Components used in a flammable aerosol supply system

Abstract

A component (2) for a non-flammable aerosol delivery article (1) and a method of forming the component. The component includes a body (7) formed from a sheet of aerosol-generating material, the body (7) having a void (8), and at least one tube (11) disposed in the void within the body. The sheet of aerosol-generating material has an interior edge that at least partially defines a closed end of the void. The void has an open end at a plane of the end of the body. The application also discloses an apparatus for manufacturing the component.

Description

Technical Field of the Invention

[0001] The present invention relates to components of a non-combustible aerosol supply article and a method of forming such components. Background of the Invention

[0002] Certain delivery systems generate an aerosol during use, which is inhaled by a user. For example, a tobacco heating device heats an aerosol-forming substrate, such as tobacco, to form an aerosol by heating the substrate without burning it. Such delivery systems generally include a heating device having a heating element that, when heated, heats the aerosol-forming substrate to emit an aerosol. SUMMARY OF THE INVENTION

[0003] According to an embodiment of the present invention, in a first aspect, a component for a non-combustible aerosol delivery system is provided, the component comprising a body formed from a sheet of aerosol-forming material and having a void, and at least one tube disposed within the void of the body, the sheet of aerosol-forming material having an internal edge that at least partially defines a closed end of the void, the void having an open end in a plane of an end of the body.

[0004] In some embodiments, the sheet of aerosol-forming material can comprise a plurality of elongated strips extending between laterally extending bands of aerosol-forming material.

[0005] In some embodiments, the first internal edge can be a cut in the sheet of aerosol-forming material.

[0006] In some embodiments, the sheet of aerosol-forming material can comprise a slit forming the first internal edge.

[0007] In some embodiments, the sheet of aerosol-forming material can comprise an opening, the edge of the opening comprising the first internal edge of the sheet material.

[0008] In some embodiments, the cross-section of the opening may be substantially rectangular.

[0009] In some embodiments, the sheet of aerosol-generating material can comprise a first outer edge and a second outer edge at the axial ends of the sheet material.

[0010] In some embodiments, at least one tube may be arranged coaxially with the body of the aerosol-generating material.

[0011] In some embodiments, the end of the tube may be arranged in the plane of the end of the body of the aerosol-generating material.

[0012] In some embodiments, the tube may be configured to accommodate a susceptor.

[0013] In some embodiments, the tube can contain at least one reactive substance and / or aerosol-modifying substance.

[0014] In some embodiments, the tube may be formed from paper.

[0015] In some embodiments, the end of the tube may be arranged to contact and engage with the closed end wall of the void.

[0016] In some embodiments, the first inner edge may be arranged at an interval in the range of about 5 mm to about 45 mm longitudinally from the open end of the void.

[0017] In another aspect of the present invention, a method of manufacturing a component for a delivery system is provided, the method comprising the steps of providing an assembly comprising at least one tube and a sheet of aerosol - generating material having a first inner edge and a second inner edge; disposing the sheet material within a body such that the body has a void that houses at least one tube between the first inner edge and the second inner edge, wherein the first inner edge and the second inner edge at least partially define a closed end of the void; and cutting the body between the first inner edge and the second inner edge to provide two body portions having a void with an open end.

[0018] In some embodiments, the step of providing the assembly comprises cutting a sheet of aerosol - generating material to form a plurality of elongated strips of aerosol - generating material.

[0019] In some embodiments, the step of providing the assembly can include forming a first inner edge and a second inner edge in the sheet material.

[0020] In some embodiments, the step of forming a first inner edge and a second inner edge in the sheet material can include cutting the sheet material to form the first inner edge and the second inner edge and, optionally, cutting through the entire thickness of the sheet material to form the first inner edge and the second inner edge.

[0021] In some embodiments, the step of forming a first inner edge and a second inner edge can include cutting the sheet material using a knife and / or a laser.

[0022] In some embodiments, the step of forming a first inner edge and a second inner edge can include forming slits in the sheet material.

[0023] In some embodiments, the step of forming the first inner edge and the second inner edge comprises forming an opening in the sheet material such that the edges of the opening include the first inner edge and the second inner edge of the sheet material, and optionally, the opening is substantially rectangular.

[0024] In some embodiments, the step of forming the opening can include forming a notch in the sheet material.

[0025] In some embodiments, the step of providing the assembly can include providing a sheet material having a first inner edge and a second inner edge, and then supplying at least one tube to the sheet material. Optionally, the step of providing the assembly can include forming the first inner edge and the second inner edge in the sheet material, and then supplying at least one object to the sheet material.

[0026] In some embodiments, the step of providing the assembly can include providing the sheet material, supplying at least one object to the sheet material, and then forming the first inner edge and the second inner edge in the sheet material.

[0027] The method can further include the step of crimping the sheet material, and optionally, crimping the sheet material to a crimp depth in the range of 0.1 mm to 2 mm.

[0028] The method can further include the step of crimping the sheet material after the first inner edge and the second inner edge are formed.

[0029] The method can further include the step of crimping the sheet material before the first inner edge and the second inner edge are formed.

[0030] In some embodiments, the step of providing the assembly can include providing a continuous web of sheet material.

[0031] The method can further include forming a plurality of internal edges at regular intervals in the continuous web.

[0032] The method can include moving the continuous web and, as the continuous web moves along a conveyance path, supplying at least one tube at regular intervals.

[0033] In some embodiments, the step of disposing the sheet material on the body can include gathering the sheet material to form the body.

[0034] In some embodiments, the first wall portion can be defined by gathering a first internal edge of the sheet material, and / or the second wall portion can be defined by gathering a second internal edge of the sheet material.

[0035] The method may detect information indicating at least one internal edge of the sheet material.

[0036] The method can include controlling the position at which at least one tube is supplied to the sheet material based on information indicating at least one internal edge detected by a sensor.

[0037] The method can include controlling a tube supply device based on information indicating the position of at least one internal edge detected by a sensor to control the position at which at least one tube is supplied to the sheet material, and optionally, controlling the timing and / or frequency of distributing at least one tube to the sheet material.

[0038] In another aspect of the present invention, there is provided an apparatus for manufacturing components for a delivery system, the apparatus comprising an edge forming device configured to form a first internal edge in a sheet of aerosol-generating material, a tube supply device configured to dispose at least one tube on the sheet of aerosol-generating material, and a body forming device configured to dispose the sheet of aerosol-generating material within a body such that the body comprises a void for accommodating at least one tube, wherein the first internal edge at least partially defines a boundary of the void.

[0039] Embodiments of the present invention are described by way of example only with reference to the accompanying drawings.

Brief Description of the Drawings

[0040]

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Figure 10

[0041] As used herein, the term "delivery system" is intended to encompass systems that deliver at least one substance to a user, (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smoking materials) a combustible aerosol supply system such as a cigarette, cigarillo, cigar, and pipe tobacco or self-rolled or self-made tobacco, and a non-combustible aerosol supply system that releases compounds from an aerosol-forming material without burning the aerosol-forming material, such as an electronic cigarette, a tobacco heating product, and a hybrid system that generates an aerosol using a combination of an aerosol-forming material, including, but not limited to, oral products such as lozenges, gums, patches, articles containing inhalable powders, and oral tobacco containing chewing tobacco or moist chewing tobacco, a delivery system without an aerosol that delivers at least one substance to a user through the oral cavity, nose, skin, or otherwise, wherein the at least one substance may or may not contain nicotine, a delivery system without an aerosol and includes.

[0042] According to the present disclosure, a "combustible" aerosol supply system is a system in which an aerosol-forming material that constitutes the aerosol supply system (or a component thereof) is burned or ignited during use to facilitate the delivery of at least one substance to a user.

[0043] In some embodiments, the delivery system is a combustible aerosol supply system such as a system selected from the group consisting of a cigarette, cigarillo, and cigar.

[0044] In some embodiments, the present disclosure relates to components such as filters, filter rods, filter segments, tobacco rods, spills, aerosol modifier release components such as capsules, threads, or beads, or papers such as plug wraps, tip papers, or cigarette papers for use in a combustible aerosol supply system.

[0045] According to the present disclosure, a "non-combustible" aerosol supply system is a system in which the aerosol-generating material that constitutes the aerosol supply system (or a component thereof) is not combusted or burned to facilitate the delivery of at least one substance to the user.

[0046] In some embodiments, the delivery system is a non-combustible aerosol supply system such as a non-combustible aerosol supply system that is powered.

[0047] In some embodiments, the non-combustible aerosol supply system is an electronic cigarette, also known as a suction device or an electronic nicotine delivery system (ENDS), but it should be noted that the presence of nicotine in the aerosol-generating material is not a prerequisite.

[0048] In some embodiments, the non-combustible aerosol supply system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a tobacco heating system.

[0049] In some embodiments, the non-combustible aerosol supply system is a hybrid system that uses a combination of aerosol-generating materials to generate an aerosol, and one or more of the aerosol-generating materials may be heated. Each of the aerosol-generating materials can be in the form of, for example, a solid, liquid, or gel, and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material can include plant-based materials such as, for example, tobacco or non-tobacco products.

[0050] Typically, a non-combustible aerosol supply system can include a non-combustible aerosol supply device and a consumable used with the non-combustible aerosol supply device.

[0051] In some embodiments, the present disclosure relates to consumables configured to be used with a non-combustible aerosol supply device and including an aerosol-forming material. These consumables may sometimes be referred to as articles throughout the present disclosure.

[0052] In some embodiments, a non-combustible aerosol supply system, a non-combustible aerosol supply device of a non-combustible aerosol supply system, etc. can include a power source and a controller. The power source may be, for example, a power supply or a heat source. In some embodiments, the heat source includes a carbon substrate, and the carbon substrate can be energized to disperse power in the form of heat to a heat transfer material adjacent to the aerosol-forming material or the heat source.

[0053] In some embodiments, a non-combustible aerosol supply system can include an area for accommodating a consumable, an aerosol generator, an aerosol generation area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0054] In some embodiments, consumables used with a non-combustible aerosol supply device can include an aerosol-forming material, an aerosol-forming material storage area, a component for transferring the aerosol-forming material, an aerosol generator, an aerosol generation area, a housing, wrapping paper, a filter, a mouthpiece, and / or an aerosol modifier.

[0055] In some embodiments, the present disclosure relates to components such as filters, filter rods, filter segments, tobacco rods, spills, etc., aerosol modifier release components such as capsules, threads, or beads, or papers such as plug wrap or papers such as chip papepe used in a non-combustible aerosol supply system.

[0056] In some embodiments, the delivery system is a non-aerosol delivery system that delivers at least one substance to the user through the oral cavity, nose, skin, or otherwise, without forming an aerosol, including, but not limited to, oral products such as lozenges, gums, patches, articles containing inhalable powders, and oral tobacco including hookah or moist hookah tobacco, and the at least one substance may or may not contain nicotine.

[0057] In some embodiments, the substance to be delivered may be an aerosol-generating material or a material not intended for aerosolization. Optionally, any of the materials can include one or more active ingredients, one or more fragrances, one or more aerosol-forming materials, and / or one or more other functional materials.

[0058] In some embodiments, the substance to be delivered contains an active substance.

[0059] As used herein, the active substance may be a physiologically active material, a material intended to achieve or enhance a physiological response. The active substance may be selected, for example, from dietary supplements, nootropics, psychoactive substances. The active substance can be naturally occurring or synthetically obtained. The active substance can include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12 or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance can include one or more components, derivatives, or extracts of tobacco, cannabis, or other plant substances.

[0060] In some embodiments, the active substance contains nicotine. In some embodiments, the active substance contains caffeine, melatonin or vitamin B12.

[0061] As mentioned herein, the active substance can include one or more components, derivatives, or extracts of cannabis, such as one or more cannabinoids or terpenes.

[0062] As mentioned herein, the active substance can include, or can be derived from, one or more phytochemicals or their components, derivatives, or extracts. As used herein, the term "phytochemical" includes, but is not limited to, any material derived from a plant, including extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, rinds, etc. Alternatively, the material can contain an active agent that naturally occurs in the phytochemical and is synthetically obtained. The material can be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, sheets, etc. Examples of phytochemicals include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, dandelion, lemongrass, perilla, spearmint, rooibos, chamomile, flax, ginger, ginkgo, nettles, hibiscus, laurel, licorice, matcha, mate tea, orange peel, papaya, rose, sage, green tea or black tea, thyme, clove, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, lavender, lemon peel, mint, bilberry, nasturtium flower, vanilla, wintergreen, perilla, turmeric, turmeric, coriander, perilla, orange flower, camellia, blackcurrant, cotoneaster, pepper, mace, damiana, marjoram, olive, lemon balm, lemon basil, chive, caraway, vervain, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof. Mint may be selected from mint varieties such as peppermint, lime mint, chocolate mint, curly mint, wild mint, horsemint, pineapple mint, pennyroyal mint, English spearmint, and apple mint.

[0063] In some embodiments, the active substance comprises or is derived from one or more vegetable substances or their components, derivatives, or extracts, and the vegetable substance is tobacco.

[0064] In some embodiments, the active substance comprises or is derived from one or more vegetable substances or their components, derivatives, or extracts, and the vegetable substance is selected from eucalyptus, star anise, cocoa, and hemp.

[0065] In some embodiments, the active substance comprises or is derived from one or more vegetable substances or their components, derivatives, or extracts, and the vegetable substance is selected from rooibos and perilla.

[0066] In some embodiments, the delivered substance contains a fragrance.

[0067] As used herein, the terms "flavoring" and "flavorant" refer to materials that can be used in products for adult consumers, where permitted by local regulations, to create a desired taste, aroma or other physical sensation.The material can include naturally occurring flavoring materials, vegetable substances, extracts of vegetable substances, synthetically obtained materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, phoebe leaf, chamomile, fenugreek, clove, maple, mate tea, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, redberry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, papaya, rhubarb, grape, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, mint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, frankincense, bergamot, geranium, cart, naswar, kinma, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange flower, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang, sage, perilla, wasabi, pepper, ginger, coriander, coffee, hemp, peppermint oil from any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, nettle, hibiscus, laurel, mate, orange peel, rose, green tea or black tea such as tea, thyme, vaccinium, nasturtium flower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, perilla, turmeric plant, coriander, ginger, katsumade, blackcurrant, lithospermum, pepper, mace, damiana, marjoram, olive, lemon balm, lemon basil, chive, caraway, verbena, tarragon, limonene, thymol, camphor), flavor enhancers, bitter receptor site blockers, activators or stimulants of sensory receptor sites, sugar and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, vegetable substances, or bad breath preventives.The material can be imitation, synthetic, or natural ingredients, or mixtures thereof. The material can be in any suitable form, such as a liquid like oil, a solid like powder, or a gas.

[0068] In some embodiments, the flavorant includes menthol, spearmint, and / or peppermint. In some embodiments, the flavorant includes flavor components of cucumber, blueberry, citrus, and / or redberry. In some embodiments, the flavorant includes eugenol. In some embodiments, the flavorant includes flavor components extracted from tobacco. In some embodiments, the flavorant includes flavor components extracted from cannabis.

[0069] In some embodiments, the flavorant can include sensory substances that are typically chemically induced and are intended to achieve a bodily sensation that is perceived by stimulating the fifth cranial nerve (trigeminal nerve) in addition to or instead of the olfactory or gustatory nerves, and these can include agents that produce a sensation of heat, cold, tingling, or numbing effects. Suitable heat effect agents can be, among others, vanillyl ethyl ether, and suitable coolants can be, among others, eucalyptol or WS-3.

[0070] The aerosol-forming material is a material that can generate an aerosol when energized, for example, by heating, irradiation, or some other method. The aerosol-forming material can be in the form of, for example, a solid, a liquid, or a gel, and may or may not contain an active substance and / or a flavorant. In some embodiments, the aerosol-forming material can include an "amorphous solid" which may alternatively be referred to as a "single crystal solid" (i.e., non-fibrous). In some embodiments, the amorphous solid can be a dried gel. An amorphous solid is a solid material that holds some fluid, such as a liquid, inside. In some embodiments, the aerosol-forming material can include from about 50 wt%, 60 wt%, or 70 wt% of amorphous solid to about 90 wt%, 95 wt%, or 100 wt% of amorphous solid.

[0071] The aerosol generating material can include one or more active substances and / or fragrances, one or more aerosol forming materials, and optionally one or more other functional materials.

[0072] The aerosol forming material can include one or more components capable of forming an aerosol. In some embodiments, the aerosol forming material can 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, phenyl benzyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0073] One or more other functional materials can include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0074] The material can be present on or in a support to form a substrate. The support can be, for example, paper, card, cardboard, thick paper, reconstituted material, plastic material, ceramic material, composite material, glass, metal, or alloy, or can include these. In some embodiments, the support includes a susceptor. In some embodiments, the susceptor is incorporated inside the material. In some alternative embodiments, the susceptor is on one or both sides of the material.

[0075] A consumable is an article that contains or consists of an aerosol - generating material and is intended to be partially or entirely consumed by the user during use. The consumable can comprise one or more other components such as an aerosol - generating material storage region, a component for transferring the aerosol - generating material, an aerosol - generating region, a housing, wrapping paper, a mouthpiece, a filter and / or an aerosol modifier. The consumable can also comprise an aerosol - generating device such as a heater that radiates heat to cause the aerosol - generating material to generate an aerosol during use. The heater can comprise, for example, a combustible substance, a material capable of being heated by electrical conduction, or a susceptor.

[0076] A susceptor is a material that can be heated by allowing a fluctuating magnetic field, such as an alternating magnetic field, to penetrate it. The susceptor can be a conductive material, so that when a fluctuating magnetic field penetrates it, it causes inductive heating of the heating material. The heating material can be a magnetic material, so that when a fluctuating magnetic field penetrates it, it causes magnetic hysteresis heating of the heating material. The susceptor can be both conductive and magnetic, so that the susceptor can be heated by both heating mechanisms. A device configured to generate a fluctuating magnetic field is referred to herein as a magnetic field generator.

[0077] An aerosol modifier is a substance, usually disposed downstream of the aerosol - generating region, that is configured to alter the aerosol, for example, by changing the taste, aroma, acidity or another characteristic of the generated aerosol. The aerosol modifier may be provided within an aerosol - modifier release component operable to selectively release the aerosol modifier.

[0078] The aerosol modifier can be, for example, an additive or an adsorbent. The aerosol modifier can comprise, for example, one or more of a flavorant, a colorant, water, and a carbon adsorbent. The aerosol modifier can be, for example, a solid, a liquid, or a gel. The aerosol modifier can be in the form of a powder, a thread or granules. The aerosol modifier may not contain a filter medium.

[0079] An aerosol generating device is a device configured to generate an aerosol from an aerosol generating material. In some embodiments, the aerosol generating device is a heater configured to apply thermal energy to the aerosol generating material to release one or more volatile substances from the aerosol generating material to form an aerosol. In some embodiments, the aerosol generating device is configured to generate an aerosol from the aerosol generating material without heating. For example, the aerosol generating device may be configured to apply one or more of vibration, increased pressure, or electrostatic energy to the aerosol generating material.

[0080] The delivery system described herein may be implemented as a combustible aerosol supply system, a non-combustible aerosol supply system, or a delivery system without an aerosol.

[0081] Next, referring to FIG. 1, an embodiment of a non-combustible aerosol delivery article 1 is shown. The non-combustible aerosol supply article 1 includes a component 2 that is a component for a non-combustible aerosol supply system 1 in the current example, and a filter component 3. That is, the component 2 is a component that generates a non-combustible aerosol.

[0082] The outer wrap 4 surrounds the filter component 3 and a part of the component 2. The outer wrap 4 includes a tip 4 that attaches the component 2 to the filter component 3. The component 2 is surrounded by a rod wrapper 6. The filter component 3 can include, for example, but not only, a filter material such as tow or sheet material such as cellulose acetate.

[0083] Component 2 includes an aerosol - forming material 10 disposed inside the body 7 such that the body 7 includes an internal void 8 that houses at least one tube 11. The void 8 includes an open end at one end of the component 2. In the present example, at least one tube 11 may be formed from paper. However, in alternative embodiments, at least one tube 11 may be formed from, for example, but not limited to, an extruded or sheet form of tobacco material with a binder and / or fibrous material and / or glycerol, a non - tobacco material such as plastic, which may optionally be in an extruded form, a sheet of airlaid or non - woven fabric, a laminate such as a bilayer with a metal such as aluminum or a paper layer, or a sheet formed from a dry gel sheet that may contain glycerol and / or menthol and / or other flavorings. Additionally, the body may be porous or non - porous.

[0084] At least one tube 11 is arranged coaxially with the body 7 of the aerosol - forming material 10. The body 7 is generally rod - shaped. In the present embodiment, at least one tube 11 extends along a part of the length of the body 7 of the aerosol - forming material 10.

[0085] The body 7 is generally cylindrical. The cylindrical body may be, for example, but not limited to, a cylinder, an elliptical cylinder, a hyperbolic cylinder, or a parabolic cylinder. However, those skilled in the art will recognize that other shapes are possible. In the present example, the body 7 forms a plug 7. In the present embodiment, the component is an aerosol - forming component 2.

[0086] In the present embodiment, the aerosol - forming material 10 can include a plant - based material such as a tobacco material.

[0087] The plant-based material may be a particulate or granular material. In some embodiments, the plant-based material is a powder. Alternatively, or in addition thereto, the tobacco material can include tobacco strips, strands or fibers. For example, the tobacco material can include tobacco particles, granules, fibers, strips and / or strands. In some embodiments, the tobacco material consists of tobacco material particles or granules. The tobacco material can include recycled tobacco material.

[0088] The sheet or cut sheet of aerosol-generating material can contain nicotine in an amount of from about 0.1% to about 0.3% by weight relative to the sheet or sheet material.

[0089] Recycled tobacco in paper form may be the aerosol-generating material described herein. The recycled tobacco in paper form may be any type of recycled tobacco in paper form known in the art.

[0090] The aerosol-generating material 10 can include an aerosol-forming material. The aerosol-forming material includes one or more components capable of forming an aerosol. The aerosol-forming material includes one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, phenyl benzyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In some examples, the aerosol-forming material is glycerol or propylene glycol.

[0091] The aerosol - generating material 10 can include a binder. The binder is arranged to bind the components of the aerosol - generating material to form a sheet or a cut - sheet. The binder can at least partially cover the surface of the tobacco material. When the tobacco material is in the form of fine particles, the binder can bind by at least partially covering the surface of the tobacco particles.

[0092] The aerosol - generating material 10 can include a filler. In some embodiments, the sheet or cut - sheet includes a filler. The filler is generally a non - tobacco component, that is, a component that does not contain components derived from tobacco. The filler can 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 can be non - tobacco fibers such as wood fibers, pulp, or wheat fibers. The filler can be a material containing cellulose, or the material can contain derivatives of cellulose. The filler component can be a non - tobacco molding material or a non - tobacco extrusion molding material.

[0093] In certain embodiments that include a filler, the filler is a fiber. For example, the filler can be an organic filler material of fibers such as wood, wood pulp, hemp fiber, cellulose or cellulose derivatives. Without wishing to be bound by theory, it is thought that including a fibrous filler increases the tensile strength of the material.

[0094] The aerosol - generating material 10 herein can include an aerosol modifier such as any of the flavors described herein. In one embodiment, the aerosol - generating material includes menthol. When the aerosol - generating material is incorporated into an article for use in an aerosol supply system, the article may be referred to as an article containing menthol.

[0095] In some embodiments, the aerosol-forming material 10 can include an aerosol-forming “amorphous solid,” which may alternatively be referred to as a “single crystal solid” (i.e., non-fibrous). In some embodiments, the amorphous solid can include a dried gel. The amorphous solid is a solid material that holds some fluid, such as a liquid, inside. The amorphous solid can include a fragrance. In some embodiments, the amorphous solid further includes an active substance. The active substance may be a tobacco extract. In some embodiments, the amorphous solid can include one or more active substances and / or fragrances, one or more aerosol-forming materials, and optionally one or more other functional materials. The amorphous solid may be provided as a plurality of elongated strips.

[0096] The aerosol-forming material 10 can include a mixture of an aerosolizable material and an amorphous solid material as described herein. Such an aerosol-forming material can provide an aerosol with a desired fragrance profile during use, since additional fragrance can be introduced into the aerosol-forming material by being included in the amorphous solid material component. The fragrance provided within the amorphous solid material can be held more stably within the amorphous solid material as compared to a fragrance directly added to the tobacco material, resulting in a more consistent fragrance profile among the manufactured articles.

[0097] In some embodiments, the aerosol-forming material 10 is collected and / or deployed to form the body 7 such that at least one tube 11 is held within the void 8 inside the body 7.

[0098] In the present embodiment, the aerosol - generating material 10 is crimped before being disposed within the body 7. For example, the aerosol - generating material 10 is passed through a pair of crimper rollers. Crimping can make it easier to collect the aerosol - generating material 10 to form the body. Crimping can also increase the length of the aerosol - generating material that can be used to form a body of a particular volume. As the amount of the aerosol - generating material 10 within the body increases, the surface area of the aerosol - generating material 10 can increase, and thus the amount of aerosol that can be formed by the aerosol - generating material 10 increases.

[0099] In some embodiments, the aerosol - generating material 10 is crimped to a crimp depth of at least 0.1 mm, and in some examples, to a crimp depth of at least 0.2 mm, 0.3 mm, 0.4 mm, 0.5 mm, 0.6 mm, 0.7 mm, 0.8 mm, 0.9 mm, 1 mm, 1.5 mm, or 2 mm. In some embodiments, the aerosol - generating material 10 is crimped to a crimp depth of at most 2 mm. In some embodiments, the aerosol - generating material 10 is crimped to a crimp depth in the range of 0.1 mm to 2 mm, and in some examples, in the range of 0.1 mm to 1 mm, or in the range of 0.2 mm to 0.7 mm.

[0100] The crimp depth (also known as the "crimp factor") refers to the depth of the grooves formed in the aerosol - generating material 10 by crimping. That is, when the aerosol - generating material is crimped, when observed from the first side of the aerosol - generating material, a plurality of valleys are formed in the aerosol - generating material 10, and the crimp depth is the depth of the valleys. Crimping can form a zig - zag shape or another shape. In some embodiments, the spacing between adjacent grooves of the crimped aerosol - generating material 10 is in the range of 0.1 - 3 mm, and in some examples, in the range of 0.2 - 2 mm.

[0101] In some embodiments, the aerosol-generating material 10 is heated as it is crimped. For example, the aerosol-generating material 10 may be passed between crimp rollers, one or both of which are heated.

[0102] Component 2 is configured for use in a non-combustible aerosol supply device comprising an aerosol-generating device for insertion into the aerosol-generating part of component 2. The aerosol-generating device may be a heating element for resistive heating or inductive heating. Component 2 is configured to house the aerosol-generating device within rod 7 of the aerosol-generating material 10.

[0103] In some embodiments, the filter component 3 comprises a cooling section 13 disposed adjacent and immediately downstream of component 2 of the aerosol-generating material 10. In the present embodiment, the cooling section 13 is in contact with the source of the aerosol-generating material 10. The filter component 2 comprises, at the mouth end of the article 1, a body 14 of material downstream of the cooling section 13 and a hollow tubular element 15 downstream of the body 14 of material.

[0104] The cooling section 13 can comprise at least one hollow channel. The cooling section 13 may be formed, for example, but not exclusively, from a plurality of layers of paper wound in parallel and joined at the seams, or a layer of paper wound in a spiral, a cardboard tube, a tube formed using papier-mâché type processes, a molded or extruded plastic tube or the like. The cooling section 13 is manufactured to have sufficient rigidity to withstand the axial compressive forces and bending moments that may occur during the manufacture and use of the article 1.

[0105] Each of the body 14 of material and the hollow tubular element 15 defines a substantially cylindrical overall outer shape and shares a longitudinal axis. The body 14 of material is wrapped in a first plug wrap 17. In the present example, the body 14 of material is formed from fibrous tow. The tow can comprise plasticized cellulose acetate tow.

[0106] In other examples, various materials can be used to form the body 14 of the material. For example, the body 14 can be formed from paper, similar to known paper filters used for, e.g., tobacco rather than corn. For example, paper or other cellulose-based materials can be folded and / or crimped and provided as one or more portions of the sheet material forming the body 14. Alternatively, the body 14 can be formed from corn other than cellulose acetate, such as, for example, polylactic acid (PLA), fibrous corn, or other materials described herein with respect to similar materials. The hollow tubular element 15 can be formed as described above in relation to the body 14 of the material.

[0107] In the present example, the hollow tubular element 15, the body 14 of the material, and the cooling section 13 are combined using a second plug wrap 18 that is wrapped around all three parts. It will be understood that any of the parts may be omitted from the filter component 3.

[0108] The outer wrap, i.e., the tip wrapper 4, is wrapped over the entire length of the filter component 3 and a portion of the rod 7 of the aerosol-generating material 10 and has an adhesive on its inner surface for connecting the filter component 3 and the rod of the aerosol-generating material 10. In the present example, the rod of the aerosol-generating material 10 is wrapped with a rod wrapper paper 6 that forms a first wrap material, and the tip wrapper 4 forms an outer wrap material and extends over at least a portion of the rod of the aerosol-generating material 10 to connect the filter component 3, also known as a mouthpiece, and the rod of the aerosol-generating material 10. In some examples, the tip wrapper 4 can extend over only a portion of the rod of the aerosol-generating material 10.

[0109] As shown in FIG. 2, the filter component 3 can include an aerosol modifier provided inside the body 14 of the material. In the present embodiment, the aerosol modifier is provided in the form of capsules 19. In other examples, the aerosol modifier can be provided in other forms, such as a material injected into the body 14 of the material, or a material provided on a thread, for example, a thread carrying a flavorant or other aerosol modifier, and this thread can also be disposed inside the body 14 of the material.

[0110] The capsule 19 can comprise a fragile capsule, such as a capsule having a solid, fragile shell that surrounds, for example, a liquid payload. In the present example, a single capsule 19 is used. The capsule 19 is entirely embedded within the body 14 of the material. In other words, the capsule 19 is entirely surrounded by the material forming the body 14. In other examples, a plurality of fragile capsules, such as two, three, or more fragile capsules 19, may be disposed inside the body 14 of the material.

[0111] The capsule 19 has a core - shell structure. In other words, the capsule 19 comprises a shell that encapsulates a liquid agent, such as a flavorant or other agent, and the liquid agent can be any of the flavorants or aerosol modifiers described herein. The shell of the capsule 19 can be ruptured by the user to release the flavorant or other agent into the body 7 of the material.

[0112] Referring to FIG. 3, the component 2 is shown. The component 2 comprises a first end 21 and a second end 22. At least the outer dimensions of the first end 21 and the second end 22 match. In the present embodiment, the first end 21 is the free end of the component 2 that is farthest from the filter component 3, and the second end 22 is adjacent to the filter component 3, that is, closest to the mouthpiece 2. The first end 21 comprises a first face 23, and the second end 22 comprises a second face 24.

[0113] As shown in FIGS. 3 and 4, the component 2 includes at least one tube 11. At least one tube 11 is disposed in the void 8 of the component 2 to form the core portion 26 of the component 2. The core portion 26 extends longitudinally along the length of the longitudinal axis X of the component 2. In the present embodiment, the core portion 26 extends longitudinally along a part of the length of the longitudinal axis X of the component 2.

[0114] The component 2 further includes an outer portion 27. The outer portion 27 extends longitudinally along the length of the longitudinal axis X. In the present embodiment, the outer portion 27 extends over the entire length of the component 2. The outer portion 27 includes a first end face 28 and an opposite second end face 29. In the present embodiment, the first end face 28 extends in the same plane as the first face 23 of the first end 21 of the component 2, and the second end face 29 extends in the same plane as the second face 24 of the second end 22 of the component 2.

[0115] The outer portion 27 surrounds the core portion 26. Accordingly, the core portion 26 is disposed radially inside the outer portion 27. The outer portion 27 contains an aerosol-generating material 10 configured to generate an aerosol when heated.

[0116] In the present embodiment, as shown in FIG. 4, the first end face 28 has an annular cross-section, and the second end face 29 has a circular cross-section, which will be described in more detail below. However, it will be understood that in alternative embodiments, the faces 28, 29 may have cross-sections different from those shown.

[0117] At least one tube 11 includes a first end face 31 and an opposite second end face 32. In the present embodiment, the first end face 31 extends in the same plane as the first end of the aerosol-generating material 10 of the component 2. That is, the first end face 31 of the tube 11 extends in the same plane as the first end face 28 of the outer portion 27.

[0118] In the present embodiment, the second end face 32 extends in a plane spaced apart from the plane in which the second end face 29 of the outer portion 27 extends. In some examples, the plane in which the second end face 32 extends and the plane in which the second end face 29 extends are parallel to each other.

[0119] Accordingly, the outer portion 27 includes an annular portion 33 and a circular portion 34. The annular portion 33 may be referred to as a tubular portion. The circular portion 34 may be referred to as a cylindrical portion. The annular portion 33 surrounds at least one tube 11 and has an annular cross-section. Accordingly, the annular portion 33 extends longitudinally from the plane in which the first end face 31 of the tube 11 extends to the plane in which the second end face 32 of the tube 11 extends. A void 8 is formed inside the annular portion 33 of the aerosol-generating material 10. The circular portion 34 extends longitudinally from the plane in which the second end face 32 of the tube 11 extends to the plane in which the second end face 24 of the aerosol-generating material 10 extends.

[0120] In the present embodiment, at least one tube 11 is a hollow tube. The hollow tube 11 may be generally cylindrical. Accordingly, in the present embodiment, the shape of the cross-section of the hollow tube 31 is annular in a plane extending perpendicular to the longitudinal axis of the core portion 26.

[0121] In the present embodiment, the hollow tube 11 includes a cavity 36, i.e., a surrounding wall 35 surrounding the hollow. In the present embodiment, the surrounding wall 35 is annular in cross-section. The surrounding wall 35 can have a thickness in the range of about 50 μm to about 1 mm. Additionally, or alternatively, the surrounding wall 35 has hardness or stiffness in at least about 50% of the range. That is, the surrounding wall can withstand a crushing force in the range of about 0.1 N before deformation occurs. The crushing force may be applied in a direction perpendicular to the longitudinal axis X.

[0122] The cavity 36 extends longitudinally along the length of the tube 11 from the first end face 31 to the second end face 32. The cavity 36 is configured to accommodate a heating element during use. Thus, the cavity 36 can have a diameter in the range of about 1 mm to about 5 mm. In some examples, the cavity 36 can have a diameter in the range of about 2 mm to 4 mm. The cavity 36 is open at the first end 31 of the tube 11 and is configured to accommodate a heating element.

[0123] In the present embodiment, the tube 11 is formed from paper. Thus, the paper tube 11 may be formed from a plurality of layers of paper wound parallel and joined at the seams, or a layer of paper wound in a spiral, a cardboard tube, or a tube formed using papier-mâché type processes.

[0124] However, in an alternative embodiment, it will be understood that the first material may be, for example, but not limited to, one of another paper material, bandcast tobacco, recycled paper tobacco, or an amorphous solid.

[0125] In the present embodiment, the outer portion 27 of the component 2 comprises a first wall 43A. The first wall 43A defines an end of the cylindrical portion 34 of the outer portion 27 of the component 2. The first wall 43A extends in a plane generally parallel to the first end 21 and the second end 22 of the component 2. At least one tube 11 may be adjacent to the first wall 43A. The first wall 43A is formed in the aerosol-forming material 10 by using a slit 41, which will be described in more detail below.

[0126] Referring to FIG. 5, a sheet 100 of the aerosol - generating material 10 forming the component 2 is shown. The aerosol - generating material 10 of the component 2 comprises a first outer edge 10A and a second outer edge 10B, which are opposite ends of the aerosol - generating material 10. The first outer edge 10A and the second outer edge 10B extend substantially parallel to each other. When the aerosol - generating material 10 is arranged to form the body 7, the first outer edge 10A forms the first axial end 7A of the body 7, and the second outer edge 10B forms the second axial end 7B of the body 7. During the manufacturing process, it should be understood that the second outer edge 10B may not be formed until the component 2 is cut from the continuous rod, which will be described in more detail below.

[0127] The aerosol - generating material 10 further comprises a third outer edge 10C and a fourth outer edge 10D. The third outer edge 10C and the fourth outer edge 10D extend substantially parallel to each other and substantially perpendicular to the first outer edge 10A and the second outer edge 10B. When the aerosol - generating material 10 is arranged to form the body 7, the third outer edge 10C and the fourth outer edge 10D are substantially parallel to the central axis A - A of the component 2. The sheet of the aerosol - generating material 10 may be generally rectangular.

[0128] The aerosol - generating material 10 forming the component 2 comprises a first slit 41.

[0129] The first slit 41 extends in a direction generally perpendicular to the third outer edge 10C and the fourth outer edge 10D of the aerosol - generating material 10. The first slit 41 extends in a direction generally parallel to the first outer edge 10A and the second outer edge 10B.

[0130] The width of the aerosol generating material 10 (indicated by the arrow "W" in Fig. 5) is measured between the third outer edge 10C and the fourth outer edge 10D of the aerosol generating material 10. In some embodiments, the width W of the aerosol generating material 10 ranges from 30 mm to 400 mm when the aerosol generating material 10 is laid flat, and in some examples, it ranges from 40 mm to 300 mm, from 50 mm to 280 mm, from 75 mm to 225 mm, or from 100 mm to 200 mm.

[0131] In some embodiments, the first slit 41 is spaced from the third outer edge 10C and the fourth outer edge 10D. In other words, the first slit 41 does not extend across the entire width W of the aerosol generating material 10.

[0132] The first slit 41 forms the first inner edge 43 of the aerosol generating material 10. That is, when the aerosol generating material 10 is collected to form the body 7, the first slit 41 enables the aerosol generating material 10 to be collected on the first side, such as the downstream side during use, of at least one tube 11 so that the first inner edge 43 at least partially defines the boundary of the void 8 containing at least one tube 11. Thus, the first inner edge 43 can form the first wall portion 43A.

[0133] Thus, the first inner edge 43 enables the aerosol generating material 10 to be collected on one side of the void 8 and at least partially or completely define the boundary of the void 8 to prevent at least one tube 11 from exiting the first end of the void 8. This improves the arrangement of at least one tube 11 inside the component 4.

[0134] In some embodiments, the first inner edge 43 is axially spaced from the second outer edge 10B by a distance in the range of 10 mm to 80 mm. In some embodiments, the first inner edge 43 is axially spaced from the second outer edge 10B by a distance in the range of 20 mm to 70 mm, or in the range of 30 mm to 60 mm.

[0135] In some embodiments, at least a portion of the first slit 41 extends linearly, and in some examples, the entire first slit 41 extends linearly. However, it should be understood that in other embodiments, the first slit 41 may be curved, for example, and at least partially or entirely non-linear. In one embodiment (not shown), the first slit 41 follows a zigzag path.

[0136] In some embodiments, the first inner edge 43 is continuous. In other embodiments, the first inner edge 43 is intermittent, and one or more intermediate portions of the aerosol-forming material 10 connecting adjacent portions of the first inner edge 43 are inserted therein at various locations.

[0137] In some embodiments, the first wall portion 43A defines a boundary around the entire central axis A of the component 4.

[0138] The first wall portion 43A is porous. In the present example, the inhalant can flow through the layer of the aerosol-forming material 10 collected in the first wall portion 43A.

[0139] In some embodiments, when the aerosol-forming material 10 is laid flat, the length L1 of the first inner edge 43 is in the range of 5 mm to 360 mm, and in some examples, in the range of 5 mm to 270 mm.

[0140] During the manufacturing process, the aerosol-forming material 10 is formed into a continuous rod collected around at least one tube 11. The continuous rod is then cut into individual components 2.

[0141] As described above, at least one tube 11 may be provided to the aerosol-forming material 10 prior to or simultaneously with the formation of the aerosol-forming material 10 into the body 7. However, the at least one tube 11 may be a double-length tube 11.

[0142] In some embodiments, the body 7 is surrounded by a wrapper 6, such as a wrapping paper. The wrapper 6 can assist in holding the aerosol-forming material 10 in the shape of the body 7, for example by preventing the aerosol-forming material 10 from unfolding.

[0143] Referring to FIG. 6, a sheet 110 of the aerosol-forming material 10 for forming the double-length component 2 is shown. The aerosol-forming material 10 of the double-length component 2 comprises a first outer edge 10A' and a second outer edge 10B', which are opposite ends of the aerosol-forming material 10. The first outer edge 10A' and the second outer edge 10B' extend substantially parallel to each other. When the aerosol-forming material 10 is arranged to form the body 7, the first outer edge 10A' forms the first axial end 7A' of the body 7 and the second outer edge 10B' forms the second axial end 7B' of the body 7. It will be understood that the second outer edge 10B' may not be formed until components are cut from the continuous rod during the manufacturing process.

[0144] The aerosol-forming material 10 further comprises a third outer edge 10C and a fourth outer edge 10D. The third outer edge 10C and the fourth outer edge 10D extend substantially parallel to each other and substantially perpendicular to the first outer edge 10A' and the second outer edge 10B'. When the aerosol-forming material 10 is arranged to form the body 7, the third outer edge 10C and the fourth outer edge 10D are substantially parallel to the central axis A-A of the component. The sheet of the aerosol-forming material 10 may be generally rectangular.

[0145] The aerosol-forming material 10 that forms the doubled component 2 includes a first slit 41 and a second slit 42.

[0146] The first slit 41 extends in a direction generally perpendicular to the third outer edge 10C and the fourth outer edge 10D of the aerosol-forming material 10. The first slit 41 extends in a direction generally parallel to the first outer edge 10A' and the second outer edge 10B' of the aerosol-forming material 10.

[0147] In some embodiments, the first slit 41 is spaced from the third outer edge 10C and the fourth outer edge 10D. In other words, the first slit 41 does not extend across the entire width W of the aerosol-forming material 10.

[0148] The second slit 42 extends in a direction generally perpendicular to the third outer edge 10C and the fourth outer edge 10D of the aerosol-forming material 10. In other words, the second slit 42 does not extend across the entire width (indicated by arrow "W" in FIG. 6) of the aerosol-forming material 10.

[0149] The first slit 41 forms a first inner edge 43 of the aerosol-forming material 10. The second slit 42 forms a second inner edge 44 of the aerosol-forming material 10. That is, when the aerosol-forming material 10 is collected to form the body 7, the first slit 41 enables the aerosol-forming material 10 to be collected on a first side, such as the downstream side, of at least one tube 11 such that the first inner edge 43 at least partially defines a boundary of the void 8 containing at least one tube 11. Accordingly, the first inner edge 43 can form a first wall portion 43A.

[0150] Similarly, when the aerosol-forming material 10 is collected to form the body 7, the second slit 42 allows the aerosol-forming material 10 to be collected on a second side, such as the upstream side, of at least one tube 11, such that the second internal edge 44 at least partially defines the boundary of the void 8 containing at least one tube 11. Thus, the second internal edge 44 can form a second wall portion 44A.

[0151] Thus, the first internal edge 43 allows the aerosol-forming material 10 to be collected on one side of the void 8 and at least partially or fully define the boundary of the void 8, preventing at least one tube 11 from exiting the first end of the void 8. This improves the placement of at least one tube 11 inside component 2.

[0152] The second internal edge 44 allows the aerosol-forming material 10 to be collected on one side of the void 8 and at least partially or fully define the boundary of the void 8, preventing at least one tube 11 from exiting the second end of the void 8. This improves the placement of at least one tube 11 inside component 2.

[0153] In some embodiments, the first internal edge 43 and the second internal edge 44 are axially spaced by a distance in the range of 10 mm to 80 mm. In some embodiments, the first internal edge 43 and the second internal edge 44 are axially spaced by a distance in the range of 12 mm to 60 mm, or in the range of 15 mm to 30 mm. Thus, the length of the cavity 36 of a single component 2 can be in the range of about 5 mm to 40 mm.

[0154] In some embodiments, at least a portion of the first slit 41 and the second slit 42 extends linearly, and in some examples, the entire first slit 41 and / or the second slit extends linearly. However, it should be understood that in other embodiments, the first slit 41 and / or the second slit 42 may be curved, for example, and at least partially or entirely non-linear. In one embodiment (not shown), the first outer edge and / or the second outer edge follows a zigzag path.

[0155] In some embodiments, the first inner edge 43 is continuous. In other embodiments, the first inner edge 43 is intermittent, and one or more intermediate portions of the aerosol-generating material 10 connecting adjacent portions of the first inner edge 43 are inserted therein in places. Similarly, the second inner edge 44 may be continuous or intermittent.

[0156] The first inner edge 43 and the second inner edge 44 may be provided on both sides of at least one tube 11 and may face in opposite directions.

[0157] The double-length component 2 comprises a first end 3A' and a second end 3B'. In the present example, the first inner edge 43 is disposed between at least one object 11 and the first end 3A' of the double-length component 2. In other embodiments, the first inner edge 43 is disposed between at least one tube 11 and the second end 3B' of the component 2.

[0158] In the present embodiment, the second inner edge 44 is disposed between at least one tube 11 and the second end 3B' of the component 2. In other embodiments, the second inner edge 44 is disposed between at least one tube 11 and the first end 3A' of the component 2.

[0159] In some embodiments, the first wall portion 43A and / or the second wall portion 44A define a boundary around the entire central axis A of the component 2. In some embodiments, the first wall portion 43A defines a boundary around the entire central axis A of the component. Additionally, the second wall portion 44A defines a boundary around the entire central axis A of the component 3.

[0160] The first wall portion 43A and the second wall portion 44B are porous. In the present example, the inhalant can flow through the layer of the aerosol-generating material 10 collected in the first wall portion 43A and the layer of the aerosol-generating material 10 collected in the second wall portion 44A.

[0161] In some embodiments, an annular portion 33 of the aerosol-generating material 10 surrounds at least one tube 11. The first inner edge 43 and the second inner edge 44 may be provided on opposite sides of the annular portion 33 of the aerosol-generating material 10. The annular portion 33 may be generally tubular or cylindrical. A void 8 is formed inside the annular portion 33 of the aerosol-generating material 10.

[0162] In some embodiments, when the aerosol-generating material 10 is placed flat, the length L1 of the first inner edge 43 ranges from 5 mm to 360 mm, and in some examples, from 5 mm to 270 mm.

[0163] In some embodiments, when the aerosol-generating material 10 is placed flat, the length L2 of the second inner edge 44 ranges from 5 mm to 360 mm, and in some examples, from 5 mm to 270 mm.

[0164] In some embodiments, the first inner edge 43 and / or the second inner edge 44 are spaced apart from the third outer edge 10C and / or the fourth outer edge 10D by at least 3 mm, and in some examples, at least 4 mm, 5 mm, 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm when the aerosol-generating material 10 is placed flat.

[0165] At the end of the manufacturing process, the doubled component 2 is bisected through its vertical center, i.e., cut in a plane perpendicular to the vertical axis at the midpoint of the vertical axis of component 2, to divide the doubled component 2 into two separate components 2. The two components 2 are substantially mirror images of each other.

[0166] When the manufacturing process forms a continuous rod, the first component is then formed by separating the first component from the continuous rod by a first cut passing through at least one tube 11 and the annular portion 33, and the second component 2 is separated from the continuous rod by a second cut passing through the aerosol-forming material 10 between the annular portions 33, i.e., through the tubular portion 34.

[0167] Referring now to FIG. 7, a sheet 115 of the aerosol-forming material 10 of an alternative embodiment of component 2 is shown. The sheet 115 of the aerosol-forming material 10 of FIG. 7 is similar to the aforementioned sheet 110 of the aerosol-forming material 10, with similar features retaining the same reference numerals, but the first slit 41 and the second slit 42 are omitted and replaced by an opening 120. The opening 120 extends from a first inner edge 121 of the aerosol-forming material 10 to a second edge 122 of the aerosol-forming material 10.

[0168] The opening 120 may be formed as a notch in the aerosol-forming material 10, for example, by cutting out a portion of the aerosol-forming material 10 from the remainder of the aerosol-forming material 10 to form the first opening 120. For example, the first opening 120 may be formed by punching out the portion from the aerosol-forming material 10.

[0169] In other embodiments, the first opening 120 may be formed by another method, such as cutting the aerosol-forming material 10 using one or more lasers. In another embodiment, the aerosol-forming material 10 may be molded in a mold such that the first opening 120 is formed in the aerosol-forming material when the aerosol-forming material 10 is molded.

[0170] In the present example, the first opening 120 is rectangular. However, in other embodiments, the first opening 120 may have another shape.

[0171] The sheet 115 of the aerosol-generating material 10 can further comprise additional openings, such as the second opening 121 shown in FIG. 7, configured to form further voids in the manufacturing process of the component 2.

[0172] Referring now to FIG. 8, a block diagram representing one embodiment of a method of manufacturing a component 2 for a delivery system is shown. The method comprises providing (step S1) an assembly comprising at least one tube 11 and an aerosol-generating material 10 comprising a first internal edge 43, and disposing (step S2) the aerosol-generating material 10 within the body 7 such that the body 7 comprises a void 8 that houses the at least one tube 11, wherein the first internal edge 43 at least partially or fully defines the boundary of the void 8.

[0173] In some embodiments, the step of providing (S1) the assembly comprises forming the first internal edge in the aerosol-generating material 10. Alternatively, the aerosol-generating material 10 may be provided with a first internal edge 43 pre-formed therein.

[0174] In some embodiments, the step of forming the first internal edge 43 in the aerosol-generating material 10 comprises cutting the aerosol-generating material 10 to form the first internal edge 43, and in some examples, cutting through the entire thickness of the aerosol-generating material 10 to form the first internal edge 43.

[0175] In some embodiments, the step of forming the first internal edge 43 includes cutting the aerosol-generating material 10 using a suitable cutting device such as a knife and / or a laser. In some embodiments, the step of forming the first internal edge includes forming a slit in the aerosol-generating material.

[0176] In some embodiments, the step of forming the first internal edge includes forming an aperture in the aerosol-generating material such that the edge of the aperture includes the first internal edge of the aerosol-generating material. The aperture may be substantially rectangular or another shape.

[0177] In some embodiments, the step of providing the assembly (S1) includes providing an aerosol-generating material having a first internal edge and then supplying at least one tube to the aerosol-generating material. In some examples, the step of providing the assembly includes forming a first internal edge in the aerosol-generating material and then supplying at least one tube to the aerosol-generating material.

[0178] In other embodiments, the step of providing the assembly (S1) includes providing the aerosol-generating material, supplying at least one tube to the aerosol-generating material, and then forming a first internal edge in the aerosol-generating material.

[0179] In some embodiments, the method includes the step of crimping the aerosol-generating material. In some examples, the method includes the step of crimping the aerosol-generating material to a crimp depth as previously described. In some embodiments, the method includes heating the aerosol-generating material when crimping the aerosol-generating material.

[0180] The method can include the step of crimping the aerosol - generating material after an internal edge or each internal edge is formed, or the step of crimping the aerosol - generating material before an internal edge or each internal edge is formed.

[0181] In some embodiments, the method includes the step of supplying at least one tube to the aerosol - generating material using a tube - supplying device, such as a tube - delivery wheel.

[0182] In some embodiments, the aerosol - generating material of the assembly has a second internal edge, and the step of disposing the aerosol - generating material within the body includes disposing the aerosol - generating material such that the second internal edge forms at least partially, or entirely, the boundary of the void.

[0183] In some embodiments, the step of providing the assembly (S1) includes forming a second internal edge in the aerosol - generating material. In some embodiments, the second internal edge is formed in the same manner as the first internal edge described above.

[0184] In some embodiments, the step of providing the assembly (S1) includes providing a continuous web of the aerosol - generating material.

[0185] In some embodiments, the method includes cutting a continuous web of aerosol - forming material (and any surrounding wrapper) after disposing the aerosol - forming material within the body. In some embodiments, cutting the continuous web of aerosol - forming material forms one or more individual components. In some embodiments, cutting the continuous web of aerosol - forming material after disposing the aerosol - forming material within the body includes cutting the web such that a component of a single length (i.e., the final length used in the delivery system) is formed. In other embodiments, cutting the continuous web of aerosol - forming material after disposing the aerosol - forming material within the body includes cutting the web such that a multi - length component is formed that can later be cut (before or after attachment to further components such as a tobacco rod) to form a component of a single length.

[0186] FIG. 9 shows an example of a continuous web 200 of sheet material.

[0187] In the present example, the continuous web 200 is intermittently cut (along the dashed line "Z-Z" in Figure 9) in the region between adjacent first and second internal edges 43 and 44 to separate a portion of the aerosol-forming material 10 from the remainder of the continuous web 200. In the present example, the continuous web 200 and an overlying plug wrap (not shown) are cut in said region once the aerosol-forming material has been collected into the body and wrapped around the plug wrap. That is, the web 200 is cut after being formed into a rod containing at least one tube 11. In some embodiments, the rod is cut such that each separated portion of the aerosol-forming material 10 corresponds to the final length of the component (i.e., the cut rod is a single-length component). In other embodiments, the rod is cut such that each separated portion of the aerosol-forming material 10 corresponds to a multiple of the final length of the component (e.g., the cut rod is a double-length component that is later cut to form a single-length component, or is three, four, five, six, seven, eight or more times the final length of the component). In some embodiments, each separated portion of the aerosol-forming material includes one or more pairs of a first internal edge and a second internal edge.

[0188] In some embodiments, the method includes the step of forming a plurality of internal edges at regular intervals in the continuous web. For example, the method can include the step of forming first, second, third and / or fourth internal edges at regular intervals in the continuous web. In the example of Figure 9, in the web 200, a plurality of first internal edges 43 are formed at regular intervals (see arrow "D2" in Figure 9), and a plurality of second internal edges 44 are formed at regular intervals (indicated by arrow "D3" in Figure 9) in the web 200.

[0189] The distance D2 between each of the first inner edges 43 and / or the distance D3 between each of the second inner edges 44 can be in the range of 40 mm to 100 mm, and in some examples can be in the range of 80 mm to 90 mm. In some embodiments, the distance D2 and / or D3 is at least 40 mm, and optionally at least 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, 90 mm, 95 mm. In some embodiments, the distance D2 and / or D3 is at most 100 mm, and preferably at most 95 mm, 90 mm, 85 mm, 80 mm, 75 mm, 70 mm, 65 mm, 60 mm, 55 mm, 50 mm, 45 mm.

[0190] Each of the first inner edges 43 is arranged at a distance (indicated by the arrow "D1" in FIG. 9) from each of the second inner edges 44, and at least one object 11 is disposed between each pair of the first inner edge 43 and the second inner edge 44. When the aerosol-forming material of the web 200 is collected to form the body, the first inner edge 43 and the second inner edge 44 allow the aerosol-forming material to be collected together so as to at least partially define the boundary of a void containing at least one tube 11 with the first inner edge 43 and the second inner edge 44. In other embodiments, one of the first inner edge 43 and the second inner edge 44 may be omitted. In further embodiments, a third inner edge and / or a fourth inner edge (not shown) may be formed in the continuous web 200, and optionally, at least one further tube (not shown) may be disposed in the web 200 in the vicinity of the third inner edge and / or the fourth inner edge.

[0191] In some embodiments, the distance D1 between the first internal edge 43 and the second internal edge 44 ranges from 10 mm to 90 mm, and in some embodiments, it ranges from 20 mm to 45 mm. In some embodiments, the first internal edge 43 and the second internal edge 44 are spaced apart by at least 10 mm, and in some examples, at least 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, or 90 mm of distance D1. In some embodiments, the first internal edge 43 and the second internal edge 44 are spaced apart by at most 90 mm, and in some examples, at most 85 mm, 80 mm, 75 mm, 70 mm, 65 mm, 60 mm, 55 mm, 50 mm, 45 mm, 40 mm, 35 mm, 30 mm, 25 mm, 20 mm, 15 mm, or 10 mm of distance D1.

[0192] In some embodiments (not shown), the web comprises a third and a fourth internal edge, and the distance between the third internal edge and the fourth internal edge ranges from 10 mm to 90 mm. In some embodiments, the third internal edge and the fourth internal edge are spaced apart by at least 3 mm, and in some examples, at least 10 mm, 15 mm, 20 mm, 25 mm, 30 mm, 35 mm, 40 mm, 45 mm, 50 mm, 55 mm, 60 mm, 65 mm, 70 mm, 75 mm, 80 mm, 85 mm, or 90 mm of distance. In some embodiments, the third internal edge and the fourth internal edge are spaced apart by at most 50 mm, and in some examples, at most 85 mm, 80 mm, 75 mm, 70 mm, 65 mm, 60 mm, 55 mm, 50 mm, 45 mm, 40 mm, 35 mm, 30 mm, 25 mm, 20 mm, 15 mm, or 10 mm of distance.

[0193] In some embodiments, the method includes moving a continuous web 200 along a conveyance path (indicated by arrow "Y" in FIG. 9) and supplying at least one tube 11 (and / or at least one additional object) at regular intervals as the continuous web 200 moves along the conveyance path Y. The at least one tube 11 may be disposed between a first inner edge 43 and a second inner edge 44, or may be disposed in the vicinity of one of the first inner edge 43 or the second inner edge 44 if one of the first inner edge 43 and the second inner edge 44 is omitted.

[0194] In some embodiments, the width of the web 200 (indicated by arrow "W1" in FIG. 9) ranges from 30 mm to 400 mm, and in some examples, ranges from 40 mm to 300 mm, from 50 mm to 280 mm, from 75 mm to 225 mm, or from 100 mm to 200 mm.

[0195] In some embodiments, the width W1 of the web 200 is at least 30 mm, and in some examples, is at least 40 mm, 50 mm, 75 mm, 100 mm, 125 mm, 150 mm, 175 mm, 190 mm, 250 mm, 280 mm, 300 mm, or 400 mm.

[0196] In some embodiments, the width W1 of the web 200 is at most 400 mm, and in some examples, is at most 300 mm, 280 mm, 250 mm, 225 mm, 200 mm, 175 mm, 150 mm, 125 mm, or 100 mm.

[0197] In the foregoing example, a web 200 of continuous sheet material having inner edges 43, 44 is then collected and formed into a body that is later cut to form individual components (or multi-length components), but in an alternative embodiment (not shown), the web is cut into individual sheets, and then the aerosol-generating material is provided with inner edges and at least one tube is supplied to the aerosol-generating material.

[0198] In some embodiments, the step of disposing the aerosol - generating material within the body (S2) includes collecting the aerosol - generating material and forming the body.

[0199] In some embodiments, the first wall portion is defined by collecting a first inner edge of the aerosol - generating material, and / or the second wall portion is defined by collecting a second inner edge of the aerosol - generating material. In embodiments where the aerosol - generating material further comprises a third inner edge and / or a fourth inner edge, the method can include the step of collecting the third inner edge and / or the fourth inner edge of the aerosol - generating material to define respective third wall portions and / or fourth wall portions. In some embodiments, the assembly comprises at least one additional tube. The step of disposing the aerosol - generating material within the body (S2) can include disposing the aerosol - generating material such that the body comprises a second void that houses at least one additional tube, and the third inner edge at least partially defines the boundary of the second void. In some embodiments, the step of disposing the aerosol - generating material within the body (S2) includes disposing the aerosol - generating material such that the fourth inner edge at least partially defines the boundary of the second void.

[0200] The third inner edge and / or the fourth inner edge may be formed in the same manner as previously described with reference to the first inner edge and / or the second inner edge.

[0201] In some embodiments, the method further includes the step of connecting the component to a further component of the delivery system, for example, a further component such as a further component of a combustible or non - combustible aerosol supply mechanism. In one embodiment, the further component is a filter component 3 and may be connected to the component by wrapping paper such as chip paper.

[0202] Next, referring to FIG. 10, an embodiment of an apparatus 300 for manufacturing components for a delivery system is shown.

[0203] The apparatus 300 includes a source 301 of aerosol-forming material 10, a crimper device 302, and an edge-forming device 303 including a first pair 304 of cutting drums and a second pair 305 of cutting drums. The apparatus 300 further includes an adhesive applicator 306, a tube supply device 307, and a body-forming device 308.

[0204] In the present example, the source 301 is a reel 301 of aerosol-forming material 10 that is supplied along a conveyance path (indicated by arrow "Y" in FIG. 10). The aerosol-forming material 10 can be supplied along the conveyance path Y, for example, by rollers and / or belts, as will be apparent to those skilled in the art. In the present example, the aerosol-forming material 10 is supplied to the body-forming device 308 as a continuous web 200.

[0205] In the present example, the crimper device 302 includes a first crimper roller 302A and a second crimper roller 302B. However, in other embodiments, the crimper device 302 may be omitted, or may have another configuration that alternatively or additionally includes an embossing device, such as an embossing roller.

[0206] The crimper device 302 is configured to crimp the aerosol-forming material 10 passing between rollers 302A and 302B. In some embodiments, the crimper device 302 is configured to crimp the aerosol-forming material 10 to a crimp depth in the range of, for example, from 0.1 mm to 2 mm, in some examples from 0.1 mm to 1 mm, or from 0.2 mm to 0.7 mm, as previously described. In some embodiments, the crimper device 302 is configured to heat the aerosol-forming material, for example, one or both of the rollers 302A, 302B may be heated. In one such embodiment, one or both of the crimper rollers 302A, 302B comprise one or more heating elements, such as a resistive heating element.

[0207] In the present example, the crimper device 302 is configured to crimp the aerosol-forming material 10 before the edge-forming device 303 forms the internal edge(s). In an alternative embodiment (not shown), the crimper device 302 is configured to crimp the aerosol-forming material 10 after the edge-forming device 303 has formed the internal edge(s).

[0208] The first pair 304 of cutting drums comprises a shearing drum 304A and a support drum 304B. The shearing drum 304A comprises a plurality of knives 304C configured to sequentially contact the aerosol-forming material 10 as the aerosol-forming material 10 passes between the shearing drum 304A and the support drum 304B to form a first slit in the aerosol-forming material 10 of the web 200. The knives 304C are arranged at regular intervals around the central axis of the shearing drum 304A so as to form the first slit in the aerosol-forming material 10 at regular intervals. The distance between each first slit can be selected by adjusting the distance between adjacent knives 304C and / or the number of knives 304C of the shearing drum 304A.

[0209] The second pair 305 of cutting drums comprises a shearing drum 305A and a support drum 304B. The shearing drum 305A comprises a plurality of knives 305C configured to sequentially contact the aerosol-forming material 10 as the aerosol-forming material 10 passes between the shearing drum 305A and the support drum 305B to form a second slit in the aerosol-forming material 10 of the web 200. The knives 305C are arranged at regular intervals around the central axis of the shearing drum 305A so as to form second slits in the aerosol-forming material 10 at regular intervals. The distance between each second slit can be selected by adjusting the distance between adjacent knives 305C and / or the number of knives 305C of the shearing drum 305A.

[0210] In some embodiments, the rotation of the first pair 304 of cutting drums and the rotation of the second pair 305 of cutting drums may be synchronized.

[0211] The first slit forms a first inner edge of the aerosol-forming material 10, and the second slit forms a second inner edge of the aerosol-forming material 10. The first slit and the second slit and / or the first inner edge and the second inner edge can have any of the slit / inner edge features described, including similar shapes and / or dimensions.

[0212] In an alternative embodiment (not shown), a pair of cutting drums forms both a first inner edge and a second inner edge. For example, one knife or set of knives forms the first inner edge and a second knife or set of knives forms the second inner edge. In other embodiments, the first inner edge or the second inner edge is omitted.

[0213] In some embodiments, the first pair 304 and / or the second pair 305 of cutting drums may be replaced by one or more cutting lasers configured to form a slit or opening in the aerosol-forming material to form an inner edge of the aerosol-forming material 10.

[0214] In the present example, the edge forming device 303 forms a slit in the aerosol generating material 10. In other embodiments, the edge forming device 303 forms an opening that forms an internal edge in the aerosol generating material 10. For example, the edge forming device 303 may be configured to form a notch in the aerosol generating material 10 to form an opening or each opening. In one such embodiment, the cutting device 303 comprises a punch drum with a plurality of protrusions, the plurality of protrusions punching out a portion of the aerosol generating material 10 and removing it from the remaining portion of the aerosol generating material 10 to form an opening. The opening can have any of the characteristics of the openings described above, including similar shapes and / or dimensions.

[0215] In some embodiments, the edge forming device 303 is configured to form a first internal edge, the first internal edge passing through a tube supply device and then disposing at least one tube in the aerosol generating material. In another embodiment, the edge forming device is configured to form a first internal edge after the tube supply device has disposed at least one tube in a first portion of the aerosol generating material.

[0216] The adhesive applicator 306 is configured to apply an adhesive to the aerosol generating material 10, for example, by spraying the adhesive or applying the adhesive using a roller or brush. Alternatively, the adhesive may be supplied to the aerosol generating material 10 by gravity. When the aerosol generating material 10 moves along the transport path Y and passes through the adhesive applicator 306, the adhesive is applied to the aerosol generating material 10. The adhesive applicator 306 can supply the adhesive to the aerosol generating material 10 by means of a compressed gas through the nozzle 306A. It should be appreciated that in some embodiments the adhesive applicator 306 may be omitted.

[0217] The tube supply device 307 is configured to supply at least one tube to the continuous web at regular intervals. The tube supply device 307 may be configured to arrange at least one tube on the first surface of the first inner edge and the second surface of the second inner edge such that at least one tube is arranged between the first edge and the second edge of the aerosol generating material.

[0218] The tube supply device 307 includes a hopper 307A and a screw feeder 307B. The hopper 307A contains tubes. The screw feeder 307B is configured to supply tubes from the hopper 307A to the aerosol generating material 10 when the aerosol generating material 10 moves along the conveying path Y and passes through the tube supply device 307.

[0219] In an alternative embodiment (not shown), the screw feeder 307B is replaced by an alternative tube supply device such as a belt that supplies tubes to the aerosol generating material. In some embodiments (not shown), the tubes are stored in a container and supplied to the aerosol generating material through a pipe using compressed gas.

[0220] In some embodiments, the tube supply device 307 includes a tube delivery wheel.

[0221] The body forming device 308 includes tongs 308A. The aerosol generating material 10 is supplied to the tongs 308A. The cross-sectional area of the tongs 308A is reduced so that the aerosol generating material 10 is collected together to form a body when passing through the tongs 308A.

[0222] The body forming device 308 may place the aerosol generating material 10 within a body of material surrounded by wrapping paper (not shown). The body and the wrapping paper may form a continuous rod and may then be cut into segments so as to be contained within the delivery system. In some embodiments, the device further comprises a component cutting device configured to cut the rod into components / segments of a single length or multiple lengths.

[0223] The body forming device 308 is configured to place the aerosol generating material 10 within the body such that the body comprises a void for accommodating at least one tube. When the web of aerosol generating material is collected to form the body, the first inner edge 43 and the second inner edge 44 allow the aerosol generating material to be collected together such that the first inner edge 43 and the second inner edge 44 at least partially, or wholly, define the boundary of a void containing at least one tube 11.

[0224] In some embodiments, the edge forming device 303 is configured to provide the aerosol generating material 10 with third and / or fourth slits or apertures to respectively form third and / or fourth internal edges in the aerosol generating material 10. In one embodiment, the first pair 304 of cutting drums is configured to form a first internal edge and a third internal edge in the aerosol generating material 10, and the second pair 305 of cutting drums is configured to form a second internal edge and a fourth internal edge in the aerosol generating material 10. In another embodiment (not shown), the edge forming device 303 includes a third pair (not shown) of cutting drums configured to form a third internal edge (e.g., form a third slit / aperture in the aerosol generating material), and / or a fourth pair (not shown) of cutting drums configured to form a fourth internal edge (e.g., form a fourth slit / aperture in the aerosol generating material). In yet another embodiment (not shown), a pair of cutting drums forms all of the first, second, third, and fourth internal edges. In another embodiment (not shown), one or more lasers may be used to form the first, second, third, and fourth internal edges.

[0225] The third slit / aperture and the fourth slit / aperture and / or the third internal edge and the fourth internal edge can have any of the features of the slits / internal edges described, including similar shapes and / or dimensions.

[0226] The tube supply device 307 is configured to arrange at least one additional tube in the aerosol - generating material 10. For example, the tube supply device 307 can include a second hopper (not shown) and a second screw feeder (not shown). The second hopper further contains tubes. The second screw feeder is configured to supply additional tubes from the second hopper to the aerosol - generating material 10 when the aerosol - generating material 10 moves along the conveyance path Y and passes through the tube supply device 307. In an alternative embodiment (not shown), the second screw feeder is replaced by an alternative tube supply device, such as a belt that supplies additional tubes to the aerosol - generating material. In some embodiments (not shown), the additional tubes are stored in a container and are supplied to the aerosol - generating material through a pipe using compressed gas.

[0227] In such embodiments, the body - forming device 308 is configured to arrange the aerosol - generating material 10 in the body such that the body has a second void that houses at least one additional tube, and a third inner edge at least partially or entirely forms the boundary of the second void, and a fourth inner edge at least partially or entirely forms the boundary of the second void.

[0228] In some embodiments, the body - forming device 308 is configured to collect a first inner edge of the aerosol - generating material to form a first wall portion. In some embodiments, the body - forming device 308 is configured to collect a second inner edge of the aerosol - generating material to form a second wall portion. In some embodiments, the body - forming device 308 is configured to collect a third inner edge of the aerosol - generating material to form a third wall portion. In some embodiments, the body - forming device 308 is configured to collect a fourth inner edge of the aerosol - generating material to form a fourth wall portion.

[0229] In some embodiments, the device 300 comprises a sensor 350 (shown in FIG. 10) configured to detect information indicating at least one internal edge 43, 44 of the aerosol-generating material (e.g., one or more of the first, second, third, and / or fourth internal edges).

[0230] In some embodiments, the device 300 further comprises a controller 360 (shown in FIG. 10) configured to control the position of at least one tube based on information indicating at least one internal edge detected by the sensor 350.

[0231] In some embodiments, the controller 360 controls the tube supply device 307 based on information indicating the position of at least one internal edge detected by the sensor 350 in order to control the position of at least one tube and / or a further tube. Additionally or alternatively, the controller 360 is configured to control the speed at which the aerosol-generating material 10 is conveyed along the conveyance path Y in order to control the position of at least one tube and / or a further tube.

[0232] The sensor 350 can comprise a camera (not shown) configured to detect each respective first comprehensive edge passing through the camera. Alternatively or in addition, the sensor can comprise another type of sensor (not shown), such as an optical gate, a capacitive sensor, a magnetic or Hall effect sensor, or an ultrasonic sensor. In some embodiments, the sensor 350 or one or more further sensors additionally or alternatively detect the second, third, and / or fourth internal edges.

[0233] The controller 360 can comprise a memory 361 and a processor 362. The memory 361 can be configured to store instructions and / or information, and the processor 362 can be configured to execute instructions.

[0234] The controller 302 may be configured to control the tube supply device 307 based on information indicating the position of at least one internal edge detected by the sensor 350 so as to align at least one tube in the space between adjacent first and second internal edges, for example, by controlling the timing and / or frequency at which at least one tube is dispensed into the aerosol-forming material 10. For example, in an embodiment where the tube supply device 307 comprises a tube insertion wheel, the controller 360 controls the rotational speed of the tube insertion wheel. Additionally or alternatively, the controller 360 may be configured to control the speed at which the aerosol-forming material 10 is conveyed along the conveyance path Y in order to control the position of at least one tube, for example, by controlling the speed of a belt, drum and / or roller that conveys the aerosol-forming material 10 along the conveyance path Y. Again, this serves to align at least one tube in the space between adjacent first and second internal edges (and / or at least one further tube in a second space between adjacent third and fourth internal edges).

[0235] Controlling the position of at least one tube / at least one further tube supplied to the aerosol-forming material 10 based on information indicating at least one first, second, third and / or fourth internal edge detected by a sensor helps to ensure that the at least one tube / further tube does not become misaligned with respect to the aerosol-forming material 10, for example by the aerosol-forming material stretching or slipping in the conveyance path. However, it should be understood that in other embodiments the sensor(s) may be omitted.

[0236] The various embodiments described herein are provided only to assist in the understanding and teaching of the claimed features. These embodiments are provided only as representative examples and are not exclusive and / or exhaustive. 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 defined by the claims or limitations on equivalents of the claims, and it should be understood that other embodiments can be utilized and modifications can be made without departing from the scope of the claimed invention. The various embodiments of the present invention can appropriately include, consist of, or consist essentially of an appropriate combination of disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Additionally, the present disclosure can include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. A component for a non-combustible aerosol delivery system, the component comprising: a body formed from a sheet of aerosol generating material, the body having voids; and at least one tube disposed within the voids inside the body. The component further comprises: the sheet of aerosol generating material having an internal edge that at least partially defines a closed end of the voids; and the voids having open ends in a plane at an end of the body.

2. The component according to claim 1, wherein the sheet of aerosol generating material comprises a plurality of elongated strips extending between bands extending in a lateral direction of the aerosol generating material.

3. The component according to claim 1 or 2, wherein the internal edge comprises a first internal edge that is a cut edge of the sheet of aerosol generating material.

4. The component according to claim 3, wherein the sheet of aerosol generating material comprises a slit forming the first internal edge.

5. The component according to claim 1, wherein the sheet of aerosol generating material has an opening, the internal edge comprises a first internal edge, and an edge of the opening comprises the first internal edge of the sheet material.

6. The component according to claim 5, wherein a cross-section of the opening is substantially rectangular.

7. The component according to claim 1, wherein the sheet of aerosol generating material has first and second external edges at axial ends of the sheet material, and the first internal edge is substantially parallel to the first and / or second external edges.

8. The component according to claim 1, wherein the at least one tube is disposed coaxially with the body of the aerosol generating material.

9. The component according to claim 1, wherein ends of the tube are disposed in the plane at an end of the body of the aerosol generating material.

10. The component according to claim 1, wherein the tube is configured to accommodate a susceptor.

11. The component according to claim 1, wherein the tube contains at least one reactive substance and / or aerosol modifying substance.

12. The component according to claim 1, wherein the tube is formed from paper.

13. The component according to claim 1, wherein ends of the tube are disposed in contact and engagement with the closed end of the voids. Component according to claim 1, wherein the inner edge is a first inner edge, and the first inner edge is arranged at an interval in the range of about 5 mm to about 45 mm in the longitudinal direction from the open end of the gap.

15. A method of manufacturing a component for a delivery system, comprising: providing an assembly comprising at least one tube and a sheet of aerosol - generating material having a first inner edge and a second inner edge; placing the sheet material within a body such that the body has a gap for receiving the at least one tube between the first inner edge and the second inner edge; placing the first inner edge and the second inner edge such that they at least partially define a closed end of the gap; cutting the body between the first inner edge and the second inner edge to provide two body portions having a gap with an open end; and a method.

16. The method according to claim 15, wherein providing the assembly includes cutting the sheet of aerosol - generating material to form a plurality of elongated strips of aerosol - generating material.

17. The method according to claim 15, wherein providing the assembly includes forming the first inner edge and the second inner edge in the sheet material.

18. The method according to claim 17, wherein forming the first inner edge and the second inner edge in the sheet material includes cutting the sheet material to form the first inner edge and the second inner edge, and optionally cutting through the entire thickness of the sheet material to form the first inner edge and the second inner edge.

19. The method according to claim 18, wherein forming the first inner edge and the second inner edge includes cutting the sheet material using a knife and / or a laser.

20. The method according to any one of claims 17 to 19, wherein forming the first inner edge and the second inner edge includes forming slits in the sheet material.

21. The step of forming the first internal edge and the second internal edge includes forming an opening in the sheet material such that the edge of the opening comprises the first internal edge and the second internal edge of the sheet material, and optionally, the opening is substantially rectangular, the method according to any one of claims 17 to 19.

22. The method according to claim 21, wherein forming the opening includes forming a notch in the sheet material.

23. The step of providing the assembly includes providing the sheet material having the first internal edge and the second internal edge, and then supplying the at least one tube to the sheet material, and optionally, the step of providing the assembly includes forming the first internal edge and the second internal edge in the sheet material, and then supplying at least one object to the sheet material, the method according to claim 15.

24. The method according to claim 17, wherein the step of providing the assembly includes providing the sheet material, supplying at least one object to the sheet material, and then forming the first internal edge and the second internal edge in the sheet material.

25. The method according to claim 15, including the step of crimping the sheet material, and optionally, the step of crimping the sheet material to a crimp depth in the range of 0.1 mm to 2 mm.

26. The method according to claim 25, including the step of crimping the sheet material after the first internal edge and the second internal edge are formed.

27. The method according to claim 25, including the step of crimping the sheet material before the first internal edge and the second internal edge are formed.

28. The method according to claim 17, wherein the step of providing the assembly includes providing a continuous web of sheet material.

29. The method according to claim 28, including the step of forming a plurality of internal edges at regular intervals in the continuous web.

30. The method according to claim 28 or 29, comprising the step of moving the continuous web and the step of supplying the at least one tube at regular intervals as the continuous web moves along the conveying path.

31. The method according to claim 17, wherein the step of disposing the sheet material within the body includes collecting the sheet material to form the body.

32. The method according to claim 31, wherein the first wall portion is defined by collecting the first inner edge of the sheet material and / or the second wall portion is defined by collecting the second inner edge of the sheet material.

33. The method according to claim 17, comprising the step of detecting information indicating at least one inner edge of the sheet material.

34. The method according to claim 33, comprising the step of controlling the position at which the at least one tube is supplied to the sheet material based on information indicating the at least one inner edge detected by the sensor.

35. The method according to claim 34, comprising the step of controlling the tube supply device based on the information indicating the position of the at least one inner edge detected by the sensor to control the position at which the at least one tube is supplied to the sheet material, and optionally the step of controlling the timing and / or frequency of distributing the at least one tube to the sheet material.

36. An apparatus for manufacturing components for a delivery system, an edge forming device configured to form a first inner edge on a sheet of aerosol generating material, a tube supply device configured to dispose at least one tube on the sheet of aerosol generating material, a body forming device configured to dispose the sheet of aerosol generating material within a body, the body comprising a void for accommodating the at least one tube comprising the apparatus, wherein the first inner edge at least partially defines a boundary of the void. Method

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