Articles for use in non-flammable aerosol delivery systems

Abstract

An article is disclosed for use in or as part of an aerosol delivery system. The article comprises an aerosol-generating material 3 and a heat transfer material 40 for distributing heat from a first region of the aerosol-generating material to a second region of the aerosol-generating material. The heat transfer material 40 has a thermal conductivity of at least 220 W / mK. The heat transfer material 40 may include one or more separate material portions in contact with the first and second regions, such as rods, wires, fibers, threads, or ribbons. The heat transfer material may contain or include carbon.

Description

Technical Field

[0001] The present disclosure relates to an article for use in a non-combustible aerosol supply system. Background

[0002] Certain delivery systems generate an aerosol during use and the user inhales the aerosol. For example, a tobacco heating device heats an aerosol-forming substrate such as tobacco to form an aerosol by heating the substrate rather than 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

[0003] According to some embodiments, an article for use in an aerosol supply system or as part of an aerosol supply system, comprising an aerosol-generating material and a heat transfer material for distributing heat from a first region of the aerosol-generating material to a second region of the aerosol-generating material, the heat transfer material having a thermal conductivity of at least 220 W / mK, is provided.

[0004] In some embodiments, the thermal conductivity of the heat transfer material is less than about 5000 W / mK, 4000 W / mK, 3000 W / mK, 2000 W / mK, or 1000 W / mK. In some embodiments, the thermal conductivity of the heat transfer material is greater than about 300 W / mK, 400 W / mK, or 500 W / mK. In some embodiments, the thermal conductivity of the heat transfer material ranges from about 220 to 5000 W / mK, 220 to 4000 W / mK, 220 to 3000 W / mK, 220 to 2000 W / mK, 220 to 1000 W / mK, 220 to 500 W / mK, 300 to 5000 W / mK, 300 to 4000 W / mK, 300 to 3000 W / mK, 300 to 2000 W / mK, 300 to 1000 W / mK, 300 to 500 W / mK, or 220 to 470 W / mK.

[0005] In some embodiments, the weight of the heat transfer material present in the article ranges from about 1 to 25 mg, 1 to 20 mg, 1 to 15 mg, 1 to 10 mg, or 1 to 5 mg, hi some embodiments, the weight ratio of the heat transfer material to the aerosol-forming material is about 1:10 to 1:100.

[0006] In some embodiments, the heat transfer material includes at least one separate material portion in thermal contact with the first and second regions of the aerosol-generating material. The heat transfer material can include a single material portion. The heat transfer material can be in the form of a rod, wire, fiber, thread, or ribbon extending through at least a portion of the aerosol-generating material.

[0007] In some embodiments, the heat transfer material extends through the length of the aerosol-generating material. If the aerosol-generating material is generally cylindrical, the heat transfer material can extend along some or all of the length of the material. The heat transfer material can be elongated and can extend parallel to or along the axis of the aerosol-generating material. As described below, the heat transfer material can be pumped or extruded into the aerosol-generating material during the manufacture of the article.

[0008] In some embodiments, the heat transfer material extends along less than the length of the aerosol-generating material. The heat transfer material can extend along at least 10% of the length of the aerosol-generating material. The heat transfer material can extend along up to about 90% of the length of the aerosol-generating material. In some embodiments, the length of the heating element is in the range of 10-90%, 10-80%, 10-70%, 10-60%, or 10-50% of the length of the aerosol-generating material.

[0009] The heat transfer material can be separate and distinct from the aerosol-generating material. The heat transfer material can include a single material portion, or multiple separate material portions in thermal contact with the respective first and second regions of the aerosol-generating material. For example, the heat transfer material can be formed from three or more separate material portions within the aerosol-generating material, such as 3 to 20, 3 to 10, or 3 to 5 separate material portions.

[0010] In some embodiments, the heat transfer material may be formed from multiple portions of material. In some embodiments, the heat transfer material may be more generally distributed throughout the aerosol-generating material, as opposed to being formed into one or more separate, distinct portions of material. In some embodiments, the heat transfer material may be considered to be mixed with the aerosol-generating material. In some embodiments, the heat transfer material is in the form of particles or a powder.

[0011] In some embodiments, the heat transfer material is non-metallic.

[0012] In some embodiments, the heat transfer material contains or includes carbon. The heat transfer material may be formed from or include one of graphene, diamond, graphite, pyrolytic graphite, carbon fiber, graphene fiber, or graphite fiber. Some of these materials have thermal conductivity values of 4000 W / mK for graphene, 2200 W / mK for diamond, and 1700 W / mK for pyrolytic graphite. The heat transfer material may be provided with a backing material, such as paper.

[0013] In some embodiments, the aerosol-forming material comprises reconstituted tobacco. A heat transfer material, which may include carbon or graphite as described above, can be mixed with the reconstituted tobacco. Reconstituted tobacco typically includes wood pulp, although the heat transfer material of the present disclosure may replace some or all of the wood pulp.

[0014] In some embodiments, the article is heated by an external heating element outside the aerosol-forming material. In other embodiments, the article is heated by an internal heating element that is inserted into the aerosol-forming material during use.

[0015] The heating element inserted into the aerosol-forming material may be an electrically heated element or a susceptor heated by induction heating or magnetic hysteresis heating. The heating element may be part of the article. The heating element may be inserted into the article during manufacture. Alternatively, the heating element may be part of an aerosol supply device that uses the article, and the insertion of the heating element into the aerosol-forming material occurs when the article is inserted into the aerosol supply device.

[0016] Such a heating element may be formed from metal.

[0017] In some embodiments, the heat transfer material has openings, pores, or cavities. The article may further comprise an amorphous solid, an active substance, or a fragrance. The amorphous solid, active substance, or fragrance can be disposed in one or more of the openings, pores, or cavities of the heat transfer material.

[0018] According to some embodiments, there is provided an aerosol supply system comprising a non-combustible aerosol supply device, a heating element, and the above-described article.

[0019] In some embodiments, the aerosol supply device comprises a power source for supplying power to the heating element, and the heating element heats the aerosol-forming material by electrical conduction. This type of heating element may be part of the aerosol supply device.

[0020] In some embodiments, the aerosol supply device comprises a magnetic field generator, and the heating element is a susceptor that heats the aerosol-forming material by induction heating and / or magnetic hysteresis heating.

[0021] In some embodiments, the aerosol supply device comprises a heat generating power source, and the heating element of the article is a second heat transfer material for transferring heat to the aerosol generating material.

[0022] The susceptor or the second heat transfer material may be part of the article or part of the aerosol supply device.

[0023] According to some embodiments, a method of manufacturing an article for use in an aerosol supply system or as part of an aerosol supply system, the article comprising an aerosol generating material, the method comprising adding a heat transfer material for distributing heat from a first region of the aerosol generating material to a second region of the aerosol generating material, the heat transfer material having a thermal conductivity of at least 220 W / mK, is provided.

[0024] The step of adding the heat transfer material can include the step of feeding or extruding the heat transfer material into the aerosol generating material. Alternatively, the step of adding the heat transfer material can include the step of mixing the heat transfer material with the aerosol generating material.

[0025] In some embodiments, a rod, wire, fiber, thread, or ribbon of the heat transfer material can be fed into the aerosol generating material during manufacture. If the aerosol generating material is formed from a plurality of scored tobacco strips, the heat transfer material can be fed into the plurality of strips during manufacture of the article. As described above, the heat transfer material can contain carbon and can be graphite such as graphite fiber.

[0026] Hereinafter, embodiments will be described only by way of example with reference to the accompanying drawings.

Brief Description of the Drawings

[0027]

Figure 1

Figure 1a

Figure 1b

Figure 1c

Figure 1d

Figure 2a

Figure 2b

Figure 3

Figure 4

Figure 5

[0028] As used herein, the term "delivery system" is intended to encompass a system for delivering at least one substance to a user, and this includes Combustible aerosol supply systems such as cigarettes, cigars, cigars, and tobacco for pipes or hand - rolled or handmade cigarettes, whether based on tobacco, tobacco derivatives, expanded tobacco, reclaimed tobacco, tobacco substitutes, or other smoking materials, and Non - combustible aerosol supply systems that release compounds from aerosol - generating materials without burning the aerosol - generating materials, such as electronic cigarettes, tobacco - heating products, and hybrid systems for generating aerosols using combinations of aerosol - generating materials. Including, but not limited to, oral products such as troches, gums, patches, articles containing inhalable powders, and oral tobacco including snus or moist snuff, an aerosol-free delivery system is included that delivers at least one substance, which may or may not contain nicotine, to the user orally, nasally, transdermally, or by another method without forming an aerosol.

[0029] According to the present disclosure, a "non-combustible" aerosol supply system is a system in which an aerosol-generating material (or its components), which is a component of the aerosol supply system, does not burn or combust in order to facilitate the delivery of at least one substance to the user.

[0030] In some embodiments, the delivery system is a non-combustible aerosol supply system such as a powered non-combustible aerosol supply system.

[0031] In some embodiments, the non-combustible aerosol supply system is an electronic cigarette, also known as a vaping 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 essential.

[0032] 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.

[0033] In some embodiments, the non-combustible aerosol supply system is a hybrid system for generating an aerosol using a combination of aerosol-generating materials, one or more of which can 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, for example, tobacco or non-tobacco products.

[0034] Typically, a non-combustible aerosol supply system can comprise a non-combustible aerosol supply device and a consumable for use with the non-combustible aerosol supply device.

[0035] In some embodiments, the present disclosure relates to consumables that contain an aerosol-generating material and are configured for use with a non-combustible aerosol supply device. These consumables may sometimes be referred to as articles throughout the present disclosure.

[0036] As used herein, the terms "upstream" and "downstream" are relative terms defined with respect to the direction in which the mainstream aerosol is drawn through an article or device during use.

[0037] In some embodiments, a non-combustible aerosol supply system, such as its non-combustible aerosol supply device, can comprise a power source and a controller. The power source may be, for example, a power supply or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon matrix that can be activated to disperse power in the form of heat to an aerosol-generating material or a heat-transfer material proximate to the heat-generating power source.

[0038] In some embodiments, the non-combustible aerosol supply system comprises a region for receiving a consumable, an aerosol generator, an aerosol generation region, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0039] In some embodiments, consumables for use with a non-combustible aerosol supply device can comprise an aerosol-generating material, an aerosol-generating material storage region, aerosol-generating material transfer components, an aerosol generator, an aerosol generation region, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0040] In some embodiments, the consumable includes a substance to be delivered. The substance to be delivered may be an aerosol-forming material or a material not intended for aerosolization. Optionally, any of the materials can include one or more active ingredients, one or more flavorings, one or more aerosol-forming materials, and / or one or more other functional materials.

[0041] In some embodiments, the substance to be delivered can include an active substance.

[0042] As used herein, the active substance may be a physiologically active material that is a material intended to effect or enhance a physiological response. The active substance may be selected, for example, from nutraceuticals, known drugs, and psychoactive substances. The active substance may be of natural origin or synthetically obtained. The active substance can include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6 or B12 or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance can include one or more components, derivatives, or extracts of tobacco, cannabis, or another plant-based substance.

[0043] In some embodiments, the active substance includes nicotine. In some embodiments, the active substance includes caffeine, melatonin, or vitamin B12.

[0044] As described herein, the active substance may include one or more botanical substances or their components, derivatives, or extracts, or may be derived therefrom. As used herein, the term "botanical substance" includes, but is not limited to, any material derived from plants, including extracts, leaves, bark, fibers, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc. Alternatively, the material can include active compounds naturally present in synthetically obtained botanical substances. The material may be in the form of a liquid, gas, solid, powder, micropowder, crushed particles, granules, pellets, fragments, chips, sheets, etc. Examples of botanical substances are tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo leaf, purslane, hibiscus, laurel, licorice, matcha, mate, orange peel, papaya, rose, sage, tea such as 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, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, silantro, bergamot, orange flower, myrtle, blackcurrant, valerian, 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.The mint may be selected from the following mint varieties, namely, Mentha Arvensis, Mentha c.v., Mentha niliaca, Mentha piperita, Mentha piperita citrata c.v., Mentha piperita c.v., Mentha spicata crispa, Mentha cordifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata c.v., and Mentha suaveolens.

[0045] In some embodiments, the active substance comprises or is derived from one or more plant substances or components, derivatives, or extracts thereof, and the plant substance is tobacco.,

[0046] In some embodiments, the active substance comprises or is derived from one or more plant substances or components, derivatives, or extracts thereof, and the plant substances are selected from eucalyptus, star anise, cocoa, and hemp.

[0047] In some embodiments, the active substance comprises or is derived from one or more plant substances or components, derivatives, or extracts thereof, and the plant substances are selected from rooibos and fennel.

[0048] In some embodiments, the substance to be delivered comprises a fragrance.

[0049] As used herein, the terms "flavor" and "flavorant" refer to materials that, when permitted by regional regulations, can be used to create a desired taste, aroma, or other somatosensorial sensation in products for adult consumers.These ingredients may be naturally derived flavoring materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (aniseed), cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit). , papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang ila Sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil of any species of Mentha genus, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, yerba mate, orange peel, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, bell pepper, mace, damian marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.The materials may be imitation, synthetic or natural ingredients, or mixtures thereof. The materials may be in any suitable form, for example, a liquid such as an oil, a solid such as a powder, or a gas.

[0050] In some embodiments, the flavoring includes menthol, spearmint, and / or peppermint. In some embodiments, the flavoring includes cucumber, blueberry, citrus, and / or red berry flavoring ingredients. In some embodiments, the flavoring includes eugenol. In some embodiments, the flavoring includes flavoring ingredients extracted from tobacco. In some embodiments, the flavoring includes flavoring ingredients extracted from cannabis.

[0051] In some embodiments, the flavoring agent may include a sensate intended to achieve a somatosensory sensation typically perceived chemically induced by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the scent or taste nerves, and may include agents that provide a heating, cooling, tingling, or anesthetic effect. A suitable heating agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol WS-3.

[0052] An aerosol-generating material is a material that can generate an aerosol when activated, for example, by heating, irradiation, or in any other way. The aerosol-generating material may be in solid, liquid, or gel form and may or may not contain active substances and / or flavorings. The aerosol-generating material may also be incorporated into an article for use in an aerosol generating system.

[0053] As used herein, the term "tobacco material" refers to any material that includes tobacco or its derivatives or substitutes. The tobacco material may be in any suitable form. The term "tobacco material" can include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material can include one or more of ground tobacco, tobacco fibers, cut tobacco, extruded tobacco, tobacco stems, tobacco laminas, reconstituted tobacco, and / or tobacco extracts.

[0054] A consumable is an article that includes or consists of an aerosol - generating material that is intended to be partially or wholly consumed by a user during use. The consumable can comprise one or more other components, such as an aerosol - generating material storage area, an aerosol - generating material transfer component, an aerosol - generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. The consumable can also comprise an aerosol generator, such as a heater that generates heat during use to generate an aerosol from the aerosol - generating material. The heater can comprise, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0055] A susceptor is a material that can be heated by the penetration of a fluctuating magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, and the penetration of a fluctuating magnetic field into the conductive material causes inductive heating of the heating material. The heating material may be a magnetic material, and the penetration of a fluctuating magnetic field into the magnetic material causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, and 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.

[0056] An aerosol modifier is a substance that is typically disposed downstream of the aerosol generation region and is configured to modify the generated aerosol, for example, by changing the taste, fragrance, sourness, or another characteristic of the aerosol. The aerosol modifier may be provided within an aerosol modifier release component operable to selectively release the aerosol modifier.

[0057] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier can include, for example, one or more of a flavorant, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, a thread, or granules. The aerosol modifier may not include a filter medium.

[0058] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to apply thermal energy to the aerosol-generating material and release one or more volatile substances from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to apply to the aerosol-generating material one or more of vibration, high pressure, or electrostatic energy.

[0059] The filament tow material described in this specification can include cellulose acetate fiber tow. The filament tow may be formed using other materials for forming fibers such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1,4-butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers, or combinations thereof. The filament tow may be plasticized using an appropriate plasticizer for the tow such as triacetin where the material is cellulose acetate tow or the tow may not be plasticized. The tow can have any appropriate specifications, for example, the fiber can have other cross-sections such as a "Y" shape or an "X" shape, the denier per filament value is 2.5 to 15 denier per filament, for example, 8.0 to 11.0 denier per filament, and the total denier value is 5,000 to 50,000, for example, 10,000 to 40,000.

[0060] In the drawings described in this specification, the same reference numerals are used to indicate equivalent features, articles, or components.

[0061] Figure 1 is a side cross-sectional view of article 1 for use in an aerosol delivery system.

[0062] Article 1 includes a mouthpiece 2 and an aerosol generation portion connected to the mouthpiece 2. In this example, the aerosol generation portion includes a source of aerosol generation material in the form of a cylindrical rod of aerosol generation material 3. In other examples, the aerosol generation portion can include a cavity for receiving a source of aerosol generation material. The aerosol generation material can include a plurality of strands or pieces of aerosol generation material. For example, the aerosol generation material can include a plurality of strands or pieces of aerosolizable material and / or a plurality of strands or pieces of amorphous solid as described below. In some embodiments, the aerosol generation material is composed of a plurality of strands or pieces of aerosolizable material.

[0063] In this example, the cylindrical rod of the aerosol-generating material 3 comprises a plurality of strands and / or shreds of the aerosol-generating material and is surrounded by a wrapper 10. In this example, the wrapper 10 is a moisture-impermeable wrapper.

[0064] The plurality of strands or shreds of the aerosol-generating material may be aligned within the aerosol-generating portion such that their longitudinal dimensions are aligned parallel to the longitudinal axis X-X' of the article 1. Alternatively, the strands or shreds may be arranged such that their longitudinal dimensions, when aligned, cross the longitudinal axis of the article.

[0065] At least about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, or 95% of the plurality of strands or shreds may be arranged such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the article. Most of the strands or shreds may be arranged such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the article. In some embodiments, about 95% to about 100% of the plurality of strands or shreds are arranged such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the article. In some embodiments, substantially all of the strands or shreds are arranged in the aerosol-generating portion such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the aerosol-generating portion of the article.

[0066] When most of the strands or shreds are arranged in the aerosol-generating portion such that their longitudinal axes are parallel to the longitudinal axis of the aerosol-generating portion of the article, the force required to insert the aerosol generator into the aerosol-generating material can be relatively small. This can make the article easier to use.

[0067] In this example, the rod of aerosol-forming material 3 has a circumference of about 22.7 mm. In alternative embodiments, the rod of aerosol-forming material 3 can have any suitable circumference, for example, from about 20 mm to about 26 mm.

[0068] 1a-1d, an example of an aerosol-forming material 3 including a heat transfer material is shown. In FIGS. 1a-1c, the aerosol-forming material 3 is shown generally as being formed from a plurality of strands 31 arranged generally parallel to the longitudinal axis of the article 1.

[0069] The embodiment of Figure 1a has a single fiber 40 of heat transfer material centrally located within the aerosol-generating material 3 and extending generally along the axis of the article 1. The heat transfer material is formed from graphite fibers that are fed into the aerosol-generating material 3 during manufacture.

[0070] FIG. 1b shows an embodiment having a plurality of fibers 40 of heat transfer material dispersed in the aerosol-forming material 3.

[0071] FIG. 1c shows an embodiment having two fibers 40 of heat transfer material in the aerosol-forming material 3, leaving the central region of the aerosol-forming material 3 free of heat transfer material.

[0072] FIG. 1 d shows an embodiment having multiple discrete portions 41 of heat transfer material dispersed generally throughout the aerosol-forming material 3 .

[0073] Article 1 is configured for use in a non-combustible aerosol delivery device that includes an aerosol generator that is inserted into the aerosol-generating portion. In this example, the aerosol generator is a heater, and the article is configured to receive the aerosol generator in a rod of aerosol-generating material.

[0074] The mouthpiece 2 comprises a cooling part 8, also referred to as a cooling element, which is arranged immediately downstream of and adjacent to the source of the aerosol-generating material 3. In this example, the cooling part 8 abuts against the source of the aerosol-generating material. The mouthpiece 2 also comprises, in this example, a material body 6 downstream of the cooling part 8 and a hollow tubular element 4 at the mouth end of the article 1 downstream of the material body 6.

[0075] The cooling part 8 comprises a hollow channel having an inner diameter of from about 1 mm to about 4 mm, for example from about 2 mm to about 4 mm. In this example, the hollow channel has an inner diameter of about 3 mm. The hollow channel extends along the entire length of the cooling part 8. In this example, the cooling part 8 comprises a single hollow channel. In an alternative embodiment, the cooling part may comprise a plurality of channels, for example two, three or four channels. In this example, the single hollow channel is substantially cylindrical, although in alternative embodiments other channel shapes / cross-sections may be used. The hollow channel can provide a space in which the aerosol drawn into the cooling part 8 can expand and cool. In all embodiments, the cooling part is configured to limit the cross-sectional area of one or more hollow channels and to limit the displacement of the tobacco into the cooling part during use.

[0076] The moisture-impermeable wrapper 10 has low friction with the aerosol-generating material, so that when the aerosol generator is inserted onto the rod of the aerosol-generating material, strands and / or shreds of the aerosol-generating material can be more easily displaced longitudinally into the cooling part. By providing the cooling part 8 immediately adjacent to the source of the aerosol-generating material and having an internal channel with a diameter in this range, when the aerosol generator is inserted onto the rod of the aerosol-generating material, the longitudinal displacement of strands and / or shreds of the aerosol-generating material is reduced, which is advantageous. By reducing the displacement of the aerosol-generating material during use, a more consistent packing density of the aerosol-generating material along the length of the rod and / or within the cavity is obtained, so that more consistent and improved aerosol generation can be achieved, which is advantageous.

[0077] The cooling portion 8 preferably has a radial wall thickness, which can be measured, for example, using calipers. The wall thickness of the cooling portion 8 for a given outer diameter of the cooling portion defines the inner diameter of the cavity enclosed by the walls of the cooling portion 8. The cooling portion 8 can have a wall thickness of at least about 1.5 mm and up to about 2 mm. In this example, the cooling portion 8 has a wall thickness of about 2 mm. Providing a cooling portion 8 with a wall thickness within this range improves retention of the supply of aerosol-generating material in the aerosol-generating portion during use by reducing longitudinal displacement of strands and / or strips of aerosol-generating material when the aerosol generator is inserted into an article.

[0078] Cooling portion 8 is formed from filament tow. Other configurations may be used, such as multiple layers of paper wound in parallel and abutting at a seam to form cooling portion 8, or spirally wound paper layers, cardboard tubes, tubes formed using a cohesive paper type process, molded or extruded plastic tubes, etc. Cooling portion 8 is manufactured to be sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacturing and use of article 1.

[0079] The wall material of the cooling portion 8 may be relatively non-porous, such that at least 90% of the aerosol generated by the aerosol-generating material 3 passes longitudinally through the one or more hollow channels rather than through the wall material of the cooling portion 8. For example, at least 92% or at least 95% of the aerosol generated by the aerosol-generating material 3 may pass longitudinally through the one or more hollow channels.

[0080] The filament tow forming the cooled portion 8 preferably has a total fineness of less than 45,000, more preferably less than 42,000. This total fineness has been found to allow for the formation of a cooled portion 8 that is not too dense. The total fineness is preferably at least 20,000, more preferably at least 25,000. In preferred embodiments, the filament tow forming the cooled portion 8 has a total fineness of 25,000 to 45,000, more preferably 35,000 to 45,000. The cross-sectional shape of the filaments in the tow is preferably "Y" shaped, although other shapes, such as "X" shaped filaments, may be used in other embodiments.

[0081] The filament tow forming the cooling portion 8 preferably has a denier per filament greater than 3. This denier per filament has been found to allow for the formation of a tubular element 4 that is not too dense. The denier per filament is preferably at least 4, more preferably at least 5. In a preferred embodiment, the filament tow forming the hollow tubular element 4 has a denier per filament between 4 and 10, more preferably between 4 and 9. In one example, the filament tow forming the cooling portion 8 is formed from cellulose acetate and has an 8Y40,000 tow containing 18% plasticizer, such as triacetin.

[0082] The density of the material forming the cooling portion 8 is preferably at least about 0.20 grams per cubic centimeter (g / cc), more preferably at least about 0.25 g / cc. The density of the material forming the cooling portion 8 is preferably less than about 0.80 grams per cubic centimeter (g / cc), more preferably less than 0.6 g / cc. In some embodiments, the density of the material forming the cooling portion 8 is from 0.20 to 0.8 g / cc, more preferably from 0.3 to 0.6 g / cc, or from 0.4 g / cc to 0.6 g / cc, or about 0.5 g / cc. These densities have been found to provide a good balance between the high hardness imparted by the higher density material and minimizing the total weight of the article. For the purposes of the present disclosure, the "density" of the material forming the cooling portion 8 refers to the density of the filament tow forming the element with any plasticizer incorporated. The density can be determined by dividing the total weight of the material forming the cooling portion 8 by the total volume of the material forming the cooling portion 8, and the total volume can be calculated using appropriate measurements of the material forming the cooling portion 8 obtained, for example, using calipers. If necessary, the appropriate dimensions can be measured using a microscope.

[0083] The length of the cooling portion 8 is preferably less than about 30 mm. The length of the cooling portion 8 is more preferably less than about 25 mm. The length of the cooling portion 8 is even more preferably less than about 20 mm. Additionally or alternatively, the length of the cooling portion 8 is preferably at least about 10 mm. The length of the cooling portion 8 is preferably at least about 15 mm. In some preferred embodiments, the length of the cooling portion 8 is from about 15 mm to about 20 mm, more preferably from about 16 mm to about 19 mm. In this example, the length of the cooling portion 8 is 19 mm.

[0084] The cooling portion 8 is arranged around the void within the mouthpiece 2 that acts as the cooling portion and defines this void. The void provides a chamber through which the heated and volatilized components generated by the rod of the aerosol-forming material 3 flow. The cooling portion 8 is hollow so as to provide a chamber for aerosol accumulation, but has sufficient rigidity to withstand the axial compressive forces and bending moments that can occur during manufacture and during use of the article 1. The cooling portion 8 causes a physical displacement between the aerosol-forming material 3 and the material body 6. The physical displacement brought about by the cooling portion 8 can provide a temperature gradient across the length of the cooling portion 8.

[0085] The mouthpiece 2 preferably comprises a cavity having an internal volume of more than 110 mm 3 It has been found that by providing at least this volume of cavity, improved aerosol formation becomes possible. The mouthpiece 2 is formed, for example, within the cooling portion 8 and has an internal volume of more than 110 mm 3 and more preferably more than 130 mm 3 and more preferably still comprises a cavity having an internal volume of more than 130 mm, enabling further improvement of the aerosol. In some examples, the internal cavity is from about 130 mm 3 to about 230 mm 3 for example about 134 mm 3 or 227 mm 3 and has a volume of.

[0086] The cooling portion 8 may be configured to provide a temperature difference of at least 40 degrees Celsius between the heated and volatilized components entering at the first upstream end of the cooling portion 8 and the heated and volatilized components exiting at the second downstream end of the cooling portion 8. The cooling portion 8 is preferably configured to provide a temperature difference of at least 60 degrees Celsius, more preferably at least 80 degrees Celsius, and even more preferably at least 100 degrees Celsius between the heated and volatilized components entering at the first upstream end of the cooling portion 8 and the heated and volatilized components exiting at the second downstream end of the cooling portion 8. This temperature difference across the length of the cooling portion 8 protects the material body 6, which is sensitive to temperature, from the high temperature of the aerosol-forming material 3 when heated.

[0087] In use, the aerosol-generating portion may exhibit a pressure drop of about 15 to about 40 mmH 2 O. In some embodiments, the aerosol-generating portion exhibits a pressure drop across the aerosol-generating portion of about 15 to about 30 mmH 2 O.

[0088] The aerosol-forming material has a density of about 400 mg / cm within the aerosol-generating region. 3 ~about 900mg / cm 3 A packing density greater than this may make it difficult to insert the aerosol generator of the aerosol delivery device into the aerosol-generating material, and may increase the pressure drop. 3 A packing density less than 0.05 can reduce the stiffness of the article. Additionally, if the packing density is too low, the aerosol-generating material cannot effectively grip the aerosol generator of the aerosol supply.

[0089] At least about 70% of the volume of the aerosol-generating portion is filled with the aerosol-generating material. In some embodiments, between about 75% and about 85% of the volume of the cavity is filled with the aerosol-generating material.

[0090] In this embodiment, the moisture-impermeable wrapper 10 surrounding the rod of the aerosol-generating material includes an aluminum foil. In other embodiments, the wrapper 10 includes a paper wrapper, which optionally includes a barrier coating that renders the material of the wrapper substantially moisture-impermeable. The aluminum foil has been found to be particularly effective in enhancing the formation of aerosol within the aerosol-generating material 3. In this example, the aluminum foil has a metal layer with a thickness of about 6 μm. In this example, the aluminum foil has a paper backing. However, in an alternative configuration, the aluminum foil may have other thicknesses, such as a thickness of 4 μm to 16 μm. The aluminum foil need not have a paper backing and may, for example, have a backing formed from another material that helps to provide the foil with an appropriate tensile strength, or may have no backing material. A metal layer or foil other than aluminum may be used. The total thickness of the wrapper is preferably 20 μm to 60 μm, more preferably 30 μm to 50 μm, thereby providing a wrapper with appropriate structural integrity and heat transfer characteristics. The tensile force that can be applied to the wrapper until it breaks may be a force exceeding 3,000 grams, such as a force of 3,000 to 10,000 grams or a force of 3,000 to 4,500 grams. If the wrapper includes paper or a paper backing, i.e., a cellulosic material, the wrapper can have a basis weight exceeding about 30 gsm. For example, the wrapper can have a basis weight of about 40 gsm to about 70 gsm. Such a basis weight imparts high rigidity to the rod of the aerosol-generating material. The high rigidity provided by a wrapper having this range of basis weights can make the rod of the aerosol-generating material 3 more resistant to the occurrence of wrinkles or other deformations due to the forces exerted on the article during use, for example, when inserting the article into the device and / or when inserting the heat generator into the article. Providing a rod of the aerosol-generating material with high rigidity can be advantageous when the plurality of strands or shreds of the aerosol-generating material are aligned within the aerosol-generating portion such that their longitudinal dimensions are aligned parallel to the longitudinal axis.This is because the longitudinally aligned strands or strips of aerosol-generating material can impart less stiffness to the rod of aerosol-generating material than when the strands or strips are not aligned, and the increased stiffness of the rod of aerosol-generating material can enable the article to withstand the increased forces to which the article is subjected during use.

[0091] In this example, the non-breathable wrapper 10 is also substantially non-breathable. In an alternative embodiment, the wrapper 10 preferably has a breathability of less than 100 Coresta units, more preferably less than 60 Coresta units. It has been found that wrappers with low breathability, for example, having a breathability of less than 100 Coresta units, more preferably less than 60 Coresta units, enhance aerosol formation in the aerosol-forming material 3. Without wishing to be bound by theory, it is hypothesized that this is due to reduced loss of aerosol compounds through the wrapper 10. The breathability of the wrapper 10 can be measured in accordance with ISO 2965:2009, which relates to the measurement of breathability of materials used as cigarette paper, filter plug wrap, and filter bonding paper.

[0092] The body of material 6 and the hollow tubular element 4 each define a generally cylindrical overall outer shape and share a common longitudinal axis. The body of material 6 is wrapped in a first plug wrap 7. The first plug wrap 7 preferably has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. The first plug wrap 7 preferably has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The first plug wrap 7 is preferably a non-porous plug wrap having an air permeability of, for example, less than 100 Coresta units, for example, less than 50 Coresta units. However, in other embodiments, the first plug wrap 7 may be a porous plug wrap having an air permeability of, for example, greater than 200 Coresta units.

[0093] The length of the material body 6 is preferably less than about 15 mm. More preferably, the length of the material body 6 is less than about 12 mm. Additionally or alternatively, the length of the material body 6 is at least about 5 mm. Preferably, the length of the material body 6 is at least about 8 mm. In some preferred embodiments, the length of the material body 6 is from about 5 mm to about 15 mm, more preferably from about 6 mm to about 12 mm, still more preferably from about 6 mm to about 12 mm, and most preferably about 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. In this example, the length of the material body 6 is 10 mm.

[0094] In this example, the material body 6 is formed from filament tow. In this example, the tow used for the material body 6 has a denier per filament (d.p.f.) of 5 and a total fineness of 25,000. In this example, the tow includes plasticized cellulose acetate tow. The plasticizer used for the tow comprises about 9 wt% of the tow. In this example, the plasticizer is triacetin. In other examples, different materials may be used to form the material body 6. For example, the material body 6 may be formed from paper, similar to a paper filter known for use in cigarettes, rather than tow. For example, paper or other cellulosic materials can be provided as one or more portions of a sheet material, and the sheet material is folded and / or crimped to form the material body 6. The sheet material can have a basis weight of 15 gsm to 60 gsm, such as 20 to 50 gsm. The sheet material can have a basis weight of, for example, any of 15 - 25 gsm, 25 - 30 gsm, 30 - 40 gsm, 40 - 45 gsm, and 45 - 50 gsm. Additionally or alternatively, the sheet material can have a width of 50 mm to 200 mm, such as 60 mm to 150 mm, or 80 mm to 150 mm. For example, the sheet material can have a basis weight of 20 - 50 gsm and a width of 80 mm to 150 mm. Thereby, for example, a cellulosic material body can have an appropriate pressure drop for an article having the dimensions described herein.

[0095] Alternatively, the material body 6 may be formed from a tow other than cellulose acetate, such as polylactic acid (PLA), filaments, or other materials described herein or similar materials. The tow is preferably formed from cellulose acetate. The tow preferably has at least 5 d.p.f., whether formed from cellulose acetate or other materials. To obtain a sufficiently uniform material body 6, the tow preferably has a denier per filament of 12 d.p.f. or less, preferably 11 d.p.f. or less, and more preferably 10 d.p.f. or less.

[0096] The total fineness of the tow forming the material body 6 is preferably at most 30,000, more preferably at most 28,000, and even more preferably at most 25,000. These total fineness values provide a tow that occupies a small proportion of the cross-sectional area of the mouthpiece 2, resulting in a smaller pressure drop across the mouthpiece 2 than a tow having a higher total fineness value. For an appropriate hardness of the material body 6, the tow preferably has a total fineness of at least 8,000, more preferably at least 10,000. The denier per filament is preferably 5 - 12, and the total fineness is preferably 10,000 - 25,000. The cross-sectional shape of the filaments of the tow is preferably a "Y" shape, but in other embodiments, other shapes such as an "X" shaped filament with the same d.p.f. and total fineness values provided herein may be used.

[0097] Regardless of the material used to form the material body 6, the pressure drop across the material body 6 may be, for example, 0.3 - 5 mmWG per 1 mm length of the material body 6, for example, 0.5 mmWG - 2 mmWG per 1 mm length of the material body 6. The pressure drop may be, for example, 0.5 - 1 mmWG per 1 mm length, 1 - 1.5 mmWG per 1 mm length, or 1.5 - 2 mmWG per 1 mm length. The total pressure drop across the material body 6 may be, for example, 3 mmWG - 8 mWG, or 4 mmWG - 7 mmWG. The total pressure drop across the material body 6 may be about 5, 6, or 7 mmWG.

[0098] As shown in FIG. 1, the mouthpiece 2 of the article 1 comprises an upstream end 2a adjacent to the rod of the aerosol-forming material 3 and a downstream end 2b remote from the rod of the aerosol-forming material 3. At the downstream end 2b, the mouthpiece 2 has a hollow tubular element 4 formed from a filament tow. It has been found to be advantageous that, during use of the article 1, at the downstream end 2b of the mouthpiece which contacts the consumer's mouth, the temperature of the outer surface of the mouthpiece 2 is significantly reduced. Additionally, it has been found that the use of the tubular element 4 also significantly reduces the temperature of the outer surface of the mouthpiece 2 upstream of the tubular element 4. Without wishing to be bound by theory, this is assumed to be due to the tubular element 4 passing aerosol near the centre of the mouthpiece 2, thereby suppressing the transfer of heat from the aerosol to the outer surface of the mouthpiece 2.

[0099] The "wall thickness" of the hollow tubular element 4 corresponds to the thickness of the wall of the tube 4 in the radial direction. This can be measured, for example, using calipers. Advantageously, the wall thickness is greater than 0.9 mm, more preferably greater than 1.0 mm. Preferably, the wall thickness is substantially constant around the entire circumference of the wall of the hollow tubular element 4. However, if the wall thickness is not substantially constant, the wall thickness is greater than 0.9 mm, more preferably greater than 1.0 mm, at any point around the hollow tubular element 4. In this example, the wall thickness of the hollow tubular element 4 is approximately 1.3 mm.

[0100] Preferably, the length of the hollow tubular element 4 is less than about 20 mm. More preferably, the length of the hollow tubular element 4 is less than about 15 mm. Even more preferably, the length of the hollow tubular element 4 is less than about 10 mm. Additionally or alternatively, the length of the hollow tubular element 4 is at least about 5 mm. Preferably, the length of the hollow tubular element 4 is at least about 6 mm. In some preferred embodiments, the length of the hollow tubular element 4 is from about 5 mm to about 20 mm, more preferably from about 6 mm to about 10 mm, even more preferably from about 6 mm to about 8 mm, and most preferably about 6 mm, 7 mm, or about 8 mm. In this example, the length of the hollow tubular element 4 is 7 mm.

[0101] The density of the hollow tubular element 4 is preferably at least about 0.25 grams per cubic centimeter (g / cc), more preferably at least about 0.3 g / cc. The density of the hollow tubular element 4 is preferably less than about 0.75 grams per cubic centimeter (g / cc), more preferably less than 0.6 g / cc. In some embodiments, the density of the hollow tubular element 4 is 0.25-0.75 g / cc, more preferably 0.3-0.6 g / cc, more preferably 0.4 g / cc-0.6 g / cc, or about 0.5 g / cc. These densities have been found to provide a good balance between the high hardness imparted by higher density materials and the lower heat transfer characteristics of lower density materials. For purposes of this disclosure, the "density" of the hollow tubular element 4 refers to the density of the filament tow forming the element, including any plasticizers incorporated therein. The density can be determined by dividing the total weight of the hollow tubular element 4 by the total volume of the hollow tubular element 4, which can be calculated using appropriate measurements of the hollow tubular element 4, for example obtained with calipers. If necessary, appropriate dimensions can be measured using a microscope.

[0102] The filament tow forming the hollow tubular element 4 preferably has a total fineness of less than 45,000, more preferably less than 42,000. This total fineness has been found to allow the formation of a tubular element 4 that is not too dense. The total fineness is preferably at least 20,000, more preferably at least 25,000. In a preferred embodiment, the filament tow forming the hollow tubular element 4 has a total fineness of 25,000 to 45,000, more preferably 35,000 to 45,000. The cross-sectional shape of the filaments in the tow is preferably "Y" shaped, although other shapes, such as "X" shaped filaments, may be used in other embodiments.

[0103] The filament tow forming the hollow tubular element 4 preferably has a denier per filament greater than 3. This denier per filament has been found to allow for the formation of a tubular element 4 that is not too dense. The denier per filament is preferably at least 4, more preferably at least 5. In a preferred embodiment, the filament tow forming the hollow tubular element 4 has a denier per filament between 4 and 10, more preferably between 4 and 9. In one example, the filament tow forming the hollow tubular element 4 is formed from cellulose acetate and has a 7.3Y36,000 tow containing 18% plasticizer, such as triacetin.

[0104] Preferably, the hollow tubular element 4 has an inner diameter greater than 3.0 mm. A smaller inner diameter would result in the aerosol passing through the mouthpiece 2 and reaching the consumer's mouth at a faster rate than desired, causing the aerosol to become too warm, for example reaching temperatures greater than 40°C or 45°C. More preferably, the hollow tubular element 4 has an inner diameter greater than 3.1 mm, and even more preferably greater than 3.5 mm or 3.6 mm. In one embodiment, the hollow tubular element 4 has an inner diameter of about 4.7 mm.

[0105] Preferably, the hollow tubular element 4 comprises 15% to 22% by weight of plasticizer. In the case of cellulose acetate tow, the plasticizer is preferably triacetin, although other plasticizers such as polyethylene glycol (PEG) may also be used. More preferably, the hollow tubular element 4 comprises 16% to 20% by weight of plasticizer, for example, about 17%, about 18%, or about 19%.

[0106] In this example, the first hollow tubular element 4, the material body 6, and the cooling portion 8 are combined using a second plug wrap 9, and this second plug wrap 9 is wrapped around all three parts. The second plug wrap 9 preferably has a basis weight of less than 50 gsm, more preferably about 20 gsm to 45 gsm. The second plug wrap 9 preferably has a thickness of 30 μm to 60 μm, more preferably 35 μm to 45 μm. The second plug wrap 9 is preferably a non-porous plug wrap having a gas permeability of less than 100 Gurley units, for example less than 50 Gurley units. However, in an alternative embodiment, the second plug wrap 9 may be a porous plug wrap having a gas permeability of more than 200 Gurley units, for example.

[0107] In this example, the article 1 has an outer circumference of about 23 mm. In other examples, the article may be provided in any of the formats described herein having an outer circumference of, for example, 20 mm to 26 mm. Since the article is heated to emit an aerosol, an improvement in heating efficiency can be achieved by using an article having a smaller outer circumference within this range, for example a circumference of less than 23 mm. It has also been found that a circumference of more than 19 mm for the article is particularly effective in achieving an improved aerosol by heating while maintaining an appropriate product length. Articles having a circumference of 20 mm to 24 mm, more preferably 20 mm to 23 mm, have been found to provide a good balance between performing effective aerosol delivery and enabling efficient heating.

[0108] The tip paper 5 is wrapped around the entire length of the mouthpiece 2 and a part of the rod of the aerosol-generating material 3, and has an adhesive on its inner surface to connect the mouthpiece 2 and the rod 3. In this example, the rod of the aerosol-generating material 3 is wrapped by a wrapper 10 that forms a first wrapping material, and the tip paper 5 forms an outer wrapping material that extends at least partially over the rod of the aerosol-generating material 3 to connect the mouthpiece 2 and the rod 3. In some examples, the tip paper can extend only partially over the rod of the aerosol-generating material.

[0109] In this example, the chip paper 5 extends over 5 mm on the rod of the aerosol-generating material 3. Alternatively, it may extend over 3 mm to 10 mm, or more preferably 4 mm to 6 mm, on the rod 3 to securely attach the mouthpiece 2 and the rod 3. The chip paper can have a basis weight of more than 20 gsm, such as more than 25 gsm, or preferably more than 30 gsm, such as 37 gsm. It has been found that with basis weights in these ranges, a chip paper can be obtained that has an acceptable tensile strength while having sufficient flexibility to wrap around the article 1 and adhere to itself along the longitudinal butt joint of the paper. After being wrapped around the mouthpiece, the outer circumference of the chip paper 5 is approximately 23 mm.

[0110] The article has a ventilation level of approximately 10% of the aerosol drawn through the article. In alternative embodiments, the article can have a ventilation level of 1% to 20%, such as 1% to 12%, of the aerosol drawn through the article. These levels of ventilation help to increase the concentration of the aerosol inhaled by the user at the mouth end 2b and assist in the cooling process of the aerosol. The ventilation part is provided directly in the mouthpiece 2 of the article 1. In this example, the ventilation part is provided in the cooling part 8, which has been found to be particularly advantageous for assisting the aerosol generation process. The ventilation part is in this case provided by perforations 12 formed as a single row of laser perforations located 13 mm from the mouth end 2b downstream of the mouthpiece 2. In alternative embodiments, two or more rows of ventilation perforations may be provided. These perforations pass through the chip paper 5, the second plug wrap 9, and the cooling part 8. In alternative embodiments, the ventilation part may be provided at other positions of the mouthpiece, such as the material body 6 or the first tubular element 4. The article is preferably configured such that perforations are provided at approximately 28 mm or less from the upstream end of the article 1, preferably at 20 mm to 28 mm from the upstream end of the article 1. In this example, the opening is provided at approximately 25 mm from the upstream end of the article.

[0111] Figure 2a is a side cross-sectional view of a further article 1' comprising a capsule-containing mouthpiece 2'. Figure 2b is a cross-sectional view of the capsule-containing mouthpiece shown in Figure 2a taken along line A-A'. The article 1' and the capsule-containing mouthpiece 2' are the same as the article 1 and the mouthpiece 2 shown in Figure 1, except that the aerosol modifier is provided in the material body 6 in the form of capsules 11 in this example, and the oil-resistant first plug wrap 7' surrounds the material body 6. In other examples, the aerosol modifier can be provided in other forms such as a material injected into the material body 6, or can be provided on a thread disposed within the material body 6, for example, a thread that holds a flavorant or other aerosol modifier.

[0112] The capsules 11 can include breakable capsules, for example, capsules having a fragile solid shell surrounding a liquid payload. In this example, a single capsule 11 is used. The capsule 11 is completely embedded within the material body 6. In other words, the capsule 11 is completely surrounded by the material forming the material body 6. In other examples, a plurality of breakable capsules, for example two, three or more breakable capsules, may be disposed within the material body 6. The length of the material body 6 can be increased to accommodate the required number of capsules. In examples where a plurality of capsules are used, the individual capsules may be the same as each other or may be different from each other with respect to size and / or capsule payload. In other examples, a plurality of material bodies 6, each including one or more capsules, may be provided.

[0113] The capsule 11 has a core-shell structure. In other words, the capsule 11 includes a shell that encapsulates a liquid agent such as a flavoring agent or other auxiliary agent, which can be any one of the flavoring agents or aerosol modifiers described in this specification. The user can rupture the shell of the capsule to release the flavoring agent or other auxiliary agent into the material body 6. The first plug wrap 7' can include a barrier coating that makes the material of the plug wrap substantially impermeable to the liquid payload of the capsule 11. Alternatively or in addition, the second plug wrap 9 and / or the chip paper 5 can include a barrier coating that makes the material of the plug wrap and / or the chip paper substantially impermeable to the liquid payload of the capsule 11.

[0114] In this example, the capsule 11 is spherical and has a diameter of about 3 mm. In other examples, other shapes and sizes of the capsule may be used. For example, the capsule can have a diameter of less than 4 mm, or less than 3.5 mm, or less than 3.25 mm. In an alternative embodiment, the capsule can have a diameter of more than about 3.25 mm, such as more than 3.5 mm, or more than 4 mm. The total weight of the capsule 11 may range from about 10 mg to about 50 mg.

[0115] In this example, the capsule 11 is disposed at the longitudinal center position within the material body 6. That is, the center of the capsule 11 is disposed 5 mm from each end of the material body 6. In this example, the center of the capsule is disposed 36 mm from the upstream end of the article 1. The capsule is preferably disposed such that its center is from 28 mm to 38 mm, more preferably from 34 mm to 38 mm, from the upstream end of the article 1. In this example, the center of the capsule is disposed 12 mm from the downstream end of the mouthpiece 2b. By providing the capsule at this position, the volatilization of the capsule contents is enhanced due to the proximity of the capsule to the aerosol generating portion of the article heated during use, and the user can easily reach the capsule and rupture it with a finger because it is sufficiently far from the aerosol generating portion inserted into the aerosol supply system during use.

[0116] In other examples, the capsule 11 may be disposed at a position other than the longitudinal center position of the material body 6, that is, near the downstream end rather than the upstream end of the material body 6, or near the upstream end rather than the downstream end of the material body 6. The mouthpiece 2' is preferably configured such that the capsule 11 and the vent hole 12 are longitudinally offset from each other in the mouthpiece 2'. For example, the vent hole 12 may be provided immediately upstream of the capsule position, that is, about 1 mm to about 10 mm upstream of the capsule position.

[0117] The aerosol-generating material comprises a sheet or shredded sheet of aerosolizable material. The aerosolizable material is arranged to generate an aerosol when heated.

[0118] The sheet or shredded sheet comprises a first surface and a second surface opposite the first surface. The dimensions of the first surface and the second surface are the same. The first surface and the second surface of the sheet or shredded sheet can have any shape. For example, the first surface and the second surface may be square, rectangular, oval, or circular. Irregular shapes are also envisioned.

[0119] The first surface and / or the second surface of the sheet or shredded sheet may be relatively uniform (e.g., relatively smooth), or may be non-uniform or irregular. For example, the first surface and / or the second surface of the sheet may be textured or patterned to define a relatively rough surface. In some embodiments, the first surface and / or the second surface are relatively rough.

[0120] The smoothness of the first surface and the second surface can be affected by several factors such as the areal density of the sheet or shredded sheet, the nature of the components constituting the aerosolizable material, or whether the surface of the material has been treated, for example embossed, engraved, or modified by other means, to impart a pattern or texture.

[0121] The areas of the first and second surfaces are each defined by a first dimension (e.g., width) and a second dimension (e.g., length). The measured values of the first dimension and the second dimension can have a ratio of 1:1 or greater than 1:1, and thus, the sheet or the shredded sheet can have an "aspect ratio" of 1:1 or greater than 1:1. As used herein, the term "aspect ratio" is the ratio of the measured value of the first dimension of the first or second surface to the measured value of the second dimension of the first or second surface. A "1:1 aspect ratio" means that the measured value of the first dimension (e.g., width) is the same as the measured value of the second dimension (e.g., length). An "aspect ratio greater than 1:1" means that the measured value of the first dimension (e.g., width) is different from the measured value of the second dimension (e.g., length). In some embodiments, the first and second surfaces of the sheet or the shredded sheet have an aspect ratio greater than 1:1, such as 1:2, 1:3, 1:4, 1.5, 1:6, 1:7, or more.

[0122] The shredded sheet can comprise one or more strands or pieces of aerosolizable material. In some embodiments, the shredded sheet comprises a plurality (e.g., two or more) strands or pieces of aerosolizable material. The strands or pieces of aerosolizable material can have an aspect ratio of 1:1. In embodiments, the strands or pieces of aerosolizable material have an aspect ratio greater than 1:1. In some embodiments, the strands or pieces of aerosolizable material have an aspect ratio of from about 1.5 to about 1:16, i.e., about 1.5, 1:6, 1:7, 1:8, 1:9, 1:10, 1:11, or 1:12. When the aspect ratio of the strand or piece is greater than 1:1, the strand or piece includes a longitudinal dimension or length that extends between a first end of the strand or piece and a second end of the strand or piece.

[0123] When a shredded sheet comprises multiple strands or strips of material, the dimensions of each strand or strip can vary among different strands or strips. For example, the shredded sheet can include a first population of strands or strips and a second population of strands or strips, where the dimensions of the strands or strips in the first population are different from the dimensions of the strands or strips in the second population. In other words, the multiple strands or strips can include a first population of strands or strips having a first aspect ratio and a second population of strands or strips having a second aspect ratio that is different from the first aspect ratio.

[0124] The first dimension, i.e., cut width, of the strands or strips of aerosolizable material is between 0.9 mm and 1.5 mm. Incorporating strands or strips of aerosolizable material having a cut width less than 0.9 mm into an article for use in a non-combustion aerosol delivery system can increase the pressure drop across the article to a level that makes the article unsuitable for use in a non-combustion aerosol delivery device. However, if the strands or strips have a cut width greater than 2 mm (e.g., greater than 2 mm), it can be difficult to insert the strands or strips of aerosolizable material into the article during manufacturing. In a preferred embodiment, the cut width of the strands or strips of aerosolizable material is between about 1 mm and 1.5 mm.

[0125] The strands or strips of material are formed by shredding a sheet of aerosolizable material. The sheet of aerosolizable material may be cut transversely, e.g., in a cross-cut shredding process, to define a cut length of the strands or strips of aerosolizable material in addition to a cut width. Preferably, the cut length of the shredded aerosolizable material is at least 5 mm, e.g., at least 10 mm, or at least 20 mm. The cut length of the shredded aerosolizable material may be less than 60 mm, less than 50 mm, or less than 40 mm.

[0126] In some embodiments, multiple strands or strips of aerosolizable material are provided, and at least one of the multiple strands or strips of aerosolizable material has a length greater than about 10 mm. Alternatively or additionally, at least one of the multiple strands or strips of aerosolizable material can have a length of about 10 mm to about 60 mm, or about 20 mm to about 50 mm. Each of the multiple strands or strips of aerosolizable material can have a length of about 10 mm to about 60 mm, or about 20 mm to about 50 mm.

[0127] The sheet or chopped sheet of aerosolizable material has a thickness of at least about 100 μm. The sheet or chopped sheet can have a thickness of at least about 120 μm, 140 μm, 160 μm, 180 μm, or 200 μm. In some embodiments, the sheet or chopped sheet has a thickness of about 150 μm to about 300 μm, about 151 μm to about 299 μm, about 152 μm to about 298 μm, about 153 μm to about 297 μm, about 154 μm to about 296 μm, about 155 μm to about 295 μm, about 156 μm to about 294 μm, about 157 μm to about 293 μm, about 158 μm to about 292 μm, about 159 μm to about 291 μm, or about 160 μm to about 290 μm. In some embodiments, the sheet or shredded sheet has a thickness of about 170 μm to about 280 μm, about 180 to about 270 μm, about 190 to about 260 μm, about 200 μm to about 250 μm, or about 210 μm to about 240 μm.

[0128] The thickness of the sheet or chopped sheet can vary between the first and second sides. In some embodiments, the individual strips or sections of aerosolizable material have a minimum thickness of about 100 μm across their area. In some cases, the individual strips or sections of aerosolizable material have a minimum thickness of about 0.05 mm or about 0.1 mm across their area. In some cases, the individual strips, strands, or sections of aerosolizable material have a maximum thickness of about 1.0 mm across their area. In some cases, the individual strips or sections of aerosolizable material have a maximum thickness of about 0.5 mm or about 0.3 mm across their area.

[0129] The thickness of the sheet may be determined using ISO 534:2011 "Paper and paperboard - Measurement of thickness".

[0130] If the sheet or shredded sheet of aerosolizable material is too thick, heating efficiency may be reduced. This may adversely affect power consumption during use, for example, the power consumption required to release a fragrance from the aerosolizable material. Conversely, if the aerosolizable material is too thin, it may be difficult to manufacture and handle. Very thin materials are more difficult to cast and may be prone to breakage, which may interfere with aerosol formation during use.

[0131] It is hypothesized that if the sheet or shredded sheet of aerosolizable material is too thin (eg, less than 100 μm), it may not have adequate strength to be pulled lengthwise without breaking.

[0132] Approximately 100g / m 2 ~about 250g / m 2 It is hypothesized that sheets or shredded sheets having a thickness of at least about 100 μm with an areal density of at least about 100 μm are less likely to tear, crack, or otherwise deform during manufacturing. A thickness of at least about 100 μm can have a favorable effect on the overall structural integrity and strength of the sheet or shredded sheet. For example, this thickness can have good tensile strength and therefore be relatively easy to process.

[0133] The thickness of the sheet or shredded sheet may also be related to its areal density, i.e., increasing the thickness of the sheet or shredded sheet may increase the areal density of the sheet or shredded sheet.

[0134] Conversely, reducing the thickness of the sheet or chopped sheet may reduce the areal density of the sheet or chopped sheet. For the avoidance of doubt, when areal density is referred to herein, it refers to the average areal density calculated for a given strip, strand, section, or sheet of aerosolizable material, which is calculated by measuring the surface area and weight of the given strip, strand, section, or sheet of aerosolizable material.

[0135] The sheet or shredded sheet of aerosol-forming material has a mass of about 100 g / m 2 ~about 250g / m 2 The sheet or shredded sheet has an areal density of about 110 g / m 2 ~about 240g / m 2 , about 120g / m 2 ~about 230g / m 2 , about 130g / m 2 ~Approx. 220g / m 2 , or about 140 g / m 2 ~about 210g / m 2 In some embodiments, the sheet or shredded sheet may have an areal density of about 130 g / m 2 ~Approx. 190g / m 2 , about 140g / m 2 ~Approx. 180g / m 2 , about 150g / m 2 ~Approx. 170g / m 2 In a preferred embodiment, the sheet or shredded sheet has an areal density of about 160 g / m 2 It has an areal density of

[0136] Approximately 100g / m 2 ~about 250g / m 2 The areal density of about 180 gsm is believed to contribute to the strength and flexibility of the sheet or shredded sheet. Furthermore, a rod comprising a shredded sheet of aerosolizable material having an areal density of about 180 gsm and a minimum thickness of 220-230 μm can be filled such that the aerosolizable material stays in place within the rod, maintains a desired weight of tobacco material (e.g., about 300 mg) within the rod, and delivers acceptable organoleptic characteristics (e.g., taste and odor) when heated in a non-combustible aerosol delivery device.

[0137] The flexibility of the sheet or shredded sheet is believed to depend, at least in part, on the thickness and areal density of the sheet or shredded sheet. Thicker sheets or shredded sheets may be less flexible than thinner sheets or shredded sheets. Also, the greater the areal density of the sheet, the less flexible the sheet or shredded sheet. The combination of thickness and areal density of the aerosolizable material described herein is believed to provide a relatively flexible sheet or shredded sheet. This flexibility can provide various advantages when the aerosolizable material is incorporated into an article for use in a non-combustible aerosol delivery device. For example, when inserting an aerosol generator into the aerosol-generating material, the strands or strips can easily deform and bend, facilitating insertion of the aerosol generator (e.g., a heater) into the material and improving retention of the aerosol generator by the aerosolizable material.

[0138] The areal density of the sheet or chopped sheet of aerosol-generating material can affect the roughness of the first and second sides of the sheet or chopped sheet. By varying the areal density, the roughness of the first and / or second sides can be adjusted.

[0139] The average volume density of a sheet or shredded sheet of aerosol-forming material can be calculated from the thickness of the sheet and the areal density of the sheet. The average volume density is about 0.2 g / cm 3 Super, about 0.3g / cm 3 or about 0.4 g / cm 3 In some embodiments, the average bulk density is about 0.2 g / cm 3 ~Approx. 1g / cm 3 , about 0.3g / cm 3 ~Approx. 0.9g / cm 3 , approximately 0.4 g / cm 3 ~Approx. 0.9g / cm 3 , about 0.5g / cm 3 ~Approx. 0.9g / cm 3 , or about 0.6 g / cm 3 ~Approx. 0.9g / cm 3 may be.

[0140] According to an aspect of the present disclosure, there is provided a sheet or shredded sheet of aerosolizable material comprising a tobacco material, an aerosol-forming material, and a binder, the sheet or shredded sheet having a density of greater than about 0.4 g / cm 3 super, an aerosol-generating material is provided. In some embodiments, the density is from about 0.4 g / cm 3 to about 2.9 g / cm 3 from about 0.4 g / cm 3 to about 1 g / cm 3 from about 0.6 g / cm 3 to about 1.6 g / cm 3 or from about 1.6 g / cm 3 to about 2.9 g / cm 3 .

[0141] The sheet or shredded sheet can have a tensile strength of at least 4 N / 15 mm.

[0142] If the sheet or shredded sheet has a tensile strength of less than 4 N / 15 mm, the sheet or shredded sheet is prone to tearing, breaking, or otherwise deforming during manufacture and / or incorporation into an article for use in a non-combustible aerosol supply system. The tensile strength can be measured using ISO1924:2008.

[0143] The aerosol-generating material can include a tobacco material. The sheet or shredded sheet of aerosolizable material can include a tobacco material.

[0144] The tobacco material can be a particulate or granular material. In some embodiments, the tobacco material is a powder. Alternatively or in addition, the tobacco material can include tobacco shreds, strands, or fibers. For example, the tobacco material can include tobacco particles, granules, fibers, shreds, and / or strands. In some embodiments, the tobacco material is composed of particles or granules of tobacco material.

[0145] The density of the tobacco material affects the rate at which heat conducts through the material. When the density is low, for example, less than 900 mg / cc, heat conducts more slowly through the material, enabling a more sustained aerosol release.

[0146] The tobacco material can include a regenerated tobacco material having a density of less than about 900 mg / cc, such as a paper regenerated tobacco material. For example, the aerosol-forming material can include a regenerated tobacco material having a density of less than about 800 mg / cc. Alternatively or in addition, the aerosol-forming material can include a regenerated tobacco material having a density of at least 350 mg / cc.

[0147] The regenerated tobacco material may be provided in the form of shredded sheets. The sheets of the regenerated tobacco material can have any suitable thickness. The regenerated tobacco material can have a thickness of at least about 0.145 mm, such as at least about 0.15 mm or at least about 0.16 mm. The regenerated tobacco material can have a maximum thickness of about 0.30 mm or 0.25 mm, for example, the thickness of the regenerated tobacco material can be less than about 0.22 mm or less than about 0.2 mm. In some embodiments, the regenerated tobacco material can have an average thickness in the range of 0.175 mm to 0.195 mm.

[0148] In some embodiments, the tobacco is a particulate tobacco material. Each particle of the particulate tobacco material can have a maximum dimension. As used herein, the term "maximum dimension" refers to the longest straight-line distance from any point on the surface or particle face of a tobacco particle to any other point on the surface or particle face of the same tobacco particle. The maximum dimension of the particles of the particulate tobacco material can be measured using scanning electron microscopy (SEM).

[0149] The maximum dimension of each particle of the tobacco material can be at most about 200 μm. In some embodiments, the maximum dimension of each particle of the tobacco material is at most about 150 μm.

[0150] The population of particles of the tobacco material can have a particle size distribution (D90) of at least about 100 μm. In some embodiments, the population of particles of the tobacco material has a particle size distribution (D90) of about 110 μm, at least about 120 μm, at least about 130 μm, at least about 140 μm, or at least about 150 μm. In embodiments, the population of particles of the tobacco material has a particle size distribution (D90) of about 150 μm. Sieve analysis may be used to determine the particle size distribution of the particles of the tobacco material.

[0151] A particle size distribution (D90) of at least about 100 μm is believed to contribute to the tensile strength of a sheet or shredded sheet of aerosolizable material.

[0152] A particle size distribution (D90) of less than 100 μm provides a sheet or shredded sheet of aerosolizable material with good tensile strength. However, including such fine tobacco material particles in the sheet or shredded sheet can increase the density of the sheet or shredded sheet. When the sheet or shredded sheet is incorporated into an article for use in a non-combustion aerosol delivery system, this higher density can reduce the fill value of the tobacco material. Advantageously, a balance between sufficient tensile strength and appropriate density (and therefore fill value) can be achieved when the particle size distribution (D90) is at least about 100 μm.

[0153] The particle size of the particulate tobacco material can also affect the roughness of the sheet or shredded sheet of aerosol-forming material. It is hypothesized that forming a sheet or shredded sheet of aerosol-forming material by incorporating larger particles of tobacco material reduces the density of the sheet or shredded sheet of aerosol-forming material.

[0154] The tobacco material can include tobacco obtained from any part of the tobacco plant. In some embodiments, the tobacco material includes tobacco leaf. The sheet or shredded sheet can include from 5% to about 90% by weight of tobacco leaf.

[0155] The tobacco material can include laminar tobacco and / or tobacco stems, such as midrib stems. The laminar tobacco can be present in an amount of 0% to about 100%, about 20% to about 100%, about 40% to about 100%, about 40% to about 95%, about 45% to about 90%, about 50% to about 85%, or about 55% to about 80% by weight of the sheet or shredded sheet and / or tobacco material. In some embodiments, the tobacco material consists of, or consists essentially of, laminar tobacco material.

[0156] The tobacco material may contain tobacco stems in an amount of from 0% to about 100% by weight, from about 0% to about 50% by weight, from about 0 to about 25% by weight, from about 0 to about 20% by weight, or from about 5 to about 1.5% by weight of the sheet or shredded sheet.

[0157] In some embodiments, the tobacco material comprises a combination of lamina and tobacco stems. In some embodiments, the tobacco material may comprise about 40% to about 95% lamina and about 5% to about 60% stems, or about 60% to about 95% lamina and about 5% to about 40% stems, or about 80% to about 95% lamina and about 5% to about 20% stems, by weight of the sheet or shredded sheet of aerosolizable material.

[0158] Incorporating stems can reduce the stickiness of the aerosolizable material. Incorporating tobacco materials, including stem tobacco, into the aerosolizable material can increase its burst strength.

[0159] The sheet or shredded sheet of aerosolizable material can have a burst strength of at least about 75 g, at least about 100 g, or at least about 200 g.

[0160] If the breaking strength is too low, the sheet or shredded sheet can be relatively brittle. As a result, the sheet or shredded sheet may break during the manufacturing process of the aerosolizable material. For example, when the sheet is shredded by a cutting process to form a shredded sheet, the sheet may break into pieces or fragments during cutting.

[0161] The tobacco material described herein may contain nicotine. The nicotine content is 0.1 to 3% by weight of the tobacco material, and for example, it may be 0.5 to 2.5% by weight of the tobacco material. Additionally or alternatively, the tobacco material contains 10% to 90% by weight of tobacco leaves having a nicotine content of more than about 1% by weight or more than about 1.5% by weight of the tobacco leaves. Tobacco leaves, such as cut rag tobacco, have a nicotine content of, for example, 1% to 5% by weight of the tobacco leaves.

[0162] The sheet or shredded sheet of the aerosolizable material can contain nicotine in an amount of about 0.1% to about 3% by weight of the sheet or shredded sheet.

[0163] Recycled paper tobacco may be present in the aerosol - generating material described herein. Recycled paper tobacco refers to a tobacco material formed by a process in which tobacco raw materials are extracted using a solvent to obtain a residue containing an extract of soluble substances and a fibrous material, and then (usually after concentration and optionally after further treatment), the extract is redeposited on the fibrous material (usually after purification of the fibrous material and optionally adding a portion of non - tobacco fibers) and remixed with the fibrous material from the residue. The remixing process is similar to a papermaking process.

[0164] The reconstituted tobacco may be any type of reconstituted tobacco known in the art. In certain embodiments, the reconstituted tobacco is made from raw materials including one or more of tobacco shreds, tobacco stems, and whole leaf tobacco. In further embodiments, the reconstituted tobacco is made from raw materials consisting of tobacco shreds and / or whole leaf tobacco and tobacco stems. However, in other embodiments, chips, fines, and rice husks may be used instead or in addition to the raw materials.

[0165] Reconstituted tobacco for use in the tobacco materials described herein may be prepared by methods known to those skilled in the art for preparing reconstituted tobacco.

[0166] In embodiments, the reconstituted tobacco is present in an amount of from 5% to 90%, from 10% to 80%, or from 20% to 70% by weight of the aerosol-forming material.

[0167] The aerosol-generating material includes an aerosol-forming material. The aerosol-forming material includes one or more components capable of forming an aerosol. The aerosol-forming material includes one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. Preferably, the aerosol-forming material is glycerol or propylene glycol.

[0168] The sheet or shredded sheet of aerosolizable material includes an aerosol-forming material. The aerosol-forming material is provided in an amount of up to about 50% by weight of the sheet or shredded sheet on a dry weight basis. In some embodiments, the aerosol-forming material is provided in an amount of about 5% to about 40% by weight of the sheet or shredded sheet on a dry weight basis, about 10% to about 30% by weight of the sheet or shredded sheet on a dry weight basis, or about 10% to about 20% by weight of the sheet or shredded sheet on a dry weight basis.

[0169] The sheet or shredded sheet can also include water. The sheet or shredded sheet of aerosolizable material can include water in an amount less than about 15%, less than about 10%, or less than about 5% by weight of the aerosolizable material. In some embodiments, the aerosolizable material includes water in an amount between about 0% and about 15%, or between about 5% and about 15% by weight of the aerosolizable material.

[0170] The sheet or shredded sheet of aerosolizable material can include water and aerosol-forming material in a total amount of less than about 30% by weight of the sheet or shredded sheet of aerosolizable material, or less than about 25% by weight of the sheet or shredded sheet of aerosolizable material. Incorporating water and aerosol-forming material into the sheet or shredded sheet of aerosolizable material in an amount less than about 30% by weight of the sheet or shredded sheet of aerosolizable material can advantageously reduce the stickiness of the sheet. This can improve the ease with which the aerosolizable material can be handled during processing. For example, it can be easier to roll a sheet of aerosolizable material to form a bobbin of material and then unwind the bobbin without the layers of the sheet sticking to each other. Reducing stickiness also reduces the tendency of strands or pieces of shredded material to clump together or stick to each other, further improving processing efficiency and final product quality.

[0171] The sheet or shredded sheet may include a binder. The binder is arranged to bind the components of the aerosol-forming material together to form the sheet or shredded sheet. The binder may at least partially coat the surface of the tobacco material. If the tobacco material is in particulate form, the binder may at least partially coat the surface of the tobacco particles to bind the particles together.

[0172] The binder may be selected from one or more compounds selected from the group consisting of alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the binder comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, gum arabic, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the binder comprises alginate and / or pectin or carrageenan. In a preferred embodiment, the binder comprises guar gum.

[0173] The binder may be present in an amount of about 1 to about 20% by weight of the sheet or chopped sheet, or 1 to about 10% by weight of the sheet or chopped sheet of aerosolizable material. For example, the binder may be present in an amount of about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, or 10% by weight of the sheet or chopped sheet of aerosolizable material.

[0174] The aerosol generating material can include a filler. In some embodiments, the sheet or shredded sheet includes a filler. The filler is typically a non-tobacco component, i.e., a component that does not contain tobacco-derived raw materials. The filler can include one or more inorganic filler materials, such as appropriate inorganic adsorbents like calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and molecular sieves. The filler can be non-tobacco fibers such as wood fibers or wood pulp or wheat fibers. The filler can be a material containing cellulose or a material containing a derivative of cellulose. The filler component can be a non-tobacco cast material or a non-tobacco extruded material.

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

[0176] The filler can also contribute to the texture of the sheet or shredded sheet of aerosolizable material. For example, a fibrous filler such as wood or wood pulp can provide a sheet or shredded sheet of aerosolizable material having a relatively rough first and second surface. Conversely, a non-fibrous particulate filler such as powdered chalk can provide a sheet or shredded sheet of aerosolizable material having a relatively smooth first and second surface. In some embodiments, the aerosolizable material includes a combination of different filler materials.

[0177] The filler component can be present in an amount of 0 to 20% by weight of the sheet or shredded sheet, or in an amount of 1 to 10% by weight of the sheet or shredded sheet. In some embodiments, the filler component is absent.

[0178] The filler can help improve general structural properties such as the tensile strength and burst strength of the aerosolizable material.

[0179] In the compositions described herein, when amounts are indicated in % by weight, unless otherwise specified to the contrary, this refers to a dry weight basis. Thus, any water that may be present in the aerosol-forming material, or any of its components, is completely ignored for the purpose of determining % by weight. The water content of the aerosol-forming materials described herein may vary, for example, and may be from 5 to 15% by weight. The water content of the aerosol-forming materials described herein may vary, for example, depending on the temperature, pressure, and humidity conditions under which the composition is maintained. The water content can be determined by Karl-Fischer analysis, as is known to those skilled in the art. On the other hand, to avoid misunderstanding, any component other than water, even if the aerosol-forming material is a liquid phase component such as glycerol or propylene glycol, is included in the weight of the aerosol-forming material. However, when the aerosol-forming material is supplied to the tobacco component of the aerosol-forming material, or the filler component (if present) of the aerosol-forming material, instead of or in addition to being added separately to the aerosol-forming material, the aerosol-forming material is included in the weight of the "aerosol-forming material" at the % by weight defined herein, and not in the weight of the tobacco component or the filler component. Any other raw materials present in the tobacco component are included in the weight of the tobacco component, whether non-tobacco-derived (e.g., non-tobacco fibers in the case of recycled paper tobacco).

[0180] The aerosol-forming material herein can include an aerosol modifier, such as any of the flavorings described herein. In one embodiment, the aerosol-forming material includes menthol. When the aerosol-forming material is incorporated into an article for use in an aerosol delivery system, the article can be referred to as a mentholated article. The aerosol-forming material can include 0.5 mg to 20 mg of menthol, 0.7 mg to 20 mg of menthol, 1 mg to 18 mg, or 8 mg to 16 mg of menthol. In this example, the aerosol-forming material includes 16 mg of menthol. The aerosol-forming material can include 1% to 8% by weight of menthol, preferably 3% to 7% by weight of menthol, and more preferably 4% to 5.5% by weight of menthol. In one embodiment, the aerosol-forming material includes 4.7% by weight of menthol. Such high levels of menthol loading can be achieved by using a high percentage of reconstituted tobacco material, for example, greater than 50% by weight of the tobacco material. Alternatively or additionally, for example, using a larger amount of tobacco material can allow for a higher level of menthol loading to be achieved, for example, about 500 mm 3 More than, or preferably about 1000 mm 3 An aerosol-forming material such as tobacco material is used.

[0181] In some embodiments, the composition comprises an aerosol-forming "amorphous solid," which may also be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may comprise a dry gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within it. In some instances, the amorphous solid is 1 to 60 wt % of a gelling agent; 0.1 to 50 wt % of an aerosol-forming material; and 0.1 to 80 wt% of a fragrance, These weights are calculated on a dry weight basis. In some further embodiments, the amorphous solid is 1 to 50 wt % of a gelling agent; 0.1 to 50 wt % of an aerosol-forming material; contains 30 to 60 wt% of a fragrance, and these weights are calculated on a dry weight basis.

[0182] The amorphous solid material may be provided in the form of a sheet or shredded sheet. The amorphous solid material may take the same form as the sheet or shredded sheet of the aerosolizable material, as described above.

[0183] Preferably, the amorphous solid can contain about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, or 35 wt% of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid can contain 1 to 50 wt%, 5 to 45 wt%, 10 to 40 wt%, or 20 to 35 wt% of a gelling agent. In some embodiments, the gelling agent includes a hydrophilic colloid. In some embodiments, the gelling agent includes one or more compounds selected from the group consisting of alginates, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent includes one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, gum arabic, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. Optionally, the gelling agent includes alginate and / or pectin and may be mixed with a curing agent (such as a calcium source) during the formation of the amorphous solid. Optionally, the amorphous solid can contain calcium-crosslinked alginate and / or calcium-crosslinked pectin.

[0184] In some embodiments, the gelling agent comprises alginate, and the alginate is present in the amorphous solid in an amount of 10-30 wt% (calculated on a dry weight basis) of the amorphous solid. In some embodiments, the alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginate and at least one additional gelling agent, such as pectin.

[0185] In some embodiments, the amorphous solid may include a gelling agent including carrageenan.

[0186] Preferably, the amorphous solid can comprise from about 0.1 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt%, or 10% to about 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt% of the aerosol-forming material (all calculated on a dry weight basis). The aerosol-forming material can act as a plasticizer. For example, the amorphous solid can comprise from 0.5 to 40 wt%, from 3 to 35 wt%, or from 10 to 25 wt% of the aerosol-forming material. In some cases, the aerosol-forming material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some cases, the aerosol-forming material comprises, consists essentially of, or consists of glycerol.

[0187] The amorphous solid comprises a flavoring agent. Suitably, the amorphous solid can comprise up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% flavoring agent.

[0188] In some cases, the amorphous solid can include at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% flavoring (all calculated on a dry weight basis).

[0189] For example, the amorphous solid can include 1-80 wt%, 10-80 wt%, 20-70 wt%, 30-60 wt%, 35-55 wt%, or 30-45 wt% flavoring. In some cases, the flavoring includes, consists essentially of, or consists of menthol.

[0190] In some cases, the amorphous solid may further comprise an emulsifier that emulsifies the molten flavor during manufacture. For example, the amorphous solid may comprise about 5 wt% to about 15 wt%, preferably about 10 wt%, of an emulsifier (calculated on a dry weight basis). The emulsifier may include gum arabic.

[0191] In some embodiments, the amorphous solid is a hydrogel and contains less than about 20 wt% water, calculated on a wet weight basis. In some cases, the hydrogel can contain less than about 15 wt%, 12 wt%, or 10 wt% water, calculated on a wet weight basis. In some cases, the hydrogel can contain at least about 1 wt%, 2 wt%, or at least about 5 wt% water (wet weight basis).

[0192] In some embodiments, the amorphous solid further comprises an active substance. For example, in some cases, the amorphous solid further comprises a tobacco material and / or nicotine. In some cases, the amorphous solid can comprise 5 to 60 wt% (calculated on a dry weight basis) of a tobacco material and / or nicotine. In some cases, the amorphous solid can comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of an active substance. In some cases, the amorphous solid can comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of a tobacco material. For example, the amorphous solid can comprise 10 to 50 wt%, 15 to 40 wt%, or 20 to 35 wt% of a tobacco material. In some cases, the amorphous solid can comprise from about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% (calculated on a dry weight basis) of nicotine. For example, the amorphous solid can comprise 1 to 20 wt%, 2 to 18 wt%, or 3 to 12 wt% of nicotine.

[0193] In some cases, the amorphous solid comprises an active substance such as a tobacco extract. In some cases, the amorphous solid can comprise 5 to 60 wt% (calculated on a dry weight basis) of a tobacco extract. In some cases, the amorphous solid can comprise from about 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of a tobacco extract. For example, the amorphous solid can comprise 10 to 50 wt%, 15 to 40 wt%, or 20 to 35 wt% of a tobacco extract. The tobacco extract can contain nicotine at a concentration such that the amorphous solid contains from 1 wt%, 1.5 wt%, 2 wt%, or 2.5 wt% to about 6 wt%, 5 wt%, 4.5 wt%, or 4 wt% (calculated on a dry weight basis) of nicotine.

[0194] In some cases, nicotine other than that obtained from tobacco extracts may not be present in the amorphous solid.

[0195] In some embodiments, the amorphous solid does not contain tobacco material but contains nicotine. In some such cases, the amorphous solid can contain from about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% (calculated on a dry weight basis) of nicotine. For example, the amorphous solid can contain 1 to 20 wt%, 2 to 18 wt%, or 3 to 12 wt% of nicotine.

[0196] In some cases, the total content of the active substance and / or fragrance can be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of the active substance and / or fragrance can be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0197] In some cases, the total content of the tobacco material, nicotine, and fragrance can be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of the active substance and / or fragrance can be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0198] The amorphous solid may be made from a gel, and this gel can further contain a solvent contained at 0.1 to 50 wt%. However, including a solvent in which the fragrance dissolves may reduce the stability of the gel, and the fragrance may crystallize from the gel. Thus, in some cases, the gel does not contain a solvent in which the fragrance dissolves.

[0199] In some embodiments, the amorphous solid contains a filler of less than 60 wt%, for example, 1 wt% to 60 wt%, or 5 wt% to 50 wt%, or 5 wt% to 30 wt%, or 10 wt% to 20 wt%.

[0200] In other embodiments, the amorphous solid comprises less than 20 wt%, preferably less than 10 wt%, or less than 5 wt% filler. Optionally, the amorphous solid comprises less than 1 wt% filler, and in some cases, no filler.

[0201] When filler is present, the filler can include one or more inorganic filler materials, such as suitable inorganic adsorbents like calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and molecular sieves. The filler can include one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives. In certain cases, the amorphous solid does not include calcium carbonate such as chalk.

[0202] In certain embodiments that include filler, the filler is fibrous. For example, the filler can be a fibrous organic filler material such as wood pulp, hemp fiber, cellulose, or cellulose derivatives. Without wishing to be bound by theory, it is believed that including a fibrous filler in the amorphous solid can increase the tensile strength of the material.

[0203] In some embodiments, the amorphous solid does not include tobacco fibers.

[0204] In some examples, the amorphous solid in the form of a sheet can have a tensile strength of from about 200 N / m to about 1500 N / m. In some examples where the amorphous solid does not include filler, the amorphous solid can have a tensile strength of 200 N / m to 400 N / m, or 200 N / m to 300 N / m, or about 250 N / m. Such tensile strength can be particularly suitable for embodiments where the amorphous solid material is shredded after being formed into a sheet and incorporated into an aerosol generating article.

[0205] In some examples where the amorphous solid comprises a filler, the amorphous solid can have a tensile strength of 600 N / m to 1500 N / m, or 700 N / m to 900 N / m, or about 800 N / m. Such tensile strength can be particularly suitable for embodiments where the amorphous solid material is included in an aerosol generating article as a wound sheet, preferably in the form of a tube.

[0206] In some cases, the amorphous solid may consist essentially of, or consist of, a gelling agent, water, an aerosol forming material, a flavor, and optionally an active substance.

[0207] In some cases, the amorphous solid may consist essentially of, or consist of, a gelling agent, water, an aerosol forming material, a flavor, and optionally a tobacco material and / or a nicotine source.

[0208] The amorphous solid can include one or more active substances and / or flavors, one or more aerosol forming materials, and optionally one or more other functional materials.

[0209] The aerosol generating material can include a paper-recycled tobacco material. The composition can alternatively or additionally include any of the tobacco forms described herein. The aerosol generating material can comprise a sheet or shredded sheet comprising a tobacco material containing 10 wt% to 90 wt% tobacco leaves, the aerosol forming material being provided in an amount of up to about 20 wt% of the sheet or shredded sheet, and the remaining portion of the tobacco material comprising paper-recycled tobacco.

[0210] When the aerosol generating material includes an amorphous solid material, the amorphous solid material can be a dry gel containing menthol. In alternative embodiments, the amorphous solid can have any of the compositions described herein.

[0211] Improved articles can be produced that include an aerosol-generating material that includes a first component that includes a sheet or shredded sheet of aerosolizable material and a second component that includes an amorphous solid, with material properties (e.g., density) and specifications (e.g., thickness, length, and cut width) that fall within the ranges described herein.

[0212] In some cases, the amorphous solid can have a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness can range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm. Materials having a thickness of about 0.09 mm can be used. The amorphous solid can include two or more layers, and the thicknesses described herein refer to the combined thickness of these layers.

[0213] The thickness of the amorphous solid material can be measured using calipers or a microscope, such as a scanning electron microscope (SEM), as known to those skilled in the art, or any other suitable technique known to those skilled in the art.

[0214] If the amorphous solid is too thick, heating efficiency may decrease. This may adversely affect power consumption during use, for example, the power consumption required to release a fragrance from the amorphous solid. Conversely, if the amorphous solid for aerosol formation is too thin, it may be difficult to manufacture and handle. Very thin materials are more difficult to cast, more fragile, and may interfere with aerosol formation during use. In some cases, the individual strips or slices of the amorphous solid have a minimum thickness of about 0.015 mm across their area. In some cases, the individual strips or slices of the amorphous solid have a minimum thickness of about 0.05 mm or about 0.1 mm across their area. In some cases, the individual strips or slices of the amorphous solid have a maximum thickness of about 1.0 mm across their area. In some cases, the individual strips or slices of the amorphous solid have a maximum thickness of about 0.5 mm or about 0.3 mm across their area.

[0215] In some cases, the thickness of the amorphous solid may vary by no more than 25%, 20%, 15%, 10%, 5%, or 1% over its area.

[0216] By providing a sheet or shredded sheet of an amorphous solid material and an aerosolizable material having different areal density values from each other below a given percentage, the mixture of these materials becomes difficult to separate. In some examples, the areal density of the amorphous solid material may be 50% to 150% of the areal density of the aerosolizable material. For example, the areal density of the amorphous solid material may be 60% to 140% of the areal density of the aerosolizable material, or 70% to 110% of the areal density of the aerosolizable material, or 80% to 120% of the areal density of the aerosolizable material.

[0217] In the embodiments described herein, the amorphous solid material can be incorporated into an article in the form of a sheet. The amorphous solid material in the form of a sheet can be shredded and then incorporated into an article, and it is preferred that it can be mixed with an aerosolizable material such as a sheet or shredded sheet of the aerosolizable material described herein.

[0218] In further embodiments, the sheet of amorphous solid can be further incorporated as a flat sheet, as a collected or bundled sheet, as a pressure-bonded sheet, or as a wound sheet (i.e., in the form of a tube). In some such cases, the amorphous solid of these embodiments may be included in an aerosol-generating article as a sheet such as a sheet surrounding a rod containing an aerosolizable material. For example, the sheet of amorphous solid may be formed on a wrapper surrounding an aerosolizable material such as tobacco.

[0219] The amorphous solid in the form of a sheet can have any suitable areal density such as from about 30 g / m 2 to about 150 g / m 2 In some cases, the sheet may be from about 55 g / m 2 to about 135 g / m 2 or from about 80 to about 120 g / m 2 or from about 70 to about 110 g / m 2 or particularly from about 90 to about 110 g / m 2 or preferably about 100 g / m2 These ranges can provide a density similar to that of cut rag tobacco, thereby providing a mixture of these materials that is less likely to separate. Such areal densities can be particularly suitable when the amorphous solid material is included in the aerosol product as a shredded sheet (discussed further below). In some cases, the sheet can have a mass per unit area of about 30-70 g / m. 2 , 40~60g / m 2 , or 25 to 60 g / m 2 and the sheet can be used to encase an aerosolizable material, such as the aerosolizable materials described herein.

[0220] The aerosol-forming material can include a mixture of the aerosolizable material described herein and an amorphous solid material. Such aerosol-forming materials can provide a desirable flavor profile for the aerosol during use because additional flavorings can be incorporated into the aerosol-forming material by including them in the amorphous solid material component. The flavorings provided in the amorphous solid material can be more stably retained within the amorphous solid material compared to flavorings added directly to the tobacco material, resulting in a more consistent flavor profile among articles manufactured according to the present disclosure.

[0221] As previously mentioned, tobacco materials having a density of at least 350 mg / cc to less than about 900 mg / cc, preferably about 600 mg / cc to about 900 mg / cc, have been found to be advantageous in providing a more sustained aerosol release. To provide an aerosol with a consistent flavor profile, the amorphous solid material components of the aerosol-forming material should be uniformly dispersed throughout the rod. This can be achieved by casting the amorphous solid material to provide an amorphous solid material having a thickness as described herein and an areal density similar to that of the tobacco material, and by processing the amorphous solid material as described below to ensure uniform dispersion throughout the aerosol-forming material.

[0222] As previously mentioned, optionally, the aerosol-generating material comprises a plurality of strips of amorphous solid material. When the aerosol-generating portion comprises a plurality of strands and / or strips of a sheet of aerosolizable material and a plurality of strips of amorphous solid material, the material properties and / or dimensions of these at least two components may be appropriately selected to ensure relatively uniform mixing of the components and in other ways to reduce separation or unmixing of the components during or after manufacture of the rod of aerosol-generating material.

[0223] The longitudinal dimension of the plurality of strands or strips may be approximately the same as the length of the aerosol-generating portion. The plurality of strands and / or strips may have a length of at least about 5 mm.

[0224] Figure 3 shows a simplified view of the components of an embodiment of non-combustion aerosol delivery device 100. Notably, in Figure 3, the elements of non-combustion aerosol delivery device 100 are not drawn to scale. To simplify Figure 3, elements not relevant to understanding the present embodiment have been omitted.

[0225] As shown in FIG. 3, non-combustion aerosol delivery device 100 is a non-combustion aerosol delivery device having housing 101 with area 102 for receiving item 1.

[0226] Region 102 is positioned to receive item 1. When item 1 is received in region 102, at least a portion of the aerosol-generating material is in thermal proximity to heater 103. When item 1 is fully received in region 102, at least a portion of the aerosol-generating material can be in direct contact with heater 103. The aerosol-forming substrate emits various volatile compounds at different temperatures. By controlling the maximum operating temperature of electrically heated aerosol-generating system 100, the selective emission of undesirable compounds can be controlled by preventing the emission of selected volatile compounds.

[0227] As shown in FIG. 4, there is an electrical energy supply source 104, such as a rechargeable lithium-ion battery, within the housing 101. A controller 105 is connected to the heater 103, the electrical energy supply source 104, and a user interface 106, such as a button or a display. The controller 105 controls the power supplied to the heater 103 in order to adjust the temperature of the heater 103. Usually, the aerosol-forming substrate is heated to a temperature of 250 to 450 degrees Celsius.

[0228] FIG. 5 is a schematic cross-sectional view of a non-combustible aerosol supply device of the type shown in FIG. 3, in which the heater 103 is inserted into the aerosol-generating material 3 of the article 1. The non-combustible aerosol supply device is shown in a state engaged with the aerosol-generating article 1 for a user to consume the aerosol-generating article 1.

[0229] The housing 101 of the non-combustible aerosol supply device defines a region 102 in the form of a cavity that is open at the proximal end (or mouth end) for receiving the aerosol-generating article 1 to be consumed. A heating assembly including the heater 103 is mounted at the distal end of the cavity. The heater 103 is held by a heater mounting base (not shown) such that the active heating region of the heater is disposed within the cavity. When the aerosol-generating article 1 is fully received within the cavity, the active heating region of the heater 103 is disposed within the aerosol-generating portion of the aerosol-generating article 1.

[0230] The heater 103 is configured to be inserted into the aerosol-generating material 3. The heater 103 is formed in the form of a blade that terminates at a tip. That is, the length dimension of the heater is larger than its width dimension, and the width dimension is larger than the thickness dimension. The first and second surfaces of the heater are defined by the width and length of the heater.

[0231] When the article 1 is pressed into the cavity, the tapered tip of the heater engages the aerosol-generating material 3. The blades are shaped to easily insert into and remove from the aerosol-generating material 3. By applying force to the article 1, the heater penetrates the aerosol-generating material 3. When the article 1 is properly engaged with the non-combustible aerosol delivery device, the heater 103 is inserted into the aerosol-generating material 3. When the heater is activated, the aerosol-generating material 3 is heated and volatile substances are generated or released. When the user draws on the mouthpiece 2, air is drawn into the article 1, and the volatile substances condense to form an inhalable aerosol. This aerosol passes through the mouthpiece 2 of the article 1 and into the user's mouth.

[0232] 5 includes two fibers 40 of heat transfer material in the aerosol-generating material 3. These fibers transfer heat received from the heater 103 to other areas of the aerosol-generating material 3, providing a more uniform heat distribution.

[0233] Generally, the heat transfer materials of the present disclosure aid in the distribution of heat through the aerosol-forming material, allowing for more uniform heat distribution and avoiding localized hot spots.

[0234] In some embodiments, the heat transfer material is non-metallic. Such materials can have the advantage of being relatively lightweight and having low thermal mass. Therefore, such materials do not significantly add weight to the article and are more efficient at transferring heat from one area to another.

[0235] A combination of a metallic heating element and a non-metallic heat transfer material such as graphite is believed to be an advantageous combination for achieving heat distribution through the aerosol-forming material.

[0236] The various embodiments described herein are presented merely to assist in the understanding and teaching of the claimed features. These embodiments are presented as merely representative specific examples of the embodiments and are not inclusive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered as limiting the scope of the invention to that defined in the claims or to the equivalents of the claims, and it should be understood that other embodiments may be used and modifications may be made without departing from the scope of the claimed invention. The various embodiments of the present invention may preferably include, consist of, or consist essentially of suitable combinations of disclosed elements, components, features, parts, steps, means, etc. other than those expressly set forth herein. Additionally, the present disclosure may include other inventions that are not currently claimed but may be claimed in the future.

Claims

1. An article for use in an aerosol supply system or as part of an aerosol supply system, comprising: an aerosol generating material; and a heat transfer material for distributing heat from a first region of the aerosol generating material to a second region of the aerosol generating material, wherein the heat transfer material has a thermal conductivity of at least 220 W / mK, and the heat transfer material is in the form of a rod, wire, fiber, thread, or ribbon extending through at least a portion of the aerosol generating material.

2. The article according to claim 1, wherein the thermal conductivity of the heat transfer material is less than 5000 W / mK, 4000 W / mK, 3000 W / mK, 2000 W / mK, or 1000 W / mK.

3. The article according to claim 1, wherein the thermal conductivity of the heat transfer material is greater than 300 W / mK, 400 W / mK, or 500 W / mK.

4. The article according to claim 1, wherein the thermal conductivity of the heat transfer material ranges from 220 to 5000 W / mK, 220 to 4000 W / mK, 220 to 3000 W / mK, 220 to 2000 W / mK, 220 to 1000 W / mK, 220 to 500 W / mK, 300 to 5000 W / mK, 300 to 4000 W / mK, 300 to 3000 W / mK, 300 to 2000 W / mK, 300 to 1000 W / mK, 300 to 500 W / mK, or 220 to 470 W / mK.

5. The article according to claim 1, wherein the weight of the heat transfer material present in the article ranges from 1 to 25 mg, 1 to 20 mg, 1 to 15 mg, 1 to 10 mg, or 1 to 5 mg.

6. The article according to claim 1, wherein the weight ratio of the heat transfer material to the aerosol generating material ranges from 1:10 to 1:

100.

7. The article according to claim 1, wherein the heat transfer material includes at least one separate material portion in thermal contact with the first region and the second region of the aerosol generating material.

8. The article according to claim 1, wherein the heat transfer material is elongated and extends parallel to the axis of the article.

9. The article according to claim 1, wherein the heat transfer material extends along the length of the aerosol generating material.

10. The article according to claim 1, wherein the heat transfer material extends less than the length of the aerosol generating material.

11. The article according to claim 10, wherein the heat transfer material extends along at least 10% of the length of the aerosol generating material.

12. The article according to claim 10, wherein the heat transfer material extends along up to 90% of the length of the aerosol - generating material.

13. The article according to claim 10, wherein the length of the heat transfer material is in the range of 10 - 90%, 10 - 80%, 10 - 70%, 10 - 60%, or 10 - 50% of the length of the aerosol - generating material.

14. The article according to claim 1, wherein the heat transfer material comprises a plurality of distinct material portions that are in thermal contact with respective first and second regions of the aerosol - generating material.

15. The article according to claim 1, wherein the heat transfer material is mixed with the aerosol - generating material.

16. The article according to claim 15, wherein the heat transfer material is in the form of particles or powder.

17. The article according to claim 1, wherein the aerosol - generating material comprises a reconstituted tobacco and the heat transfer material is mixed with the reconstituted tobacco.

18. The article according to claim 1, wherein the heat transfer material contains or comprises carbon.

19. The article according to claim 18, wherein the heat transfer material is one of graphene, graphite, carbon fiber, graphene fiber, or graphite fiber.

20. The article according to claim 1, wherein the heat transfer material has openings, pores, or cavities.

21. The article according to claim 1, further comprising an amorphous solid, an active substance, or a fragrance.

22. The article according to claim 21, wherein the amorphous solid, the active substance, or the fragrance is disposed in one or more openings, pores, or cavities of the heat transfer material.

23. The article according to any one of claims 1 - 22, further comprising a heating element.

24. The article according to claim 23, wherein the heating element is a susceptor.

25. A non - combustible aerosol supply device, a heating element, and an article according to any one of claims 1 - 22 comprising an aerosol supply system.

26. The aerosol supply system according to claim 25, wherein the aerosol supply device comprises a power source for supplying power to the heating element, and the heating element heats the aerosol - generating material by electrical conduction.

27. The aerosol supply system according to claim 25, wherein the aerosol supply device comprises a magnetic field generator, and the heating element is a susceptor that heats the aerosol - generating material by induction heating and / or magnetic hysteresis heating.

28. The aerosol supply system according to claim 25, wherein the aerosol supply device comprises a heat generating power source, and the heating element of the article is a second heat transfer material for transferring heat to the aerosol generating material.

29. The aerosol supply system according to claim 25, wherein the article comprises the heating element.

30. The aerosol supply system according to claim 25, wherein the aerosol supply device comprises the heating element.

31. A method of manufacturing an article for use in or as part of an aerosol supply system, wherein the article comprises an aerosol generating material, the method comprising the step of adding a heat transfer material for distributing heat from a first region of the aerosol generating material to a second region of the aerosol generating material, the heat transfer material having a thermal conductivity of at least 220 W / mK and being in the form of a rod, wire, fiber, thread, or ribbon extending through at least a portion of the aerosol generating material.

32. The method according to claim 31, wherein the step of adding the heat transfer material comprises feeding the heat transfer material into the aerosol generating material.

33. The method according to claim 31, wherein the step of adding the heat transfer material comprises extruding the heat transfer material into the aerosol generating material.

34. The method according to claim 31, wherein the step of adding the heat transfer material comprises mixing the heat transfer material with the aerosol generating material.

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