Articles for aerosol delivery systems

Abstract

The present invention relates to an article (1) for use as or as part of an aerosol delivery system. The article may be a consumable for a combustion aerosol delivery system or a non-combustion aerosol delivery system. The article comprises a component (4) having an upstream end (41) and a downstream end (42). The component comprises a first material (7) and a second material (8) comprising an amorphous solid material (9). The amorphous solid material extends substantially longitudinally through the component between the upstream and downstream ends and has a length of at least about 70% of the length of the component between the upstream and downstream ends. The present invention also relates to a component for the article, a non-combustion aerosol delivery system, and a method of making the article.

Description

Field

[0001] The present invention relates to an article, for example an article for use as or as part of an aerosol delivery system. The article may be a consumable for a combustion aerosol delivery system or a non-combustion aerosol delivery system. Packaging for the article, a non-combustion aerosol delivery system, and a method for making the article are also described. Background of the Invention

[0002] Smoking articles, such as cigarettes, cigars, etc., burn tobacco to produce tobacco smoke during use. Attempts have been made to provide alternatives to these articles by creating products that release compounds without combustion. Examples of such products are so-called "heat-not-burn" products or tobacco heating devices or products that release compounds by heating, rather than burning, smoking material. Summary of the Invention

[0003] According to a first aspect of the invention there is provided an article for use as or as part of an aerosol delivery system, the article comprising a component having an upstream end and a downstream end, the component comprising a first material and a second material, the second material comprising an amorphous solid material extending substantially longitudinally through the component between the upstream and downstream ends and having a length that is at least about 70% of the length of the component between the upstream and downstream ends.

[0004] In some embodiments, the second material comprises a plurality of elongated strips of amorphous solid material, the plurality of elongated strips extending substantially parallel to one another.

[0005] In some embodiments, the plurality of elongate strips includes between 2 and 50 strips, or between 5 and 25 strips, or between 7 and 21 strips.

[0006] In some embodiments, the second material comprises at least one strip having an upstream end and a downstream end, the upstream end of the strip extending to within 5 mm of the upstream end of the component and the downstream end of the strip extending to within 5 mm of the downstream end of the component.

[0007] In some embodiments, the second material comprises a sheet material, and the tensile strength of the second material in the longitudinal direction is at least about 4 N / 15 mm, and / or in the range of about 170 N / 15 mm to about 200 N / 15 mm.

[0008] In some embodiments, the amorphous solid material comprises the substance to be delivered, hi some embodiments, the substance to be delivered is menthol.

[0009] In some embodiments, the amorphous solid material comprises in the range of 2 mg to about 20 mg of menthol.

[0010] In some embodiments, the second material at least partially surrounds the first material.

[0011] In some embodiments, the second material is disposed within the first material and / or the second material is disposed within the first material and is substantially surrounded on all sides by the first material.

[0012] In some embodiments, the first material is an aerosol-generating material.

[0013] In some embodiments, the aerosol-forming material includes a tobacco material.

[0014] In some embodiments, the tobacco material is a cut rag tobacco material or a reconstituted tobacco material.

[0015] In some embodiments, the components form an aerosol-generating portion of the article.

[0016] In some embodiments, the first material comprises a filter material, and optionally, the first material comprises a paper filter material having a density between about 0.1 and about 0.45 grams per cubic centimeter.

[0017] In some embodiments, the components form an aerosol-modifying portion of the article.

[0018] In some embodiments, the components form an aerosol modifying portion of an article that is a combustion-based aerosol delivery system.

[0019] In some embodiments, the article is rod-shaped.

[0020] In some embodiments, the component further comprises a wrapper configured to surround the first material and the second material.

[0021] In a second aspect of the present invention there is provided a package of articles comprising a plurality of articles as claimed in any one of claims 1 to 19, wherein the amount of substance to be delivered within each article varies by less than 5%.

[0022] In a third aspect of the present invention, there is provided a non-combustion aerosol delivery system comprising an article according to any one of claims 1 to 19.

[0023] In a fourth aspect of the present invention there is provided an amorphous solid material for use in an article according to any one of claims 1 to 19.

[0024] In some embodiments, the amorphous solid material is configured to extend substantially longitudinally through the component between the upstream and downstream ends and has a length that is at least about 70% of the length of the component between the upstream and downstream ends.

[0025] In some embodiments, the amorphous solid material, when incorporated into an article, extends substantially longitudinally through the component between the upstream and downstream ends and has a length that is at least about 70% of the length of the component between the upstream and downstream ends.

[0026] In some embodiments, the tensile strength of the amorphous solid material is in the range of about 2 N / 15 mm to about 300 N / 15 mm.

[0027] In some embodiments, the length of the amorphous solid material is within the range of about 8 mm to about 48 mm.

[0028] In some embodiments, the width of the amorphous solid material is in the range of about 0.5 mm to about 3 mm.

[0029] In some embodiments, the aspect ratio of the amorphous solid material is in the range of about 2.5 to about 100.

[0030] In some embodiments, the amorphous solid material is 50 mm 2 In some embodiments, the substance to be delivered is in the range of 0.25 mg to about 1 mg per tablet. In some embodiments, the substance to be delivered is menthol.

[0031] In a fifth aspect of the present invention there is provided a component for use in an article according to any one of claims 1 to 19, the component having an upstream end and a downstream end, the component comprising a first material and a second material, the second material comprising an amorphous solid material extending substantially longitudinally through the component between the upstream and downstream ends and having a length of at least about 70% of the length of the component between the upstream and downstream ends.

[0032] In a sixth aspect of the present invention there is provided a method of manufacturing an article as claimed in any one of claims 1 to 19, the method comprising the steps of providing a first material for forming into a component of the article, transporting the first material continuously through an assembly apparatus, and adding at least one continuous amorphous solid material to the first material.

[0033] In some embodiments, the method further includes unwinding the ribbon of amorphous solid material from a bobbin and cutting the ribbon of amorphous solid material into a plurality of elongated strips.

[0034] In some embodiments, the method further comprises feeding a plurality of elongated strips of amorphous solid state material directly to an assembly apparatus prior to the component forming device.

[0035] In some embodiments, the method further includes winding a plurality of elongated strips of the amorphous solid state material onto a bobbin in preparation for addition to the first material in an assembly apparatus.

[0036] In some embodiments, the method further includes winding the ribbon of amorphous solid state material and the first material simultaneously onto the same bobbin.

[0037] In some embodiments, the ribbon of amorphous solid material and the first material are co-wound.

[0038] In some embodiments, the method further includes simultaneously unwinding the ribbon of amorphous solid state material and the first material from a bobbin.

[0039] In some embodiments, the cutting of the ribbon of amorphous solid material and the first material may occur simultaneously.

[0040] In some embodiments, the first material is reconstituted tobacco.

[0041] In some embodiments, the method may further include aligning the at least one continuous amorphous solid material with the first material before the amorphous solid material and the first material are fed to a component formation device of the assembly apparatus.

[0042] In some embodiments, the method may further include aligning a plurality of ribbons of the continuous amorphous solid material with the first material at intervals across a width of the first material.

[0043] In some embodiments, the method may further include aligning at least one continuous amorphous solid material with the first material prior to simultaneously cutting the amorphous solid material and the first material.

[0044] In some embodiments, the method may further include aligning multiple ribbons of the continuous amorphous solid material with the first material at intervals across a width of the first material such that gaps exist between adjacent ribbons of the continuous amorphous solid material.

[0045] In some embodiments, the method may further include aligning the at least one continuous amorphous solid material with the first material after the amorphous solid material and the first material are cut.

[0046] In some embodiments, the method may further include cutting the plurality of ribbons of the continuous amorphous solid material into a plurality of strips to form a plurality of strips, which are then aligned with the first material and spaced across a width of the first material such that there are gaps between adjacent strips of the continuous amorphous solid material.

[0047] In some embodiments, the method further includes spirally winding a plurality of elongated strips of the amorphous solid state material onto a bobbin in preparation for addition to the first material in an assembly apparatus.

[0048] In some embodiments, the method further comprises twisting the plurality of elongated strips of amorphous solid material prior to winding the plurality of elongated strips onto a bobbin to form a rope that is fed to an assembly apparatus prior to the component forming device.

[0049] In some embodiments, the method further includes transporting the first material and at least one strip of amorphous solid material through a component formation device, forming a seamless component, encasing the seamless component in a wrapper, and cutting the seamless component into individual components.

[0050] In some embodiments, the method step of cutting the seamless component releases tension in at least one strip of amorphous solid material, causing the amorphous solid material to decrease in length to both ends of the component.

[0051] In some embodiments, the method further comprises combining the component with other components of the article to form the article.

[0052] In a seventh aspect of the invention, there is provided a method of producing an amorphous solid state material, comprising the steps of unwinding a ribbon of amorphous solid state material from a bobbin and severing the ribbon of amorphous solid state material into a plurality of elongated strips.

[0053] In a seventh aspect of the present invention there is provided an amorphous solid material formed by a process as defined in claim 41.

[0054] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief description of the drawings]

[0055] [Figure 1]1 is a schematic cross-sectional side view of a first embodiment of a consumable for use with a non-combustion aerosol delivery device. [Diagram 2] FIG. 2 is a schematic cross-sectional side view of a second embodiment of a delivery system. [Diagram 3] FIG. 3 is a schematic side view of a non-combustion aerosol delivery device for generating aerosol from the consumable aerosol-generating material of FIG. 1 or FIG. 2. [Figure 4] FIG. 1 is a perspective schematic diagram of a ribbon of amorphous solid material. [Diagram 5] FIG. 2 is a side schematic view of a plurality of elongated strips formed into a rope. [Figure 6] FIG. 1 is a front perspective view of a first embodiment of a bobbin of multiple elongated strips of amorphous solid. [Figure 7] FIG. 13 is a front perspective view of a second embodiment of a bobbin of multiple elongated strips of amorphous solid. [Figure 8] FIG. 1 is a perspective schematic view of a cutting device for cutting ribbons of amorphous solid. [Figure 9] FIG. 2 is a perspective schematic view of multiple elongated strips of amorphous solid being fed into a consumable component fabrication machine. [Figure 10] FIG. 2 is a schematic diagram of a ribbon of a second material aligned over a sheet of a first material. [Figure 11] FIG. 11 is a cross-sectional schematic diagram of an aerosol generating component portion formed from the material configuration shown in FIG. [Figure 12] FIG. 2 is a schematic diagram of multiple ribbons of a second material aligned over a sheet of a first material. [Figure 13] FIG. 13 is a cross-sectional schematic diagram of an aerosol generating component portion formed from the material configuration shown in FIG. [Figure 14] FIG. 1 is a schematic diagram of a portion of an apparatus for forming a delivery system. [Figure 15] FIG. 1 is a schematic diagram of a portion of an apparatus for forming a delivery system. Detailed Description

[0056] The present invention relates to an article for a consumable for use in a delivery system.

[0057] As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user; A combustion aerosol delivery system, such as tobacco (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smoking materials) for cigarettes, cigarillos, cigars, and pipes, or for hand-rolled or hand-made cigarettes; a non-combustion aerosol delivery system that releases a compound from an aerosol-generating material without combusting the aerosol-generating material, such as an e-cigarette, a tobacco heating product, and a hybrid system for generating an aerosol using a combination of aerosol-generating materials; Includes.

[0058] According to the present disclosure, a "combustion-based" aerosol delivery system is an aerosol delivery system in which the constituent aerosol-generating materials of the aerosol delivery system (or its components) are combusted or burned during use to facilitate delivery of at least one substance to a user.

[0059] In some embodiments, the delivery system is a combustion aerosol delivery system, such as a system selected from the group consisting of a cigarette, a cigarillo, and a cigar. In some embodiments, the present disclosure relates to a component for use in a combustion-based aerosol delivery system, such as a filter, a filter rod, a filter segment, or an aerosol modifier-releasing component.

[0060] According to this disclosure, a "non-combustion" aerosol delivery system is an aerosol delivery system in which the constituent aerosol-generating materials of the aerosol delivery system (or its components) are not combusted or burned to facilitate delivery of at least one substance to a user.

[0061] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0062] In some embodiments, the non-combustion aerosol delivery system is an e-cigarette, also known as a vaping device or an electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0063] In some embodiments, the non-combustion aerosol delivery system is a hybrid system for generating an aerosol using a combination of aerosol-generating materials, where one or more of the aerosol-generating materials may be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not include 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, a tobacco product or a non-tobacco product.

[0064] Typically, 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.

[0065] In some embodiments, the present disclosure relates to consumables that include an aerosol-generating material and are configured for use with a non-combustion aerosol delivery device. These consumables may be referred to as articles throughout this disclosure.

[0066] In some embodiments, the non-combustion aerosol delivery system may 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.

[0067] In some embodiments, a consumable for use with a non-combustion aerosol delivery device may comprise an aerosol generating material, an aerosol generating material storage region, an aerosol generating material transport component, an aerosol generator, an aerosol generating region, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0068] 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 former materials, and / or one or more other functional materials.

[0069] In some embodiments, the substance to be delivered comprises an active agent.

[0070] The active substance used herein may be a bioactive material, which is a material intended to obtain or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, psychotropic drugs. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another botanical substance.

[0071] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0072] As described herein, the active material may include or be derived from one or more botanical materials or their components, derivatives, or extracts. 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, and the like. Alternatively, the material may include synthetically obtained active compounds naturally present in the botanical material. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, pieces, strips, sheets, and the like. Exemplary botanicals include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay leaf, licorice (licorice), matcha, yerba mate, orange peel, papaya, rose, sage, tea, such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. , lemon peel, mint, juniper, elderflower, vanilla, wintergreen, sedge, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, black currant, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha arventis, 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 cardifolia), horse mint (Memtha longifolia), pineapple mint (Mentha suaveolens variegata), pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata cv), and apple mint (Mentha suaveolens).

[0073] 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.

[0074] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, the botanical substances being selected from eucalyptus, star anise, cocoa, and hemp.

[0075] 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.

[0076] In some embodiments, the substance to be delivered comprises a fragrance.

[0077] As used herein, the terms "flavor" and "flavoring agent" mean materials that can be used to create a desired taste, aroma, or other somatosensory sensation in products for adult consumers, where local regulations permit.Such materials may be naturally occurring flavoring materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice (licorice), hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, peppermint, aniseed (aniseed), cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, Tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberries, mulberry, 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, mint oil from any species of Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay leaf, yerba mate, orange peel, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiogamaguma, curcuma, cilantro, myrtle, black currant, valerian, pimen The composition may include other additives such as oleaginous compounds, such as oleic acid, stearyl alcohol, stearyl alcohol, sorbitol, glyceryl-stearate, sorbitol, isopropyl alcohol, stearyl alcohol ...The materials may be replicas, synthetic or natural components, 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.

[0078] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus fruit, 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.

[0079] In some embodiments, the flavorings may include sensates intended to obtain somatic sensations usually chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the smell or taste nerves, and these sensates may include agents that provide a heating effect, a cooling effect, a tingling effect, a numbing effect. A suitable heating effect agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucolyptol, WS-3.

[0080] An aerosol-generating material is a material that can generate an aerosol when, for example, heated, irradiated, or excited in any other way. The aerosol-generating material may be in the form of a solid, liquid, or gel, which may or may not contain actives and / or flavorings. In some embodiments, the aerosol-generating material may comprise an "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can hold some amount of fluid, such as a liquid, within it. In some embodiments, the aerosol-generating material may comprise, for example, about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0081] In some embodiments, the amorphous solid comprises 1-60 wt % gelling agent, 0.1-50 wt % aerosol former, and 0.1-80 wt % flavoring, these weights being calculated on a dry weight basis.

[0082] In some further embodiments, the amorphous solid comprises 1-50 wt % gelling agent, 0.1-50 wt % aerosol former, and 30-60 wt % flavoring, these weights calculated on a dry weight basis.

[0083] In some further embodiments, the amorphous solid comprises the aerosol former material, gelling agent, and optional filler in an amount of about 40-80 wt% of the amorphous solid (i.e., in some instances the filler is present in the amorphous solid and in other instances the filler is absent from the amorphous solid), the gelling agent and filler, taken together, are in an amount of about 10-60 wt% of the amorphous solid (i.e., the gelling agent and filler, taken together, comprise about 10-60 wt% of the amorphous solid), and the amorphous solid also optionally comprises an active and / or flavoring in an amount of up to about 20 wt% of the amorphous solid (i.e., the amorphous solid comprises ≦20 wt% active).

[0084] The amorphous solid material may be formed from a dried gel. It has been found that using the above composition ratios means that the flavor compounds are stabilized within the gel matrix when the gel sets, allowing a higher flavor loading to be achieved than in a non-gel composition. The flavor (e.g., menthol) is stabilized at a high concentration and the product has a good shelf life. In some cases, the amorphous solid may have a thickness of about 0.015 mm to about 1.5 mm. Suitably, the thickness may be within the range of about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm, 0.3 mm, or 1 mm. The inventors have found that in some embodiments, a material having a thickness of 0.2 mm is particularly suitable. The amorphous solid may comprise two or more layers, and the thicknesses described herein refer to the total thickness of those layers.

[0085] If the amorphous solid is too thick, the heating efficiency is compromised, which negatively impacts power consumption during use. Conversely, if the amorphous solid is too thin, it is difficult to manufacture and handle. Very thin materials are more difficult to cast and can be fragile, compromising aerosol formation during use.

[0086] Suitably, the amorphous solid may comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, or 35 wt% to about 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, or 35 wt% of the gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise from 1 to 60 wt%, 5 to 60 wt%, 20 to 60 wt%, 25 to 55 wt%, 30 to 50 wt%, 35 to 45 wt%, 5 to 45 wt%, 10 to 40 wt%, or 20 to 35 wt% of the gelling agent.

[0087] The amorphous solid may comprise a gelling agent, which may include one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum, and mixtures thereof.

[0088] In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent may comprise one or more compounds selected from the group consisting of 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 alginates, pectins, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, polydimethylsiloxane (PDMS), sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the gelling agent comprises alginates and / or pectins, which may be combined with a hardening agent (such as a calcium source) during the formation of the amorphous solid. In some cases, the amorphous solid may comprise calcium cross-linked alginates and / or calcium cross-linked pectins.

[0089] The cellulose gelling agent may be selected from the group consisting of hydroxymethylcellulose, hydroxyethylcellulose, hydroxypropylcellulose, carboxymethylcellulose (CMC), hydroxypropylmethylcellulose (HPMC), methylcellulose, ethylcellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof.

[0090] In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethyl cellulose, guar gum, or acacia gum.

[0091] In some embodiments, the gelling agent comprises (or is) one or more non-cellulosic gelling agents, including, but not limited to, agar, xanthan gum, gum arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginate, and combinations thereof. In preferred embodiments, the non-cellulose based gelling agent is alginate or agar.

[0092] In some embodiments, the amorphous solid comprises alginate and pectin, and the ratio of alginate to pectin is between 1:1 and 10:1. The ratio of alginate to pectin is typically >1:1, i.e., alginate is present in an amount greater than the amount of pectin. In some examples, the ratio of alginate to pectin is between about 2:1 and 8:1, or between about 3:1 and 6:1, or approximately 4:1.

[0093] In some embodiments, the amorphous solid comprises a filler in an amount between 1 and 30 wt% of the amorphous solid, such as between 5 and 25 wt% or between 10 and 20 wt%. In some examples, the amorphous solid comprises a filler in an amount greater than 1 wt%, 5 wt%, or 8 wt% of the amorphous solid. In some examples, the amorphous solid comprises a filler in an amount less than 40 wt%, 30 wt%, 20 wt%, 15 wt%, 12 wt%, 10 wt%, 5 wt%, or 1 wt% of the amorphous solid. In other examples, the amorphous solid does not comprise a filler.

[0094] In some examples, the amorphous solids include gelling agent and filler, taken together, in an amount from about 10 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, 55 wt%, or in an amount from about 60 wt%. In some examples, the amount of gelling agent and filler, taken together, is no more than 85 wt%, 80 wt%, 75 wt%, 70 wt%, 65 wt% of the amorphous solids, or no more than 60 wt% of the amorphous solids. In some examples, the amorphous solids include gelling agent and filler, taken together, in an amount from about 20-60 wt%, 25-55 wt%, 30-50 wt%, or 35-45 wt% of the amorphous solids.

[0095] When present, the filler may include one or more inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. The filler may include one or more organic filler materials such as wood pulp, cellulose, and cellulose derivatives. In certain cases, the amorphous solid does not include calcium carbonate, such as chalk.

[0096] In some examples including a filler, the filler may be fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fiber, cellulose, or cellulose derivatives. Without wishing to be bound by theory, it is believed that the inclusion of a fibrous filler in the amorphous solid can increase the tensile strength of the material.

[0097] In some instances, the amorphous solid is free of tobacco fiber. In certain instances, the amorphous solid is free of fibrous material.

[0098] In some embodiments, the amorphous solid may comprise from about 0.1 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt%, or 10 wt% to about 80 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt% of the aerosol former material (all calculated on a dry weight basis). For example, the amorphous solid may comprise from 0.5 to 40 wt%, from 3 to 35 wt%, or from 10 to 25 wt% of the aerosol former material.

[0099] The aerosol former material may act as a plasticizer. If the plasticizer content is too high, the amorphous solid may absorb water resulting in a material that does not provide a proper consumer experience upon use. If the plasticizer content is too low, the amorphous solid may become brittle and brittle.

[0100] In some embodiments, the aerosol former contained in the amorphous solid comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin, esters of polyhydric alcohols, such as glycerol monoacetate, glycerol diacetate, or glycerol triacetate, and / or aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetracanedioate.

[0101] In some cases, the aerosol former material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol, In some cases, the aerosol former material comprises, consists essentially of, or consists of glycerol.

[0102] The amorphous solid material may include a combustion retarding salt. As used herein, a combustion retarding salt is a compound consisting of an ionic collection of cations and anions. As used herein, a salt is a salt whose anion and / or whose cation may be effective in retarding combustion. In some embodiments, the salt is an inorganic salt.

[0103] In some embodiments, the salt is a halide salt, i.e., has a halide anion. In some embodiments, the salt is a chloride salt or a bromide salt. The presence of high concentrations of chloride or bromide has been shown to retard combustion.

[0104] In some embodiments, the salts are alkali metal salts, i.e., have an alkali metal cation. In some embodiments, the salts have an alkaline earth metal cation. In some embodiments, the salts have a zinc cation or an iron cation, such as a ferric cation or a ferrous cation. In some embodiments, the salts have an ammonium cation or a phosphonium cation.

[0105] In some embodiments, the salt may be an alkali metal halide, such as sodium chloride or potassium chloride. The salt may be an alkaline earth metal halide, such as magnesium chloride, calcium chloride, etc. The salt may be another metal halide, such as zinc chloride or sodium bromide.

[0106] In some embodiments, the salt has a carboxylate anion, for example, the salt may be an alkali metal carboxylate, such as potassium citrate, potassium succinate, potassium malate, potassium acetate, potassium tartrate, potassium oxalate, sodium citrate, sodium succinate, sodium acetate, or sodium malate.

[0107] In other embodiments, the salt has an anion selected from borate, carbonate, phosphate, sulfate, or sulfamate.

[0108] Factors that may influence the selection of the salt include, for example, the melting point, which may be preferred to be at least 450° C. In some embodiments, the salt is water soluble. In some embodiments, the salt is selected to impart a desired pH to the material to which it is added. In some embodiments, the salt does not significantly change the pH of the material.

[0109] In some embodiments, the flame retardant salt selected may have one or more advantageous properties, such as inertness, solubility in the precursor liquid, solubility, distribution in an amorphous solid material or a precursor material to an amorphous solid material, density, or other properties known in the art.

[0110] In some embodiments, the flame retardant salt comprises, consists essentially of, or consists of sodium chloride, potassium chloride, sodium bromide, and / or potassium bromide.

[0111] Depending on the flame retardant properties or other physical properties desired, the salt components may be present in free base form, salt form, or as complexes or solvates. The flame retardant salts may be of any density and any crystal structure.

[0112] In some embodiments, the flame retardant salt is incorporated into or added to an amorphous solid material dissolved in a solvent or liquid carrier. In some embodiments, the flame retardant salt is suspended in a liquid carrier. The solvent or liquid carrier may be an aqueous or organic liquid, and may be polar or non-polar depending on the appropriate application.

[0113] The liquid carrier or precursor solvent may be advantageously selected to be easily removed during manufacture of the flame-retardant material to leave the flame-retardant salt within or on the amorphous solid material.

[0114] In some embodiments, the liquid carrier is a mixture of liquids, including aqueous liquids (water) and non-aqueous liquids (e.g., glycerol), when the water is removed after application of the salt, the glycerol is retained within the amorphous solid material, where it provides flexibility and aids in aerosol formation upon heating.

[0115] The amorphous solid may include a colorant. The addition of a colorant may modify the appearance of the amorphous solid. The presence of a colorant in the amorphous solid may enhance the appearance of the amorphous solid and the aerosol-forming material. Adding a colorant to the amorphous solid may allow the amorphous solid to be color-matched to other components of the aerosol-forming material or other components of an article comprising the amorphous solid.

[0116] Depending on the desired color of the amorphous solid, various colorants may be used. The color of the amorphous solid may be, for example, white, green, red, purple, blue, brown, or black. Other colors are also envisioned. Natural or synthetic colorants may be used, such as natural or synthetic dyes, food grade colors, and pharmaceutical grade colors. In certain embodiments, the colorant is caramel, which may give the amorphous solid a brown appearance. In such embodiments, the color of the amorphous solid may be similar to the color of other components (such as tobacco materials) in the aerosol-generating material that includes the amorphous solid. In some embodiments, the addition of a colorant to the amorphous solid makes the amorphous solid visually indistinguishable from other components in the aerosol-generating material.

[0117] The colorant may be incorporated during the formation of the amorphous solid (e.g., when forming a suspension including the materials that will form the amorphous solid) or the colorant may be applied to the amorphous solid after its formation (e.g., by spraying the colorant onto the amorphous solid).

[0118] The aerosol-forming materials can include one or more active agents and / or flavorings, one or more aerosol former materials, and optionally one or more other functional materials.

[0119] The aerosol-generating material can include an acid. The acid can be an organic acid. In some of these embodiments, the acid can be at least one of a monobasic acid, a dibasic acid, and a tribasic acid. In some such embodiments, the acid can contain at least one carboxyl functional group. In some such embodiments, the acid can be at least one of an alpha hydroxy acid, a carboxylic acid, a dicarboxylic acid, a tricarboxylic acid, and a keto acid. In some such embodiments, the acid can be an alpha keto acid.

[0120] In some such embodiments, the acid may be at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic acid, and pyruvic acid.

[0121] Suitably, the acid is lactic acid. In other embodiments, the acid is benzoic acid. In other embodiments, the acid may be an inorganic acid. In some of these embodiments, the acid may be a mineral acid. In some such embodiments, the acid may be at least one of sulfuric acid, hydrochloric acid, boric acid, and phosphoric acid. In some embodiments, the acid is levulinic acid.

[0122] The inclusion of an acid is particularly preferred in embodiments in which the aerosol-forming material includes nicotine. In such embodiments, the presence of an acid can stabilize dissolved species in the suspension in which the aerosol-forming material is formed. The presence of an acid can reduce or substantially prevent evaporation of nicotine during drying of the suspension, thereby reducing the loss of nicotine during production.

[0123] In certain embodiments, the aerosol forming materials include a gelling agent, including a cellulosic and / or non-cellulosic gelling agent, an active agent, and an acid.

[0124] In some embodiments, the aerosol-generating material comprises one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiol acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclo (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), and cannabielsoin (CBE), cannabicitran (CBT). The aerosol-forming material may include one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).

[0125] The aerosol-forming material may include cannabidiol (CBD).

[0126] The aerosol-forming material may include nicotine and cannabidiol (CBD).

[0127] The aerosol-forming material may include nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

[0128] The aerosol former material may include one or more components capable of forming an aerosol. In some embodiments, the aerosol former material may include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, 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. In some embodiments, the aerosol former comprises one or more polyhydric alcohols, such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin, esters of polyhydric alcohols, such as glycerol monoacetate, glycerol diacetate, or glycerol triacetate, and / or aliphatic esters of mono-, di-, or polycarboxylic acids, such as dimethyl dodecanedioate and dimethyl tetracanedioate.

[0129] The one or more other functional ingredients may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0130] As used herein, the term "tobacco material" means any material that contains tobacco or a tobacco derivative or substitute. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. Tobacco materials may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco lamina, reconstituted tobacco, and / or tobacco extracts.

[0131] The tobacco may include a filler component. The filler component is generally a non-tobacco component, i.e. a component that does not contain any components derived from tobacco. The filler component may be a non-tobacco fiber, such as wood fiber or pulp or wheat fiber. The filler component may also be an inorganic material, such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, etc. The filler component may also be a non-tobacco casting material, or a non-tobacco extrusion material. The filler component may be present in an amount of 0-20% by weight of the tobacco material, or in an amount of 1-10% by weight of the composition. In some embodiments, no filler component is present.

[0132] The tobacco material may include an aerosol former material. In some embodiments, the aerosol former material of the tobacco material may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. Glycerol may be present in an amount of 10-20% by weight of the tobacco material, such as 13-16% by weight of the composition, or about 14 or 15% by weight of the composition. Propylene glycol, when present, may be present in an amount of 0.1-0.3% by weight of the composition.

[0133] The aerosol former material may be included in any component, such as any tobacco component of the tobacco material, and / or in the filler component, if present. Alternatively, or in addition, the aerosol former material may be added separately to the tobacco material. In either case, the total amount of aerosol former material in the tobacco material may be as defined herein.

[0134] In one example, the aerosol former material can include an amorphous solid material containing 40% menthol, 16% glycerol, 20% binder (alginate / pectin mixture), and 20% fiber (wood pulp).

[0135] A consumable is an article that includes or is composed of an aerosol-generating material, and is intended to be consumed in part or in whole by a user during use. The consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transport component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. The consumable may also include an aerosol generator, such as a heater that radiates heat to cause the aerosol-generating material to generate an aerosol upon use. The heater may include, for example, a combustible material, a material that can be heated by electrical conduction, or a susceptor. The consumable may be of any shape or size suitable for a smoking device. In a preferred embodiment of the present invention, the consumable is rod-shaped.

[0136] An aerosol modifier is a substance configured to modify the generated aerosol, for example by changing the taste, flavor, acidity, or another characteristic of the aerosol, typically located downstream of the aerosol-generation region. The aerosol modifier may be provided within an aerosol modifier-releasing component operable to selectively release the aerosol modifier.

[0137] 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 filtration material.

[0138] By way of example, rod shaped articles are often named according to the length of the product: "regular" (typically in the range of 68-75 mm, e.g., about 68 mm to about 72 mm), "short" or "mini" (68 mm or less), "king size" (typically in the range of 75-91 mm, e.g., about 79 mm to about 88 mm), "long" or "super king" (typically in the range of 91-105 mm, e.g., about 94 mm to about 101 mm), and "ultra long" (typically in the range of about 110 mm to about 121 mm).

[0139] The articles are also named according to the circumference of the product: "regular" (approximately 23-25 ​​mm), "wide" (over 25 mm), "slim" (approximately 22-23 mm), "demi-slim" (approximately 19-22 mm), "super slim" (approximately 16-19 mm), and "micro-slim" (less than approximately 16 mm).

[0140] Thus, an article in a king size, super slim format, for example, would have a length of about 83 mm and a circumference of about 17 mm.

[0141] Each format can be made with mouthpieces of various lengths. The length of the mouthpiece will be about 30mm to 50mm. Tipping paper connects the mouthpiece to the aerosol-generating material and will usually have a length longer than the mouthpiece, for example 3 to 10mm longer, such that the tipping paper covers the mouthpiece and overlaps the aerosol-generating material, for example in the form of a rod of substrate material, connecting the mouthpiece to the rod.

[0142] The articles described herein and their aerosol-generating materials and mouthpieces can be made in any of the formats described above, but are not limited to such.

[0143] The filamentary tow or filter material described herein can include cellulose acetate fiber tow. The filamentary tow can be formed using other materials used to form fibers, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers, or combinations thereof. The filamentary tow can be plasticized with a plasticizer suitable for the tow, such as triacetin, if the material is cellulose acetate tow, or the tow can be unplasticized. The tow can have any suitable specification, such as fibers having a "Y"-shaped, "X"-shaped, or "O"-shaped cross section. The fibers of the tow can have a filament denier value between 2.5 and 15 denier per filament, for example a filament denier value between 8.0 and 11.0 denier per filament, and a total fineness value between 5,000 and 50,000, for example a total fineness value between 10,000 and 40,000. The cross section of the fiber has an isoperimetric ratio L of 25 or less, preferably 20 or less, more preferably 15 or less. 2 / A, where L is the perimeter of the cross section and A is the area of ​​the cross section. Such fibers have a relatively small surface area for a given denier per filament, which improves the delivery of aerosols to consumers. The filter materials described herein also include cellulose-based materials, such as paper. Such materials can have a relatively low density, such as between about 0.1 and about 0.45 grams per cubic centimeter, to allow air and / or aerosols to pass through the material. Although described as a filter material, such materials may have a primary purpose, such as to increase resistance to attraction of components not related to filtration per se.

[0144] Referring now to FIG. 1 , there is shown a cross-sectional schematic side view of a first embodiment of an article 1 for use with a non-combustion aerosol delivery device. The article 1 may be for use as an aerosol delivery system or as part of an aerosol delivery system. The article may be a tobacco heating product consumable. The article 1 comprises at least one component 2, 3, 4. The at least one component may be a tobacco heating product consumable component. Each component 2, 3, 4 has an upstream end 5 and a downstream end 6. The upstream end 5 and the downstream end 6 are spaced apart in the longitudinal direction. That is, the upstream end 5 and the downstream end 6 are spaced apart in a direction along the longitudinal axis of the components 2, 3, 4.

[0145] 1, in this embodiment, article 1 comprises three components 2, 3, 4. The three components are a filter component 2, a heat transfer collar component 3, e.g., a hollow tubular element, and an aerosol-generating portion component 4. However, it will be appreciated that article 1 can comprise any number of components, i.e., one or more components.

[0146] 1, the filter element 2 is in the form of a cylindrical rod, however, it will be appreciated that in alternative embodiments, such as those described above, the filter element 2 may take other forms.

[0147] In this embodiment, the filter component 2 is formed from a single segment 21. However, it will be appreciated that in alternative embodiments, the filter component 2 may comprise multiple segments 21. Each segment 21 may have a configuration similar to segment 41 described herein. The filter component 2 comprises an upstream end 22 and a downstream end 23. The upstream end 22 abuts the heat transfer collar component 3. The downstream end 23 forms the mouthpiece end of the filter component 2, and when a user draws on the filter component 2, aerosol passes through the mouthpiece end and out of the article 1.

[0148] The filter component 2 comprises a filtration material, such as, but not limited to, cellulose acetate tow. Alternatively, or in addition, the filter component 2 may comprise or be constructed of any of the filter materials or filamentary tows described herein, such as a paper filter material having a density between about 0.1 and about 0.45 grams per cubic centimeter. In this embodiment, the filter component 2 further comprises a wrapper 24. The wrapper 24 surrounds the filter component. In some embodiments, the wrapper 24 may be omitted.

[0149] In this embodiment, the heat transfer collar component 3 is in the form of a cylindrical rod, however, as noted above, it will be appreciated that in alternative embodiments the heat transfer collar component 3 may take other forms.

[0150] In this embodiment, the heat transfer collar component 3 is formed from a single segment 31. However, it will be appreciated that in alternative embodiments, the heat transfer collar component 3 may comprise multiple segments 31. Each segment 31 may have a configuration similar to the segments described herein. The heat transfer collar component 3 is configured to cool the aerosol formed in the aerosol generating portion component 4.

[0151] The heat transfer collar component 3 is disposed between the filter component 2 and the aerosol-generation component 4. The heat transfer collar component 3 has an upstream end 32 and a downstream end 33. The upstream end 32 abuts the filter component 2. The downstream end 33 abuts the aerosol-generation component 4.

[0152] The heat transfer collar component 3 comprises a chamber 34. The chamber 34 extends longitudinally between an upstream end 32 and a downstream end 33 of the heat transfer collar component 3. In this embodiment, the chamber 34 extends from the upstream end 32 to the downstream end 33 such that the upstream end 32 and the downstream end 33 of the heat transfer collar component 3 are open ended. In this embodiment, the chamber 34 is cylindrical. That is, the shape of the chamber 34 conforms to the shape of the heat transfer collar component 3. However, it will be appreciated that in alternative embodiments, the cross-sectional shape of the chamber 34 may differ from the cross-sectional shape of the heat transfer collar component 3 in a plane perpendicular to the longitudinal axis of the heat transfer collar component 3. The chamber 34 is defined by at least one wall 35 of the heat transfer collar component 3.

[0153] At least one wall 35 of the heat transfer collar component 3 can comprise a filtration material, such as, but not limited to, cellulose acetate tow, or any of the filter materials and filamentary tows described herein. In this embodiment, the heat transfer collar component 3 can further comprise a wrapper 36. The wrapper 36 surrounds the heat transfer component 3. In some embodiments, the wrapper 36 may be omitted, particularly in embodiments where the wall 35 of the heat transfer collar component 3 is formed from an impermeable material, such as, but not limited to, a plastic material, such as a polymer-based plastic material, such as polyethylene.

[0154] In this embodiment, the aerosol-generating component 4 is in the form of a cylindrical rod, however, as mentioned above, it will be appreciated that in alternative embodiments the aerosol-generating component 4 may take any other form.

[0155] In this embodiment, the aerosol generating subcomponent 4 is formed from a single segment 41. However, it will be appreciated that in alternative embodiments, the aerosol generating subcomponent 4 may comprise multiple segments. Each segment 41 may have a similar form to the segments described herein. The aerosol generating subcomponent 4 is configured to generate an aerosol during use.

[0156] In this embodiment, the aerosol-generating subcomponent 4 is disposed upstream of the heat transfer collar component 3. The aerosol-generating subcomponent 4 has an upstream end 41 and a downstream end 42. The downstream end 42 of the aerosol-generating subcomponent 4 abuts the upstream end 32 of the heat transfer collar component 3.

[0157] Although described above in rod form, it will be appreciated that the aerosol-generating portion segment 4 may be provided in other forms, for example a plug, sachet, or packet of material within the article.

[0158] In this embodiment, the aerosol-generating component 4 further comprises a wrapper 44. The wrapper 44 surrounds the aerosol-generating component 4. The article 1 may further comprise a tipping wrapper 45 that connects one or more of the components 2, 3, 4 to one another. In this embodiment, a wrapper surrounds each of the filter component 2, the heat transfer collar component 3, and the aerosol-generating component 4.

[0159] In FIG. 1 , the aerosol-generating portion 4 of the article 1 comprises a first material 7 and a second material 8. In this embodiment, the first material 7 of the aerosol-generating portion 4 comprises an aerosol-generating material as described herein. In this embodiment, the first material 7 is a tobacco material 45 as described herein. In this embodiment, the tobacco material 45 comprises cut rag tobacco. The cut rag tobacco may be cut rag reconstituted tobacco. Alternatively, the tobacco material 45 may be any of the materials discussed herein. For example, the first material may be an amorphous solid material as described herein. In another example, the first material 7 may be a tobacco material 45, such as a reconstituted tobacco material.

[0160] In this embodiment, the tobacco material 45 is randomly arranged in the aerosol-generating portion 4. That is, the tobacco material 45 is not arranged in any particular orientation within the aerosol-generating portion 4. Additionally, or alternatively, the tobacco material 45 may be in the form of separate portions each having a length that is less than half the length of the aerosol-generating portion 4. In alternative examples, the tobacco material 45 or other first material may be arranged in a non-random or orderly fashion, such as multiple strips of the first material extending longitudinally across the length of the aerosol-generating portion 4.

[0161] 1, the second material 8 comprises an amorphous solid material 9. The amorphous solid material 9 may comprise, consist essentially of, or consist of any of the materials or combinations of materials described above.

[0162] As shown in FIG. 1, the amorphous solid material 9 extends substantially longitudinally across the aerosol generating component 4 between the upstream end 5 and the downstream end 6. That is, the amorphous solid material 9 extends substantially parallel to the longitudinal axis A of the aerosol generating component 4. The length of the amorphous solid material 9 is at least about 70% of the length of the aerosol generating component 4 between the upstream end 5, 42 and the downstream end 6, 43. In some embodiments, the length of the amorphous solid material 9 can be at least about 80% of the length of the aerosol generating component 4 between the upstream end 5, 42 and the downstream end 6, 43, or at least about 90% of the length of the aerosol generating component 4. In some embodiments, the length of the amorphous solid material 9 can be in the range of about 8 mm to about 70 mm, for example, about 10 mm to about 48 mm, about 12 mm to about 42 mm, or about 12 mm to about 20 mm.

[0163] In some embodiments, the second material 8 may include two or more amorphous solid materials 9. For example, the second material 8 may include a first amorphous solid material 9 including a first substance to be delivered, and a second amorphous solid material 9 including a second substance to be delivered. In other embodiments, the difference between the first and second amorphous solid materials 9 may be the amount of substance to be delivered that they contain, i.e., the first and second amorphous solid materials 9 may include the same substance to be delivered, but the first amorphous solid material 9 may include more or less of the first substance to be delivered than the second amorphous solid material 9. As will be described in more detail below, the first and second amorphous solid materials 9 may also be provided in the component 4 in various forms.

[0164] In this embodiment, the second material 8 comprises a plurality of elongated strips 10 of amorphous solid material 9. That is, the amorphous solid material 9 is cut into a plurality of elongated strips 10 and added to the first material 7 of the component 4. The plurality of elongated strips 10 of amorphous solid material 9 preferably extend substantially parallel to one another. Furthermore, the plurality of elongated strips 10 of amorphous solid material 9 may extend substantially parallel to the longitudinal axis of the aerosol generating component 4. The parallel and longitudinal configuration of the amorphous solid material 8 may help to orient the first material 7 and / or provide a flow path from the upstream end 5, 42 to the downstream end 6, 43 of the aerosol generating component 4 that allows a larger pressure drop across the aerosol generating component 4. The pressure drop across the aerosol generating component 4 when closed, i.e. when there is no venting, may be between about 50 mmWG and about 200 mmWG. The pressure drop across the aerosol generation component 4 when open, ie, vented, may be between about 20 mmWG and about 100 mmWG.

[0165] The plurality of long strips 10 may include between 2 and 50 strips. The plurality of long strips 10 may preferably include between 5 and 25 strips. More preferably, the plurality of long strips 10 may include between 7 and 21 strips. Each of the plurality of long strips 10 may have a width between about 0.1 mm and about 80 mm, preferably between about 0.5 mm and about 10 mm. More preferably, each of the plurality of long strips 10 may have a width between about 0.75 mm and 5 mm. Even more preferably, each of the plurality of long strips 10 may have a width between about 1 mm and 3 mm. Even more preferably, each of the plurality of long strips 10 may have a width between about 2 mm and 3 mm, in particular 2.25 mm.

[0166] In some embodiments, each of the plurality of long strips 10 may have the same width. However, it will be appreciated that in alternative embodiments, at least one long strip 10 of the plurality of long strips 10 may have a different width than at least one of the other long strips 10.

[0167] It will be appreciated that the width of each of the elongated strips 10 will have an impact on the pressure drop experienced across the components 2, 3, 4 in which the elongated strips 10 are incorporated. For example, the wider the elongated strips, the lower the pressure drop. Conversely, the smaller or thinner the width of each of the elongated strips 10, the higher the pressure drop.

[0168] In some embodiments, the aspect ratio of the amorphous solid material 9 may be in the range of about 2.5 to about 100. The aspect ratio is the ratio of the length of the amorphous solid material to the width of the amorphous solid material.

[0169] In this embodiment, the second material 8 includes at least one strip 10 having an upstream end 11 and a downstream end 12. The upstream end 11 of the at least one strip 10 of the second material 8 is disposed within 5 mm of the upstream end 5 of the component 4. The downstream end 12 of the at least one strip 10 of the second material 8 is disposed within 5 mm of the downstream end 6 of the component 4. In alternative embodiments, the upstream end 11 of the at least one strip 10 of the second material 8 may be disposed within about 3 mm of the upstream end 5 of the component 4 and / or the downstream end 12 of the at least one strip 10 of the second material 8 may be disposed within about 3 mm of the downstream end 6 of the component 4.

[0170] In some embodiments, the upstream end 11 of the at least one strip 10 of the second material 8 is disposed inside the aerosol-generation portion 4. That is, the upstream end 11 of the at least one strip 10 of the second material 8 is longitudinally spaced from the upstream end 5, 42 of the aerosol-generation portion 4.

[0171] The upstream end 11 of the at least one strip 10 of second material 8 is preferably hidden from view by the first material 7. In some embodiments, the downstream end 12 of the at least one strip 10 of second material 8 is disposed inside the component 4. That is, the downstream end 12 of the at least one strip 10 of second material 8 is longitudinally spaced from the downstream end 6 of the component 4. The downstream end 13 of the at least one strip 10 of second material 8 is preferably hidden from view by the first material 7. Hiding the ends 11, 12 of the second material 8 from view at the ends of the aerosol generating portion component 4 reduces a negative user perception of the strip of second material 8 in the aerosol generating portion component 4.

[0172] The second material 8 may comprise a sheet material. That is, the amorphous solid material 9 or the plurality of elongate strips 10 of the amorphous solid material 9 may comprise a sheet material. The tensile strength of the second material in the longitudinal direction is preferably greater than about 2 N / 15 mm, such as greater than about 3 N / 15 mm, or greater than about 4 N / 15 mm. The tensile strength of the second material in the longitudinal direction is preferably in the range of about 2 N / 15 mm to about 300 N / 15 mm. More preferably, the tensile strength of the second material 8 in the longitudinal direction is in the range of about 120 N / 15 mm to about 250 N / 15 mm, such as in the range of about 170 N / 15 mm to about 200 N / 15 mm.

[0173] The amorphous solid material 9 may include a substance to be delivered. The substance to be delivered may be any one of the substances described above. The substance to be delivered may be menthol. The amorphous solid material 9 in the aerosol generating portion 4 may include in the range of about 2 mg to about 20 mg of menthol. Preferably, the amorphous solid material 9 includes about 15 g of menthol.

[0174] In some embodiments, the amorphous solid material 9 is 50 mm 2 Each capsule may contain menthol in an amount ranging from 0.25 mg to about 1 mg.

[0175] The second material 8 can at least partially surround the first material 7. That is, in some embodiments, the amorphous solid material 8 can at least partially surround the first material 7. In some embodiments, the solid material 8 can surround the first material 7. In this embodiment, a plurality of elongated strips 10 of the amorphous solid material 9 at least partially surround the first material 7.

[0176] In some embodiments, the at least one strip 10 of the second material 8 may be colored. The at least one strip 10 may be colored to stand out against the color of the first material 7. The colored at least one strip 10 thus informs the consumer that the article 1 includes an amorphous solid material 9. The color of the at least one strip 10 of the amorphous solid material 9 may indicate or identify the substance to be delivered by the at least one strip 10 of the amorphous solid material 9. In such embodiments, the end 11 of the at least one strip 10 of the amorphous solid material 9 may be visible to the consumer prior to use.

[0177] As shown in FIG. 1, at least one elongated strip 10 of amorphous solid material 9 is disposed on an outer surface of the first material 7. The at least one elongated strip 10 disposed on the outer surface of the first material 7 has a width that partially surrounds the first material. FIG. 1 shows a cross-sectional view of the article 1 and therefore only shows two elongated strips 10 of amorphous solid material 9 that partially surround the first material 7. However, it will be appreciated that more than two elongated strips 10 may partially surround the first material 7. Furthermore, in some embodiments, multiple elongated strips 10 of amorphous solid material 9 may be distributed such that they at least partially surround the first material 7 but have gaps between adjacent elongated strips 10.

[0178] In some embodiments, the second material 8 may be disposed within the first material 7, as shown in Figure 1. That is, the amorphous solid material 9 may be disposed within the first material 7 such that it extends through and is at least partially surrounded by the first material 7. As shown in Figure 1, a plurality of elongated strips 10 of the amorphous solid material 9 may be disposed within the first material 7 such that it extends through and is at least partially surrounded by the first material 7. This may facilitate delivery of the substance to be delivered to the user.

[0179] As noted above, it will be appreciated that more than one amorphous solid material 9 may be provided in the component 4. For example, a first amorphous solid material 9 may at least partially surround the first material 7 and a second amorphous material 9 may be disposed within the first material 7. In another example, each amorphous solid material may at least partially surround and / or be disposed within the first material 7. It will be appreciated that the amorphous solid materials 9 may be provided in a variety of forms. For example, one amorphous solid material 9 may be provided as a ribbon of non-strip cut material and another amorphous solid material 9 may be provided as a plurality of elongated strips 10, i.e., strip cut ribbons.

[0180] The aerosol-generating portion component 4 described above forms the aerosol-generating portion of the article for a non-combustion aerosol delivery system.

[0181] Referring now to Figure 2, an alternative embodiment of an article 50 according to the present invention is shown. The article 50 shown in Figure 2 is generally the same as the first embodiment of article 1 described above in relation to Figure 1, and therefore will not be described in detail here. Furthermore, features and components of the alternative article 50 that are the same as features and components of article 1 described above retain the same terminology and reference numbers.

[0182] However, the second embodiment of article 50 differs from the first embodiment of article 1 in that the heat transfer collar 3 is omitted and in that the component comprising the amorphous solid material 9 is the filter component 2 .

[0183] Further, in a second embodiment of article 50, first material 7 of filter component 2 comprises a filtration material. The filtration material can include, but is not limited to, any of the filter materials or filamentary tow materials described herein, such as, for example, acetate acetate tow, or cellulose-based materials, such as, for example, a paper filter material having a density between about 0.1 and about 0.45 grams per cubic centimeter.

[0184] The filter component 2 described above can form the filter component 2 of an article for a non-combustion aerosol delivery system or a combustion delivery system.

[0185] It will be appreciated that in other embodiments, the component comprising the amorphous solid material 9 may be the heat transfer collar component 3 .

[0186] Referring to Figure 3, a side schematic view of a non-combustion aerosol delivery device 100 for generating an aerosol from the aerosol generating subcomponent 4 of the article 1 of Figure 1 is shown. The non-combustion aerosol delivery device 100 generates an aerosol from an aerosol generating medium / material, such as the aerosol material of the consumable 110, as described above. Broadly speaking, the device 100 can be used to heat a replaceable article 110 comprising an aerosol generating medium or filter segment, such as the articles 1, 50 shown in Figures 1 or 2 or described elsewhere herein, to generate an aerosol or other inhalable medium that is inhaled by a user of the device 100. The device 100 and the replaceable article 110 together form a system.

[0187] The device 100 comprises a housing 102 (in the form of an outer cover) that surrounds and houses the various components of the device 100. The device 100 has an opening 104 at one end through which the article 110 may be inserted for heating by the heating assembly. In use, the article 110 may be fully or partially inserted into the heating assembly where it may be heated by one or more components of the heater assembly.

[0188] The device 100 may further include a user-operable element 112, such as a button or switch, that when pressed operates the device 100. For example, a user may turn the device 100 on by operating the switch 112.

[0189] The device 100 may also include electrical components, such as a socket / port 114 that can accept a cable to charge a battery in the device 100. For example, the socket 114 may be a charging port, such as a USB charging port.

[0190] 4, there is shown an amorphous solid material 9. The amorphous solid material 9 is in the form of a ribbon 120. The ribbon 120 of amorphous solid material 8 is wound on a reel 121 which may be placed on a bobbin (not shown) for feeding to an assembly apparatus (not shown), as will be described in more detail below. The ribbon 120 of amorphous solid material 9 is a mass of amorphous solid material 8 that has not been cut into a plurality of elongated strips.

[0191] Referring now briefly to FIG. 5, there is shown an amorphous solid material 9 cut into a plurality of long strips 10. The amorphous solid material 9 may be cut into the plurality of long strips 10 by a cutting device (not shown), as will be described in more detail below. As shown in FIG. 5, the plurality of long strips 10 of amorphous solid material 8 are twisted into a rope 130. The rope 130 of long strips 10 of amorphous solid material 9 may have a higher tensile strength than the untwisted plurality of long strips 10 or ribbons 120 of amorphous solid material 9, which may aid in the manufacturing process. The rope 130 of amorphous solid material 9 may be wound onto a bobbin (not shown) and fed directly from the bobbin to an assembly apparatus (not shown).

[0192] 1-5 and the above description, it will be appreciated that the amorphous solid material 9 may be provided to the components 2, 3, 4 in any of the forms described above, i.e., a ribbon, a plurality of elongated strips, or a rope of twisted elongated strips. It will be appreciated that when more than one amorphous solid material 9 is present, the amorphous solid material 9 may be present in more than one form.

[0193] 6, a plurality of long strips 10 of amorphous solid material 9 are shown wound on a bobbin 140. The plurality of long strips 10 are randomly wound on the bobbin 140 after the ribbon has been strip cut, i.e. cut into long strips. The plurality of long strips 10 of amorphous solid material 9 may be unwound from the bobbin 140 and fed directly to an assembly machine (not shown) during the manufacture of a component.

[0194] 7, there is shown a bobbin 150 on which are wound multiple long strips 10 of amorphous solid material 9. In this embodiment, the multiple long strips 10 of amorphous solid material 9 are spirally wound around the bobbin 150. That is, the multiple long strips 10 of amorphous solid material 9 are wound around the bobbin 150 at an angle to a plane extending perpendicular to the axis of rotation of the bobbin 150. The multiple long strips 10 of amorphous material 9 are wound from one end of the bobbin to the other to form a layer 151 of long strips 10 on the bobbin 150.

[0195] Between each layer 151 of the long strips 10 of amorphous solid material 9 is a sheet 152. The sheet 152 is configured to prevent the long strips 10 of amorphous solid material 9 in one layer 151 from sticking to the long strips 10 of amorphous solid material 9 in an adjacent layer. The sheet 152 is sacrificial, that is, the sheet 152 is removed from the amorphous solid material 9 during the manufacturing process. The sheet 152 may be formed from, for example, but not limited to, paper.

[0196] 8, an exemplary cutting device 160 configured to cut a ribbon 161 of amorphous solid material 9 into a plurality of elongated strips 10 of amorphous solid material 9 is shown. The cutting device 160 comprises at least one rotary cutting knife 162 connected to a rotatable shaft 163. In this embodiment, the shaft 163 extends substantially horizontally from a frame 164 of the cutting device 160, and the at least one rotary knife extends substantially vertically from the shaft 163. The cutting device 160 preferably comprises a plurality of cutting knives 162. The plurality of cutting knives 162 cut the ribbon 161 of amorphous solid material 9 into a plurality of elongated strips 10 of amorphous solid material 9.

[0197] The plurality of cutting knives 162 are spaced apart in a direction parallel to the longitudinal axis of the shaft 163. The plurality of cutting knives 163 are spaced apart a distance equal to the desired width of the elongated strips 10. The cutting knives 162 are preferably equally spaced apart such that the widths of the plurality of elongated strips 10 are equal in order to provide a more consistent delivery of the substance to be delivered.

[0198] The cutting device 160 further comprises a support member 165 configured to support the weight of the amorphous solid material 8 as it is cut by the rotating knife 162. The support member 165 may be a plate extending generally horizontally from the frame 164. The support member 165 may be slightly curved to keep the amorphous solid material 9 under tension during the cutting process.

[0199] The support member 165 is disposed above the rotating shaft 163. The support member 165 includes at least one opening or slit 166 configured to allow at least one rotating knife 162 to pass through the support member 165. The support member 165 may include one slit 166 per knife 162.

[0200] In some embodiments, the cutting device 160 can include additional rollers 167, 168. The additional rollers 167, 168 can transport the amorphous solid material 9 through the cutting device 160. The additional rollers 167, 168 can also keep the amorphous solid material 9 under tension as it passes through the cutting device 160. The cutting device 160 can include one roller 167 upstream of the cutting knife 162 and one roller 168 downstream of the knife 162. The cutting device 160 may comprise a spreading mechanism. The spreading mechanism is configured to spread the long strips 10 of the amorphous solid material 9. The spreading mechanism spreads the long strips 10 before they are incorporated into the first material 7 of the article 1, 50. This advantageously reduces bunching of the long strips. That is, the spreading mechanism helps to reduce exceptional concentration or grouping of the long strips 10 in the first material 7 and to keep the long strips 10 spaced apart in the first material 7.

[0201] In one example, the spreading mechanism can include a roller having a curved surface. That is, the roller can have a curved surface in the form of a concave curve over its length. For example, the surface at the midpoint of the roller's length can have a smaller radius than the surface at the ends of the roller's length. The roller forming the spreading mechanism can be roller 168 downstream of the rotary cutting knife 162 in the cutting device 160.

[0202] In another embodiment, the rollers forming the spreading mechanism may be provided immediately upstream of the apparatus for assembling the components of the article 1, 50. This has the advantage of reducing the time that the multiple strips 10 can bunch or tangle before entering the apparatus. In some embodiments, the spreading mechanism may be formed by devices other than concave rollers.

[0203] In some embodiments, the cutting device 160 may be provided as a separate apparatus. The cutting device 160 may be used to cut the ribbon 161 of amorphous sheet material 9 into a plurality of long strips 10 of amorphous solid material 9, which are wound on bobbins, as shown in Figures 6 and 7. Alternatively, the cutting device 160 may be used to cut the ribbon 161 of amorphous sheet material 9 into a plurality of long strips 10 of amorphous solid material 9 online, i.e., the plurality of long strips 10 of amorphous solid material 9 leaving the cutting device 160 may be directly transferred to a component assembly apparatus (not shown).

[0204] In some embodiments, the cutting device 160 may be provided as a module configured to be attached to an existing component assembly apparatus (not shown). It will be understood that the cutting device 160 shown in Figure 8 is merely exemplary, and that other cutting devices may be used to cut the ribbon of amorphous solid material into a plurality of elongated strips.

[0205] In one embodiment, the ribbon 161 of amorphous solid material 9 may have a width of 18 mm. The ribbon 120 is wound on a reel and / or bobbin. The ribbon 120 is then arranged to be fed to a cutting device 160, as shown in FIG. 8. In such an embodiment, the cutting device 160 may comprise seven cutting knives 162. The seven cutting knives 162 are configured to cut the ribbon 161 into eight long strips 10. The seven cutting knives 162 are evenly spaced such that the ribbon 161 is cut into eight long strips 10, each having a width of about 2.25 mm.

[0206] In embodiments in which the first material 7 is a reconstituted tobacco material, the reconstituted tobacco material may be pulled through the cutting device 160 along with the ribbon 161 of amorphous solid material 8. Thus, both the first material 7 and the second material 8 may be cut simultaneously into a plurality of elongated strips.

[0207] In some embodiments, the width of the reconstituted tobacco material sheet may be the same as the width of the ribbon 161 of amorphous solid material 9. In other embodiments, the width of the reconstituted tobacco material sheet may be wider than the width of the ribbon 161 of amorphous solid material 9. In such embodiments, some cutting knives 162 may cut both the reconstituted tobacco material sheet and the amorphous solid material 9, and some cutting knives may only cut the reconstituted tobacco material sheet.

[0208] 9, a side perspective view of a portion of an assembly apparatus 170 for manufacturing components for an article as described above. The assembly apparatus 170 comprises a first material transfer apparatus 171. In this embodiment, the first material transfer apparatus 171 is a cut rag tobacco transfer apparatus, although it will be appreciated that in alternative embodiments, the first material transfer apparatus 171 may be a reconstituted tobacco transfer apparatus capable of transferring reconstituted tobacco in the form of a sheet or strip. The first material transfer apparatus 171 may comprise a conveyor belt. The first material transfer apparatus 171 may feed the first material 7 towards a garniture 172 of the apparatus 170. The assembly apparatus 170 further comprises a wrapping material feeder 173 comprising rollers 174 that feed wrapping material 175 to the garniture 172. The apparatus 170 further comprises a second material transfer apparatus 176 configured to feed a second material to the garniture 172. The apparatus 170 may comprise the cutting device 160 or the bobbins 140, 150 described above.

[0209] The method of manufacturing the above article 1, 50 includes the step of preparing a first material for forming the components 2, 3, 4 of the article 1, 50. For example, the first material 7 may be a tobacco material, which may be prepared by conventional steps such as drying and cutting. The method further includes the step of transporting the first material 7 continuously through an assembly device 170. For example, the first material 7 may be transported along a conveyor belt towards a garniture. The method further includes the step of adding at least one continuous amorphous solid material 9 to the first material 7.

[0210] By adding the amorphous solid material 9 to the first material 7 just before the components are formed, the known step of chopping the amorphous solid material 9 and adding it to the mixing cylinder with the first material 7 can be avoided. Avoiding the chopping and mixing step for the amorphous solid material 9 is advantageous for several reasons. First, the amorphous solid material is subjected to less kinetic excitation, so that the volatile substance to be delivered contained in the amorphous solid material is not lost as much. Second, by controlling the delivery of the amorphous solid material 9 to the first material 7, more homogeneous components 2, 3, 4 can be created. The method allows the variation of the substance to be delivered between the individual components 2, 3, 4 to be less than 5%, and in some cases less than 3%. Furthermore, there is less chance of degradation of the amorphous solid than in the mixing cylinder. Finally, safety concerns regarding the combustion of the released substance to be delivered in the mixing cylinder are avoided.

[0211] The disclosed method of forming components comprising an amorphous solid material 9 allows manufacturers to create final products with a higher content of the substance to be delivered. For example, it has been demonstrated that such a method allows components to be created with the same amount of amorphous solid material 9 containing three times more of the substance to be delivered, i.e. menthol, than with known methods. This advantageously means that products with a higher content of the substance to be delivered can be created, or that the amount of substance to be delivered required to create a product with a given content is reduced due to reduced losses of the substance to be delivered during the manufacturing process, which allows lower manufacturing costs.

[0212] In one method, a single amorphous solid material 9 is to be added to the first material 7. Such a method includes unwinding a ribbon 120 of amorphous solid material 9 from a bobbin and transporting the ribbon 120 directly to an assembly apparatus.

[0213] In one method, multiple long strips 10 of amorphous solid material 9 are to be added to the first material 7. One such method includes unwinding a ribbon 120 of amorphous solid material 9 from a bobbin and cutting the ribbon 120 of amorphous solid material 9 into multiple long strips 10. The cutting may be performed by a cutting device 160 as described above.

[0214] The method of forming an article comprising a plurality of elongated strips 10 of amorphous solid material 9 may further include feeding the plurality of elongated strips 10 of amorphous solid material 9 directly from the cutting device 160 to the assembly apparatus 170. In one method, the plurality of elongated strips 10 of amorphous solid material 9 are fed directly from the cutting device 160 to the assembly components 170 immediately prior to a component forming device, such as a garniture. Such a method is known as on-line cutting.

[0215] The method of forming an article comprising an amorphous solid material 9 in the form of a ribbon 120 or elongated strip 10 may further include the steps of transporting the first material 7 and the amorphous solid material 9 through a component formation device, forming a seamless component, encasing the seamless component in a wrapper, and cutting the seamless component into individual components.

[0216] The step of cutting the seamless component releases tension in the amorphous solid material 9 such that the amorphous solid material 9 reduces in length to the inside of both ends of the component, such that both ends of the amorphous solid material are hidden from view.

[0217] Where the first material 7 is cut rag tobacco, it is envisioned that the multiple elongated strips 10 of amorphous solid material 9 may be incorporated into the component in one of at least two ways.

[0218] In the first method, tobacco is "airlifted" onto a conveyor belt 171 and fed to a garniture section 172 where wrapping material 175 is applied. The plurality of long strips 10 are fed to a tobacco rod forming section of the component making machine. That is, the plurality of long strips 10 are fed to the part of the machine that brings together the tobacco rods to form a tobacco rod. Thus, the plurality of long strips 10 are fed in parallel with the tobacco material. The location where each of the plurality of long strips 10 meets the tobacco material on the conveyor belt 171 will determine where each of the plurality of long strips 10 may be located in the final rod component.

[0219] In the second method, the multiple elongated strips 10 are fed in parallel with the winding material 175 as it is fed to the garniture 172. Thus, the multiple elongated strips 10 are incorporated into the final component side-by-side with the winding material 175. In some embodiments, this method can result in multiple elongated strips 10 being substantially circumferentially disposed within the final component.

[0220] Alternatively, where the first material 7 comprises a plurality of elongated strips of tobacco or filter material, the plurality of elongated strips 10 of amorphous solid material 9 may be added to the first material 7 in the same way that threads are added to the first material, i.e. cast into and positioned within the stream of filter material or tobacco strip.

[0221] As mentioned above, in some embodiments, the first material 7 and the second material 8 are supplied from separate bobbins and aligned and combined upstream of the cutting device 160 before being cut into multiple strips simultaneously. It has been found that the positioning of the ribbon 120 on the first material 7 can affect the positioning of the multiple strips of the second material 8 in the final aerosol generation component portion 4.

[0222] For example, referring to Figures 10-11, it can be seen that the placement of a ribbon 120 of second material 8 centrally on a sheet of first material 7 clusters multiple strips of second material 8 in one location. This cluster of multiple strips of second material 8 is generally positioned at irregular distances from the center of the aerosol generating component portion 4.

[0223] 12-13, it can be seen that the arrangement of ribbons 120 of second material 8 in two sections separated by a gap on a sheet of first material clusters the strips of second material 8 in two separate groups. These populations of strips of second material 8 are generally positioned at irregular distances from the center of the aerosol generating component portion 4 and at irregular angular positions relative to each other.

[0224] Thus, by spreading the second material 8 into multiple smaller ribbons 120 on the sheet of first material 7, the cut strips of the second material 8 are more evenly spaced from one another on the sheet of first material 7, and a more uniform distribution of the multiple strips of the second material 8 in the first material 7 can be obtained in the final aerosol generating component portion 4 when the portion 4 is formed using a method of simultaneously strip cutting the first material 7 and the second material 8. In some embodiments, the multiple ribbons 120 of the second material 8 may be provided from multiple bobbins. Alternatively, a single ribbon may be cut into smaller ribbons that are positioned against the sheet of first material 7 before being fed to the strip cutter 160.

[0225] The positioning of the second material 8 relative to the first material 7 may be determined using an apparatus 200 similar to that shown in Fig. 14. The apparatus 200 comprises a first bobbin 201 on which the first material 7 is wound, and a second bobbin 202 on which the second material 8 is wound. The apparatus 200 is configured to perform simultaneous cutting of the first material 7 and the second material 8 using a cutting device 160 similar to that already described.

[0226] In this embodiment, the second bobbin 202 may have at least one degree of freedom, indicated by the arrow in Figure 14. That is, the second bobbin 202 may be capable of moving parallel to the axis of rotation of the bobbin 202 to change the position of the second material 8 relative to the first material 7.

[0227] The apparatus may further comprise at least one rotatable guiding drum 203 provided between the second bobbin 202 and the cutting device 160. The at least one guiding drum 203 may determine a material path of the second material 8 between the second bobbin 202 and the cutting device 160. The at least one guiding drum 203 may have at least one degree of freedom. That is, the at least one guiding drum 203 may be capable of moving parallel to the axis of rotation of the guiding drum 203 in order to change the position of the second material 8 relative to the first material 7. By moving the second bobbin 202 and the guiding drum 203, the position of the strip of the second material 8 in the final rod may be changed.

[0228] When two second bobbins 202 are used with respective guiding drums 203, the two ribbons 120 of the second material 8 can be moved relative to the first material 7 and each other. Thus, when the two ribbons of the second material 8 are aligned with the first material 7, a gap can exist between the two ribbons of the second material 8.

[0229] 15, the first material 7 and the second material 8 may be configured to be cut separately. In such an arrangement, the apparatus 300 may have a first cutting device 301 configured to cut the first material 7 and a second cutting device 302 configured to cut the second material 7. Furthermore, at least one guiding drum 203 may be arranged after the second cutting device 302 and before the gatherer.

[0230] In this embodiment, the second bobbin 202 may have at least one degree of freedom, i.e., the second bobbin 202 may be capable of moving parallel to the axis of rotation of the bobbin 202 in order to change the position of the second material 8 relative to the first material 7. Furthermore, in this embodiment, the second cutting device 302 may have at least one degree of freedom, i.e., the cutting disk of the second cutting device 302 may be capable of moving parallel to the axis of rotation of the second cutting device 302 in order to change the width of the individual strips of the second material 8.

[0231] Furthermore, at least one guiding drum 203 may have at least one degree of freedom. In the embodiment shown in FIG. 15, the first guiding drum 304 may be able to move parallel to its axis of rotation to change the position of the strip of second material 8 relative to the first material 7. Furthermore, the second guiding drum 305 has at least two degrees of freedom. That is, the second guiding drum 305 may be able to move parallel to its axis of rotation to change the position of the strip of second material 8 relative to the first material 7, and may also be able to move in the other direction perpendicular to the width of the first material 7, i.e. towards and away from the first material 7, to bring about a final position in the radial direction within the rod. Thus, when two adjacent groups of strips of the second material 8 are aligned with the first material 7, there may be a gap between the two adjacent groups.

[0232] Finally, the method may further include combining the component with other components to form an article.

[0233] In an alternative method of forming an article comprising a plurality of elongated strips 10 of amorphous solid material 9, instead of performing on-line cutting, the method may include winding the plurality of elongated strips 10 of amorphous solid material 9 onto a bobbin after the cutting step in preparation for adding the plurality of elongated strips 10 of amorphous solid material 9 to the first material 7 in the assembly apparatus 170. In one method, the winding step may further include spirally winding the plurality of elongated strips 10 of amorphous solid material 9 onto a bobbin after the cutting step in preparation for adding the plurality of elongated strips 10 of amorphous solid material 9 to the first material 7 in the assembly apparatus 170. In one method, the spiral winding step may further include disposing a sheet between layers of the elongated strips 10 of amorphous solid material 9.

[0234] In an alternative method, the ribbon of amorphous solid state material and the first material are wound simultaneously on the same bobbin. The ribbon of amorphous solid state material and the first material may be co-wound, i.e., the two materials may be layered over one another. Thus, the layers may alternate as you move radially from the center of the bobbin.

[0235] The method may further include simultaneously unwinding the ribbon of amorphous solid material and the first material from a bobbin. The materials will form a two-ply ribbon as they are removed from the bobbin. The ribbon of amorphous solid material and the first material may be simultaneously cut. In some embodiments, the first material may be reconstituted tobacco.

[0236] In one method, the step of winding the multiple long strips 10 of amorphous solid material 9 may further include twisting the multiple long strips 10 of amorphous solid material 10 to form a rope 130 to be fed to an assembly apparatus 170 prior to winding the multiple long strips 10 onto the bobbins 140, 150.

[0237] The various embodiments described herein are presented only to aid in the understanding and teaching of the claimed features. These embodiments are provided merely as a representative sample of embodiments and are not intended to be comprehensive and / or exclusive. It should be understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limitations on the scope of the invention as defined by the claims or to the equivalents of the claims, and 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 comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Moreover, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. 1. An article for use as or as part of an aerosol delivery system, comprising a component having an upstream end and a downstream end, the component comprising a first material and a second material, the second material comprising a plurality of elongated strips of amorphous solid material extending substantially parallel to one another, wherein the amorphous solid material extends substantially longitudinally through the component between the upstream end and the downstream end and has a length that is at least about 70% of the length of the component between the upstream end and the downstream end.

2. The article of claim 1 , wherein the plurality of elongated strips comprises between 2 and 50 strips, or between 5 and 25 strips, or between 7 and 21 strips.

3. 3. The article of claim 1 or 2, wherein the second material comprises at least one strip having an upstream end and a downstream end, the upstream end of the strip extending to within 5 mm of the upstream end of the component and the downstream end of the strip extending to within 5 mm of the downstream end of the component.

4. 4. The article of any one of claims 1 to 3, wherein the second material comprises a sheet material and the tensile strength of the second material in the longitudinal direction is at least about 4 N / 15 mm, and / or in the range of about 170 N / 15 mm to about 200 N / 15 mm.

5. The article of any one of claims 1 to 4, wherein the amorphous solid material comprises a substance to be delivered.

6. The article of claim 5 , wherein the substance to be delivered is menthol.

7. The article of claim 6, wherein the amorphous solid material comprises in the range of 2 mg to about 20 mg of menthol.

8. The article of any one of claims 1 to 7, wherein the second material at least partially surrounds the first material.

9. 9. The article of any one of claims 1 to 8, wherein the second material is disposed within the first material and / or the second material is disposed within the first material and is substantially surrounded on all sides by the first material.

10. The article of any one of claims 1 to 9, wherein the first material is an aerosol-forming material.

11. The article of claim 10 , wherein the aerosol-forming material comprises a tobacco material.

12. 12. The article of claim 11, wherein the tobacco material is a cut rag tobacco material or a reconstituted tobacco material.

13. The article of any one of claims 1 to 12, wherein the component forms an aerosol-generating portion of the article.

14. 10. The article of any one of claims 1 to 9, wherein the first material comprises a filter material, optionally wherein the first material comprises a paper filter material having a density of about 0.1 to about 0.45 grams per cubic centimeter.

15. The article of any one of claims 1 to 11 or claim 14, wherein the component forms an aerosol-modifying portion of the article.

16. The article of any one of claims 1 to 11 or claim 14, wherein the component forms an aerosol modifying part of the article which is a combustion based aerosol delivery system.

17. The article of any one of claims 1 to 16, which is rod-shaped.

18. The article of any one of claims 1 to 17, wherein the component further comprises a wrapper configured to surround the first and second materials.

19. A package of articles comprising the articles of any one of claims 1 to 18, wherein the amount of substance to be delivered in each article varies by less than 5%.

20. A non-combustion aerosol delivery system comprising the article of any one of claims 1 to 18.

21. 19. An amorphous solid material for use in an article according to any one of the preceding claims.

22. 22. The amorphous solid material of claim 21 , configured to extend substantially longitudinally through a component between said upstream end and said downstream end and having a length that is at least about 70% of a length of said component between said upstream end and said downstream end.

23. 22. The amorphous solid material of claim 21, when incorporated into the article of any one of claims 1 to 18, extending substantially longitudinally through the component between the upstream end and the downstream end and having a length of at least about 70% of the length of the component between the upstream end and the downstream end.

24. 24. An amorphous solid state material according to any one of claims 21 to 23, wherein the tensile strength of the amorphous solid state material is in the range of about 2 N / 15 mm to about 300 N / 15 mm.

25. 25. The amorphous solid material of any one of claims 21 to 24, having a length in the range of about 8 mm to about 48 mm.

26. 26. An amorphous solid material according to any one of claims 21 to 25, having a width in the range of about 0.5 mm to about 3 mm.

27. 27. The amorphous solid material of any one of claims 21 to 26, having an aspect ratio in the range of about 2.5 to about 100.

28. 50mm ２ 28. An amorphous solid material according to any one of claims 21 to 27, comprising in the range of 0.25 mg to about 1 mg of the substance to be delivered per tablet.

29. 30. The amorphous solid material of claim 28, wherein the substance to be delivered is menthol.

30. A component for use in an article according to any one of claims 1 to 18, having an upstream end and a downstream end, 1. A component comprising a first material and a second material, the second material comprising a plurality of elongate strips of amorphous solid material extending substantially parallel to one another, the amorphous solid material extending substantially longitudinally through the component between the upstream end and the downstream end and having a length that is at least about 70% of the length of the component between the upstream end and the downstream end.

31. A method for producing an article according to any one of claims 1 to 18, comprising the steps of: Providing a first material for forming a component of an article; transporting the first material continuously through an assembly apparatus; unwinding a ribbon of amorphous solid material from a bobbin; cutting the ribbon of amorphous solid state material into a plurality of elongated strips; adding said plurality of elongated strips of continuous amorphous solid material to said first material.

32. feeding a plurality of elongated strips of said amorphous solid state material directly to a component forming device of said assembly apparatus prior to said component forming devices; 32. The method of claim 31 , further comprising:

33. 32. The method of claim 31, further comprising winding the ribbon of amorphous solid state material and the first material simultaneously onto the same bobbin.

34. 34. The method of claim 33, wherein the ribbon of amorphous solid material and the first material are co-wound.

35. Simultaneously unwinding the ribbon of amorphous solid state material and the first material from the bobbin.

35. The method of claim 33 or 34, further comprising:

36. A method according to any one of claims 31 to 35, wherein cutting the ribbon of amorphous solid material and the first material is performed simultaneously.

37. A method according to any one of claims 33 to 36, wherein the first material is reconstituted tobacco.

38. The method of claim 31, wherein the plurality of elongated strips of continuous amorphous solid material are aligned with the first material before the amorphous solid material and the first material are fed to a component forming device of the assembly apparatus.

39. 40. The method of claim 38, wherein a plurality of ribbons of continuous amorphous solid material are aligned with and spaced across a width of the first material.

40. 40. The method of claim 38 or 39, wherein a plurality of ribbons of continuous amorphous solid material are aligned with the first material and spaced across a width of the first material such that there are gaps between adjacent ribbons of continuous amorphous solid material.

41. A method according to any one of claims 38 to 40, wherein the plurality of elongated strips of continuous amorphous solid material are aligned with the first material prior to simultaneously cutting the amorphous solid material and the first material.

42. The method of claim 38 or 39, wherein the plurality of elongated strips of continuous amorphous solid material are aligned with the first material after the amorphous solid material and the first material are cut.

43. 43. The method of claim 42, wherein a plurality of ribbons of continuous amorphous solid material are cut into strips to form a plurality of strips, which are then aligned with the first material and spaced across a width of the first material such that there are gaps between adjacent strips of continuous amorphous solid material.

44. winding a plurality of elongated strips of said amorphous solid state material onto bobbins in preparation for addition to said first material in said assembly apparatus.

33. The method of claim 32, further comprising:

45. spirally winding a plurality of elongated strips of said amorphous solid state material onto said bobbins in preparation for addition to said first material in said assembly apparatus.

45. The method of claim 44, further comprising:

46. twisting the plurality of elongated strips of amorphous solid material to form a rope to be fed to the assembly apparatus prior to the component forming device, prior to winding the plurality of elongated strips onto the bobbin.

46. ​​The method of claim 44 or 45, further comprising:

47. transporting the first material and at least one strip of the amorphous solid material through the component formation device; forming a seamless component; enclosing the seamless component in a wrapper; cutting the seamless component into separate components; The method of any one of claims 32, 38 to 46, further comprising:

48. 48. The method of claim 47, wherein the step of cutting the seamless component releases tension in at least one strip of the amorphous solid material such that the amorphous solid material reduces in length to inside both ends of the component.

49. combining said component with other components of said article to form said article.

49. The method of claim 47 or 48, further comprising:

50. A method for producing an amorphous solid material according to any one of claims 21 to 29, comprising the steps of: unwinding the ribbon of amorphous solid material from a bobbin and cutting the ribbon of amorphous solid material into a plurality of elongated strips. A method comprising:

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