Articles for use in non-combustion aerosol delivery systems

Abstract

To provide an article for use in a non-combustible aerosol provision system.SOLUTION: An article 1 comprises a mouthpiece 2 comprising a material body 6 and having an upstream end 2a and a downstream end 2b. The material body 6 comprises a sheet of amorphous solid material. The material body 6 is formed from a single gathered sheet of amorphous solid sheet material. Also disclosed is a system comprising such an article 1 and a non-combustible aerosol provision device for heating aerosol generating material 3 of the article 1, and a method of manufacturing such an article.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to articles for use in non-combustion based aerosol delivery systems and to non-combustion based aerosol delivery systems including the articles. [Background technology]

[0002] Smoking articles, such as cigarettes and cigars, burn tobacco and produce smoke during use. Other smoking articles produce inhalable aerosols or vapors by releasing compounds from a substrate without combustion. These articles are referred to as non-combustion smoking articles or aerosol delivery systems. Such articles commonly include a mouthpiece that allows the aerosol to pass through and reach the user's mouth. Summary of the Invention

[0003] A first aspect of the invention provides an article for use in a non-combustion based aerosol delivery system, the article including a mouthpiece comprising a body of material, the body of material comprising an amorphous solid material.

[0004] A second aspect of the invention provides an article for use in a non-combustion based aerosol delivery system comprising a mouthpiece according to the first aspect of the invention connected to a source of aerosol-generating material.

[0005] A third aspect of the invention provides a non-combustion aerosol delivery system comprising an article according to the second aspect of the invention and a non-combustion aerosol delivery device.

[0006] A fourth aspect of the invention provides a method for forming an article according to the first aspect of the invention. [Brief description of the drawings]

[0007] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Figure 1] FIG. 2 is a cross-sectional side view of an article including a mouthpiece for use in a non-combustion based aerosol delivery device. [Diagram 2] FIG. 2 is a cross-sectional side view of another article including a mouthpiece for use in a non-combustion based aerosol delivery device. [Diagram 3] FIG. 2 is a cross-sectional side view of another article including a mouthpiece, in this example including a second hollow member, for use in a non-combustion based aerosol delivery device. [Figure 4] FIG. 1 is a cross-sectional side view of another article including a mouthpiece, in this example including a body made of a fibrous material, for use in a non-combustion based aerosol delivery device. [Figure 5a] FIG. 2 is a side cross-sectional view of another article for use in a non-combustion based aerosol delivery device, the article including a capsule-containing mouthpiece. [Figure 5b] FIG. 5b is a cross-sectional view of the capsule-containing mouthpiece shown in FIG. 5a. [Figure 6] FIG. 4 is a perspective view of a non-combustion based aerosol delivery device for generating aerosol from the aerosol-generating material of the articles of FIGS. [Figure 7] 7 shows the device of FIG. 6 with the outer cover removed and without any items. [Figure 8] FIG. 7 is a side view showing a cross section of a portion of the device of FIG. 6. [Figure 9] FIG. 7 is an exploded view of the device of FIG. 6 with the outer cover omitted. [Figure 10A] FIG. 7 is a cross-sectional view of a portion of the device of FIG. [Figure 10B] FIG. 10B is an enlarged view of a region of the device of FIG. 10A; and [Figure 11] FIG. 1 is a flow diagram of a method for manufacturing an article for use in a non-combustion based aerosol delivery device. [Figure 12] 1 is a side view of an apparatus for producing a rod of material according to the present invention; DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user, including: Combustion-based aerosol delivery systems, such as cigarettes, cigarillos, cigars and pipes or tobacco for roll-your-own or homemade cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smoking materials); Combustion-based aerosol delivery systems, such as cigarettes, cigarillos, cigars and pipes or tobacco for roll-your-own or homemade cigarettes (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes or other smoking materials); Non-combustion aerosol delivery systems that release compounds from an aerosol-generating material without burning the aerosol-generating material, such as e-cigarettes, tobacco heating products, and hybrid systems that generate an aerosol using a combination of aerosol-generating materials; and and an aerosol-free delivery system that orally, nasally, transdermally or otherwise delivers to a user at least one substance, with or without nicotine, including, but not limited to, lozenges, gums, patches, articles containing patch-inhalable powders, and oral products such as oral tobacco, including snus or moist snus.

[0009] For purposes of this disclosure, a "combustion-based" aerosol delivery system is one that combusts the constituent aerosolizable materials of the aerosol delivery system (or its components) to facilitate delivery to a user.

[0010] For purposes of this disclosure, a "non-combustion based" aerosol delivery system is one that does not combust or burn the constituent aerosol-generating materials of the aerosol delivery system (or its components) to facilitate delivery of at least one substance to a user.

[0011] In the embodiments described herein, the delivery system is a non-combustion based aerosol delivery system, for example an electrically powered non-combustion based aerosol delivery system.

[0012] In some embodiments, the non-combustion based aerosol delivery system is an e-cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0013] In some embodiments, the non-combustion based aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system, one example of such a system is a tobacco heating system.

[0014] In some embodiments, the non-combustion aerosol delivery system is a hybrid system that uses a combination of aerosol-generating materials to generate the aerosol, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may include, for example, tobacco or a non-tobacco product.

[0015] Generally, a non-combustion aerosol delivery system may include a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device.

[0016] In some embodiments, the present disclosure relates to consumables, sometimes referred to as articles throughout this disclosure, that include an aerosol generating material and are configured for use in non-combustion based aerosol delivery devices.

[0017] In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, may include a power source and a controller. The power source may be, for example, a power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that is energized to deliver power in the form of heat to an aerosol generating material or a thermally conductive material proximate to the heat generating power source.

[0018] In some embodiments, the non-combustion based aerosol delivery system may include an area for housing a consumable, an aerosol generator, an aerosol-generation area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0019] In some embodiments, consumables for use in non-combustion based aerosol delivery systems may include an aerosol-generating material, an aerosol-generating material storage region, an aerosol-generating material transport component, an aerosol generator, an aerosol-generating region, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0020] In some embodiments, the substance delivered may be an aerosol generating material or a material not intended to be aerosolized, either of which may optionally include one or more active ingredients, one or more flavorings, one or more aerosol forming materials, and / or one or more other functional materials.

[0021] In some embodiments, the substance delivered comprises an active agent.

[0022] The active substance used in the present invention is a physiologically active substance, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, psychotropic drugs. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives or mixtures thereof. The active substance may include one or more components, derivatives or extracts of tobacco, cannabis or other plants.

[0023] In some embodiments, the active agent comprises nicotine. In some embodiments, the active agent comprises caffeine, melatonin, or vitamin B 12 Includes.

[0024] As described herein, the active agent may include or be derived from a plant or its components, derivatives or extracts. The term "plant" as used herein includes, but is not limited to, any material derived from a plant, such as extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, pods, etc. Alternatively, the material may include active compounds naturally occurring in the plant that are obtained synthetically. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, chips, strips, sheets, etc. Examples of plants include tobacco, eucalyptus, cornstarch, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay leaf, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, Lavender, lemon peel, mint, juniper, elderflower, vanilla, wintergreen, sedge, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiene, oregano, 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 species: mentha, moroccan mint, egyptian mint, peppermint, cologne mint, candy mint, curly mint, kentucky kernel mint, horse mint, pineapple mint, pennyroyal mint, english spearmint, and malva.

[0025] In some embodiments, the active agent may comprise or be derived from a plant or one or more of its components, derivatives, or extracts, and the plant is tobacco.

[0026] In some embodiments, the active agent may include or be derived from one or more of a plant or its components, derivatives or extracts, the plant being selected from eucalyptus, tallow tree, cocoa and hemp.

[0027] In some embodiments, the composition may comprise or be derived from one or more of a plant or its components, derivatives or extracts, the plant being selected from rooibos and fennel.

[0028] In some embodiments, the substance comprises a flavorant.

[0029] As used herein, the terms "flavorant" and "flavoring agent" are those permitted by local regulations and used to produce a taste, odor or other somatosensory stimulus desired by an adult consumer.They may be naturally occurring flavoring materials, plants, plant extracts, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese peppermint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, raspberry ... Roots, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey extract, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang ylang, Sage, fennel, wasabi, pimento, ginger, coriander, coffee, hemp, peppermint oil from any species of the genus Mentha, eucalyptus, burdock, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay, yerba 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, scutellaria, curcuma, cilantro, myrtle, black currant, valerian, pimento, melon. sucrose, damien, origanum, olive, lemon balm, lemon basil, chives, fennel, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter 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, mannitol, etc.) and other additives such as charcoal, chlorophyll, minerals, botanicals or breath fresheners.They may be mimetics, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example a liquid such as an oil, a solid such as a powder or a gas.

[0030] In some embodiments, the flavorant comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavorant comprises cucumber, blueberry, citrus, and / or red berry flavor components. In some embodiments, the flavorant comprises eugenol. In some embodiments, the flavorant comprises flavor components extracted from tobacco. In some embodiments, the flavorant comprises flavor components extracted from cannabis.

[0031] In some embodiments, the flavorings may include sensory elicitors, which are chemically induced and recognized in addition to or instead of the aroma or taste nerves, usually by stimulation of the fifth cranial nerve (trigeminal nerve), and which may include agents that produce a heating, cooling, tingling, or numbing sensation. A suitable heating agent is, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent is, but is not limited to, eucalyptol, WS-3.

[0032] An aerosol-generating material is a material that can generate an aerosol when excited, for example, by heating, irradiation, or in some other way. The aerosol-generating material may be in the form of a solid, liquid, or gel, for example, which may or may not contain active substances and / or flavorants. In some embodiments, the aerosol-generating material may comprise an "amorphous solid," alternatively referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that holds a fluid, such as a liquid, within it. In some embodiments, the aerosol-generating material comprises about 50 wt%, 60 wt%, or 70 wt% amorphous solid to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0033] The aerosol-generating material may include one or more active agents and / or flavorants, one or more aerosol-forming materials and, if desired, one or more other functional materials.

[0034] The aerosol forming material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol forming material may include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In other embodiments, the aerosol forming agent includes one or more polyhydric alcohols, such as 1,3-butanediol, esters of polyhydric alcohols, such as glycerol mono-, di-, or triacetate, and / or aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetradecanedioate.

[0035] The one or more functional materials may include one or more of a pH regulator, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0036] The forming material may be on or in a support to form a substrate. The support may be or include, for example, paper, cardboard, paperboard, recycled material, plastic material, ceramic material, composite material, glass, metal or metal alloy. In some embodiments, the support includes a susceptor. In some embodiments, the susceptor is embedded in the material. In some other embodiments, the susceptor is on one or both sides of the material.

[0037] A consumable is an article that includes or consists of an aerosol-generating material that is intended to be consumed, in whole or in part, by a user during use. A consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transport member, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater that radiates heat so that the aerosol-generating material generates an aerosol upon use. The heater may include, for example, a combustion-based material, a material heatable by electrical conduction, or a susceptor.

[0038] The susceptor is a material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be an electrically conductive material, such that the penetration of the varying magnetic field results in induction heating of the heating material. The heating material may be an electrically conductive material, such that the penetration of the varying magnetic field results in magnetic hysteresis heating of the heating material. The susceptor may be both electrically conductive and magnetic, such that the heating material can be heated by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0039] An aerosol modifier is a substance that is typically located downstream of the aerosol-generation region and configured to modify the generated aerosol, for example by altering the taste, flavor, acidity or another characteristic of the aerosol. The aerosol modifier may be provided within an aerosol modifier-releasing member that is operable to selectively release the aerosol modifier.

[0040] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavoring agent, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, liquid, or gel. The aerosol modifier may be a powder, string, or granule. The aerosol modifier may not include a filter material.

[0041] 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 expose the aerosol-generating material to thermal energy 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 the aerosol-generating material without applying heat. For example, the aerosol generator may be configured to expose the aerosol-generating material to one or more of vibration, high pressure, or electrostatic energy.

[0042] The aerosol-generating material may be a carrier onto which the amorphous solid is disposed. The carrier acts as a support on which the amorphous solid layer is formed to facilitate manufacturing. The carrier may provide tensile strength to the amorphous solid layer for ease of handling.

[0043] The mouthpiece of the article may comprise an amorphous solid material, suitably in the form of an assembled sheet of the amorphous solid material.

[0044] The present invention provides a mouthpiece comprising an amorphous solid material, and it has been surprisingly discovered that the inclusion of an amorphous solid material in the mouthpiece results in a better aerosol with desirable flavor characteristics and a lower temperature, improving the user's experience.

[0045] In this case, the amorphous solid material is a gathered, rolled or coiled sheet. In some cases, the sheet may be incorporated into a sheet-like mouthpiece. In other cases, the sheet may be chopped and incorporated into a mouthpiece.

[0046] Aerosol-generating materials containing amorphous solids are 30 g / m 2 ~120g / m 2 In some cases, the sheet may have any suitable areal density, such as 80 to 120 g / m 2 , or about 70-110g / m 2 Or especially about 90-110 g / m 2Or preferably about 100 g / m 2 It has a mass per unit area of

[0047] In some examples, the sheet-like amorphous solid may have a tensile strength of about 200 N / m to about 900 N / m. In some examples, such as when the amorphous solid does not include a filler, the amorphous solid may have a tensile strength of 200 N / m to 400 N / m, or 200 N / m to 300 N / m, or about 250 N / m.

[0048] In some cases, such as where the amorphous solid comprises a filler, the amorphous solid may have a tensile strength of from 600 N / m to 900 N / m, or from 700 N / m to 900 N / m, or about 800 N / m. Such tensile strengths are particularly suitable for embodiments in which the amorphous solid material is contained in the aerosol-generating article / assembly in the form of a rolled sheet, preferably a tube.

[0049] In some cases, the carrier layer may be substantially or completely impermeable to gases and / or aerosols, thereby preventing the passage of aerosols or gases through the carrier, controlling the flow and ensuring good delivery to the user.

[0050] The carrier may be any suitable material that can be used to support an amorphous solid. In some cases, the carrier may be formed from a material selected from metal foil, paper, carbon paper, greaseproof paper, ceramics, carbon allotropes such as graphite and graphene, plastic, cardboard, wood, or combinations thereof. In some cases, the carrier may comprise or consist of tobacco material, such as a sheet of reconstituted tobacco. In some cases, the carrier may be formed from a material selected from metal foil, paper, cardboard, wood, or combinations thereof. In some cases, the carrier may be a laminated structure including layers of materials selected from the above examples. In some cases, the carrier may function as a flavor carrier. For example, the carrier may be impregnated with flavorants or tobacco extracts.

[0051] In some cases, the surface of the carrier that abuts the amorphous solid may be porous. For example, in some cases the carrier comprises paper. The inventors have found that porous carriers such as paper are particularly suitable for the present invention, where the porous (paper) layer abuts and adheres strongly to the solid layer. The amorphous solid is formed by drying a gel, and without being limited to any one theory, it is believed that the slurry from which the gel is formed partially impregnates the porous carrier (e.g., paper) such that when the gel hardens and forms crosslinks, the carrier is partially bonded to the gel. This provides a strong bond between the gel and the carrier (and between the dried gel and the carrier).

[0052] Additionally, surface roughness contributes to the strength of the bond between the amorphous solid and the carrier. The inventors have found that the roughness of the paper (on the surface that abuts the carrier) is in the range of 50-1000 Bekk seconds, preferably 50-150 Bekk seconds, and more preferably 100 Bekk seconds (measured at air pressure intervals of 50.66-48.00 kPa). (The Bekk Smoothness Tester is an instrument used to measure the smoothness of a surface of paper at which air at a particular pressure leaks between a smooth glass surface and a paper sample, and the time (in seconds) for a given volume of air to seep between these surfaces is the "Bekk Smoothness.") Alternatively, a laminate of paper and greaseproof paper has been found to be particularly useful in the present invention. The paper layer abuts the amorphous solid, and the tacky amorphous solid does not readily adhere to the greaseproof paper carrier backing.

[0053] In some cases, the carrier has a diameter of about 0.010 mm to about 2.0 mm, preferably about 0.015 mm, 0.02 mm, 0.05 mm, or 0.1 mm to about 1.5 mm, 1.0 mm, or has a thickness of 0.5 mm.

[0054] In some cases, the amorphous solid layer has a thickness of about 0.015 mm to about 1.5 mm, preferably about 0.0 It has a thickness of 5 mm to about 1.5 mm or 0.05 mm to about 1.0 mm. Preferably, the thickness is The thickness may range from about 0.1 mm or 0.15 mm to about 1 mm, 0.5 mm or 0.3 mm. The amorphous solid may comprise two or more layers, and the thicknesses referred to herein refer to the combined thickness of these layers.

[0055] The thicknesses specified herein are the average thickness of the material. In some cases the thickness of the amorphous solid may vary within 25%, 20%, 15%, 10%, 5% or 1%.

[0056] Optionally, the amorphous solid may contain 1-60 wt % of a gelling agent, these weights being calculated on a dry weight basis.

[0057] Suitably, the amorphous solid may comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 27 wt% of the gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise from 1 to 50 wt%, 5 to 40 wt%, 10 to 30 wt%, or 15 to 27 wt% of the gelling agent.

[0058] The gelling agent may comprise one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum and mixtures thereof.

[0059] In some embodiments, the cellulosic gelling agent comprises hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof. is selected from the group.

[0060] In some embodiments the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethyl cellulose, guar gum or acacia gum.

[0061] In some embodiments, the gelling agent comprises (or is) one or more non-cellulosic gelling agents, including, but not limited to, agar, xanthan gum, gum arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginates, and combinations thereof, In preferred embodiments, the non-cellulosic gelling agent is alginate or agar.

[0062] In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some embodiments, the gelling agent comprises an alginate and / or a pectin, which may be mixed with a hardening agent (such as a calcium source) during the formation of the amorphous solid. In some embodiments, the amorphous solid may comprise a calcium cross-linked alginate and / or a calcium cross-linked pectin.

[0063] In some embodiments, the gelling agent comprises alginate, and the alginate is present in the amorphous solid in an amount of 10-30 wt% (calculated on a dry weight basis) of the amorphous solid. In some embodiments, the alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginate and at least one additional gelling agent, such as pectin.

[0064] In some embodiments, the amorphous solid may include a gelling agent, including carrageenan.

[0065] Suitably, the amorphous solid may comprise from about 0.1 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt%, or 10% to about 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt% of the aerosol generating agent (all calculated on a dry weight basis). The aerosol generating agent may act as a plasticizer. For example, the amorphous solid may comprise from 0.5 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt%, or 10% to about 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt% of the aerosol generating agent (all calculated on a dry weight basis). The composition may contain up to 40 wt%, 3-35 wt%, or 10-25 wt% of aerosol generating agent. In some cases, the aerosol generating agent comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some cases, the aerosol generating agent comprises, consists essentially of, or consists of glycerol. The inventors have determined that if the plasticizer content is too high, the amorphous solid will absorb water and result in a material that does not produce a suitable consumer experience upon use. The inventors have determined that if the plasticizer content is too low, the amorphous solid will become brittle and break easily. The plasticizer in the amounts specified herein provides flexibility to the amorphous solid, allowing amorphous solid sheets to be wound onto bobbins useful in the manufacture of aerosol generating articles.

[0066] The amorphous solid may include a flavoring agent. In some cases, the amorphous solid may include up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% of flavoring agent. In some cases, the amorphous solid may include at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% of flavoring agent (all calculated on a dry weight basis). For example, the amorphous solid may include 1-80 wt%, 10-80 wt%, 20-70 wt%, 30-60 wt%, 35-55 wt%, or 30-45 wt% of flavoring agent. In some cases, the flavoring agent includes, consists essentially of, or consists of menthol.

[0067] The amorphous solid may include a colorant. The appearance of the amorphous solid may be altered by adding a colorant. The presence of a colorant in the amorphous solid may enhance the appearance of the amorphous solid and the aerosol-generating material. The colorant may be added to the amorphous solid to match the color of the amorphous solid to other components of the aerosol-generating material or other components of the article that includes the amorphous solid.

[0068] Various coloring agents may be used depending on the desired color of the amorphous solid. The color of the amorphous solid may be, for example, white, green, red, purple, blue, or black. Other colors are also contemplated. Natural or synthetic coloring agents may be used, such as natural or synthetic dyes, food grade coloring agents, and pharmaceutical grade coloring agents. In certain embodiments, the coloring agent is caramel, which gives the amorphous solid a brown appearance. In such embodiments, the color of the amorphous solid may be similar to the color of other components in the aerosol-generating material that includes the amorphous solid, such as tobacco material. In some embodiments, the coloring agent is added to the amorphous solid to allow visual differentiation of other components of the aerosol-generating material.

[0069] The colorant may be incorporated into the amorphous solid during its formation (e.g., during the formation of a slurry containing the material that will form the amorphous solid) or may be applied to the amorphous solid after it has been formed. (e.g., by spraying onto an amorphous solid).

[0070] Optionally, the amorphous solid may additionally comprise an emulsifier that emulsifies the molten flavoring during manufacture. For example, the amorphous solid may comprise from about 5 wt% to about 15 wt%, preferably about 10 wt% (calculated on a dry weight basis) of an emulsifier. The emulsifier may comprise gum acacia.

[0071] In some embodiments, the amorphous solid is a hydrogel and contains less than about 20 wt% water, calculated on a wet weight basis. In some cases, the hydrogel may contain less than about 15 wt%, 12 wt%, or 10 wt% water, calculated on a wet weight basis. In some cases, the hydrogel may contain at least about 1 wt%, 2 wt%, or at least about 5 wt% water.

[0072] The amorphous solid may include an acid. The acid may be an organic acid. In some of these embodiments, the acid may be at least one of a monobasic acid, a dibasic acid, and a tribasic acid. In some such embodiments, the acid may include at least one carboxylic acid functional group. In some such embodiments, the acid may be at least one of an alpha-hydroxy acid, a carboxylic acid, a dicarboxylic acid, a tricarboxylic acid, and a keto acid. In some such embodiments, the acid may be an alpha-keto acid.

[0073] In some such 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, propanoic acid, and pyruvic acid.

[0074] A suitable 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.

[0075] In certain embodiments, the amorphous solid comprises a gelling agent comprising a cellulosic and / or non-cellulosic gelling agent, an active agent, and an acid.

[0076] In some embodiments, the amorphous solid additionally comprises an active agent. For example, in some cases, the amorphous solid additionally comprises tobacco material and / or nicotine. In some cases, the amorphous solid may comprise between 5 and 60 wt% tobacco material and / or nicotine (calculated on a dry weight basis). In some cases, the amorphous solid may comprise between about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% active agent (calculated on a dry weight basis). In some cases, the amorphous solid may comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% tobacco material (calculated on a dry weight basis). For example, the amorphous solid may comprise from 10 to 50 wt%, 15 to 40 wt%, or 20 to 35 wt% tobacco material. In some cases, the amorphous solid may comprise from about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% nicotine (calculated on a dry weight basis). For example, the amorphous solid may comprise from 1 to 20 wt%, 2 to 18 wt%, or 3 to 12 wt% nicotine.

[0077] In some cases, the amorphous solid comprises an active agent such as tobacco extract. In some cases, the amorphous solid may comprise 5-60 wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the amorphous solid may comprise from about 5 wt%, 10 wt%, 15 wt%, 20 wt% or 25 wt% to about 60 wt%, 50 wt%, 45 wt% or 40 wt%, 35 wt% or 30 wt% (calculated on a dry weight basis) of tobacco extract. For example, the amorphous solid may comprise 10-50 wt%, 14-40 wt% or 20-35 wt% of tobacco extract. The tobacco extract may contain nicotine in a concentration such that the amorphous solids contain from 1 wt%, 1.5 wt%, 2 wt%, or 2.5 wt% to about 6 wt%, 5 wt%, 4.5 wt%, or 4 wt% nicotine (calculated on a dry weight basis), and in some cases, no amorphous solid nicotine is present other than that obtained from the tobacco extract.

[0078] In some embodiments, the amorphous solid does not include tobacco material, but does include nicotine. In some such cases, the amorphous solid may include from about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% nicotine (calculated on a dry weight basis). For example, the amorphous solid may include from 1 to 20 wt%, 2 to 18 wt%, or 3 to 12 wt% nicotine.

[0079] In some cases, the combined active and flavorant content may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt% In some cases, the combined active and flavorant content may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0080] In some cases, the combined tobacco material, nicotine and flavorant content may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the combined active and / or flavorant content may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0081] The amorphous solid may be made of a gel, which may additionally contain a solvent present at 0.1-50 wt %. However, the inventors have found that the inclusion of a solvent in which the flavoring is soluble reduces the stability of the gel, and the flavoring may crystallize out of the gel. Thus, in some cases, the gel does not contain a solvent in which the flavoring is soluble.

[0082] In some embodiments, the amorphous solid comprises less than 60 wt% of the filler, such as between 1 wt% and 60 wt%, or between 5 wt% and 50 wt%, or between 5 wt% and 30 wt%, or between 10 wt% and 20 wt%.

[0083] In other embodiments, the amorphous solid contains less than 20 wt%, preferably less than 10 wt% or less than 5 wt% of a filler. In some embodiments, the amorphous solid contains less than 1 wt% of a filler, and in some cases, no filler.

[0084] If present, the filler may comprise one or more suitable inorganic adsorbents such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and molecular sieves. The filler may comprise one or more organic fillers such as wood pulp, cellulose, and cellulose derivatives. In some cases, the amorphous solid comprises less than 1 wt. % of a filler, and in some cases, no filler. In particular, in some cases, the amorphous solid comprises a calcium carbonate such as chalk.

[0085] In certain embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous filler such as wood pulp, hemp fiber, cellulose or a cellulose derivative. Without wishing to be bound by any theory, it has been determined that the inclusion of a fibrous filler in an amorphous solid increases the tensile strength of the material. This is particularly advantageous because the increased tensile strength makes it less likely that defects will be introduced into the amorphous solid during manufacturing.

[0086] In some embodiments, the amorphous solid is free of tobacco fiber, hi certain embodiments, the amorphous solid is free of fibrous material.

[0087] In some embodiments, the aerosol-generating material does not contain tobacco fibers, while in certain embodiments, the aerosol-generating material does not contain fibers.

[0088] In some cases, the amorphous solid consists essentially of or consists of a gelling agent, an aerosol generating agent, water and optionally flavorants and / or tobacco materials and / or a nicotine source.

[0089] In some cases the amorphous solid consists essentially of or consists of a gelling agent, water, an aerosol generating agent and optionally a flavorant and / or an active agent.

[0090] Induction heating is the process of heating an electrically conductive object by penetrating a varying magnetic field into the object. The process is explained by Faraday's law of electromagnetic induction and Ohm's law. An induction heater may comprise an electromagnet and a device for passing a varying electric current, such as an alternating current, through the electromagnet. When the object to be heated and the electromagnet are placed in a suitable relative position such that the varying magnetic field generated by the electromagnet penetrates the object, one or more eddy currents are generated in the object. The object has a resistance to the flow of electric current. Thus, when such eddy currents are generated in the object, they flow against the electrical resistance of the object, thereby heating the object. This process is called Joule heating, Ohmic heating, or resistive heating. An object that can be inductively heated is known as a susceptor.

[0091] In one embodiment, the susceptor is in the form of a closed circuit, which has been found to provide a stronger magnetic coupling between the susceptor and the electromagnet in use, resulting in increased or improved Joule heating.

[0092] Magnetic hysteresis heating is the process of heating an object made of a magnetic material by the penetration of the object with a changing magnetic field. A magnetic material can be thought of as containing many atomic-scale magnets or magnetic dipoles. When a magnetic field penetrates such a material, the magnetic dipoles align themselves along the magnetic field. Thus, when a changing magnetic field, such as an alternating magnetic field, e.g., one produced by an electromagnet, penetrates a magnetic material, the orientation of the magnetic dipoles changes in response to the applied changing magnetic field. This reorientation of the magnetic dipoles generates heat in the magnetic material.

[0093] When an object is both conductive and magnetic, the penetration of a changing magnetic field into the object can cause both Joule heating and magnetic hysteresis heating in the object. Furthermore, the use of magnetic materials can enhance the changing magnetic field, thereby enhancing Joule heating.

[0094] In each of the above processes, heat is generated within the object itself, rather than by conduction from an external heat source, so that a faster temperature rise and a more uniform heat distribution within the object can be achieved. This can be achieved, among other things, by the appropriate choice of material and geometry of the object, and the appropriate choice of magnitude and orientation of the varying magnetic field relative to the object. Furthermore, induction heating and magnetic hysteresis heating do not require a physical connection between the source of the varying magnetic field and the object, allowing greater design freedom and control of the heating profile, as well as lower costs.

[0095] Articles, for example rod-like articles, are often named according to the length of the product: "standard" (usually 68-75 mm, e.g. in the range from about 68 mm to about 72 mm), "short" or "mini" (68 mm or less), "king size" (usually 75-91 mm, e.g. in the range from about 79 mm to about 88 mm), "long" or "super king" (usually 91-105 mm, e.g. in the range from about 94 mm to about 101 mm), and "extra long" (usually in the range from about 110 mm to about 121 mm).

[0096] They are also named according to the circumference of the cigarette: "standard" (approximately 23-25 ​​mm), "wide" (over 25 mm), "slim" (approximately 22-23 mm), "demi-slim" (approximately 19-22 mm), "super slim" (approximately 16-19 mm) and "micro-slim" (less than 16 mm).

[0097] Thus, a king size extra thin standard cigarette, for example, is about 83 mm in length and about 17 mm in circumference.

[0098] Each format may be provided with a mouthpiece of different length. The length of the mouthpiece will be approximately 30mm to 50mm. The tipping paper connects the mouthpiece to the aerosol-generating material and will typically be longer than the mouthpiece, for example by 3-10mm, so that the tipping paper covers the mouthpiece and overlaps the aerosol-generating material, for example in the form of a rod of substrate, connecting the mouthpiece to the rod.

[0099] The articles, aerosol generating materials and mouthpieces described herein can be made in any of the formats described above, but are not limited to these.

[0100] As used herein, the terms "upstream" and "downstream" are relative terms defined with respect to the direction of mainstream smoke aerosol-generating material being drawn through an article or device in use.

[0101] The filamentary tow material described herein may include cellulose acetate fiber tow. The filamentary tow material may be formed using other materials used to form fibers, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1,4-butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate) (PBAT), starch-based materials, paper, aliphatic polyester materials, and polysaccharide polymers or combinations thereof. The filamentary tow material may be plasticized with a plasticizer suitable for the filter material, such as triacetin, if the filter material is cellulose acetate tow, or may be unplasticized. The tow may be of other cross-sections, such as "Y" or "X", with fiber deniers of 2.5 to 15, e.g., 8.0 to 11.0, and 5,000 to 50,000, e.g., 1,2,3,4,5,6,7,8,9,10,11,12,13,14,15,16,17,18,19,19,20,21,22,23,24,25,26,27,28,29,30,31,32,33,34,35,36,37,38,39,40,41,42,43,44,45,50,51,52,53,54,55,56,57,58,59,60,61,62,63,74,75,76,77,78,79,80,81,96,97,98,99,100,110,120,130,140,150,160,170,180,190,181,192,193,194,195 Any suitable specification may be used, for example fibers having a total fineness value of 10,000 to 40,000.

[0102] As used herein, the term "tobacco material" refers to any material containing tobacco or its derivatives or substitutes. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco or tobacco substitutes. Tobacco material may include one or more of powdered tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stem, reconstituted tobacco and / or tobacco extract.

[0103] The same reference numbers are used in the drawings herein to denote equivalent features, items or components.

[0104] Figure 1 is a side cross-sectional view of an article 1 for use in a non-combustion based aerosol delivery device. As shown in Figure 1, the article includes a mouthpiece 2 having an upstream end 2a and a downstream end 2b. The mouthpiece 2 includes a body of material 6 comprising a sheet of amorphous solid material. In this example, the amorphous solid material is gathered and wrapped around a first plug wrapper 7 to form a substantially cylindrical body of material 6. In this example, the body of material 6 is formed from a single gathered sheet of amorphous solid sheet material. However, in alternative embodiments, the sheet of amorphous solid material may be cut into strips prior to gathering to form the body of material 6.

[0105] In the embodiment shown in Figure 1, the article comprises a mouthpiece 2 and further comprises an aerosol-generating material 3, in this example a cylindrical rod of tobacco material, connected to the mouthpiece 2. An upstream end 2a of the mouthpiece is located adjacent the aerosol-generating material and a downstream end 2b of the mouthpiece 2 is located distal to the rod of aerosol-generating material 3.

[0106] The present invention has discovered that the provision of a body of amorphous solid material in the mouthpiece has the advantage of providing a cooling effect to the aerosol as it is drawn through the mouthpiece in use. Without wishing to be bound by any theory, it is believed that heat transferred from the aerosol to the amorphous solid material as it passes through the body of material 6 aerosolizes components of the amorphous solid material, thereby cooling the aerosol and advantageously modifying the flavor of the aerosol passing through the mouthpiece, if desired. This arrangement alleviates a traditional problem with smoking articles where the aerosol becomes too hot when it reaches the consumer's lips, and also provides a means for adding additional flavor to the aerosol without complicating manufacturing.

[0107] In this example, the length of the amorphous solid material body 6 is 40 mm.

[0108] The body may be formed using methods known to those skilled in the art for manufacturing paper filters for smoking articles. In this example, the body of amorphous solid material 6 is formed from a single assembled sheet of amorphous solid material. In another embodiment, the body of material 6 may be formed from two or more sheets of amorphous solid material or a single sheet of material that is cut into pieces before being assembled to form the body. In this case, the amorphous solid material comprises a single layer and is not laminated to a carrier material. In other embodiments, the amorphous solid material may be laminated to a carrier material such as paper or foil, and the laminated amorphous solid material may be used to form the body by any of the methods described herein.

[0109] In this case, the thickness of the amorphous solid material is 0.09 mm. In alternative embodiments, the amorphous solid material may have any suitable thickness as described herein. Preferably, the thickness of the amorphous solid material is 0.05 mm to 0.2 mm. Preferably, in any of the embodiments described herein, the thickness of the amorphous solid layer is about 50 μm to about 200 μm, or about 50 μm to about 100 μm, or about 60 μm to about 90 μm, preferably about 77 μm.

[0110] The density of the body of material 6 is determined by dividing the total weight of the body of material 6 by the total volume of the body of material 6, which can be calculated using suitable measurements of the body of material 6, for example using a vernier caliper. If necessary, suitable dimensions can also be measured using a microscope. In this case, the density of the body of material is 0.51×10 -3 g / mm 3 In another embodiment, the density of the body of material is less than 0.1×10 -3 g / mm 3 ~1×10 -3 g / mm 3 It is.

[0111] The body of material 6 is wrapped in a first plug wrapper 7. Preferably the first plug wrapper 7 has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. Preferably the first plug wrapper 7 has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. Preferably the first plug wrapper 7 is a non-porous plug wrapper, for example having a breathability of less than 100 Coresta units, for example less than 50 Coresta units. However, in other embodiments the first plug wrapper 7 may be a porous plug wrapper, for example having a breathability of more than 200 Coresta units.

[0112] Figure 2 is a cross-sectional side view of an article 1' including a mouthpiece 2' for use in a non-combustion based aerosol delivery device. The article 1' includes a body of material 6 similar to that described with reference to Figure 1, except that the length of the body of material 6 is 10 mm. In addition to the body of material 6, the mouthpiece 2' includes a hollow tubular member 8 and a body of fibrous material 4. In the embodiment shown in Figure 2, the article 1' further includes a rod of aerosol-generating material 3 connected to an upstream end 2' of the mouthpiece 2' opposite the downstream end 2' of the mouthpiece 2'.

[0113] Preferably, the length of the body of material 6 is less than about 15 mm. More preferably, the length of the body of material 6 is less than about 10 mm. Additionally or alternatively, the length of the body of material 6 is at least about 5 mm. Preferably, the length of the body of material 6 is at least about 6 mm. In some preferred embodiments, the length of the body of material 6 is between about 5 mm and about 15 mm, more preferably between about 6 mm and about 12 mm, even more preferably between about 6 mm and about 12 mm, and most preferably between about 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. In this example, the length of the body of material 6 is 10 mm.

[0114] The pressure drop or pressure differential (also referred to as resistance to drawing) across the mouthpiece, e.g., the portion of the article 1 downstream of the aerosol-generating material 3, is preferably less than about 40 mmH2O. Such a pressure drop has been found to allow sufficient aerosol, including flavor compounds, to be transferred through the mouthpiece 2 to the consumer. More preferably, the pressure drop across the mouthpiece 2 is less than about 32 mmH2O. In some embodiments, aerosols have been particularly improved by using a mouthpiece 2 having a pressure drop of less than 31 mmH2O, e.g., about 29 mmH2O, about 28 mmH2O, or about 27.5 mmH2O. Alternatively or additionally, the mouthpiece pressure drop is at least 10 mmH2O, preferably at least 15 mmH2O, and more preferably at least 20 mmH2O. In some embodiments, the mouthpiece pressure drop may be between about 15 mmH2O and 40 mmH2O. These values ​​allow the mouthpiece 2 to decelerate the aerosol as it passes through the mouthpiece 2, so that the temperature of the aerosol has time to drop before it reaches the downstream end 2b of the mouthpiece 2.

[0115] The pressure drop or pressure differential across the body of material is preferably between 0.01 mmH2O and 100 mmH2O. In some embodiments, the pressure drop across the body of material is less than about 50 mmH2O, less than about 45 mmH2O, or less than about 30 mmH2O.

[0116] In this example, the body of material 6 is located downstream adjacent and abutting a hollow tubular member 8, also referred to as a cooling member. The hollow tubular member 8 is formed from a number of paper plies that are wound in parallel to form the tubular member 8 with a joined seam. In this example, the first and second paper plies provide a double tube, but in other examples three, four or more plies may be used to form a triple, quadruple or more stacked tube. Other constructions may also be used, such as spirally wound paper plies, cardboard tubes, tubes formed using a composite paper moulding process, moulded or extruded plastic tubes or the like.

[0117] The hollow tubular member 8 may be formed using a stiff plug wrapper and / or tipping paper as the third plug wrapper 11 and / or tipping paper 5, described in more detail below, meaning that a separate tubular member is not required. The stiff plug wrapper and / or tipping paper is manufactured to have sufficient stiffness to withstand axial compressive forces and bending moments that may occur during manufacture and use of the article 1'. For example, the stiff plug wrapper and / or tipping paper may have a basis weight of 70 gsm to 120 gsm, more preferably 80 gsm to 110 gsm. Additionally or alternatively, the stiff plug wrapper and / or tipping paper may have a thickness of 80 μm to 200 μm, more preferably 100 μm to 160 μm or 120 μm to 150 μm. It is desirable to have values ​​in these ranges in both the third plug wrapper 11 and the tipping paper 5 to achieve an acceptable overall level of stiffness for the hollow tubular member 8.

[0118] The hollow tubular member 8 has a diameter of at least about 100 μm and no more than about 1.5 mm, preferably 100 μm to 1 mm, and more preferably 150 μm to 1.5 mm, as measured, for example, using a vernier caliper. It preferably has a wall thickness of 500 μm or about 300 μm. In this example the hollow tubular member 8 has a wall thickness of about 290 μm.

[0119] Preferably, the length of the hollow tubular member 8 is less than about 50 mm. More preferably, the length of the hollow tubular member 8 is less than about 40 mm. Even more preferably, the length of the hollow tubular member 8 is less than about 30 mm. Additionally or alternatively, the length of the hollow tubular member 8 is preferably at least about 10 mm. Preferably, the length of the hollow tubular member 8 is at least about 15 mm. In some preferred embodiments, the length of the hollow tubular member 8 is about 20 mm to about 30 mm, more preferably about 22 mm to about 28 mm, even more preferably about 24 mm to about 26 mm, and most preferably about 25 mm. In this example, the length of the hollow tubular member 8 is 25 mm.

[0120] The hollow tubular member 8 is positioned around the mouthpiece 2 and defines a cavity within the mouthpiece, which acts as a cooling segment. The cavity provides a chamber through which heated volatiles generated by the aerosol-generating material 3 flow. The hollow tubular member 8 is hollow to provide a chamber for the deposition of the aerosol, yet is rigid enough to withstand axial compressive forces and bending movements that may occur during manufacture and while the article 1' is in use. The hollow tubular member 8 provides a physical transition between the aerosol-generating material 3 and the body of material 6. The physical transition through the hollow tubular member 8 provides a temperature gradient over the length of the hollow tubular member 8.

[0121] The hollow tubular member 8 may be configured to provide a temperature difference of at least 40° C. between the heated and volatilized components entering the first upstream end of the hollow tubular member 8 and the heated and volatilized components exiting the second downstream end of the hollow tubular member 8. The hollow tubular member 8 is preferably configured to provide a temperature difference of at least 60° C., preferably at least 80° C., and more preferably at least 100° C., between the heated and volatilized components entering the first upstream end of the hollow tubular member 8 and the heated and volatilized components exiting the second downstream end of the hollow tubular member 8. This temperature difference along the length of the hollow tubular member 8 protects the temperature sensitive first body of material 6 from the high temperatures of the aerosol-generating material 3 when heated.

[0122] In another embodiment, the hollow tubular member 8 can be replaced by another cooling member, for example a member formed from a body of material through which the aerosol passes longitudinally and which also performs the function of cooling the aerosol, for example an amorphous solid body of material 6.

[0123] In this example, fibrous body 4 is located at the downstream mouth end 2'b of mouthpiece 2' immediately downstream of and in abutting relationship with body 6. Body 4 is wrapped in a second plug wrapper 9, which in this example is the same as first plug wrapper 7. Body 6 and body 4 each define a substantially generally cylindrical shape and share a common longitudinal axis.

[0124] In this example, the hollow tubular member 8, body 6 and fibrous body 4 are assembled using a third plug wrapper 11 which is wrapped around all three sections. Preferably, the third plug wrapper 11 has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 45 gsm. Preferably, the third plug wrapper 11 has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The third plug wrapper 11 is preferably a non-porous plug wrapper 100 having an air permeability of less than Coresta units, for example less than 50 Coresta units. However, in alternative embodiments, the third plug wrapper 11 may be a porous plug wrapper having an air permeability of, for example, greater than 200 Coresta units.

[0125] In this example, the fibrous body 4 is formed from filamentary tow. In this example, the tow used in the fibrous body 4 has a dpf of 8.4 and a total fineness of 21,000. Alternatively, the tow may have, for example, a dpf of 9.5 and a total fineness of 12,000. Alternatively, the tow may have, for example, a dpf of 8 and a total fineness of 15,000. In this example, the tow comprises plasticized cellulose acetate tow. The plasticizer used in the tow comprises about 7% by weight of the tow. In this example, the plasticizer is triacetin. In other examples, different materials may be used to form the fibrous body 4. For example, rather than tow, the fibrous body 4 may be formed from paper, as in conventional paper filters for use in, for example, cigarettes. Alternatively, the fibrous body 4 may be formed from materials other than cellulose acetate, such as polylactic acid (PLA), other materials described herein for filamentary tow, or similar materials. The tow is preferably formed from cellulose acetate. Whether formed from cellulose acetate or another material, the tow preferably has a dpf of at least 5, more preferably at least 6, and even more preferably at least 7. These values ​​of single yarn fineness provide a relatively coarse, thick-fibered tow having a smaller surface area than tows with lower single yarn finenesses, and as a result the pressure drop across the resulting mouthpiece 2' is less than tows with lower dpf values. Preferably, the tow has a single yarn fineness of 12 dpf, preferably less than 11 dpf and more preferably less than 10 dpf, to obtain a sufficiently uniform fibrous body 4.

[0126] The total fineness of the tows forming the fibrous material body 4 is preferably at most 30,000, more preferably at most 28,000 and even more preferably at most 25,000. These values ​​of total fineness provide tows that occupy a smaller proportion of the cross-sectional area of ​​the mouthpiece 2', resulting in a smaller drawing resistance and therefore a smaller pressure drop in the mouthpiece 2' than tows with higher total fineness values. For a suitable hardness of the fibrous material body 4, the tows preferably have a total fineness of at least 8,000 and more preferably at least 10,000. Preferably, the single yarn fineness is 5-12 and the total fineness is 10,000-25,000. More preferably, the single yarn fineness is 6-10 and the total fineness is 11,000-22,000. Preferably, the cross-sectional shape of the filaments in the tow is "Y" shaped, although in other embodiments other shapes can be used, such as "X" shaped filaments with the same dpf and total fineness values ​​provided herein.

[0127] Preferably, the length of the fibrous body 4 is less than about 15 mm. More preferably, the length of the fibrous body 4 is less than about 10 mm. Additionally or alternatively, the length of the fibrous body 4 is at least about 5 mm. Preferably, the length of the fibrous body 4 is at least about 6 mm. In some embodiments, the length of the fibrous body 4 is from about 5 mm to about 15 mm, more preferably from about 6 mm to about 12 mm, even more preferably from about 6 mm to about 10 mm, and most preferably about 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. In this example, the length of the fibrous body 4 is 10 mm.

[0128] In this example, the aerosol-generating material 3 is wrapped in a wrapper 10. The wrapper 10 may be, for example, a paper or paper-supported foil wrapper. In this example, the wrapper 10 is substantially impermeable to air. In another embodiment, the wrapper 10 has an air permeability of preferably less than 100 Coresta units, more preferably less than 60 Coresta units. It has been found that wrappers with low air permeability, for example less than 100 Coresta units, more preferably less than 60 Coresta units, result in improved formation of aerosols at the aerosol-generating material 3. Without wishing to be bound by any theory, it is hypothesized that this is due to less loss of aerosol compounds through the wrapper 10. The air permeability of the wrapper 10 may be measured according to ISO 2965:2009 for measurement of air permeability of materials used as cigarette papers, filter plug wrappers and filter bonding papers.

[0129] In this embodiment, the wrapper 10 comprises an aluminum foil. Aluminum foil has been found to be particularly effective in enhancing the formation of aerosol 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 backing. However, in alternative configurations, the aluminum foil may have other thicknesses, for example, between 4 μm and 16 μm. The aluminum foil may also have no backing, for example formed from another material that helps provide the foil with adequate tensile strength. Metal layers or foils other than aluminum may also be used. The total thickness of the wrapper is preferably between 20 μm and 60 μm, more preferably between 30 μm and 50 μm, to provide the wrapper with suitable structural integrity and heat transfer properties. The tension that can be applied to the wrapper before it breaks is greater than 3,000 gram force, for example between 3,000 and 10,000 gram force or between 3,000 and 4,500 gram force.

[0130] The ventilation level of the article for the aerosol drawn through the article is about 60%. In another embodiment, the article may have a ventilation level of 50% to 80%, for example 65% to 75%, of the aerosol drawn through the article. These levels of ventilation assist in slowing down the flow of aerosol drawn through the mouthpiece 2', allowing the aerosol to cool before it reaches the downstream end of the mouthpiece 2'. The ventilation is provided directly within the mouthpiece 2' of the article 1'. In this example, the ventilation is provided within the hollow tubular member 8, which has been found to be particularly beneficial in assisting the aerosol generation process. The ventilation is provided via first and second parallel rows of perforations 12, in this case formed as laser drillings, at positions 17.925 mm and 18.625 mm, respectively, from the downstream mouth end 2' of the mouthpiece 2'. These perforations pass through the tipping paper 5 and the hollow tubular member 8. In alternative embodiments, ventilation may be provided at other locations in the mouthpiece, for example within the fibrous body 4 or the first tubular member 11.

[0131] Aerosol-generating materials include materials capable of being aerosolized, also referred to as aerosol-forming materials. The aerosolizable material may be present on a substrate. The substrate may be or include, for example, paper, cardboard, paperboard, recycled aerosolizable materials, plastic materials, ceramic materials, composite materials, glass, metals, or metal alloys.

[0132] In this example the aerosol-forming material added to the aerosol-generating substrate 3 comprises 14% by weight of the aerosol-generating material 3. Preferably the aerosol-forming material comprises at least 5% by weight of the aerosol-generating material, more preferably at least 10% by weight. Preferably the aerosol-forming material comprises less than 25% by weight of the aerosol-generating material, more preferably less than 20%, for example 10%-20%, 12%-18% or 13%-16%.

[0133] Preferably, the aerosol-generating material 3 is provided as a cylindrical rod of aerosol-generating material. Regardless of the shape of the aerosol-generating material, the aerosol-generating material has a length of about 10 mm to 100 mm. In some embodiments, the length of the aerosol-generating material is preferably in the range of about 25 mm to 50 mm, more preferably in the range of about 30 mm to 45 mm, and even more preferably about 30 mm to 40 mm.

[0134] The volume of the aerosol-generating material 3 to be installed is about 200 mm 3 ~ approx. 4300mm 3 , preferably about 500 mm 3 ~1500mm 3 , more preferably about 1000 mm 3 ~ approx. 1300mm 3 For example, the distance may vary by about 1000 mm. 3 ~ approx. 1300mm 3 Providing these volumes of aerosol-generating material has been shown to advantageously achieve superior aerosols with better visibility and perception performance than those achieved with volumes selected from the lower end of the range.

[0135] The mass of the aerosol-generating material 3 provided may be greater than 200 mg, for example between about 200 mg and 400 mg, preferably between about 230 mg and 360 mg, more preferably between about 250 mg and 360 mg. It has been found advantageous to provide a greater mass of aerosol-generating material, resulting in better sensory performance compared to aerosol generated from a lower mass of tobacco material.

[0136] Preferably, the aerosol-generating material 3 is formed from a tobacco material as described herein that includes a tobacco component.

[0137] In the tobacco materials described herein, the tobacco components include reconstituted tobacco. The tobacco components include leaf tobacco, extruded tobacco and / or band-cast tobacco.

[0138] The aerosol-generating material 3 may include reconstituted tobacco material having a density of less than about 700 milligrams per cubic centimeter (mg / cc). Such tobacco materials have been found to be particularly useful in providing an aerosol-generating material that can be heated quickly to release an aerosol as compared to denser materials. For example, the inventors have tested the properties of various aerosol-generating materials, such as band-cast reconstituted tobacco material and paper reconstituted tobacco material, upon heating. For each given aerosol-generating material, during the application of heat to the material, there exists a particular zero heat flow temperature below which the net heat flow becomes endothermic, i.e., more heat enters the material than leaves it, and above which the net heat flow becomes exothermic, i.e., more heat leaves the material than enters it. Materials with densities less than 700 mg / cc have low zero heat flow temperatures. Since a significant portion of the heat flow leaving the material is through the formation of an aerosol, having a low zero heat flow temperature has a beneficial effect on the time it takes to initially release an aerosol from the aerosol-generating material. For example, they found that aerosol-generating materials having a density less than 700 mg / cc had zero heat flow temperatures less than 164°C compared to materials having a density greater than 700 mg / cc that had zero heat flow temperatures greater than 164°C.

[0139] The density of the aerosol-generating material also affects the rate at which heat travels through the material; lower densities, e.g., less than 700 mg / cc, result in a slower rate of heat travel through the material, thus allowing for a more sustained aerosol release.

[0140] Preferably, the aerosol-generating material 3 comprises reconstituted tobacco material, such as paper reconstituted tobacco material, having a density of less than about 700 mg / cc. More preferably, the aerosol-generating material 3 comprises reconstituted tobacco material having a density of less than about 600 mg / cc. Alternatively or additionally, the aerosol-generating material 3 preferably comprises reconstituted tobacco material having a density of at least 350 mg / cc, which is believed to allow for a sufficient amount of heat transfer through the material.

[0141] The tobacco material may be provided in the form of shredded tobacco. The shredded tobacco has a cut width of at least 15 pieces per inch (5.9 pieces per centimeter, equivalent to a cut width of about 1.7 mm). Preferably, the shredded tobacco has a cut width of at least 18 pieces per inch (about 7.1 pieces per centimeter, equivalent to a cut width of about 1.4 mm), more preferably at least 20 pieces per inch (7.9 pieces per centimeter, equivalent to a cut width of about 1.27 mm). In one example, the shredded tobacco has a cut width of 22 pieces per inch (8.7 pieces per centimeter, equivalent to a cut width of about 1.15 mm). Preferably, the shredded tobacco has a cut width of at least 40 pieces per inch (about 15.7 pieces per centimeter, equivalent to a cut width of about 0.64 mm). A cut width of 0.5 mm to 2.0 mm, for example 0.6 mm to 1.5 mm or 0.6 mm to 1.7 mm, has been found to result in a tobacco material that is favorable in terms of surface area to volume ratio and overall density and pressure drop of the generating material 3, particularly when heated. The shredded tobacco may be formed from a mixture of tobacco material forms, such as a mixture with one or more of reconstituted tobacco, leaf tobacco, extruded tobacco and band cast tobacco. Preferably the tobacco material comprises reconstituted tobacco or a mixture of reconstituted tobacco and leaf tobacco.

[0142] In the tobacco materials described herein, the tobacco material may include a filler component. The filler component is generally a non-tobacco component, i.e., a component that does not contain tobacco-derived components. The filler component may be a non-tobacco fiber, such as wood fiber or pulp or wheat fiber. The filler component may be an inorganic material, such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, etc. The filler component may be a non-tobacco cast material or a non-tobacco extruded material. The filler component may be present in an amount of 0-20% by weight of the tobacco material or 1-10% by weight of the composition. In some embodiments, no filler component is included.

[0143] In the tobacco materials described herein, the tobacco material comprises an aerosol-forming material. In this context, an "aerosol-forming material" is a chemical that enhances the generation of an aerosol. The aerosol-forming material may enhance the generation of an aerosol by enhancing the initial evaporation and / or condensation of a gas into an inhalable solid and / or liquid aerosol. In some embodiments, the aerosol-forming material may enhance the delivery of flavor from the aerosol-generating material. In general, any suitable aerosol-forming material or forming agent may be included in the aerosol-generating materials of the present invention, including those described herein. Other suitable aerosol forming materials include, but are not limited to, polyols such as sorbitol, glycerol, and glycols such as propylene glycol or triethylene glycol, non-polyols such as monohydric alcohols, high boiling point hydrocarbons, acids such as lactic acid, glycerol derivatives, esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate or myristates including ethyl myristate and isopropyl myristate, and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate, and dimethyl tetradecanedioate. In some embodiments, the aerosol forming material may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. Glycerol may be present in an amount of 10-20% by weight of the tobacco material, such as 13-16% by weight of the composition, or about 14% or 15% by weight of the composition. Propylene glycol, if included, may be present in an amount of 0.1-0.3% by weight of the composition.

[0144] The aerosol-forming material may be contained in any component, such as any component of the tobacco material and / or filler component, if any. Alternatively or additionally, the aerosol-forming material may be added separately to the tobacco material. In either case, the total amount of aerosol-forming material in the tobacco material may be as described herein.

[0145] The tobacco material may comprise 10-90% by weight of tobacco leaf, with the aerosol-forming material being provided in an amount of about 10% by weight of the tobacco leaf. It has been found to be advantageous to add this in a higher weight percentage to another component of the tobacco material, such as reconstituted tobacco material, to achieve a total amount of aerosol-forming material of 10%-20% by weight of the tobacco material.

[0146] The tobacco material described herein comprises nicotine, the nicotine content being between 0.5 and 1.75% by weight of the tobacco material, and may be, for example, between 0.8 and 1.5% by weight of the tobacco material. Additionally or alternatively, the tobacco material comprises 10-90% by weight of tobacco leaf having a nicotine content of more than 1.5% by weight of the tobacco leaf. It has been found advantageous to use tobacco leaf having a nicotine content of more than 1.5% in combination with a low-nicotine base material, such as reconstituted tobacco, to obtain a tobacco material having an appropriate amount of nicotine but better sensory performance than reconstituted tobacco alone. Tobacco leaf, for example shredded tobacco, may have a nicotine content of, for example, 1.5% to 5% by weight of the tobacco leaf.

[0147] The tobacco material described herein may include an aerosol modifying agent, such as any of the flavorants described herein. In one embodiment, the tobacco material includes menthol to form a mentholated article. The tobacco material may include 3 mg to 20 mg of menthol, preferably 5 mg to 18 mg, and more preferably 8 mg to 16 mg of menthol. In this example, the tobacco material includes 16 mg of menthol. The tobacco material may include 2% to 8% by weight of menthol, preferably 3% to 7% by weight of menthol, and more preferably 4% to 5.5% by weight of menthol. In one embodiment, the tobacco material includes 4.7% by weight of menthol. Such a high loading of menthol is achieved by using a high percentage of reconstituted tobacco material, for example more than 50% by weight of tobacco material. Alternatively or additionally, a high volume aerosol generating material, for example tobacco material, may be used to achieve a high aerosol generating capacity, for example about 500 mm 3 More than, or preferably 1000 mm 3Increasing menthol loading can be achieved when aerosol-generating materials such as tobacco materials are used.

[0148] For the avoidance of doubt, when amounts are given in weight percent in the compositions described herein, this means on a dry weight basis unless otherwise specified. Thus, any water present in the tobacco material or any component thereof is completely disregarded for purposes of measuring weight percent. The moisture content of the tobacco materials described herein may vary, for example, from 5 to 15 weight percent. The moisture content of the tobacco materials described herein may vary depending, for example, on the temperature, pressure and humidity conditions under which the composition is maintained. The moisture content may be measured by Karl-Fisher analysis as known to those skilled in the art. However, for the avoidance of doubt, it is to be understood that the aerosol-forming material may be a glycerol-containing material. All components other than water are included in the weight of the tobacco material, even if the components are in the liquid phase, such as propylene glycol or propylene glycol. However, if an aerosol-forming material is provided in the tobacco component of the tobacco material or in the filler element (if any) of the tobacco material instead of or in addition to being added separately to the tobacco material, the aerosol-forming material is not included in the weight of the tobacco composition or filler element, but is included in the weight of the "aerosol-forming material" in the weight percentages specified herein. All other components present in the tobacco composition are included in the weight of the tobacco component, even if they are non-tobacco-derived (e.g., non-tobacco fiber in the case of reconstituted tobacco).

[0149] In some embodiments, the tobacco material comprises a tobacco component as defined herein and an aerosol forming material as defined herein. In some embodiments, the tobacco material consists essentially of a tobacco component as defined herein and an aerosol forming material as defined herein. In some embodiments, the tobacco material consists of a tobacco component as defined herein and an aerosol forming material as defined herein.

[0150] The reconstituted tobacco is present in the tobacco component of the tobacco material described herein in an amount between 10% and 100% by weight of the tobacco component. In some embodiments, the reconstituted tobacco is present in an amount between 10% and 80% or between 20% and 70% by weight of the tobacco component. In other embodiments, the tobacco component consists essentially of reconstituted tobacco or consists of reconstituted tobacco. In a preferred embodiment, the leaf tobacco is present in the tobacco component of the tobacco material in an amount of at least about 10% by weight of the tobacco component. For example, the leaf tobacco may be present in an amount of at least 10% by weight of the tobacco component, with the remainder of the tobacco component comprising a combination of reconstituted tobacco, band-cast tobacco or band-cast reconstituted tobacco and another form of tobacco, such as tobacco particles.

[0151] By reconstituted tobacco is meant tobacco material formed by a process in which raw tobacco material is extracted with a solvent to produce a residue containing soluble extract and fibrous material, and then the extract (usually after concentration, and optionally further processing) is recombined with the fibrous material from the residue (usually after removing impurities from the fibrous material, and optionally with the addition of small amounts of non-tobacco fiber) by depositing the extract onto the fibrous material. The recombination process is similar to the papermaking process.

[0152] The reconstituted tobacco may be any type of reconstituted tobacco known in the art. In certain embodiments, the reconstituted tobacco paper is produced from a raw material comprising one or more of tobacco strips, tobacco stems, and whole tobacco. In other embodiments, the reconstituted tobacco paper is produced from a raw material consisting of tobacco strips and / or whole tobacco and tobacco stems. However, in other embodiments, trash, fines, and rice husk may alternatively or additionally be employed in the raw material.

[0153] Reconstituted tobacco for use in the tobacco materials described herein may be prepared by methods known to those skilled in the art for the preparation of reconstituted tobacco.

[0154] In this example, the article 1' has a circumference of about 21 mm (i.e., the article is in a demi-slim format). In other examples, the article can be provided in any of the formats described herein, for example with a circumference between 15 mm and 25 mm. Since the article is heated to release the aerosol, improved heating efficiency can be achieved by using an article with a smaller circumference within this range, for example a circumference less than 23 mm. It has been found that article circumferences of more than 19 mm are particularly effective for achieving improved aerosol upon heating while maintaining a suitable product length. It has been found that articles with circumferences between 19 mm and 23 mm, more preferably between 20 mm and 22 mm, provide a good combination of efficient heating while effectively delivering aerosol.

[0155] The circumference of the mouthpiece 2' is substantially the same as the circumference of the rod of aerosol-generating material 3, which allows a smooth interface between these components. In this example, the circumference of the mouthpiece 2' is approximately 20.8 mm. A tipping paper 5 is wrapped around the entire length of the mouthpiece 2' and over part of the rod of aerosol-generating material 3, has an adhesive on its inner surface, and connects the mouthpiece 2' to the rod 3. In this example, the tipping paper 5 extends 5 mm over the rod of aerosol-generating material 3, but may also extend 3 mm to 10 mm or 4 mm to 6 mm over the rod 3 to ensure a secure attachment of the mouthpiece 2' to the rod 3. The tipping paper 5 may have a basis weight greater than that of the plug wrapper used for the article 1', for example 40 gsm to 80 gsm, more preferably 50 gsm to 70 gsm, in this example 58 gsm. Basis weights in these ranges have been found to result in a tipping paper that is flexible enough to wrap the article 1 while having acceptable tensile strength and that adheres to itself along the longitudinal hold down seam of the paper. The circumference of the tipping paper 5 when wrapped around the mouthpiece 2' is approximately 21 mm.

[0156] 3 is a side cross-sectional view of another article 1''. Article 1'' is substantially similar to article 1', except that mouthpiece 2'' includes a second hollow tubular member 13 at mouth end 2''b instead of the fibrous material body 4.

[0157] The second hollow tubular member 13 is formed from filamentary tow. It has been advantageously discovered that it significantly reduces the temperature of the exterior surface of the mouthpiece 2'' at the downstream end 2''b of the mouthpiece that contacts the consumer's lips during use of the article 1''. Additionally, it has been found that the use of the tubular member 13 significantly reduces the temperature of the exterior surface of the mouthpiece 2'' even upstream of the tubular member 13. Without wishing to be bound by any theory, it is hypothesized that this is due to the tubular member 13 directing the aerosol closer to the center of the mouthpiece 2'', thus reducing the transfer of heat from the aerosol to the exterior surface of the mouthpiece 2''.

[0158] The "wall thickness" of the second hollow tubular member 13 corresponds to the radial wall thickness of the tube 13. This may be measured in the same manner as for the hollow tubular member 8. Advantageously, the wall thickness is greater than 0.9 mm, more preferably greater than or equal to 1.0 mm. Preferably, the wall thickness is substantially constant all around the wall of the tubular member 11. However, if the wall thickness is not substantially constant, the wall thickness is preferably greater than 0.9 mm, more preferably greater than or equal to 1.0 mm, anywhere around the circumference of the tubular member 11.

[0159] Preferably, the length of the second hollow tubular member 13 is less than about 20 mm. More preferably, the length of the second hollow tubular member 13 is less than about 15 mm. Even more preferably, the length of the second hollow tubular member 13 is less than about 10 mm. Additionally or alternatively, the length of the second hollow tubular member 13 is at least about 5 mm. Preferably, the length of the second hollow tubular member 13 is at least about 6 mm. In some preferred embodiments, the length of the second hollow tubular member 13 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, and most preferably about 6 mm, 7 mm, or about 8 mm. In this example, the length of the second hollow tubular member 13 is 6 mm.

[0160] Preferably, the density of the second hollow tubular member 13 is at least about 0.25 grams per cubic centimeter (g / cc), more preferably at least about 0.3 g / cc. Preferably, the density of the second hollow tubular member 13 is at least about 0.75 grams per cubic centimeter (g / cc). The density of the second hollow tubular member 13 is preferably less than 0.5 g / cc, more preferably less than 0.6 g / cc. In some embodiments, the density of the second hollow tubular member 13 is between 0.25 and 0.75 g / cc, more preferably between 0.3 and 0.6 g / cc, more preferably between 0.4 g / cc and 0.6 g / cc or about 0.5 g / cc. These densities have been found to provide a good combination of good stiffness provided by high density materials and low thermal conductivity of low density materials. For purposes of this example, the "density" of the second hollow tubular member 13 refers to the density of the filamentary tows forming the member, including any plasticizers incorporated therein. The density of the second hollow tubular member 13 may be measured in the same manner as described for the body of material 6.

[0161] The filamentary tows forming the second hollow tubular member 13 preferably have a total fineness of less than 45,000, more preferably less than 42,000. It has been found that this total fineness allows the formation of a tubular member 13 that is not too dense. Preferably, the total fineness is at least 20,000, more preferably at least 25,000. In a preferred embodiment, the filamentary tows forming the second hollow tubular member 13 have a total fineness of 25,000 to 45,000, more preferably 35,000 to 45,000. Preferably, the cross-sectional shape of the filamentary tows is "Y" shaped, although in other embodiments other shapes such as "X" shaped filaments can be used.

[0162] The filamentary tows forming the second hollow tubular member 13 preferably have a single yarn fineness greater than 3. It has been found that this single yarn fineness allows the formation of a hollow tubular member 13 that is not too dense. Preferably, the single yarn fineness is at least 4, more preferably at least 5. In a preferred embodiment, the filamentary tows forming the second hollow tubular member 13 have a single yarn fineness between 4 and 10, more preferably between 4 and 9. In one example, the filamentary tows forming the second hollow tubular member 13 are formed from cellulose acetate, e.g., 8Y40,000 tows containing 18% plasticizer, such as triacetin.

[0163] The second hollow tubular member 13 preferably has an inner diameter greater than 3.0 mm. A smaller inner diameter would result in aerosol traveling through the mouthpiece 2 to the consumer's mouth at a faster than desired rate, which would cause the aerosol to become too warm, for example reaching a temperature of greater than 40° C. or greater than 45° C. More preferably, the second hollow tubular member 13 has an inner diameter greater than 3.1 mm, or even greater than 3.0 mm. More preferably, the second hollow tubular member 13 has an inner diameter of greater than 3.5 mm or 3.6 mm. In one embodiment, the inner diameter of the second hollow tubular member 13 is about 3.9 mm.

[0164] The second hollow tubular member 13 preferably contains 15% to 22% by weight of plasticizer. In the case of cellulose acetate tow, the plasticizer is preferably triacetin, but other plasticizers such as polyethylene glycol (PEG) can also be used. More preferably, the tubular member 13 contains 16% to 20% by weight of plasticizer, for example about 17%, about 18% or about 19% by weight of plasticizer.

[0165] The combination of the hollow tubular member 8 reducing the temperature of the outer surface of the mouthpiece and the aerosol cooling effect of the body of material 6 and second hollow tubular member 13 results in a more comfortable user experience as the aerosol temperature and the temperature of the outer surface of the article at the mouth end are lower.

[0166] 4 is a side cross-sectional view of another article 1'''. Article 1''' and mouthpiece 2''' are substantially similar to article 1' and mouthpiece 2', except that a body of amorphous solid material 6 is provided at the distal end of mouthpiece 2''' adjacent and in abutting relationship to aerosol-generating material 3, and a hollow tubular member 8 is provided downstream of body of material 6 and positioned between the body of material 6 at the distal end of the mouthpiece and a fiber section 4 at the mouth end of the mouthpiece.

[0167] Providing the body 6 of amorphous solid material adjacent to the aerosol-generating material results in higher heat exposure than if the body 6 were located downstream of the cooling member. This arrangement may improve flavor release from the amorphous solid material if it contains a flavorant.

[0168] FIG. 5a is a cross-sectional side view of another article 1'''' including a capsule-containing mouthpiece 2''''. FIG. 5b is a cross-sectional side view of the capsule-containing mouthpiece shown in FIG. 5a. Article 1'''' and mouthpiece 2'''' are the same as Article 1' and mouthpiece 2', except that in addition to hollow tubular member 8, body of amorphous solid material 6, and body of fibrous material 4, mouthpiece 2'''' includes capsule-containing section 14. Capsule-containing section 14 includes an aerosol modifying agent provided in the form of capsules 15 and surrounded by an oil-resistant plug wrapper 16.

[0169] In other examples, the aerosol modifier may be provided in other forms, such as material injected into the fibrous body 4 or provided on threads, e.g., threads that carry a flavorant or other aerosol modifier and may be disposed within the fibrous body 4. The amorphous solid material forming the body 6 may also include an aerosol modifier, such as a flavorant. If the amorphous solid material includes a flavorant, the aerosol modifier included within the capsules 15 may be selected to complement the flavorant included in the amorphous solid material.

[0170] The capsule 15 has a solid, frangible shell that encloses a liquid payload. In this example, one capsule 15 is used. The capsule 15 is fully embedded within substantially the same body of material as the fibrous body of material 4. In other words, the capsule 15 is fully surrounded by the material forming the body of material 14. In other examples, multiple breakable capsules may be disposed within the fibrous body of material 14, for example two, three or more breakable capsules. The length of the body of material 14 may be increased to accommodate the required number of capsules. In examples where multiple capsules are used, the individual capsules may be identical to one another or may differ in size and / or capsule payload. In other examples, multiple bodies of material 14 may be provided, each body of material having one or more capsules.

[0171] The capsule 15 has a core-shell structure. In other words, the capsule 15 may include a shell that encapsulates a flavorant or other substance, which may be a liquid agent, such as any of the flavorants or aerosol modifiers described herein. The capsule shell may be burst by a user to release the flavorant or other substance into the body of material 14. The grease-resistant plug wrapper 16 may include a barrier coating that renders the plug wrapper material substantially impermeable to the liquid payload of the capsule 15. Alternatively or additionally, the second plug wrapper 9 and / or tipping paper 5 may include a barrier coating that renders the plug wrapper and / or tipping paper material substantially impermeable to the liquid payload of the capsule 15.

[0172] In this example, capsule 15 is spherical and has a diameter of about 3 mm. In other examples, other shapes and sizes can be used. The total weight of capsule 15 may be in the range of about 10 mg to about 50 mg.

[0173] In this example, the capsule 15 is located in a longitudinally central position within the body of material 14. That is, the capsule 15 is positioned such that its centre is 4 mm away from either end of the body of material 14. In other examples, the capsule 15 may be located other than longitudinally centrally within the body of material 14, i.e. closer to the downstream end of the body of material 14 than the upstream end, or closer to the upstream end of the body of material 14 than the downstream end. The mouthpiece 2'''' is constructed such that the capsule 15 and ventilation holes 12 are longitudinally offset from one another within the mouthpiece 2''''.

[0174] A cross section of the mouthpiece 2'''' is shown in Figure 5b. Figure 5b shows the capsule 15, the body of material 14, the grease resistant plug wrapper 16, the third plug wrapper 11 and the tipping paper 5. In another example, the capsule 15 is centred about the longitudinal axis (not shown) of the mouthpiece 2''''. The grease resistant plug wrapper 16, the third plug wrapper 11 and the tipping paper 5 are concentrically arranged around the body of material 14.

[0175] The rupturable capsule 15 has a core-shell structure, i.e., the encapsulating or barrier material forms a shell around a core containing the aerosol modifier. The shell structure prevents migration of the aerosol modifier during storage of the article 1'''', but allows for controlled release of the aerosol modifier, also referred to as aerosol modifier, during use.

[0176] In some cases, the barrier material (also referred to as the encapsulant) is frangible. The capsule is crushed or otherwise broken or destroyed by the user to release the encapsulated aerosol modifier. Typically, the capsule is broken just before heating is initiated, but the user can choose when to release the aerosol modifier. The term "frangible capsule" refers to a capsule whose shell is broken by pressure to release the core, for example, the shell can be ruptured by pressure applied by the user's finger when the user wishes to release the capsule core.

[0177] In some cases, the barrier material is heat resistant, i.e., in some cases, the barrier does not rupture but melts or fails at temperatures reached by the capsule during operation of the aerosol delivery device. In particular, the capsule located within the mouthpiece may be exposed to temperatures in the range of, for example, 30°C to 100°C, and the barrier material may continue to retain the liquid core up to at least about 50°C to 120°C.

[0178] In other cases, the capsules release the core composition upon heating, for example by swelling of the capsule melting or rupturing the barrier material.

[0179] The total weight of the capsule may be in the range of about 1 mg to about 100 mg, preferably about 5 mg to about 60 mg, about 8 mg to about 50 mg, about 10 mg to about 20 mg, or about 12 mg to about 18 mg.

[0180] The total weight of the core formulation may be in the range of about 2 mg to about 90 mg, preferably about 3 mg to about 70 mg, about 5 mg to about 25 mg, about 8 mg to about 20 mg, or about 10 mg to about 15 mg.

[0181] The capsule according to the present invention includes a core and a shell as described above. The capsule may have a crushing strength of about 4.5N to about 40N, more preferably about 5N to about 30N or about 28N (e.g., about 9.8N to about 24.5N). The capsule crushing strength is determined by the amount of the material from which the capsule is made. The force at which the capsules burst can be measured using a gauge which measures the force at which the capsules burst when removed from the casing and pressed between two flat metal plates. A suitable measuring device is a Sauter FK 50 fall gauge which has a flat-headed attachment which can be used to crush the capsules against a flat hard surface with a similar surface to the attachment.

[0182] The capsules may be substantially spherical and may be at least about 0.4 mm, 0.6 mm, 0. The capsule may have a diameter of less than about 10.0 mm, 8.0 mm, 7.0 mm, 6.0 mm, 5.5 mm, 5.0 mm, 4.5 mm, 4.0 mm, 3.5 mm or 3.2 mm. Specifically, the diameter of the capsule may be about 0.4 mm to about 10.0 mm, about 0.8 mm to about 6.0 mm, about 2.5 mm to about 5.5 mm, or about 2.8 mm to about 3.2 mm. In some cases, the capsules may have a diameter of about 3.0 mm. These dimensions are particularly suitable for incorporating the capsules into the articles described herein.

[0183] The cross-sectional area of ​​the capsule 15 at its largest cross-sectional area is less than 28%, more preferably less than 27%, and even more preferably less than 25% of the cross-sectional area of ​​the portion of the mouthpiece 2' in which the capsule 15 is provided. For example, for a spherical capsule having a diameter of 3.0 mm, the maximum cross-sectional area of ​​the capsule is less than 7.07 mm 2 For the mouthpiece 2'''' described herein having a circumference of 21 mm, the body of material 14 has a circumference of 20.8 mm, and the radius of this member is 3.31 mm, which is 34.43 mm. 2 The cross-sectional area of ​​the capsule is 20.5% of the cross-sectional area of ​​the mouthpiece 2'''' in this example. As another example, if the capsule has a diameter of 3.2 mm, its maximum cross-sectional area is 8.04 mm 2 In this case, the cross-sectional area of ​​the capsule is 23.4% of the cross-sectional area of ​​the body of material 14. A capsule having a maximum cross-sectional area of ​​less than 28% of the cross-sectional area of ​​the portion of the mouthpiece 2'''' in which the capsule 15 is provided has the advantage that the pressure drop across the mouthpiece 2'''' is reduced compared to a capsule having a larger cross-sectional area, and adequate space is left around the capsule for the aerosol to pass through without the body of material 14 removing significant chunks of aerosol as it passes through the mouthpiece 2''''.

[0184] Preferably, the pressure drop or pressure differential (also referred to as resistance to draw), measured as the opening pressure drop (i.e. ventilation openings open), decreases by less than 8 mmH2O when the capsule is broken. More preferably, the opening pressure drop decreases by less than 6 mmH2O, more preferably by less than 5 mmH2O. These values ​​are measured as averages obtained with at least 80 articles made with the same design. Such small pressure drop changes mean that other aspects of the product design, such as setting the correct ventilation level for a given product pressure drop, can be achieved whether or not the consumer chooses to break the capsule.

[0185] In some embodiments, when the aerosol-forming material 3 is heated to provide an aerosol, e.g., in a non-combustion based aerosol delivery device as described herein, the portion of the mouthpiece 2 in which the capsule is located reaches a temperature of 58-70° C. during use of the system to generate an aerosol. As a result of this temperature, the contents of the capsule are sufficiently warmed to promote volatilization of the capsule's contents, e.g., aerosol modifiers, into the aerosol formed by the system as the aerosol passes through the mouthpiece 2″″. Warming of the contents of the capsule 15 may occur before the capsule 15 is broken, e.g., so that upon breakage of the capsule 15, the contents are more likely to be released into the aerosol passing through the mouthpiece 2″″. Alternatively, the contents of the capsule 15 may be warmed to this temperature after the capsule 15 is broken, again resulting in greater release of the contents into the aerosol. Advantageously, it has been found that a mouthpiece temperature in the range of 58-70°C is high enough to make the capsule contents more likely to be released, but low enough so that the outer surface of the portion of mouthpiece 2'''' where the capsule is located reaches a temperature that is uncomfortable for a consumer to touch in order to burst capsule 15 by squeezing mouthpiece 2''''.

[0186] The capsule 15 can be broken by an external force applied to the mouthpiece 2'''', for example by a consumer crushing the mouthpiece 2'''' using a finger or other mechanism. As described above, the portion of the mouthpiece in which the capsule is located is arranged to reach a temperature of greater than 58°C during use of the aerosol delivery system to generate an aerosol. Preferably, when placed in the mouthpiece 2'''', and prior to heating of the aerosol-generating material 3, the capsule 15 has a burst strength of 1500-4000 grams force. Preferably, when placed in the mouthpiece 2'''', and within 30 seconds of using the aerosol delivery system to generate an aerosol, the capsule 15 has a burst strength of 1000-4000 grams force. Even when exposed to temperatures greater than 58°C, for example between 58°C and 70°C, the capsule 15 can maintain a burst strength in a range that is found to allow a consumer to easily crush the capsule 15, and still provide sufficient tactile feedback to the consumer that the capsule 15 has been broken. Maintaining such burst strength is accomplished by selecting a suitable gelling agent for the capsule as described herein, such as polysaccharides, including gum arabic, gellan gum, acacia gum, xanthan gum, or carrageenan, either alone or in combination with gelatin, and the capsule wall should be selected to be of a suitable thickness.

[0187] Preferably, the capsule has a burst strength of 2000-3500 grams force or 2500-3500 grams force when placed in the mouthpiece and before the aerosol-forming material is heated. Preferably, the capsule has a burst strength of 1500-4000 grams force or 1750-3000 grams force when placed in the mouthpiece and before the aerosol-forming material is heated and ...

[0188] The burst strength of the capsules can be tested using a load measuring instrument such as a Texture Analyser.

[0189] The barrier material may include one or more of a gelling agent, a bulking agent, a buffer, a colorant, and a plasticizer.

[0190] Suitably, the gelling agent may be, for example, a polysaccharide or cellulosic gelling agent, gelatin, gum, gel, wax or mixtures thereof. Suitable polysaccharides include alginates, dextrans, maltodextrins, cyclodextrins and pectins. Suitable alginates include, for example, salts of alginic acid, esterified alginates or glyceryl alginate. Salts of alginic acid include ammonium alginate, triethanolamine alginate and alginates of group I or II metal ions such as sodium alginate, potassium alginate, calcium alginate and magnesium alginate. Esterified alginates include polypropylene glycol alginate and glyceryl alginate. In one embodiment, the barrier material is sodium alginate and / or calcium alginate. Suitable cellulosic materials include methylcellulose, ethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose, cellulose acetate and cellulose ethers. The gelling agent may include one or more modified starches. The gelling agent may include carrageenan. Suitable gums include agar, gellan gum, gum arabic, pullulan gum, mannan gum, ghatti gum, tragacanth gum, karaya gum, carob, acacia gum, guar, quince seed gum and xanthan gum. Suitable gels include agar, agarose, carrageenan, freudan and furcellaran. Suitable waxes include carnauba wax. In some cases, the gelling agent may include carrageenan and / or gellan gum, which are particularly suitable for inclusion as gelling agents when the pressure required to break the resulting capsule is particularly suitable.

[0191] The barrier material may include one or more bulking agents such as starch, modified starch (such as oxidized starch) and sugar alcohols such as maltitol.

[0192] The barrier material may contain a colorant to facilitate placement of the capsule in the aerosol generating device during the manufacturing process of the aerosol generating device. The colorant is preferably selected from colorants and pigments.

[0193] The barrier material may further comprise at least one buffer, such as a citrate compound or a phosphate compound.

[0194] The barrier material may further comprise at least one plasticizer, such as glycerol, sorbitol, maltitol, triacetin, polyethylene glycol, propylene glycol or another polyhydric alcohol having plasticizing properties and in particular any acid of the mono-, di- or tri-acid type, such as citric acid, fumaric acid, malic acid, etc. The amount of plasticizer ranges from 1 to 30% by weight, preferably from 2 to 15% by weight, even more preferably from 3 to 10% by weight of the total dry weight of the shell.

[0195] The barrier material also comprises one or more filler materials. Suitable filler materials are starch derivatives such as dextrin, maltodextrin, cyclodextrin (alpha, beta or gamma) or cellulose derivatives such as hydroxypropylmethylcellulose (HPMC), hydroxypropylcellulose (HPC), methylcellulose (MC), carboxy-methylcellulose (CMC), polyvinyl alcohol, polyols or mixtures thereof. Dextrin is a preferred filler material. The amount of filler in the shell is up to 98.5% by weight, preferably 25-95% by weight, more preferably 40-80% by weight, even more preferably 50-60% by weight of the total dry weight of the shell.

[0196] The capsule shell may additionally comprise a hydrophobic outer layer, which is intended to prevent the capsule from disintegrating due to moisture. The hydrophobic outer layer is preferably selected from the group comprising waxes, in particular carnauba wax, candelilla wax or beeswax, carbowax, shellac (in alcoholic or aqueous solution), ethyl cellulose, hydroxypropyl methylcellulose, hydroxypropyl cellulose, latex compositions, polyvinyl alcohol, or combinations thereof. More preferably, the at least one moisture barrier agent is ethyl cellulose or a mixture of ethyl cellulose and shellac.

[0197] The capsule core comprises an aerosol modifier. The aerosol modifier may be any volatile substance that changes at least one property of the aerosol. For example, the aerosol substance may change the pH, sensory properties, moisture content, delivery properties or flavor. In some cases, the aerosol modifier may be selected from acids, bases, water or flavoring agents. In some embodiments, the aerosol modifier comprises one or more flavoring agents.

[0198] The flavouring may suitably be liquorice, rose oil, vanilla, lemon oil, orange oil, a mint flavouring, suitably menthol and / or peppermint oil and / or spearmint oil, or a mint oil from any species of the Mentha genus, or lavender, fennel or anise.

[0199] In some cases the flavouring agent comprises menthol.

[0200] In some cases, the capsule may comprise at least about 25% w / w flavour (based on the total weight of the capsule), preferably at least about 30% w / w flavour, 35% w / w flavour, 40% w / w flavour, 45% w / w flavour or 50% w / w flavour.

[0201] In some cases, the core may comprise at least about 25% w / w flavorant (based on the total weight of the core), preferably at least about 30% w / w flavorant, 35% w / w flavorant, 40% w / w flavorant, 45% w / w flavorant or 50% w / w flavorant. In some cases, the core may comprise up to about 75% w / w flavorant (based on the total weight of the core), preferably up to about 65% w / w flavorant, 55% w / w flavorant or 50% w / w flavorant. Specifically, the capsule may comprise flavorant in an amount in the range of 25-75% w / w (based on the total weight of the core), about 35-60% w / w or about 40-55% w / w.

[0202] The capsule may contain at least about 2 mg, 3 mg or 4 mg of aerosol modifier, preferably at least about 4.5 mg, 5 mg, 5.5 mg or 6 mg of aerosol modifier.

[0203] In some cases, the consumable comprises at least about 7 mg of the aerosol modifier, preferably at least about 8 mg of the aerosol modifier, 10 mg of the aerosol modifier, 12 mg of the aerosol modifier or 15 mg of the aerosol modifier.

[0204] Any suitable solvent may be used.

[0205] When the aerosol modifier comprises a flavouring agent, the solvent may suitably comprise a short or medium chain oil. For example, the solvent may comprise a C2-C 12 Triesters of glycerol, such as triglycerides, preferably C6-C 10 Triglycerides or Cs-C 12 The solvent may include a triglyceride. For example, the solvent may include a medium chain triglyceride (MCT-C8-C 12 ), which may be derived from palm oil and / or coconut oil.

[0206] The esters may be formed with caprylic acid and / or capric acid. For example, the solvent may include medium chain triglycerides that are caprylic triglyceride and / or capric triglyceride. For example, the solvent may include compounds identified in the CAS Registry by Nos. 73398-61-5, 65381-09-1, 85409-09-2. Such medium chain triglycerides are tasteless and odorless.

[0207] The hydrophilic lipophilic balance (HLB) of the solvent may be in the range of 9 to 13, preferably 10 to 12. The method of production of the capsules may include extrusion, optionally followed by centrifugation and hardening and / or drying. The contents of WO 2007 / 010407 A2 are incorporated by reference in their entirety.

[0208] Mouthpieces 2, 2', 2'', 2''' and 2'''' may, in alternative embodiments, each be formed from any combination of mouthpiece components described herein.

[0209] The non-combustion aerosol delivery device is used to heat the aerosol-generating material 3 of the articles 1, 1', 1'', 1''', 1'''' described herein. The non-combustion aerosol delivery device preferably includes a coil, which has been found to improve heat transfer to the articles 1, 1', 1'', 1'''', 1'''' compared to other configurations.

[0210] In some examples, the coil is configured, when in use, to heat at least one conductive heating element such that thermal energy can be conducted from the at least one conductive heating element to the aerosol-generating material, thereby causing heating of the aerosol-generating material.

[0211] In some examples, the coil is configured to generate a varying magnetic field for passage through at least one heating element, in use, thereby causing inductive heating and / or magnetic hysteresis heating of the at least one heating element. In such a configuration, the or each heating element may be referred to as a "susceptor" as defined herein. A coil configured to generate a varying magnetic field for passage through an electrically conductive heating element, in use, thereby causing inductive heating of the at least one electrically conductive heating element, may be referred to as an "induction coil" or "inductor coil."

[0212] The device may include one or more heating elements, e.g. one or more conductive heating elements, which may be suitably positioned or positionable relative to the coil to allow heating of the one or more heating elements. The one or more heating elements may be fixed relative to the coil. Alternatively, at least one heating element, e.g. at least one conductive heating element, may be included in an article 1, 1' for insertion into a heating area of ​​the device, the article 1, 1' including the aerosol-generating material 3, and removed from the heating area after use. Alternatively, the device and such article 1, 1' may include at least one respective heating element, e.g. at least one conductive heating element, and the coil causes heating of the one or more heating elements of the device and article, respectively, when the article is in the heating area.

[0213] In some cases, the coil is helical. In some cases, the coil surrounds at least a portion of a heating region of a device configured to contain the aerosol generating material. In some cases, the coil is a helical coil that surrounds at least a portion of a heating region.

[0214] In some cases, the device includes an electrically conductive heating element at least partially surrounding the heating region, and the coil surrounds at least a portion of the electrically conductive heating element. In some cases, the electrically conductive heating element is tubular. In some cases, the coil is an inductor coil. In some cases, the use of a coil allows a non-combustion based aerosol delivery device to reach an operating temperature more quickly than a non-coil aerosol delivery device. For example, a non-combustion based aerosol delivery device including a coil as described above can reach an operating temperature such that a first puff can be provided in less than 30 seconds, preferably less than 25 seconds, from initiation of the device heating program. In some cases, the device can reach an operating temperature in about 20 seconds from initiation of the device heating program.

[0215] The use of a coil as described herein in a device to induce heating of the aerosol-generating material has been found to improve the aerosol generated. For example, consumers have reported that aerosols generated by devices including coils such as those described herein feel closer to factory made cigarettes (FMC) than aerosols produced by other non-combustion based aerosol delivery systems. Without wishing to be bound by any theory, it is hypothesized that this is due to the reduced time to reach the required heating temperature when using a coil, the higher heating temperature achieved when using a coil, and / or the coil allowing such systems to simultaneously heat a relatively large amount of aerosol-generating material, resulting in an aerosol with a temperature similar to that of FMC. In FMC products, a burning ember generates a hot aerosol that heats the tobacco in the tobacco rod behind the ember as the aerosol is drawn through the rod. It is understood that this hot aerosol releases flavor compounds from the tobacco in the rod behind the burning ember. It is believed that devices including a coil as described herein can also heat an aerosol-generating material, such as a tobacco material as described herein, to release flavor compounds, resulting in an aerosol that has been reported to be more similar to an FMC aerosol.

[0216] By using an aerosol delivery system including a coil as described herein, e.g., an induction coil that heats at least a portion of the aerosol-generating material to at least 200° C., more preferably at least 220° C., an aerosol can be generated from the aerosol-generating material having certain characteristics believed to be more similar to the aerosols of FMC products. For example, when an aerosol-generating material containing nicotine is heated using an induction heater to at least 250° C. for 2 seconds, one or more of the following characteristics have been observed: At least 10 μg of nicotine is aerosolized from the aerosol generating material; the weight ratio of aerosol forming material to nicotine in the generated aerosol is at least about 2.5:1, preferably at least 8.5:1; At least 100 μg of the aerosol-forming material is aerosolized from the aerosol-generating material; The average particle or droplet size in the generated aerosol is less than about 1000 nm; The aerosol density is at least 0.1 μg / cc.

[0217] Optionally, at least 10 μg of nicotine, preferably at least 30 μg or 40 μg of nicotine, is aerosolized from the aerosol-generating material during that 2 second period under an airflow of at least 1.50 L / m. Optionally, less than about 200 μg of nicotine, preferably less than about 150 μg or less than about 125 μg of nicotine, is aerosolized from the aerosol-generating material during that 2 second period under an airflow of at least 1.50 L / m.

[0218] Optionally, at least 100 μg of aerosol forming material, preferably at least 200 μg, 500 μg or 1 mg of aerosol forming material is aerosolized from said aerosol generating material under an air flow of at least 1.50 L / m during said 2 second period. Preferably, the aerosol forming material may comprise or consist of glycerol.

[0219] As defined herein, the term "average particle or droplet size" refers to the average size of the solid or liquid components of the aerosol (i.e., the components that are suspended in the gas). When the aerosol contains suspended liquid droplets and suspended solid particles, the term refers to the average size of all components combined.

[0220] In some cases, the average particle or droplet size of the generated aerosol may be less than 900 nm, 800 nm, 700 nm, 600 nm, 500 nm, 450 nm, or 400 nm. In some cases, the average particle or droplet size may be greater than about 25 nm, 50 nm, or 100 nm.

[0221] In some cases, the density of the aerosol generated during the period may be at least 0.1 μg / cc. In some cases, the aerosol density is at least 0.2 μg / cc, 0.3 μg / cc, or 0.4 μg / cc. In some cases, the aerosol density is less than about 2.5 μg / cc, 2.0 μg / cc, 1.5 μg / cc, or 1.0 μg / cc.

[0222] The non-combustion aerosol delivery device is configured to heat the aerosol-generating material 3 of the article 1, 1', 1'', 1''', 1'''' to a maximum temperature of preferably at least 160° C. Preferably, the non-combustion aerosol delivery device is configured to heat the aerosol-forming material 3 of the article 1, 1', 1'', 1''', 1'''' to a maximum temperature of at least about 200° C., or at least about 220° C. or at least about 240° C., more preferably at least about 270° C., at least once during the heating step by the non-combustion aerosol delivery device. It has been made.

[0223] By using an aerosol delivery system including a coil as described herein, e.g., an induction coil that heats at least a portion of the aerosol-generating material to at least 200°C, more preferably at least 220°C, a higher temperature aerosol can be generated from the aerosol-generating material of Articles 1, 1', 1'', 1''', 1'''' described herein than previous devices that contribute to the generation of an aerosol that is believed to be closer to an FMC product as the aerosol exits the mouth end of mouthpiece 2, 2', 2'', 2''', 2''''. For example, the maximum aerosol temperature measured at the mouth end of Articles 1, 1', 1'', 1''', 1'''' is preferably greater than 50°C, more preferably greater than 55°C, and even more preferably greater than 56°C or 57°C. Additionally or alternatively, the maximum aerosol temperature measured at the mouth end of Articles 1, 1', 1'', 1''', 1'''' is less than 62°C, more preferably less than 60°C, and more preferably less than 59°C. In some embodiments, the maximum aerosol temperature measured at the mouth end of the article 1, 1', 1'', 1''', 1'''' is preferably between 50°C and 62°C, more preferably between 56°C and 60°C.

[0224] FIG. 6 shows an example of a non-combustion based aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium / material, such as an aerosol-generating material 3 of an article 1, 1', 1'', 1''', 1'''' described herein. In general terms, device 100 may be used to heat an exchangeable article 110 that contains an aerosol-generating medium, such as an article 1, 1', 1'', 1''', 1'''' described herein, to generate an aerosol or other inhalable medium that is inhaled by a user of device 100. Device 100 and exchangeable article 110 together form a system.

[0225] The device 100 includes a housing 102 (in the form of an outer cover) that surrounds and contains various components of the device 100. The device 100 has an opening 104 at one end through which an item 110 is inserted for heating by a heating assembly. In use, the item 110 is fully or partially inserted into the heating assembly where it is heated by one or more components of the heating assembly.

[0226] The device 100 in this example includes a first end member 106, which includes a lid 108 that is movable relative to the first end member 106 to close the opening 104 when the item 110 is not in place. Although the lid 108 is shown in an open configuration in Figure 6, the lid 108 may be moved to a closed configuration. For example, a user slides the lid 108 in the direction of arrow "B."

[0227] The device 100 may include a user-operable adjustment member 112, such as a button or switch that, when pressed, activates the device 100. For example, a user may operate the switch 112 to power the device 100 on.

[0228] Device 100 also includes electrical components such as a socket / port 114, which may accommodate a cable for charging a battery in device 100. Socket 114 may be a charging port, such as a USB charging port.

[0229] Figure 7 shows the device 100 of Figure 6 without the outer cover 102 and without the presence of the item 110. The device 100 defines a longitudinal axis 134.

[0230] As shown in Figure 7, a first end member 106 is disposed at one end of the device and a second end member 116 is disposed at the opposite end of the device 100. The first and second end members 106, 116 together at least partially define an end surface of the device 100. For example, a bottom surface of the second end member 116 at least partially defines a bottom surface of the device 100. An edge of the outer cover 102 also defines a portion of the end surface. The lid 108 in this example also defines a portion of a top surface of the device 100.

[0231] The end of the device nearest the opening 104 is also known as the proximal end (or mouth end) of the device 100 because it is closest to the user's mouth during use. In use, a user inserts an article 110 into the opening 104, operates a user control to initiate heating of the aerosol-generating material, and inhales the aerosol generated by the device, thereby causing the aerosol to flow within the device 100 along a flow path toward the proximal end of the device 100.

[0232] The other end of the apparatus away from opening 104 is also known as the distal end of device 100, as this is the end that will be away from the user's mouth during use. When a user inhales the aerosol generated by the device, the aerosol flows away from the distal end of device 100.

[0233] The device 100 further includes a power source 118. The power source 118 may be a battery, for example, a rechargeable or non-rechargeable battery. Examples of suitable batteries include lithium batteries (such as lithium ion batteries), nickel batteries (such as nickel-cadmium batteries), and alkaline batteries. The battery is electrically connected to the heating assembly and provides power as needed and under the control of a controller (not shown) to heat the aerosol-generating material. In this example, the battery is connected to a central support 120 that holds the battery 118 in place.

[0234] The device further includes at least one electronic module 122. The electronic module 122 may include, for example, a printed circuit board (PCB). The PCB 122 may support a controller, such as at least one processor and memory. The PCB 122 may also include one or more electrical tracks that electrically connect together various electronic components of the device 100. For example, battery terminals may be electrically connected to the PCB 122 so that power can be distributed throughout the device 100. The socket 114 may also be electrically coupled to a battery via the electrical tracks.

[0235] In the example of device 100, the heating assembly is an induction heating assembly, which includes various components for heating the aerosol-generating material of the article 110 via an induction heating process. Induction heating is a process of heating an electrically conductive object (such as a susceptor) by electromagnetic induction. The induction heating assembly may include an induction member, for example one or more inductor coils, and a device for passing a varying current, such as an alternating current, through the induction member. The varying current in the induction member generates a varying magnetic field. The varying magnetic field penetrates a susceptor, which is preferably positioned relative to the induction member, and generates eddy currents inside the susceptor. The susceptor has an electrical resistance to the eddy currents, and therefore the flow of eddy currents against this resistance causes the susceptor to heat by Joule heating. If the susceptor includes a ferromagnetic material, such as iron, nickel, or cobalt, heat may be generated by magnetic hysteresis losses in the susceptor, i.e., by a change in orientation of the magnetic dipoles of the magnetic material as a result of matching the varying magnetic field. Inductive heating allows for quicker heating than, for example, conductive heating, since heat is generated inside the susceptor. Furthermore, no physical contact is required between the dielectric heater and the susceptor, allowing greater flexibility in design and application.

[0236] The induction heating assembly of the example device 100 includes a susceptor structure 132 (hereinafter "susceptor"), a first inductor coil 124, and a second inductor coil 126. The first and second inductor coils 124, 126 are made from a conductive material. In this example, the first and second inductor coils 124, 126 are made from a Litz wire / cable that is wound in a helical shape to provide a helical inductor coil 124, 126. The Litz wire includes multiple individual wires that are individually insulated and twisted together to form a single wire. The Litz wire is designed to reduce skin effect losses in the conductor. In the example device 100, the first and second inductor coils 124, 126 are made from copper Litz wire with a rectangular cross section. In other examples, the Litz wire may have other cross sections, such as circular.

[0237] The first inductor coil 124 is configured to generate a first varying magnetic field for heating a first section of the susceptor 132, and the second inductor coil 126 is configured to generate a second varying magnetic field for heating a second section of the susceptor 132. In this example, the first inductor coil 124 is adjacent to the second inductor coil 126 in a direction along a longitudinal axis 134 of the device 100 (i.e., the first and second inductor coils 124, 126 do not overlap). The susceptor structure 132 may include a single susceptor or two or more susceptors. Ends 130 of the first and second inductor coils 124, 126 are connected to the PCB 122.

[0238] Of course, in some examples, the first and second inductor coils 124, 126 may have at least one different characteristic. For example, the first inductor coil 124 may have at least one different characteristic from the second inductor coil 126. For example, in one example, the first inductor coil 124 may have a different inductance value than the second inductor coil 126. In FIG. 7, the first and second inductor coils 124, 126 are different lengths such that the first inductor coil 124 is wound on a smaller section of the susceptor 132 than the second inductor coil 126. Thus, the first inductor coil 124 may have a different number of turns than the second inductor coil 126 (assuming the spacing between the individual turns is substantially the same). In yet another example, the first inductor coil 124 may be made of a different material than the second inductor coil 126. In some examples, the first and second inductor coils 124, 126 may be substantially the same.

[0239] In this example, the first and second inductor coils 124, 126 are shown wound in opposite directions. This is useful when the inductor coils are active at different times. For example, the first inductor coil 124 may be activated first to heat a first section / portion of the article 110, and then the second inductor coil 126 may be activated to heat a second section / portion of the article 110. Winding the coils in different directions helps reduce the current induced in the inductor coils when used with certain types of control circuits. In FIG. 7, the first inductor coil 124 is a right-handed spiral and the second inductor coil 126 is a left-handed spiral. However, in other embodiments, the inductor coils 124, 126 may be wound in the same direction, or the first inductor coil 124 may be a left-handed spiral and the second inductor coil 126 may be a right-handed spiral.

[0240] The susceptor 132 in this example is hollow and thus defines a receptacle in which the aerosol-generating material is received. For example, the article 110 is inserted into the susceptor 132. In this example, the susceptor 132 is tubular and has a circular cross-section.

[0241] The susceptor 132 may be made from one or more materials. Preferably, the susceptor 132 comprises carbon steel with a coating of nickel or cobalt.

[0242] In some examples, the susceptor 132 may include at least two materials that can be heated at two different frequencies for selective aerosolization of the at least two materials. For example, a first section of the susceptor 132 (heated by the first inductor coil 124) may include a first material, and a second section of the susceptor 132 (heated by the second inductor coil 126) may include a different second material. In another example, the first section may include a first and a second material, and the first and second materials may be heated separately based on the activation of the first inductor coil 124. The first and second materials may be adjacent along an axis defined by the susceptor 132 or may form different layers within the susceptor 132. Similarly, the second section may include a third and a fourth material, and the third and fourth materials may be heated separately based on the activation of the second inductor coil 126. The third and fourth materials may be adjacent along an axis defined by the susceptor 132, or may form different layers within the susceptor 132. For example, the third material may be the same as the first material and the fourth material may be the same as the second material. Alternatively, each of these materials may be different. The susceptor may include, for example, carbon steel or aluminum.

[0243] 7 further includes an insulating member 128 that is generally tubular and at least partially surrounds the susceptor 132. The insulating member 128 may be constructed from any insulating material, such as, for example, plastic. In this particular example, the insulating member is constructed from polyetheretherketone (PEEK). The insulating member 128 serves to insulate the various components of the device 100 from heat generated within the susceptor 132.

[0244] The insulating member 128 may also fully or partially support the first and second inductor coils 124, 126. For example, as shown in FIG. 7, the first and second inductor coils 124, 126 are positioned around the insulating member 128 and contact a radially outer surface of the insulating member 128. In some examples, the insulating member 128 does not abut the first and second inductor coils 124, 126. For example, a small gap may exist between the outer surface of the insulating member 128 and the inner surfaces of the first and second inductor coils 124, 126.

[0245] In a specific example, the susceptor 132 , the insulating member 128 and the first and second inductor coils 124 , 126 are coaxial about a central longitudinal axis of the susceptor 132 .

[0246] 8 is a cross-sectional side view of device 100. Outer cover 102 is shown in this example. The rectangular cross-sectional shapes of first and second inductor coils 124, 126 can be more clearly seen.

[0247] The device 100 further includes a support 136 that engages one end of the susceptor 132 to hold the susceptor 132 in place. The support 136 is connected to the second end member 116.

[0248] The device also includes a second printed circuit board 138 associated with the adjustment member 112 .

[0249] The device 100 further includes a second lid / cap 140 and a spring 142 disposed toward a distal end of the device 100. The spring 142 opens the second lid 140 to provide access to the susceptor 132. A user may open the second lid 140 to clean the susceptor 132 and / or the support 136.

[0250] The device 100 further includes an expansion chamber 144 that extends away from the proximal end of the susceptor 132 toward the opening 104 of the device. Disposed at least partially within the expansion chamber 144 is a retention clip 146 that abuts and retains the article 110 when contained within the device 100. The expansion chamber 144 is connected to the end member 106.

[0251] FIG. 9 is an exploded view of the device 100 of FIG. 8 with the outer cover 102 omitted.

[0252] Figure 10A is a cross-sectional view of a portion of the device 100 of Figure 8. Figure 10B is an enlarged view of an area of ​​Figure 10A. Figures 8A and 8B show an article 110 contained within a susceptor 132, with the article 110 sized such that its outer surface abuts the inner surface of the susceptor 132, which provides for most efficient heating. The article 110 in this example includes an aerosol-generating material 110a. The aerosol-generating material 110a is positioned within the susceptor 132. The article 110 may also include other components, such as a filter wrapper and / or a cooling structure.

[0253] 10B shows that the outer surface of the susceptor 132 is spaced from the inner surface of the inductor coils 124, 126 by a distance 150 measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 150 is about 3 mm to 4 mm, about 3 to 3.5 mm. , or approximately 3.25 mm.

[0254] 10B further illustrates that the outer surface of the insulating member 128 is spaced from the inner surface of the inductor coils 124, 126 by a distance 152 measured in a direction perpendicular to the longitudinal axis 158 of the susceptor 132. In one particular example, the distance 152 is about 0.05 mm. In another example, the distance 152 is substantially 0 mm such that the inductor coils 124, 126 abut and touch the insulating member 128.

[0255] In one example, the wall thickness 154 of the susceptor 132 is between about 0.025 mm and 1 mm, or about 0.05 mm.

[0256] In one example, the length of the susceptor 132 is about 40 mm to 60 mm, about 40 mm to 45 mm, or about 44.5 mm.

[0257] In one example, the wall thickness 156 of the insulating member 128 is between about 0.25 mm and 2 mm, between 0.25 mm and 1 mm, or about 0.5 mm.

[0258] In use, an article 1, 1', 1'', 1''', 1'''' described herein is inserted into a non-combustion aerosol delivery device, such as device 100 described with reference to Figures 6-10. At least a portion of the mouthpiece 2, 2', 2'', 2''', 2'''' of article 1, 1', 1'', 1'''', 1'''' protrudes from non-combustion aerosol delivery device 100 and is placed into the mouth of a user. An aerosol is generated by heating an aerosol-generating material 3 using device 100. The aerosol generated by the aerosol-generating material 3 travels through the mouthpiece 2, 2', 2'', 2''', 2'''', 2'''' to the user's mouth.

[0259] The articles 1, 1', 1'', 1''', 1'''' described herein are particularly advantageous when used in non-combustion based aerosol delivery devices, such as device 100 described with reference to Figures 6-10. Surprisingly, it has been found that the amorphous solid body of material 6 has a particularly significant effect on the temperature of the aerosol delivered to the mouth end of the article 1, 1', 1'', 1'''', 1''''.

[0260] Testing was performed on two comparative smoking articles and an exemplary embodiment of the invention. Comparative Examples A and B are the same as Article 1'', except that Comparative Examples A and B include a fibrous body of material 4 instead of an amorphous solid body of material 6. Comparative Example A has a ventilation level of 60% and Comparative Example B has a ventilation level of 75%. The exemplary article is the same as Article 1'', and is provided with 60% ventilation.

[0261] Testing was performed on the first two puffs of the article. Each sample was tested nine times and the resulting temperature is the average of these nine tests. Standard testing equipment was used, using the known Health Canada Intense puffing regime (55 ml puff volume applied for 2 seconds every 30 seconds). The results of the test are shown in Table 1, where the puff temperature indicates the difference between room temperature and the aerosol temperature.

[0262] As shown in Table 1, the aerosol temperatures across the first and second puffs from the exemplary article including an amorphous solid body of material are lower than the aerosol temperatures across those puffs for either Comparative Example A or B. The aerosol temperatures across puffs 1 and 2 for the exemplary article with 60% ventilation are comparable to the aerosol temperatures across puffs 1 and 2 for Comparative Example B with 75% ventilation. High ventilation levels have the effect of cooling the aerosol temperature, and therefore achieving comparable aerosol temperatures in articles with ventilation levels of 15% or less is significant.

[0263] [Table 1]

[0264] 11 illustrates a method of making an article for use in a non-combustion based aerosol delivery system. In step S101, a source of amorphous solid material in sheet form is passed through an apparatus to form the sheet material into a gathered rod of amorphous solid material.

[0265] In step S102, the assembled rod of amorphous solid material is cut to length to form a body of amorphous solid material as defined herein.

[0266] FIG. 12 is a side view of an apparatus for producing a material rod according to the present disclosure.

[0267] FIG. 12 shows an apparatus 200 for producing a body of material according to the invention, comprising a tongue 211 and a guide nozzle 212 including a funnel portion. The tongue 211 is a tapered duct having a wide inlet opening 211b and a narrow outlet opening 211a. The tongue 211 may be substantially circular in cross section and open at its underside in the form of an elongated slot (not shown) extending axially along the length of the tongue such that in cross section the tongue 211 does not form a complete circle. The tongue 211 may be located in a guide (not shown) including a forming track along which extends a continuous belt or "garniture" 215. The garniture 215 extends over a number of guide rollers 216 and is driven to be conveyed around the rollers 216 in the direction indicated by the arrow "A". A wrapper paper "P" is fed from a spool 217 onto the top surface of the garniture 215 and is conveyed past the tongue 211 by the moving garniture 215. As the wrapper paper P moves within the tongue 211, the forming track is configured to deform the garniture and the wrapper paper thereon so that, in cross-section, the wrapper paper P goes from flat as it enters the wide entrance opening 211b of the tongue 211 (as it is in the spool) to a closed circle as it exits the narrow exit opening 211a of the tongue 211, completely surrounding the formed rod.

[0268] In use, a bobbin (not shown) of amorphous solid material is fed into the funnel of the guide nozzle 212 and guided into the tongue 211, which continuously tapers to form a sheet of amorphous solid material into a rod by gathering the material as it exits the narrow distal end 211a.

[0269] As the amorphous solid material is fed into the tongue 211, it is gathered onto and carried through the tongue 211 by the wrapper paper P being transported on the garniture 215. As the amorphous solid material travels through the tongue 211, the material is compressed as the tongue 211 tapers inwardly and the wrapper paper P is folded around the outside of a pressed cylinder of gathered amorphous solid material such that as the amorphous solid material exits through the narrow exit opening 211a of the tongue 211, the amorphous solid material forms a pressed cylindrical rod surrounded by the outer wrapper paper P.

[0270] The rods formed by the methods described herein may be cut to length to form multiple bodies of material according to the present invention.

[0271] The various embodiments described herein are provided merely to aid in understanding and teaching of the claimed features. These embodiments are merely representative examples and are not exhaustive or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects of the present disclosure should not be construed as limiting the present disclosure to the claims as set forth herein or to the equivalents of the claims, and that other embodiments may be utilized or modified without departing from the scope and / or spirit of the present disclosure. Various embodiments may suitably comprise, consist of, or consist essentially of the disclosed elements, components, features, parts, steps, means, or other combinations. The present disclosure also includes other inventions that are not currently claimed but may be claimed in the future.

Claims

1. An article for use in a non-combustion based aerosol delivery system, the article comprising a mouthpiece comprising a body of material, the body of material comprising an elongated strip of an amorphous solid material.

2. 2. The article of claim 1, wherein the elongate strip is substantially aligned with a longitudinal axis of the article.

3. 3. An article according to claim 1 or 2, wherein the mouthpiece comprises a further section, the further section being a body of fibrous material or a hollow tubular member, the mouthpiece comprising a mouth end and a distal end.

4. 4. The article of claim 3, wherein the further section is located at the mouth end of the mouthpiece.

5. 5. An article according to claim 3 or 4, wherein the further section is a first further section and the mouthpiece further comprises a second further section.

6. 6. An article according to claim 5, wherein the second further section is a body of fibrous material or a hollow tubular member.

7. 7. An article according to claim 5 or 6, wherein the first further section and the second further section are both hollow tubular members.

8. 8. The article of claim 7, wherein each of the hollow tubular members is a paper tube or a hollow tubular member formed from filament tow.

9. 9. An article according to any one of claims 5 to 8, wherein the second further section is located at a distal end of the mouthpiece.

10. 7. An article according to any one of claims 3 to 6, wherein the body of material is located at a distal end of the mouthpiece.

11. 11. An article according to any one of the preceding claims, wherein the thickness of the amorphous solid material is between 0.015mm and 0.5mm, or between 0.1mm and 0.3mm, or between 0.15mm and 0.25mm.

12. 12. The article of any one of claims 1 to 11, wherein the amorphous solid material is laminated to a support.

13. 13. The article of claim 12, wherein the support is paper or foil.

14. 14. The article of any one of claims 1 to 13, wherein the amorphous solid material is wrinkled.

15. 15. An article according to any one of claims 1 to 14, wherein the amorphous solid material comprises a flavourant, optionally the flavourant being menthol.

16. 16. The article of claim 15, wherein the amorphous solid material comprises 0.1% to 65% by dry weight, or 1% to 60% by dry weight, or 10% to 55% by dry weight, preferably 40% to 50% by dry weight of menthol.

17. 17. The article of any one of claims 1 to 16, wherein the amorphous solid comprises a gelling agent, the gelling agent being one of pectin, gelatin, a polysaccharide or carrageenan.

18. 18. The article of any one of claims 1 to 17, further comprising an aerosol generating material.

19. 20. The article of claim 18, wherein the aerosol-generating material is connected to a distal end of the mouthpiece.

20. 20. A system comprising an article according to claim 18 or 19 and a non-combustion aerosol delivery device for heating the aerosol-generating material of the article.

21. 21. The system of claim 20, wherein the non-combustion based aerosol delivery device comprises a coil.

22. 22. The system of claim 20 or 21, wherein the non-combustion aerosol delivery device is configured to heat the aerosol-generating material of the article to a maximum temperature of at least 200°C.

23. 23. The system of claim 22, wherein the non-combustion aerosol delivery device is configured to heat the aerosol-generating material of the article to a maximum temperature of at least about 160°C, or at least about 200°C, or at least about 220°C, or at least about 240°C, or at least about 270°C.

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