to 1 mm, or approximately 0.5 to 0.8 mm.

[0142] In embodiments in which the recess is a channel or in which the channel extends through the plug and the channel is aligned with the axis of the article, the length of the recess may be about 5% to about 100% of the length of the plug, about 50% to about 100% of the length of the plug, about 75% to about 100% of the length of the plug, or about 90% to about 100% of the length of the plug.

[0143] In some embodiments, the recess or channel occupies up to about 60%, 50%, 20%, 10%, or 5% of the total surface area of ​​the plug.

[0144] The indentation may be of any preferred depth, but may be selected to provide the advantages described herein. As used herein, the term depth refers to the distance from the surface of the plug to the bottom and lowest point of the indentation. In some embodiments, the indentation has a depth of about 5 to about 300 μm, about 10 to about 100 μm, or about 50 to about 80 μm. The lowest point of the indentation may be measured using a SEM or by measuring the apparatus used to engrave the indentation into the plug.

[0145] The larger the volume of the recess or channel, the greater the airflow and pressure drop across the entire plug. This provides a more comfortable user experience when aerosol-generating materials are used in articles within a delivery system. Therefore, the dimensions of the recess can be selected to provide suitable airflow and pressure drop across the entire plug.

[0146] In addition, the larger the volume of the recess or channel, the higher the ratio of surface area to volume, and the more flavor is imparted to the aerosol from the first aerosol-generating material.

[0147] In some embodiments, the plug includes a channel extending through the plug. This embodiment can provide a larger flow of fluid. The channel may be positioned within the plug to optimize the movement of such fluid. The channel may extend along the entire length of the plug.

[0148] In embodiments where a channel extends through the plug, the channel may have a diameter of approximately 5 μm, 10 μm, 25 μm, 500 μm, 1 mm, or 2 mm.

[0149] Recesses or channels extending through the plug may be formed during the extrusion of the plug. This has the advantage that the recesses or channels extending through the plug are formed simultaneously with the plug, is quick, and does not require further processing steps. Using extrusion to form the channels further maintains the structure of the plug. Other methods may distort the structure or shape of the plug.

[0150] Preferably, the plug is malleable after the extrusion step and can be manipulated to add recesses or channels. The plug can then be made more rigid during the drying step after the recesses or channels have been formed.

[0151] Alternatively, the recess or channel may be formed by another process, such as drilling or cutting.

[0152] Recesses or channels may be aligned with the axis of the article, for example, such that their longitudinal dimensions are aligned parallel to the longitudinal axis X-X' of article 1. Channels may be aligned within the aerosol generating section, such that their longitudinal dimensions are aligned parallel to the longitudinal axis X-X' of article. This offers the advantage of allowing fluid to move through the article and thus providing a suitable pressure drop. This provides a pleasant experience for the user because there is suitable resistance for suction during use. This also provides improved delivery of aerosol and aerosol flavor to the user.

[0153] In some embodiments, the pressure drop across the entire plug is approximately 100 to approximately 500 mmWg. In some embodiments, the pressure drop across the entire aerosol generation section is approximately 100 to approximately 200 mmWg, approximately 200 to approximately 400 mmWg, or approximately 300 to approximately 350 mmWg.

[0154] In some embodiments, the pressure drop across the entire article is approximately 20 to 120 mmWg, 50 to 100 mmWg, and 60 to 90 mmWg.

[0155] However, if the plug has recesses and / or channels, the pressure drop can be greater. Recesses and / or channels offer the advantage that the plug provides an improved pressure drop throughout the article.

[0156] During use, the article may exhibit a pressure drop of approximately 15 to 40 mmH2O. In some embodiments, the article exhibits a pressure drop of approximately 15 to 30 mmH2O across the entire aerosol-generating section.

[0157] An exemplary embodiment of the present invention is shown in Figure 3, which shows a perspective view of an article 1 in which a plug 4 comprises a plurality of channels 15 on the outer surface of the plug 4. The channels are aligned parallel to the longitudinal axis X-X' of the article 1. In this embodiment, the channels extend along the entire length of the plug. The length of the plug 4 may be defined as the distance of the plug 4 aligned with the longitudinal axis X-X' of the article.

[0158] Another exemplary embodiment of the present invention is shown in Figure 4, which shows a cross-section (perpendicular to the longitudinal axis X-X' of the article) of a plug 4 having multiple channels 16 extending through the plug. Otherwise, the plug is monolithic. In this embodiment, the channels 16 are aligned parallel to the longitudinal axis X-X' of the article. In some embodiments, the channels are aligned parallel to one another.

[0159] In some embodiments, the plug includes a channel extending through the plug. In some embodiments, the recess or channel is configured to allow fluid to pass through the body of the plug.

[0160] The fluid can be a liquid, a gas, or a gas / liquid mixture. In some embodiments, the fluid is air or a mixture of air and aerosol, which can be produced by an aerosol-generating material when heated by an aerosol generator. In some embodiments, the fluid can move through article 1 between an upstream end 2a and a downstream end 2b, according to Figure 1. The fluid can be guided to move along the axis of the article through a channel. This distributes the fluid to desired locations within the article. This offers the advantage that the fluid can then take up flavors and active substances in the plug, a first aerosol-generating material, and / or a second aerosol-generating material. This results in improved delivery of such flavors and substances to the user.

[0161] Another aspect of the present invention provides a method for manufacturing an article. In some embodiments, a method is provided for manufacturing a first aerosol-generating material, a second aerosol-generating material, and / or a plug. In some embodiments, the first aerosol-generating material is manufactured by forming a mixture, wherein the mixture is passed through a die to form an extruded aerosol-generating material, and optionally by cutting the aerosol-generating material to form a plug. This method may include some or all of these steps.

[0162] In some embodiments, the first aerosol-generating material is produced by forming a mixture, extruding the mixture through a die to form an extruded aerosol-generating material, tooling the extruded aerosol-generating material, drying the extruded aerosol-generating material, and cutting the aerosol-generating material. This method may include some or all of these steps.

[0163] In some embodiments, a method for producing an extruded plug includes the steps of In some embodiments, the plug is made of a first aerosol-generating material, which is produced by forming a mixture, extruding the mixture through a die to form an extruded aerosol-generating material, tooling the extruded aerosol-generating material, drying the extruded aerosol-generating material, and cutting the aerosol-generating material. This method may include some or all of these steps.

[0164] The present invention enjoys the advantage that the extrusion process controls the size and shape of the first aerosol-generating material and / or plug. While we do not wish to be bound by a single reason, it should be noted that the extrusion process applies consistent pressure to the material being extruded. This means that there is consistent and precise control over the shape of the extruded aerosol-generating material. This means that the material and / or plug can be uniform, and as a result, the flavor consistency of the material and / or plug can be improved.

[0165] The materials and / or plugs are more consistent in shape and weight, which makes them suitable for packing and logistics of materials in consumables or articles.

[0166] Plugs can be manufactured with consistent precision to produce plugs of the same size and shape each time. This ensures that the components of the manufactured article fit precisely into the plug, and that the plug fits securely within the non-combustible aerosol supply system. For example, in embodiments where the article includes an aerosol generator, the plug can be manufactured to improve contact between the plug surface and the aerosol generator.

[0167] A further advantage is that, if present, recesses or channels can be formed during the extrusion process. This reduces the number of steps required to form the plug, making manufacturing faster and cheaper.

[0168] Plugs prepared in this manner enjoy the advantage of improved elasticity and, in particular, possess specific elastic properties that make the material especially suitable for retaining indentations or channels. For example, such plugs retain indentations for longer periods. The plugs are also more malleable and can therefore be adapted to more other features of the device. For example, the plugs can be adapted to the aerosol generator described herein.

[0169] The mixture may be formed by any preferred means. The mixture may be stored before extrusion or extruded immediately. The aerosol-generating material may contain the same components as the mixture. In some embodiments, the aerosol-generating material may contain additional components to the mixture. The components of the aerosol-generating material and / or mixture are described herein.

[0170] In some embodiments, a method for forming an aerosol-generating material includes forming a first composition, forming a second composition, combining the first and second compositions to form a mixture of the first and second compositions, and processing the mixture of the first and second compositions to form an aerosol-generating material. This process is shown in Figure 6.

[0171] In some embodiments, a method for forming an aerosol-generating material includes forming a mixture and processing a mixture of a first composition and a second composition to form an aerosol-generating material.

[0172] In some embodiments, the first composition, also known as the “wetting mixture,” comprises an aerosol-forming agent or wetting agent and a binder. The first composition may also comprise other liquids or suspensions disclosed herein. The first composition may be a liquid phase.

[0173] In some embodiments, the second composition, also known as the “dry mixture,” comprises tobacco material, a filler, and optionally a second binder. The second composition may also comprise other solids or gels disclosed herein. The second composition may be a solid phase. In some embodiments, the second composition does not contain a binder.

[0174] Once formed and mixed, the mixture can be extruded using any extrusion technique or apparatus known in the art to form an aerosol-generating material.

[0175] Extrusion involves feeding a precursor composition, in this case a mixture, through an orifice or die to produce an extruded aggregate. The process of applying pressure to the precursor composition in combination with shear force results in an aggregated structure that may take any shape as described herein.

[0176] Extrusion can be performed using one of the main classes of extruders: screw, sieve and basket, roll, ram, and pin barrel extruders.

[0177] Extrusion of a mixture to form a plug and / or a first aerosol-generating material offers the advantage that the first aerosol-generating material or plug is immediately formed to the desired width and height, and therefore no further molding is required. This is faster and more cost-effective compared to the manufacture of other plugs.

[0178] Forming aerosol-generating materials by extrusion has the advantage that this process combines mixing, conditioning, homogenization, and molding of the mixture.

[0179] In particular, the extrusion process can produce a first aerosol-generating material of a suitable shape. For example, the shape of a plug can be formed from the die during extrusion. This allows for the formation of a specific shape. For instance, the cross-sectional shape and width of the plug or the first aerosol-generating material can be manufactured to fit the shape and size of an article. The die can produce an aerosol-generating material with a relatively smooth surface. A smooth surface may not be achieved using other processes such as band casting.

[0180] Other materials may also be added during the extrusion process, such as bases, diluents, solid aerosol-forming agents, solid flavor modifiers, leavening agents, and other additives known in the art. This has the advantage that the additives are uniformly distributed throughout the aggregated structure formed during the extrusion process.

[0181] In some embodiments, the extruded material may undergo a tooling process. In such a tooling process, receiving portions, recesses, channels, and / or other features may be added to the material. Preferably, the extruded material is malleable and may be manipulated to add these features. This makes the tooling process faster and reduces the energy required to form the features. In addition, this reduces the impact of the tooling process on the remaining shape of the extruded material. For example, if the tooling process is performed on an extruded plug, the impact on the shape of the plug is less compared to a plug formed by other means. The tooling process may include machining, stamping, drilling, cutting, or otherwise forming features in or on the plug.

[0182] In some embodiments, the resulting extruded material is dried using any suitable drying technique known in the art. For example, microwave, infrared, air, and oven drying are suitable techniques for drying aerosol-generating materials. Water can be removed by allowing the water to evaporate from the extruded mixture at ambient temperature and pressure (e.g., 25°C and 101 kPa). Alternatively, water may be removed by applying heat to the plug (e.g., by heating to above about 25°C) and / or by reducing the atmospheric pressure surrounding the plug (e.g., to below 101 kPa).

[0183] The temperature of the drying step may be less than 100°C, and in some embodiments of the present invention, less than 90°C. The drying temperature employed may be up to about 25°C, about 30°C, about 40°C, about 50°C, about 60°C, about 70°C, about 80°C, about 90°C, or about 100°C.

[0184] The low drying temperature used is preferable because it reduces the loss of volatile components such as nicotine, glycerol, and flavors, which contribute to the flavor, taste, and texture of the final product. The material is also dried to provide suitable texture and strength. For example, an overly dried material may be brittle and lack malleability. On the other hand, if the material is too wet, it may be sticky and difficult to use in articles.

[0185] The length of the drying step can be up to approximately 5 minutes, 10 minutes, 30 minutes, 45 minutes, 60 minutes, 90 minutes, 120 minutes, or 360 minutes.

[0186] The advantage of the extrusion process is that it requires less time for the plug to dry properly. This results in less energy being used, saving energy costs, and a faster manufacturing process. While we do not wish to be bound by any particular theory, the material can be extruded using less water, and therefore the mixture requires less water. As a result, drying time is shorter, drying temperature is lower, and a suitable moisture content is achieved.

[0187] The overall moisture content (OV) of the plug also affects its physical properties. For example, if the OV is too low, the plug may not be flexible enough to withstand the processing conditions. For instance, the plug may collapse or decompose during processing. To aid in processing, sheets of aerosol-generating material may be conditioned before forming multiple elongated strips of aerosol-generating material.

[0188] In some embodiments, the mixture contains water in an amount of about 0% to about 40% by weight or about 25% to about 35% by weight of the mixture.

[0189] In some embodiments, the mixture contains oven-volatile substances in an amount of about 0% to about 40% by weight or about 25% to about 35% by weight of the mixture.

[0190] In some embodiments, the first aerosol-generating material contains water in an amount of about 0% to about 15% by weight or about 5% to about 40% by weight of the aerosol-generating material. In some embodiments, the first aerosol-generating material contains water in an amount of about 5% to about 15% by weight of the aerosol-generating material.

[0191] In some embodiments, the first aerosol-generating material contains oven-volatile material in an amount of about 0% to about 15% by weight or about 5% to about 15% by weight of the plug.

[0192] In some embodiments, the plug contains a water content of about 0 to about 15% by weight, about 5 to about 10%, or about 6.5 to about 9.5% by weight.

[0193] The water content of the aerosol-generating materials described herein may vary, for example, depending on the temperature, pressure, and humidity conditions under which the composition is maintained. The water content may be determined by Karl Fischer analysis, as is known to those skilled in the art.

[0194] Unless otherwise specified, the terms “volatile components,” “volatile substances,” “total volatile,” “volatile substance content,” and “total volatiles” used herein refer to volatile compounds, including water. The volatile substance content of a material can be measured as the mass loss when the sample is dried in a forced-draft oven at a temperature adjusted to 110°C ± 1°C for 3 hours ± 0.5 minutes. After drying, the sample is cooled to room temperature in a desiccator for approximately 30 minutes.

[0195] In some embodiments, the extruded aerosol-producing material is cut or sliced. Cutting or slicing may be performed after any one of the extrusion step, tooling step, or drying step. The first aerosol-producing material or plug material may be cut or sliced ​​horizontally (along the width rather than along the length) to produce the first aerosol-producing material or plug of known length as described herein. The extruded aerosol-producing material may be sliced ​​at short intervals to provide plugs of a selected length.

[0196] This is preferable because it allows for the manufacture of plugs with shorter lengths than those manufactured by other methods. In particular, the plugs may be sliced ​​immediately after extrusion, and therefore the plugs may be cut to have a length of less than 6 mm. This is difficult to achieve by other methods and offers the advantage of reducing the amount of plug in the article.

[0197] The plug or the first aerosol-generating material may be sliced ​​immediately after extrusion, after drying, or after further processing steps.

[0198] In some embodiments, the tensile strength of the aerosol-generating material is at least about 3, 4, 5, 6, 8, 10, 12, or 14 N / 15 mm. In some embodiments, the tensile strength of the plug is at most about 15 N / 15 mm. In some embodiments, the tensile strength of the aerosol-generating material is at most about 6, 8, 10, 12, or 14 N / 15 mm. In some embodiments, the tensile strength of the plug is at least about 3 N / 15 mm.

[0199] In some embodiments, the second aerosol-generating material is produced by forming a mixture, extruding the mixture through a die to form an extruded aerosol-generating material, and cutting the aerosol-generating material. This method may include some or all of these steps. In some embodiments, the second aerosol-generating material is produced by the same process as the first aerosol-generating material. In some embodiments, the first and second aerosol-generating materials may be produced together as a single material and then separated into the first and second aerosol-generating materials in a cutting or slicing process.

[0200] Referring again to Figure 2, the cooling section 6 comprises a hollow channel having an inner diameter of approximately 1 mm to 4 mm, for example, approximately 2 mm to 4 mm. In this example, the hollow channel has an inner diameter of approximately 3 mm. The hollow channel extends along the entire length of the cooling section 6. In this example, the cooling section 6 comprises a single hollow channel. In alternative embodiments, the cooling section may comprise 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 geometric shapes / cross-sections may be used. The hollow channel can provide a space in which an aerosol drawn into the cooling section 6 can expand and be cooled. In some embodiments, the cooling section is configured to limit the cross-sectional area of ​​the hollow channel(s) to limit the displacement of the cigarette into the cooling section during use.

[0201] The filamentous tow forming the cooling section 6 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 6 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 6 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 filament is "Y" shaped, but in other embodiments, other shapes such as "X" shaped filaments can be used.

[0202] The cooling section 6 is positioned around the void within the inlet 2, defining the void within the inlet 2, which functions as the cooling section. The void provides a chamber through which heated volatile components generated by the rod of the aerosol-generating material 3 pass. The cooling section 6 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 6 provides physical displacement between the aerosol-generating material 3 and the body 7 of the material. The physical displacement provided by the cooling section 6 can provide a thermal gradient over the entire length of the cooling section 6.

[0203] In some embodiments, the mouthpiece 2 is 110 mm 3 It is equipped with a cavity having an internal volume of at least this volume. It has been found that by providing a cavity of at least this volume, improved aerosol formation is possible. In some embodiments, the intake port 2 is formed, for example, within the cooling section 6, 110 mm 3 Super, or 130mm 3 It includes a cavity with an internal volume exceeding 130 mm², allowing for further improvement of aerosols. In some examples, the internal cavity is approximately 130 mm². 3 ~approx. 230mm 3 For example, approximately 134mm 3 or 227mm3 It has a volume of .

[0204] The cooling section 6 may be configured to provide a temperature difference of at least about 40°C between the heated volatile components entering the first upstream end of the cooling section 6 and the heated volatile components exiting the second downstream end of the cooling section 6. The cooling section 6 may be configured to provide a temperature difference of at least about 60°C, at least about 80°C, or at least about 100°C between the heated volatile components entering the first upstream end of the cooling section 6 and the heated volatile components exiting the second downstream end of the cooling section 6. This temperature difference 7 due to the length of the cooling section 6 protects the body 7 of the temperature-sensitive material from the high temperature of the aerosol-generating material 3 when the aerosol-generating material 3 is heated.

[0205] The material body 7 and the hollow tubular element 8 each define a substantially cylindrical overall shape and share a common longitudinal axis. The material body 7 is encased in a first plug wrap 9. Preferably, the first plug wrap 9 has a basis weight of less than 50 gsm, more preferably about 20 gsm to 40 gsm. Preferably, the first plug wrap 9 has a thickness of 30 μm to 60 μm, more preferably 35 μm to 45 μm. Preferably, the first plug wrap 9 is a non-porous plug wrap with 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 9 may be a porous plug wrap with an air permeability of, for example, more than 200 cholesta units.

[0206] The article may have a ventilation level of approximately 10% of the aerosol drawn through the article. In an alternative embodiment, the article may have a ventilation level of 1% to 20%, e.g., 1% to 12%, of the aerosol drawn through the article. These levels of ventilation help to increase the consistency of the aerosol inhaled by the user at the mouthpiece end 2b while assisting the aerosol cooling process. Direct ventilation of the article 1 into the mouthpiece 2 is achieved. In this example, ventilation is provided within the cooling section 6, which has been found to be particularly beneficial in assisting the aerosol generation process. The ventilation is provided through perforations 12, which are positioned 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 11, the second plug wrap 10, and the cooling section 6. In alternative embodiments, ventilation can be provided at other locations within the suction port, for example, within the material body 7 or the first tubular element 8. Preferably, the article is configured such that the perforation is 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.

[0207] The plug may include a susceptor material, which is a material that can be inductively heated by penetration due to a fluctuating magnetic field. In some embodiments, the susceptor material is a first aerosol-generating material, which can be inductively heated by penetration due to a fluctuating magnetic field.

[0208] Induction heating is a process of heating a conductive object (such as a susceptor) by electromagnetic induction. A magnetic field generator 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 within the susceptor material. 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 material contains a ferromagnetic material such as iron, nickel, or cobalt, heat may also be generated by magnetic hysteresis losses within the susceptor material, i.e., by a change in the orientation of magnetic dipoles within the magnetic material as a result of their alignment with the fluctuating magnetic field. Compared to heating by conduction, for example, induction heating generates heat within the susceptor, allowing for rapid heating. Furthermore, it becomes possible to increase the flexibility of configuration and application without requiring any physical contact between the induction heater and the susceptor.

[0209] In some embodiments, articles for use with a non-combustible aerosol supply device may comprise a second aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, packaging material, a filter, a suction nozzle, and / or an aerosol modifier.

[0210] Figure 6 shows an example of a non-combustible aerosol supply device 100 for generating an aerosol from an article 110, as described herein. Schematically, the device 100 may be used to heat a replaceable article 110, for example, article 1 illustrated in Figure 1 or described elsewhere herein, to generate an aerosol or other inhalable medium to be inhaled by the user of the device 100. The device 100 and the replaceable article 110 together form a system.

[0211] Device 100 comprises a housing 102 (in the form of an outer cover) that surrounds and accommodates various components of device 100. Device 100 has an opening 104 in one end, and an article 110 can be inserted through the opening 104 for heating by a heating assembly. When in use, the article 110 can be fully or partially inserted into the heating assembly, where it can be heated by one or more components of the heater assembly.

[0212] Device 100 may include pins or blades (not shown) for insertion into the receiving portion of the plug.

[0213] In another aspect of the present invention, a non-combustible aerosol supply system is provided, comprising an article and a non-combustible aerosol supply device.

[0214] The non-combustion aerosol supply system may further comprise another aerosol-generating material. This aerosol-generating material may be added to the first aerosol-generating material or an optional second aerosol-generating material, as described herein.

[0215] In some embodiments, the system may include an aerosol modifier. The aerosol modifier is a substance typically located downstream of the aerosol generation area, configured to modify the resulting aerosol by, for example, altering the taste, flavor, acidity, or other properties of the aerosol.

[0216] Aerosol modifiers may be, for example, additives or adsorbents. Aerosol modifiers may contain, for example, one or more of the following: flavorings, colorings, water, and carbon adsorbents. Aerosol modifiers may be, for example, solids, liquids, or gels. Aerosol modifiers may be in the form of powders, threads, or granules. Aerosol modifiers do not necessarily contain filtration materials.

[0217] The aerosol modifier may be provided within an aerosol modifier release component that is operable to selectively release the aerosol modifier. In some embodiments, a non-combustible aerosol supply system comprises an aerosol modifier release component such as a capsule, thread, or bead.

[0218] In some embodiments, the non-combustible aerosol supply system further comprises a capsule. In embodiments where the aerosol modifier release component is a capsule, the capsule may be fragile. The capsule may include a rupturable capsule, for example, a capsule having a solid, fragile shell surrounding a liquid payload. The capsule may contain a flavoring, an active substance, or other substance, such as an aerosol modifier. This offers the advantage that the user can rupture the capsule to release additional substance(s) into the non-combustible aerosol supply system and further alter the generated aerosol.

[0219] A fifth embodiment provides a method for manufacturing an extruded plug for use with an article. This method may also be called a process and may be as described herein. In some embodiments, the process includes extrusion.

[0220] In a fifth embodiment, an extruded plug manufactured by a process is provided.

[0221] The extrusion process provides the plug with the attributes described herein. For example, the density and uniformity of the plug are affected by the extrusion process. In addition, extrusion affects the surface of the plug, which can be particularly smooth or consistent. Although we do not wish to be bound by a single reason, the material is pushed through a die, which provides the plug with a certain texture. The die can be smooth, and therefore the plug can have a smooth surface texture.

[0222] The various embodiments described herein are presented solely to aid in understanding and teaching the claimed features. These embodiments are provided only as representative examples of embodiments and are not exhaustive or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered limitations to the scope of the invention as defined by the claims or to equivalents of the claims, and it should be understood that other embodiments may be used and modified without departing from the scope of the claimed invention. Various embodiments of the invention may suitably include, consist of, or essentially consist of, disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. In addition, this disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. An article for use with a non-combustible aerosol supply device, wherein the article comprises a first end having a mouthpiece and a second end distal to the first end, the second end comprising an extrusion plug comprising a first aerosol generating material.

2. The article according to claim 1, wherein the article comprises a second aerosol-generating material between the plug and the first end.

3. The article according to claim 2, wherein the second aerosol generating material is in the form of a rod.

4. The article according to any one of claims 1 to 3, wherein the extrusion plug is configured to receive the aerosol generator of the non-combustion aerosol supply device.

5. The article according to claim 4, wherein the extrusion plug comprises a receiving portion configured to receive the aerosol generator.

6. The article according to claim 4 or 5, wherein the plug is configured such that when the aerosol generator is received by the plug, the aerosol generator extends within the plug and within the second aerosol generating material.

7. The article according to any one of claims 4 to 6, wherein the aerosol generator is a pin.

8. The article according to any one of claims 1 to 7, wherein the first aerosol-generating material and / or the second aerosol-generating material comprises a plant-derived material.

9. The article according to claim 8, wherein the plug contains approximately 5% to approximately 75% by weight of plant-derived material.

10. The article according to any one of claims 1 to 9, wherein the plug comprises a channel or a recess.

11. The article according to claim 10, wherein the channel or recess is aligned with the longitudinal axis of the article.

12. The article according to claim 10 or 11, wherein the channel is configured to allow a fluid to pass through the plug.

13. The article according to any one of claims 10 to 12, wherein the channel or recess is located on the surface of the plug.

14. The article according to any one of claims 10 to 13, wherein the recess or channel has a depth of about 5 to about 300 μm.

15. The article according to any one of claims 1 to 14, wherein the plug has a length of less than 6 mm and / or the width of the plug is about 15 to about 35 mm.

16. The article according to any one of claims 1 to 15, wherein the plug substantially consists of the first aerosol-generating material.

17. The article according to any one of claims 1 to 16, wherein the plug contains water.

18. The article according to claim 17, wherein the plug contains up to approximately 15% by weight of water.

19. A method for manufacturing an article according to any one of claims 1 to 18.

20. The method according to claim 19, wherein the method includes the steps of pushing out the plug and incorporating the plug into the article.

21. A non-combustible aerosol supply system comprising an article according to any one of claims 1 to 18 and a non-combustible aerosol supply device.

22. A method for manufacturing an extrusion plug for use with an article described in any one of claims 1 to 18.

23. The method according to claim 22, wherein the process includes extrusion.

24. An extruded plug manufactured by the process described in claim 22.

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