Aerosol-forming composition

Abstract

The present disclosure relates to an aerosol-forming composition that includes an aerosol-forming material and a fibrous susceptor material, and a process for making the aerosol-forming composition.

Description

[Technical Field]

[0001] This application relates to aerosol-forming compositions, components comprising the aerosol-forming compositions, and articles for use in non-flammable aerosol delivery systems comprising the components.

[0002] In use, aerosol generating systems generate an aerosol that is inhaled by a user. For example, tobacco heating devices heat an aerosol-generating material, such as tobacco, to form an aerosol by heating but not burning the aerosol-generating material. Some aerosol generating systems include a susceptor configured to heat the aerosol-generating material and form the aerosol. Overview

[0003] According to a first aspect of the present disclosure, there is provided an aerosol-forming composition comprising an aerosol-forming material and a fibrous susceptor material.

[0004] In some embodiments, the fibrous susceptor material is permeable to the passage of gases.

[0005] In some embodiments, the fibrous susceptor material is a woven or nonwoven material.

[0006] In some embodiments, the fibrous susceptor material comprises metal fibers or carbon fibers.

[0007] In some embodiments, the fibrous susceptor material is in the form of a sheet or chopped sheet.

[0008] In some embodiments, the sheet has a thickness of 150 μm to 300 μm.

[0009] In some embodiments, the aerosol-forming material comprises a binder, an aerosol-forming agent, optionally an active agent or flavoring, and optionally a filler.

[0010] In some embodiments, the aerosol-forming material comprises plant material.

[0011] In some embodiments, the aerosol-forming composition comprises multiple strands of aerosol-forming material.

[0012] In some embodiments, the article comprises a plurality of strands of fibrous susceptor material.

[0013] In some embodiments, the strands of aerosol-forming material are substantially parallel to one another.

[0014] In some embodiments, the strands of fibrous susceptor material are substantially parallel to one another.

[0015] In some embodiments, the strands of aerosol-generating material and the strands of fibrous susceptor material are substantially parallel to one another.

[0016] In some embodiments, each of the strands of aerosol-forming material is substantially straight.

[0017] In some embodiments, each of the strands of fibrous susceptor material is substantially straight.

[0018] In some embodiments, the strands of fibrous susceptor material have a length of between 10 mm and 15 mm.

[0019] In some embodiments, the aerosol-forming composition comprises reconstituted tobacco material.

[0020] In some embodiments, the fibrous susceptor material includes fibers that are randomly oriented relative to one another.

[0021] According to a second aspect of the present disclosure, there is provided a process for producing the aerosol-forming composition of the first aspect.

[0022] In some embodiments, the process includes combining an aerosol-generating material with a fibrous susceptor material.

[0023] In some embodiments, the process includes providing a sheet of aerosol-generating material, providing a sheet of fibrous susceptor material, cutting the sheet of aerosol-generating material to form a plurality of separate portions of aerosol-generating material, cutting the sheet of fibrous susceptor material to form a plurality of separate portions of fibrous susceptor material, and combining the plurality of separate portions of aerosol-generating material with the plurality of separate portions of fibrous susceptor material to form an aerosol-generating composition.

[0024] In some embodiments, the sheet of aerosol-generating material and the sheet of fibrous susceptor material are cut simultaneously.

[0025] The aerosol-forming composition can be produced according to the process of the second embodiment.

[0026] According to a third aspect of the present disclosure, there is provided an article component for use with a non-combustible aerosol delivery device, the component comprising an aerosol-forming composition produced according to the process of the first aspect or the second aspect.

[0027] In some embodiments, the component includes a wrapper that surrounds the aerosol-forming material.

[0028] In some embodiments, the component is in the form of a rod.

[0029] In some embodiments, the component is an aerosol-generating section of an article for use with a non-flammable aerosol delivery device.

[0030] According to a fourth aspect of the present disclosure, there is provided a process for manufacturing a component according to the third aspect.

[0031] In some embodiments, the process includes inserting one or more of a plurality of separate portions of the aerosol-generating material into a wrapper, and inserting one or more of a plurality of separate portions of the fibrous susceptor material into the wrapper to form a component.

[0032] In some embodiments, the process includes combining an aerosol-forming composition with a field of fibrous susceptor material to form a mixture and surrounding the mixture with a wrapper to form the component.

[0033] In some embodiments, the process includes gathering the strands together to form a rod.

[0034] In some embodiments, the process includes longitudinally cutting a sheet of the aerosol-forming composition to produce a plurality of separate portions of the aerosol-forming material, and longitudinally cutting a sheet of the fibrous susceptor material to produce a plurality of separate portions of the fibrous susceptor material.

[0035] Components of articles for use with non-combustible aerosol delivery devices can be manufactured according to the process of the fourth aspect.

[0036] In some embodiments, the component is an aerosol-generating section of an article for use with a non-flammable aerosol delivery device.

[0037] According to a fifth aspect of the present disclosure, there is provided an article for use with a non-combustible aerosol delivery device, comprising the components of the third aspect.

[0038] 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]

[0039] [Figure 1] FIG. 1 is a perspective view of an article for use with a non-flammable aerosol delivery device. [Figure 2] 1 is a side cross-sectional view of a portion of an article for use with a non-combustible aerosol delivery device. [Figure 3] 1 is an overview of a process for manufacturing components for use with an article for use with a non-combustible aerosol delivery device. [Figure 4] FIG. 1 is a perspective view of a bobbin of aerosol-forming material. [Figure 4a] FIG. 1 is a perspective view of a bobbin of fibrous susceptor material. [Figure 5] FIG. 1 is a schematic diagram of a process for manufacturing a component for use with an article for use with a non-combustible aerosol delivery device. [Figure 6] FIG. 1 is a schematic diagram of a process for manufacturing a component for use with an article for use with a non-combustible aerosol delivery device. [Figure 7] 1 is a cross-sectional side view of an article for use with a non-combustible aerosol delivery device. [Figure 8] FIG. 1 is a schematic diagram of a non-combustible aerosol delivery device. [Figure 9] FIG. 1 is a schematic diagram of a non-combustible aerosol delivery device. [Figure 10] FIG. 1 is a schematic diagram of a non-combustible aerosol delivery device. [Figure 11] FIG. 1 is a schematic diagram of a non-combustible aerosol delivery device. Detailed Description

[0040] As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user; Combustion aerosol delivery systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or for hand-rolled or handmade cigarettes, whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smoking materials; a non-combustion aerosol delivery system that releases compounds from an aerosol-forming material without burning the aerosol-forming material, such as an electronic cigarette, tobacco heating product, or mixing system for generating an aerosol using a combination of aerosol-forming materials; an aerosol-free delivery system that delivers at least one substance, which may or may not contain nicotine, to a user orally, nasally, transdermally, or otherwise, without forming an aerosol, including, but not limited to, lozenges, gums, patches, articles containing inhalable powders, and oral products such as oral tobacco, including snus and moist snuff; Includes:

[0041] According to the present disclosure, a "non-combustible" aerosol delivery system is one in which the aerosol-generating components of the aerosol delivery system (or components thereof) are not combusted or burned to facilitate delivery of at least one substance to a user.

[0042] In some embodiments, the delivery system is a non-combustible aerosol delivery system, such as a powered non-combustible aerosol delivery system.

[0043] In some embodiments, the non-combustion aerosol delivery system is an electronic cigarette, also known as a vaping device 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.

[0044] In some embodiments, the non-combustion aerosol delivery system is an aerosol-generating material heating system, also known as a non-combustion heating system. An example of such a system is a tobacco heating system.

[0045] In some embodiments, the non-combustion aerosol delivery system is a mixing system for generating an aerosol using a combination of aerosol-forming materials, and one or more of the aerosol-forming materials can be heated. Each of the aerosol-forming materials can be, for example, in solid, liquid, or gel form, and may or may not contain nicotine. In some embodiments, the mixing system includes a liquid or gel aerosol-forming material and a solid aerosol-forming material. The solid aerosol-forming material can include, for example, tobacco or a non-tobacco product.

[0046] Typically, a non-combustible aerosol delivery system can include a non-combustible aerosol delivery device and consumables for use with the non-combustible aerosol delivery system.

[0047] In some embodiments, the present disclosure relates to articles that include aerosol-generating materials and are configured for use with non-combustible aerosol delivery devices. These articles are sometimes referred to as consumables throughout this disclosure.

[0048] As used herein, the terms "upstream" and "downstream" are relative terms defined in relation to the direction in which mainstream aerosol is drawn through the article or device in use.

[0049] In some embodiments, a non-combustion aerosol delivery system, e.g., a non-combustion aerosol delivery device of a non-combustion aerosol delivery system, can include a power source and a controller. The power source can be, for example, an electrical power source or a heat source. In some embodiments, the heat source includes a carbon substrate that can be excited to dissipate power in the form of heat to an aerosol-generating material or a heat transfer material in proximity to the heat source.

[0050] In some embodiments, the non-combustion aerosol delivery system includes an area for receiving an article for use in the non-combustion aerosol delivery system, an aerosol generator, an aerosol-generation area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0051] In some embodiments, an article for use with a non-combustible aerosol delivery device includes an aerosol-forming composition including an aerosol-forming material, an aerosol-forming composition storage region, an aerosol-forming composition transfer component, an aerosol generator, an aerosol-generating region, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0052] In the figures described herein, like reference numerals are used to describe equivalent features, items or components.

[0053] FIG. 1 is a perspective view of an article for use with a non-flammable aerosol delivery device.

[0054] Article 1 comprises a mouthpiece 2 and an aerosol-generation section 3 connected to mouthpiece 2. In this example, aerosol-generation section 3 comprises an aerosol-generating composition 3a in the form of a cylindrical rod. Article 1 comprises an upstream end 2a and a downstream end 2b spaced from upstream end 2a.

[0055] The aerosol-forming composition 3a includes an aerosol-forming material and a fibrous susceptor material that is heatable using induction heating.

[0056] Induction heating is a process of heating a conductive object (such as a susceptor) by electromagnetic induction. A magnetic field generator can include an induction element, e.g., one or more inductor coils, and a device for passing a variable current, such as an alternating current, through the induction element. The variable current in the induction element generates a variable magnetic field. The variable magnetic field penetrates a susceptor appropriately positioned relative to the induction element and generates eddy currents within the susceptor. The susceptor has an electrical resistance to eddy currents, and the flow of eddy currents against this resistance heats the susceptor by Joule heating. If the susceptor contains a ferromagnetic material, such as iron, nickel, or cobalt, heat can also be generated by magnetic hysteresis losses in the susceptor, i.e., by varying the orientation of magnetic dipoles in the magnetic material as a result of alignment with the varying magnetic fields. In induction heating, heat is generated within the susceptor, allowing for faster heating than, for example, conduction heating. Furthermore, no physical contact is required between the induction heater and the susceptor, allowing for greater flexibility in construction and application.

[0057] The fibrous susceptor material includes a plurality of fibers formed from a material that can be heated by penetration of a varying magnetic field. Examples of such materials include metals such as steel, copper, aluminum, and steel, and non-metals such as carbon, carbon fiber, graphite, and silicon carbide. The fibers can be made from other materials that can be heated by penetration.

[0058] The fibers can be randomly oriented relative to each other, or each can have the same orientation.

[0059] The fibrous susceptor material can be in the form of a woven sheet, a nonwoven sheet, or a sintered sheet. The fibrous susceptor material can be a metallic needle-punched felt, typically formed by entangling fibers through needle punching.

[0060] Nonwoven materials typically include sheet or web structures formed by entangling fibers or filaments or by perforating films. They can be formed mechanically, thermally, or chemically. They are generally flat or tufted porous sheets made directly from discrete fibers or molten material. Nonwoven materials are not made by weaving or knitting and do not require the transformation of fibers into yarns.

[0061] Needlepunched nonwoven fabrics can be made from a variety of fibrous webs (e.g., carded webs) in which the fibers are mechanically bonded together by fiber entanglement and friction after fine needle barbs repeatedly penetrate the fibrous web.

[0062] The fibrous material may be porous, which allows the aerosol to pass through the fibrous susceptor material, making the fibrous susceptor material particularly suitable for use in articles for use with non-combustion aerosol delivery devices.

[0063] The fibrous susceptor material may include a mixture of fibers that are heatable by penetration with a fluctuating magnetic field and fibers that are not heatable by penetration with a fluctuating magnetic field. For example, the fibrous susceptor material may include metal fibers woven with synthetic or non-synthetic yarns, such as cotton, nylon, or polyester. The fibrous susceptor material may include a mixture of fibers made from different materials that are heatable by penetration with a fluctuating magnetic field. For example, the fibrous susceptor material may include a mixture of metal fibers and carbon fibers. The presence of fibers made from different materials can increase the strength and robustness of the fibrous susceptor material.

[0064] The fibrous susceptor material can have a relatively large surface area-to-volume ratio, which can help improve contact between the fibrous susceptor material and the aerosol-generating material in intimate contact with the fibrous susceptor material. Therefore, heat generated by the fibrous susceptor material during use is efficiently transferred to the surrounding aerosol-generating material. Furthermore, due to the relatively large surface area-to-volume ratio, a relatively low mass of the fibrous susceptor material may be required to achieve sufficient heating of the aerosol-generating material during use.

[0065] The fibrous susceptor material can be a flexible or rigid sheet material. The fibrous susceptor can be in the form of a continuous sheet or a discontinuous sheet such as a mesh or web. In some embodiments, the fibrous susceptor comprises multiple strands or strips of the fibrous susceptor material. When the fibrous susceptor material is a flexible sheet, it can be wound up with sufficient flexibility to form a bobbin of fibrous susceptor material. This makes the fibrous susceptor material easier to handle during manufacturing. Furthermore, fibrous sheets can be more easily cut (e.g., into strands or strips) than other types of susceptor materials. This makes the fibrous susceptor particularly suitable for rapid continuous manufacturing techniques.

[0066] When the fibrous susceptor material is in the form of a sheet, the sheet can have a thickness of about 1 μm to about 500 μm. The susceptor material can have a thickness of about 150 μm to about 300 μm. The sheet of fibrous susceptor material can be chopped to form chopped sheets of fibrous susceptor material. The chopped sheets can be mixed with an aerosol-generating material also in the form of chopped sheets.

[0067] The aerosol-forming composition includes an aerosol-forming material, which may include a binder and an aerosol-forming agent.

[0068] An aerosol-forming material is a material capable of generating an aerosol when activated, for example, by heating, irradiation, or in any other manner. The aerosol-forming material can be in the form of a solid, liquid, or semi-solid, such as a gel, and may or may not contain an active substance and / or flavoring.

[0069] The aerosol-generating composition includes at least one aerosol-generating material. The aerosol-generating material may include multiple aerosol-generating materials. The multiple aerosol-generating materials may be the same or different. For example, the aerosol-generating composition may include a first aerosol-generating material and a second aerosol-generating material. Additional (e.g., third, fourth, fifth, or more) aerosol-generating materials may also be included in the composition.

[0070] At least one of the aerosol-generating materials may be an aerosol-generating material that includes a binder (which may be a gelling agent) and an aerosol-forming agent. Optionally, an active substance and / or a bulking agent may also be present. Optionally, a solvent, such as water, may also be present, and one or more other components of the aerosol-generating material may or may not be soluble in the solvent.

[0071] In some embodiments, the binder includes or is a gelling agent. The binder can include one or more compounds selected from the group including alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the binder includes 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 binder includes a hydrocolloid. In some cases, the binder includes alginate and / or pectin and may be combined with a stiffening agent (calcium source), etc., during formation of the aerosol-forming material. In some cases, the aerosol-forming material may include calcium-crosslinked alginate and / or calcium-crosslinked pectin.

[0072] The binder may comprise one or more compounds selected from cellulosic binders, non-cellulosic binders, guar gum, acacia gum, and mixtures thereof.

[0073] In some embodiments, the cellulosic binder is selected from the group consisting of hydroxymethyl cellulose, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose (CMC), hydroxypropyl methyl cellulose (HPMC), methyl cellulose, ethyl cellulose, cellulose acetate (CA), cellulose acetate butyrate (CAB), cellulose acetate propionate (CAP), and combinations thereof.

[0074] In some embodiments, the binder comprises (or is) one or more of hydroxyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethyl cellulose, guar gum, or acacia gum.

[0075] In some embodiments, the binder comprises one or more non-cellulosic binders (or is one or more non-cellulosic gelling agents), including, but not limited to, agar, xanthan gum, gum arabic, guar gum, locust bean gum, pectin, carrageenan, starch, alginic acid, and combinations thereof. In preferred embodiments, the non-cellulose-based binder is alginic acid or agar.

[0076] In some examples, the aerosol-forming material includes the binder in an amount of about 5-40 wt %, or about 15-40 wt %, of the aerosol-forming material. That is, the aerosol-forming material may include the binder in an amount of about 5-40 wt %, or about 15-40 wt %, of the aerosol-forming material, based on the dry weight of the aerosol-forming material. In some examples, the aerosol-forming material includes the binder in an amount of about 20-40 wt %, or about 15-35 wt %, of the aerosol-forming material.

[0077] In some examples, the binder contains alginic acid in an amount of about 5-40 wt% or 15-40 wt% of the aerosol-forming material. That is, the aerosol-forming material contains alginic acid in an amount of about 5-40 wt% or 15-40 wt% by dry weight of the aerosol-forming material. In some examples, the aerosol-forming material contains alginic acid in an amount of about 20-40 wt% or about 15-35 wt% of the aerosol-forming material.

[0078] In some examples, the binder comprises pectin in an amount of about 3-15 wt% of the aerosol-forming material, i.e., the aerosol-forming material comprises pectin in an amount of about 3-15 wt% of the aerosol-forming material, based on the dry weight of the aerosol-forming material. In some examples, the aerosol-forming material comprises pectin in an amount of about 5-10 wt% of the aerosol-forming material.

[0079] In some examples, the guar gum is present in the binder in an amount of about 3-40 wt% of the aerosol-forming material. That is, the aerosol-forming material contains guar gum in an amount of about 3-40 wt% based on the dry weight of the aerosol-forming material. In some examples, the aerosol-forming material contains guar gum in an amount of about 5-10 wt% of the aerosol-forming material. In some examples, the aerosol-forming material contains guar gum in an amount of about 15-40 wt%, about 20-40 wt%, or about 15-35 wt% of the aerosol-forming material.

[0080] In some embodiments, the alginic acid is present in an amount of at least about 50 wt% of the binder. In some embodiments, the aerosol-forming material includes alginic acid and pectin, and the ratio of alginic acid to pectin is 1:1 to 10:1. The ratio of alginic acid to pectin is typically greater than 1:1, i.e., the alginic acid is present in an amount greater than the amount of pectin. In some embodiments, the ratio of alginic acid to pectin is about 2:1 to 8:1, or about 3:1 to 6:1, or approximately 4:1.

[0081] The aerosol-forming material can be formed by forming a slurry and then drying the slurry to form a solid. The inclusion of a binder in the slurry results in the aerosol-forming material being formed from a dried gel. It has been discovered that the inclusion of a binder in the aerosol-forming material stabilizes flavor compounds, such as menthol, within the gel matrix, allowing for higher flavor loadings than non-gel compositions. The flavoring (e.g., menthol) is stable at high concentrations, and the product has a good shelf life.

[0082] In some embodiments, the binder comprises alginic acid, and the binder is present in the aerosol-forming material in an amount of 10-30 wt%, 20-35 wt%, or 25-30 wt% of the slurry / aerosol-forming material (calculated on a dry weight basis). In some embodiments, alginic acid is the only binder present in the aerosol-forming material. In other embodiments, the binder comprises alginic acid and at least one additional binder, such as pectin.

[0083] The aerosol-forming material may include an aerosol-forming agent. An "aerosol-forming agent" (also referred to herein as an aerosol-forming agent material) is an agent that facilitates the generation of an aerosol. The aerosol-forming agent can facilitate the generation of an aerosol by promoting the initial vaporization and / or condensation of a gas into an inhalable solid and / or liquid aerosol. In some embodiments, the aerosol-forming agent can improve the delivery of flavorants from the aerosol-forming material. Generally, any suitable aerosol-forming agent material or agent can be included in the aerosol-forming materials of the present invention, including those described herein. Other suitable aerosol-forming materials include, but are not limited to, polyols such as sorbitol, glycerol, and glycols such as propylene glycol or triethylene glycol; non-polyols such as monohydric alcohols, high-boiling hydrocarbons; acids such as lactic acid; glycerol derivatives; esters such as diacetin, triacetin, triethylene glycol diacetate, triethyl citrate, or myristic acid, including ethyl myristate and isopropyl myristate, and aliphatic carboxylic acid esters such as methyl stearate, dimethyl dodecanedioate, and dimethyl tetradecanedioate.

[0084] The aerosol-forming agent may be present in the aerosol-forming material in an amount up to about 80 wt% of the aerosol-forming material, such as from about 0.1 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt%, or 10% to about 80 wt%, 75 wt%, 70 wt%, 65 wt%, 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt% of the aerosol-forming material. In some embodiments, the aerosol-forming material comprises the aerosol-forming agent in an amount of about 40-80 wt%, 40-75 wt%, 50-70 wt%, or 55-65 wt%.

[0085] In some embodiments, the aerosol-forming agent can be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. Glycerol can be present in an amount of 10-20% by weight of the tobacco material, such as 13-16% by weight of the composition, or about 14% or 15% by weight of the composition. Propylene glycol, when present, can be present in an amount of 0.1-0.3% by weight of the composition.

[0086] The aerosol former may act as a plasticizer. 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 consists essentially of glycerol or consists of glycerol. It has been established that if the plasticizer content is too high, the aerosol-generating material may absorb water, resulting in a material that does not produce a proper consumption experience during use. It has been established that if the plasticizer content is too low, the aerosol-generating material may become brittle and easily break. The plasticizer content specified herein provides flexibility to the aerosol-generating material, allowing the sheet to be wound onto a bobbin, which may be useful for producing consumable products or allowing the sheet to be transported before shredding.

[0087] The aerosol-forming agent can enhance the mouthfeel, and generally the sensory characteristics, of the aerosol generated by the aerosol-forming material when heated and inhaled by a user, particularly when the aerosol-forming material contains a relatively large amount (e.g., >40 wt%) of the aerosol-forming agent. The ability of the aerosol-forming material to retain a large amount of the aerosol-forming agent can reduce the need to add other components of the aerosol-forming material, such as expanded plant matter material, along with large amounts of the aerosol-forming agent. This can improve production efficiency.

[0088] The aerosol-forming material may include a filler. The filler is generally a non-tobacco component, i.e., a component that does not contain tobacco-derived materials. The filler component may be a non-tobacco fiber, such as wood fiber or pulp or wheat fiber. The filler component may also be an inorganic material, such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, etc. The filler component may also be a non-tobacco cast material or a non-tobacco extrusion material. The filler component may be present in an amount of 0-20% by weight of the tobacco material, or in an amount of 1-10% by weight of the composition. In some embodiments, no filler component is present.

[0089] In some cases, the aerosol-forming material comprises 5-50 wt%, 10-40 wt%, or 15-30 wt% filler. In some such cases, the aerosol-forming material comprises at least 1 wt% filler, e.g., at least 5 wt%, at least 10 wt%, at least 20 wt%, at least 30 wt%, at least 40 wt%, or at least 50 wt% filler. In exemplary embodiments, the aerosol-forming material comprises 5-25 wt% filler, including fibers. Preferably, the filler consists of or is in the form of fibers.

[0090] In some embodiments, the aerosol-forming material contains less than 60 wt% filler, such as between 1 wt% and 60 wt%, or between 5 wt% and 50 wt%, or between 5 wt% and 30 wt%, or between 10 wt% and 20 wt%.

[0091] In other embodiments, the aerosol-forming material contains less than 20 wt%, preferably less than 10 wt% or less than 5 wt% filler.

[0092] The filler may include one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives (such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)). Inorganic fillers, such as calcium carbonate or chalk, may also be used. In some embodiments, the aerosol-forming material does not include calcium carbonate, such as chalk.

[0093] Preferably, 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 (such as methylcellulose, hydroxypropylcellulose, and carboxymethylcellulose (CMC)). Without wishing to be bound by theory, it is believed that including a fibrous filler in the aerosol-generating material can increase the tensile strength of the material. In addition, the inclusion of a fibrous filler has been found to improve the handling of the aerosol-generating material during production. In particular, the resulting aerosol-generating material has been found to be less "sticky" and, as a result, more easily shredded during production. Therefore, the inclusion of a fibrous filler can increase production efficiency and reduce the likelihood of machine stoppages during shredding. The inclusion of a fibrous filler in the aerosol-generating material also means that the aerosol-generating material is less likely to clump together (e.g., clump) when shredded. When shredded aerosol-generating material is included in a consumable product, the reduced clumping optimizes the distribution of the shredded aerosol-generating material in the consumable product. Therefore, having each consumable contain a similar amount of chopped aerosol-generating material can likely improve the uniformity of flavor loading within a batch of consumables and / or within a given consumable.

[0094] In some embodiments, the aerosol-generating material comprises the substance to be delivered, which may include one or more active ingredients, one or more flavorings, one or more aerosol former materials, and / or one or more other functional materials.

[0095] In some embodiments, the substance to be delivered comprises an active agent.

[0096] As used herein, an active substance may be a physiologically active material, which is a material intended to achieve or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, and psychoactive substances. The active substance may be naturally derived or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or components, derivatives (including, but not limited to, the corresponding acidic forms of these materials, where appropriate), or combinations thereof. The active substance may also include one or more components, derivatives, or extracts of tobacco, cannabis, or another botanical substance.

[0097] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0098] As described herein, the active substance may comprise or be derived from one or more botanical substances, or components, derivatives, or extracts thereof. As used herein, the term "botanical substance" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc. Alternatively, the material may comprise synthetically derived active compounds naturally occurring in the botanical substance. The material may be in the form of a liquid, gas, solid, powder, dust, ground particles, granules, pellets, fragments, strips, sheets, etc. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. , lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, pimento, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, kavi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: common mint (Mentha arvensis), grapefruit mint (Mentha cv), Egyptian mint (Mentha niliaca), peppermint (Mentha piperita), lime mint (Mentha piperita citrata cv), chocolate mint (Mentha piperita cv), curly mint (Mentha spicata crispa), wild mint (Mentha cordifolia), horse mint (Mentha longifolia), pineapple mint (Mentha suaveolens variegata), pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata cv), and apple mint (Mentha suaveolens).

[0099] In some embodiments, the active substance comprises or is derived from one or more botanical substances, or components, derivatives, or extracts thereof, and the botanical substance is tobacco material.

[0100] As used herein, the term "tobacco material" refers to material derived from a plant of the Nicotiana species. The selection of the plant of the Nicotiana species is not limited, and the type or types of tobacco used may vary. 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, leaf tobacco, tobacco stems, reconstituted tobacco, and / or tobacco extract. As used herein, "leaf tobacco" refers to cut laminar tobacco.

[0101] In some embodiments, the tobacco material is selected from flue-cured or Virginia, burley, sun-cured, Maryland, dark (fire-cured), dark (air-cured), light (air-cured), Indian (air-cured), Red Russian, and rustica tobaccos, and mixtures thereof, as well as various other rare or specialty tobaccos (green or cured). Tobacco materials produced through any other type of tobacco processing that can modify the tobacco taste, such as fermented tobacco or genetic engineering or hybridization techniques, are also within the scope of this disclosure. For example, it is contemplated that tobacco plants can be genetically engineered or hybridized to increase or decrease the production of a component, property, or attribute.

[0102] In some embodiments, the tobacco material is sun-cured tobacco selected from Indian Kurnool and Oriental tobaccos, including Izmir, Basma, Samsun, Katerini, Prelip, Komotini, Xanthi, and Yambol tobaccos. In some embodiments, the tobacco material is dark (air-cured) tobacco selected from Passanda, Cubano, Jatin, and Beski tobaccos. In some embodiments, the tobacco material is light (air-cured) tobacco selected from North Wisconsin and Galpao tobaccos. In some embodiments, the tobacco material is selected from Brazilian tobacco, including Matafina and Bahia tobacco, hi some embodiments, the tobacco material is selected from Criollo, Pilotto Cubano, Olor, Green River, Isabela DAC, White Pata, Elulu, Jatim, Madura, Kasturi, Connecticut Seed, Broadleaf, Connecticut, Pennsylvania, Italian (air-cured), Paraguayan (air-cured), and Wansucker tobacco.

[0103] For the preparation of smokeable / electronic smoking or smokeless tobacco products, plants of the Nicotiana species may be subjected to a curing method. Certain types of tobacco may be subjected to different types of curing methods, such as flue-curing or sun-drying. Preferably, but not necessarily, the cured harvested tobacco is aged.

[0104] Tobacco can be harvested at different stages of growth, for example, when the plant reaches a level of maturity and the lower leaves can be harvested while the upper leaves are still growing.

[0105] In some embodiments, at least a portion of a plant of a Nicotiana species (e.g., at least a portion of the tobacco material) is used in an immature form, i.e., in some embodiments, the plant or at least a portion of the plant is harvested before reaching a stage normally considered ripe or mature.

[0106] In some embodiments, at least a portion of a plant of the Nicotiana species (e.g., at least a portion of the tobacco material) is used in a mature form. That is, in some embodiments, the plant or at least a portion of the plant is harvested when the plant (or plant portion) has reached a point traditionally considered ripe, overripe, or mature, and harvesting can be done using tobacco harvesting techniques traditionally used by farmers. Both Oriental and Burley tobacco plants can be harvested. Additionally, Virginia tobacco leaves can be harvested or picked according to the position of their petioles.

[0107] Nicotiana species may be selected for the content of various compounds present in the plant. For example, plants may be selected based on the fact that they produce relatively large amounts of one or more of the compounds (i.e., volatile compounds of interest) that are desired to be isolated. In certain embodiments, Nicotiana species plants are particularly cultivated because they are rich in leaf surface compounds. Tobacco plants may be grown in greenhouses, growth chambers, or outdoor fields, or grown hydroponically.

[0108] Various parts or portions of a Nicotiana species plant may be utilized. In some embodiments, the whole plant or substantially the whole plant is harvested and used as is. As used herein, the term "substantially the whole plant" means that at least 90% of the plant is harvested, such as at least 95% of the plant, for example, at least 99% of the plant. Alternatively, in some embodiments, various parts or pieces of the plant are harvested or separated for further use after harvest. In some embodiments, the tobacco material is selected from the leaves, stems, petioles, and various combinations of these parts of the plant. Thus, the tobacco material of the present disclosure may comprise the whole Nicotiana species plant or any part of the plant.

[0109] The tobacco material may comprise or consist of reconstituted tobacco, tobacco lamina, paper reconstituted tobacco, extruded tobacco, band-cast reconstituted tobacco, band-cast reconstituted tobacco, or a combination of reconstituted tobacco and another form of tobacco such as tobacco lamina or tobacco granules.

[0110] In some embodiments, the aerosol-forming material is substantially free of plant material. In particular, in some embodiments, the aerosol-forming material is substantially free of tobacco.

[0111] In some embodiments, the active agent comprises or is derived from one or more botanical substances, or components, derivatives, or extracts thereof, and the botanical substances are selected from eucalyptus, star anise, cocoa, and hemp.

[0112] In some embodiments, the active agent comprises or is derived from one or more botanical substances, or components, derivatives, or extracts thereof, and the botanical substances are selected from rooibos and fennel.

[0113] In some embodiments, the substance to be delivered comprises a fragrance.

[0114] As used herein, the terms "flavor" and "flavoring" refer to materials that may be used, where local regulations permit, to create a desired taste, aroma, or other somatosensory sensation in products intended for adult consumers.These ingredients may be naturally derived flavoring materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed, cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit, etc.). Fruits: papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberries, mulberries, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang-ylang Orchids, sage, fennel, wasabi, bell peppers, ginger, coriander, coffee, hemp, mint oil of any species of the genus Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, yerba mate, orange peel, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, pimento, mace, Damian marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.The materials may be imitation, synthetic or natural ingredients, or mixtures thereof. The materials may be in any suitable form, for example, a liquid such as an oil, a solid such as a powder, or a gas.

[0115] In some embodiments, the flavoring includes menthol, spearmint, and / or peppermint. In some embodiments, the flavoring includes cucumber, blueberry, citrus, and / or red berry flavoring ingredients. In some embodiments, the flavoring includes eugenol. In some embodiments, the flavoring includes flavoring ingredients extracted from tobacco. In some embodiments, the flavoring includes flavoring ingredients extracted from cannabis.

[0116] In some embodiments, the aerosol-forming material may contain up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% flavoring. In some cases, the aerosol-forming material may contain at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% flavoring (all calculated on a dry weight basis). For example, the aerosol-forming material may contain 1-80 wt%, 10-80 wt%, 20-70 wt%, 30-60 wt%, 35-55 wt%, or 30-45 wt% flavoring. In exemplary embodiments, the aerosol-forming material contains 35-50 wt% flavoring. In some cases, the flavoring comprises, consists essentially of, or consists of menthol.

[0117] In some embodiments, the flavoring agent may include a sensory elicitor intended to achieve a somatosensory sensation typically perceived chemically induced by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the scent or taste nerves, and may include agents that provide a heating, cooling, tingling, or anesthetic effect. A suitable heating agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol WS-3.

[0118] The aerosol-forming composition may include an aerosol-forming material in the form of an "amorphous solid." An amorphous solid may be a "monolithic solid." In some embodiments, the aerosol-forming material may be a dry gel.

[0119] The aerosol-generating composition may include an aerosol-generating material in the form of an aerosol-generating film. The aerosol-generating film may be formed by combining a binder, such as a gelling agent, with a solvent, such as water, an aerosol-forming agent, and one or more other ingredients, such as an active agent, to form a slurry, and then heating the slurry to volatilize at least some of the solvent and form the aerosol-generating film. The slurry may be heated to remove at least about 60 wt%, 70 wt%, 80 wt%, 85 wt%, or 90 wt% of the solvent. The aerosol-generating film may be a continuous or discontinuous film, such as a construction of separate portions of film on a substrate. The aerosol-generating film may be substantially free of tobacco.

[0120] The aerosol-generating material may include or be a sheet, which may optionally be chopped to form chopped sheets. The sheet of aerosol-generating material may be cut lengthwise and / or widthwise, for example, in a cross-cut chopping process, to define a cut width as well as a cut length of the strands or strips of aerosol-generating material.

[0121] The aerosol-generating material can be in the form of strands or strips of material. These strands or strips can have a thickness (measured with a caliper) of about 150 μm to about 300 μm, about 200 μm to about 300 μm, or about 200 μm to about 250 μm. Such a thickness allows the aerosol-generating material to dry efficiently during manufacturing and provides the flexibility necessary for processing.

[0122] The strands or strips of aerosol-forming material can have a length of about 10 mm to 15 mm. In some embodiments, the strands or strips of aerosol-forming material can have a length of about 10 mm, 11 mm, 12 mm, 13 mm, 14 mm, or 15 mm.

[0123] The aerosol-forming composition can include strands or flakes of aerosol-forming material mixed with strands or flakes of fibrous susceptor material. The strands or flakes of aerosol-forming material can have a length that is the same as, or within, for example, 10 or 20% of, the length of the strands or flakes of fibrous susceptor material.

[0124] Each strand or strip of aerosol-generating material can have a similar thickness to each strand or strip of fibrous susceptor material. In some embodiments, the thickness of the aerosol-generating material is the same as (or within 20% or 10% of) the thickness of the fibrous susceptor material. Matching the thickness of the aerosol-generating material and the fibrous susceptor material in this manner can facilitate mixing of the two materials and help improve the homogeneity of the final mixture. This also means that the two materials can be cut using the same equipment (e.g., the same cutting tool).

[0125] Each strand or strip of aerosol-generating material can have a similar length to each strand or strip of fibrous susceptor material. In some embodiments, the length of the aerosol-generating material is the same as (or within 20% or 10% of) the length of the fibrous susceptor material. Matching the lengths of the aerosol-generating material and the fibrous susceptor material in this manner can facilitate mixing of the two materials and help improve the homogeneity of the final mixture. This also means that the two materials can be cut using the same equipment (e.g., the same cutting tool). Furthermore, the strands or strips of aerosol-generating material can be aligned with the strands or strips of fibrous susceptor material when incorporated into the aerosol-generating section of an article for use with a non-combustion aerosol delivery device. Because the lengths of the two materials are the same or similar, the strands or strips of aerosol-generating material can be uniformly heated along their length by the strands or strips of fibrous susceptor material.

[0126] The aerosol-generating composition can include any combination of the above aerosol-generating materials. For example, the aerosol-generating composition can include a mixture of aerosol-generating materials, at least one of which includes a binder and an aerosol-forming agent. In some embodiments, the aerosol-generating composition includes a (e.g., first) aerosol-generating material that includes a binder and an aerosol-forming agent, and a (e.g., second) different aerosol-generating material. For example, the second aerosol-generating material can be a plant material such as tobacco lamina.

[0127] In some embodiments, the aerosol-generating material is prepared by forming a slurry including components of the aerosol material or its precursor, forming a layer of the slurry, solidifying the slurry to form a gel, and drying to form the aerosol-generating material. Optionally, the step of solidifying the gel can include applying a solidifying agent to the slurry. In some embodiments, the solidifying agent is sprayed onto the slurry, such as on top of the slurry.

[0128] In some embodiments, the solidifying agent comprises or consists of calcium acetate, calcium formate, calcium carbonate, calcium bicarbonate, calcium chloride, calcium lactate, or a combination thereof. In some embodiments, the solidifying agent comprises or consists of calcium formate and / or calcium lactate. In particular embodiments, the solidifying agent comprises or consists of calcium formate. It has been determined that the use of calcium formate as the solidifying agent typically results in aerosol-generating materials having higher tensile strength and higher resistance to elongation.

[0129] The total amount of hardening agent, such as a calcium source, may be 0.5 to 5 wt % (calculated on a dry weight basis). Preferably, the total amount may be about 1 wt %, 2.5 wt %, or 4 wt % to about 4.8 wt % or 4.5 wt %. It has been found that adding too little hardening agent can result in an aerosol-forming material that does not stabilize the aerosol-forming material components, causing these components to drop out of the aerosol-forming material. It has been found that adding too much solidifying agent can result in an aerosol-forming material that is very sticky and therefore difficult to handle.

[0130] When the aerosol-forming material does not contain tobacco, a larger amount of hardener may need to be applied. Thus, in some cases, the total amount of hardener may be 0.5 to 12 wt%, such as 5 to 10 wt%, calculated on a dry weight basis. Preferably, the total amount may be about 5 wt%, 6 wt%, or 7 wt% to about 12 wt% or 10 wt%. In this case, the aerosol-forming material typically does not contain tobacco.

[0131] The process includes forming a layer of the slurry. This typically involves spraying, casting, or extruding the slurry. In examples, the slurry layer is formed by electrostatically spraying the slurry. In examples, the slurry layer is formed by casting the slurry.

[0132] In some instances, all steps of the process occur at least partially simultaneously (e.g., during electrostatic spraying). In some instances, steps of the process occur sequentially.

[0133] The aerosol-forming material may comprise 1-60 wt% gelling agent, 0.1-70 wt% aerosol former material, 5-50% filler in the form of fibers, and 0.1-80 wt% flavoring and / or active agent.

[0134] The aerosol-forming material may comprise 10-40 wt% gelling agent, 10-70 wt% aerosol former material, 20-40 wt% bulking agent, and optionally 10-50 wt% flavoring.

[0135] In an embodiment, the aerosol-forming material comprises alginate in an amount of 32.8 wt %, glycerol in an amount of 19.2 wt %, and menthol in an amount of 48 wt %.

[0136] In an embodiment, the aerosol-forming material comprises alginate in an amount of 26.2 wt%, glycerol in an amount of 15.4 wt%, menthol in an amount of 38.4 wt%, and fiber (derived from wood pulp) in an amount of 20 wt%.

[0137] In an embodiment, the aerosol-forming material comprises alginate in an amount of 32 wt%, pectin in an amount of 8 wt%, and glycerol in an amount of 60 wt%.

[0138] In an embodiment, the aerosol-forming material comprises alginate in an amount of 24 wt%, pectin in an amount of 6 wt%, cellulose fiber in an amount of 10 wt%, and glycerol in an amount of 60 wt%.

[0139] In an embodiment, the aerosol-forming material comprises carboxymethyl cellulose (CMC) in an amount of about 7 wt%, cellulose fibers (derived from wood pulp) in an amount of about 43 wt%, and glycerol in an amount of about 50 wt%.

[0140] The aerosol-forming composition includes an aerosol-forming material and a fibrous susceptor material. The composition can include an admixture of the aerosol-forming material and the fibrous susceptor material. The aerosol-forming composition and the fibrous susceptor material can be in direct contact with each other, which can facilitate rapid heat transfer from the fibrous susceptor material to the aerosol-forming composition when a varying magnetic field is applied and the fibrous susceptor material heats.

[0141] 2 is a cross-sectional side view of the aerosol-generating section 3 of the article 1. The aerosol-generating section 3 includes an aerosol-generating component composition 4. The aerosol-generating composition 4 is bounded by a wrapper 5. The aerosol-generating composition includes a plurality of strands of aerosol-generating material and a plurality of strands of fibrous susceptor material. The strands of aerosol-generating material and fibrous susceptor material are arranged such that their longitudinal axes are aligned parallel to each other and to the longitudinal axis X-X' of the aerosol-generating section 3. This can facilitate airflow through the aerosol-generating section during use.

[0142] In alternative embodiments, the aerosol-generating material and the fibrous susceptor material can be randomly oriented relative to one another. In some embodiments, the strands or aerosol-generating material and the fibrous susceptor material are corrugated or coiled.

[0143] FIG. 3 is an overview of a process that can be used to manufacture the aerosol-generation section 3. The process can include cutting a sheet of aerosol-generating material and cutting a sheet of fibrous susceptor material. This forms a plurality of separate portions of aerosol-generating material and a plurality of separate portions of fibrous susceptor material. The separate portions of aerosol-generating material and the separate portions of fibrous susceptor material can be strands or strips. The separate portions of aerosol-generating material and fibrous susceptor material are then combined to form a mixture. The aerosol-generating material and fibrous susceptor material can be mixed by any suitable means. For example, the two materials can be mixed in a mixer. The mixture can then be surrounded by a wrapper to form a rod, which is then cut into segments to form the aerosol-generation section 3.

[0144] Alternatively, separate portions of aerosol-generating material and fibrous susceptor material may be inserted into a wrapper to form a rod, which may then be cut into segments to form the aerosol-generating sections 3 .

[0145] Prior to being cut, the aerosol-generating and / or fibrous susceptor material may be provided in the form of a wound bobbin.

[0146] 4 is a perspective view of a bobbin 6 containing a sheet of fibrous susceptor material 7 wound around a central spindle 8. The fibrous material 7 is flexible, allowing it to be easily wound without damage. The fibrous material 7 of the bobbin 6 has a free end 9 that allows the bobbin to be unwound. A similar bobbin can be provided (instead of the fibrous material) containing a sheet of aerosol-generating material. The free end 9 can be fed into a machine that continuously cuts the sheet.

[0147] FIG. 4a is a perspective view of a bobbin 10 containing a sheet of aerosol-generating material 11 wound around a central spindle 8'. The aerosol-generating material 7 is flexible and has sufficient tensile strength to be easily wound without damage. The sheet of aerosol-generating material 11 on the bobbin 10 has a free end 9' that allows the bobbin to be unwound. Similar bobbins containing sheets of aerosol-generating material can also be provided. The free end 9' can be fed into a machine that continuously cuts the sheet.

[0148] 5 is a schematic diagram of a process for manufacturing the aerosol-generating section 3. A bobbin 6 containing a sheet 7 of fibrous susceptor material is provided, and a separate bobbin 10 containing a sheet 11 of aerosol-generating material is provided. The sheet of fibrous susceptor material 7 is fed to a cutter 12, while the sheet of aerosol-generating material 11 is fed to a cutter 13. The cutter 12 cuts the fibrous susceptor material 7 into multiple strands 14 of fibrous susceptor material. Meanwhile, the cutter 13 cuts the sheet 11 of aerosol-generating material into multiple strands 15 of aerosol-generating material. The multiple strands 15 of aerosol-generating material and the multiple strands 14 of fibrous susceptor material are combined and surrounded by a wrapper to form a rod 16. A cutter 17 cuts the rod to form the aerosol-generating section 3.

[0149] FIG. 6 is a schematic diagram of an alternative process for manufacturing an aerosol-generating section 3′. A bobbin 6 containing a sheet of fibrous susceptor material 7 is provided, and a separate bobbin 10 containing a sheet of aerosol-generating material 11 is provided. The sheet of aerosol-generating material 11 and the sheet of fibrous susceptor material 7 are fed to a cutter 12. The cutter 12 both cuts the aerosol-generating sheet 11 into multiple strands 14 of aerosol-generating material and cuts the sheet of fibrous susceptor material 7 into multiple strands 15 of fibrous susceptor material. The cutter simultaneously cuts both the sheet of aerosol-generating material 11 and the sheet of fibrous susceptor material 7, thereby improving manufacturing efficiency. The multiple strands 14 of aerosol-generating material and the multiple strands 15 of fibrous susceptor material are combined and surrounded by a wrapper to form a rod 16. A cutter 17 cuts the rod to form the aerosol-generating section 3′.

[0150] In some embodiments, the process can be configured to control the relative amounts and distributions of the fibrous susceptor material and the aerosol-generating material in the aerosol-generation section 3, 3′. For example, in the embodiment shown in FIG. 5, the rate at which the fibrous susceptor material is cut can be slower than the rate at which the sheet of aerosol-generating material is cut to provide an aerosol-generation section that includes less fibrous susceptor material. The distribution of the fibrous susceptor material in the aerosol-generation section can be controlled by controlling the point at which the fibrous susceptor material is combined with the aerosol-generating material.

[0151] Components formed according to these processes can be used to form articles for use with non-combustion aerosol delivery devices.

[0152] 7 shows a cross-sectional side view of the article 1 shown in FIG. 1. The article 1 includes a mouthpiece 2 and an aerosol-generation section 3 connected to the mouthpiece 2. In this example, the aerosol-generation section 3 includes a rod of aerosol-generating material 3 that includes an aerosol-generating composition comprising an aerosol-generating material described herein and a fibrous susceptor material. The article 1 includes an upstream end 2a and a downstream end 2b distal from the aerosol-generation section 3.

[0153] In this example, the aerosol-forming composition includes a plurality of strands and / or strips of aerosol-forming material 3, surrounded by a wrapper 90. In this example, wrapper 90 is a moisture-impermeable wrapper.

[0154] Multiple strands or strips of aerosol-generating material can be aligned within the aerosol-generation section with their longitudinal dimensions aligned parallel to the longitudinal axis X-X' of the article 1. Alternatively, the strands or strips can be generally arranged with their aligned longitudinal dimensions transverse to the longitudinal axis of the article.

[0155] At least about 10%, 20%, 30%, 40%, 50%, 60%, 70%, 80%, 90%, or 95% of the plurality of strands or strips can 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 within the aerosol-generation section of the article such that their longitudinal dimensions are aligned parallel to the longitudinal axis of the aerosol-generation section.

[0156] Mouthpiece 2 includes a cooling section 100, also referred to as a cooling element, positioned immediately downstream of and adjacent to a source of aerosol-forming composition 3. In this example, cooling section 100 is in abutting relationship with the source of aerosol-forming material. Mouthpiece 2 also includes, in this example, a body of material 110 downstream of cooling section 100, and a hollow tubular element 120 at the mouth end of article 1 downstream of body of material 110.

[0157] The cooling section 100 includes 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 hollow channel has an inner diameter of about 3 mm. The hollow channel extends along the entire length of the cooling section 100. In this example, the cooling section 100 includes a single hollow channel. In alternative embodiments, the cooling section may include multiple channels, for example, two, three, or four channels. In this example, the single hollow channel is substantially cylindrical, although other channel shapes / cross-sections may be used in alternative embodiments. The hollow channel may provide space in which aerosol drawn into the cooling section 100 can expand and cool. In all embodiments, the cooling section is configured to limit the cross-sectional area of ​​the hollow channel and limit the displacement of tobacco into the cooling section during use.

[0158] The cooling section 100 preferably has a radial wall thickness, which can be measured, for example, with calipers. The wall thickness of the cooling section 100 for a given outer diameter of the cooling section defines the inner diameter of the cavity enclosed by the walls of the cooling section 100. The cooling section 100 can have a wall thickness of at least 1.5 mm and up to about 2 mm. In this example, the cooling section 100 has a wall thickness of about 2 mm. The inventors have advantageously found that providing a cooling section 100 with a wall thickness within this range improves retention of the source of aerosol-generating material in the aerosol-generating section during use by reducing longitudinal displacement of strands and / or strips of aerosol-generating material when the aerosol generator is inserted into an article.

[0159] Cooling section 100 is formed from filament tow. Multiple paper layers are parallel wrapped and butt-stitched to form cooling section 10, or other configurations may be used, such as spirally wound paper, cardboard tubes, tubes formed using a papier-mâché process, molded or extruded plastic tubes, or the like. Cooling section 100 is manufactured to be sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacturing and use of article 1.

[0160] The wall material of the cooling section 100 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 100. 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.

[0161] The filament tows forming the cooling section 100 preferably have a total fineness of less than 45,000, more preferably less than 42,000. This total fineness has been found to allow for the formation of a cooling section 100 that is not too dense. The total fineness is preferably at least 20,000, more preferably at least 25,000. In a preferred embodiment, the filament tows forming the cooling section 120 have a total fineness of 25,000 to 45,000, more preferably 35,000 to 45,000. The cross-sectional shape of the filaments in the tow is preferably "Y" shaped, although other shapes, such as "X" shaped filaments, can be used in other embodiments.

[0162] The filament tows forming the cooling section 100 preferably have a monofilament fineness greater than 3. This monofilament fineness has been found to allow for the formation of tubular elements 120 that are not too dense. Preferably, the monofilament fineness is at least 4, more preferably at least 5. In a preferred embodiment, the filament tows forming the hollow tubular elements 120 have a monofilament fineness of 4 to 10, more preferably 4 to 9. In one example, the filament tows forming the cooling section 100 have a Y40,000 tow formed from cellulose acetate and containing 18% plasticizer, such as triacetin.

[0163] The density of the material forming the cooling section 100 is preferably at least about 0.20 grams per cubic centimeter (g / cc), and more preferably at least about 0.25 g / cc. The density of the material forming the cooling section 100 is preferably less than about 0.80 grams per cubic centimeter (g / cc), and more preferably less than about 0.6 g / cc. In some embodiments, the density of the material forming the cooling section 100 is between 0.20 and 0.8 g / cc, more preferably between 0.3 and 0.6 g / cc, or between 0.4 g / cc and 0.6 g / cc, or about 0.5 g / cc. These densities have been found to provide a good balance between the improved stiffness afforded by a higher density material and minimizing the overall weight of the article. For purposes of this invention, the "density" of the material forming the cooling section 100 refers to the density of any filament tows forming the element that incorporate any plasticizers. Density can be determined by dividing the total weight of the material forming cooling section 100 by the total volume of the material forming cooling section 100, which can be calculated using appropriate measurements of the material forming cooling section 100, for example, obtained using calipers. If necessary, appropriate dimensions can be measured using a microscope.

[0164] Preferably, the length of the cooling section 100 is less than about 30 mm. More preferably, the length of the cooling section 100 is less than about 25 mm. Even more preferably, the length of the cooling section 100 is less than about 20 mm. Additionally or alternatively, the length of the cooling section 100 is preferably at least about 10 mm. Preferably, the length of the cooling section 100 is at least about 15 mm. In some preferred embodiments, the length of the cooling section 100 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 100 is 19 mm.

[0165] The cooling section 100 is disposed around and defines a cavity within the mouthpiece 2 that acts as the cooling section. The cavity provides a chamber through which heated volatile components generated by the rod of aerosol-forming material 3 flow. The cooling section 100 is hollow and provides an aerosol accumulation chamber that 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 100 provides a physical displacement between the aerosol-forming material 3 and the body of material 110. The physical displacement provided by the cooling section 100 provides a thermal gradient across the length of the cooling section 100.

[0166] Mouthpiece 2 has an internal volume of 110mm 3 Preferably, it includes a larger cavity. It has been found that providing a cavity of at least this volume allows for improved aerosol formation. More preferably, the mouthpiece 2 has an internal volume of 110 mm 3 More than 130mm, preferably 3 Further improvements to the aerosol can be achieved by including a cavity larger than about 130 mm (e.g., a cavity formed within the cooling section 100). In some examples, the internal cavity is approximately 130 mm. 3 ~about 230mm 3 , for example, about 134 mm 3 or 227 mm 3 Includes the volume of

[0167] Cooling section 100 can be configured to provide a temperature difference of at least 40° C. between the heated volatile components entering the first upstream end of cooling section 100 and the heated volatile components exiting the second downstream end of cooling section 100. Cooling section 100 is preferably configured to provide a temperature difference of at least 60° C., more preferably at least 80° C., and even more preferably at least 100° C. between the heated volatile components entering the first upstream end of cooling section 100 and the heated volatile components exiting the second downstream end of cooling section 100. This temperature difference across the length of cooling section 100 protects temperature-sensitive body of material 110 from the high temperatures of aerosol-generating material 3 when heated.

[0168] In use, the aerosol-generation section may exhibit a pressure drop of about 15 to about 40 mmH 0. In some embodiments, the aerosol-generation section exhibits a pressure drop across the aerosol-generation section of about 15 to about 30 mmH 0.

[0169] The aerosol-forming material may have a packing density within the aerosol-generating section of from about 400 mg / cm to about 900 mg / cm. Higher packing densities may increase pressure drop.

[0170] 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.

[0171] In this embodiment, the moisture-impermeable wrapper 90 surrounding the rod of aerosol-forming material comprises aluminum foil. In another embodiment, the wrapper 90 comprises a paper wrapper, optionally including a barrier coating that renders the wrapper material substantially moisture-impermeable. Aluminum foil has been found to be particularly effective in promoting aerosol formation within the aerosol-forming material 3. In this example, the aluminum foil has a metal layer having a thickness of approximately 6 μm. In this example, the aluminum foil has a paper backing. However, in alternative configurations, the aluminum foil can have other thicknesses, for example, a thickness of 4 μm to 16 μm. The aluminum foil also need not have a paper backing and can have a backing formed from another material, for example, to help provide the foil with adequate tensile strength, or can have no backing material at all. Metal layers or foils other than aluminum can also be used. The total thickness of the wrapper is preferably 20 μm to 60 μm, more preferably 30 μm to 50 μm, which can provide a wrapper with adequate structural integrity and heat transfer properties. The pulling force that can be applied to the wrapper before it breaks can be greater than 3,000 grams of force, for example, 3,000 to 10,000 grams of force, or 3,000 to 4,500 grams of force. When the wrapper comprises paper or a paper backing, i.e., a cellulose-based 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. Such a basis weight provides high stiffness to the rod of aerosol-generating material. The high stiffness provided by a wrapper having a basis weight in this range can make the rod of aerosol-generating material 3 more resistant to wrinkling or other deformation due to forces experienced by the article during use. Providing a rod of aerosol-generating material with high stiffness can be advantageous when multiple strands or strips of aerosol-generating material are aligned within the aerosol-generation section with their longitudinal dimensions aligned parallel to the longitudinal axis.This is because the longitudinally aligned strands or strips of aerosol-generating material can impart less stiffness to the rod of aerosol-generating material than when the strands or strips are not aligned, and the increased stiffness of the rod of aerosol-generating material can enable the article to withstand the increased forces to which the article is subjected during use.

[0172] In this example, the moisture-impermeable wrapper 90 is also substantially impermeable to air. In an alternative embodiment, the wrapper 90 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 within the aerosol-generating material 3. Without wishing to be bound by theory, it is hypothesized that this is due to reduced loss of aerosol compound in the wrapper 90. The permeability of the wrapper 90 can be measured in accordance with ISO 2965:2009, relating to the determination of the air permeability of materials used as cigarette paper, filter plug wrap, and filter bonding paper.

[0173] The body of material 110 and the hollow tubular element 120 each define a substantially cylindrical overall outer shape and share a common longitudinal axis. The body of material 110 is rolled into a first plug wrap 130. The first plug wrap 130 preferably has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. The first plug wrap 130 preferably has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The first plug wrap 130 is preferably 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 130 can be a porous plug wrap, e.g., having a permeability of greater than 200 Coresta units.

[0174] Preferably, the length of the body of material 110 is less than about 15 mm. More preferably, the length of the body of material 110 is less than about 12 mm. Additionally or alternatively, the length of the body of material 110 is at least about 5 mm. Preferably, the length of the body of material 110 is at least about 8 mm. In some preferred embodiments, the length of the body of material 110 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 110 is 10 mm.

[0175] In this example, the body of material 110 is formed from filament tow. In this example, the tow used in the body of material 110 has a single fiber fineness (dpf) of 5 and a total fiber fineness of 25,000. In this example, the tow comprises plasticized cellulose acetate tow. The plasticizer used in the tow accounts for approximately 9% by weight of the tow. In this example, the plasticizer is triacetin. In other examples, different materials can be used to form the body of material 110. For example, rather than tow, the body 1100 can be formed from paper, for example, in a manner similar to paper filters known for use in cigarettes. For example, the paper or other cellulose-based material can be provided as one or more portions of a sheet material that is folded and / or corrugated to form the body 110. The sheet material can have a basis weight of 15 gsm to 60 gsm, for example, 20 to 50 gsm. The sheet material may 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 may have a width ranging from 50 mm to 200 mm, e.g., from 60 mm to 150 mm or from 80 mm to 150 mm. For example, the sheet material may have a basis weight of 20 to 50 gsm and a width of 80 mm to 150 mm. This may allow, for example, the cellulose-based body to have an appropriate pressure drop for an article having dimensions as described herein.

[0176] Alternatively, the body 110 can be formed from tow other than cellulose acetate, such as polylactic acid (PLA), other materials described herein with respect to filament 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. To achieve a sufficiently uniform body 110 of material, the tow preferably has a monofilament fineness of 12 dpf or less, preferably 11 dpf or less, and even more preferably 10 dpf or less.

[0177] The total fineness of the tow forming the body of material 110 is preferably at most 30,000, more preferably at most 28,000, and even more preferably at most 25,000. These total fineness values ​​provide the tow with a smaller percentage of the cross-sectional area of ​​the mouthpiece 2, resulting in a lower pressure drop across the mouthpiece 2 than tows with higher total fineness values. For a body of material 110 of appropriate stiffness, the tow preferably has a total fineness of at least 8,000, more preferably at least 10,000. The single fineness is preferably 5 to 12, and the total fineness is preferably 10,000 to 25,000. The cross-sectional shape of the filaments of the tow is preferably "Y" shaped, although other shapes, such as "X" shaped filaments, may be used in other embodiments, having the same dpf and total fineness values ​​provided herein.

[0178] Regardless of the material used to form body 110, the pressure drop across body 110 can be, for example, 0.3-5 mmWG per mm of length of body 110, such as 0.5-2 mmWG per mm of length of body 110. The pressure drop can be, for example, 0.5-1 mmWG / mm of length, 1-1.5 mmWG / mm of length, or 1.5-2 mmWG / mm of length. The total pressure drop across body 110 can be, for example, 3-8 mmWG, or 4-7 mmWG. The total pressure drop across body 110 can be about 5, 6, or 7 mmWG.

[0179] As shown in FIG. 7 , the mouthpiece 2 of the article 1 has an upstream end 2c adjacent to the rod of aerosol-forming material 3 and a downstream end 2b remote from the rod of aerosol-forming material 3. The mouthpiece 2 has a hollow tubular element 120 formed from filament tow at the downstream end 2b. This has been found to advantageously significantly reduce the temperature of the outer surface of the mouthpiece 2 at the downstream end 2b of the mouthpiece, which contacts the consumer's mouth, when the article 1 is in use. In addition, the use of the tubular element 120 has also been found to significantly reduce the temperature of the outer surface of the mouthpiece 2 further upstream of the tubular element 120. Without wishing to be bound by theory, it is hypothesized that this is due to the tubular element 120 causing the aerosol to pass closer to the center of the mouthpiece 2, thereby reducing heat transfer from the aerosol to the outer surface of the mouthpiece 2.

[0180] The "wall thickness" of hollow tubular element 120 corresponds to the thickness of the wall of tube 10 in the radial direction. This can be measured, for example, using calipers. Advantageously, the wall thickness is greater than 0.9 mm, more preferably 1.0 mm or greater. Preferably, the wall thickness is substantially constant throughout the wall of hollow tubular element 120. 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 hollow tubular element 120. In this example, the wall thickness of hollow tubular element 120 is approximately 1.3 mm.

[0181] Preferably, the length of the hollow tubular element 120 is less than about 20 mm. More preferably, the length of the hollow tubular element 120 is less than about 15 mm. Even more preferably, the length of the hollow tubular element 120 is less than about 10 mm. Additionally or alternatively, the length of the hollow tubular element 120 is at least about 5 mm. Preferably, the length of the hollow tubular element 120 is at least about 6 mm. In some preferred embodiments, the length of the hollow tubular element 120 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 120 is 7 mm.

[0182] The density of the hollow tubular element 120 is preferably at least about 0.25 grams per cubic centimeter (g / cc), more preferably at least about 0.3 g / cc. The density of the hollow tubular element 120 is preferably less than about 0.75 grams per cubic centimeter (g / cc), more preferably less than about 0.6 g / cc. In some embodiments, the density of the hollow tubular element 120 is between 0.25 and 0.75 g / cc, more preferably between 0.3 and 0.6 g / cc, more preferably between 0.4 g / cc and 0.6 g / cc, or about 0.5 g / cc. These densities have been found to provide a good balance between the improved stiffness 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 120 refers to the density of the filament tow forming the element, including any plasticizer incorporated therein. The density can be determined by dividing the total weight of the hollow tubular element 120 by the total volume of the hollow tubular element 120, which can be calculated using appropriate measurements of the hollow tubular element 120, for example, obtained using calipers. If necessary, appropriate dimensions can be measured using a microscope.

[0183] The filament tow forming the hollow tubular element 120 preferably has a total fineness of less than 45,000, more preferably less than 42,000. This total fineness has been found to allow for the formation of a tubular element 120 that is not too dense. The total fineness is preferably at least 20,000, more preferably at least 25,000. In a preferred embodiment, the filament tow forming the hollow tubular element 120 has a total fineness of 25,000 to 45,000, more preferably 35,000 to 45,000. The cross-sectional shape of the filaments in the tow is preferably "Y" shaped, although other shapes, such as "X" shaped filaments, can be used in other embodiments.

[0184] The filament tow forming the hollow tubular element 120 preferably has a monofilament fineness greater than 3. This monofilament fineness has been found to allow for the formation of a tubular element 120 that is not too dense. Preferably, the monofilament fineness is at least 4, more preferably at least 5. In a preferred embodiment, the filament tow forming the hollow tubular element 120 has a monofilament fineness of 4 to 10, more preferably 4 to 9. In one example, the filament tow forming the hollow tubular element 120 has a 7.3Y36,000 tow formed from cellulose acetate and includes 18% plasticizer, such as triacetin. Preferably, hollow tubular element 120 has an inner diameter greater than 3.0 mm. A smaller diameter may undesirably increase the velocity of the aerosol passing through mouthpiece 2 and into the consumer's mouth, resulting in the aerosol becoming too warm, for example reaching temperatures greater than 40° C. or even greater than 45° C. More preferably, hollow tubular element 120 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, hollow tubular element 120 has an inner diameter of about 4.7 mm.

[0185] Preferably, hollow tubular element 120 contains 15% to 22% by weight of plasticizer. For cellulose acetate tow, the plasticizer is preferably triacetin, although other plasticizers, such as polyethylene glycol (PEG), can also be used. More preferably, tubular element 120 contains 16% to 20% by weight of plasticizer, for example, about 17%, about 18%, or about 19%.

[0186] In this example, the first hollow tubular element 120, the body of material 110, and the cooling section 100 are combined using a second plug wrap 140 wrapped around all three sections. The second plug wrap 140 preferably has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 45 gsm. The second plug wrap 140 preferably has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The second plug wrap 140 is preferably non-porous, e.g., having a permeability of less than 100 Coresta units, e.g., less than 50 Coresta units. However, in alternative embodiments, the second plug wrap 140 can be porous, e.g., having a permeability of greater than 200 Coresta units.

[0187] In this example, Article 1 has a circumference of approximately 23 mm. In other examples, the article may be provided in any of the formats described herein, for example, having a circumference of 20 mm to 26 mm. Because the article is heated to release the aerosol, improved heating efficiency can be achieved using an article having a smaller circumference within this range, for example, a circumference of less than 23 mm. It has also been found that an article circumference of greater than 19 mm is particularly effective for achieving improved aerosol upon heating while maintaining an adequate product length. Articles having a circumference of 20 mm to 24 mm, more preferably 20 mm to 23 mm, have been found to provide a good balance between effective aerosol delivery and efficient heating.

[0188] Tipping paper 150 is wrapped around the entire length of mouthpiece 2 and a portion of the rod of aerosol-generating material 3 and has adhesive on its inner surface to connect mouthpiece 2 and rod 3. In this example, the rod of aerosol-generating material 3 is wrapped in wrapper 90, which forms a first wrapping material, and tipping paper 150 forms an outer wrapping material that extends at least partially over the rod of aerosol-generating material 3 and connects mouthpiece 2 and rod 3. In some examples, the tipping paper can extend only partially over the rod of aerosol-generating material.

[0189] In this example, the tipping paper 150 extends 5 mm over the rod of aerosol-forming material 3, but it may alternatively extend 3 mm to 10 mm, or more preferably 4 mm to 6 mm, over the rod 3 to securely attach the mouthpiece 2 to the rod 3. The tipping paper may have a basis weight of greater than 20 gsm, for example greater than 25 gsm, or preferably greater than 30 gsm, for example 37 gsm. Basis weights in these ranges have been found to provide tipping paper with acceptable tensile strength yet sufficient flexibility to wrap around the article 1 and adhere to itself along the paper's longitudinal lap seam. After being wrapped around the mouthpiece 2, the tipping paper 150 has a circumference of approximately 23 mm.

[0190] The article has a ventilation level of approximately 10% of the aerosol drawn through the article. In an alternative embodiment, the article can have a ventilation level of 1% to 20%, for example 1% to 12%, of the aerosol drawn through the article. These levels of ventilation help to increase the concentration of aerosol inhaled by the user at the mouth end 2b and aid in the aerosol cooling process. The ventilation is provided directly in the mouthpiece 2 of the article 1. In this example, the ventilation is provided in the cooling section 100, which has been found to be particularly advantageous in aiding the aerosol generation process. The ventilation is provided by perforations 160, in this case formed as a single row of laser perforations located 13 mm from the mouth end 2b downstream of the mouthpiece 2. In an alternative embodiment, more than one row of ventilation perforations may be provided. These perforations pass through the tipping paper 150, the second plug wrap 140, and the cooling section 100. In alternative embodiments, the vent may be located elsewhere in the mouthpiece, for example in the body of material 110 or the first tubular element 120. The article is preferably 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.

[0191] Article 1 is suitable for use with a non-combustible aerosol delivery device.

[0192] FIG. 8 shows an example of a non-combustible aerosol delivery device 18 having a proximal end 18a and a distal end 18b.

[0193] In general, device 18 can be used to cause an article described herein, including an aerosol-forming composition that includes a fibrous susceptor and an aerosol-forming material, to generate an aerosol that is inhaled by a user of device 18. Device 18 and the article (not shown) together form a system.

[0194] The device 18 comprises a magnetic field generator including a coil 20 configured to generate a varying magnetic field that generates heat in a susceptor within the article, which in turn heats the resulting aerosol to form the aerosol.

[0195] The device 18 includes a housing 19 that encloses and contains the various components of the device 18. The device 18 has an opening 21 at one end through which an item can be inserted. In use, the item can be fully or partially inserted into the heating assembly.

[0196] Device 18 may also include a user-actuable control element 22, such as a button or switch, that, when pressed, operates device 18. For example, a user may turn device 18 on by operating switch 22.

[0197] The device 18 may also include an electrical component such as a socket / port 23 that can receive a cable for charging a power source 24 of the device 18. For example, the socket 23 may be a charging port, such as a USB charging port.

[0198] In use, a user inserts an item into opening 21 and operates user control 22 to initiate heating of the aerosol-generating material, utilizing the aerosol generated within the device, causing the aerosol to flow through device 18 along the flow path toward proximal end 18a of device 18.

[0199] The other end of the device furthest from opening 21 may be known as the distal end 18b of device 18, as it is the end furthest from the user's mouth during use. When a user utilizes the aerosol generated within the device, the aerosol flows away from the distal end of device 18.

[0200] The power source 24 can be, for example, a battery, such as a rechargeable or non-rechargeable battery. Examples of suitable batteries include, for example, lithium batteries (such as lithium-ion batteries), nickel batteries (such as nickel-cadmium batteries), and alkaline batteries. The battery is electrically coupled to the magnetic field generator to provide power under the control of a controller (not shown) when the aerosol-forming material needs to be heated.

[0201] The device further includes at least one electronics module 25. The electronics module 25 may include, for example, a printed circuit board (PCB). The PCB 25 may support at least one controller, such as a processor and memory. The PCB 25 may also include one or more electrical tracks for electrically connecting together various electronic components of the device 18. For example, battery terminals (not shown) may be electrically connected to the PCB 25 so that power can be distributed throughout the device 18. The socket 23 may also be electrically coupled to a battery via electrical tracks.

[0202] The device 18 includes a magnetic field generator including a coil 20 configured to inductively heat a susceptor within the article.

[0203] Coil 20 is an inductor coil. Inductor coils are made from a conductive material. In this example, the inductor coil is made from litz wire / cable that is spirally wound to form a helical inductor coil. Litz wire includes multiple individual wires that are individually insulated and twisted together to form a single wire. Litz wire is designed to reduce skin effect losses in the conductor. In exemplary device 18, the inductor coil is made from copper, and the litz wire has a rectangular cross section. In other examples, the litz wire can have other cross sections, such as circular.

[0204] The inductor coil 20 is configured to generate a first varying magnetic field for heating a susceptor of the article. The inductor coil 20 can be connected to a PCB 25.

[0205] The device includes an inductor coil support tube 26. The coil support tube 26 is defined by an outer surface and an inner surface. The outer surface of the coil support tube supports the inductor coil of the magnetic field generator 20. The inner surface defines a cavity into which an item can be inserted. The tube 26 is preferably made from a material that is not heatable by penetration by the varying magnetic field. This prevents the inductor from heating the tube during use and also reduces power consumption.

[0206] Referring to FIG. 9, the device 18′ includes two magnetic field generators, including a first inductor coil 20a and a second inductor coil 20b. The first inductor coil 20a is configured to generate a first varying magnetic field for heating a susceptor in the article 1, and the second inductor coil 20b is configured to generate a second varying magnetic field for heating a second susceptor. In this example, the first inductor coil 20a is adjacent to the second inductor coil 20b in a direction along the longitudinal axis of the device 18′ (i.e., the first inductor coil 20a and the second inductor coil 20b do not overlap). The first inductor coil 20a and the second inductor coil 20b can be connected to a PCB. The first and second coils are supported by a coil support tube 26′.

[0207] It will be appreciated that in some examples, the first inductor coil 20a and the second inductor coil 20b can have at least one characteristic that differs from one another. For example, the first inductor coil 20a can have at least one characteristic that differs from the second inductor coil 20b. More specifically, in one example, the first inductor coil 20a can have a different inductance value than the second inductor coil 20b. The first inductor coil 20a and the second inductor coil 20b can be different lengths. Thus, the first inductor coil 20a can include a different number of turns than the second inductor coil 20b (assuming the spacing between individual turns is substantially the same). In yet another example, the first inductor coil 20a can be made of a different material than the second inductor coil 20b. In some examples, the first inductor coil 20a and the second inductor coil 20b can be substantially identical.

[0208] In this example, the first inductor coil 20a and the second inductor coil 20b are wound in opposite directions. This can be useful when the inductor coils are active at different times. For example, initially, the first inductor coil 20a may be operating to heat a first section / portion of an article, and at a later time, the second inductor coil 20b may be operating to heat a second section / portion of the article. Winding the coils in opposite directions helps reduce current buildup in inactive coils when used in conjunction with certain types of control circuitry. In FIG. 9, the first inductor coil 20a is a right-handed spiral, and the second inductor coil 20b is a left-handed spiral. However, in other embodiments, the inductor coils 20a and 20b can be wound in the same direction, or the first inductor coil 20a can be a left-handed spiral and the second inductor coil 20b can be a right-handed spiral.

[0209] In use, the article 1 described herein can be inserted into a non-combustible aerosol delivery device, such as devices 18 and 18′ described with reference to FIGS. 10 and 11. At least a portion of the mouthpiece 2 of the article 1 protrudes from the non-combustible aerosol delivery device 18, 18′ and can be placed in a user's mouth. An aerosol is generated using the device 18, 18′ by heating an aerosol-generating section 3 containing an aerosol-generating material and a susceptor at least partially embedded in the aerosol-generating material. The aerosol generated by the aerosol-generating material passes through the mouthpiece 2 and into the user's mouth.

[0210] 10, the magnetic field generator comprises a single coil 20. The magnetic field generator is configured to inductively heat a susceptor in the aerosol-generation section 3 by generating a varying magnetic field.

[0211] The outer surface of article 1 can be dimensioned so that the outer surface of article 1 abuts the inner surface of coil support tube 26. This ensures that the aerosol-generation section is closer to coil 20 and therefore most efficient for heating.

[0212] 11 shows an article 1 described herein received within a coil support tube 26' of a device 18'. The magnetic field generator includes two coils 20a and 20b, which allow different parts of the aerosol-generation section 3 to be heated at different times and / or to different temperatures by controlling the activation of coils 20a, 20b.

[0213] The various embodiments described herein are presented solely as an aid in understanding and teaching of the claimed features. These embodiments are provided only as a representative sample of embodiments and are not intended to be exhaustive and / or exclusive. It is understood that the advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be considered limitations on the scope of the invention as defined by the claims or equivalents thereof, and that other embodiments may be utilized and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably include, 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. In addition, the present disclosure may include other inventions not claimed herein but which may be claimed in the future.

Claims

1. A method of manufacturing a device comprising: an aerosol-generating material in the form of a sheet or chopped sheets; and a fibrous susceptor material; The aerosol-forming composition, wherein the fibrous susceptor material is in the form of a sheet or chopped sheet.

2. 10. The aerosol forming composition of claim 1, wherein the fibrous susceptor material is permeable to the passage of gas.

3. 3. The aerosol-forming composition of claim 1, wherein the fibrous susceptor material is a woven or nonwoven material.

4. The aerosol-forming composition of claim 1 , wherein the fibrous susceptor material comprises metal fibers or carbon fibers.

5. 5. The aerosol-forming composition of claim 4, wherein the sheet has a thickness of from 150 μm to 300 μm.

6. the aerosol-forming material is a binder; and an aerosol former; and Optionally, an active substance or fragrance; and Optionally, a filler; and 10. The aerosol-forming composition of claim 1, comprising:

7. The aerosol-forming composition of claim 1 , wherein the aerosol-forming material comprises a plant material.

8. The aerosol-forming composition of claim 1 , wherein the aerosol-forming composition comprises a plurality of strands of aerosol-forming material.

9. The aerosol forming composition of claim 1 , wherein the article comprises a plurality of strands of the fibrous susceptor material.

10. 9. The aerosol-forming composition of claim 8, wherein the strands of aerosol-forming material are substantially parallel to one another.

11. 10. The aerosol forming composition of claim 9, wherein the strands of fibrous susceptor material are substantially parallel to one another.

12. 12. The aerosol-forming composition of claim 10 or 11, wherein the strands of aerosol-forming material and the strands of fibrous susceptor material are substantially parallel to one another.

13. 10. The aerosol-forming composition of claim 9, wherein each of the strands of aerosol-forming material is substantially straight.

14. 10. The aerosol forming composition of claim 9, wherein each of the strands of fibrous susceptor material is substantially straight.

15. 10. The aerosol forming composition of claim 9, wherein the strands of fibrous susceptor material have a length of between 10 mm and 15 mm.

16. 10. The aerosol-forming composition of claim 1, wherein the aerosol-forming composition comprises reconstituted tobacco material.

17. 10. The aerosol-forming composition of claim 1, wherein the fibrous susceptor material comprises fibers that are randomly oriented relative to one another.

18. 10. A process for producing the aerosol-forming composition of claim 1, the process comprising combining the aerosol-forming material with the fibrous susceptor material.

19. The process comprises: providing a sheet of the aerosol-generating material; providing a sheet of said fibrous susceptor material; cutting the sheet of aerosol-generating material to form a plurality of separate portions of aerosol-generating material; cutting the sheet of fibrous susceptor material to form a plurality of separate portions of fibrous susceptor material; combining the plurality of discrete portions of aerosol-forming material with the plurality of discrete portions of fibrous susceptor material to form the aerosol-forming composition; 20. The process of claim 18, comprising:

20. 20. The process of claim 19, wherein the sheet of aerosol-generating material and the sheet of fibrous susceptor material are cut simultaneously.

21. 10. A component of an article for use with a non-combustible aerosol delivery device, said component comprising the composition of claim 1.

22. 22. The component of claim 21, wherein the component comprises a wrapper surrounding the aerosol-forming composition.

23. 23. The component of claim 22, wherein the component is in the form of a rod.

24. 22. The component of claim 21, wherein the component is an aerosol-generating section of an article for use with a non-combustible aerosol delivery device.

25. 22. A process for manufacturing a component according to claim 21, said process comprising: Inserting one or more of the plurality of discrete portions of aerosol-forming material into a wrapper; inserting one or more of a plurality of separate portions of fibrous susceptor material into the wrapper to form the component; The process includes:

26. 22. A process for manufacturing a component according to claim 21, said process comprising: combining an aerosol-forming composition with a field of fibrous susceptor material to form a mixture; surrounding the mixture with a wrapper to form the component; The process includes:

27. 27. The process of claim 25 or 26, wherein the process includes gathering strands of the aerosol-generating material and the fibrous susceptor material together to form a rod.

28. 26. The process of claim 25, wherein the process comprises longitudinally cutting a sheet of an aerosol-forming composition to produce the plurality of discrete portions of aerosol-forming material, and longitudinally cutting a sheet of a fibrous susceptor material to produce the plurality of discrete portions of fibrous susceptor material.

29. 22. The component of claim 21, wherein the component is an aerosol-generating section of an article for use with a non-combustible aerosol delivery device.

30. 30. An article for use with a non-combustion aerosol delivery device, comprising the component of claim 29.

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