Articles used in non-flammable aerosol delivery systems

Abstract

An article (2) for use in a non-flammable aerosol delivery system is described, the article (2) comprising an aerosol generating material (3), a heating element (13) for heating the aerosol generating material, and an electrical connector arrangement (14) for removably connecting the heating element to a power source. A non-flammable aerosol generating system is also described, the system comprising the article, a method of making the article, a heating element for use in the non-flammable aerosol delivery system, and a non-flammable aerosol delivery system comprising the heating element.

Description

[Technical Field]

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

[0002] During use, aerosol generating systems generate an aerosol that is inhaled by a user. For example, tobacco heating devices heat an aerosol-generating substrate, such as tobacco, to form an aerosol by heating without combustion. Some aerosol generating systems generally include a mouthpiece through which the aerosol passes and reaches the user's mouth. Summary of the Invention

[0003] According to a first aspect, the present specification provides an article for use in a non-flammable aerosol delivery system, the article comprising: an aerosol-generating material; a heating element for heating the aerosol-generating material; and an electrical connector arrangement for removably connecting the heating element to a power source.

[0004] According to a second aspect, there is provided a non-flammable aerosol generation system comprising an article according to the first aspect and an aerosol generation device comprising a power source configured to contact the electrical connector and thereby transfer power to a heating element of the article.

[0005] According to a third aspect, there is provided a method of manufacturing an article according to the first aspect, the method comprising the steps of providing an aerosol-generating material; inserting a heating element into the aerosol-generating material; and providing an electrical connector arrangement for removably connecting the heating element to a power source.

[0006] According to a fourth aspect, there is provided a heating element for use in a non-flammable aerosol delivery system, the heating element comprising an electrical connector arrangement for removably connecting the heating element to a power source.

[0007] According to a fifth aspect, there is provided a non-flammable aerosol delivery system comprising: an aerosol delivery device comprising a heating element according to the fourth aspect; a power source configured to electrically connect to the heating element; and an article for use in the non-flammable aerosol delivery system, the article comprising an aerosol-generating material configured to receive the heating element.

[0008] 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]

[0009] [Figure 1] 1 is a side cross-sectional view of an article for use with a non-flammable aerosol delivery device, including a mouthpiece and a heating element. [Figure 2a] FIG. 1 is a side cross-sectional view of a further article for use with a non-flammable aerosol delivery device, in this example an article including a capsule-containing mouthpiece. [Figure 2b] 2b is a cross-sectional view of the capsule-containing mouthpiece shown in FIG. 2a. [Figure 3] FIG. 1 is a side cross-sectional view of an article for use with a non-flammable aerosol delivery device having a mouthpiece and an alternative heating element. [Figure 4] FIG. 1 is a side cross-sectional view of an article for use with a non-flammable aerosol delivery device having a mouthpiece and an alternative heating element. [Figure 5a] 2 is a cross-sectional view of a non-flammable aerosol delivery device with the article of FIG. 1 inserted therein. [Figure 5b] 2 is a cross-sectional view of the non-flammable aerosol delivery device with the article of FIG. 1 inserted therein, the article having an alternative electrical connector configuration. [Figure 6] 4 is a cross-sectional view of a non-flammable aerosol delivery device with the article of FIG. 3 inserted therein. [Figure 7] FIG. 7 is a simplified schematic diagram of components within the housing of the aerosol delivery device shown in FIGS. 5a, 5b, and 6. DETAILED DESCRIPTION OF THE INVENTION

[0010] As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user; combustible aerosol delivery systems, such as cigarettes for pipes, roll-up or rewind cigarettes, cigars, and tobacco (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smokable materials); a non-combustible aerosol delivery system that releases compounds from an aerosol-generating material without burning the aerosol-generating material, such as an e-cigarette, a tobacco heating product, and a hybrid system that generates an aerosol using a combination of aerosol-generating materials; and aerosol-free delivery systems that deliver at least one substance to a user orally, nasally, transdermally, or otherwise without forming an aerosol, including, but not limited to, oral products such as lozenges, gums, patches, articles containing inhalable powders, and oral tobacco products including snuff or moist snuff, wherein the at least one substance may or may not contain nicotine.

[0011] According to this disclosure, a "non-flammable" aerosol delivery system is one in which the constituent aerosol-generating materials (or components thereof) of the aerosol delivery system are not combusted or burned to facilitate delivery of at least one substance to a user.

[0012] In some embodiments, the delivery system is a non-flammable aerosol delivery system, such as a powered non-flammable aerosol delivery system.

[0013] In some embodiments, the non-combustible aerosol delivery system is an electronic cigarette, also known as a vaporizer or electronic nicotine delivery system (END), although it should be noted that the presence of nicotine in the aerosol-generating material is not a requirement.

[0014] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. One example of such a system is a tobacco heating system.

[0015] In some embodiments, the non-combustible aerosol delivery system is a hybrid system that generates aerosol using a combination of aerosol-generating materials, one or more of which can be heated. Each of the aerosol-generating materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-generating material and a solid aerosol-generating material. The solid aerosol-generating material may, for example, include tobacco or a non-tobacco product.

[0016] Typically, a non-flammable aerosol delivery system may include a non-flammable aerosol delivery device and consumables for use with the non-flammable aerosol delivery device.

[0017] In some embodiments, the present disclosure relates to consumables that include aerosol-generating materials and are configured for use with non-flammable aerosol delivery devices. These consumables may be referred to as articles throughout this disclosure.

[0018] As used herein, the terms "upstream" and "downstream" are relative terms defined with respect to the direction of mainstream aerosol being drawn through the article or device in use.

[0019] In some embodiments, a non-combustible aerosol delivery system, such as the non-combustible aerosol delivery device, can include a power source and a controller. The power source can be, for example, a power source or a heat generating power source. In some embodiments, the heat generating power source includes a carbon substrate that can be energized to deliver power in the form of heat to an aerosol-generating material or a heat transfer material proximate the heat generating power source.

[0020] In some embodiments, the non-flammable aerosol delivery system comprises an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0021] In some embodiments, consumables for use with a non-flammable aerosol delivery device may include an aerosol-generating material, an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol generator, an aerosol-generating area, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0022] In some embodiments, the consumable product includes a substance to be delivered. The substance to be delivered may be an aerosol-generating material or a material not intended to be aerosolized. Optionally, either material may include one or more active ingredients, one or more flavoring agents, one or more aerosol-forming materials, and / or one or more other functional materials.

[0023] In some embodiments, the substance to be delivered comprises an active agent.

[0024] As used herein, the term "active substance" may refer to 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, nutritional supplements, and psychoactive substances. The active substance may be naturally occurring or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, thiamin, 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 plant.

[0025] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0026] As described herein, the active substance may comprise or be derived from one or more plants or their components, derivatives, or extracts. As used herein, the term "botanical" 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 a synthetically obtained active compound naturally occurring in the plant. The material may be in the form of a liquid, gas, solid, powder, dust, crushed particles, granules, pellets, chips, strips, sheets, etc. Examples of plants 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, perilla, curcuma, turmeric, sandalwood, coriander, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, ribeye, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha arventis, Mentha cv, Mentha niliaca, Mentha piperita, Mentha piperita citrata cv, Mentha piperita cv, Mentha spicata crispa, Mentha cardifolia, Mentha longifolia, Mentha suaveolens variegata, Mentha pulegium, Mentha spicata cv and Mentha suaveolens.

[0027] In some embodiments, the active agent comprises or is derived from one or more plants or components, derivatives or extracts thereof, and the plant is tobacco.

[0028] In some embodiments, the active agent comprises or is derived from one or more plants or components, derivatives, or extracts thereof, wherein the plants are selected from eucalyptus, star anise, cocoa, and hemp.

[0029] In some embodiments, the active agent comprises or is derived from one or more plants or components, derivatives or extracts thereof, wherein the plants are selected from rooibos and fennel.

[0030] In some embodiments, the substance to be delivered comprises a flavoring agent.

[0031] As used herein, the terms "flavor" and "flavoring agent" refer to materials that may be used, where local regulations permit, to create a desired taste, aroma, or other somatic sensation in products intended for adult consumers.They may be derived from naturally occurring flavoring materials, plants, plant extracts, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, peppermint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruits, paprika, etc.). Ear, rhubarb, grape, 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, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine , ylang-ylang, sage, fennel, wasabi, pimento, ginger, coriander, coffee, hemp, mint oil from Mentha species, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, yerba mate, orange skin, rose, tea such as green or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, perilla, curcuma, coriander, myrtle, black currant, valerian, pimento, The additives may include other additives such as: mace, damian, marjoram, olive, lemon balm, lemon basil, chives, kalbi, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter 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 charcoal, chlorophyll, minerals, botanicals, or breath fresheners.They may be imitation, synthetic or natural ingredients or blends thereof. They may be in any suitable form, for example, a liquid such as an oil, a solid such as a powder, or a gas.

[0032] In some embodiments, the flavoring agent comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring agent comprises cucumber, blueberry, citrus, and / or red berry flavoring components. In some embodiments, the flavoring agent comprises eugenol. In some embodiments, the flavoring agent comprises a flavoring component extracted from tobacco. In some embodiments, the flavoring agent comprises a flavoring component extracted from cannabis.

[0033] In some embodiments, flavoring agents may include those intended to achieve somatic sensations, usually chemically induced and perceived by stimulation of the fifth cranial nerve (trigeminal nerve), in addition to or instead of aroma or taste sensations, and these may include agents that provide heating, cooling, tingling, or numbing effects. Suitable heating agents may be, but are not limited to, vanillyl ethyl ether, and suitable cooling agents may be, but are not limited to, eucoliptol, WS-3.

[0034] An aerosol-generating material is a material that can generate an aerosol when, for example, heated, irradiated, or otherwise energized. The aerosol-generating material may be in the form of a solid, liquid, or gel, which may or may not contain an active substance and / or flavoring. The aerosol-generating material may also be incorporated into an article for use in an aerosol generating system.

[0035] As used herein, the term "tobacco material" refers to any material containing tobacco or its derivatives or substitutes. The tobacco material may be in any suitable form. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco lamina, reconstituted tobacco, and / or tobacco extract.

[0036] A consumable is an article containing or consisting of an aerosol-generating material, some or all of which is intended to be consumed during use by a user. A consumable may include one or more other components, such as an aerosol-generating material storage area, an aerosol-generating material transfer component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. A consumable may also include an aerosol generator, such as a heater, that emits heat to cause the aerosol-generating material to generate an aerosol during use. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor.

[0037] A susceptor is a material that can be heated by penetration with a changing magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, such that penetration by the changing magnetic field causes induction heating of the heating material. The heating material may be a magnetic material, such that penetration by the changing magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, such that the susceptor is heatable by both heating mechanisms. An apparatus configured to generate a changing magnetic field is referred to herein as a magnetic field generator.

[0038] 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 other property of the aerosol. The aerosol modifier may be provided in an aerosol modifier-releasing component operable to selectively release the aerosol modifier.

[0039] 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 filtering material.

[0040] An aerosol generator is a device configured to generate an aerosol from an aerosol-generating material. In some embodiments, the aerosol generator is a heater configured to provide thermal energy to the aerosol-generating material to release one or more volatile substances from the aerosol-generating material and form an aerosol. In some embodiments, the aerosol generator is configured to generate an aerosol from the aerosol-generating material without heating. For example, the aerosol generator may be configured to apply one or more of vibration, pressure increase, or electrostatic energy to the aerosol-generating material.

[0041] The filamentary tow material described herein can include cellulose acetate fiber tow. The filamentary tow can also be formed using other materials used to form fibers, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers, or combinations thereof. The filamentary tow can be plasticized with a tow-appropriate plasticizer, such as triacetin, when the material is cellulose acetate tow, or the tow can be unplasticized. The tow can have any suitable specifications, such as fibers with other cross sections, such as a "Y" or "X" shape, and have a filamentary denier value of 2.5 to 15 denier per filament, e.g., 8.0 to 11.0 denier per filament, and a total denier value of 5,000 to 50,000, e.g., 10,000 to 40,000.

[0042] In the figures described herein, like reference numerals are used to denote equivalent features, items or components.

[0043] FIG. 1 is a side cross-sectional view of an article 1 for use in an aerosol delivery system.

[0044] Article 1 comprises a mouthpiece 2 and an aerosol-generating section connected to mouthpiece 2. In this example, the aerosol-generating section comprises a source of aerosol-generating material in the form of a cylindrical rod of aerosol-generating material 3. In other examples, the aerosol-generating section may comprise a cavity for receiving the source of aerosol-generating material.

[0045] The article 1 further includes a heating element 13 for heating the aerosol-generating material 3. The heating element 13 may be at least partially disposed within the aerosol-generating material 3. In this example, the heating element 13 is embedded in the aerosol-generating material 3. Thus, the heating element is configured to heat the aerosol-generating material internally. However, in other examples, a portion of the heating element 13 may be disposed external to the aerosol-generating material. For example, a portion of the heating element 13 may protrude outside the aerosol-generating material 3. In another example, the heating element 13 may be disposed around the outer periphery of the rod of aerosol-generating material 3 so that heat is applied to the outer surface of the aerosol-generating material 3.

[0046] Heating element 13 may be any suitable heating element capable of receiving electrical power to generate an electrical current in element 13, whereby the resistance of heating element 13 to the flow of electrical current generates heat. For example, heating element 13 may be any electrically conductive material, such as a metal. In this example, heating element 13 is an electrically conductive metal.

[0047] The article further comprises an electrical connector arrangement 14 for removably connecting the heating element to a power source. As described in more detail below with reference to FIG. 3, the article 1 is configured for use in a non-flammable aerosol delivery device comprising a power source for transmitting power to the heater element 13. The electrical connector arrangement 14 may be provided in physical contact with the heating element 13 or may form part of the heating element. In particular, the electrical connector arrangement 14 is electrically connected to the heater element 13 and configured to removably connect the heating element 13 to a power source.

[0048] The electrical connector arrangement may be provided to protrude from or be flush with the outer surface of the article 1. In this example, the electrical connector protrudes from the upstream end of the aerosol-forming material. Additionally, as shown in FIG. 1, the electrical connector arrangement may be provided to protrude from the upstream end of the aerosol-forming material 3, forming the most upstream end of the article.

[0049] 1, the electrical connector arrangement 14 and the heating element 13 together form a pin inserted into the aerosol-generating material 3, with the heating element 13 being a first pin portion of the pin extending along the length of the aerosol-generating material 3 and the electrical connector arrangement 14 being a second pin portion connected to the first pin portion and extending generally perpendicular to the length of the article. Thus, the pin, including the heating element 13 and the electrical connector arrangement 14, provides a single, simple element capable of receiving electrical energy from a power source provided in contact with the electrical connector arrangement 14 and generating an electrical current to generate heat and heat the aerosol-generating material.

[0050] The second pin portion 14 may be provided to cover the outer surface of the most upstream end of the aerosol-generating material 3, thereby forming a cap at the most upstream end of the article. In this way, during insertion of the heating element 13, the second pin portion 14 serves as a cap on the end of the article. This may help prevent aerosol-generating material, which may be dislodged during insertion of the heating element 13, from falling off the rod of aerosol-generating material 3, thereby improving the user experience. Furthermore, during use of the article 1 with an aerosol generating device, the second pin portion 14, acting as a cap, may prevent condensation generated during use from dripping onto the aerosol generating device and avoid contact between the electronics of the aerosol generating device and condensation from the article 1. Furthermore, the appearance of the article may be neat and tidy.

[0051] The first pin portion 13 corresponding to the heating element may extend along substantially the entire length of the rod of aerosol-generating material 3 when the pins 13, 14 are inserted into the rod of aerosol-generating material 3. In other examples, the first pin portion 13 may extend only partway along the rod of aerosol-generating material 3. In examples, the pin length may be between 10 mm and 25 mm. In some examples, the pin length may be between 11 mm and 23 mm. In some examples, the pin length may be between 11 mm and 12.5 mm. In other examples, the pin length may be between 20 mm and 23 mm. Those skilled in the art will recognize that the pins may be any suitable length.

[0052] The electrical connector 14 may be formed of any suitable electrically conductive material to transfer power from the power source to the heating element 13. In particular, the electrical connector may be metallic. The resistivity of the metal forming the electrical connector 14 may be substantially the same as or similar to the resistivity of the metal forming the heating element 13, such that the electrical connector 14 also generates heat when current is transferred therethrough, in addition to the heating element 13.

[0053] In some examples, the electrical connector arrangement 14 includes a magnetic material. The magnetic material may be a ferromagnetic material, such as iron. As described in more detail below, when coupled to an aerosol generating device having a power source including an electromagnet, the electrical connector arrangement 14 can thus magnetically couple to the electromagnet when the electromagnet is activated. This can help improve contact between the electrical connector arrangement 14 and thereby improve the efficiency of electrical transfer to the heating element. Furthermore, the magnetic coupling can help secure the article 1 within the aerosol generating device.

[0054] The electrical connector arrangement 14 preferably includes two terminal portions. For example, the surface of the second pin portion 14 may be divided into two portions each functioning as a terminal for contacting a respective electrical terminal of the power source of the aerosol generating device.

[0055] The heating element 13 and electrical connector arrangement 14 may be provided in the aerosol-generating material 3 during manufacture of the article 1. In this way, the user does not need to insert a heater that forms part of the aerosol-generating device or a separate heater pin into the aerosol-generating material 3. This avoids pin breakage, which can sometimes occur when a user inserts a pin into the aerosol-generating material 3. However, in other examples, the pin may be provided separately for the user to insert themselves prior to use.

[0056] The aerosol-generating material may include multiple strands or strips of aerosol-generating material. For example, the aerosol-generating material may include multiple strands or strips of aerosolizable material and / or multiple strands or strips of amorphous solid, as described below. In some embodiments, the aerosol-generating material consists of multiple strands or strips of aerosolizable material.

[0057] In this example, a cylindrical rod of aerosol-forming material 3 includes multiple strands and / or strips of aerosol-forming material and is surrounded by a wrapper 10. In this example, wrapper 10 is a moisture-impermeable wrapper.

[0058] In this example, wrapper 10 may be pre-perforated or formed of highly porous paper. In this manner, airflow can be introduced into the rod of aerosol-forming material to allow airflow as the user inhales on the article. This may be useful when second pin portion 14 covers the end face of the article to reduce or prevent air from otherwise flowing through the article from the end of the rod.

[0059] In the examples described herein, the electrical connector arrangement 14 is a conductive electrical connector arrangement 14. However, in other examples, the electrical connector arrangement 14 may be an inductive electrical connector arrangement. That is, the second pin portion 14 may be provided in the form of an induction coil, such as a pancake induction coil. Thus, the second pin portion 14 may receive inductively generated power from a power source, such as an induction transmitter within the aerosol-forming device. The coil may be configured to conduct power through the heating element 13 of the pin, thereby heating the aerosol-forming material 3.

[0060] It will be appreciated that any other suitable means for conductively or inductively transferring power to heating element 13 to heat the aerosol-forming material may be utilized.

[0061] Multiple strands or strips of aerosol-generating material may be aligned within the aerosol-generating section with their longitudinal dimensions aligned parallel to the longitudinal axis X-X' of the article 1. Alternatively, the strands or strips may be generally disposed with their aligned longitudinal dimensions transverse to the longitudinal axis of the article.

[0062] At least about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, or 95% of the plurality of strands or strips may be arranged such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the article. A majority of the strands or strips may be arranged such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the article. In some embodiments, between about 95% and about 100% of the plurality of strands or strips are arranged such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the article. In some embodiments, substantially all of the strands or strips are arranged in the aerosol-generation section of the article such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the aerosol-generation section.

[0063] If the majority of the strands or strips are positioned in the aerosol-generating section with their longitudinal axes parallel to the longitudinal axis of the aerosol-generating section of the article, the force required to insert the heater element into the aerosol-generating material can be relatively low. If the heater element is inserted during manufacture, this can result in an article that is easier to manufacture. If the heater element is inserted by the user prior to use, this results in an article that is easier to use.

[0064] In this example, the rod of aerosol-forming material 3 has a circumference of about 22.7 mm. In alternative embodiments, the rod of aerosol-forming material 3 may have any suitable circumference, for example, from about 20 mm to about 26 mm.

[0065] Mouthpiece 2 includes a cooling section 8, also referred to as a cooling element, positioned immediately downstream and adjacent to aerosol-forming material 3. In this example, cooling section 8 is in abutting relationship with a source of aerosol-forming material. Mouthpiece 2 also includes, in this example, a body of material 6 downstream of cooling section 8 and a hollow tubular element 4 downstream of body of material 6 at the mouth end of article 1.

[0066] The cooling section 8 comprises a hollow channel having an inner diameter of about 1 mm to about 4 mm, for example, about 2 mm to about 4 mm. In this example, the inner diameter of the hollow channel is about 3 mm. The hollow channel extends along the entire length of the cooling section 8. In this example, the cooling section 8 comprises a single hollow channel. In alternative embodiments, the cooling section can comprise multiple channels, for example, two, three, or four channels. In this example, the single hollow channel is generally cylindrical, but in alternative embodiments, other channel shapes / cross-sections may be used. The hollow channel can provide space in which aerosol drawn into the cooling section 8 can expand and cool. In all embodiments, the cooling section is configured to restrict the cross-sectional area of ​​the hollow channel to restrict the movement of tobacco into the cooling section in use.

[0067] The moisture-impermeable wrapper 10 may provide lower friction with the aerosol-generating material, thereby allowing the strands and / or strips of aerosol-generating material to be more easily displaced longitudinally within the cooling section when an aerosol generator is inserted into the rod of aerosol-generating material. Providing a cooling section 8 directly adjacent to the source of aerosol-generating material and including an inner channel having a diameter in this range preferably reduces longitudinal displacement of the strands and / or strips of aerosol-generating material when an aerosol generator is inserted into the rod of aerosol-generating material. Reducing displacement of the aerosol-generating material during use may preferably result in a more consistent packing density of the aerosol-generating material along the length of the rod and / or within the cavity, thereby resulting in more consistent and improved aerosol generation.

[0068] The radial wall thickness of the cooling section 8 can preferably be measured, for example, using a caliper. The wall thickness of the cooling section 8 defines the inner diameter of the cavity enclosed by the walls of the cooling section 8 for a given outer diameter of the cooling section. The cooling section 8 can have a wall thickness of at least about 1.5 mm and up to about 2 mm. In this example, the wall thickness of the cooling section 8 is on the order of 2 mm. The inventors have found that providing a cooling section 8 with a wall thickness within this range preferably improves retention of the supply of aerosol-generating material within the aerosol-generating section during use by reducing longitudinal displacement of the strands and / or strips of aerosol-generating material when the aerosol generator is inserted into an article.

[0069] Cooling section 8 is formed from filamentary tow. Multiple parallel wound paper layers with butt seams or other structures such as spirally wound layers of paper, cardboard tubes, tubes formed using a paper-mache process, molded or extruded plastic tubes, etc. can be used to form cooling section 8. Cooling section 8 is fabricated to be sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacturing and use of article 1.

[0070] The wall material of the cooling section 8 may be relatively non-porous such that at least 90% of the aerosol generated by the aerosol-generating material 3 passes longitudinally through the one or more hollow channels rather than through the wall material of the cooling section 8. For example, at least 92% or at least 95% of the aerosol generated by the aerosol-generating material 3 may pass longitudinally through the one or more hollow channels.

[0071] The filamentary tows forming the cooling section 8 preferably have a total denier of less than 45,000, more preferably less than 42,000. This total denier has been found to allow for the formation of a cooling section 8 that is not overly dense. Preferably, the total denier is at least 20,000, more preferably at least 25,000. In preferred embodiments, the filamentary tows forming the cooling section 8 have a total denier of 25,000 to 45,000, more preferably 35,000 to 45,000. Preferably, the cross-sectional shape of the filaments in the tows is "Y" shaped, although other shapes, such as "X" shaped filaments, can be used in other embodiments.

[0072] The filamentary tows forming the cooling section 8 preferably have a denier per filament greater than 3. This denier per filament has been found to allow for the formation of tubular elements 4 that are not overly dense. Preferably, the denier per filament is at least 4, more preferably at least 5. In a preferred embodiment, the filamentary tows forming the hollow tubular elements 4 have a denier per filament of 4 to 10, more preferably 4 to 9. In one example, the filamentary tows forming the cooling section 8 are 8Y40,000 tows formed from cellulose acetate and containing 18% plasticizer, such as triacetin.

[0073] Preferably, the density of the material forming the cooling section 8 is at least about 0.20 grams per cubic centimeter (g / cc), more preferably at least about 0.25 g / cc. Preferably, the density of the material forming the cooling section 8 is less than about 0.80 grams per cubic centimeter (g / cc), more preferably less than 0.6 g / cc. In some embodiments, the density of the material forming the cooling section 8 is between 0.20 and 0.8 g / cc, more preferably between 0.3 and 0.6 g / cc, or between 0.4 and 0.6 g / cc, or about 0.5 g / cc. These densities have been found to achieve a good balance between the improved hardness provided by higher density materials and minimizing the overall weight of the article. For purposes of the present invention, the "density" of the material forming the cooling section 8 refers to the density of any filamentary tows forming the element, including any plasticizers incorporated therein. Density can be determined by dividing the total weight of the material forming the cooling section 8 by the total volume of the material forming the cooling section 8, which can be calculated using appropriate measurements of the material forming the cooling section 8, for example, made using a caliper. If necessary, a microscope may be used to measure the appropriate dimensions.

[0074] Preferably, the length of the cooling section 8 is less than about 30 mm. More preferably, the length of the cooling section 8 is less than about 25 mm. Even more preferably, the length of the cooling section 8 is less than about 20 mm. Additionally or alternatively, the length of the cooling section 8 is preferably at least about 10 mm. Preferably, the length of the cooling section 8 is at least about 15 mm. In some preferred embodiments, the length of the cooling section 8 is between about 15 mm and about 20 mm, more preferably between about 16 mm and about 19 mm. In this example, the length of the cooling section 8 is 19 mm.

[0075] The cooling section 8 is disposed around the mouthpiece 2 and defines an air gap within the mouthpiece 2 that functions as the cooling section. The air gap forms a chamber through which heated volatile components generated by the rod of aerosol-generating material 3 flow. The cooling section 8 is hollow to form 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 article 1. The cooling section 8 creates a physical displacement between the aerosol-generating material 3 and the body of material 6. The physical displacement created by the cooling section 8 can create a thermal gradient across the length of the cooling section 8.

[0076] Preferably, the mouthpiece 2 is 110 mm 3 It has been found that providing a cavity of at least this volume allows for improved aerosol formation. More preferably, the mouthpiece 2 is formed, for example, within the cooling section 8 and has an internal volume of more than 110 mm 3 Larger, even more preferably 130mm 3 The cavity has a larger internal volume, allowing for further improvement of the aerosol. In some examples, the internal cavity is about 130 mm 3 ~about 230mm 3 , for example, about 134 mm 3 or 227mm 3 Includes the volume of

[0077] Cooling section 8 may be configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile components entering the first upstream end of cooling section 8 and the heated volatile components exiting the second downstream end of cooling section 8. Cooling section 8 is preferably configured to provide a temperature difference of at least 60°C, preferably at least 80°C, and more preferably at least 100°C between the heated volatile components entering the first upstream end of cooling section 8 and the heated volatile components exiting the second downstream end of cooling section 8. This temperature difference across the length of cooling section 8 protects the temperature sensitive body of material 6 from the high temperatures of aerosol-generating material 3 when heated.

[0078] In use, the aerosol-generation section may exhibit a pressure drop of about 15 to about 40 mmH 2 O. In some embodiments, the aerosol-generation section exhibits a pressure drop across the aerosol-generation section of about 15 to about 30 mmH 2 O.

[0079] The aerosol-generating material is approximately 400 mg / cm in the aerosol-generating section. 3 ~about 900mg / cm 3 A packing density of 400 mg / cm or less may be required. Higher packing densities may make it difficult to insert the heating element into the aerosol-generating material and increase the pressure drop. 3 If the packing density is too low, the aerosol-forming material may not grip the heating element effectively.

[0080] At least about 70% of the volume of the aerosol-generating section is filled with aerosol-generating material. In some embodiments, between about 75% and about 85% of the volume of the cavity is filled with aerosol-generating material.

[0081] In this embodiment, the moisture-impermeable wrapper 10 surrounding the rod of aerosol-generating material comprises aluminum foil. In other embodiments, the wrapper 10 includes a wrapper that optionally includes a barrier coating to render the wrapper material substantially moisture-impermeable. Aluminum foil has been found to be particularly effective in promoting aerosol formation within the aerosol-generating material 3. In this example, the aluminum foil has a metal layer approximately 6 μm thick. In this example, the aluminum foil has a paper substrate. However, in alternative configurations, the aluminum foil can be of other thicknesses, for example, between 4 μm and 16 μm. The aluminum foil also need not have a paper backing, but can have a backing formed from other materials, for example, to help provide the foil with adequate tensile strength, or can be unbacked. Metal layers or foils other than aluminum can also be used. The total thickness of the wrapper is preferably between 20 μm and 60 μm, more preferably between 30 μm and 50 μm, to provide a wrapper with adequate structural integrity and heat transfer properties. The tension that can be applied to the wrapper before it breaks can be greater than 3,000 grams, e.g., 3,000 to 10,000 grams, or 3,000 to 4,500 grams. When the wrapper comprises paper or a paper substrate, i.e., a cellulosic material, the wrapper can have a basis weight greater than about 30 gsm. For example, the wrapper can have a basis weight in the range of about 40 gsm to about 70 gsm. The inventors have found that such a basis weight advantageously provides improved rigidity to the rod of aerosol-generating material. The improved rigidity provided by a wrapper having a basis weight in this range can make the rod of aerosol-generating material 3 more resistant to crumpling or other deformation under forces experienced by the article, for example, when the article is inserted into an in-use device and / or when a heater element is inserted into the article.Achieving a rod of aerosol-generating material with increased stiffness can be beneficial when multiple strands or strips of aerosol-generating material are aligned within the aerosol-generating section with their longitudinal dimensions aligned parallel to the longitudinal axis, because the rod of aerosol-generating material may be less stiff than if the longitudinally aligned strands or strips of aerosol-generating material were not aligned. The improved stiffness of the rod of aerosol-generating material enables the article to withstand increased forces to which it is subjected during use.

[0082] In this example, the moisture-impermeable wrapper 10 is also substantially impermeable to air. In an alternative embodiment, the wrapper 10 preferably has a permeability of less than 100 Coresta units, more preferably less than 60 Coresta units. It has been found that a low-permeability wrapper, for example, having a permeability of less than 100 Coresta units, more preferably less than 60 Coresta units, results in improved aerosol formation in the aerosol-generating material 3. Without wishing to be bound by theory, it is hypothesized that this is due to reduced loss of aerosol compounds through the wrapper 10. The permeability of the wrapper 10 can be measured in accordance with ISO 2965:2009, which relates to the measurement of air permeability of materials used as cigarette paper, filter plug wrap, and filter bonding paper.

[0083] The body of material 6 and the hollow tubular element 4 each define a generally cylindrical overall outer shape and share a common longitudinal axis. The body of material 6 is wrapped in a first plug wrap 7. Preferably, the first plug wrap 7 has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. Preferably, the first plug wrap 7 has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. Preferably, the first plug wrap 7 is a non-porous plug wrap, e.g., having a permeability of less than 100 Coresta units, e.g., less than 50 Coresta units. However, in other embodiments, the first plug wrap 7 can be a porous plug wrap, e.g., having a permeability of greater than 200 Coresta units.

[0084] Preferably, the length of the body of material 6 is less than about 15 mm. More preferably, the length of the body of material 6 is less than about 12 mm. Additionally or alternatively, the length of the body of material 6 is at least about 5 mm. Preferably, the length of the body of material 6 is at least about 8 mm. In some preferred embodiments, the length of the body of material 6 is between about 5 mm and about 15 mm, more preferably between about 6 mm and about 12 mm, even more preferably between about 6 mm and about 12 mm, and most preferably about 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. In this example, the length of the body of material 6 is 10 mm.

[0085] In this example, the body of material 6 is formed from filamentary tow. In this example, the tow used in the body of material 6 has a denier per filament (dpf) of 5 and a total denier of 25,000. In this example, the tow includes plasticized cellulose acetate tow. The plasticizer used in the tow constitutes approximately 9% of the tow by weight. In this example, the plasticizer is triacetin. In other examples, a different material can be used to form the body of material 6. For example, rather than tow, the body 6 can be formed from paper, in a manner similar to paper filters known for use in cigarettes. For example, the paper or other cellulosic material can be formed as one or more pieces of sheet material that are folded and / or crimped to form the body 6. The sheet material can have a basis weight of 15 gsm to 60 gsm, for example, 20 to 50 gsm. The sheet material can have a basis weight ranging from, for example, 15 to 25 gsm, 25 to 30 gsm, 30 to 40 gsm, 40 to 45 gsm, and 45 to 50 gsm. Additionally or alternatively, the sheet material can have a width ranging from 50 mm to 200 mm, such as 60 mm to 150 mm, or 80 mm to 150 mm. For example, the sheet material can have a basis weight of 20 to 50 gsm and a width of 80 mm to 150 mm. This allows, for example, the cellulosic body to have an appropriate pressure drop for an article having the dimensions described herein.

[0086] Alternatively, the body 6 can be formed from a tow other than cellulose acetate, such as polylactic acid (PLA), other materials described herein for filamentary tow, or similar materials. The tow is preferably formed from cellulose acetate. Whether formed from cellulose acetate or another material, the tow preferably has a dpf of at least 5. Preferably, to achieve a sufficiently uniform material body 6, the tow has a denier per filament of 12 dpf or less, preferably 11 dpf or less, and even more preferably 10 dpf or less.

[0087] The total denier of the tow forming the body of material 6 is preferably at most 30,000, more preferably at most 28,000, and even more preferably at most 25,000. These total denier values ​​provide the tow with a reduced proportion of the cross-sectional area of ​​the mouthpiece 2, resulting in a lower pressure drop across the mouthpiece 2 than tow with a higher total denier. For appropriate hardness of the body of material 6, the tow preferably has a total denier of at least 8,000, more preferably at least 10,000. Preferably, the denier per filament is 5 to 12, with a total denier of 10,000 to 25,000. Preferably, the cross-sectional shape of the filaments of the tow is "Y" shaped, although other shapes, such as "X" shaped filaments, having the same dpf and total denier values ​​as provided herein can be used in other embodiments.

[0088] Regardless of the material used to form the body 6, the pressure drop across the body 6 can be, for example, 0.3 to 5 mmWG per mm of length of the body 6, such as 0.5 to 2 mmWG per mm of length of the body 6. The pressure drop can be, for example, 0.5 to 1 mmWG / mm of length, 1 to 1.5 mmWG / mm of length, or 1.5 to 2 mmWG / mm of length. The total pressure drop across the body 6 can be, for example, 3 to 8 mmWG, or 4 to 7 mmWG. The total pressure drop across the body 6 can be about 5, 6, or 7 mmWG.

[0089] As shown in FIG. 1 , the mouthpiece 2 of the article 1 includes an upstream end 2a adjacent the rod of aerosol-generating material 3 and a downstream end 2b distal to the rod of aerosol-generating material 3. At the downstream end 2b, the mouthpiece 2 has a hollow tubular element 4 formed from filamentary tow. This has been found to significantly reduce the temperature of the exterior surface of the mouthpiece 2, preferably at the downstream end 2b of the mouthpiece that contacts the consumer's mouth when the article 1 is in use. Additionally, the use of the tubular element 4 has also been found to significantly reduce the temperature of the exterior surface of the mouthpiece 2, even upstream of the tubular element 4. Without wishing to be bound by theory, it is hypothesized that this is due to the tubular element 4 directing the aerosol toward the center of the mouthpiece 2, thus reducing heat transfer from the aerosol to the exterior surface of the mouthpiece 2.

[0090] The "wall thickness" of the hollow tubular element 4 corresponds to the thickness of the wall of the tube 4 in the radial direction. This can be measured, for example, using a caliper. The wall thickness is suitably greater than 0.9 mm, more preferably 1.0 mm or greater. 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 1.0 mm or greater, at any point around the circumference of the hollow tubular element 4. In this example, the wall thickness of the hollow tubular element 4 is approximately 1.3 mm.

[0091] Preferably, the length of the hollow tubular element 4 is less than about 20 mm. More preferably, the length of the hollow tubular element 4 is less than about 15 mm. Even more preferably, the length of the hollow tubular element 4 is less than about 10 mm. Additionally or alternatively, the length of the hollow tubular element 4 is at least about 5 mm. Preferably, the length of the hollow tubular element 4 is at least about 6 mm. In some preferred embodiments, the length of the hollow tubular element 4 is between about 5 mm and about 20 mm, more preferably between about 6 mm and about 10 mm, even more preferably between about 6 mm and about 8 mm, and most preferably about 6 mm, 7 mm, or about 8 mm. In this example, the length of the hollow tubular element 4 is 7 mm.

[0092] Preferably, the density of the hollow tubular element 4 is at least about 0.25 grams per cubic centimeter (g / cc), more preferably at least about 0.3 g / cc. Preferably, the density of the hollow tubular element 4 is less than about 0.75 grams per cubic centimeter (g / cc), more preferably less than 0.6 g / cc. In some embodiments, the density of the hollow tubular element 4 is between 0.25 and 0.75 g / cc, more preferably between 0.3 and 0.6 g / cc, more preferably between 0.4 and 0.6 g / cc, or about 0.5 g / cc. These densities have been found to provide a good balance between the improved hardness provided by higher density materials and the lower heat transfer characteristics of lower density materials. For purposes of this invention, the "density" of the hollow tubular element 4 refers to the density of the filamentary tow forming the element, including any plasticizers incorporated therein. The density can be determined by dividing the total weight of the hollow tubular element 4 by the total volume of the hollow tubular element 4, and the total volume can be calculated using appropriate measurements of the hollow tubular element 4, for example, made using calipers. If necessary, appropriate dimensions can be measured using a microscope.

[0093] The filamentary tows forming the hollow tubular element 4 preferably have a total denier of less than 45,000, more preferably less than 42,000. This total denier has been found to allow for the formation of a tubular element 4 that is not excessively dense. Preferably, the total denier is at least 20,000, more preferably at least 25,000. In preferred embodiments, the filamentary tows forming the hollow tubular element 4 have a total denier of 25,000 to 45,000, more preferably 35,000 to 45,000. Preferably, the cross-sectional shape of the filaments in the tow is "Y" shaped, although other shapes, such as "X" shaped filaments, can be used in other embodiments.

[0094] The filamentary tows forming the hollow tubular elements 4 preferably have a denier per filament greater than 3. This denier per filament has been found to allow for the formation of tubular elements 4 that are not overly dense. Preferably, the denier per filament is at least 4, more preferably at least 5. In a preferred embodiment, the filamentary tows forming the hollow tubular elements 4 have a denier per filament between 4 and 10, more preferably between 4 and 9. In one example, the filamentary tows forming the hollow tubular elements 4 are formed from cellulose acetate and have a 7.3Y36,000 tow containing 18% plasticizer, such as triacetin.

[0095] The hollow tubular element 4 preferably has an inner diameter greater than 3.0 mm. A smaller diameter may cause the aerosol to pass through the mouthpiece 2 and reach the consumer's mouth at an undesirably increased rate, resulting in the aerosol becoming excessively warm, for example reaching temperatures above 40°C or even above 45°C. More preferably, the hollow tubular element 4 has an inner diameter greater than 3.1 mm, and even more preferably greater than 3.5 mm or 3.6 mm. In one embodiment, the inner diameter of the hollow tubular element 4 is about 4.7 mm.

[0096] The hollow tubular element 4 preferably contains 15% to 22% by weight of plasticizer. In the case of cellulose acetate tow, the plasticizer is preferably triacetin, although other plasticizers such as polyethylene glycol (PEG) can also be used. More preferably, the hollow tubular element 4 contains 16% to 20% by weight of plasticizer, for example, about 17%, about 18%, or about 19%.

[0097] In this example, the first hollow tubular element 4, the body of material 6, and the cooling section 8 are combined using a second plug wrap 9 that is wrapped around all three sections. Preferably, the second plug wrap 9 has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 45 gsm. Preferably, the second plug wrap 9 has a thickness of 30 μm to 60 μm, more preferably between 35 μm and 45 μm. The second plug wrap 9 is preferably a non-porous plug wrap having a permeability of less than 100 Coresta units, for example, less than 50 Coresta units. However, in alternative embodiments, the second plug wrap 9 can be a porous plug wrap having a permeability of, for example, more than 200 Coresta units.

[0098] In this example, Article 1 has a circumference of approximately 23 mm. In other examples, the article can be formed in any of the formats described herein, for example, with a circumference of 20 mm to 26 mm. Because the article is heated to release the aerosol, improved heating efficiency can be achieved using articles with lower circumferences within this range, for example, circumferences less than 23 mm. Article circumferences greater than 19 mm have also been found to be particularly effective for achieving improved aerosol delivery upon heating while maintaining an adequate product length. Articles with circumferences of 20 mm to 24 mm, more preferably 20 mm to 23 mm, have been found to achieve a good balance between enabling efficient heating and achieving effective aerosol delivery.

[0099] The tipping paper 5 is wrapped around a portion of the rod of aerosol-generating material 3 along the entire length of the mouthpiece 2 and has adhesive on its inner surface to connect the mouthpiece 2 and the rod 3. In this example, the rod of aerosol-generating material 3 is wrapped in a wrapper 10 that forms a first packaging material, and the tipping paper 5 forms an outer packaging material that extends at least partially over the rod of aerosol-generating material 3 to connect the mouthpiece 2 and the rod 3. In some examples, the tipping paper may extend only partially over the rod of aerosol-generating material.

[0100] In this example, the tipping paper 5 extends 5 mm over the rod of aerosol-generating material 3, but alternatively, it may extend 3 mm to 10 mm, or more preferably 4 mm to 6 mm, over the rod 3 to provide a secure attachment between the mouthpiece 2 and the rod 3. The tipping paper may have a basis weight of greater than 20 gsm, e.g., greater than 25 gsm, or preferably greater than 30 gsm, e.g., 37 gsm. These basis weight ranges have been found to result in tipping paper with acceptable tensile strength while being flexible enough to wrap around the article 1 and adhere to itself along the paper's longitudinal lap seam. The circumference of the tipping paper 5, when wrapped around the mouthpiece 2, is approximately 23 mm.

[0101] The article has a ventilation level of approximately 10% of the aerosol drawn through the article. In alternative embodiments, the article can have a ventilation level of 1% to 20%, e.g., 1% to 12%, of the aerosol drawn through the article. These levels of ventilation help to increase the consistency of the aerosol inhaled by the user at the mouth end 2b while assisting the aerosol cooling process. Ventilation is provided directly within the mouthpiece 2 of the article 1. In this example, ventilation is provided within the cooling section 8, which has been found to be particularly beneficial in assisting the aerosol generation process. Ventilation is provided via perforations 12, in this case formed as a single row of laser perforations, located 13 mm downstream from the mouth end 2b of the mouthpiece 2. In alternative embodiments, two or more rows of ventilation perforations may be provided. These perforations pass through the tipping paper 5, the second plug wrap 9, and the cooling section 8. In alternative embodiments, ventilation can be provided elsewhere within the mouthpiece, for example, within the body of material 6 or the first tubular element 4. Preferably, the article is configured so that the perforations are located no more than about 28 mm from the upstream end of the article 1, preferably between 20 mm and 28 mm from the upstream end of the article 1. In this example, the opening is located about 25 mm from the upstream end of the article.

[0102] The aerosol-generating material includes a sheet or shredded sheet of aerosolizable material configured to generate an aerosol when heated.

[0103] The sheet or shredded sheet has a first surface and a second surface opposite the first surface. The first and second surfaces have matching dimensions. The first and second surfaces of the sheet or shredded sheet can have any shape. For example, the first and second surfaces can be square, oblong, rectangular, or circular. Irregular shapes are also contemplated.

[0104] The first and / or second surfaces of the sheet or shredded sheet may be relatively uniform (e.g., they may be relatively smooth), or may be uneven or irregular. For example, the first and / or second surfaces of the sheet may be textured or patterned to define a relatively rough surface. In some embodiments, the first and / or second surfaces are relatively rough.

[0105] The smoothness of the first and second surfaces can be influenced by many factors, such as the areal density of the sheet or shredded sheet, the nature of the components that make up the aerosolizable material, or whether the surface of the material has been manipulated, for example, embossed, scored, or otherwise modified to impart a pattern or texture.

[0106] The areas of the first and second surfaces are defined by a first dimension (e.g., width) and a second dimension (e.g., length), respectively. The first and second dimensional measurements can have a ratio of 1:1 or greater, and thus the sheet or shredded sheet can have an "aspect ratio" of 1:1 or greater. As used herein, the term "aspect ratio" refers to the ratio of the first dimensional measurement of the first or second surface to the second dimensional measurement of the first or second surface. An "aspect ratio of 1:1" means that the first dimensional measurement (e.g., width) and the second dimensional measurement (e.g., length) are identical. An "aspect ratio greater than 1:1" means that the first dimensional measurement (e.g., width) and the second dimensional measurement (e.g., length) are different. In some embodiments, the first and second surfaces of the sheet or shredded sheet have an aspect ratio of greater than 1:1, such as 1:2, 1:3, 1:4, 1:5, 1:6, 1:7 or more.

[0107] The chopped sheet may include one or more strands or strips of aerosolizable material. In some embodiments, the chopped sheet includes multiple (e.g., two or more) strands or strips of aerosolizable material. The strands or strips of aerosolizable material may have an aspect ratio of 1:1. In one embodiment, the strands or strips of aerosolizable material have an aspect ratio of greater than 1:1. In some embodiments, the strands or strips of aerosolizable material have an aspect ratio of about 1:5 to about 1:16, or about 1:5, 1:6, 1:7, 1:8, 1:9, 1:10, 1:11, or 1:12. When the aspect ratio of a strand or strip is greater than 1:1, the strand or strip includes a longitudinal dimension or length extending between a first end of the strand or strip and a second end of the strand or strip.

[0108] When the shredded sheet includes multiple strands or strips of material, the dimensions of each strand or strip can vary among different strands or strips. For example, the shredded sheet can include a first set of strands or strips and a second set of strands or strips, where the dimensions of the first set of strands or strips are different from the dimensions of the second set of strands or strips. In other words, the multiple strands or strips can include a first set of strands or strips having a first aspect ratio and a second set of strands or strips having a second aspect ratio that is different from the first aspect ratio.

[0109] The first dimension or cut width of the strand or strip of aerosolizable material is between 0.9 mm and 1.5 mm. If a strand or strip of aerosolizable material having a cut width less than 0.9 mm is incorporated into an article for use in a non-flammable aerosol delivery system, the pressure drop across the article may increase to a level that renders the article unsuitable for use in a non-flammable aerosol delivery device. However, if the strand or strip has a cut width greater than 2 mm (e.g., greater than 2 mm), it may be difficult to insert the strand or strip of aerosolizable material into the article during its manufacture. In a preferred embodiment, the cut width of the strand or strip of aerosolizable material is between about 1 mm and 1.5 mm.

[0110] The strands or strips of material are formed by shredding a sheet of aerosolizable material. The sheet of aerosolizable material can be cut widthwise, for example, by a cross-cut shredding process, to define the cut length of the strands or strips of aerosolizable material in addition to the cut width. The cut length of the shredded aerosolizable material is preferably at least 5 mm, for example, at least 10 mm, or at least 20 mm. The cut length of the shredded aerosolizable material can be less than 60 mm, less than 50 mm, or less than 40 mm.

[0111] In some embodiments, multiple strands or strips of aerosolizable material are provided, and at least one of the multiple strands or strips of aerosolizable material has a length greater than about 10 mm. At least one of the multiple strands or strips of aerosolizable material can alternatively or additionally have a length of about 10 mm to about 60 mm, or about 20 mm to about 50 mm. Each of the multiple strands or strips of aerosolizable material can have a length of about 10 mm to about 60 mm, or about 20 mm to about 50 mm.

[0112] The sheet or chopped sheet of aerosolizable material has a thickness of at least about 100 μm. The sheet or chopped sheet can have a thickness of at least about 120 μm, 140 μm, 160 μm, 180 μm, or 200 μm. In some embodiments, the sheet or chopped sheet has a thickness of about 150 μm to about 300 μm, about 151 μm to about 299 μm, about 152 μm to about 298 μm, about 153 μm to about 297 μm, about 154 μm to about 296 μm, about 155 μm to about 295 μm, about 156 μm to about 294 μm, about 157 μm to about 293 μm, about 158 ​​μm to about 292 μm, about 159 μm to about 291 μm, or about 160 μm to about 290 μm. In some embodiments, the sheet or shredded sheet has a thickness of about 170 μm to about 280 μm, about 180 to about 270 μm, about 190 to about 260 μm, about 200 μm to about 250 μm, or about 210 μm to about 240 μm.

[0113] The thickness of the sheet or shredded sheet may vary between the first and second surfaces. In some embodiments, the individual strips or pieces of aerosolizable material have a minimum thickness of about 100 μm across their area. In some cases, the individual strips or pieces of aerosolizable material have a minimum thickness of about 0.05 mm or about 0.1 mm across their area. In some cases, the individual strips, strands, or pieces of aerosolizable material have a maximum thickness of about 1.0 mm across their area. In some cases, the individual strips or pieces of aerosolizable material have a maximum thickness of about 0.5 mm or about 0.3 mm across their area.

[0114] The thickness of the sheet can be determined using ISO 534:2011 "Paper and paperboard - Determination of thickness".

[0115] The inventors have established that if the sheet or shredded sheet of aerosolizable material is too thick, heating efficiency may be impaired. This may adversely affect power consumption during use, for example, power consumption for releasing flavoring from the aerosolizable material. Conversely, if the aerosolizable material is too thin, it may be difficult to manufacture and handle; very thin materials are more difficult to cast, more fragile, and may impair aerosol formation during use.

[0116] It is hypothesized that if the sheet or shredded sheet of aerosolizable material is too thin (e.g., less than 100 μm), it may be necessary to increase the cut width of the shredded sheet to achieve sufficient loading of the aerosolizable material when the shredded sheet is incorporated into an article. As previously mentioned, increasing the cut width of the shredded sheet can increase the pressure drop, which is undesirable.

[0117] having a thickness of at least about 100 μm and about 100 g / m 2 ~about 250g / m 2It is hypothesized that sheets or shredded sheets with an areal density of at least about 100 μm are less likely to tear, rip, or deform during their manufacture. A thickness of at least about 100 μm can have a positive effect on the overall structural integrity and strength of the sheet or shredded sheet. For example, it can have good tensile strength and therefore be relatively easy to process.

[0118] The thickness of the sheet or shredded sheet also appears to affect its areal density, i.e., increasing the thickness of the sheet or shredded sheet can increase the areal density of the sheet or shredded sheet.

[0119] Conversely, reducing the thickness of the sheet or chopped sheet may reduce the areal density of the sheet or chopped sheet. For the avoidance of doubt, when areal density is referred to herein, it refers to the average areal density calculated for a given strip, strand, piece or sheet of aerosolizable material, where areal density is calculated by measuring the surface area and weight of a given strip, strand, piece or sheet of aerosolizable material.

[0120] The sheet or shredded sheet of aerosol-generating material has a mass of about 100 g / m 2 ~about 250g / m 2 The sheet or shredded sheet has an areal density of about 110 g / m 2 ~about 240g / m 2 , about 120g / m 2 ~about 230g / m 2 , about 130g / m 2 ~about 220g / m 2 or approximately 140 g / m 2 ~about 210g / m 2 In some embodiments, the sheet or shredded sheet may have an areal density of about 130 g / m 2 ~Approx. 190g / m 2 , about 140g / m 2 ~Approx. 180g / m 2 , about 150g / m 2 ~Approx. 170g / m 2In a preferred embodiment, the sheet or shredded sheet has an areal density of about 160 g / m 2 has an areal density of

[0121] Approximately 100g / m 2 ~about 250g / m 2 The areal density of about 180 gsm is believed to contribute to the strength and flexibility of the sheet or shredded sheet. Additionally, a rod comprising a shredded sheet of aerosolizable material having an areal density of about 180 gsm and a minimum thickness of 220 μm to 230 μm can be packaged so that the aerosolizable material remains in place within the rod, while maintaining a desired weight of tobacco material within the rod (e.g., about 300 mg) and delivering acceptable organoleptic characteristics (e.g., taste and odor) when heated in a non-combustible aerosol delivery device.

[0122] The flexibility of the sheet or shredded sheet is believed to depend, at least in part, on the thickness and areal density of the sheet or shredded sheet. Thicker sheets or shredded sheets may be less flexible than thinner sheets or shredded sheets. Also, the greater the areal density of the sheet, the less flexible the sheet or shredded sheet. The total thickness and areal density of the aerosolizable material described herein is believed to result in a relatively flexible sheet or shredded sheet. This flexibility can provide various advantages when the aerosolizable material is incorporated into an article for use in a non-flammable aerosol delivery device. For example, the strands or strips can easily deform and bend when an aerosol generator is inserted into the aerosol-generating material, thereby facilitating insertion of the aerosol generator (e.g., a heater) into the material and improving retention of the aerosol generator by the aerosolizable material.

[0123] The areal density of the sheet or chopped sheet of aerosol-generating material affects the roughness of the first and second surfaces of the sheet or chopped sheet. By varying the areal density, the roughness of the first and / or second surfaces can be adjusted.

[0124] The average volume density of a sheet or shredded sheet of aerosol-generating material can be calculated from the thickness of the sheet and the areal density of the sheet. The average volume density is about 0.2 g / cm 3 , about 0.3g / cm 3 or approximately 0.4 g / cm 3 In some embodiments, the average bulk density is about 0.2 g / cm 3 ~Approx. 1g / cm 3 , about 0.3g / cm 3 ~Approx. 0.9g / cm 3 , approximately 0.4 g / cm 3 ~Approx. 0.9g / cm 3 , about 0.5g / cm 3 ~Approx. 0.9g / cm 3 or approximately 0.6 g / cm 3 ~Approx. 0.9g / cm 3 is.

[0125] According to one aspect of the present disclosure, there is provided an aerosol-generating material comprising a sheet or shredded sheet of aerosolizable material comprising a tobacco material, an aerosol-forming material, and a binder, wherein the sheet or shredded sheet has an aerosol yield of about 0.4 g / cm 3 In some embodiments, the density is greater than about 0.4 g / cm 3 ~Approx. 2.9g / cm 3 , approximately 0.4 g / cm 3 ~Approx. 1g / cm 3 , about 0.6 cm 3 ~approx. 1.6cm 3 or about 1.6 cm 3 ~Approx. 2.9cm 3 is.

[0126] The sheet or shredded sheet may have a tensile strength of at least 4N / 15mm.

[0127] If the sheet or shredded sheet has a tensile strength of less than 4 N / 15 mm, the sheet or shredded sheet may tear, break, or deform during its manufacture and / or subsequent incorporation into an article for use in a non-flammable aerosol delivery system. Tensile strength may be measured using ISO 1924:2008.

[0128] The aerosol-forming material comprises a tobacco material. The sheet or shredded sheet of aerosolizable material comprises a tobacco material.

[0129] The tobacco material may be a granular or particulate material. In some embodiments, the tobacco material is a powder. Alternatively or additionally, the tobacco material may comprise tobacco strips, strands, or fibers. For example, the tobacco material may comprise tobacco particles, granules, fibers, strips, and / or strands. In some embodiments, the tobacco material consists of particles or granules of tobacco material.

[0130] The density of the tobacco material affects the rate at which heat is conducted through the material, with lower densities, e.g., below 900 mg / cc, conducting heat more slowly through the material and thus allowing for a more sustained release of aerosol.

[0131] The tobacco material can include a reconstituted tobacco material, such as a paper reconstituted tobacco material, having a density of less than about 900 mg / cc. For example, the aerosol-forming material can include a reconstituted tobacco material having a density of less than about 800 mg / cc. Alternatively or additionally, the aerosol-forming material can include a reconstituted tobacco material having a density of at least 350 mg / cc.

[0132] The reconstituted tobacco material can be provided in the form of a shredded sheet. The sheet of reconstituted tobacco material can have any suitable thickness. The reconstituted 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 reconstituted tobacco material can have a maximum thickness of about 0.30 mm or 0.25 mm; for example, the reconstituted tobacco material can have a thickness of less than about 0.22 mm, or less than about 0.2 mm. In some embodiments, the reconstituted tobacco material can have an average thickness in the range of 0.175 mm to 0.195 mm.

[0133] In some embodiments, the tobacco is a particulate tobacco material. Each particle of the particulate tobacco material may have a maximum dimension. As used herein, the term "maximum dimension" refers to the longest linear distance from the surface of a particle of tobacco or any point on the surface of a particle to any other surface point on the same particle of tobacco or on the surface of a particle. The maximum dimension of a particle of particulate tobacco material can be measured using a scanning electron microscope (SEM).

[0134] The maximum dimension of each particle of the tobacco material can be up to about 200 μm. In some embodiments, the maximum dimension of each particle of the tobacco material is up to about 150 μm.

[0135] The population of particles of the tobacco material may have a particle size distribution (D90) of at least about 100 μm. In some embodiments, the population of particles of the tobacco material has a particle size distribution (D90) of about 110 μm, at least about 120 μm, at least about 130 μm, at least about 140 μm, or at least about μm. In one embodiment, the population of particles of the tobacco material has a particle size distribution (D90) of about 150 μm. Sieve analysis can also be used to determine the particle size distribution of the particles of the tobacco material.

[0136] A particle size distribution (D90) of at least about 100 μm is believed to contribute to the tensile strength of a sheet or shredded sheet of aerosolizable material.

[0137] A particle size distribution (D90) of less than 100 μm provides a sheet or shredded sheet of aerosolizable material with good tensile strength. However, including fine particles of such tobacco material in the sheet or shredded sheet can increase its density. This high density can reduce the fill value of the tobacco material when the sheet or shredded sheet is incorporated into an article for use in a non-burning aerosol delivery system. Preferably, a balance between satisfactory tensile strength and appropriate density (and therefore fill value) can be achieved when the particle size distribution (D90) is at least about 100 μm.

[0138] The particle size of the particulate tobacco material can also affect the roughness of the sheet or shredded sheet of aerosol-generating material. It is hypothesized that forming the sheet or shredded sheet of aerosol-generating material by incorporating relatively larger particles of tobacco material reduces the density of the sheet or shredded sheet of aerosol-generating material.

[0139] The tobacco material may include tobacco obtained from any part of the tobacco plant. In some embodiments, the tobacco material includes tobacco leaf.

[0140] The sheet or shredded sheet can contain from 5% to about 90% tobacco by weight.

[0141] The tobacco material may include flank tobacco and / or tobacco stems, such as midrib stalks. The flank tobacco can be present in an amount of from 0% to about 100%, from about 20% to about 100%, from about 40% to about 100%, from about 40% to about 95%, from about 45% to about 90%, from about 50% to about 85%, or from about 55% to about 80% by weight of the sheet or shredded sheet and / or tobacco material. In some embodiments, the tobacco material consists of, or consists essentially of, flank tobacco material.

[0142] The tobacco material may contain tobacco stems in an amount of from 0% to about 100%, from about 0% to about 50%, from about 0 to about 25%, from about 0 to about 20%, or from about 5 to about 15% by weight of the sheet or shredded sheet.

[0143] In some embodiments, the tobacco material comprises a combination of lamina and tobacco stems. In some embodiments, the tobacco material may comprise about 40% to about 95% lamina and about 5% to about 60% stems, or about 60% to about 95% lamina and about 5% to about 40% stems, or about 80% to about 95% lamina and about 5% to about 20% stems, by weight of the sheet or shredded sheet of aerosolizable material.

[0144] The inventors have found that incorporating stems can reduce the stickiness of the aerosolizable material. The inventors have also surprisingly found that incorporating tobacco material, including stem tobacco, into the aerosolizable material can increase its burst strength.

[0145] The sheet or shredded sheet of aerosolizable material may have a burst strength of at least about 75 g, at least about 100 g, or at least about 200 g.

[0146] If the burst strength is too low, the sheet or shredded sheet may be relatively brittle. As a result, breakage of the sheet or shredded sheet may occur during the process of producing the aerosolizable material. For example, if the sheet is shredded by a cutting process to form the shredded sheet, the sheet may break into small pieces or fragments when cut.

[0147] The tobacco material described herein contains nicotine. The nicotine content may be 0.1 to 3% by weight of the tobacco material, for example, 0.5 to 2.5% by weight of the tobacco material. Additionally or alternatively, the tobacco material contains 10% to 90% by weight of tobacco leaves, with a nicotine content of greater than about 1% or greater than about 1.5% by weight of the tobacco leaves. Tobacco leaves, such as cut rag tobacco, may have a nicotine content of, for example, 1% to 5% by weight of the tobacco leaves.

[0148] The sheet or shredded sheet of aerosolizable material may include nicotine in an amount of about 0.1% to about 3% by weight of the sheet or shredded sheet.

[0149] Tobacco reconstituted with paper may also be present in the aerosol-forming materials described herein. Paper reconstituted tobacco refers to tobacco material formed by a process in which tobacco feedstock is extracted with a solvent to obtain a soluble extract and a residue containing fibrous material, and then the extract (usually after concentration, and optionally after further processing) is recombined with the fibrous material from the residue by deposition of the extract onto the fibrous material (usually after purifying the fibrous material, and optionally with the addition of a portion of non-tobacco fiber). The recombination process is similar to that used to make paper.

[0150] The paper-reconstituted tobacco may be any type of paper-reconstituted tobacco known in the art.In certain embodiments, the paper-reconstituted tobacco is made from raw materials including one or more of tobacco strips, tobacco stems, and whole leaf tobacco.In further embodiments, the paper-reconstituted tobacco is made from a feedstock consisting of tobacco strips and / or whole leaf tobacco, and tobacco stems.However, in other embodiments, scraps, fines, and wineings can be used as feedstock instead or in addition.

[0151] Paper-reconstituted tobacco for use in the tobacco materials described herein can be prepared by methods known to those skilled in the art for preparing paper-reconstituted tobacco.

[0152] In embodiments, the paper reconstituted tobacco is present in an amount between 5% and 90% by weight, between 10% and 80% by weight, or between 20% and 70% by weight of the aerosol-forming material.

[0153] The aerosol-generating material includes an aerosol-forming material. The aerosol-forming material includes one or more components capable of forming an aerosol. The aerosol-forming material includes one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixture, benzyl benzoate, benzyl phenyl acetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. Preferably, the aerosol-forming material is glycerol or propylene glycol.

[0154] The sheet or shredded sheet of aerosolizable material includes an aerosol-forming material in an amount of up to about 50% by dry weight of the sheet or shredded sheet. In some embodiments, the aerosol-forming material is present in an amount of about 5% to about 40% by dry weight of the sheet or shredded sheet, about 10% to about 30% by dry weight of the sheet or shredded sheet, or about 10% to about 20% by dry weight of the sheet or shredded sheet.

[0155] The sheet or shredded sheet may also include water. The sheet or shredded sheet of aerosolizable material may include water in an amount less than about 15%, less than about 10%, or less than about 5% by weight of the aerosolizable material. In some embodiments, the aerosolizable material includes water in an amount between about 0% and about 15%, or between about 5% and about 15% by weight of the aerosolizable material.

[0156] The sheet or shredded sheet of aerosolizable material may contain water and a total amount of aerosol-forming material of less than about 30% by weight of the sheet or shredded sheet of aerosolizable material, or less than about 25% by weight of the sheet or shredded sheet of aerosolizable material. It is believed that incorporating water and aerosol-forming agents into the sheet or shredded sheet of aerosolizable material in an amount less than about 30% by weight of the sheet or shredded sheet of aerosolizable material advantageously reduces the stickiness of the sheet. This can improve the ease with which the aerosolizable material can be handled during processing. For example, it may be easier to roll a sheet of aerosolizable material to form a bobbin of material and then unwind the bobbin without the layers of the sheet sticking to each other. Reducing stickiness also reduces the tendency of strands or strips of shredded material to clump or stick together, thereby further improving processing efficiency and final product quality.

[0157] The sheet or shredded sheet includes a binder configured to bind the components of the aerosol-forming material together to form the sheet or shredded sheet. The binder may at least partially coat the surface of the tobacco material. If the tobacco material is in particulate form, the binder may at least partially coat the surface of the tobacco particles and bind them together.

[0158] The binder may be selected from one or more compounds selected from the group including alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the binder comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the binder comprises alginate and / or pectin or carrageenan. In a preferred embodiment, the binder comprises guar gum.

[0159] The binder may be present in an amount of about 1 to about 20% by weight of the sheet or shredded sheet, or in an amount of 1 to about 10% by weight of the sheet or shredded sheet of aerosolizable material. For example, the binder may be present in an amount of about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, or 10% by weight of the sheet or shredded sheet of aerosolizable material.

[0160] The aerosol-generating material may include a filler material. In some embodiments, the sheet or shredded sheet includes a filler material. The filler material is generally a non-tobacco component, i.e., a component that does not contain components derived from tobacco. The filler material may include one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents, such as molecular sieves. The filler material may be wood fiber or non-tobacco fiber, such as pulp or wheat fiber. The filler material may be a material containing cellulose or a material containing a derivative of cellulose. The filler component may also be a non-tobacco cast material or a non-tobacco extruded material.

[0161] In certain embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood, wood pulp, hemp fiber, cellulose, or a cellulose derivative. Without wishing to be bound by theory, it is believed that the inclusion of a fibrous filler may increase the tensile strength of the material.

[0162] The filler material can also contribute to the texture of the sheet or shredded sheet of aerosolizable material. For example, a fibrous filler material, such as wood or wood pulp, can provide a sheet or shredded sheet of aerosolizable material with relatively rough first and second surfaces. Conversely, a non-fibrous particulate filler material, such as powdered chalk, can provide a sheet or shredded sheet of aerosolizable material with relatively smooth first and second surfaces. In some embodiments, the aerosolizable material includes a combination of different filler materials.

[0163] The filler component may be present in an amount of 0-20% by weight of the sheet or shredded sheet, or in an amount of 1-10% by weight of the sheet or shredded sheet, hi some embodiments, no filler component is present.

[0164] The filler material can serve to improve the general structural properties of the aerosolizable material, such as its tensile strength and burst strength.

[0165] For the avoidance of doubt, when amounts are expressed in terms of weight percent in the compositions described herein, this refers to a dry weight basis unless specifically indicated to the contrary. Therefore, any water that may be present in the aerosol-forming material or any of its components is completely ignored for purposes of determining weight percent. The water content of the aerosol-forming materials described herein may vary, for example, from 5 to 15% by weight. The water content of the aerosol-forming materials described herein may vary, for example, depending on the temperature, pressure, and humidity conditions under which the composition is maintained. The water content can be determined by Karl Fischer analysis, as known to those skilled in the art. However, for the avoidance of doubt, any components other than water are included in the weight of the aerosol-forming material, even if the aerosol-forming material is a liquid-phase component such as glycerol or propylene glycol. However, if an aerosol-forming material is contained in the tobacco component of the aerosol-forming material or in the filler component (if present) of the aerosol-forming material instead of or in addition to being added separately to the aerosol-forming material, the aerosol-forming material is not included in the weight of the tobacco component or filler component, but is included in the weight of the "aerosol-forming material" in terms of weight percent as defined herein. All other components present in the tobacco component are included in the weight of the tobacco component, even if they are of non-tobacco origin (e.g., non-tobacco fiber in the case of tobacco reconstituted in paper).

[0166] The aerosol-generating material herein can include an aerosol modifier, such as any of the flavorings described herein. In one embodiment, the aerosol-generating material includes menthol. When the aerosol-generating material is incorporated into an article for use in an aerosol delivery system, the article can be referred to as a mentholated article. The aerosol-generating material can include 0.5 mg to 20 mg of menthol, 0.7 mg to 20 mg of menthol, 1 mg to 18 mg, or 8 mg to 16 mg of menthol. In this example, the aerosol-generating material includes 16 mg of menthol. The aerosol-generating material can include 1% to 8% menthol by weight, preferably 3% to 7% menthol by weight, and more preferably 4% to 5.5% menthol by weight. In one embodiment, the aerosol-generating material includes 4.7% menthol by weight. Such high levels of menthol loading can be achieved using a high proportion of reconstituted tobacco material, for example, greater than 50% by weight of the tobacco material. Alternatively or additionally, the use of a large amount of, for example, tobacco material, may be such that the aerosol-forming material, for example, tobacco material, is about 500 mm 3 Beyond, or appropriately, about 1000 mm 3 This can increase the menthol loading levels that can be achieved when more than 100g of menthol is used.

[0167] In some embodiments, the composition comprises an aerosol-forming "amorphous solid," which may alternatively be referred to as a (i.e., non-fibrous) "monolithic solid." In some embodiments, the amorphous solid may comprise a dry gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within it. In some instances, the amorphous solid is 1 to 60 wt. % of a gelling agent; 0.1 to 50 wt. % of an aerosol-forming material; 0.1 to 80% by weight of a flavoring agent, Here, these weights are calculated on a dry weight basis. In some further embodiments, the amorphous solid is 1 to 50 wt. % of a gelling agent; 0.1 to 50 wt. % of an aerosol-forming material; 30 to 60% by weight of a flavoring agent, Here, these weights are calculated on a dry weight basis.

[0168] The amorphous solid material may be provided in the form of sheets or chopped sheets. The amorphous solid material may take the same form as the sheets or chopped sheets of aerosolizable material described above.

[0169] Suitably, the amorphous solid may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% to about 60%, 50%, 45%, 40%, or 35% by weight of gelling agent (all calculated on a dry weight basis). For example, the amorphous solid may comprise 1-50%, 5-45%, 10-40%, or 20-35% by weight of gelling agent. In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group including alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some embodiments, the gelling agent comprises alginate and / or pectin and may be combined with a coagulation agent (such as a calcium source) during the formation of the amorphous solid. In some embodiments, the amorphous solid may comprise calcium-crosslinked alginate and / or calcium-crosslinked pectin.

[0170] In some embodiments, the gelling agent comprises alginate, and the alginate is present in the amorphous solid in an amount of 10-30% by weight (calculated on a dry weight basis) of the amorphous solid. In some embodiments, the alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginate and at least one additional gelling agent, such as pectin.

[0171] In some embodiments, the amorphous solid may include a gelling agent including carrageenan.

[0172] Suitably, the amorphous solid may comprise from about 0.1%, 0.5%, 1%, 3%, 5%, 7%, or 10% to about 50%, 45%, 40%, 35%, 30%, or 25% by weight of the aerosol former material (all calculated on a dry weight basis). The aerosol former may act as a plasticizer. For example, the amorphous solid may comprise from 0.5 to 40%, 3 to 35%, or 10 to 25% by weight of the aerosol former material. In some cases, the aerosol former material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some cases, the aerosol former material comprises, consists essentially of, or consists of glycerol.

[0173] The amorphous solid comprises a flavoring. Suitably, the amorphous solid may comprise up to about 80%, 70%, 60%, 55%, 50% or 45% by weight of flavoring.

[0174] In some cases, the amorphous solid may comprise at least about 0.1%, 1%, 10%, 20%, 30%, 35%, or 40% by weight of flavoring (all calculated on a dry weight basis).

[0175] For example, the amorphous solid may comprise 1-80%, 10-80%, 20-70%, 30-60%, 35-55%, or 30-45% by weight of flavoring. In some cases, the flavoring comprises, consists essentially of, or consists of menthol.

[0176] In some cases, the amorphous solid may further comprise an emulsifier to emulsify the molten flavoring during manufacture. For example, the amorphous solid may comprise about 5% to about 15% by weight (calculated on a dry weight basis), suitably about 10% by weight, of an emulsifier. The emulsifier may comprise gum acacia.

[0177] In some embodiments, the amorphous solid is a hydrogel and contains less than about 20% water by weight, calculated on a wet weight basis. In some cases, the hydrogel may contain less than about 15%, 12%, or 10% water by weight, calculated on a wet weight basis. In some cases, the hydrogel may contain at least about 1%, 2%, or at least about 5% water by weight (WWB).

[0178] In some embodiments, the amorphous solid further comprises an active substance. For example, in some cases, the amorphous solid further comprises tobacco material and / or nicotine. In some cases, the amorphous solid may comprise 5 to 60% by weight (calculated on a dry weight basis) of tobacco material and / or nicotine. In some cases, the amorphous solid may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% to about 70%, 60%, 50%, 45%, 40%, 35%, or 30% by weight (calculated on a dry weight basis) of the active substance. In some cases, the amorphous solid may comprise from about 1%, 5%, 10%, 15%, 20%, or 25% to about 70%, 60%, 50%, 45%, 40%, 35%, or 30% by weight (calculated on a dry weight basis) of tobacco material. For example, the amorphous solid may comprise 10-50%, 15-40%, or 20-35% by weight of tobacco material. In some cases, the amorphous solid may comprise from about 1%, 2%, 3%, or 4% to about 20%, 18%, 15%, or 12% by weight of nicotine (calculated on a dry weight basis). For example, the amorphous solid may comprise 1-20%, 2-18%, or 3-12% by weight of nicotine.

[0179] In some cases, the amorphous solid includes an active substance such as tobacco extract. In some cases, the amorphous solid may include 5-60% by weight (calculated on a dry weight basis) of tobacco extract. In some cases, the amorphous solid may include about 5%, 10%, 15%, 20%, or 25% by weight to about 60%, 50%, 45%, 40%, 35%, or 30% by weight of tobacco extract (calculated on a dry weight basis). For example, the amorphous solid may include 10-50%, 15-40%, or 20-35% by weight of tobacco extract. The tobacco extract may contain nicotine at a concentration such that the amorphous solid includes 1%, 1.5%, 2%, or 2.5% by weight to about 6%, 5%, 4.5%, or 4% by weight of nicotine (calculated on a dry weight basis).

[0180] In some cases, no nicotine may be present in the amorphous solid other than that arising from the tobacco extract.

[0181] In some embodiments, the amorphous solid does not contain tobacco material but does contain nicotine. In some such cases, the amorphous solid may contain from about 1%, 2%, 3%, or 4% to about 20%, 18%, 15%, or 12% by weight of nicotine (calculated on a dry weight basis). For example, the amorphous solid may contain from 1 to 20%, 2 to 18%, or 3 to 12% by weight of nicotine.

[0182] In some cases, the total content of actives and / or flavorings may be at least about 0.1%, 1%, 5%, 10%, 20%, 25%, or 30% by weight, In some cases, the total content of actives and / or flavorings may be less than about 90%, 80%, 70%, 60%, 50%, or 40% by weight (all calculated on a dry weight basis).

[0183] In some cases, the total content of tobacco material, nicotine, and flavorings may be at least about 0.1%, 1%, 5%, 10%, 20%, 25%, or 30% by weight. In some cases, the total content of actives and / or flavorings may be less than about 90%, 80%, 70%, 60%, 50%, or 40% by weight (all calculated on a dry weight basis).

[0184] The amorphous solid may be made from a gel, which may further contain a solvent present at 0.1 to 50% by weight. However, the present inventors have established that the inclusion of a solvent in which the flavoring agent is soluble may decrease gel stability and cause the flavoring agent to crystallize from the gel. Therefore, in some cases, the gel does not contain a solvent in which the flavoring agent is soluble.

[0185] In some embodiments, the amorphous solid comprises less than 60% by weight of filler, e.g., between 1% and 60% by weight, or between 5% and 50% by weight, or between 5% and 30% by weight, or between 10% and 20% by weight.

[0186] In other embodiments, the amorphous solid contains less than 20% by weight of filler, suitably less than 10% by weight or less than 5% by weight. In some cases, the amorphous solid contains less than 1% by weight of filler, and in some cases no filler.

[0187] If present, the filler may include one or more inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. The filler may also include one or more organic filler materials such as wood pulp, cellulose, and cellulose derivatives. In certain cases, the amorphous solid does not include calcium carbonate, such as chalk.

[0188] 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 including a fibrous filler in an amorphous solid can increase the tensile strength of the material.

[0189] In some embodiments, the amorphous solid does not include tobacco fiber.

[0190] In some examples, the amorphous solid in sheet form may have a tensile strength of about 200 N / m to about 1500 N / m. In some examples, such as when the amorphous solid does not include a filler, the amorphous solid may have a tensile strength of 200 N / m to 400 N / m, or 200 N / m to 300 N / m, or about 250 N / m. Such tensile strengths may be particularly suitable for embodiments in which the amorphous solid material is formed as a sheet and then shredded and incorporated into an aerosol product.

[0191] In some instances, for example, when the amorphous solid includes a filler, the amorphous solid may have a tensile strength of 600 N / m to 1500 N / m, or 700 N / m to 900 N / m, or about 800 N / m. Such tensile strengths may be particularly suitable for embodiments in which the amorphous solid material is included in the aerosol product article as a rolled sheet, suitably in the form of a tube.

[0192] In some cases, the amorphous solid may consist essentially of or consist of a gelling agent, water, an aerosol-forming agent, a flavoring agent, and optionally an active agent.

[0193] In some cases, the amorphous solid may consist essentially of or consist of a gelling agent, water, an aerosol-forming agent, a flavoring agent, and optionally a tobacco material and / or a nicotine source.

[0194] The amorphous solid may include one or more active agents and / or flavoring agents, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0195] The aerosol-forming material can include tobacco material reconstituted with paper. The composition can alternatively or additionally include any of the tobacco forms described herein. The aerosol-forming material can include a sheet or shredded sheet containing tobacco material comprising 10% to 90% by weight of tobacco leaf, wherein the aerosol-forming material comprises up to about 20% by weight of the sheet or shredded sheet, with the remainder of the tobacco material comprising tobacco reconstituted with paper.

[0196] When the aerosol-forming material comprises an amorphous solid material, the amorphous solid material may be a dry gel comprising menthol. In alternative embodiments, the amorphous solid may have any composition described herein.

[0197] The inventors have found that improved articles can be produced that include aerosol-generating materials, preferably comprising a first component comprising a sheet or shredded sheet of aerosolizable material and a second component comprising an amorphous solid, wherein the material properties (e.g., density) and specifications (e.g., thickness, length, and cut width) fall within the ranges described herein.

[0198] In some cases, the amorphous solid may have a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness may range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm. The inventors have found that materials as thin as 0.09 mm can be used. The amorphous solid may include two or more layers, and the thicknesses described herein refer to the combined thickness of those layers.

[0199] The thickness of the amorphous solid material can be measured using a caliper 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.

[0200] The inventors have determined that if the amorphous solid is too thick, heating efficiency may decrease. This may adversely affect power consumption during use, for example, power consumption for releasing flavorings from the amorphous solid. Conversely, if the aerosol-forming amorphous solid is too thin, it may be difficult to manufacture and handle; very thin materials are more difficult to cast, more fragile, and may impair aerosol formation during use. In some cases, the individual strips or pieces of the amorphous solid have a minimum thickness of about 0.015 mm across their area. In some cases, the individual strips or pieces of the amorphous solid have a minimum thickness of about 0.05 mm or about 0.1 mm across their area. In some cases, the individual strips or pieces of the amorphous solid have a maximum thickness of about 1.0 mm across their area. In some cases, the individual strips or pieces of the amorphous solid have a maximum thickness of about 0.5 mm or about 0.3 mm across their area.

[0201] In some cases, the thickness of the amorphous solid may vary by no more than 25%, 20%, 15%, 10%, 5%, or 1% over its area.

[0202] The inventors have found that by providing an amorphous solid material and a sheet or shredded sheet of aerosolizable material having areal density values ​​that differ from each other by less than a predetermined percentage, segregation in a mixture of these materials is reduced. In some examples, the areal density of the amorphous solid material may be 50% to 150% of the areal density of the aerosolizable material. For example, the areal density of the amorphous solid material may be 60% to 140% of the density of the aerosolizable material, or 70% to 110% of the areal density of the aerosolizable material, or 80% to 120% of the areal density of the aerosolizable material.

[0203] In embodiments described herein, the amorphous solid material may be incorporated into the article in sheet form. The amorphous solid material in sheet form may be shredded and then incorporated into the article and suitably mixed with an aerosolizable material, such as a sheet or shredded sheet of aerosolizable material described herein.

[0204] In further embodiments, the amorphous solid sheet may further be incorporated as a flat sheet, as a gathered or bundled sheet, as a crimped sheet, or as a rolled sheet (i.e., in the form of a tube). In some such cases, the amorphous solid of these embodiments may be included in the aerosol product as a sheet, such as a sheet circumscribing a rod containing the aerosolizable material. For example, the amorphous solid sheet may be formed on a paper wrapper surrounding an aerosolizable material such as a cigarette.

[0205] The amorphous solid in sheet form is approximately 30 g / m 2 ~about 150g / m 2 In some cases, the sheet may have a density of about 55 g / m 2 ~Approx. 135g / m 2 , or about 80 to about 120 g / m2 , or about 70 to about 110 g / m 2 , or particularly about 90 to about 110 g / m 2 , or suitably about 100 g / m 2 These ranges can achieve densities similar to that of cut rag tobacco, resulting in a mixture of these materials that does not readily separate. Such areal densities can be particularly appropriate when the amorphous solid material is included in the aerosol product as a shredded sheet (discussed further below). In some cases, the sheet can have a mass per unit area of ​​about 30-70 g / m. 2 , 40~60g / m 2 , or 25-60g / m 2 and may be used to encase aerosolizable materials such as those described herein.

[0206] The aerosol-forming material may comprise a mixture of the aerosolizable material described herein and an amorphous solid material. Such aerosol-forming materials can achieve an aerosol with a desirable flavor profile during use because additional flavorings can be introduced into the aerosol-forming material by inclusion in the amorphous solid material component. Flavorings contained within the amorphous solid material may be more stably retained within the amorphous solid material compared to flavorings added directly to the tobacco material, resulting in a more consistent flavor profile among articles manufactured in accordance with the present disclosure.

[0207] As discussed above, tobacco materials having a density of at least 350 mg / cc to less than about 900 mg / cc, preferably about 600 mg / cc to about 900 mg / cc, have been found to advantageously provide a more sustained release of aerosol. To achieve an aerosol with a consistent flavor profile, the amorphous solid material components of the aerosol-forming material should be uniformly distributed throughout the rod. The inventors have found that this can be advantageously achieved by casting the amorphous solid material to a thickness as described herein to achieve an amorphous solid material having an areal density similar to that of the tobacco material, and by processing the amorphous solid material as described below to ensure uniform distribution throughout the aerosol-forming material.

[0208] As noted above, optionally, the aerosol-generating material includes multiple strips of amorphous solid material. When the aerosol-generating section includes multiple strands and / or strips of aerosolizable material sheets and multiple strips of amorphous solid material, the material properties and / or dimensions of the at least two components can be otherwise appropriately selected to ensure relatively uniform mixing of the components and to reduce separation or non-mixing of the components during or after production of the rod of aerosol-generating material.

[0209] The longitudinal dimension of the plurality of strands or strips may be substantially the same as the length of the aerosol-generating section. The plurality of strands and / or strips may have a length of at least about 5 mm.

[0210] Figure 2a is a side cross-sectional view of a further article 1' including a capsule-containing mouthpiece 2'. Figure 2b is a cross-sectional view of the capsule-containing mouthpiece shown in Figure 2a through line A-A'. Article 1' and capsule-containing mouthpiece 2' are the same as article 1 and mouthpiece 2 shown in Figure 1, except that the aerosol modifier is provided within body of material 6 in the form of capsules 11 in this example, and an oil-resistant first plug wrap 7' surrounds body of material 6. In other examples, the aerosol modifier may be provided in other forms, such as a material introduced within body of material 6, or may be provided on a thread that supports, for example, a flavoring or other aerosol modifier that may be disposed within body of material 6.

[0211] The capsule 11 can include a breakable capsule, for example, a capsule having a solid, frangible shell surrounding a liquid payload. In this example, a single capsule 11 is used. The capsule 11 is completely embedded within the body of material 6. In other words, the capsule 11 is completely surrounded by the material forming the body 6. In other examples, multiple breakable capsules, for example, two, three, or more breakable capsules, can be disposed within the body of material 6. The length of the body of material 6 can be increased to accommodate the number of capsules required. In examples where multiple capsules are used, the individual capsules can be identical to one another or can differ from one another in terms of size and / or capsule payload. In other examples, multiple bodies of material 6 can be provided, each containing one or more capsules.

[0212] Capsule 11 has a core-shell structure. In other words, capsule 11 includes a shell that encapsulates a liquid agent, such as a flavoring or other agent, which may be any of the flavorings or aerosol modifiers described herein. The capsule shell can be broken by a user to release the flavoring or other agent into body 6 of material. First plug wrap 7′ can include a barrier coating to render the plug wrap material substantially impermeable to the liquid payload of capsule 11. Alternatively or additionally, second plug wrap 9 and / or tipping paper 5 can include a barrier coating to render the plug wrap and / or tipping paper material substantially impermeable to the liquid payload of capsule 11.

[0213] In this example, capsule 11 is spherical and has a diameter of about 3 mm. In other examples, other capsule shapes and sizes can be used. For example, the capsule can have a diameter of less than 4 mm, or less than 3.5 mm, or less than 3.25 mm. In alternative embodiments, the capsule can have a diameter greater than about 3.25 mm, e.g., greater than 3.5 mm, or greater than 4 mm. The total weight of capsule 11 can range from about 10 mg to about 50 mg.

[0214] In this example, capsule 11 is positioned at a longitudinally central location within body 6 of material. That is, capsule 11 is positioned so that its center is 5 mm from each end of body 6 of material. In this example, the center of the capsule is positioned 36 mm from the upstream end of article 1. Preferably, the capsule is positioned so that its center is 28 mm to 38 mm from the upstream end of article 1, more preferably 34 mm to 38 mm from the upstream end of article 1. In this example, the center of the capsule is positioned 12 mm from the downstream end 2b of the mouthpiece. By locating the capsule in this location, the capsule's proximity to the aerosol-generation section of the article, which is heated during use, improves the volatility of the capsule contents, while being sufficiently far from the aerosol-generation section that is inserted into the aerosol delivery system during use, allowing the user to easily access the capsule and pop it with their fingers.

[0215] In other examples, the capsule 11 can be positioned at a position other than the longitudinal center within the body of material 6, i.e., closer to the downstream end of the body of material 6 than the upstream end, or closer to the upstream end of the body of material 6 than the downstream end. Preferably, the mouthpiece 2' is configured so that the capsule 11 and the vent hole 12 are offset from each other in the longitudinal direction within the mouthpiece 2'. For example, the vent hole 12 may be provided immediately upstream of the capsule position, i.e., about 1 mm to about 10 mm upstream of the capsule position.

[0216] 3 is a side cross-sectional view of a further article 1″ that includes a different heating element and electrical connector configuration than the example of FIG. 1. Article 1″ is otherwise identical to article 1 and mouthpiece 2 shown in FIG. 1, with like reference numerals indicating corresponding features.

[0217] In the example of Figure 3, rather than providing the heating element 13 and electrical connector arrangement 14 as pins as in the example of Figure 1, a wire heating element 13' is provided in the aerosol-generating material 3. The wire element 13' may be, for example, a conductive metal, and may generate heat through electrical resistance when an electric current is passed through the wire 13'. The wire element 13' may be any suitable conductive material that heats when an electric current is applied.

[0218] This allows the wire element 13' to heat the aerosol-generating material to generate an aerosol that is consumed by a user of the article 1". In the example of FIG. 3, the wire element 13' is a loop of wire disposed within the aerosol-generating material. Compared to the example of FIG. 1, a larger surface area of ​​the aerosol-generating material may be in contact with the wire loop rather than the pin, allowing for more efficient heating of the aerosol-generating material.

[0219] The wire element 13' may include an electrical connector arrangement 14' for removably connecting the heating element 13' to a power source so that electrical power can be supplied to the wire element 13' for heating. In the example of FIG. 3, the wire element 13' has first and second ends that protrude slightly from the upstream-most end of the rod of aerosol-generating material 3. The electrical connector arrangement 14' is provided for connecting the first and second ends of the wire element 13' to a power source. The electrical connector is provided on the outer surface of the aerosol-generating material and includes first and second terminal portions 14a', 14b' connected to the first and second ends of the wire element 13', respectively. The first and second terminal portions 14a', 14b' are provided for connection to respective first and second terminal portions of a power source, thereby forming a closed circuit for power transmission. The first and second terminal portions 14a', 14b' are configured to physically contact the power source to conduct electrical power to the heating element.

[0220] The first and second terminal portions 14a', 14b' may take the form of first and second plates. The plates may extend generally perpendicular to the length of the article. The plates may be flat plates configured to contact corresponding flat terminals of the power supply of the aerosol generating device. However, the plates may be shaped in any alternative manner, so long as they are capable of contacting corresponding surfaces of the terminals of the power supply to transfer power to the heating element 13'.

[0221] 4 is a cross-sectional side view of an additional article 1''' that includes a different heating element and electrical connector configuration than the example of FIG. 3. Otherwise, article 1''' is the same as article 1'' shown in FIG. 3, with like reference numerals indicating corresponding features.

[0222] In the example of FIG. 4, wire element 13″ is provided as a helical loop. The helical loop 13″ can provide a much larger surface area of ​​contact between the aerosol-generating material 3 and wire element 13″ for efficient heating. Therefore, article 1 may require less power to be supplied by the aerosol generating device to heat a given volume of aerosol-generating material compared to a single loop or pin example. Electrical connector configuration 14′ may be substantially the same as that described above with respect to article 1″ of FIG. 3.

[0223] 4 may include extruding a helical wire element with the aerosol-generating material while forming a rod of the aerosol-generating material 3. In this case, the rod may be cut at a location where the helical strands are spaced a predetermined distance apart so that first and second terminal portions connected to the ends of the helical strands can contact respective terminal portions of a power source for the aerosol-generating device.

[0224] In some examples, the electrical connector 14' of Figures 3 and / or 4 may be an inductive connector. That is, the heating element 13' or 13" may be connected to or form part of an inductive coil for receiving inductively transmitted power. For example, the aerosol generating device may include an inductive transmitter that, when activated, induces an electrical current in the heating element 13', 13".

[0225] Figure 5a shows a schematic cross-sectional view of a non-combustible aerosol delivery device 100 that engages an aerosol product product 1 for consumption by a user. The components of one embodiment of the non-combustible aerosol delivery device 100 are shown in simplified form. Notably, in Figure 5a, the elements of the non-combustible aerosol delivery device 100 are not drawn to scale. Elements that are not relevant to understanding this embodiment have been omitted to simplify Figure 5a.

[0226] As shown in FIG. 5 a, the non-combustible aerosol dispenser 100 includes a housing 101 that includes an area 102 for receiving the item 1 .

[0227] The region 102 is positioned to receive the item 1. When the item 1 is received within the region 102, at least a portion of the electrical connector 103 contacts the power source 104. In the diagram of FIG. 5a, a gap is shown between the electrical connector 103 and the power source 104 for clarity of elements. However, it will be understood that in use, the connector 103 and the power source are in physical and electrical contact to conduct power to the connector arrangement 103. In particular, when the item 1 is fully received within the region 102, at least a portion of the electrical connector 103 can be in direct contact with the power source 104. However, it will be understood that in instances where the power source is an inductive transmitter and the electrical connector 103 is an inductive receiver, direct physical contact between the electrical connector 103 and the power source 104 is not required.

[0228] The power supply 104 supplies power to an electrical connector 103, which transfers power to the heating element 105. The power transferred to the heating element 105 generates an electric current in the heating element 105, which heats due to its resistance. The heating element 105 heats the surrounding aerosol-forming material. The aerosol-forming material releases a series of volatile compounds at different temperatures. The power generated by the power supply 104 may be controlled by a user to change the temperature generated by the heating element 105. By controlling the maximum operating temperature of the electrically heated aerosol generating system 100, the selective release of undesirable compounds can be controlled by preventing the release of selected volatile compounds.

[0229] 1, the electrical connector 103 may include a magnetic material configured to magnetically couple with an electromagnet of the aerosol generation device 100. In particular, the power source 104 may include an electromagnet configured to magnetically couple with the electrical connector arrangement 103 when activated.

[0230] The use of an electromagnet as part of the power source 104 and magnetic-electrical connector arrangement 103 can securely hold the item 1 within the device 100. The electromagnet can be activated after the device is inserted and while the device is being used so that the magnet does not withdraw the pin before or after the device is inserted. In some examples, the electromagnet can be activated and deactivated by the user, for example, by using an activation button on the device. In other examples, the electromagnet can be automatically activated. For example, a weak magnetic field detected when the pin is near the electromagnet can automatically activate the electromagnet, turning it on and magnetically coupling the electrical connector arrangement 103 to the power source 104. This can make the item and device easier to use and safer, as the item may be less likely to become dislodged from the aerosol generator during use.

[0231] However, it will be appreciated that the article 1 may be held within the aerosol generating device by alternative means, for example, a clamp, or retaining rib, or other retaining member may be provided on the aerosol generating device to hold the article 1 within the device.

[0232] FIG. 5b illustrates an alternative electrical connector configuration 103 comprising a threaded screw configuration. The threaded screw configuration is configured to screw into a complementary receptor 104b of the power source. In this case, the complementary receptor 104b is a complementary thread. Electrical contact is made via the complementary thread. An additional electrical contact 104a can be provided at the base of the hollow cavity of the aerosol delivery device 100 and can be configured to electrically contact the end of the electrical connector configuration 103 that is inserted into the device 100. In this example, the heating element 105 is a pin with a threaded screw head as the electrical connector configuration 103. That is, the electrical connector configurations 103 together form a pin with a threaded screw head. However, it will be appreciated that the heating element 105 can comprise any suitable electrical connector configuration 103. In one example, the heating element can comprise a bayonet connector configuration that electrically connects the heating element 105 to the power source 104.

[0233] FIG. 6 shows a schematic cross-sectional view of a different non-combustible aerosol delivery device 100′ engaging an aerosol product product 1″ for consumption by a user. Similar to FIGS. 5a and 5b, the components of one embodiment of the non-combustible aerosol delivery device 100′ are shown in simplified form. Notably, in FIG. 6, the elements of the non-combustible aerosol delivery device 100 are not drawn to scale. Elements not relevant to understanding this embodiment have been omitted to simplify FIG. 6.

[0234] As shown in FIG. 6, non-flammable aerosol delivery device 100′ comprises a non-flammable aerosol delivery device having a housing 101 with an area 102 for receiving an article 1″. Device 100′ is substantially similar to device 100 of FIG. 1, except that power source 104′ is shown as having two complementary terminals for contacting electrical connector arrangement 103′, i.e., the terminals of heating element 105′ of article 1″. Power source 104′ is configured to transmit power to heating element 105′ through the plate of electrical connector arrangement 103′. In the example of FIG. 6, electrical connector 103′ is shown spaced apart from power source 104′ for clarity, but it will be appreciated that electrical connector 103′ directly contacts the terminals of power source 104′ to conduct power between device 100′ and heating element 103′. In other examples, heating element 103′ may be entirely contained within aerosol-generating material 3 and configured to be heated by induction. In such cases, the device may include an inductive transmitter that inductively transfers power to a heating element to heat the aerosol-forming material and generate the aerosol.

[0235] The terminals of the power source 104' may be provided in the form of pogo pins. Such pins include springs that absorb shock upon insertion of the item 1'' while biasing the terminals toward the terminals of the heating element to improve contact. In this manner, power transfer can be improved by improving physical and electrical contact between the terminals. Furthermore, wear and tear on the contacts can be reduced by including springs in the pogo pins. Thus, the lifespan of the device 100' can be improved.

[0236] As shown in Figure 7, within housing 101 is a power supply 104 that may comprise an energy source, for example, a rechargeable lithium-ion battery. A controller 107 is connected to power supply 104 and to a user interface 106, which may be, for example, buttons or a display. Controller 107 controls the power supplied by power supply 104 to regulate the temperature generated by heating element 105. Typically, the aerosol-forming substrate is heated to a temperature between 250°C and 450°C.

[0237] The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not exhaustive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be construed as limitations on the scope of the invention as defined by the claims or limitations on the equivalents of the claims, and it should be understood that other embodiments may be utilized 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 specifically described herein. Furthermore, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. 1. An article for use in a non-flammable aerosol delivery system, comprising: an aerosol-generating material; and a heating element for heating the aerosol-forming material; and an electrical connector arrangement for removably connecting the heating element to a power source; Equipped with the electrical connector arrangement is formed of an electrically conductive material to transfer electrical power from the power source to the heating element; the electrical connector arrangement and the heating element together form a pin that is inserted into the aerosol-generating material, the heating element being a first pin portion of the pin that extends along the length of the aerosol-generating material, and the electrical connector arrangement being a second pin portion connected to the first pin portion and extending generally perpendicular to the length of the article; The article, wherein the second pin portion covers an outer surface of an upstream-most end of the aerosol-forming material, thereby forming a cap on the upstream-most end of the article.

2. The article of claim 1 , wherein the heating element is at least partially disposed within the aerosol-forming material.

3. The article of claim 2 , wherein the electrical connector arrangement forms part of or is in physical contact with the heating element.

4. The article of claim 3 , wherein the electrical connector arrangement protrudes from or is flush with an outer surface of the article.

5. The article of claim 4 , wherein the article comprises a mouth and an aerosol-generating end, and the electrical connector arrangement projects from an upstream end of the aerosol-generating material.

6. The article of claim 1 , wherein the electrical connector configuration is at least one of a bayonet-type connector and a screw-type connector.

7. The article of claim 4 , wherein the electrical connector arrangement projects from an upstream end of the aerosol-forming material and forms an upstream-most end of the article.

8. The article of claim 1 , wherein the electrical connector arrangement comprises first and second terminal portions for connecting to respective first and second terminal portions of the power source.

9. The article of claim 1 , wherein the electrical connector arrangement comprises a magnetic material configured to magnetically couple to an electromagnet forming part of the power source.

10. The article of claim 1 , further comprising a mouth end section disposed downstream of the aerosol-forming material.

11. The article of claim 10 , wherein the mouth end section comprises at least one filter segment.

12. 11. The article of claim 10, wherein the mouth end section comprises a cooling section disposed downstream of the aerosol-forming material, the cooling section comprising a hollow channel.

13. The article of claim 10 , wherein the mouth end section comprises a hollow tubular element forming the downstream extreme end of the article.

14. An article according to any one of claims 1 to 13; an aerosol generating device comprising a power source configured to contact the electrical connector arrangement and thereby transfer power to the heating element of the article; A non-flammable aerosol generating system comprising:

15. 15. The non-flammable aerosol generating system of claim 14, wherein the aerosol generating device comprises an electromagnet for magnetically coupling to a magnetic portion of the electrical connector arrangement when the electrical connector arrangement is in physical contact with the power source.

16. 15. The non-flammable aerosol generating system of claim 14, wherein the power source of the aerosol generating device comprises first and second electrical terminals for connection to first and second terminals of the article.

17. A method for producing an article according to any one of claims 1 to 13, comprising the steps of: Providing an aerosol-generating material; inserting a heating element into the aerosol-forming material; providing an electrical connector arrangement for removably connecting the heating element to a power source; Including, the electrical connector arrangement is formed of an electrically conductive material to transfer electrical power from the power source to the heating element; the electrical connector arrangement and the heating element together form a pin that is inserted into the aerosol-generating material, the heating element being a first pin portion of the pin that extends along the length of the aerosol-generating material, and the electrical connector arrangement being a second pin portion connected to the first pin portion and extending generally perpendicular to the length of the article; the second pin portion covers an outer surface of the upstream-most end of the aerosol-forming material, thereby forming a cap on the upstream-most end of the article. method.

18. 1. A heating element for use in a non-flammable aerosol delivery system, comprising: an electrical connector arrangement for removably connecting said heating element to a power source; The heating element, wherein the electrical connector arrangement is formed of an electrically conductive material to transfer electrical power from the power source to the heating element.

19. 20. The heating element of claim 18, wherein the electrical connector arrangement comprises a threaded screw arrangement configured to removably connect to a complementary receptor of the power source.

20. 20. The heating element of claim 18, wherein the electrical connector arrangement comprises a bayonet connector arrangement configured to removably connect to a complementary receptor of the power source.

21. 20. The heating element of claim 18, wherein the electrical connector arrangement comprises a pogo pin arrangement configured to removably connect to a complementary receptor of the power source.

22. 1. A non-flammable aerosol delivery system comprising: A heating element according to any one of claims 18 to 21; an aerosol delivery device comprising a power source configured to be electrically connected to the heating element; an article for use in the non-flammable aerosol delivery system, the article including an aerosol-generating material configured to receive the heating element; A non-flammable aerosol delivery system comprising:

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