Consumables for aerosol delivery systems

Abstract

The present invention relates to a consumable for use in a non-combustible aerosol delivery system. The consumable comprises an aerosol-generating segment containing at least one aerosol-generating material and a mouthpiece segment containing a section of amorphous solid material. The present invention also relates to a non-combustible aerosol delivery system employing such a consumable, a method for manufacturing the consumable, and uses of the section of amorphous solid material.

Description

[Technical Field]

[0001] The present invention relates to a consumable for use in an aerosol delivery system, a non-combustible aerosol delivery system, a method for manufacturing the consumable, and the use of a section of amorphous solid material. [Background technology]

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

[0003] According to a first aspect of the present invention, there is provided a consumable for use in a non-combustible aerosol delivery system, comprising an aerosol-generating segment including at least one aerosol-generating material and a mouthpiece segment including a section of amorphous solid material.

[0004] In some embodiments, the consumable has the form of a rod having a first end and a second end, the rod including multiple portions, one of the multiple portions including a section of amorphous solid material and at least one portion including at least one aerosol-generating material.

[0005] In some embodiments, the section of amorphous solid material comprises a collected sheet of amorphous solid material.

[0006] In some embodiments, the section of amorphous solid material comprises an elongated strip of amorphous solid material. Optionally, the elongated strip is substantially aligned with a longitudinal axis of the consumable.

[0007] In some embodiments, the amorphous solid material has a thickness of about 0.5 mm to about 2 mm or about 1 mm to about 2 mm.

[0008] In some embodiments, the amorphous solid material is provided on a support material. Optionally, the support material is paper or foil.

[0009] In some embodiments, the support material comprises a susceptor.

[0010] In some embodiments, the amorphous solid material is compressed.

[0011] In some embodiments, the amorphous solid material comprises a gelling agent. Optionally, the gelling agent is one or more selected from the group consisting of carboxymethylcellulose, alginate, pectin, gelatin, polysaccharides, guar gum, and carrageenan.

[0012] In some embodiments, the amorphous solid material comprises an aerosol-forming material. Optionally, the aerosol-forming material is one or more selected from the group consisting of erythritol, propylene glycol, glycerol, vegetable glycerin, triacetin, sorbitol, and xylitol.

[0013] In some embodiments, the amorphous solid material comprises a flavoring agent, and optionally the flavoring agent is menthol.

[0014] In some embodiments, at least one aerosol-forming material in the portion comprises a tobacco material.

[0015] In some embodiments, the tobacco material comprises reconstituted tobacco material, and optionally comprises paper reconstituted tobacco material.

[0016] In some embodiments, the mouthpiece segment further comprises a body of fibrous material.

[0017] In some embodiments, the mouthpiece segment comprises a hollow tubular element. Optionally, the hollow tubular element is a paper tube or is formed from filament tow.

[0018] In some embodiments, the hollow tubular element is disposed between the section of amorphous solid material and the portion containing the aerosol-forming material.

[0019] In some embodiments, the section of amorphous solid material and the portion containing the aerosol-forming material are immediately adjacent to one another.

[0020] In some embodiments, the consumable comprises a hollow tubular element at the oral end.

[0021] In some embodiments, the mouthpiece comprises one or more flavor modifying elements. Optionally, the flavor modifying elements are capsules.

[0022] According to a second aspect of the present invention, there is provided a non-combustible aerosol delivery system comprising a non-combustible aerosol delivery device and a consumable product according to the first aspect.

[0023] According to a third aspect of the present invention there is provided a method for manufacturing a consumable product according to the first aspect, comprising collecting a sheet of amorphous solid material to form a section of amorphous solid material.

[0024] According to a fourth aspect of the present invention there is provided a method for manufacturing a consumable product according to any one of claims 1 to 25, comprising cutting a sheet of amorphous solid material to form a plurality of strips of amorphous solid material from which sections of amorphous solid material are formed.

[0025] In some embodiments, the strips have a cut length of at least about 5 mm.

[0026] According to a fifth aspect of the present invention there is provided the use of a section of amorphous solid material in a consumable for reducing the temperature of the aerosol during use of the consumable in a non-combustible aerosol delivery system.

[0027] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0028] [Figure 1] 1 is a cross-sectional side view of a first embodiment of a consumable for use with a non-combustible aerosol delivery device. [Figure 2] 10 is a cross-sectional side view of a second embodiment of a consumable for use with a non-combustible aerosol delivery device. [Figure 3] 10 is a cross-sectional side view of a third embodiment of a consumable for use with a non-combustible aerosol delivery device. [Figure 4] 10 is a cross-sectional side view of a fourth embodiment of a consumable for use with a non-combustible aerosol delivery device. FIG. [Figure 5] 10 is a cross-sectional side view of a fifth embodiment of a consumable for use with a non-combustible aerosol delivery device. FIG. [Figure 6] FIG. 6 is a perspective view of a non-combustible aerosol delivery device for generating aerosol from the consumable aerosol-forming material of FIGS. 1-5. DETAILED DESCRIPTION OF THE INVENTION

[0029] The present invention relates to a consumable product for use in a non-combustible aerosol delivery system, the consumable product comprising an aerosol-generating segment including at least one aerosol-generating material and a mouthpiece segment including a section of amorphous solid material.

[0030] An aerosol-generating material is a material that can generate an aerosol when, for example, heated, irradiated, or in any other way energized. The aerosol-generating material can include one or more active substances and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0031] Amorphous solid materials are aerosol-generating materials because they can generate an aerosol when heated, irradiated, or otherwise energized. However, when placed in the mouthpiece segment of a consumable, amorphous solid materials cannot be directly heated by an aerosol delivery device. The amorphous material is heated by exposure to heated aerosol generated by heating the aerosol-generating segment of the consumable.

[0032] As the heated aerosol generated by heating the aerosol-generation segment of the consumable passes through a section of amorphous material, the amorphous material acts as a heat sink, lowering the temperature of the aerosol. The amorphous material can be heated by the heated aerosol generated from the aerosol-generation segment of the consumable, thereby releasing volatile components, such as aerosol-forming agents and flavorings, from the amorphous solid material.

[0033] It is important that the amorphous solid material does not melt or change phase upon exposure to the heated aerosol, so that a consumable product containing a section of amorphous solid material substantially maintains its structural integrity during use.

[0034] In some embodiments, the temperature of the heated aerosol before contacting the amorphous solid material is between about 250° C. and about 60° C., depending on the location of the section of amorphous solid material in the consumable.

[0035] The aerosol is cooled as it passes through the section of amorphous solid material, which in some embodiments reduces the temperature of the aerosol by an additional 10° C. compared to the effect of a similarly sized section containing conventional cellulose acetate tow.

[0036] The overall temperature drop of the aerosol as it travels from the aerosol-generating material that generated it to the mouth end of the consumable depends on several factors, including, for example, the nature of the consumable portion through which the aerosol passes and the location of the consumable portion within the consumable, and the overall format (i.e., length and diameter) of the consumable.

[0037] Nevertheless, it is clear that the section of amorphous solid material has heat sink properties that can be used to control the temperature of the aerosol as it reaches the user.

[0038] In some embodiments, the temperature of the aerosol as it exits the section of amorphous solid material is between about 180° C. and about 40° C. depending on the location of the section of amorphous solid material in the consumable.

[0039] In some embodiments, the section of amorphous solid material has a length of from about 7 mm to about 30 mm, optionally from about 10 mm to about 20 mm.

[0040] During use of the consumable, the amorphous solid material acts as a heat sink, lowering the temperature of the generated aerosol by heating the aerosol-generating material of the consumable. Without wishing to be bound by any one particular theory, it is hypothesized that the high density of the amorphous solid material and its ability to absorb water / vapor contribute to the absorption of heat. In some embodiments, when a hot puff occurs, a section of the amorphous solid material can be optimized to absorb the vapor generated in the first few puffs.

[0041] When the heated aerosol contacts a section of amorphous solid material, at least a portion (and in some cases most) of the vapor present in the aerosol condenses into the solid amorphous solid material rather than remaining in the gas phase, thus preventing the vapor from traveling to the consumer's mouth and condensing on the lips / oral cavity, causing a burning sensation.

[0042] In addition to reducing the temperature of the aerosol, the amorphous solid material can also generate an aerosol and / or vapor thereof when heated by the aerosol from the aerosol-forming material. In some embodiments, this aerosol generated by the amorphous solid material contains ingredients with desired properties, including sensory and mouthfeel, and optionally one or more actives and / or flavorings.

[0043] The consumables can have several advantages in addition to improving the temperature of the aerosol delivered to the user. Other heat sinks tend to remove volatile materials from the aerosol as it passes through. This can result in an aerosol with poor taste and poor active material delivery. In contrast, fewer components are removed from the aerosol when it passes through a section of amorphous solid material. Indeed, in some embodiments, as briefly discussed above, the amorphous solid material can release desirable components into the aerosol.

[0044] Additionally, the consumables experience a good closing pressure drop.

[0045] Amorphous Solid Materials An amorphous solid material may also be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid material may be a dry gel. An amorphous solid material is a solid material that can retain some fluid, such as a liquid, within it.

[0046] The amorphous solid material comprises one or more aerosol-forming materials. Optionally, the amorphous solid material can further comprise one or more active agents and / or flavorings, and / or optionally one or more other functional materials.

[0047] The one or more other functional ingredients may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0048] The amorphous solid material can suitably comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, or 35 wt% of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid material can comprise 1-50 wt%, 5-45 wt%, 10-40 wt%, or 20-35 wt% of a gelling agent. In some embodiments, the gelling agent comprises a hydrocolloid.

[0049] In some embodiments, the gelling agent comprises one or more compounds selected from the group including 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 gelling agent comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, gum arabic, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some embodiments, the gelling agent comprises alginate and / or pectin and may be mixed with a hardening agent (such as a calcium source) during formation of the amorphous solid material. In some embodiments, the amorphous solid material may comprise calcium-crosslinked alginate and / or calcium-crosslinked pectin.

[0050] In some embodiments, the gelling agent comprises alginate, and the alginate is present in the amorphous solid material in an amount of 10-30 wt% (calculated on a dry weight basis) of the amorphous solid material. In some embodiments, the alginate is the only gelling agent present in the amorphous solid material. In other embodiments, the gelling agent comprises alginate and at least one additional gelling agent, such as pectin.

[0051] In some embodiments, the amorphous solid material can include a gelling agent that includes carrageenan.

[0052] The amorphous solid material can suitably 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). For example, the amorphous solid material can comprise from 0.5 to 40 wt%, from 3 to 35 wt%, or from 10 to 25 wt% of the aerosol-forming material.

[0053] As used herein, the aerosol-forming material may include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate.

[0054] In some cases, the aerosol-forming material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, vegetable glycerin (VG), triacetin, sorbitol, and xylitol. In some cases, the aerosol-forming material comprises, consists essentially of, or consists of glycerol.

[0055] When included in an amorphous solid material, the aerosol-forming material can act as a plasticizer. Therefore, it may be desirable to include more aerosol-forming material in an amorphous solid material where the gelling agent used would otherwise be a brittle material. Thus, for example, if the gelling agent is alginate, it may include at least 7 wt. % or more of an aerosol-forming material, such as glycerol. This amount of aerosol-forming material provides the alginate-based amorphous solid material with the necessary level of plasticity to allow for the formation of a consumable section without breakage.

[0056] In some embodiments, the amorphous solid material comprises a flavoring agent. Depending on the nature of the flavoring agent, the amorphous solid material can suitably comprise up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% of flavoring agent. In some cases, the amorphous solid material can comprise at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% of flavoring agent (all calculated on a dry weight basis).

[0057] For example, the amorphous solid material 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.

[0058] Flavorings provided in the amorphous solid material are more stably retained within the amorphous solid material than flavorings added directly to the tobacco material, which can result in a more consistent flavor profile among the consumables disclosed herein.

[0059] In some embodiments, the amorphous solid material is fragrance-free.

[0060] In some cases, the amorphous solid material may further include an emulsifier to emulsify the flavoring agent during manufacturing. In embodiments where the flavoring agent is solid at room temperature, the flavoring agent may be heated to a molten form and mixed with the emulsifier. The amorphous solid material may include about 0.1 wt%, about 0.2 wt%, or about 0.5 wt% to about 15 wt%, preferably about 10 wt%, of an emulsifier (calculated on a dry weight basis). Suitable emulsifiers include sorbitan (e.g., SPAN), polysorbates (e.g., TWEEN), and gum arabic.

[0061] In some embodiments, the amorphous solid material 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) (WWB).

[0062] In some embodiments, where local regulations permit, the amorphous solid material further comprises an active substance. For example, in some cases, the amorphous solid material further comprises tobacco material and / or nicotine. In some cases, the amorphous solid material can comprise 5 to 60 wt% (calculated on a dry weight basis) of tobacco material and / or nicotine. In some cases, the amorphous solid material 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 the active substance. In some cases, the amorphous solid material 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% tobacco material (calculated on a dry weight basis). For example, the amorphous solid material can comprise from 10 to 50 wt%, 15 to 40 wt%, or 20 to 35 wt% tobacco material. In some cases, the amorphous solid material can comprise from about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% nicotine (calculated on a dry weight basis). For example, the amorphous solid material can include 1-20 wt%, 2-18 wt%, or 3-12 wt% nicotine.

[0063] In some cases, where local regulations permit, the amorphous solid material includes an active agent such as tobacco extract. In some cases, the amorphous solid material can include 5-60 wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the amorphous solid material can include about 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of tobacco extract. For example, the amorphous solid material can include 10-50 wt%, 15-40 wt%, or 20-35 wt% of tobacco extract. The tobacco extract can contain nicotine in a concentration such that the amorphous solid material 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% nicotine (calculated on a dry weight basis).

[0064] In some cases, no nicotine other than that obtained from the tobacco extract may be present in the amorphous solid material.

[0065] In some embodiments, the amorphous solid material does not include tobacco material but does include nicotine. In some such cases, the amorphous solid material can include from about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% nicotine (calculated on a dry weight basis). For example, the amorphous solid can include from 1 to 20 wt%, 2 to 18 wt%, or 3 to 12 wt% nicotine.

[0066] In some cases, the total content of actives and / or fragrances may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of actives and / or fragrances may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0067] In some cases, the total content of tobacco material, nicotine, and flavorings may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of actives and / or flavorings may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0068] The amorphous solid material may be made from a gel, which may further contain a solvent present at 0.1 to 50 wt %. However, the present inventors have found that the inclusion of a solvent in which the fragrance dissolves may reduce the stability of the gel, and the fragrance may crystallize from the gel. Therefore, in some cases, the gel does not contain a solvent in which the fragrance dissolves.

[0069] In some embodiments, the amorphous solid material comprises less than 60 wt% of filler, for example, between 1 wt% and 60 wt%, or between 5 wt% and 50 wt%, or between 5 wt% and 30 wt%, or between 10 wt% and 20 wt%.

[0070] In other embodiments, the amorphous solid material contains less than 20 wt%, preferably less than 10 wt% or less than 5 wt% filler. In some cases, the amorphous solid material contains less than 1 wt% filler, and in some cases, no filler.

[0071] When present, the filler may comprise one or more inorganic filler materials, such as suitable inorganic adsorbents, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and molecular sieves. The filler may comprise one or more organic filler materials, such as wood pulp, cellulose and cellulose derivatives, including microcrystalline cellulose. In certain cases, the amorphous solid material does not comprise calcium carbonate, such as chalk.

[0072] In certain embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material, such as wood pulp, hemp fiber, cellulose, or a cellulose derivative. Without wishing to be bound by theory, it is believed that the inclusion of a fibrous filler in an amorphous solid material can increase the tensile strength of the material.

[0073] In some embodiments, the amorphous solid material does not include tobacco fiber.

[0074] In some embodiments, the amorphous solid material is provided in the form of a sheet.

[0075] In some embodiments, such as when the amorphous solid material does not include a filler, the amorphous solid material may have a tensile strength of 200 N / m to 400 N / m, or 200 N / m to 300 N / m, or about 250 N / m. Such tensile strengths may be particularly suitable for embodiments in which the amorphous solid material is formed into a sheet that is subsequently shredded and incorporated into an aerosol product.

[0076] In some embodiments, such as when the amorphous solid material is used in sheet form, a filler is included to enhance tensile strength. In some embodiments, the amorphous solid material can have a tensile strength of at least about 2000 N / m and / or up to about 5000 N / m. In some embodiments, the tensile strength can be about 3000 to about 4000 N / m. Such tensile strengths can be particularly suitable for embodiments in which the amorphous solid material is included in a consumable product as a rolled sheet.

[0077] In some cases, the amorphous solid material may consist essentially of or consist of a gelling agent, water, an aerosol-forming material, a flavoring agent, and optionally an active agent.

[0078] In some cases, the amorphous solid material may consist essentially of or consist of a gelling agent, water, an aerosol-forming material, flavorings, and optionally a tobacco material and / or a nicotine source.

[0079] In some examples, the amorphous solid material comprises 1 to 60 wt% gelling agent, 0.1 to 50 wt% aerosol forming agent, 0 to 20 wt% bulking agent, and 0.1 to 80 wt% flavoring agent, the weights being calculated on a dry weight basis.

[0080] A plug of amorphous solid material As previously mentioned, the consumable includes a section or plug of amorphous solid material. In some embodiments, the section or plug of amorphous solid material is formed from a sheet of amorphous solid material. In some embodiments, the section or plug consists of or consists essentially of a sheet of amorphous solid material.

[0081] In some embodiments, a section or plug of amorphous solid material comprises, for example, about 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, 60 wt%, or 70 wt% amorphous solid material to about 70 wt%, 75 wt%, 80 wt%, 85 wt%, 90 wt%, 95 wt%, or 100 wt% amorphous solid material. In some embodiments, the section or plug consists essentially of amorphous solid material. In some embodiments, the section or plug consists of amorphous solid material. In embodiments where the amorphous solid material is in the form of a sheet or shredded sheet, the section or plug comprises about 25 vol% to about 70 vol% amorphous solid material. In embodiments where the amorphous solid material is in the form of beads, the section or plug comprises at least about 50 vol%, optionally about 50 vol% to about 80 vol% amorphous solid material.

[0082] In some embodiments, the sheets of amorphous solid material are incorporated into sections or plugs as collected or bundled sheets, or as crimped sheets. The sheets may be in collected, rolled, or coiled form. In other embodiments, the sheets are shredded and then collected into sections or plugs, optionally surrounded by a wrapper or another sheet material that holds the material together. In some embodiments, the sections or plugs can further include an inert sheet or other inert filler in addition to the amorphous solid material to provide a desired fill volume. The inclusion of such filler can also reduce the overall weight of the sections and consumables.

[0083] In some embodiments, the section or plug of amorphous solid material comprises, for example, about 50%, 60%, or 70% to about 80%, 85%, or 90% by volume of amorphous solid material, which ensures that the pressure drop across the consumable is not affected by the section of amorphous solid material.

[0084] In some embodiments, the amorphous solid material in the form of a sheet has a mass of about 30 g / m 2 ~about 150g / m 2 In some cases, the sheet may have an areal density of about 55 g / m 2 ~Approx. 135g / m 2 , or about 80 to about 120 g / m 2 , or about 70 to about 110 g / m 2 , or particularly about 90 to about 110 g / m 2 , or preferably about 100 g / m 2 Such areal densities may be particularly suitable when the amorphous solid material is included in the aerosol product as shredded sheets.

[0085] A section or plug of amorphous solid material is 30 g / m 2 ~Approx. 120g / m 2In some cases, the sheet may have a density of 80 to 120 g / m 2 , or approximately 70 to 110 g / m 2 , or in particular about 90 to 110 g / m 2 , or preferably about 100 g / m 2 The mass per unit area may be 0.015 .mu.m.

[0086] In some cases, the sheet of amorphous solid material may include a carrier layer that may be substantially or completely impermeable to gases and / or aerosols, thereby preventing the aerosol or gas from passing through the carrier, thereby controlling flow and ensuring good delivery to the user.

[0087] The carrier may be any suitable material that can be used to support an amorphous solid material. In some cases, the carrier may be formed from a material selected from metal foil, paper, carbon paper, greaseproof paper, ceramic, carbon allotropes such as graphite and graphene, plastic, cardboard, wood, or a combination thereof. In some cases, the carrier may include or be composed of tobacco material, such as a sheet of reconstituted tobacco. In some cases, the carrier may be formed from a material selected from metal foil, paper, cardboard, wood, or a combination thereof. In some cases, the carrier itself may be a laminated structure containing layers of materials selected from the foregoing list. In some cases, the carrier may also function as a flavor carrier. For example, the carrier may be impregnated with flavorings or tobacco extract.

[0088] In some embodiments, the carrier or support includes a susceptor. In some embodiments, the susceptor is embedded in the carrier. In some alternative embodiments, the susceptor is on one or both sides of the carrier.

[0089] In some cases, the surface of the carrier that contacts the amorphous solid material may be porous. For example, in some cases, the carrier includes paper. The inventors have found that porous carriers such as paper are particularly suitable for the present invention, where a porous (paper) layer contacts and forms a strong bond with a layer of amorphous solid material. The amorphous solid material is formed by drying a gel, and without being limited by theory, it is believed that the gel-forming slurry partially impregnates the porous carrier (e.g., paper), so that when the gel hardens and forms crosslinks, the carrier is partially bonded to the gel. This results in a strong bond between the gel and the carrier (and the dried gel and the carrier).

[0090] Furthermore, surface roughness can contribute to the strength of the bond between the amorphous solid material and the carrier. The inventors have found that the roughness of the paper (the surface that abuts the carrier) can be 50 to 1000 Bekk seconds, preferably 50 to 150 Bekk seconds, and preferably 100 Bekk seconds (measured over a pressure range of 50.66 to 48.00 kPa). (The Bekk smoothness tester is an instrument used to measure the smoothness of paper surfaces. In this tester, air at a specific pressure is forced between a smooth glass surface and a paper sample. The time (in seconds) for a fixed volume of air to penetrate between these surfaces is the "Bekk smoothness.")

[0091] In some embodiments, a laminate of paper and greaseproof paper can be used, where the paper layer abuts the amorphous solid material, and the sticky amorphous solid material does not readily stick to the carrier backing of the greaseproof paper.

[0092] In some cases, the carrier can have a thickness of from about 0.01 mm to about 2 mm, preferably from about 0.015 mm, 0.02 mm, 0.05 mm, or 0.1 mm to about 1.5 mm, 1 mm, or 0.5 mm.

[0093] In some cases, the amorphous solid material layer can have a thickness of about 0.015 mm to about 1.5 mm, preferably about 0.05 mm to about 1.5 mm or 0.05 mm to about 1 mm. Suitably, the thickness can be about 0.1 mm or 0.15 mm to about 1 mm, 0.5 mm, or 0.3 mm. The amorphous solid material may include two or more layers, and the thicknesses described herein refer to the total thickness of these layers.

[0094] 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.

[0095] The inventors have determined that if the amorphous solid material is too thin, it can be difficult to manufacture and handle: very thin materials are more difficult to cast, are prone to breakage, and can interfere with aerosol formation during use.

[0096] In some cases, the individual strips or slices of amorphous solid material in the carrier layer have a minimum thickness of about 0.015 mm across their area. In some cases, the individual strips or slices of amorphous solid material 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 amorphous solid material have a maximum thickness of about 1.0 mm across their area. In some cases, the individual strips or slices of amorphous solid material have a maximum thickness of about 0.5 mm or about 0.3 mm across their area.

[0097] In embodiments in which the sheet of amorphous solid material does not include a carrier layer, the amorphous solid material can have a thickness of at least about 1 mm and / or not more than about 2 mm. The amorphous solid material may include two or more layers, and the thicknesses described herein refer to the total thickness of those layers of amorphous solid material.

[0098] For the avoidance of doubt, when areal density is referred to herein, it refers to the average areal density calculated for a given strip, piece or sheet of amorphous solid material, which are calculated by measuring the surface area and weight of the given strip, piece or sheet of amorphous solid material.

[0099] The thicknesses specified herein are the average thickness of the material. In some cases, the thickness of the amorphous solid material may vary by 25%, 20%, 15%, 10%, 5%, or 1% or less.

[0100] Aerosol-forming material portion The consumable comprises an aerosol-generating segment that includes at least one aerosol-generating material in addition to a section or plug of amorphous solid material.

[0101] In some embodiments, the aerosol-generating material includes one or more actives and / or flavorings. In some embodiments, the material includes tobacco or other plant-derived material. When the aerosol-generating material includes tobacco, heating the material releases volatile tobacco components, including nicotine and flavor or aroma compounds.

[0102] In some embodiments, the portion of the consumable that includes at least one aerosol-forming material includes tobacco material. As used herein, the term "tobacco material" refers to any material that includes tobacco or a derivative or substitute thereof. 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 fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco lamina, reconstituted tobacco, and / or tobacco extract.

[0103] The tobacco material can be provided in the form of cut rag tobacco. The cut rag tobacco can have a cut width of at least 15 notches per inch (approximately 5.9 notches per cm, equivalent to a cut width of approximately 1.7 mm). The cut rag tobacco preferably has a cut width of at least 18 notches per inch (approximately 7.1 notches per cm, equivalent to a cut width of approximately 1.4 mm), more preferably at least 20 notches per inch (approximately 7.9 notches per cm, equivalent to a cut width of approximately 1.27 mm). In one example, the cut rag tobacco has a cut width of 22 notches per inch (approximately 8.7 notches per cm, equivalent to a cut width of approximately 1.15 mm). Preferably, the cut rag tobacco has a cut width of 40 notches per inch (approximately 15.7 notches per cm, equivalent to a cut width of approximately 0.64 mm). A cut width of 0.5 mm to 2.0 mm, for example 0.6 mm to 1.7 mm or 0.6 mm to 1.5 mm, has been found to provide a preferred tobacco material, particularly with respect to the surface area to volume ratio when heated, and the overall density and pressure drop of the rod of aerosol-forming material. Cut rag tobacco can be formed from a mixture of tobacco material forms, for example, a mixture of one or more of reconstituted tobacco, leaf tobacco, extruded tobacco, and band-cast tobacco. Preferably, the tobacco material comprises reconstituted tobacco or a mixture of reconstituted tobacco and leaf tobacco.

[0104] The tobacco material can have any suitable thickness. The 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 tobacco material can have a maximum thickness of about 0.25 mm; for example, the tobacco material can have a thickness of less than about 0.22 mm or less than about 0.2 mm. In some embodiments, the tobacco material can have an average thickness of 0.175 mm to 0.195 mm. Such thicknesses can be particularly appropriate when the tobacco material is a reconstituted tobacco material.

[0105] The tobacco material can include a reconstituted tobacco material, such as a paper reconstituted tobacco material, having a density of less than about 700 mg / cc. For example, the aerosol-forming material can include a reconstituted tobacco material having a density of less than about 600 mg / cc. Alternatively or additionally, the aerosol-forming material 3 can include a reconstituted tobacco material having a density of at least 350 mg / cc.

[0106] In some embodiments, the aerosol-forming material includes a filler component. The filler component is generally a non-tobacco component, i.e., a component that does not contain tobacco-derived materials. The filler component may be a non-tobacco fiber, such as wood fiber or pulp or wheat fiber. The filler component may be an inorganic material, such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, or magnesium carbonate. The filler component may be a non-tobacco cast material or a non-tobacco extrusion material. The filler component may be present in an amount of 0-20% by weight of the tobacco material or 1-10% by weight of the composition. In some embodiments, no filler component is present.

[0107] In some embodiments, the aerosol-generating material comprises an aerosol-forming material.

[0108] In some embodiments, the aerosol-forming material included with the tobacco material may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. Glycerol may be present in an amount of 10-20% by weight of the tobacco material, such as 13-16% by weight of the composition, or about 14% or 15% by weight of the composition. Propylene glycol, when present, may be present in an amount of 0.1-0.3% by weight of the composition.

[0109] The tobacco material can contain 10% to 90% by weight of tobacco leaf, with the aerosol-forming material being provided in an amount of up to about 10% by weight of the tobacco leaf. To achieve an overall level of aerosol-forming material of 10% to 20% by weight of the tobacco material, it has been found to be advantageous to add a greater weight percentage of the aerosol-forming material to another component of the tobacco material, such as reconstituted tobacco material.

[0110] The tobacco material described herein contains nicotine. The nicotine content may be 0.5 to 1.75% by weight of the tobacco material, for example, 0.8 to 1.5% by weight of the tobacco material. Additionally or alternatively, the tobacco material may contain 10% to 90% by weight of tobacco leaf and have a nicotine content greater than 1.5% by weight of the tobacco leaf. It has been found advantageous to use tobacco leaf having a nicotine content greater than 1.5% in combination with a lower-nicotine base material, such as reconstituted tobacco, to provide a tobacco material with an appropriate nicotine level while still having better sensory performance than reconstituted tobacco alone. Tobacco leaf, such as cut rag tobacco, may have a nicotine content of 1.5% to 5% by weight of the tobacco leaf.

[0111] The tobacco material described herein may contain an aerosol modifying agent, such as any of the flavorings described herein. In one embodiment, the tobacco material contains menthol to form a mentholated article. The tobacco material may contain 3 mg to 20 mg of menthol, preferably 5 mg to 18 mg, and more preferably 8 mg to 16 mg of menthol. In this example, the tobacco material contains 16 mg of menthol. The tobacco material may contain 2% to 8% by weight of menthol, preferably 3% to 7% by weight of menthol, and more preferably 4% to 5.5% by weight of menthol. In one embodiment, the tobacco material contains 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, using a larger amount of aerosol-forming material, such as tobacco material, can increase the achievable level of menthol loading, for example, about 500 mm. 3 More than, or preferably about 1000 mm 3 An aerosol-forming material such as tobacco material is used.

[0112] In embodiments, the tobacco material comprises a tobacco component as defined herein and an aerosol-forming material as defined herein. In embodiments, the tobacco material consists essentially of a tobacco component as defined herein and an aerosol-forming material as defined herein. In embodiments, the tobacco material consists of a tobacco component as defined herein and an aerosol-forming material as defined herein.

[0113] The reconstituted tobacco may be present in the tobacco component of the tobacco material described herein in an amount of 10% to 100% by weight of the tobacco component. In embodiments, the reconstituted tobacco is present in an amount of 10% to 80% by weight or 20% to 70% by weight of the tobacco component. In further embodiments, the tobacco component consists essentially of reconstituted tobacco, or consists of reconstituted tobacco. In a preferred embodiment, the leaf tobacco is present in the tobacco component of the tobacco material in an amount of at least 10% by weight of the tobacco component. For example, the leaf tobacco may be present in an amount of at least 10% by weight of the tobacco component, with the remainder of the tobacco component comprising reconstituted tobacco, band-cast reconstituted tobacco, or a combination of band-cast reconstituted tobacco and tobacco granules, or another form of tobacco. The leaf tobacco may be present in an amount of up to 40% to 60% of the tobacco material, with the remainder of the tobacco component suitably comprising reconstituted tobacco, band-cast reconstituted tobacco, or a combination of band-cast reconstituted tobacco and tobacco granules, or another form of tobacco.

[0114] Reconstituted tobacco paper refers to tobacco material formed by a process in which tobacco raw material is extracted with a solvent to obtain a residue containing a soluble extract and fibrous material, and then (usually after concentration, and optionally after further processing) the extract is recombined with the fibrous material from the residue (usually after purification of the fibrous material, and optionally with the addition of a portion of non-tobacco fiber) by depositing the extract on the fibrous material. The recombination process is similar to the papermaking process.

[0115] 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.

[0116] 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.

[0117] The density of the tobacco material affects the rate at which heat is conducted through the material; lower densities, for example densities below 700 mg / cc, allow for a more sustained aerosol release because heat is conducted more slowly through the material.

[0118] In some embodiments, the aerosol-generating material comprises a mixture of at least two aerosol-generating materials. In such embodiments, the mixture can comprise a first component comprising a tobacco material and a second component comprising an amorphous solid material as described herein. Such aerosol-generating materials can provide an aerosol with a desired flavor profile upon use, for example, by incorporating additional flavorings into the amorphous solid material component. As previously discussed, tobacco materials having a density of at least 350 mg / cc and less than about 700 mg / cc have been found to be advantageous, leading to more sustained aerosol release. To provide an aerosol with a consistent flavor profile, the amorphous solid material component of the aerosol-generating material should be uniformly dispersed throughout the rod. This can be achieved by casting the amorphous solid material to have a surface density similar to that of the tobacco material and processing the amorphous solid material to ensure uniform dispersion throughout the aerosol-generating material.

[0119] In some embodiments, a uniform mixture of tobacco material components and amorphous solid material components can be achieved when the amorphous solid material in sheet form is shredded. The chopped amorphous solid material preferably has a cut width of 0.75 mm to 2 mm, e.g., 1 mm to 1.5 mm. The strands of amorphous solid material formed by shredding may be cut transversely, e.g., by a cross-cut shredding process, to define a cut length of the shredded amorphous solid material in addition to the cut width. The chopped amorphous solid material preferably has a cut length of at least 5 mm, e.g., at least 10 mm, or at least 20 mm. The chopped amorphous solid material may have a cut length of less than 60 mm, less than 50 mm, or less than 40 mm. In some embodiments, the chopped amorphous solid material preferably has a non-uniform cut length to achieve a uniform mixture of the shredded amorphous solid material and cut rag tobacco. Although referred to as the cut length, the length of the pieces or strips of amorphous solid material may alternatively or additionally depend on a dimension of the material determined during manufacture, for example the width of the sheet of material being produced.

[0120] In an exemplary embodiment, the aerosol-generating material includes a first component comprising tobacco material, for example provided as cut rag tobacco, in an amount of 50% to 98%, for example 80% to 95%, and a second component comprising shredded amorphous solid material in an amount of 2% to 50%, for example 5% to 20%.

[0121] Substance to be delivered Consumables for use with non-combustible aerosol delivery devices include aerosol-forming materials that are intended to be partially or completely consumed by a user during use.

[0122] In some embodiments, the substance to be delivered comprises an active agent. The substance to be delivered may be present in any one or more of the aerosol-forming materials included in the consumable.

[0123] As used herein, an active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, and psychoactive substances. The active substance may be naturally derived or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another botanical substance.

[0124] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0125] As described herein, the active substance may comprise or be derived from one or more botanical substances, or components, derivatives, or extracts thereof. As used herein, the term "botanical substance" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc. Alternatively, the material may comprise active compounds naturally occurring in synthetically obtained botanical substances. The material may be in the form of a liquid, gas, solid, powder, fine powder, ground particles, granules, pellets, fragments, strips, sheets, etc. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. , lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, bell pepper, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, kavi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: common mint (Mentha arvensis), grapefruit mint (Mentha cv), Egyptian mint (Mentha niliaca), peppermint (Mentha piperita), lime mint (Mentha piperita citrata cv), chocolate mint (Mentha piperita cv), curly mint (Mentha spicata crispa), wild mint (Mentha cordifolia), horse mint (Mentha longifolia), pineapple mint (Mentha suaveolens variegata), pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata cv), and apple mint (Mentha suaveolens).

[0126] In some embodiments, the active substance comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substance is tobacco.

[0127] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substances are selected from eucalyptus, star anise, cocoa, and hemp.

[0128] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0129] In some embodiments, the aerosol-generating material in the aerosol-generating segment of the consumable comprises an active agent, hi some embodiments, the amorphous solid material does not comprise an active agent.

[0130] In some embodiments, the substance to be delivered comprises a fragrance.

[0131] As used herein, the terms "flavor" and "flavoring" refer to materials that may be used, where local regulations permit, to create a desired taste, aroma, or other somatosensory sensation in products intended 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.

[0132] 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.

[0133] In some embodiments, the flavoring agent may include a sensory elicitor 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.

[0134] In some embodiments, the aerosol-generating material segment of the consumable product includes a flavoring. In some embodiments, the amorphous solid material includes a flavoring. In other embodiments, the amorphous solid material does not include a flavoring.

[0135] In some embodiments, the consumable product, in addition to the aerosol-generating segment including at least one aerosol-generating material and the mouthpiece segment including a section of amorphous solid material, may further comprise one or more of an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol-generating area, a housing, a wrapper, a filter, and / or an aerosol modifier.

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

[0137] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavoring, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, a string, or granules. The aerosol modifier may not include a filtration material.

[0138] In some embodiments, the aerosol modifier can be provided as an infused material in the consumable or can be provided in a thread that can also be disposed within the mouthpiece segment, such as a thread that carries a flavoring or other aerosol modifier.

[0139] In some embodiments, the aerosol modifying agent is provided in a breakable capsule, e.g., a capsule having a solid, frangible shell surrounding a liquid payload. A single capsule or multiple capsules may be used. In some embodiments, one or more capsules are disposed in the mouthpiece, e.g., embedded in a plug of fibrous material.

[0140] In other embodiments, the aerosol modifier or other warming material is provided in a wrapper surrounding the consumable, such as a mouthpiece wrapper. The aerosol modifier may be located on either the inward-facing surface or the outward-facing surface.

[0141] Consumable Design Consumables, also referred to herein as articles, may be in the form of rods. Such rods are often named according to the length of the product, including "regular" (typically 68-75 mm, e.g., about 68 mm to about 72 mm), "short" or "mini" (68 mm or less), "king size" (typically 75-91 mm, e.g., about 79 mm to about 88 mm), "long" or "super king" (typically 91-105 mm, e.g., about 94 mm to about 101 mm), and "ultra long" (typically about 110 mm to about 121 mm).

[0142] Articles are also named according to the circumference of the product: "regular" (approximately 23-25 ​​mm), "wide" (over 25 mm), "slim" (approximately 22-23 mm), "demi-slim" (approximately 19-22 mm), "super-slim" (approximately 16-19 mm), and "micro-slim" (less than approximately 16 mm).

[0143] Thus, a king-size, super slim format article would have, for example, a length of about 83 mm and a circumference of about 17 mm. The articles described herein, as well as the aerosol-forming materials and mouthpieces thereof, can be made in any of the above formats, without being limited thereto.

[0144] Each format may be manufactured with segments of different lengths. As previously described, some segments contain at least one aerosol-generating material and a first plug or section of amorphous solid material. The rods are comprised of cylindrical segments that can be aligned and placed in abutting relation to form a rod-shaped consumable.

[0145] In some embodiments, the consumable can have a circumference of about 21 mm or about 23 mm. The length of the consumable can be, for example, 75 mm, 63 mm, 57 mm, or 48 mm. Some consumables can have a length of less than 35 mm. In such short consumables, the portion containing the aerosol-forming material can extend along about 50% to about 75% of the length of the consumable.

[0146] As previously described, the consumable includes an aerosol-generating segment including at least one aerosol-generating material and a mouthpiece segment including a section of amorphous solid material. The aerosol-generating segment can include multiple sections. At least one of the sections includes one or more aerosol-generating materials. Other sections may be cavities separating the sections of the consumable. In some embodiments, one or more of the sections in the aerosol-generating segment of the consumable can include the amorphous solid material as the aerosol-generating material.

[0147] Additionally or alternatively, the consumable mouthpiece segment may include multiple sections.

[0148] As used herein, the terms "upstream" and "downstream" are relative terms defined with respect to the direction in which mainstream aerosol is drawn through an article or device during use.

[0149] The mouthpiece segment can have a length of about 30 mm to 50 mm. Tipping paper can connect the mouthpiece to an adjacent portion of the consumable.

[0150] In some embodiments, the mouthpiece segment includes a section containing a filament tow material, such as cellulose acetate fiber tow. The filament tow may be formed using other materials used to form fibers, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1-4 butanediol succinate) (PBS), poly(butylene adipate-cotterephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers, or combinations thereof. If the material is cellulose acetate tow, the filament tow may be plasticized using an appropriate plasticizer for the tow, such as triacetin, or the tow may be unplasticized.

[0151] In some embodiments, the portion including filament tow material includes a plug or body of filament tow material.

[0152] In some embodiments, the mouthpiece segment includes a plug or body of filament tow material at the oral end. Alternatively or additionally, the mouthpiece segment includes a plug or body of filament tow material at the distal end, positioned adjacent to an adjacent portion of the consumable.

[0153] In some embodiments, the mouthpiece segment can include one or more hollow tubular elements.

[0154] In some embodiments, the mouthpiece segment includes a hollow tubular element at the oral end. Alternatively or additionally, the mouthpiece segment includes a hollow tubular element at the distal end, positioned adjacent to an adjacent portion of the consumable.

[0155] In some embodiments, the hollow tubular element is a paper tube, hi other embodiments, the hollow tubular element is formed from a filament tow.

[0156] It has been found that a hollow tubular element disposed in the mouthpiece advantageously significantly reduces the temperature of the outer surface of the mouthpiece at the downstream end of the mouthpiece that contacts the consumer's mouth during use. In addition, it has also been found that the use of a tubular element significantly reduces the temperature of the outer surface of the mouthpiece upstream of the hollow tubular element. Without wishing to be bound by theory, it is hypothesized that this is because the tubular element passes the aerosol near the center of the mouthpiece, thereby inhibiting the transfer of heat from the aerosol to the outer surface of the mouthpiece.

[0157] The "wall thickness" of a hollow tubular element corresponds to the thickness of the tube wall 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 wall of the hollow tubular element 4. However, if the wall thickness is not substantially constant, the wall thickness is preferably greater than 0.9 mm, more preferably greater than 1.0 mm, at any point around the hollow tubular element 4.

[0158] In some embodiments, the length of the hollow tubular element is less than about 20 mm. Optionally, the length of the hollow tubular element is less than about 15 mm or less than about 10 mm. Additionally or alternatively, the length of the hollow tubular element is at least about 5 mm, at least about 6 mm, or between about 5 mm and about 20 mm, between about 6 mm and about 10 mm, between about 6 mm and about 8 mm, or has a length of about 6 mm, 7 mm, or about 8 mm.

[0159] In some embodiments, the density of the hollow tubular element is at least about 0.25 grams per cubic centimeter (g / cc), at least about 0.3 g / cc, and / or less than about 0.75 grams per cubic centimeter (g / cc), or less than 0.6 g / cc. In some embodiments, the density of the hollow tubular element is 0.25-0.75 g / cc, 0.3-0.6 g / cc, 0.4-0.6 g / cc, or about 0.5 g / cc. These densities have been found to provide a good balance between the high hardness provided by higher density materials and the lower heat transfer characteristics of lower density materials. For purposes of the present invention, the "density" of the hollow tubular element refers to the density of the filament tow forming the element, including any incorporated plasticizer. Density can be determined by dividing the total weight of the hollow tubular element by the total volume of the hollow tubular element, which can be calculated using appropriate measurements of the hollow tubular element, for example, obtained with calipers. If necessary, the appropriate dimensions can be measured using a microscope.

[0160] In some embodiments, the hollow tubular element has an inner diameter greater than 3 mm. Smaller inner diameters may result in the aerosol passing through the mouthpiece 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. In some embodiments, the hollow tubular element has an inner diameter greater than 3.1 mm, more preferably greater than 3.5 mm or 3.6 mm. In one embodiment, the hollow tubular element has an inner diameter of about 3.9 mm.

[0161] In some embodiments, the hollow tubular element defines a void within the mouthpiece that acts as a cooling segment. The void provides a chamber through which heated volatile components generated by the aerosol-generating material flow. The hollow tubular element is hollow to provide a chamber for aerosol accumulation, yet is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and use of the consumable. The hollow tubular element provides a physical displacement between the aerosol-generating material and the plug of filter material. The physical displacement provided by the hollow tubular element provides a temperature gradient across the length of the hollow tubular element.

[0162] In some embodiments, the mouthpiece is at least 450 mm 3 The mouthpiece includes a cavity having an internal volume of at least this volume. It has been found that providing a cavity of at least this volume allows for improved aerosol formation. Such a cavity size provides sufficient space within the mouthpiece to allow for cooling of heated volatile components, which may result in an aerosol that is too warm, and thus allows the aerosol-generating material to be exposed to higher temperatures than would otherwise be possible.

[0163] In some embodiments, the hollow tubular element may be configured to provide a temperature difference of at least 40° C. between the heated volatilized components entering the first, upstream end of the hollow tubular element and the heated volatilized components exiting the second, downstream end of the hollow tubular element. Preferably, the hollow tubular element is configured to provide a temperature difference of at least 60° C., at least 80° C., or at least 100° C. This temperature difference across the length of the hollow tubular element protects the plug of temperature-sensitive filter material from the high temperatures of the aerosol-forming material when heated.

[0164] In some embodiments, the section of amorphous solid material is disposed adjacent to the aerosol-generation segment. The section of amorphous solid material can have a length of about 5 mm to about 20 mm. In some embodiments, the section of amorphous solid material can have a length of about 7 mm to about 15 mm.

[0165] In some embodiments, the consumable comprises two or more shorter sections of amorphous solid material, at least one of which is disposed in the mouthpiece segment.

[0166] In some embodiments, the portion containing at least one aerosol-generating material is located at the distal end of the consumable. This portion containing at least one aerosol-generating material can have a length of about 5 mm to about 20 mm. In some embodiments, this portion can have a length of about 7 mm to about 15 mm. Alternatively, the consumable can include two or more shorter portions of aerosol-generating material. In some embodiments, the portions of aerosol-generating material are longer than the section of amorphous solid material.

[0167] In some embodiments, the portion containing at least one aerosol-generating material may be located immediately adjacent to a section of amorphous solid material, or these portions of the consumable may be separated by a further portion containing, for example, a hollow tubular element or a plug of fibrous tow.

[0168] In some embodiments, the overall length of the portion of the consumable containing the aerosol-forming material and the amorphous solid material is between about 10 mm and about 50 mm, or between about 25 mm and about 40 mm.

[0169] In some embodiments, the aerosol-forming material is enclosed in a wrapper. The wrapper may be, for example, a paper or paper-lined foil wrapper. In this example, the wrapper is substantially non-breathable. In alternative embodiments, the wrapper has a breathability of less than 100 Coresta units, or less than 60 Coresta units. It has been found that wrappers with such low breathability enhance aerosol formation in the aerosol-forming material. Without wishing to be bound by theory, it is hypothesized that this is due to reduced loss of aerosol compounds through the wrapper. The breathability of the wrapper 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.

[0170] In some embodiments, the wrapper comprises aluminum foil. Aluminum foil has been found to be particularly effective in enhancing aerosol formation within the aerosol-generating material. For example, the aluminum foil can have a metal layer approximately 6 μm thick. In some embodiments, the aluminum foil has a paper backing. However, in alternative configurations, the aluminum foil may have other thicknesses, for example, a thickness of 4 μm to 16 μm. The aluminum foil need not have a paper backing; for example, it may have a backing formed from another material that helps to provide the foil with adequate tensile strength, or it may have no backing material at all. Metal layers or foils other than aluminum may also be used. The total thickness of the wrapper is preferably 20 μm to 60 μm, more preferably 30 μm to 50 μm, which provides a wrapper with adequate structural integrity and heat transfer properties. The tensile force that can be applied to the wrapper before it breaks may be greater than 3,000 grams of force, for example, 3,000 to 10,000 grams of force, or 3,000 to 4,500 grams of force.

[0171] In some embodiments, the consumable is ventilated. For example, the consumable can have a ventilation level of about 75% of the aerosol drawn through the article. In alternative embodiments, the consumable can have a ventilation level of 50% to 80%, e.g., 65% to 75%, of the aerosol drawn through the article. These levels of ventilation help slow the flow of aerosol drawn through the mouthpiece, thereby allowing the aerosol to cool sufficiently before it reaches the downstream end of the mouthpiece. Ventilation may be provided directly in the mouthpiece of the article. In some embodiments, venting is provided in a hollow tubular element of the mouthpiece, which has been found to be particularly advantageous in aiding the aerosol generation process.

[0172] In some embodiments, the vent is provided by first and second parallel rows of perforations, formed, for example, as laser perforations, located 15 mm to 20 mm from the downstream oral end of the mouthpiece. In alternative embodiments, the vent may be provided elsewhere in the mouthpiece, for example in the body of material or the hollow tubular element at the oral end.

[0173] In some embodiments, the aerosol-generating segment of the consumable is a cylindrical rod of aerosol-generating material. Regardless of the form or configuration of the aerosol-generating material, the aerosol-generating material preferably has a length of about 10 mm to 100 mm. In some embodiments, the length of the aerosol-generating material is preferably about 25 mm to 50 mm, more preferably about 30 mm to 45 mm, and even more preferably about 30 mm to 40 mm.

[0174] The volume of the aerosol-generating material provided is approximately 200 mm 3 ~approx. 4300mm 3 , approximately 500 mm 3 ~1500mm 3 , or approximately 1000 mm 3 ~approx. 1300mm 3These volumes can vary, for example, in the range of about 1000 mm 3 ~approx. 1300mm 3 It has been found advantageous to provide a superior aerosol with higher visibility and perceptibility than that achieved with a volume selected from the lower end of the range.

[0175] The mass of aerosol-forming material provided may be greater than 200 mg, for example, between about 200 mg and 400 mg, between about 230 mg and 360 mg, or between about 250 mg and 360 mg. Providing a larger mass of aerosol-forming material has been found to be advantageous in improving sensory performance compared to aerosols generated from smaller masses of tobacco material.

[0176] Delivery System As used herein, the term "delivery system" is intended to encompass systems that deliver at least one substance to a user, including non-combustion aerosol delivery systems that release compounds from an aerosol-forming material without burning the aerosol-forming material, such as electronic cigarettes, tobacco heating products, and hybrid systems for generating aerosols using a combination of aerosol-forming materials.

[0177] According to the present disclosure, a "non-combustible" aerosol delivery system is one in which the aerosol-generating materials (or components thereof) that are components of the aerosol delivery system do not burn or combust to facilitate delivery of at least one substance to a user.

[0178] In some embodiments, the delivery system is a non-combustible aerosol delivery system, such as a powered non-combustible aerosol delivery system.

[0179] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a tobacco heating system.

[0180] In some embodiments, the non-combustion aerosol delivery system generates an aerosol using a combination of aerosol-forming materials, one or more of which may be heated, each of which may or may not contain nicotine.

[0181] Generally, a non-combustible aerosol delivery system can include a non-combustible aerosol delivery device and a consumable item for use with the non-combustible aerosol delivery device.

[0182] A non-combustion aerosol delivery device, also referred to herein as an aerosol generator, is an apparatus 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, releasing one or more volatile substances from the aerosol-generating material to form an aerosol. In some embodiments, the aerosol generator is configured to generate the aerosol from the aerosol-generating material without applying heat. For example, the aerosol generator may be configured to apply one or more of vibration, high pressure, or electrostatic energy to the aerosol-generating material.

[0183] In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, can include a power source and a controller. The power source can be, for example, an electrical source or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon substrate to which energy can be applied to dissipate power in the form of heat to an aerosol-generating material or a heat-transfer material proximate the heat-generating power source.

[0184] In some embodiments, the non-combustible aerosol delivery system can include an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0185] In some embodiments, the non-combustion aerosol delivery device heats different portions of the consumable separately, e.g., for different times and / or at different temperatures, and the consumable design accommodates heating arrangements that ensure the different aerosol-generating materials are heated to the correct temperatures to provide an aerosol for inhalation having the desired composition.

[0186] In some embodiments, the non-combustion aerosol delivery system comprises a device with two or more heating zones, which can separately heat different parts of the aerosol-generating segment of the consumable, meaning that the design of the consumable can be configured to best utilize the heating zones.

[0187] Different parts or portions of the aerosol-generating segment of the consumable may be heated to different temperatures, or the heating zones may be activated at different times.

[0188] In the drawings described herein, the same reference numerals are used to denote like features, items or components.

[0189] FIG. 1 is a cross-sectional side view of a consumable or article 1 for use in an aerosol delivery system according to a first embodiment.

[0190] Article 1 comprises a mouthpiece 2 and an aerosol-generation segment 3. The aerosol-generation segment comprises a cylindrical rod containing a section or plug of aerosol-generating material 5. The mouthpiece segment comprises a section of amorphous solid material 4 and a mouth-end plug of filament tow material 6. Disposed between the portion of aerosol-generating material 5 and the section of amorphous solid material 4 is a hollow tubular element 7. In the illustrated embodiment, hollow tubular element 7 is a cardboard tube.

[0191] Although described above in the form of a rod, the aerosol-forming material may be provided in other forms, such as a plug, pouch, or packet of material within the article.

[0192] In some embodiments, the aerosol-forming material 5 is tobacco material. In the illustrated example, the tobacco material preferably comprises reconstituted tobacco material. Alternatively, or in addition, the tobacco material may comprise any of the forms described herein. The tobacco material contains between 10% and 90% by weight of tobacco leaf, with the aerosol-forming material being provided in an amount of up to about 10% by weight of the leaf tobacco, and the remainder of the tobacco material comprising reconstituted tobacco.

[0193] In the illustrated example, the amorphous solid material is a dry gel comprising menthol. In alternative embodiments, the amorphous solid material can have any of the compositions described herein.

[0194] In the embodiments described herein, the amorphous solid material can be incorporated into the article in the form of a sheet. The sheet of amorphous solid material can be incorporated as a flat sheet, as a collected or bundled sheet, as a pressed sheet, or as a rolled sheet (i.e., in the form of a tube). In some such cases, the amorphous solid material of these embodiments can be included in the aerosol product article as a sheet, such as a sheet surrounding a rod of aerosolizable material (e.g., tobacco). For example, the sheet of amorphous solid material can be formed into a wrapping paper that surrounds an aerosolizable material such as tobacco. Alternatively, the amorphous solid material in sheet form can be shredded before being incorporated into the article. In some embodiments, the shredded material comprises elongated strips of amorphous solid material. The elongated strips can be substantially aligned with the longitudinal axis of the consumable article.

[0195] The segment containing the aerosol-forming material 3 may be provided in the form of a rod containing cut rag reconstituted tobacco. The aerosol-forming material may be any of the materials described herein.

[0196] FIG. 2 is a cross-sectional side view of an alternative embodiment of a consumable or article 1 for use in an aerosol delivery system.

[0197] In this embodiment, article 1 comprises a mouthpiece 2 comprising a hollow tubular element 7 at its oral end adjacent to a section of amorphous solid material 4, which in turn abuts a further hollow tubular element 7. Article 1 further comprises an aerosol-generating segment 3 comprising a section of aerosol-generating material 5.

[0198] In the embodiment shown, the mouth end hollow tubular element 8 is formed from filament tow material. The other hollow tubular elements 7 may be paper tubes.

[0199] 3, in a further embodiment, mouthpiece 2 of article 1 comprises a hollow tubular element 8 at its oral end adjacent to a plug of material such as filament tow 6, the other end of which abuts a section of amorphous solid material 4. A further hollow tubular element 7 is disposed between the section of amorphous solid material 4 and the section of aerosol-forming material 5.

[0200] In the illustrated embodiment, the mouth end hollow tubular element 8 is formed from filament tow material. The plug of filament tow 6 has a frangible capsule 9 embedded within the material, the capsule having a payload that holds a flavoring agent. Such a capsule may be included in the plug of filament tow shown in FIG. 3 or any other suitable section of the consumable in any of the illustrated consumables.

[0201] 4, a section of amorphous solid material 4 is positioned adjacent to the aerosol-generating segment 3. In this embodiment, the mouthpiece 2 of the article 1 comprises a hollow tubular element 8 at its mouth end adjacent to a plug of material such as a filament tow 6, the other end of which abuts a further hollow tubular element 7.

[0202] 5, a longer section of amorphous solid material 4 is positioned adjacent to the aerosol-generating segment 3. In this embodiment, the mouthpiece 2 of the article 1 comprises a hollow tubular element 8 at its oral end adjacent to a plug of material such as a filament tow 6, the other end of which abuts the section of amorphous solid material 4.

[0203] In the embodiment shown in Figures 1-5, Article 1 has a circumference of approximately 21 mm (i.e., the article is in a demi-slim format). In other embodiments, the article may be provided in any of the formats described herein, for example, having a circumference of 15 mm to 25 mm. Because the article is heated to release the aerosol, improved heating efficiency can be achieved using articles having smaller circumferences within this range, for example, circumferences less than 23 mm. It has also been found that article circumferences greater than 19 mm are particularly effective for achieving improved aerosol upon heating while maintaining an adequate product length. Articles having circumferences of 19 mm to 23 mm, more preferably 20 mm to 22 mm, have been found to provide a good balance between effective aerosol delivery and allowing efficient heating.

[0204] The circumference of each section of the rod is approximately the same, allowing for a smooth transition between sections. In the illustrated embodiment, the circumference of each section is approximately 20.8 mm. One or more wrappers are wrapped around and attached to the rod-shaped consumable to hold each section in place. The wrapper is selected to have acceptable tensile strength while being flexible enough to wrap around the article 1 and attach to itself along the longitudinal lap seam of the paper. After wrapping, the circumference of the rod is approximately 21 mm.

[0205] According to the embodiments described herein, a pack may be provided that includes a plurality of the consumables or articles described herein.

[0206] Figure 6 shows an example of a non-combustion aerosol delivery device 100 for generating an aerosol from an aerosol-generating medium / material, such as the aerosol-generating material of the consumables 110 described herein. Generally, device 100 can be used to heat a replaceable article 110 containing an aerosol-generating medium, such as article 1 shown in any one of Figures 1-5 or described elsewhere herein, to generate an aerosol or other inhalable medium that is inhaled by a user of device 100. Device 100 and replaceable article 110 together form a system.

[0207] The device 100 comprises a housing 102 (in the form of an outer cover) that surrounds and houses the various components of the device 100. The device 100 has an opening 104 at one end through which an item 110 can be inserted for heating by a heating assembly. In use, the item 110 can be fully or partially inserted into the heating assembly, and the item 110 can be heated by one or more components of the heating assembly.

[0208] The device 100 of this example includes a first end member 106 including a lid 108 that is movable relative to the first end member 106 to close the opening 104 when the item 110 is not in place. In Figure 6, the lid 108 is shown in an open configuration, but the lid 108 can be moved to a closed configuration. For example, a user can slide the lid 108 in the direction of arrow "B."

[0209] Device 100 may include a user-operable control element 112, such as a button or switch that, when pressed, operates device 100. For example, a user may turn device 100 on by operating switch 112.

[0210] Device 100 may include an electrical component, such as a socket / port 114, that can accept a cable for charging a battery in device 100. For example, socket 114 may be a charging port, such as a USB charging port.

[0211] For the avoidance of doubt, when amounts are expressed in weight percent (wt%) in the compositions described herein, this refers to a dry weight basis unless otherwise specified. Therefore, any water that may be present in the tobacco material, or any of its components, is completely ignored for purposes of determining the wt%. The moisture content of the tobacco material described herein may vary, for example, from 5 to 15 wt%. The moisture content of the tobacco material described herein may vary depending on, for example, the temperature, pressure, and humidity conditions under which the composition is maintained. The moisture content can be determined by Karl Fischer analysis, as known to those skilled in the art. For the avoidance of doubt, even if the aerosol-forming material is a liquid-phase component, such as glycerol or propylene glycol, any components other than water are included in the weight of the tobacco material. However, when an aerosol-forming material is provided in the tobacco component of the tobacco material, or in the filler component (if present) of the tobacco material, instead of or in addition to being added separately to the tobacco material, the aerosol-forming material is not included in the weight of the tobacco component or filler component, but is included in the weight of the "aerosol-forming material" at the wt% defined herein. Any other materials present in the tobacco component are included in the weight of the tobacco component, even if they are of non-tobacco origin (eg, non-tobacco fiber in the case of reconstituted tobacco).

[0212] The various embodiments described herein are presented merely to aid in the understanding and teaching of the claimed features. These embodiments are presented as merely representative examples of embodiments and are not intended to be comprehensive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be construed as limiting the scope of the invention as 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. Various embodiments of the invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those explicitly set forth herein. Additionally, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. 1. A consumable for use in a non-flammable aerosol delivery system, comprising: an aerosol-generating segment including at least one aerosol-generating material; a mouthpiece segment including a section of amorphous solid material; Equipped with The consumable product, wherein the amorphous solid material comprises a gelling agent.

2. 10. The consumable of claim 1, having the form of a rod having a first end and a second end, the rod including a plurality of portions, one of the plurality of portions including a section of the amorphous solid material and at least one portion including at least one aerosol-forming material.

3. 3. The consumable product of claim 1 or 2, wherein the section of amorphous solid material comprises a collected sheet of amorphous solid material.

4. 3. The consumable product of claim 1 or 2, wherein the section of amorphous solid material comprises an elongated strip of amorphous solid material.

5. The consumable of claim 4 , wherein the elongated strip is substantially aligned with a longitudinal axis of the consumable.

6. The consumable product of any one of claims 1 to 5, wherein the amorphous solid material has a thickness of about 0.5 mm to about 2 mm or about 1 mm to about 2 mm.

7. The consumable product of any one of claims 1 to 6, wherein the amorphous solid material is provided on a support material.

8. The consumable product of claim 7 , wherein the support material is paper or foil.

9. The consumable of claim 7 or 8, wherein the support material comprises a susceptor.

10. The consumable product of any one of claims 1 to 9, wherein the amorphous solid material is compressed.

11. 10. The consumable product of claim 1, wherein the gelling agent is one or more selected from the group consisting of carboxymethylcellulose, alginate, pectin, gelatin, polysaccharides, guar gum, and carrageenan.

12. The consumable product of any one of claims 1 to 11, wherein the amorphous solid material comprises an aerosol-forming material.

13. 13. The consumable product of claim 12, wherein the aerosol-forming material is one or more selected from the group consisting of erythritol, propylene glycol, glycerol, vegetable glycerin, triacetin, sorbitol, and xylitol.

14. The consumable product of any one of claims 1 to 13, wherein the amorphous solid material comprises a flavoring agent.

15. The consumable product described in claim 14, wherein the flavoring is menthol.

16. The consumable product of any one of claims 1 to 15, wherein the at least one aerosol-forming material in the portion comprises tobacco material.

17. A consumable product as described in claim 16, wherein the tobacco material includes regenerated tobacco material, and optionally includes paper regenerated tobacco material.

18. A consumable product according to any preceding claim, wherein the mouthpiece segment further comprises a body of fibrous material.

19. A consumable product according to any preceding claim, wherein the mouthpiece segment comprises a hollow tubular element.

20. 20. The consumable product of claim 19, wherein the hollow tubular element is a paper tube or is formed from a filament tow.

21. 21. The consumable product of claim 19 or 20, wherein the hollow tubular element is disposed between the section of amorphous solid material and the portion containing the aerosol-forming material.

22. The consumable product of any preceding claim, wherein the section of amorphous solid material and the portion containing the aerosol-forming material are immediately adjacent to each other.

23. A consumable product according to any one of the preceding claims, comprising a hollow tubular element at the oral end.

24. The consumable product of any one of claims 1 to 23, wherein the mouthpiece segment comprises one or more flavour modifying elements.

25. 25. The consumable product of claim 24, wherein the flavor modification element is a capsule.

26. a non-combustible aerosol delivery device; A consumable product according to any one of claims 1 to 25; A non-flammable aerosol delivery system comprising:

27. A method for manufacturing a consumable product according to any one of claims 1 to 25, comprising collecting a sheet of amorphous solid material to form a section of amorphous solid material.

28. 26. A method for manufacturing a consumable product according to any one of claims 1 to 25, comprising cutting a sheet of amorphous solid material to form a plurality of strips of amorphous solid material from which sections of amorphous solid material are formed.

29. 29. The method of claim 28, wherein the strips have a cut length of at least about 5 mm.

30. Use of a section of amorphous solid material including a gelling agent in a consumable to reduce the temperature of the aerosol during use of the consumable in a non-combustible aerosol delivery system.

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