Articles for use in non-flammable aerosol delivery systems

Abstract

The article for use in a non-combustible aerosol delivery system includes a source of aerosol-forming material and / or a cavity for receiving the source of aerosol-forming material, and a downstream portion including the source of aerosol-forming material and / or a capsule located about 28 mm to about 38 mm from the distal end of the cavity. A non-combustible aerosol delivery system including the article is also described.

Description

[Technical field]

[0001] The present invention relates to an article for use in a non-combustion aerosol delivery system and to a non-combustion aerosol delivery system.

[0002] Certain tobacco industry products generate an aerosol during use, which is inhaled by the user. For example, tobacco heating devices heat an aerosol-generating substrate, such as tobacco, to form an aerosol by heating, rather than burning, the substrate. Such tobacco industry products typically include a mouthpiece through which the aerosol is delivered to the user's mouth. Overview

[0003] According to some embodiments described herein, in a first aspect, there is provided an article for use in a non-combustion aerosol delivery system, the article comprising an aerosol-generating component surrounded by a wrapping material comprising a cellulosic material, the cellulosic material having a basis weight greater than about 40 grams per square meter.

[0004] According to some embodiments described herein, in a second aspect, there is provided an article for use in a non-combustion aerosol delivery system, the article comprising: an aerosol generating component comprising a rod of aerosol generating material, the rod of aerosol generating material having a length of less than 30 mm and wrapped with a first wrapping material, the rod of aerosol generating material being wrapped with an outer wrapping material extending at least partially over the rod of aerosol generating material.

[0005] According to some embodiments described herein, in a third aspect there is provided a non-combustion aerosol delivery system comprising a non-combustion aerosol delivery device and an article according to the first or second aspect.

[0006] Embodiments of the invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0007] [Figure 1a] FIG. 2 is a cross-sectional side view of an article including a capsule-containing mouthpiece for use with a non-combustion aerosol delivery device. [Figure 1b] FIG. 1b is a cross-sectional view of the capsule-containing mouthpiece shown in FIG. [Diagram 2] FIG. 1 is a cross-sectional view of a non-combustion aerosol delivery device. [Diagram 3] FIG. 4 is a simplified schematic diagram of components within a housing of the aerosol delivery device shown in FIG. 3. [Figure 4] 3 is a cross-sectional view of the non-combustion aerosol delivery device shown in FIG. 2 with the article shown in FIG. 1 inserted into the device. Detailed Description

[0008] As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user, including: Combustible aerosol delivery systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or hand-rolled or hand-made cigarettes, whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smoking materials; a non-combustion aerosol delivery system that releases a compound from an aerosol-forming material without burning the aerosol-forming material, such as an electronic cigarette, a tobacco heating product, and a hybrid system for generating an aerosol using a combination of aerosol-forming materials; These include, but are not limited to, lozenges, gums, patches, articles including inhalable powders, and oral products such as oral tobacco, including snus or moist snuff, and aerosol-free delivery systems that deliver at least one substance, which may or may not contain nicotine, to a user orally, nasally, transdermally, or otherwise, without forming an aerosol.

[0009] According to the present disclosure, a "non-combustible" aerosol delivery system is one in which the aerosol-generating materials (or components thereof) that are components of the aerosol delivery system do not burn or ignite to facilitate delivery of at least one substance to a user.

[0010] In some embodiments, the delivery system is a non-combustible aerosol delivery system, such as a powered non-combustible aerosol delivery system.

[0011] In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not required.

[0012] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a tobacco heating system.

[0013] In some embodiments, the non-combustion aerosol delivery system is a hybrid system for generating an aerosol using a combination of aerosol-generating materials, one or more of which may be heated. Each of the aerosol-generating materials may be, for example, in 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.

[0014] Generally, a non-combustion aerosol delivery system can include a non-combustion aerosol delivery device and a consumable for use with the non-combustion aerosol delivery device.

[0015] In some embodiments, the present disclosure relates to consumables that include aerosol generating materials and are configured for use with non-combustion aerosol delivery devices. These consumables may be referred to as articles throughout this disclosure.

[0016] As used herein, the terms "upstream" and "downstream" are relative terms defined with respect to the direction in which mainstream aerosol is drawn through an article or device during use.

[0017] In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, can include a power source and a controller. The power source can 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 can be activated to dissipate power in the form of heat to an aerosol generating material or a heat transfer material in proximity to the heat generating power source.

[0018] In some embodiments, the non-combustible aerosol delivery system can include an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0019] In some embodiments, consumables for use with a non-combustible aerosol delivery device may include an aerosol generating material, an aerosol generating material storage area, an aerosol generating material transfer component, an aerosol generator, an aerosol generating area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0020] In some embodiments, the substance to be 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 to be delivered can include an active agent.

[0022] An active substance as used herein may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. An active substance may be selected from, for example, dietary supplements, known drugs, psychoactive substances. An active substance may be naturally derived or synthetically obtained. An active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. An active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another botanical substance. In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0023] As described herein, the active material may include or be derived from one or more botanical materials or components, derivatives, or extracts thereof. As used herein, the term "botanical material" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, shells, and the like. Alternatively, the material may include active compounds naturally occurring in synthetically obtained botanical materials. The material may be in the form of a liquid, gas, solid, powder, fine powder, ground particles, granules, pellets, pieces, strips, sheets, and the like. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, bay leaf, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. , lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, bell pepper, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, kavi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha arvensis, Grapefruit mint (Mentha cv), Egyptian mint (Mentha niliaca), Peppermint (Mentha piperita), Lime mint (Mentha piperita citrata cv), Chocolate mint (Mentha piperita cv), Curly mint (Mentha spicata crispa), Wild mint (Mentha cordifolia), Horse mint (Mentha longifolia), Pineapple mint (Mentha suaveolens variegata), Pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata cv), and Apple mint (Mentha suaveolens).

[0024] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substance is tobacco.

[0025] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substances are selected from eucalyptus, star anise, cocoa, and hemp.

[0026] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0027] In some embodiments, the substance delivered comprises a fragrance.

[0028] As used herein, the terms "flavor" and "flavoring agent" refer to materials that may be used, where local regulations permit, to create a desired taste, aroma, or other somatosensorial sensation in products intended for adult consumers.These materials may be naturally derived flavoring materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherries, berries, red berries, cranberries, peaches, apples, oranges, mangoes, clementines, lemons, limes, tropical fruits, and the like). , papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberries, mulberries, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang ylang sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, any type of mint oil of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, 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, shiso, curcuma, cilantro, myrtle, black currant, valerian, bell pepper, mace, damian, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.The materials may be replicas, synthetic or natural ingredients, or mixtures thereof. The materials may be in any suitable form, for example, a liquid such as an oil, a solid such as a powder, or a gas.

[0029] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus, and / or red berry flavor ingredients. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavor ingredients extracted from tobacco. In some embodiments, the flavoring comprises flavor ingredients extracted from cannabis.

[0030] In some embodiments, the flavorings may include sensates intended to achieve somatosensory sensations that are typically chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the scent or taste nerves, and may include agents that provide a heating, cooling, tingling, or anesthetic effect. A suitable heating agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol WS-3.

[0031] An aerosol-generating material is a material that can generate an aerosol when activated, for example by heating, irradiation, or in any other way. The aerosol-generating material may be in the form of a solid, liquid, or gel, and may or may not contain active substances and / or flavorings. The aerosol-generating material may be incorporated into an article for use in an aerosol generating system.

[0032] As used herein, the term "tobacco material" refers to any material that includes tobacco or its derivatives or substitutes. The tobacco material may be in any suitable form. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco lamina, reconstituted tobacco, and / or tobacco extract.

[0033] A consumable is an article that includes or is composed of an aerosol-generating material that is intended to be consumed, in part or in whole, 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 transfer component, 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 generates heat during use to cause the aerosol-generating material to generate an aerosol. The heater may include, for example, a combustible material, a material that can be heated by electrical conduction, or a susceptor.

[0034] A 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, where the penetration of the varying magnetic field results in inductive heating of the heating material. The heating material may be a magnetic material, where 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, where the susceptor is heatable by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0035] 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 changing the taste, flavor, acidity, or another characteristic of the aerosol. The aerosol modifier may be provided within an aerosol modifier-emitting component that is operable to selectively emit the aerosol modifier.

[0036] 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, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, a string, or a granule. The aerosol modifier may not include a filter material.

[0037] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to apply thermal energy to the aerosol-generating material 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 heating. For example, the aerosol generator may be configured to apply one or more of vibration, high pressure, or electrostatic energy to the aerosol-generating material.

[0038] The filament tow material described herein can include cellulose acetate fiber tow. The filament tow 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-coterophthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers, or combinations thereof. The filament tow may be plasticized with an appropriate plasticizer for the tow, such as triacetin, where the material is cellulose acetate tow or the tow may be unplasticized. The tow can have any suitable specification, for example, the fibers have other cross sections such as "Y" shaped or "X" shaped, with a single fineness value of 2.5 to 15 denier per filament, for example, 8.0 to 11.0 denier per filament, and a total fineness value of 5,000 to 50,000, for example, 10,000 to 40,000.

[0039] In the drawings described herein, the same reference numerals are used to denote like features, items or components.

[0040] Figure 1a is a cross-sectional side view of an article 1 comprising a capsule-containing mouthpiece 2. Figure 1b is a cross-sectional view through line A-A' of the capsule-containing mouthpiece shown in Figure 1a.

[0041] The article 1 comprises a mouthpiece 2 and an aerosol-generating portion connected to the mouthpiece 2. In this example, the mouthpiece 2 comprises a body of material 6 in which an aerosol modifier is provided, in this example in the form of capsules 11. In other examples, the aerosol modifier may be provided in other forms, such as a material injected into the body of material 6, or may be provided in threads which may also be located within the body of material 6, for example threads carrying flavourings or other aerosol modifiers.

[0042] The mouthpiece 2 also comprises a cooling portion 8, also referred to as a cooling element, which is located immediately downstream and adjacent to the source of aerosol-generating material 3. In this example, the cooling portion 8 abuts the aerosol-generating portion. The body of material 6 is located downstream of the cooling portion 8. The mouthpiece 2 further comprises a hollow tubular element 4 at the mouth end of the article 1, downstream of the body of material 6.

[0043] The capsule 11 may comprise a breakable capsule, for example a capsule having a solid frangible shell surrounding a liquid payload. In this example, a single capsule 11 is used. The capsule 11 is fully embedded within the body of material 6. In other words, the capsule 11 is fully surrounded by the material forming the body of material 6. In other examples, multiple breakable capsules may be disposed within the body of material 6, for example two, three or more breakable capsules. The length of the body of material 6 may be increased to accommodate the required number of capsules. In examples using multiple capsules, the individual capsules may be identical to each other or may differ from each other in terms of size and / or capsule payload. In other examples, multiple bodies of material 6 may be provided, each containing one or more capsules.

[0044] Capsule 11 has a core-shell structure. In other words, capsule 11 includes a shell that encapsulates a liquid agent, such as a flavorant or other auxiliary agent, which may be any one of the flavorants or aerosol modifiers described herein. The shell of the capsule can be ruptured by the user to release the flavorant or other auxiliary agent into the body of material 6.

[0045] In this example, capsule 11 is spherical and has a diameter of about 3 mm. In other examples, other shapes and sizes of capsules may be used. For example, the capsule may have a diameter of less than 4 mm, or less than 3.5 mm, or less than 3.25 mm. In alternative embodiments, the capsule may have a diameter of more than about 3.25 mm, such as more than 3.5 mm, or more than 4 mm. The total weight of capsule 11 may range from about 10 mg to about 50 mg.

[0046] Preferably, the length of the material 6 is less than about 15 mm. More preferably, the length of the material 6 is less than about 12 mm. Additionally or alternatively, the length of the material 6 is at least about 5 mm. Preferably, the length of the material 6 is at least about 8 mm. In some preferred embodiments, the length of the material 6 is about 5 mm to about 15 mm, more preferably about 6 mm to about 12 mm, even more preferably about 6 mm to about 12 mm, and most preferably about 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. In this example, the length of the material 6 is 10 mm.

[0047] In this example, the capsule 11 is located at a central longitudinal position within the body of material 6. That is, the capsule 11 is located with its centre 5 mm from each end of the body of material 6. In this example, the centre of the capsule is located 36 mm from the upstream end of the article 1. The capsule is preferably located 28 mm to 38 mm from the upstream end of the article 1, more preferably 34 mm to 38 mm from the upstream end of the article 1. In this example, the centre of the capsule is located 12 mm from the downstream end of the mouthpiece 2b. Providing the capsule in this position enhances volatilisation of the capsule contents by being close to the aerosol-generating part of the article which is heated during use, and is sufficiently far from the aerosol-generating part which is inserted into the aerosol delivery system during use to allow the user to easily reach the capsule and burst it with their fingers.

[0048] In other examples, the capsule 11 may be positioned at a position other than the longitudinal center of the material body 6, i.e. closer to the downstream end of the material body 6 than the upstream end, or closer to the upstream end of the material body 6 than the downstream end.

[0049] The body of material 6 is wrapped in a first plug wrap 7. In this example, the first plug wrap 7 includes a barrier coating that renders the plug wrap material substantially impermeable to the liquid payload of the capsule 11. Alternatively or in addition, the second plug wrap 9 and / or tipping paper 5 can include a barrier coating that renders the plug wrap and / or tipping paper material substantially impermeable to the liquid payload of the capsule 11.

[0050] The first plug wrap 7 preferably has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. The first plug wrap 7 preferably has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The first plug wrap 7 is preferably a non-porous plug wrap having an air permeability of, for example, less than 100 Coresta units, for example less than 50 Coresta units. However, in other embodiments the first plug wrap 7 may be a porous plug wrap having an air permeability of, for example, more than 200 Coresta units.

[0051] In this example, the body of material 6 is formed from filament tow. In this example, the tow used in the body of material 6 has a denier per filament (dpf) of 5 and a total fineness of 25,000. In this example, the tow comprises plasticized cellulose acetate tow. The plasticizer used in the tow comprises about 9% by weight of the tow. In this example, the plasticizer is triacetin. In other examples, different materials may be used to form the body of material 6. For example, the body of material 6 may be formed from paper rather than tow, for example, similar to paper filters known for use in cigarettes. For example, the paper or other cellulosic material may be provided as one or more pieces of sheet material, which is folded and / or crimped to form the body of material 6. The sheet material may have a basis weight of 15 gsm to 60 gsm, for example 20 to 50 gsm. The sheet material may have a basis weight of, for example, any of 15-25 gsm, 25-30 gsm, 30-40 gsm, 40-45 gsm, and 45-50 gsm. Additionally or alternatively, the sheet material may have a width of 50 mm to 200 mm, such as 60 mm to 150 mm, or 80 mm to 150 mm. For example, the sheet material may have a basis weight of 20-50 gsm and a width of 80 mm to 150 mm. This may allow, for example, a cellulosic body of material to have an appropriate pressure drop for an article having the dimensions described herein.

[0052] Alternatively, the mass 6 may be formed from a tow other than cellulose acetate, such as polylactic acid (PLA), other materials described herein for filament tows, or similar materials. The tow is preferably formed from cellulose acetate. The tow, whether formed from cellulose acetate or other materials, preferably has a denier per filament of at least 5 d.pf. To obtain a sufficiently uniform mass 6, the tow preferably has a denier per filament of 12 d.pf or less, preferably 11 d.pf or less, and more preferably 10 d.pf or less.

[0053] The total fineness of the tows forming the body 6 is preferably at most 30,000, more preferably at most 28,000, and even more preferably at most 25,000. These total fineness values ​​provide tows that occupy a smaller percentage of the cross-sectional area of ​​the mouthpiece 2, and therefore provide a lower pressure drop across the mouthpiece 2 than tows having higher total fineness values. For adequate hardness of the body 6, the tows preferably have a total fineness of at least 8,000, more preferably at least 10,000. The denier per filament is preferably 5-12, and the total fineness is preferably 10,000-25,000. The cross-sectional shape of the filaments of the tow is preferably "Y" shaped, although other shapes may be used in other embodiments, such as "X" shaped filaments with the same values ​​of dpf and total fineness values ​​provided herein.

[0054] Regardless of the material used to form the body of material 6, the pressure drop across the body of material 6 may be, for example, 0.3-5 mmWG per mm of length of the body of material 6, for example, 0.5-2 mmWG per mm of length of the body of material 6. The pressure drop may be, for example, 0.5-1 mmWG per mm of length, 1-1.5 mmWG per mm of length, or 1.5-2 mmWG per mm of length. The total pressure drop across the body of material 6 may be, for example, 3 mmWG-8 mmWG, or 4 mmWG-7 mmWG. The total pressure drop across the body of material 6 may be about 5, 6, or 7 mmWG.

[0055] The article has an aeration level of about 10% of the aerosol drawn through the article. In alternative embodiments, the article may have an aeration level of 1% to 20%, for example 1% to 12%, of the aerosol drawn through the article. These levels of aeration help to increase the concentration of aerosol inhaled by the user at the mouth end 2b, as well as aiding the cooling process of the aerosol. The vent is provided directly in the mouthpiece 2 of the article 1. In this example, the vent is provided in the cooling section 8, which has been found to be particularly advantageous in aiding the aerosol generation process. The vent is provided by perforations 12, in this case formed as a single row of laser perforations located 13 mm from the mouth end 2b downstream of the mouthpiece 2. In alternative embodiments, more than one row of ventilation perforations may be provided. These perforations pass through the tipping paper 5, the second plug wrap 9 and the cooling section 8. In alternative embodiments, the vent may be provided in other locations of the mouthpiece, for example in the material body 6 or the first tubular element 4. The article is preferably configured so that the perforations are located approximately 28 mm or less from the upstream end of the article 1, preferably between 20 mm and 28 mm from the upstream end of the article 1. In this example, the opening is located approximately 25 mm from the upstream end of the article.

[0056] The mouthpiece 2 is preferably configured such that the capsule 11 and the vent hole 12 are offset from each other in the longitudinal direction of the mouthpiece 2. For example, the vent hole 12 may be provided immediately upstream of the capsule position, that is, about 1 mm to about 10 mm upstream of the capsule position.

[0057] In this example, the aerosol-generating portion comprises a source of aerosol-generating material in the form of a cylindrical rod of aerosol-generating material 3. In other examples, the aerosol-generating portion may comprise a cavity for receiving the source of aerosol-generating material. The aerosol-generating material may comprise a plurality of strands or strips of aerosol-generating material. For example, the aerosol-generating material may comprise a plurality of strands or strips of aerosolizable material and / or a plurality of strands or strips of an amorphous solid, as described below. In some embodiments, the aerosol-generating material is comprised of a plurality of strands or strips of aerosolizable material. The aerosol-generating material is not crimped. In alternative embodiments, the aerosol-generating material may be crimped.

[0058] In this example, a cylindrical rod of aerosol-forming material 3 comprises multiple strands and / or strips of aerosol-forming material and is surrounded by a wrapper 10 .

[0059] Multiple strands or strips of aerosol-generating material may be aligned within the aerosol-generating portion such that their longitudinal dimensions are aligned parallel to the longitudinal axis X-X' of the article 1. Alternatively, the strands or strips may be generally disposed such that their aligned longitudinal dimensions are transverse to the longitudinal axis of the article.

[0060] At least about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, or 95% of the plurality of strands or strips may be arranged such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the article. A majority of the strands or strips may be arranged such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the article. In some embodiments, between about 95% and about 100% of the plurality of strands or strips are arranged such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the article. In some embodiments, substantially all of the strands or strips are arranged in the aerosol-generating portion of the article such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the aerosol-generating portion.

[0061] The inventors have found that if the majority of the strands or strips are arranged in the aerosol-generating portion such that their longitudinal axes are parallel to the longitudinal axis of the aerosol-generating portion of the article, the force required to insert the aerosol generator into the aerosol-generating material may be relatively small, which may make the article easier to use.

[0062] In use, the aerosol-generating portion may exhibit a pressure drop of about 15 to about 40 mmH 2 O. In some embodiments, the aerosol-generating portion exhibits a pressure drop across the aerosol-generating portion of about 15 to about 30 mmH 2 O.

[0063] The aerosol-generating material has a density of about 400 mg / cm within the aerosol-generating portion. 3 ~about 900mg / cm 3 A packing density of 400 mg / cm can be achieved. A packing density higher than this can make it difficult to insert the aerosol generator of the aerosol delivery device into the aerosol-generating material, and can increase the pressure drop. 3 A packing density less than 0.05 can reduce the stiffness of the article. Additionally, if the packing density is too low, the aerosol-generating material cannot effectively grip the aerosol generator of the aerosol supply.

[0064] At least about 70% of the volume of the aerosol-generating portion is filled with the aerosol-generating material, hi some embodiments, between about 75% and about 85% of the volume of the cavity is filled with the aerosol-generating material.

[0065] In this example, the rod of aerosol-generating material 3 has a circumference of about 22.7 mm. In alternative embodiments, the rod of aerosol-generating material 3 can have any suitable circumference, for example, a circumference of about 20 mm to about 26 mm.

[0066] The article 1 is configured for use in a non-combustion aerosol delivery device that includes an aerosol generator for insertion into an aerosol-generating portion, in this example the aerosol generator is a heater, and the article is configured to receive the aerosol generator in a rod of aerosol-generating material.

[0067] In this embodiment, the wrapper 10 surrounding the rod of aerosol-generating material comprises a cellulosic material having a basis weight of greater than about 40 grams per square meter. For example, the cellulosic material can have a basis weight of about 40 gsm to about 70 gsm. The inventors have found that such a basis weight is advantageous in providing high stiffness to the rod of aerosol-generating material. In this example, the wrapper 10 comprises a paper wrapper.

[0068] The increased stiffness provided by a wrapper having a basis weight of greater than about 40 gsm may make the rod of aerosol-generating material 3 more resistant to wrinkling or other deformation due to forces experienced by the article during use, e.g., when inserting the article into a device and / or inserting a heat generator into the article. Providing a rod of aerosol-generating material with increased stiffness may be advantageous when multiple strands or strips of aerosol-generating material are aligned within the aerosol-generating portion such that their longitudinal dimensions are aligned parallel to the longitudinal axis. This is because the longitudinally aligned strands or strips of aerosol-generating material may provide the rod of aerosol-generating material with less stiffness than when the strands or strips are not aligned. The increased stiffness of the rod of aerosol-generating material may enable the article to withstand the increased forces experienced by the article during use. In other embodiments, the wrapper 10 optionally includes a barrier coating that renders the wrapper material substantially moisture impermeable. For example, a layer of aluminum foil on the wrapper 10 has been found to be particularly effective in enhancing aerosol formation within the aerosol-generating material 3. For example, the wrapper may be provided with a layer of aluminum foil having a thickness of about 4 μm to 16 μm, such as about 6 μm. Metal layers or foils other than aluminum may also be used. The total thickness of the wrapper is preferably 20 μm to 90 μm, more preferably 30 μm to 60 μm, to provide the wrapper with adequate structural integrity and heat transfer properties. The tensile force that can be applied to the wrapper before it breaks may be greater than 3,000 grams of force, such as 3,000 to 10,000 grams of force or 3,000 to 4,500 grams of force.

[0069] In this example, the wrapper 10 is also substantially non-breathable. In an alternative embodiment, the wrapper 10 preferably has a breathability of less than 100 Coresta units, more preferably less than 60 Coresta units. It has been found that low breathability wrappers, for example having a breathability of less than 100 Coresta units, more preferably less than 60 Coresta units, enhance aerosol formation in the aerosol-generating material 3. Without wishing to be bound by theory, it is hypothesized that this is due to less loss of aerosol compounds through the wrapper 10. The breathability of the wrapper 10 can be measured in accordance with ISO 2965:2009 for measurement of breathability of materials used as cigarette papers, filter plug wraps, and filter bonding papers.

[0070] Tipping paper 5 is wrapped around the entire length of mouthpiece 2 and a portion of the rod of aerosol-generating material 3 and has adhesive on its inner surface to connect mouthpiece 2 and rod 3. In this example, the rod of aerosol-generating material 3 is wrapped with wrapper 10 forming a first wrapping material, and tipping paper 5 forms an outer wrapping material that extends at least partially over the rod of aerosol-generating material 3 and connects mouthpiece 2 and rod 3. In some examples, the tipping paper may only extend partially over the rod of aerosol-generating material.

[0071] In this example, the tipping paper 5 extends 5 mm over the rod of aerosol-generating material 3, but may alternatively extend 3 mm to 10 mm, or more preferably 4 mm to 6 mm, over the rod 3 to securely attach the mouthpiece 2 to the rod 3. The tipping paper may have a basis weight of more than 20 gsm, such as more than 25 gsm, or preferably more than 30 gsm, such as 37 gsm. Basis weights in these ranges have been found to provide tipping paper with acceptable tensile strength yet sufficient flexibility to wrap around the article 1 and adhere to itself along the longitudinal lap seam of the paper. In this example, the circumference of the tipping paper 5 after being wrapped around the mouthpiece is about 23 mm.

[0072] The cooling portion 8 comprises a hollow channel having an inner diameter of about 1 mm to about 4 mm, for example about 2 mm to about 4 mm. In this example, the hollow channel has an inner diameter of about 3 mm. The hollow channel extends along the entire length of the cooling portion 8. In this example, the cooling portion 8 comprises a single hollow channel. In alternative embodiments, the cooling portion may comprise multiple channels, for example, two, three, or four channels. In this example, the single hollow channel is generally cylindrical, but in alternative embodiments, other channel shapes / cross sections may be used. The hollow channel may provide a space in which aerosol drawn into the cooling portion 8 may expand and cool. In all embodiments, the cooling portion is configured to limit the cross-sectional area of ​​the hollow channel or channels and to limit the displacement of tobacco into the cooling portion during use.

[0073] When the aerosol generator is inserted into the rod of aerosol-generating material 3, the strands and / or strips of aerosol-generating material may be displaced longitudinally into the cooling portion 8. The inventors have found that by providing the cooling portion 8 directly adjacent to the source of aerosol-generating material and by providing an internal channel having a diameter in this range, longitudinal displacement of the strands and / or strips of aerosol-generating material is advantageously reduced when the aerosol generator is inserted into the rod of aerosol-generating material. The inventors have found that reducing the displacement of the aerosol-generating material during use advantageously results in a more consistent packing density of the aerosol-generating material along the length of the rod and / or within the cavity, resulting in more consistent and improved aerosol generation.

[0074] The rod of aerosol-generating material 3 and the cooling portion 8 each have a cross-sectional area measured perpendicular to the longitudinal axis of the article 1, as shown by line X-X' in FIG. 1. The cooling portion is configured such that one or more hollow channels occupy a maximum percentage of the cross-sectional area of ​​the cooling portion, such as less than about 45% of the cross-sectional area, less than about 32% of the cross-sectional area, or less than 25% of the cross-sectional area. In this example, the hollow channels occupy about 31% of the cross-sectional area of ​​the cooling portion. Additionally or alternatively, the hollow channels may occupy at least about 4%, or at least about 6%, or at least about 8% of the cross-sectional area of ​​the cooling portion. In some examples, the hollow channels occupy between 4% and 32% of the cross-sectional area of ​​the cooling portion. Table 1 shows exemplary percentages of the cross-sectional area of ​​the cooling portion occupied by hollow channels with inner diameters of 3 mm or 3.9 mm for a range of diameters of the cooling portion. For purposes of this calculation, the cross-sectional area of ​​the cooling section is calculated based on the diameter of the cooling section without the tipping paper attached, and the measurements are based on the dimensions of the cooling section directly abutting the aerosol-generating section.

[0075] [Table 1] The cooling portion 8 preferably has a radial wall thickness, which can be measured, for example, using calipers. The wall thickness of the cooling portion 8 for a given outer diameter of the cooling portion defines the inner diameter of the cavity enclosed by the walls of the cooling portion 8. The cooling portion 8 may have a wall thickness of at least about 1.5 mm and up to about 2 mm. In the present example, the cooling portion 8 has a wall thickness of about 1.5 mm. The inventors have found that providing a cooling portion 8 with a wall thickness within this range advantageously improves retention of the source of aerosol-generating material in the aerosol-generating portion during use by reducing longitudinal displacement of strands and / or strips of aerosol-generating material when the aerosol generator is inserted into an article.

[0076] Cooling portion 8 is formed from filament tow. Multiple layers of paper wound in parallel and abutted at a seam to form cooling portion 8 may be used, or other configurations may be used, such as spirally wound layers of paper, cardboard tubes, tubes formed using co-packed paper type processes, molded or extruded plastic tubes, etc. Cooling portion 8 is manufactured to be sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacture and use of article 1.

[0077] The wall material of the cooling portion 8 may be relatively non-porous, such that at least 90% of the aerosol generated by the aerosol-generating material 3 passes longitudinally through the one or more hollow channels rather than through the wall material of the cooling portion 8. For example, at least 92% or at least 95% of the aerosol generated by the aerosol-generating material 3 may pass longitudinally through the one or more hollow channels.

[0078] The filament tows forming the cooling portion 8 preferably have a total fineness of less than 45,000, more preferably less than 42,000. This total fineness has been found to allow the formation of a cooling portion 8 that is not too dense. The total fineness is preferably at least 20,000, more preferably at least 25,000. In a preferred embodiment, the filament tows forming the cooling portion 8 have a total fineness of between 25,000 and 45,000, more preferably between 35,000 and 45,000. The cross-sectional shape of the filaments of the tow is preferably "Y" shaped, although in other embodiments other shapes may be used, such as "X" shaped filaments.

[0079] The filament tows forming the cooling portion 8 preferably have a denier per filament of greater than 3. It has been found that this denier per filament allows the formation of a tubular element 4 that is not too dense. The denier per filament is preferably at least 4, more preferably at least 5. In a preferred embodiment, the filament tows forming the hollow tubular element 4 have a denier per filament of between 4 and 10, more preferably between 4 and 9. In one example, the filament tows forming the cooling portion 8 are made of cellulose acetate and have a 8Y40,000 tow with 18% plasticizer, such as triacetin.

[0080] The density of the material forming the cooling portion 8 is preferably at least about 0.20 grams per cubic centimeter (g / cc), more preferably at least about 0.25 g / cc. The density of the material forming the cooling portion 8 is preferably less than about 0.80 grams per cubic centimeter (g / cc), more preferably less than 0.6 g / cc. In some embodiments, the density of the material forming the cooling portion 8 is between 0.20 and 0.8 g / cc, more preferably between 0.3 and 0.6 g / cc, or 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 balance between the increased hardness imparted by a denser material and minimizing the total weight of the article. For purposes of the present invention, the "density" of the material forming the cooling portion 8 refers to the density of the filament tow forming the element in which any plasticizer is incorporated. The density can be determined by dividing the total weight of the material forming the cooling portion 8 by the total volume of the material forming the cooling portion 8, which can be calculated using appropriate measurements of the material forming the cooling portion 8, for example, obtained using a caliper. If necessary, the appropriate dimensions can be measured using a microscope.

[0081] Preferably, the length of the cooling portion 8 is less than about 30 mm. More preferably, the length of the cooling portion 8 is less than about 25 mm. Even more preferably, the length of the cooling portion 8 is less than about 20 mm. Additionally or alternatively, it is preferred that the length of the cooling portion 8 is at least about 10 mm. It is preferred that the length of the cooling portion 8 is at least about 15 mm. In some preferred embodiments, the length of the cooling portion 8 is between about 15 mm and about 20 mm, more preferably between about 16 mm and about 19 mm. In this example, the length of the cooling portion 8 is 19 mm.

[0082] The cooling portion 8 is disposed around and defines a cavity in the mouthpiece 2 that acts as the cooling portion. The cavity provides a chamber through which heated volatile components generated by the aerosol-generating material 3 flow. The cooling portion 8 is hollow to provide a chamber for aerosol accumulation, yet rigid enough to withstand axial compressive forces and bending moments that may occur during manufacture and use of the article 1. The cooling portion 8 provides a physical displacement between the aerosol-generating material 3 and the body of material 6. The physical displacement provided by the cooling portion 8 can provide a temperature gradient across the length of the cooling portion 8.

[0083] Mouthpiece 2 is 110mm 3 It is preferred that the mouthpiece 2 has a cavity having an internal volume of at least 110 mm. It has been found that providing a cavity of at least this volume allows for improved aerosol formation. The mouthpiece 2 is formed, for example, in the cooling portion 8 and has an internal volume of 110 mm. 3 More than 130mm, preferably 3 More preferably, the inner cavity has an internal volume of about 130 mm or more, allowing for further improvement of the aerosol. 3 ~about 230mm 3 , for example, about 134 mm 3 Or 227mm 3 It has a volume of:

[0084] The cooling section 8 may be configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile components entering the first upstream end of the cooling section 8 and the heated volatile components exiting the second downstream end of the cooling section 8. The cooling section 8 is preferably configured to provide a temperature difference of at least 60 degrees Celsius, preferably at least 80 degrees Celsius, and more preferably at least 100 degrees Celsius, between the heated volatile components entering the first upstream end of the cooling section 8 and the heated volatile components exiting the second downstream end of the cooling section 8. This temperature difference over the length of the cooling section 8 protects the temperature sensitive body of material 6 from the high temperatures of the aerosol-generating material 3 when heated.

[0085] The body of material 6 and the hollow tubular element 4 each define a generally cylindrical overall outline and share a common longitudinal axis.

[0086] As shown in FIG. 1 , the mouthpiece 2 of the article 1 has an upstream end 2a adjacent the rod of aerosol-generating material 3 and a downstream end 2b remote from the rod of aerosol-generating material 3. At the downstream end 2b, the mouthpiece 2 has a hollow tubular element 4 formed from a filament tow. This has been found to be advantageous as it significantly reduces the temperature of the exterior surface of the mouthpiece 2 at the downstream end 2b of the mouthpiece which contacts the consumer's mouth during use of the article 1. In addition, it has been found that the use of the tubular element 4 also significantly reduces the temperature of the exterior surface of the mouthpiece 2 upstream of the tubular element 4. Without wishing to be bound by theory, it is hypothesized that this is because the tubular element 4 passes the aerosol near the center of the mouthpiece 2, thereby inhibiting the transfer of heat from the aerosol to the exterior surface of the mouthpiece 2.

[0087] The "wall thickness" of the hollow tubular element 4 corresponds to the thickness of the wall of the tube 4 in the radial direction. This can be measured, for example, using a caliper. The wall thickness is advantageously greater than 0.9 mm, more preferably greater than 1.0 mm. The wall thickness is preferably substantially constant around the entire wall of the hollow tubular element 4. However, if the wall thickness is not substantially constant, the wall thickness is preferably greater than 0.9 mm, more preferably greater than 1.0 mm, at any point around the hollow tubular element 4. In the present example, the wall thickness of the hollow tubular element 4 is approximately 1.3 mm.

[0088] The length of the hollow tubular element 4 is preferably less than about 20 mm. More preferably, the length of the hollow tubular element 4 is less than about 15 mm. Even more preferably, the length of the hollow tubular element 4 is less than about 10 mm. Additionally or alternatively, the length of the hollow tubular element 4 is at least about 5 mm. The length of the hollow tubular element 4 is preferably at least about 6 mm. In some preferred embodiments, the length of the hollow tubular element 4 is about 5 mm to about 20 mm, more preferably about 6 mm to about 10 mm, even more preferably about 6 mm to about 8 mm, and most preferably about 6 mm, 7 mm, or about 8 mm. In this example, the length of the hollow tubular element 4 is 7 mm.

[0089] The density of the hollow tubular element 4 is preferably at least about 0.25 grams per cubic centimeter (g / cc), more preferably at least about 0.3 g / cc. The density of the hollow tubular element 4 is preferably less than about 0.75 grams per cubic centimeter (g / cc), more preferably less than 0.6 g / cc. In some embodiments, the density of the hollow tubular element 4 is 0.25-0.75 g / cc, more preferably 0.3-0.6 g / cc, more preferably 0.4 g / cc-0.6 g / cc, or about 0.5 g / cc. These densities have been found to provide a good balance between the high hardness imparted by the higher density material and the lower heat transfer properties of the lower density material. For purposes of the present invention, the "density" of the hollow tubular element 4 refers to the density of the filament tow forming the element with any plasticizer incorporated therein. The density can be determined by dividing the total weight of the hollow tubular elements 4 by the total volume of the hollow tubular elements 4, which can be calculated using suitable measurements of the hollow tubular elements 4, for example obtained with a caliper. If necessary, suitable dimensions can be measured using a microscope.

[0090] The filament tows forming the hollow tubular elements 4 preferably have a total fineness of less than 45,000, more preferably less than 42,000. This total fineness has been found to allow the formation of tubular elements 4 that are not too dense. The total fineness is preferably at least 20,000, more preferably at least 25,000. In a preferred embodiment, the filament tows forming the hollow tubular elements 4 have a total fineness of between 25,000 and 45,000, more preferably between 35,000 and 45,000. The cross-sectional shape of the filaments of the tow is preferably "Y" shaped, although in other embodiments other shapes may be used, such as "X" shaped filaments.

[0091] The filament tows forming the hollow tubular elements 4 preferably have a denier per filament greater than 3. This denier per filament has been found to allow for the formation of tubular elements 4 that are not too dense. The denier per filament is preferably at least 4, more preferably at least 5. In a preferred embodiment, the filament tows forming the hollow tubular elements 4 have a denier per filament between 4 and 10, more preferably between 4 and 9. In one example, the filament tows forming the hollow tubular elements 4 are formed from cellulose acetate and have a 7.3Y36,000 tow with 18% plasticizer, such as triacetin.

[0092] Preferably, the hollow tubular element 4 has an internal diameter of more than 3.0 mm. A smaller internal diameter would result in a faster than desired velocity of the aerosol passing through the mouthpiece 2 to the consumer's mouth, which may result in the aerosol becoming too warm, for example reaching a temperature of more than 40° C. or more than 45° C. More preferably, the hollow tubular element 4 has an internal diameter of more than 3.1 mm, even more preferably more than 3.5 mm or 3.6 mm. In one embodiment, the internal diameter of the hollow tubular element 4 is about 4.7 mm.

[0093] The hollow tubular element 4 preferably comprises 15% to 22% by weight of plasticizer. In the case of cellulose acetate tow, the plasticizer is preferably triacetin, although other plasticizers such as polyethylene glycol (PEG) may be used. More preferably, the hollow tubular element 4 comprises 16% to 20% by weight of plasticizer, for example about 17%, about 18%, or about 19% plasticizer.

[0094] In this example, the first hollow tubular element 4, the body of material 6 and the cooling portion 8 are combined using a second plug wrap 9, which is wrapped around all three portions. The second plug wrap 9 preferably has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 45 gsm. The second plug wrap 9 preferably has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The second plug wrap 9 is preferably a non-porous plug wrap having an air permeability of less than 100 Coresta units, for example less than 50 Coresta units. However, in alternative embodiments, the second plug wrap 9 may be a porous plug wrap having an air permeability of, for example, more than 200 Coresta units.

[0095] In this example, the article 1 has a circumference of about 23 mm. In other examples, the article may be provided in any of the formats described herein, for example, having a circumference of 20 mm to 26 mm. Since the article is heated to release an aerosol, improved heating efficiency can be achieved using an article having a smaller circumference within this range, for example, a circumference of less than 23 mm. It has also been found that an article circumference of more than 19 mm is particularly effective for achieving improved aerosol upon heating while maintaining a suitable product length. An article having a circumference of 20 mm to 24 mm, more preferably 20 mm to 23 mm, has been found to provide a good balance between providing effective aerosol delivery and allowing efficient heating. The rod of aerosol-generating material 3 preferably has a length of less than about 25 mm, preferably less than about 20 mm, preferably less than about 15 mm. In this example, the rod of aerosol-generating material 3 has a length of about 12 mm.

[0096] The aerosol-generating material comprises a sheet or chopped sheets of aerosolizable material arranged to generate an aerosol upon heating.

[0097] The sheet or shredded sheet has a first side and a second side opposite the first side. The first and second sides are of matching dimensions. The first and second sides of the sheet or shredded sheet can have any shape. For example, the first and second sides can be square, rectangular, oval, or circular. Irregular shapes are also envisioned.

[0098] The first and / or second sides of the sheet or shredded sheet may be relatively uniform (e.g., relatively smooth) or may be uneven or irregular. For example, the first and / or second sides of the sheet may be textured or patterned to define a relatively rough surface. In some embodiments, the first and / or second sides are relatively rough.

[0099] The smoothness of the first and second surfaces can be affected by several factors, such as the surface density of the sheet or chopped sheet, the nature of the components that make up the aerosolizable material, or whether the surface of the material has been treated, e.g., embossed, engraved, or otherwise modified, to impart a pattern or texture.

[0100] The area of ​​the first and second sides is defined by a first dimension (e.g., width) and a second dimension (e.g., length), respectively. The measurements of the first and second dimensions can have a ratio of 1:1 or more than 1:1, and thus the sheet or shredded sheet can have an "aspect ratio" of 1:1 or more than 1:1. As used herein, the term "aspect ratio" is the ratio of the measurement of the first dimension of the first or second side to the measurement of the second dimension of the first or second side. "Aspect ratio of 1:1" means that the measurement of the first dimension (e.g., width) and the measurement of the second dimension (e.g., length) are the same. "Aspect ratio of more than 1:1" means that the measurement of the first dimension (e.g., width) and the measurement of the second dimension (e.g., length) are different. In some embodiments, the first and second sides of the sheet or chopped sheet have an aspect ratio of greater than 1:1, such as 1:2, 1:3, 1:4, 1.5, 1:6, 1:7, or more.

[0101] The chopped sheet can comprise one or more strands or strips of aerosolizable material. In some embodiments, the chopped sheet comprises multiple (e.g., two or more) strands or strips of aerosolizable material. The strands or strips of aerosolizable material can have an aspect ratio of 1:1. In embodiments, the strands or strips of aerosolizable material have an aspect ratio of greater than 1:1. In some embodiments, the strands or strips of aerosolizable material have an aspect ratio of about 1.5 to about 1:16, i.e., about 1.5, 1:6, 1:7, 1:8, 1:9, 1:10, 1:11, or 1:12. When the aspect ratio of the strands or strips is greater than 1:1, the strands or strips include a longitudinal dimension or length that extends between a first end of the strand or strip and a second end of the strand or strip.

[0102] When a chopped sheet comprises a plurality of strands or strips of material, the dimensions of each strand or strip may vary among different strands or strips. For example, a chopped sheet may include a first population of strands or strips and a second population of strands or strips, where the dimensions of the strands or strips of the first population are different from the dimensions of the strands or strips of the second population. In other words, the plurality of strands or strips may include a first population of strands or strips having a first aspect ratio and a second population of strands or strips having a second aspect ratio that is different from the first aspect ratio.

[0103] The first dimension, i.e., the cut width, of the strands or strips of aerosolizable material is between 0.9 mm and 1.5 mm. The inventors have found that when strands or strips of aerosolizable material having a cut width less than 0.9 mm are incorporated into an article for use in a non-combustion aerosol delivery system, the pressure drop across the article may increase to a level that renders the article unsuitable for use in a non-combustion aerosol delivery device. However, if the strands or strips have a cut width greater than 2 mm (e.g., greater than 2 mm), it may be difficult to insert the strands or strips of aerosolizable material into the article during manufacture. In a preferred embodiment, the cut width of the strands or strips of aerosolizable material is between about 1 mm and 1.5 mm.

[0104] The strands or strips of material are formed by chopping a sheet of aerosolizable material. The sheet of aerosolizable material may be cut transversely, for example in a cross-cut chopping process, to define a cut length of the strands or strips of aerosolizable material in addition to a cut width. The cut length of the chopped aerosolizable material is preferably at least 5 mm, for example at least 10 mm, or at least 20 mm. The cut length of the chopped aerosolizable material may be less than 60 mm, less than 50 mm, or less than 40 mm.

[0105] In some embodiments, a plurality of strands or strips of aerosolizable material are provided, and at least one of the plurality of strands or strips of aerosolizable material has a length greater than about 10 mm. Alternatively or additionally, at least one of the plurality of strands or strips of aerosolizable material can have a length between about 10 mm and about 60 mm, or between about 20 mm and about 50 mm. Each of the plurality of strands or strips of aerosolizable material can have a length between about 10 mm and about 60 mm, or between about 20 mm and about 50 mm.

[0106] The sheet or chopped sheet of aerosolizable material has a thickness of at least about 100 μm. The sheet or chopped sheet can have a thickness of at least about 120 μm, 140 μm, 160 μm, 180 μm, or 200 μm. In some embodiments, the sheet or chopped sheet has a thickness of about 150 μm to about 300 μm, about 151 μm to about 299 μm, about 152 μm to about 298 μm, about 153 μm to about 297 μm, about 154 μm to about 296 μm, about 155 μm to about 295 μm, about 156 μm to about 294 μm, about 157 μm to about 293 μm, about 158 ​​μm to about 292 μm, about 159 μm to about 291 μm, or about 160 μm to about 290 μm. In some embodiments, the sheet or shredded sheet has a thickness of about 170 μm to about 280 μm, about 180 to about 270 μm, about 190 to about 260 μm, about 200 μm to about 250 μm, or about 210 μm to about 240 μm.

[0107] The thickness of the sheet or chopped sheet may vary between the first and second sides. In some embodiments, the individual strips or sections of aerosolizable material have a minimum thickness of about 100 μm across their area. In some cases, the individual strips or sections of aerosolizable material have a minimum thickness of about 0.05 mm or about 0.1 mm across their area. In some cases, the individual strips, strands, or sections of aerosolizable material have a maximum thickness of about 1.0 mm across their area. In some cases, the individual strips or sections of aerosolizable material have a maximum thickness of about 0.5 mm or about 0.3 mm across their area.

[0108] The thickness of the sheet may be determined using ISO 534:2011 "Paper and paperboard - Measurement of thickness".

[0109] The inventors have determined that if the sheet or shredded sheet of aerosolizable material is too thick, the heating efficiency may be reduced. This may negatively impact the power consumption during use, for example, the power consumption to release the fragrance from the aerosolizable material. Conversely, if the aerosolizable material is too thin, it may be difficult to manufacture and handle. Very thin materials are more difficult to cast and may be prone to breaking, which may interfere with aerosol formation during use.

[0110] It is hypothesized that if the sheet or chopped sheet of aerosolizable material is too thin (e.g., less than 100 μm), the chopped sheet may need to be cut to a larger width in order to achieve sufficient loading of the aerosolizable material when it is incorporated into an article. As previously mentioned, increasing the chopped sheet cut width is undesirable as it may increase the pressure drop.

[0111] Approximately 100g / m 2 ~about 250g / m 2 It is hypothesized that a sheet or chopped sheet having a thickness of at least about 100 μm with an areal density of at least about 100 μm will be less likely to tear, crack, or otherwise deform during manufacturing. A thickness of at least about 100 μm can have a favorable effect on the overall structural integrity and strength of the sheet or chopped sheet. For example, this thickness can have good tensile strength and therefore be relatively easy to process. The thickness of the sheet or chopped sheet may also be related to its areal density, i.e., increasing the thickness of the sheet or chopped sheet may increase the areal density of the sheet or chopped sheet.

[0112] Conversely, decreasing the thickness of the sheet or chopped sheet may decrease the areal density of the sheet or chopped sheet. For the avoidance of doubt, when areal density is referred to herein, it refers to the average areal density calculated for a given strip, strand, section, or sheet of aerosolizable material, which is calculated by measuring the surface area and weight of the given strip, strand, section, or sheet of aerosolizable material.

[0113] The sheet or chopped sheet of aerosol-generating material has a mass of about 100 g / m 2 ~about 250g / m 2 The sheet or shredded sheet has an areal density of about 110 g / m 2 ~about 240g / m 2 , about 120g / m 2 ~about 230g / m 2 , about 130g / m 2 ~about 220g / m 2 , or about 140 g / m 2 ~about 210g / m 2 In some embodiments, the sheet or shredded sheet may have an areal density of about 130 g / m 2 ~Approx. 190g / m 2 , about 140g / m 2 ~Approx. 180g / m 2 , about 150g / m 2 ~Approx. 170g / m 2 In a preferred embodiment, the sheet or shredded sheet has an areal density of about 160 g / m 2 has an areal density of

[0114] Approximately 100g / m 2 ~about 250g / m 2 It is believed that the areal density of about 180 gsm contributes to the strength and flexibility of the sheet or shredded sheet. Furthermore, the inventors have found that a rod comprising a shredded sheet of aerosolizable material having an areal density of about 180 gsm and a minimum thickness of 220-230 μm can be loaded such that the aerosolizable material stays in place within the rod, maintains a desired weight of tobacco material (e.g., about 300 mg) within the rod, and delivers acceptable organoleptic characteristics (e.g., taste and odor) when heated in a non-combustion aerosol delivery device.

[0115] The flexibility of the sheet or chopped sheet is believed to depend, at least in part, on the thickness and areal density of the sheet or chopped sheet. A thicker sheet or chopped sheet may be less flexible than a thinner sheet or chopped sheet. Also, the greater the areal density of the sheet, the less flexible the sheet or chopped sheet. It is believed that the combination of thickness and areal density of the aerosolizable material described herein provides a relatively flexible sheet or chopped sheet. This flexibility can provide various advantages when the aerosolizable material is incorporated into an article for use in a non-combustion aerosol delivery device. For example, when an aerosol generator is inserted into the aerosol generating material, the strands or strips can easily deform and bend, facilitating the insertion of the aerosol generator (e.g., a heater) into the material and improving the retention of the aerosol generator by the aerosolizable material.

[0116] The inventors have found that the areal density of the sheet or chopped sheet of aerosol-generating material affects the roughness of the first and second sides of the sheet or chopped sheet. By varying the areal density, the roughness of the first and / or second sides can be adjusted.

[0117] The average volume density of a sheet or chopped sheet of aerosol-generating material can be calculated from the thickness of the sheet and the areal density of the sheet. The average volume density is about 0.2 g / cm 3 Super, about 0.3g / cm 3 or about 0.4 g / cm 3 In some embodiments, the average bulk density is about 0.2 g / cm 3 ~Approx. 1g / cm 3 , about 0.3g / cm 3 ~Approx. 0.9g / cm 3 , about 0.4g / cm 3 ~Approx. 0.9g / cm 3 , about 0.5g / cm 3 ~Approx. 0.9g / cm 3 , or about 0.6 g / cm 3 ~Approx. 0.9g / cm 3 may be also possible.

[0118] According to an aspect of the disclosure, a method for producing an aerosolizable material is provided comprising the steps of: providing a sheet or chopped sheet of aerosolizable material comprising a tobacco material, an aerosol-forming material, and a binder, the sheet or chopped sheet having a viscosity of about 0.4 g / cm 3 In some embodiments, the density is greater than about 0.4 g / cm. 3 ~Approx. 2.9g / cm 3 , about 0.4g / cm 3 ~Approx. 1g / cm 3 , approx. 0.6 cm 3 ~ approx. 1.6cm 3 , or about 1.6 cm 3 ~Approx. 2.9cm 3 It is.

[0119] The sheet or shredded sheet may have a tensile strength of at least 4N / 15mm.

[0120] The inventors have found that if the sheet or chopped sheet has a tensile strength of less than 4N / 15mm, the sheet or chopped sheet is prone to tearing, breaking, or otherwise deforming during manufacture and / or subsequent incorporation into an article for use in a non-flammable aerosol delivery system. Tensile strength may be measured using ISO 1924:2008.

[0121] The aerosol-forming material comprises a tobacco material. The sheet or shredded sheet of aerosolizable material comprises a tobacco material.

[0122] The tobacco material may be a particulate or granular material. In some embodiments, the tobacco material is a powder. Alternatively or in addition, the tobacco material may comprise tobacco flakes, strands, or fibers. For example, the tobacco material may comprise tobacco particles, granules, fibers, flakes, and / or strands. In some embodiments, the tobacco material is comprised of particles or granules of tobacco material.

[0123] The density of the tobacco material affects the rate at which heat is conducted through the material, with lower densities, for example densities below 900 mg / cc, allowing for a more sustained aerosol release as heat is conducted through the material more slowly.

[0124] The tobacco material can include a reconstituted tobacco material, such as a paper reconstituted tobacco material, having a density of less than about 900 mg / cc. For example, the aerosol-forming material can include a reconstituted tobacco material having a density of less than about 800 mg / cc. Alternatively or in addition, the aerosol-forming material can include a reconstituted tobacco material having a density of at least 350 mg / cc.

[0125] The reconstituted tobacco material may be provided in the form of a shredded sheet. The sheet of reconstituted tobacco material may have any suitable thickness. The reconstituted tobacco material may have a thickness of at least about 0.145 mm, such as at least about 0.15 mm or at least about 0.16 mm. The reconstituted tobacco material may have a maximum thickness of about 0.30 mm or 0.25 mm, for example, the reconstituted tobacco material may have a thickness of less than about 0.22 mm or less than about 0.2 mm. In some embodiments, the reconstituted tobacco material may have an average thickness in the range of 0.175 mm to 0.195 mm.

[0126] In some embodiments, the tobacco is a particulate tobacco material. Each particle of the particulate tobacco material can have a maximum dimension. As used herein, the term "maximum dimension" refers to the longest linear distance from any point on the surface or face of a particle of tobacco to any other point on the surface or face of the same particle of tobacco. The maximum dimension of a particle of a particulate tobacco material can be measured using scanning electron microscopy (SEM).

[0127] The maximum dimension of each particle of the tobacco material may be up to about 200 μm. In some embodiments, the maximum dimension of each particle of the tobacco material is up to about 150 μm.

[0128] The population of particles of the tobacco material may have a particle size distribution (D90) of at least about 100 μm. In some embodiments, the population of particles of the tobacco material has a particle size distribution (D90) of at least about 110 μm, at least about 120 μm, at least about 130 μm, at least about 140 μm, or at least about μm. In embodiments, the population of particles of the tobacco material has a particle size distribution (D90) of about 150 μm. Sieve analysis may be used to determine the particle size distribution of the particles of the tobacco material.

[0129] A particle size distribution (D90) of at least about 100 μm is believed to contribute to the tensile strength of a sheet or chopped sheet of aerosolizable material.

[0130] The inventors have found that a particle size distribution (D90) of less than 100 μm provides a sheet or shredded sheet of aerosolizable material with good tensile strength. However, the inclusion of such fine particles of tobacco material in the sheet or shredded sheet may result in a high density of the sheet or shredded sheet. When the sheet or shredded sheet is incorporated into an article for use in a non-burning aerosol delivery system, this higher density may reduce the loading value of the tobacco material. The inventors have found that a particle size distribution (D90) of at least about 100 μm advantageously achieves a balance between sufficient tensile strength and suitable density (and therefore loading value).

[0131] The particle size of the particulate tobacco material can also affect the roughness of the sheet or chopped sheet of aerosol-generating material. It is hypothesized that forming a sheet or chopped sheet of aerosol-generating material by incorporating relatively large particles of tobacco material reduces the density of the sheet or chopped sheet of aerosol-generating material.

[0132] The tobacco material can include tobacco obtained from any part of the tobacco plant. In some embodiments, the tobacco material includes tobacco leaf. The sheet or shredded sheet can include from 5% to about 90% tobacco leaf by weight.

[0133] The tobacco material can include laminar tobacco and / or tobacco stems, such as midrib stems. Laminar tobacco can be present in an amount of 0% to about 100%, about 20% to about 100%, about 40% to about 100%, about 40% to about 95%, about 45% to about 90%, about 50% to about 85%, or about 55% to about 80% by weight of the sheet or shredded sheet and / or tobacco material. In some embodiments, the tobacco material consists or consists essentially of laminar tobacco material.

[0134] The tobacco material may include tobacco stems in an amount of from 0% to about 100%, from about 0% to about 50%, from about 0 to about 25%, from about 0 to about 20%, or from about 5 to about 1.5% by weight of the sheet or shredded sheet.

[0135] In some embodiments, the tobacco material comprises a combination of lamina and tobacco stems. In some embodiments, the tobacco material can comprise about 40% to about 95% of the lamina and about 5% to about 60% of the stems, or about 60% to about 95% of the lamina and about 5% to about 40% of the stems, or about 80% to about 95% of the lamina and about 5% to about 20% of the stems, by weight of the sheet or shredded sheet of aerosolizable material.

[0136] The inventors have found that the incorporation of stems can reduce the stickiness of the aerosolizable material. The inventors have also found that the incorporation of tobacco materials, including stem tobacco, into the aerosolizable material unexpectedly increases its burst strength.

[0137] The sheet or chopped sheet of aerosolizable material may have a burst strength of at least about 75 g, at least about 100 g, or at least about 200 g.

[0138] If the burst strength is too low, the sheet or chopped sheet may be relatively brittle. As a result, fracture of the sheet or chopped sheet may occur during the manufacturing process of the aerosolizable material. For example, when the sheet is chopped to form the chopped sheet by a cutting process, the sheet may crumble or break into pieces or fragments upon cutting.

[0139] The tobacco material described herein contains nicotine. The nicotine content may be 0.1-3% by weight of the tobacco material, for example 0.5-2.5% by weight of the tobacco material. Additionally or alternatively, the tobacco material comprises 10%-90% by weight of tobacco leaves having a nicotine content of more than about 1% or more than about 1.5% by weight of the tobacco leaves. Tobacco leaves, for example cut rag tobacco, have a nicotine content of, for example, 1%-5% by weight of the tobacco leaves. The sheet or chopped sheet of aerosolizable material may include nicotine in an amount of about 0.1% to about 3% by weight of the sheet or chopped sheet.

[0140] Reconstituted tobacco paper may be present in the aerosol-generating materials described herein. Reconstituted tobacco paper refers to tobacco material formed by a process in which tobacco raw material is extracted with a solvent to obtain a residue containing soluble extract and fibrous material, and then (usually after concentration, optionally after further processing) the extract is recombined with fibrous material from the residue by depositing the extract on the fibrous material (usually after purification of the fibrous material, optionally with the addition of a portion of non-tobacco fiber). The recombination process is similar to the papermaking process.

[0141] The reconstituted tobacco paper may be any type of reconstituted tobacco paper known in the art. In certain embodiments, the reconstituted tobacco paper is made from raw materials including one or more of tobacco shreds, tobacco stems, and whole tobacco. In further embodiments, the reconstituted tobacco paper is made from raw materials consisting of tobacco shreds and / or whole tobacco, and tobacco stems. However, in other embodiments, chips, fines, and rice husks may be used instead or in addition to the raw materials.

[0142] Reconstituted tobacco for use in the tobacco materials described herein may be prepared by methods known to those skilled in the art for preparing reconstituted tobacco.

[0143] In embodiments, the reconstituted tobacco is present in an amount between 5% and 90%, between 10% and 80%, or between 20% and 70% by weight of the aerosol-forming material.

[0144] The aerosol generating material includes an aerosol forming material. The aerosol forming material includes one or more components capable of forming an aerosol. The aerosol forming material includes one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. The aerosol forming material is preferably glycerol or propylene glycol.

[0145] The sheet or chopped sheet of aerosolizable material includes an aerosol-forming material. The aerosol-forming material is provided in an amount of up to about 50% by weight of the sheet or chopped sheet on a dry weight basis. In some embodiments, the aerosol-forming material is provided in an amount of about 5% to about 40% by weight of the sheet or chopped sheet on a dry weight basis, about 10% to about 30% by weight of the sheet or chopped sheet on a dry weight basis, or about 10% to about 20% by weight of the sheet or chopped sheet on a dry weight basis.

[0146] The sheet or chopped sheet may also include water. The sheet or chopped sheet of aerosolizable material may include water in an amount of less than about 15%, less than about 10%, or less than about 5% by weight of the aerosolizable material. In some embodiments, the aerosolizable material includes water in an amount of about 0% to about 15% or about 5% to about 15% by weight of the aerosolizable material.

[0147] The sheet or chopped sheet of aerosolizable material may include water and aerosol-forming materials in a total amount of less than about 30% by weight of the sheet or chopped sheet of aerosolizable material, or less than about 25% by weight of the sheet or chopped sheet of aerosolizable material. Incorporating water and aerosol-forming materials into the sheet or chopped sheet of aerosolizable material in an amount of less than about 30% by weight of the sheet or chopped sheet of aerosolizable material may advantageously reduce the stickiness of the sheet. This may improve the ease with which the aerosolizable material can be handled during processing. For example, it may be easier to roll a sheet of aerosolizable material to form a bobbin of material and then unwind the bobbin without the layers of the sheet sticking to each other. Reducing stickiness may also reduce the tendency of strands or pieces of chopped material to clump together or stick to each other, further improving processing efficiency and final product quality.

[0148] The sheet or chopped sheet includes a binder. The binder is arranged to bind the components of the aerosol-forming material to form the sheet or chopped sheet. The binder can at least partially coat a surface of the tobacco material. If the tobacco material is in particulate form, the binder can at least partially coat a surface of the tobacco particles to bind the particles together. The binder may be selected from one or more compounds selected from the group consisting of alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the binder comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, gum arabic, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the binder comprises alginate and / or pectin or carrageenan. In a preferred embodiment, the binder comprises guar gum.

[0149] The binder may be present in an amount of about 1 to about 20% by weight of the sheet or chopped sheet, or 1 to about 10% by weight of the sheet or chopped sheet of aerosolizable material. For example, the binder may be present in an amount of about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, or 10% by weight of the sheet or chopped sheet of aerosolizable material.

[0150] The aerosol-generating material may include a filler. In some embodiments, the sheet or shredded sheet includes a filler. The filler is typically a non-tobacco component, i.e., a component that does not include tobacco-derived raw materials. The filler may include one or more inorganic filler materials, for example, 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 be a non-tobacco fiber, such as wood fiber or wood pulp or wheat fiber. The filler may be a material that includes cellulose or a material that includes a derivative of cellulose. The filler component may be a non-tobacco cast material or a non-tobacco extrusion material.

[0151] In certain embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material, such as wood, wood pulp, hemp fiber, cellulose, or a cellulose derivative. Without wishing to be bound by theory, it is believed that the inclusion of fibrous fillers can increase the tensile strength of the material.

[0152] Fillers can also contribute to the texture of the sheet or chopped sheet of aerosolizable material. For example, a fibrous filler, such as wood or wood pulp, can provide a sheet or chopped sheet of aerosolizable material with relatively rough first and second sides. Conversely, a non-fibrous particulate filler, such as powdered chalk, can provide a sheet or chopped sheet of aerosolizable material with relatively smooth first and second sides. In some embodiments, the aerosolizable material includes a combination of different filler materials. The filler component may be present in an amount of 0-20% by weight of the sheet or chopped sheet, or in an amount of 1-10% by weight of the sheet or chopped sheet, hi some embodiments, no filler component is present.

[0153] Fillers can serve to improve general structural properties such as tensile strength and burst strength of the aerosolizable material.

[0154] In the compositions described herein, when amounts are given in weight percent, for the avoidance of doubt, this refers to a dry weight basis, unless expressly stated otherwise. Thus, any water that may be present in the aerosol-forming material, or any component thereof, is completely ignored for purposes of determining the weight percent. The water content of the aerosol-forming material described herein may vary, and may be, for example, 5-15% by weight. The water content of the aerosol-forming material described herein may vary, for example, depending on the temperature, pressure, and humidity conditions under which the composition is maintained. The water content may be determined by Karl-Fischer analysis, as known to those skilled in the art. However, for the avoidance of doubt, even if the aerosol-forming material is a liquid phase component, such as glycerol or propylene glycol, any component other than water is included in the weight of the aerosol-forming material. However, when an aerosol-forming material is provided to the tobacco component of the aerosol-forming material, or to the filler component (if present) of the aerosol-forming material, instead of or in addition to being added separately to the aerosol-forming material, the aerosol-forming material is not included in the weight of the tobacco component or filler component, but is included in the weight of the "aerosol-forming material" in weight percent as defined herein. Any other materials present in the tobacco component are included in the weight of the tobacco component, even if they are of non-tobacco origin (eg, non-tobacco fiber in the case of reconstituted tobacco). The aerosol-generating material herein may include an aerosol modifying agent, such as any of the flavorants described herein. In one embodiment, the aerosol-generating material includes menthol. When the aerosol-generating material is incorporated into an article for use in an aerosol delivery system, the article may be referred to as a mentholated article. The aerosol-generating material may include 0.5 mg to 20 mg of menthol, 0.7 mg to 20 mg of menthol, 1 mg to 18 mg, or 8 mg to 16 mg of menthol. In this example, the aerosol-generating material includes 16 mg of menthol. The aerosol-generating material may include 1% to 8% by weight of menthol, preferably 3% to 7% by weight of menthol, more preferably 4% to 5.5% by weight of menthol. In one embodiment, the aerosol-generating material includes 4.7% by weight of menthol. Such high levels of menthol loading may be achieved using a high percentage of reconstituted tobacco material, for example greater than 50% by weight of the tobacco material. Alternatively or additionally, for example, using a larger amount of tobacco material, a higher level of menthol loading can be achieved, for example about 500 mm 3 More than, or preferably about 1000 mm 3 In one embodiment, an aerosol-forming material such as a tobacco material is used. In some embodiments, the composition comprises an aerosol-forming "amorphous solid," which may also be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may comprise a dry gel. An amorphous solid is a solid material that is capable of holding some fluid, such as a liquid, within it.

[0155] In some instances, the amorphous solid is 1 to 60 wt % of a gelling agent; 0.1 to 50 wt % of an aerosol-forming material; Contains 0.1 to 80 wt% of a fragrance, These weights are calculated on a dry weight basis. In some further embodiments, the amorphous solid is 1 to 50 wt % of a gelling agent; 0.1 to 50 wt % of an aerosol-forming material; Contains 30 to 60 wt% of fragrance, These weights are calculated on a dry weight basis.

[0156] The amorphous solid material may be provided in the form of a sheet or chopped sheets. The amorphous solid material may take the same form as the sheets or chopped sheets of aerosolizable material, as described above.

[0157] Suitably, the amorphous solid can 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%, or 35 wt% of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid can comprise from 1 to 50 wt%, 5 to 45 wt%, 10 to 40 wt%, or 20 to 35 wt% of a gelling agent. In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group including alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohols, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum guar gum, carrageenan, agarose, gum arabic, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some embodiments, the gelling agent comprises alginate and / or pectin and may be mixed with a hardening agent (such as a calcium source) during formation of the amorphous solid. In some embodiments, the amorphous solid may comprise calcium cross-linked alginate and / or calcium cross-linked pectin.

[0158] In some embodiments, the gelling agent comprises alginate, and the alginate is present in the amorphous solid in an amount of 10-30 wt% of the amorphous solid (calculated on a dry weight basis). 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 further gelling agent, such as pectin.

[0159] In some embodiments, the amorphous solid may include a gelling agent that includes carrageenan.

[0160] Suitably, the amorphous solid can 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-forming material (all calculated on a dry weight basis). The aerosol-forming material can act as a plasticizer. For example, the amorphous solid can comprise from 0.5 to 40 wt%, from 3 to 35 wt%, or from 10 to 25 wt% of the aerosol-forming material. In some cases, the aerosol-forming material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some cases, the aerosol-forming material comprises, consists essentially of, or consists of glycerol.

[0161] The amorphous solid comprises a flavouring. Suitably, the amorphous solid can comprise up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% flavouring. In some cases, the amorphous solids can include at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% flavoring (all calculated on a dry weight basis).

[0162] For example, the amorphous solid can include 1-80 wt%, 10-80 wt%, 20-70 wt%, 30-60 wt%, 35-55 wt%, or 30-45 wt% flavoring. In some cases, the flavoring includes, consists essentially of, or consists of menthol.

[0163] In some cases, the amorphous solids may further comprise an emulsifier that emulsifies the molten flavor during manufacture. For example, the amorphous solids may comprise about 5 wt% to about 15 wt%, preferably about 10 wt%, of an emulsifier (calculated on a dry weight basis). The emulsifier may include gum arabic.

[0164] 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 can contain less than about 15 wt%, 12 wt%, or 10 wt% water, calculated on a wet weight basis. In some cases, the hydrogel can contain at least about 1 wt%, 2 wt%, or at least about 5 wt% water (on a wet weight basis).

[0165] In some embodiments, the amorphous solid further comprises an active substance. For example, in some cases, the amorphous solid further comprises tobacco material and / or nicotine. In some cases, the amorphous solid can comprise 5 to 60 wt% tobacco material and / or nicotine (calculated on a dry weight basis). In some cases, the amorphous solid can comprise 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% (calculated on a dry weight basis) of an active substance. In some cases, the amorphous solid can comprise 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% (calculated on a dry weight basis) of tobacco material. For example, the amorphous solid can comprise 10-50 wt%, 15-40 wt%, or 20-35 wt% of tobacco material. In some cases, the amorphous solid can comprise about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% of nicotine (calculated on a dry weight basis). For example, the amorphous solid can comprise 1-20 wt%, 2-18 wt%, or 3-12 wt% of nicotine.

[0166] In some cases, the amorphous solid comprises an active agent such as tobacco extract. In some cases, the amorphous solid can comprise 5-60 wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the amorphous solid can comprise about 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of tobacco extract. For example, the amorphous solid can comprise 10-50 wt%, 15-40 wt%, or 20-35 wt% of tobacco extract. The tobacco extract can 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).

[0167] In some cases, no nicotine other than that obtained from the tobacco extract may be present in the amorphous solid.

[0168] In some embodiments, the amorphous solid does not include tobacco material, but does include nicotine. In some such cases, the amorphous solid can 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 can include from 1 to 20 wt%, 2 to 18 wt%, or 3 to 12 wt% nicotine.

[0169] In some cases, the total content of actives and / or fragrances 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 total content of actives and / or fragrances 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).

[0170] In some cases, the total content of tobacco material, nicotine, and flavorings 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 total content of actives and / or flavorings 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).

[0171] The amorphous solid may be made of a gel, which may further include a solvent present at 0.1-50 wt%. However, the present inventors have found that the inclusion of a solvent in which the fragrance dissolves may reduce the stability of the gel, and the fragrance may crystallize from the gel. Thus, in some cases, the gel does not include a solvent in which the fragrance dissolves.

[0172] In some embodiments, the amorphous solid comprises less than 60 wt% of the filler, for example, 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%.

[0173] In other embodiments, the amorphous solid comprises less than 20 wt%, preferably less than 10 wt%, or less than 5 wt% of a filler. In some cases, the amorphous solid comprises less than 1 wt% of a filler, and in some cases, no filler.

[0174] When present, the filler may comprise one or more inorganic filler materials, such as 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 filler materials, such as wood pulp, cellulose, and cellulose derivatives. In certain cases, the amorphous solid does not comprise calcium carbonate, such as chalk.

[0175] In certain embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material, such as wood pulp, hemp fiber, cellulose, or a cellulose derivative. Without wishing to be bound by theory, it is believed that the inclusion of a fibrous filler in an amorphous solid can increase the tensile strength of the material.

[0176] In some embodiments, the amorphous solid does not include tobacco fiber.

[0177] In some cases, the amorphous solid in the form of a sheet may have a tensile strength of about 200 N / m to about 1500 N / m. In some cases, such as where 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. Such tensile strengths may be particularly suitable for embodiments in which the amorphous solid material is formed into a sheet and then chopped and incorporated into an aerosol product.

[0178] In some instances, such as when the amorphous solid comprises a filler, the amorphous solid may have a tensile strength of from 600 N / m to 1500 N / m, or from 700 N / m to 900 N / m, or about 800 N / m. Such tensile strengths may be particularly suitable for embodiments in which the amorphous solid material is included in the aerosol product article as a rolled sheet, preferably in the form of a tube.

[0179] In some cases, the amorphous solid may consist essentially of, or consist of, a gelling agent, water, an aerosol forming material, a flavoring agent, and optionally an active agent.

[0180] In some cases, the amorphous solid may consist essentially of or consist of gelling agents, water, aerosol forming materials, flavorings, and optionally tobacco materials and / or a nicotine source.

[0181] The amorphous solid can include one or more active agents and / or flavorings, one or more aerosol forming materials, and optionally one or more other functional materials.

[0182] The aerosol-generating material may comprise a paper reconstituted tobacco material. The composition may alternatively or additionally comprise any of the tobacco forms described herein. The aerosol-generating material may comprise a sheet or shredded sheet comprising a tobacco material comprising 10% to 90% by weight of tobacco leaves, the aerosol-forming material being provided in an amount of up to about 20% by weight of the sheet or shredded sheet, the remainder of the tobacco material comprising paper reconstituted tobacco.

[0183] When the aerosol-forming material comprises an amorphous solid material, the amorphous solid material may be a dry gel comprising menthol, hi alternative embodiments, the amorphous solid may have any of the compositions described herein.

[0184] The inventors have discovered that improved articles can be advantageously produced that comprise an aerosol-generating material that includes a first component that includes a sheet or chopped sheets of aerosolizable material and a second component that includes an amorphous solid, and that have material properties (e.g., density) and specifications (e.g., thickness, length, and cut width) that are within the ranges described herein.

[0185] In some cases, the amorphous solid can have a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness can range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm. The inventors have found that materials having a thickness of about 0.09 mm can be used. The amorphous solid can include two or more layers, and the thicknesses described herein refer to the combined thickness of these layers.

[0186] The thickness of the amorphous solid material can be measured using calipers or a microscope, such as a scanning electron microscope (SEM), as known to those of skill in the art, or any other suitable technique known to those of skill in the art.

[0187] The inventors have confirmed that if the amorphous solid is too thick, the heating efficiency may decrease. This may adversely affect the power consumption during use, for example, the power consumption for releasing the fragrance from the amorphous solid. Conversely, if the amorphous solid for aerosol formation is too thin, it may be difficult to manufacture and handle. Very thin materials are more difficult to cast, are more likely to break, and may interfere with aerosol formation during use. In some cases, each strip or slice of the amorphous solid has a minimum thickness of about 0.015 across its area. In some cases, each strip or slice of the amorphous solid has a minimum thickness of about 0.05 mm or about 0.1 mm across its area. In some cases, each strip or slice of the amorphous solid has a maximum thickness of about 1.0 mm across its area. In some cases, each strip or slice of the amorphous solid has a maximum thickness of about 0.5 mm or about 0.3 mm across its area.

[0188] In some cases, the thickness of the amorphous solid may vary by no more than 25%, 20%, 15%, 10%, 5%, or 1% over its area.

[0189] The inventors have found that by providing sheets or chopped sheets of amorphous solid material and aerosolizable material that have areal density values ​​that differ from each other by less than a given percentage, the mixture of these materials is less likely to separate. In some examples, the areal density of the amorphous solid material may be between 50% and 150% of the areal density of the aerosolizable material. For example, the areal density of the amorphous solid material may be between 60% and 140% of the areal density of the aerosolizable material, or between 70% and 110% of the areal density of the aerosolizable material, or between 80% and 120% of the areal density of the aerosolizable material.

[0190] In the embodiments described herein, the amorphous solid material may be incorporated into the article in the form of a sheet. Suitably, the amorphous solid material in the form of a sheet may be chopped before being incorporated into the article and mixed into an aerosolizable material, such as a sheet or chopped sheet of the aerosolizable material described herein.

[0191] In further embodiments, the sheet of the amorphous solid can further be incorporated as a flat sheet, as a collected or bound sheet, as a pressed sheet, or as a rolled sheet (i.e., in the form of a tube). In some such cases, the amorphous solid of these embodiments may be included in the aerosol product as a sheet, such as a sheet surrounding a rod containing an aerosolizable material. For example, the sheet of the amorphous solid may be formed into a wrapping paper that surrounds an aerosolizable material such as tobacco.

[0192] The amorphous solid in the form of a sheet has a mass of about 30 g / m 2 ~about 150g / m 2 In some cases, the sheet may have a density of about 55 g / m 2 ~Approx. 135g / m 2 , or about 80 to about 120 g / m 2, or about 70 to about 110 g / m 2 , or in particular from about 90 to about 110 g / m 2 or preferably about 100 g / m 2 These ranges can provide a density similar to that of cut rag tobacco, thereby providing a mixture of these materials that is less prone to separation. Such areal densities can be particularly suitable when the amorphous solid material is included in the aerosol product as a shredded sheet (discussed further below). In some cases, the sheet can have a mass per unit area of ​​about 30-70 g / m 2 , 40~60g / m 2 , or 25 to 60 g / m 2 and the sheet can be used to encase aerosolizable materials, such as those described herein.

[0193] The aerosol-generating material may comprise a mixture of an aerosolizable material as described herein and an amorphous solid material. Such an aerosol-generating material may provide a desired flavor profile to the aerosol during use, since additional flavorings may be introduced into the aerosol-generating material by including them in the amorphous solid material component. The flavorings provided in the amorphous solid material may be more stably retained within the amorphous solid material compared to flavorings added directly to the tobacco material, resulting in a more consistent flavor profile between articles manufactured according to the present disclosure.

[0194] As previously mentioned, it has been found that tobacco materials having a density of at least 350 mg / cc to less than about 900 mg / cc, preferably about 600 mg / cc to about 900 mg / cc, advantageously lead to a more sustained aerosol release. In order to provide an aerosol with a consistent flavor profile, the amorphous solid material components of the aerosol-generating material should be uniformly distributed throughout the rod. The inventors have found that this can be advantageously achieved by casting the amorphous solid material to provide an amorphous solid material having a thickness as described herein and an areal density similar to that of the tobacco material, and by treating the amorphous solid material as described below to ensure uniform distribution throughout the aerosol-generating material.

[0195] As previously mentioned, optionally the aerosol-generating material comprises a plurality of strips of amorphous solid material. Where the aerosol-generating portion comprises a plurality of strands and / or strips of a sheet of aerosolizable material and a plurality of strips of amorphous solid material, the material properties and / or dimensions of these at least two components may be suitably selected to ensure that relatively uniform mixing of the components is possible and in other manners to reduce separation or unmixing of the components during or after manufacture of the rod of aerosol-generating material.

[0196] The longitudinal dimension of the plurality of strands or strips may be about the same as the length of the aerosol-generating portion. The plurality of strands and / or strips may have a length of at least about 5 mm.

[0197] Components of an embodiment of non-combustion aerosol delivery device 100 are shown in simplified form in Figure 2. Notably, in Figure 2, the elements of non-combustion aerosol delivery device 100 are not drawn to scale. To simplify Figure 2, elements that are not relevant to an understanding of the present embodiment have been omitted.

[0198] As shown in FIG. 2, non-combustion aerosol delivery device 100 is a non-combustion aerosol delivery device having a housing 101 with an area 102 for receiving an item 1 .

[0199] Region 102 is positioned to receive article 1. When article 1 is received in region 102, at least a portion of the aerosol-generating material is in thermal proximity to heater 103. When article 1 is fully received in region 102, at least a portion of the aerosol-generating material may be in direct contact with heater 103. The aerosol-generating material releases various volatile compounds at different temperatures. By controlling the maximum operating temperature of electrically heated aerosol-generating system 100, selective release of undesirable compounds can be controlled by preventing release of selected volatile compounds.

[0200] As shown in Figure 4, within the housing 101 is an electrical energy source 104, such as a rechargeable lithium ion battery. A controller 105 is connected to the heater 103, the electrical energy source 104, and a user interface 106, such as a button or display. The controller 105 controls the power supplied to the heater 103 to regulate the temperature of the heater 103. Typically, the aerosol-forming substrate is heated to a temperature of between 250 and 450 degrees Celsius.

[0201] Figure 4 is a schematic cross-sectional view of a non-combustion aerosol delivery device of the type shown in Figure 3, in which a heater 103 is inserted into the aerosol-generating material 3 of the article 1. The non-combustion aerosol delivery device is shown engaged with the aerosol product 1 for a user to consume the aerosol product 1.

[0202] The housing 101 of the non-combustible aerosol delivery device defines an area 102 in the form of a cavity open at a proximal end (or mouth end) for receiving the aerosol product article 1 for consumption. A heating assembly including a heater 103 is suspended at the distal end of the cavity. The heater 103 is held by a heater mount (not shown) such that an active heating area of ​​the heater is located within the cavity. When the aerosol product article 1 is fully received within the cavity, the active heating area of ​​the heater 103 is located within the aerosol generating portion of the aerosol product article 1.

[0203] The heater 103 is configured to be inserted into the aerosol-generating material 3. The heater 103 is formed in the form of a blade terminating in a tip. That is, the length dimension of the heater is greater than its width dimension, which is greater than its thickness dimension. A first side and a second side of the heater are defined by the width and length of the heater.

[0204] When the article 1 is pressed into the cavity, the tapered tip of the heater engages the aerosol-generating material 3. The blades are shaped to be easily inserted and removed from the aerosol-generating material 3. By applying force to the article 1, the heater penetrates the aerosol-generating material 3. When the article 1 is properly engaged with the non-combustible aerosol delivery device, the heater 103 is inserted into the aerosol-generating material 3. When the heater is activated, the aerosol-generating material 3 is heated and volatile substances are generated or released. When the user inhales on the mouthpiece 2, air is drawn into the article 1 and the volatile substances condense to form an inhalable aerosol. The aerosol passes through the mouthpiece 2 of the article 1 and into the user's mouth.

[0205] The inventors have found that the aerosol generator can be inserted relatively easily into the aerosolizable material. Furthermore, after the aerosol generator is inserted into the aerosolizable material, the article is held securely. This makes the article and device easier to use and also safer, as the article may be less likely to become dislodged from the aerosol generator during use.

[0206] Various embodiments described herein are presented merely to aid in the understanding and teaching of the claimed features. These embodiments are presented merely as representative examples of embodiments and are not all-inclusive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limiting the scope of the invention as defined in the claims or to the equivalents of the claims, and it is understood that other embodiments may be used and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably include, consist of, or consist essentially of any suitable combination of the disclosed elements, parts, features, portions, steps, means, etc., other than those expressly set forth herein. In addition, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. 1. An article for use in a non-flammable aerosol delivery system, the article having an upstream end and a downstream end, a source of aerosol-forming material and / or a cavity for receiving a source of aerosol-forming material, the source having a length of less than 20 mm; a downstream portion including a capsule having its center located about 28 mm to about 38 mm from the upstream end of the article; An article comprising:

2. The article of claim 1 , wherein the capsule is disposed about 34 mm to about 38 mm from the upstream end of the article.

3. The article of claim 1 , wherein the source of aerosol-forming material and / or the cavity is surrounded by a moisture-impermeable wrapper.

4. The article of claim 3 , wherein the non-vapor permeable wrapper comprises a metal layer.

5. The article of claim 4 , wherein the metal layer is formed from aluminum.

6. The article of claim 5 , wherein the non-vulnerable wrapper has a basis weight of greater than about 40 gsm, or greater than about 45 gsm, or greater than about 50 gsm.

7. 10. The article of claim 1, further comprising a tubular portion adjacent the source of aerosol-generating material and / or the cavity, the tubular portion having an inner diameter of from about 1 mm to about 4 mm, or from about 2.5 mm to about 3.9 mm, or from about 2.7 mm to about 3.5 mm, or from about 2.9 mm to about 3.1 mm.

8. The article of claim 7 , wherein the tubular portion comprises a fibrous tow.

9. 10. The article of claim 1, wherein the source of aerosol-forming material and / or the cavity has a length greater than about 11 mm.

10. 10. The article of claim 1, wherein the source of aerosol-forming material and / or the cavity has a length of less than about 18 mm.

11. 10. The article of claim 1, wherein the length of the article is at least 46 mm, or between 46 mm and 60 mm, or between 46 mm and 52 mm, or about 48 mm.

12. 10. The article of claim 1, wherein the source of aerosol-generating material has a longitudinal dimension, the source of aerosol-generating material comprising a plurality of longitudinally aligned strands or strips of aerosol-generating material.

13. The article of claim 12 , wherein the strands or strips of aerosol-forming material extend in the longitudinal direction along substantially the entire length of the source of aerosol-forming material.

14. The article of claim 12 , wherein the aerosol-forming material comprises reconstituted tobacco material.

15. 10. The article of claim 1, wherein the article comprises a breathability level of about 25%, about 20%, about 12%, about 10%, about 5%, or about 0%.

16. 16. The article of claim 15, wherein the ventilation level is provided by openings, the openings being located no more than about 28 mm from the upstream end of the article, between 20 mm and 28 mm from the upstream end of the article, or about 25 mm from the upstream end of the article.

17. a tubular portion adjacent the source of aerosol-generating material and / or the cavity, 17. The article of claim 16, wherein a vent is provided in the tubular portion.

18. The article of claim 17 , wherein the vent is located in the downstream portion.

19. 20. The article of claim 18, wherein the vent is located immediately upstream of the capsule.

20. The aerosol-generating material comprises a sheet or chopped sheet of aerosolizable material comprising a tobacco material, an aerosol-forming material, and a binder, the sheet or chopped sheet having a thickness of at least about 100 μm and a mass of at least about 100 g / m ２ ~Approx. 250g / m ２ The article of claim 1 having an areal density of

21. 21. The article of claim 20, wherein the aerosolizable material comprises a filler.

22. The article of claim 1 , wherein the aerosol-forming material is unpressed.

23. A non-flammable aerosol delivery device; An article according to any one of claims 1 to 22. A non-flammable aerosol delivery system comprising:

24. 24. The non-combustion aerosol delivery system of claim 23, wherein the non-combustion aerosol delivery device comprises a heating element configured for insertion into an aerosol generating component of the article.

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