Components for articles

Abstract

The present invention relates to a component (3) for a non-combustion aerosol delivery article and a method of forming the component. The component comprises a longitudinally extending core section (26) and a longitudinally extending outer section (27) surrounding the core section and including an aerosol-generating substrate configured to generate an aerosol when heated. The core section comprises a first material configured to receive a heating element. The method includes providing an assembly comprising a sheet of aerosol-generating substrate and the first material, and disposing the sheet of aerosol-generating substrate and the first material on the component such that the sheet of aerosol-generating substrate forms an outer section surrounding the core section formed by the first material.

Description

Technical field of the invention

[0001] BACKGROUND OF THE INVENTION The present invention relates to components for non-combustion aerosol delivery articles and methods of forming the components.

[0002] Certain delivery systems generate an aerosol during use, which is inhaled by the user. For example, tobacco heating devices heat an aerosol-generating substrate, such as tobacco, to form an aerosol by heating rather than burning the substrate. Such delivery systems generally include a heating device having a heating element that, when heated, heats the aerosol-generating substrate to release the aerosol. Summary of the Invention

[0003] According to an embodiment of the present invention, in a first aspect, there is provided a component for a non-combustion aerosol delivery article for use in a non-combustion aerosol delivery system, the component comprising: a longitudinally extending core section; and a longitudinally extending outer section surrounding the core section and including an aerosol-generating substrate configured to generate an aerosol when heated, the core section comprising a first material configured to receive a heating element.

[0004] In some embodiments, the core section and the outer section may be formed coaxially.

[0005] In some embodiments, the core section may comprise a tube having a cavity, the cavity configured to receive a heating element.

[0006] In some embodiments, the cavity may extend the entire length of the core section.

[0007] In some embodiments, the tube may be configured to maintain a gap from the heating element when the heating element is inserted into the tube.

[0008] In some embodiments, the inner surface of the tube may be embossed, the embossed portion being configured to minimize contact with the heating element when the heating element is inserted into the tube.

[0009] In some embodiments, the tube may have a stiffness in the range of about 50% to about 98%.

[0010] In some embodiments, the first material forming the core section may be paper.

[0011] In some embodiments, the core section may comprise a loosely gathered sheet.

[0012] In some embodiments, the loose sheets may be gathered together to form a central column of material.

[0013] In some embodiments, the first material forming the loose sheet may be at least one of a paper material, bandcast tobacco, reconstituted tobacco, or an amorphous solid material.

[0014] In some embodiments, the first material may be a porous paper material.

[0015] In some embodiments, the porosity of the first material may range from about 50 Coresta units to about 10,000 Coresta units.

[0016] In some embodiments, the first material may include at least one active agent, and / or an aerosol-modifying agent, and / or a fragrance.

[0017] In some embodiments, the first material may include a coating configured to provide an aerosol.

[0018] In some embodiments, the aerosol-generating substrate may comprise a plurality of elongated strips extending substantially parallel to one another in the longitudinal direction.

[0019] In some embodiments, the aerosol-generating substrate may optionally be corrugated to a depth in the range of about 20 um to about 1 mm.

[0020] In some embodiments, the component may be an aerosol-generating component of a non-combustion aerosol delivery system.

[0021] In another aspect of the invention, an article is provided that includes a component.

[0022] In another aspect of the invention, a method of forming a component for a non-combustion aerosol delivery article is provided, the method comprising the steps of providing an assembly comprising a sheet of aerosol-generating substrate and a first material, and arranging the sheet of aerosol-generating substrate and the first material on the component such that the sheet of aerosol-generating substrate forms an outer section surrounding a core section formed by the first material.

[0023] In some embodiments, the first material and the aerosol-generating substrate may be formed coaxially.

[0024] The method may further include gathering the aerosol-generating material around the first material to form a coaxial rod.

[0025] In some embodiments, the gathering step can include providing a stream of aerosol-generating material to a gatherer and gathering the stream of aerosol-generating material around the first material.

[0026] In some embodiments, the gathering step can include providing multiple streams of aerosol-generating material to a gatherer, the multiple streams of aerosol-generating material being disposed at various locations around the first material.

[0027] In some embodiments, providing the assembly may include providing a pre-formed tube of the first material.

[0028] In some embodiments, providing the assembly may include providing a sheet of a first material and forming a tube from the sheet of the first material.

[0029] In some embodiments, providing the assembly may include providing an adhesive on a sheet of a first material and allowing the adhesive to dry before assembling the aerosol-generating substrate around the first material.

[0030] In some embodiments, providing the assembly may include providing a sheet of a first material and gathering the sheet of material together with a sheet of aerosol-generating material to form a coaxial rod.

[0031] 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]

[0032] [Figure 1] FIG. 1 is a side on cross-sectional view of the article. [Figure 2] FIG. 2 is a side cross-sectional view of the article. [Figure 3] FIG. 2 is a side cross-sectional view of a component of the article. [Figure 4] FIG. 1 is an end view of a component of an article. [Figure 5] FIG. 2 is a side cross-sectional view of a component of the article. [Figure 6] 1 is a schematic diagram of an apparatus for forming a component of an article. [Figure 7] 1 is a schematic diagram of an apparatus for forming a component of an article. Detailed Description

[0033] SUMMARY OF THE INVENTION The present invention relates to an article for a consumable for use in a delivery system. 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 tobacco (whether based on tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, tobacco substitutes, or other smoking materials) for cigarettes, cigarillos, cigars, and pipes, or for hand-rolled or handcrafted cigarettes; a non-combustion aerosol delivery system that releases a compound from an aerosol-forming material without burning the aerosol-forming material, such as an e-cigarette, a tobacco heating product, and a hybrid system for generating an aerosol using a combination of aerosol-forming materials; Includes:

[0034] According to the present disclosure, a "combustion-based" aerosol delivery system is an aerosol delivery system in which the constituent aerosol-generating materials of the aerosol delivery system (or its components) are combusted or burned during use to facilitate delivery of at least one substance to a user.

[0035] In some embodiments, the delivery system is a combustion aerosol delivery system, such as a system selected from the group consisting of a cigarette, a cigarillo, and a cigar.

[0036] In some embodiments, the present disclosure relates to a component for use in a combustion-based aerosol delivery system, such as a filter, a filter rod, a filter segment, or an aerosol modifier-releasing component.

[0037] According to the present disclosure, a "non-combustion" aerosol delivery system is an aerosol delivery system in which the constituent aerosol-generating materials of the aerosol delivery system (or its components) are not combusted or burned to facilitate delivery of at least one substance to a user.

[0038] In some embodiments, the delivery system is a non-combustion aerosol delivery system, such as a powered non-combustion aerosol delivery system.

[0039] In some embodiments, the non-combustion aerosol delivery system is an e-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.

[0040] In some embodiments, the non-combustion aerosol delivery system is a hybrid system for generating an aerosol using a combination of aerosol-forming materials, where one or more of the aerosol-forming materials may be heated. Each of the aerosol-forming materials may be, for example, in solid, liquid, or gel form and may or may not contain nicotine. In some embodiments, the hybrid system includes a liquid or gel aerosol-forming material and a solid aerosol-forming material. The solid aerosol-forming material may include a plant-based material, such as a tobacco product or a non-tobacco product.

[0041] Typically, a non-combustion aerosol delivery system can include a non-combustion aerosol delivery device and a consumable item for use with the non-combustion aerosol delivery device.

[0042] In some embodiments, the present disclosure relates to consumables that include an aerosol-forming material and are configured for use with a non-combustion aerosol delivery device. These consumables may be referred to as articles throughout this disclosure.

[0043] In some embodiments, the non-combustion aerosol delivery system may include an area for receiving a consumable, an aerosol generator, an aerosol-generating area, a housing, a mouthpiece, a filter, and / or an aerosol modifier.

[0044] In some embodiments, a consumable for use with a non-combustion aerosol delivery device may comprise an aerosol-generating material, an aerosol-generating material storage region, an aerosol-generating material transfer component, an aerosol generator, an aerosol-generating region, a housing, a wrapper, a filter, a mouthpiece, and / or an aerosol modifier.

[0045] In some embodiments, the substance to be delivered can be an aerosol-generating material or a material not intended to be aerosolized, either of which can optionally include one or more active ingredients, one or more flavoring agents, one or more aerosol-forming materials, and / or one or more other functional materials.

[0046] In some embodiments, the substance to be delivered comprises an active agent.

[0047] As used herein, an active substance may be a bioactive material, which is a material intended to obtain or enhance a physiological response. The active substance may be selected from, for example, dietary supplements, nootropics, and psychotropic drugs. The active substance may be naturally occurring or synthetically derived. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another plant material.

[0048] In some embodiments, the active agent comprises nicotine, hi some embodiments, the active agent comprises caffeine, melatonin, or vitamin B12.

[0049] As described herein, an active substance may comprise or be derived from one or more botanical substances or their components, derivatives, or extracts. 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 present 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. Exemplary botanicals include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo, hazel, hibiscus, bay leaf, licorice (licorice), matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaves, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. , lemon peel, mint, juniper, elderflower, vanilla, wintergreen, sedge, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, black currant, valerian, pimento, mace, damien, marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: Mentha arventis, 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 cardifolia), horse mint (Mentha longifolia), pineapple mint (Mentha suaveolens variegata), pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata cv), and apple mint (Mentha suaveolens).

[0050] 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 substance is tobacco.

[0051] In some embodiments, the active agent comprises or is derived from one or more botanical substances or components, derivatives, or extracts thereof, wherein the botanical substances are selected from eucalyptus, star anise, cocoa, and hemp.

[0052] 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.

[0053] In some embodiments, the substance to be delivered comprises a fragrance.

[0054] As used herein, the terms "flavor" and "flavoring" mean materials that can be used to create a desired taste, aroma, or other somatosensory sensation in products for adult consumers, where local regulations permit.Such materials may be naturally occurring flavoring materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice (licorice), hydrangea, eugenol, magnolia leaf, chamomile, fenugreek, clove, maple, matcha, menthol, mint, aniseed (aniseed), cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, Tropical fruits, papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel nut, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang Ylang, sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil from any species of Mentha, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo, hazel, hibiscus, bay leaf, yerba mate, orange peel, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaves, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, Pedunculaceae, curcuma, cilantro, myrtle, black currant, valerian, pimen The flavor enhancers may include other additives such as citric acid, citric acid, citric acid derivatives (e.g. ...The materials may be imitation, synthetic or natural components, 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.

[0055] In some embodiments, the flavoring comprises menthol, spearmint, and / or peppermint. In some embodiments, the flavoring comprises cucumber, blueberry, citrus fruit, and / or red berry flavoring ingredients. In some embodiments, the flavoring comprises eugenol. In some embodiments, the flavoring comprises flavoring ingredients extracted from tobacco. In some embodiments, the flavoring comprises flavoring ingredients extracted from cannabis.

[0056] In some embodiments, the flavoring agent may include a sensate intended to produce somatic sensations typically chemically induced by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the smell or taste nerves, and these sensates may include agents that provide a heating effect, a cooling effect, a tingling effect, or a numbing effect. Suitable heating agents may include, but are not limited to, vanillyl ethyl ether, and suitable cooling agents may include, but are not limited to, eucolyptol, WS-3.

[0057] An aerosol-generating material is a material that can generate an aerosol when, for example, heated, irradiated, or excited in any other way. The aerosol-generating material may be in the form of a solid, liquid, or gel, which may or may not contain, for example, an active substance and / or a flavoring. In some embodiments, the aerosol-generating material may comprise an "amorphous solid," sometimes referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may be a dry gel. An amorphous solid is a solid material that can retain some amount of fluid, such as a liquid, within it. In some embodiments, the aerosol-generating material may comprise, for example, about 50 wt%, 60 wt%, or 70 wt% to about 90 wt%, 95 wt%, or 100 wt% amorphous solid.

[0058] In some embodiments, the amorphous solid comprises 1-60 wt % gelling agent, 0.1-50 wt % aerosol former, and 0.1-80 wt % flavoring, these weights calculated on a dry weight basis.

[0059] In some further embodiments, the amorphous solid comprises 1-50 wt % gelling agent, 0.1-50 wt % aerosol former, and 30-60 wt % flavoring, these weights calculated on a dry weight basis.

[0060] In some further embodiments, the amorphous solid comprises the aerosol former material, gelling agent, and optional filler in an amount of about 40-80 wt% of the amorphous solid (i.e., in some instances the filler is present in the amorphous solid and in other instances the filler is absent from the amorphous solid), the gelling agent and filler, taken together, are in an amount of about 10-60 wt% of the amorphous solid (i.e., the gelling agent and filler, taken together, comprise about 10-60 wt% of the amorphous solid), and the amorphous solid also optionally comprises an active and / or flavoring in an amount of up to about 20 wt% of the amorphous solid (i.e., the amorphous solid comprises ≦20 wt% of the active).

[0061] The amorphous solid material may be formed from a dried gel. It has been found that using the above composition ratios means that the flavor compounds are stabilized within the gel matrix when the gel hardens, allowing for higher flavor loadings to be achieved than in non-gel compositions. The flavor (e.g., menthol) is stabilized at a high concentration, and the product has a good shelf life.

[0062] In some cases, the amorphous solid can have a thickness of about 0.015 mm to about 1.5 mm. Suitably, the thickness may be within a range of about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm, 0.3 mm, or 1 mm. The inventors have found that in some embodiments, a material having a thickness of 0.2 mm is particularly suitable. The amorphous solid can comprise two or more layers, and the thicknesses described herein refer to the total thickness of those layers.

[0063] If the amorphous solid is too thick, heating efficiency is compromised, which negatively impacts power consumption during use. Conversely, if the amorphous solid is too thin, it is difficult to manufacture and handle. Very thin materials are more difficult to cast and can be fragile, impairing aerosol formation during use.

[0064] Suitably, the amorphous solid can comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, 25 wt%, 30 wt%, or 35 wt% to about 60 wt%, 55 wt%, 50 wt%, 45 wt%, 40 wt%, or 35 wt% of the gelling agent (all calculated on a dry weight basis). For example, the amorphous solid can comprise 1-60 wt%, 5-60 wt%, 20-60 wt%, 25-55 wt%, 30-50 wt%, 35-45 wt%, 5-45 wt%, 10-40 wt%, or 20-35 wt% of the gelling agent.

[0065] The amorphous solid may comprise a gelling agent, which may include one or more compounds selected from cellulosic gelling agents, non-cellulosic gelling agents, guar gum, acacia gum, and mixtures thereof.

[0066] In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent may comprise one or more compounds selected from the group consisting of alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, acacia gum, fumed silica, polydimethylsiloxane (PDMS), sodium silicate, kaolin, and polyvinyl alcohol. In some embodiments, the gelling agent comprises alginate and / or pectin, which may be combined with a hardening agent (such as a calcium source) during the formation of the amorphous solid. In some embodiments, the amorphous solid may comprise calcium-crosslinked alginate and / or calcium-crosslinked pectin.

[0067] The cellulose gelling agent may be 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.

[0068] In some embodiments, the gelling agent comprises (or is) one or more of hydroxyethyl cellulose, hydroxypropyl cellulose, hydroxypropyl methylcellulose (HPMC), carboxymethyl cellulose, guar gum, or acacia gum.

[0069] In some embodiments, the gelling agent comprises (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, alginate, and combinations thereof. In some embodiments, the non-cellulose-based gelling agent is alginate or agar.

[0070] In some embodiments, the amorphous solid comprises alginate and pectin, and the ratio of alginate to pectin is between 1:1 and 10:1. The ratio of alginate to pectin is typically greater than 1:1, meaning that the alginate is present in an amount greater than the amount of pectin. In some examples, the ratio of alginate to pectin is between about 2:1 and 8:1, or between about 3:1 and 6:1, or approximately 4:1.

[0071] In some embodiments, the amorphous solid comprises a filler in an amount of 1-30 wt% of the amorphous solid, such as 5-25 wt% or 10-20 wt%. In some examples, the amorphous solid comprises a filler in an amount greater than 1 wt%, 5 wt%, or 8 wt% of the amorphous solid. In some examples, the amorphous solid comprises a filler in an amount less than 40 wt%, 30 wt%, 20 wt%, 15 wt%, 12 wt%, 10 wt%, 5 wt%, or 1 wt% of the amorphous solid. In other examples, the amorphous solid does not comprise a filler.

[0072] In some examples, the amorphous solids comprise gelling agent and filler, collectively, in an amount of from about 10 wt%, 20 wt%, 25 wt%, 30 wt%, 35 wt%, 40 wt%, 45 wt%, 50 wt%, 55 wt%, or from about 60 wt%. In some examples, the amount of gelling agent and filler, collectively, is no more than 85 wt%, 80 wt%, 75 wt%, 70 wt%, 65 wt% of the amorphous solids, or no more than 60 wt% of the amorphous solids. In some examples, the amorphous solids comprise gelling agent and filler, collectively, in an amount of from about 20-60 wt%, 25-55 wt%, 30-50 wt%, or 35-45 wt% of the amorphous solids.

[0073] When present, the filler may include one or more inorganic filler materials such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents such as molecular sieves. The filler may also include one or more organic filler materials such as wood pulp, cellulose, and cellulose derivatives. In certain cases, the amorphous solid does not include calcium carbonate, such as chalk.

[0074] In some examples that include a filler, the filler may be fibrous. For example, the filler may be a fibrous organic filler material such as wood pulp, hemp fiber, cellulose, or a cellulose derivative. Without wishing to be bound by theory, it is believed that the inclusion of a fibrous filler in the amorphous solid can increase the tensile strength of the material.

[0075] In some instances, the amorphous solid is free of tobacco fiber. In certain instances, the amorphous solid is free of fibrous material.

[0076] In some embodiments, the amorphous solid may comprise from about 0.1 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt%, or 10 wt% to about 80 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt% of the aerosol former material (all calculated on a dry weight basis). For example, the amorphous solid may comprise 0.5-40 wt%, 3-35 wt%, or 10-25 wt% of the aerosol former material.

[0077] The aerosol former material may act as a plasticizer. If the plasticizer content is too high, the amorphous solid may absorb water, resulting in a material that does not provide a satisfactory consumer experience upon use. If the plasticizer content is too low, the amorphous solid may become brittle and easily break.

[0078] In some embodiments, the aerosol former contained in the amorphous solid comprises one or more polyhydric alcohols such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin, esters of polyhydric alcohols such as glycerol monoacetate, glycerol diacetate, or glycerol triacetate, and / or aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetracanedioate.

[0079] In some cases, the aerosol former material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some cases, the aerosol former material comprises, consists essentially of, or consists of glycerol.

[0080] The amorphous solid material may include a combustion retarding salt. As used herein, a combustion retarding salt is a compound consisting of an ionic assembly of a cation and an anion. As used herein, a salt is a salt whose anion and / or cation may be effective in retarding combustion. In some embodiments, the salt is an inorganic salt.

[0081] In some embodiments, the salt is a halide salt, i.e., has a halide anion. In some embodiments, the salt is a chloride salt or a bromide salt. The presence of high concentrations of chloride or bromide has been shown to retard combustion.

[0082] In some embodiments, the salt is an alkali metal salt, i.e., has an alkali metal cation. In some embodiments, the salt has an alkaline earth metal cation. In some embodiments, the salt has a zinc cation or an iron cation, such as a ferric or ferrous cation. In some embodiments, the salt has an ammonium cation or a phosphonium cation.

[0083] In some embodiments, the salt may be an alkali metal halide such as sodium chloride or potassium chloride. The salt may be an alkaline earth metal halide such as magnesium chloride, calcium chloride, etc. The salt may be another metal halide such as zinc chloride or sodium bromide.

[0084] In some embodiments, the salt has a carboxylate anion, for example, the salt may be an alkali metal carboxylate such as potassium citrate, potassium succinate, potassium malate, potassium acetate, potassium tartrate, potassium oxalate, sodium citrate, sodium succinate, sodium acetate, or sodium malate.

[0085] In other embodiments, the salt has an anion selected from borate, carbonate, phosphate, sulfate, or sulfamate.

[0086] Factors that may influence the selection of the salt include, for example, melting point, which may be at least 450°C. In some embodiments, the salt is water soluble. In some embodiments, the salt is selected to impart a desired pH to the material to which it is added. In some embodiments, the salt does not significantly change the pH of the material.

[0087] In some embodiments, the selected flame retardant salt may have one or more advantageous properties, such as inertness, solubility in the precursor liquid, solubility, distribution in the amorphous solid material or precursor material to the amorphous solid material, density, or other properties known in the art.

[0088] In some embodiments, the flame retardant salt comprises, consists essentially of, or consists of sodium chloride, potassium chloride, sodium bromide, and / or potassium bromide.

[0089] Depending on the flame retardant properties or other desired physical properties, the salt components may be present in free base form, salt form, or as a complex or solvate. The flame retardant salts may be of any density and any crystalline structure.

[0090] In some embodiments, the flame retardant salt is incorporated into or added to an amorphous solid material dissolved in a solvent or liquid carrier. In some embodiments, the flame retardant salt is suspended in a liquid carrier. The solvent or liquid carrier may be an aqueous or organic liquid, and may be polar or non-polar depending on the appropriate application.

[0091] The liquid carrier or precursor solvent may be advantageously selected to be easily removed during manufacture of the flame-retardant material to leave the flame-retardant salt in or on the amorphous solid material.

[0092] In some embodiments, the liquid carrier is a mixture of liquids, including an aqueous liquid (water) and a non-aqueous liquid (e.g., glycerol). When the water is removed after application of the salt, the glycerol is retained within the amorphous solid material, where it provides flexibility and aids in aerosol formation upon heating.

[0093] The amorphous solid can include a colorant. The addition of a colorant can change the appearance of the amorphous solid. The presence of a colorant in the amorphous solid can enhance the appearance of the amorphous solid and the aerosol-forming material. Adding a colorant to the amorphous solid can color-match the amorphous solid to other components of the aerosol-forming material or other components of an article comprising the amorphous solid.

[0094] Various colorants may be used depending on the desired color of the amorphous solid. The color of the amorphous solid may be, for example, white, green, red, purple, blue, brown, or black. Other colors are also contemplated. Natural or synthetic colorants may be used, such as natural or synthetic dyes, food-grade colors, and pharmaceutical-grade colors. In certain embodiments, the colorant is caramel, which can impart a brown appearance to the amorphous solid. In such embodiments, the color of the amorphous solid may be similar to the color of other components (such as tobacco material) in the aerosol-forming material that includes the amorphous solid. In some embodiments, the addition of a colorant to the amorphous solid makes the amorphous solid visually indistinguishable from other components in the aerosol-forming material.

[0095] The colorant may be incorporated during the formation of the amorphous solid (e.g., when forming a suspension containing the materials that will form the amorphous solid), or the colorant may be applied to the amorphous solid after its formation (e.g., by spraying the colorant onto the amorphous solid).

[0096] The aerosol-forming materials may include one or more active agents and / or fragrances, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0097] The aerosol-generating material can include an acid. The acid can be an organic acid. In some of these embodiments, the acid can be at least one of a monobasic acid, a dibasic acid, and a tribasic acid. In some such embodiments, the acid can contain at least one carboxyl functional group. In some such embodiments, the acid can be at least one of an alpha hydroxy acid, a carboxylic acid, a dicarboxylic acid, a tricarboxylic acid, and a keto acid. In some such embodiments, the acid can be an alpha keto acid.

[0098] In some such embodiments, the acid may be at least one of succinic acid, lactic acid, benzoic acid, citric acid, tartaric acid, fumaric acid, levulinic acid, acetic acid, malic acid, formic acid, sorbic acid, benzoic acid, propanoic acid, and pyruvic acid.

[0099] Suitably, the acid is lactic acid. In other embodiments, the acid is benzoic acid. In other embodiments, the acid may be an inorganic acid. In some of these embodiments, the acid may be a mineral acid. In some such embodiments, the acid may be at least one of sulfuric acid, hydrochloric acid, boric acid, and phosphoric acid. In some embodiments, the acid is levulinic acid.

[0100] In some embodiments, when the aerosol-forming material includes nicotine, an acid is included. In such embodiments, the presence of the acid can stabilize dissolved species in the suspension from which the aerosol-forming material is formed. The presence of the acid can reduce or substantially prevent evaporation of nicotine during drying of the suspension, thereby reducing nicotine loss during manufacturing.

[0101] In certain embodiments, the aerosol-forming material comprises a gelling agent, including a cellulosic gelling agent and / or a non-cellulosic gelling agent, an active agent, and an acid.

[0102] In some embodiments, the aerosol-forming material comprises one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD), tetrahydrocannabinol (THC), tetrahydrocannabinolic acid (THCA), cannabidiolic acid (CBDA), cannabinol (CBN), cannabigerol (CBG), cannabichromene (CBC), cannabicyclo (CBL), cannabivarin (CBV), tetrahydrocannabivarin (THCV), cannabidivarin (CBDV), cannabichromevarin (CBCV), cannabigerovarin (CBGV), cannabigerol monomethyl ether (CBGM), and cannabielsoin (CBE), cannabicitran (CBT).

[0103] The aerosol-forming material may include one or more cannabinoid compounds selected from the group consisting of cannabidiol (CBD) and THC (tetrahydrocannabinol).

[0104] The aerosol-forming material may include cannabidiol (CBD).

[0105] The aerosol-forming material may include nicotine and cannabidiol (CBD).

[0106] The aerosol-forming material may include nicotine, cannabidiol (CBD), and THC (tetrahydrocannabinol).

[0107] The aerosol former material may include one or more components capable of forming an aerosol, and in some embodiments, the aerosol former material may include one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In some embodiments, the aerosol former comprises one or more polyhydric alcohols such as propylene glycol, triethylene glycol, 1,3-butanediol, and glycerin, esters of polyhydric alcohols such as glycerol monoacetate, glycerol diacetate, or glycerol triacetate, and / or aliphatic esters of mono-, di-, or polycarboxylic acids such as dimethyl dodecanedioate and dimethyl tetracanedioate.

[0108] The one or more other functional ingredients may include one or more of a pH adjuster, a colorant, a preservative, a binder, a filler, a stabilizer, and / or an antioxidant.

[0109] As used herein, the term "tobacco material" means any material containing tobacco or a tobacco derivative or substitute. The term "tobacco material" may include one or more of tobacco, tobacco derivatives, expanded tobacco, reconstituted tobacco, or tobacco substitutes. The tobacco material may include one or more of ground tobacco, tobacco fiber, cut tobacco, extruded tobacco, tobacco stems, tobacco lamina, reconstituted tobacco, and / or tobacco extract.

[0110] The tobacco material can include a filler component. The filler component is generally a non-tobacco component, i.e., a component that does not contain tobacco-derived components. The filler component can be a non-tobacco fiber, such as wood fiber or pulp or wheat fiber. The filler component can also be an inorganic material, such as chalk, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, etc. The filler component can also be a non-tobacco casting material or a non-tobacco extrusion material. The filler component can 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.

[0111] The tobacco material may include an aerosol former material. In some embodiments, the aerosol former material of the tobacco material may be glycerol, propylene glycol, or a mixture of glycerol and propylene glycol. Glycerol may be present in an amount of 10-20% by weight of the tobacco material, such as 13-16% by weight of the composition, or about 14 or 15% by weight of the composition. Propylene glycol, when present, may be present in an amount of 0.1-0.3% by weight of the composition.

[0112] The aerosol former material may be included in any component of the tobacco material, for example in any tobacco component and / or in the filler component, if present. Alternatively, or in addition, the aerosol former material may be added separately to the tobacco material. In either case, the total amount of aerosol former material in the tobacco material may be as defined herein.

[0113] In one example, the aerosol former material can include an amorphous solid material containing 40% menthol, 16% glycerol, 20% binder (alginate / pectin mixture), and 20% fiber (wood pulp).

[0114] A consumable is an article containing or consisting of an aerosol-forming material, the article intended to be consumed, in part or in whole, by a user during use. The consumable may include one or more other components, such as an aerosol-forming material storage area, an aerosol-forming material transport component, an aerosol-generating area, a housing, a wrapper, a mouthpiece, a filter, and / or an aerosol modifier. The consumable may also include an aerosol generator, such as a heater that radiates heat to cause the aerosol-generating material to generate an aerosol upon use. The heater may include, for example, a combustible material, a material heatable by electrical conduction, or a susceptor. The consumable may be of any shape or size suitable for a smoking device. In one embodiment of the present invention, the consumable is rod-shaped.

[0115] The susceptor is a material that can be heated by penetration by a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material such that penetration of the susceptor by the varying magnetic field causes induction heating of the heating material. The heating material may be a magnetic material such that penetration of the heating material by the varying magnetic field causes magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic such that the susceptor is heatable by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0116] An aerosol modifier is a substance, typically located downstream of the aerosol-generation region, configured to modify the generated aerosol, for example, by altering the taste, flavor, acidity, or another characteristic of the aerosol. The aerosol modifier may be provided within an aerosol modifier-releasing component operable to selectively release the aerosol modifier.

[0117] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavoring, a coloring, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, a string, or granules. The aerosol modifier may not include a filtration material.

[0118] By way of example, rod-shaped articles are often named according to the length of the product: "regular" (typically in the range of 68-75 mm, e.g., about 68 mm to about 72 mm), "short" or "mini" (68 mm or less), "king size" (typically in the range of 75-91 mm, e.g., about 79 mm to about 88 mm), "long" or "super king" (typically in the range of 91-105 mm, e.g., about 94 mm to about 101 mm), and "ultra long" (typically in the range of about 110 mm to about 121 mm).

[0119] Articles are also named according to the circumference of the product: "regular" (approximately 23-25 ​​mm), "wide" (over 25 mm), "slim" (approximately 22-23 mm), "demi-slim" (approximately 19-22 mm), "super-slim" (approximately 16-19 mm), and "micro-slim" (less than approximately 16 mm).

[0120] Thus, an article in the king size, super slim format, for example, would have a length of about 83 mm and a circumference of about 17 mm.

[0121] Each format can be made with mouthpieces of various lengths, ranging from about 30 mm to 50 mm in length. Tipping paper connects the mouthpiece to the aerosol-generating material and typically has a length longer than the mouthpiece, e.g., 3 to 10 mm, such that the tipping paper covers the mouthpiece and overlaps and connects the mouthpiece to the aerosol-generating material, e.g., in the form of a rod of substrate material.

[0122] The articles described herein and their aerosol-forming materials and mouthpieces can be made in any of the above formats, including, but not limited to, those described above.

[0123] The filamentary tow or filter material described herein can include cellulose acetate fiber tow. The filamentary tow can be formed using other materials used to form fibers, such as polyvinyl alcohol (PVOH), polylactic acid (PLA), polycaprolactone (PCL), poly(1-4 butanediol succinate) (PBS), poly(butylene adipate-co-terephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers, or combinations thereof. When the filamentary tow is cellulose acetate tow, it can be plasticized with a plasticizer suitable for the tow, such as triacetin, or the tow can be unplasticized. The tow can have any suitable specification, such as fibers having a "Y"-shaped, "X"-shaped, or "O"-shaped cross section. The fibers of the tow can have a filament denier value between 2.5 and 15 denier per filament, e.g., a filament denier value between 8.0 and 11.0 denier per filament, and a total fineness value between 5,000 and 50,000, e.g., a total fineness value between 10,000 and 40,000. The cross section of the fiber can have an isoperimetric ratio L of 25 or less, 20 or less, or 15 or less. 2 / A, where L is the perimeter of the cross section and A is the area of ​​the cross section. Such fibers have a relatively small surface area for a given denier per filament, which improves aerosol delivery to the consumer. The filter materials described herein also include cellulose-based materials such as paper. Such materials can have a relatively low density, such as between about 0.1 and about 0.45 grams per cubic centimeter, to allow air and / or aerosols to pass through the material. While described as a filter material, such materials may have a primary purpose, such as increasing resistance to attraction of components not related to filtration itself.

[0124] FIG. 1 shows a cross-sectional side view of an article 1 for use in a non-combustion aerosol delivery system.

[0125] In this embodiment, article 1 includes a mouthpiece 2 and a component 3 connected to mouthpiece 2. Component 3 is an aerosol-generating section that includes an aerosol-generating substrate formed from a source of aerosol-generating material. The source of aerosol-generating material may be in the form of a cylindrical rod of aerosol-generating material 4, as shown. In other examples, the aerosol-generating section may include a cavity for receiving the source of aerosol-generating material.

[0126] The aerosol-generating material may comprise multiple elongated strips 5 of aerosol-generating material. For example, in some embodiments, the aerosol-generating material 4 may comprise multiple elongated strips 5 of aerosolizable material and / or multiple elongated strips 5 of amorphous solid material. In some embodiments, the aerosol-generating material 4 is comprised of multiple elongated strips 5 of aerosolizable material. In some embodiments, the aerosol-generating material 4 may be corrugated. Optionally, the aerosol-generating material 4 may be corrugated to a depth within a range of about 20 um to about 1 mm. The sheet of aerosol-generating material 4 may have a thickness of about 200 um to about 250 um.

[0127] In this embodiment, the cylindrical rod of aerosol-forming material 4 is surrounded by a wrapper 6. The wrapper 6 may be a moisture-impermeable wrapper.

[0128] In embodiments in which the aerosol-generating material 4 comprises multiple elongated strips 5, the multiple elongated strips 5 of aerosol-generating material 4 may be aligned within the aerosol-generation section with their longitudinal dimensions in parallel alignment with the longitudinal axis X of the component 3. Alternatively, the strips 5 may be generally aligned with their longitudinal dimensions aligned transverse to the longitudinal axis X of the component 3.

[0129] When the chopped sheet comprises multiple strips 5 of material, the dimensions of each strip 5 may vary among the various strips. For example, the chopped sheet or aerosol-generating material may comprise a first population of strips 5 and a second population of strips 5, where the dimensions of the strips in the first population are different from the dimensions of the strips in the second population. In other words, the multiple strips 5 may include a first population of strips 5 having a first aspect ratio and a second population of strips 5 having a second aspect ratio that is different from the first aspect ratio. The first dimension or cut width of the strips 5 of aerosolizable material 4 is between about 0.8 mm and 5 mm, in some embodiments, between about 0.9 mm and 2 mm, and in some embodiments, between about 0.9 mm and 1.5 mm.

[0130] Component 3 is configured for use in a non-combustion aerosol delivery device that includes an aerosol generator for insertion into the aerosol-generating section of component 3. The aerosol generator may be a heating element that is a resistive heating element or an inductive heating element. Component 3 is configured to receive the aerosol generator onto a rod of aerosol-generating material 4.

[0131] In some embodiments, mouthpiece 2 can include a cooling section 8 positioned immediately downstream of and adjacent to component 3 of aerosol-forming material 4. In this embodiment, cooling section 8 is in abutting relationship with the source of aerosol-forming material 4. Mouthpiece 2 includes a body of material 7 downstream of cooling section 8 and a hollow tubular element 9 at the mouth end of article 1 downstream of body of material 7.

[0132] Cooling section 8 may comprise at least one hollow channel. Cooling section 8 may be formed from, for example, but not limited to, multiple layers of parallel-wound paper with butt seams or spirally wound paper layers, a cardboard tube, a tube formed using a papier-mache type process, a molded or extruded plastic tube, or the like. Cooling section 8 is manufactured to be sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacturing and use of article 1.

[0133] The body of material 7 and hollow tubular element 9 each define a substantially cylindrical overall outer shape and share a common longitudinal axis. The body of material 7 is wrapped within a first plug wrap 12. In this example, the body of material 7 is formed from filamentary tow. The tow may include plasticized cellulose acetate tow.

[0134] In other examples, different materials may be used to form the body of material 7. For example, the body 7 may be formed from paper rather than tow, in a manner similar to known paper filters, e.g., for use in cigarettes. For example, paper, or other cellulose-based material, may be provided as one or more sections of sheet material that are folded and / or corrugated to form the body 7. Alternatively, the body 7 may be formed from a tow other than cellulose acetate, e.g., polylactic acid (PLA), other materials described herein for filamentary tow, or similar materials. The hollow tubular element 9 may be formed as described above in connection with the body of material 7.

[0135] In this example, the hollow tubular element 9, body of material 7, and cooling section 8 are combined using a second plug wrap 13 that is wrapped around all three sections. It will be appreciated that any one of the sections may be omitted from the mouthpiece 2.

[0136] Tipping paper 15 is wrapped around the entire length of mouthpiece 2 and over a portion of the rod of aerosol-generating material 4 and has adhesive on its inner surface for connecting mouthpiece 2 and rod of aerosol-generating material 4. In this example, the rod of aerosol-generating material 4 is wrapped within wrapper 10, which forms a first wrapping material, and tipping paper 15 forms an outer wrapping material that extends at least partially over the rod of aerosol-generating material 4 and connects mouthpiece 2 and rod of aerosol-generating material 4. In some examples, tipping paper 15 may extend only partially over the rod of aerosol-generating material 4.

[0137] As shown in Figure 2, the mouthpiece 2 may include an aerosol modifier provided within the body of material 7. In this example, the aerosol modifier is provided in the form of capsules 17. In other examples, the aerosol modifier may be provided in other forms, such as a material infused within the body of material 7 or provided on a thread, such as a thread loaded with a flavoring or other aerosol modifier, which may also be disposed within the body of material 7.

[0138] The capsule 17 may include a breakable capsule, for example, a capsule having a solid, breakable shell surrounding a liquid payload. In this example, a single capsule 17 is used. The capsule 17 is fully embedded in the body of material 7. In other words, the capsule 17 is fully surrounded by the material forming the body 7. In other examples, multiple breakable capsules, for example, two, three, or more breakable capsules 17, may be disposed within the body of material 7.

[0139] Capsule 17 has a core-shell structure. In other words, capsule 17 comprises a shell that encapsulates a liquid agent, for example, a flavoring or other agent, which may be any one of the flavorings or aerosol-modifying agents described herein. The shell of capsule 17 may be ruptured by the user to release the flavoring or other agent into body 7.

[0140] Referring to Figure 3, the component 3 has a first end 21 and an opposing second end 22. At least the outer dimensions of the first end 21 and the second end 22 match. In this embodiment, the first end 21 is the free end of the component 3 that is farthest from the mouthpiece 2, and the second end 22 abuts the mouthpiece 2, i.e., is closest to the mouthpiece 2. The first end 21 has a first surface 23, and the second end 24 has a second surface 24. In this embodiment, the first surface 23 and the second surface 24 match.

[0141] 3 and 4, the component 3 comprises a core section 26. The core section 26 extends longitudinally along the length of the longitudinal axis X of the component 3. In this embodiment, the core section 26 extends the length of the component 3. The component 3 further comprises an outer section 27. The outer section 27 extends longitudinally along the length of the longitudinal axis A. In this embodiment, the outer section 27 extends the length of the component.

[0142] The outer section 27 comprises a first end surface 28 and an opposing second end surface 29. In this embodiment, the first end surface 28 extends in the same plane as the first surface 23 of the first end 21 of the component 3, and the second end surface 29 extends in the same plane as the second surface 24 of the second end 22 of the component 3. In this embodiment, the first end surface 28 and the second end surface 29 are coincident.

[0143] The outer section 27 surrounds the core section 26. Thus, the core section 26 is disposed radially inward of the outer section 27. The outer section 27 comprises an aerosol-generating material 4, which is configured to generate an aerosol when heated. The aerosol-generating material 4 in the outer section 27 of the component 3 may be a sheet material or a plurality of elongated strips 5, as previously described. The core section 26 comprises a first material 30, which is configured to receive a heating element during use.

[0144] In this embodiment, the core section 26 and the outer section 27 are coaxially formed, i.e., the longitudinal axis extending through the center of the core section 26 coincides with the longitudinal axis extending through the center of the outer section 27.

[0145] The outer section 27 therefore has a cross-section that is ring-shaped in a plane perpendicular to its longitudinal axis, and the first end section 28 and the second end section 29 therefore have annular cross-sections.

[0146] The aerosol-forming material 4 forming the outer section 27 can include tobacco material. The sheet or chopped sheet of aerosol-forming material 4 forming the outer section 27 can include a plant-based material, such as tobacco material.

[0147] The plant-based material may be a particulate or granular material. The tobacco material may be a particulate or granular material. In some embodiments, the tobacco material is a powder. Alternatively, or in addition, the tobacco material may comprise tobacco strips, strands, or fibers. For example, the tobacco material may comprise tobacco particles, granules, fibers, strips, and / or strands. In some embodiments, the tobacco material is comprised of particles or granules of tobacco material. The tobacco material may include reconstituted tobacco material.

[0148] The sheet or chopped sheet of aerosol-forming material may comprise nicotine in an amount of about 0.1% to about 0.3% by weight of the sheet or sheet material.

[0149] Reconstituted tobacco may also be present in the aerosol-forming materials described herein. The reconstituted tobacco may be any type of reconstituted tobacco known in the art.

[0150] The aerosol-generating material includes an aerosol-forming material. The aerosol-forming material includes one or more components capable of forming an aerosol. The aerosol-forming material includes one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, meso-erythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributylene, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. In some examples, the aerosol-forming material is glycerol or propylene glycol.

[0151] The sheet or chopped sheet includes a binder. The binder is arranged to bind the components of the aerosol-forming material together to form the sheet or chopped sheet. The binder may at least partially coat the surface of the tobacco material. If the tobacco material is in particulate form, the binder may at least partially coat the surface of the tobacco particles to bind them together.

[0152] The aerosol-generating material may include a filler. In some embodiments, the sheet or shredded sheet includes a filler. The filler is generally a non-tobacco component, i.e., a component that does not contain tobacco-derived ingredients. The filler may include one or more inorganic filler materials, such as calcium carbonate, perlite, vermiculite, diatomaceous earth, colloidal silica, magnesium oxide, magnesium sulfate, magnesium carbonate, and suitable inorganic adsorbents, such as molecular sieves. The filler may be a non-tobacco fiber, such as wood fiber or pulp or wheat fiber. The filler may be a cellulose-containing material, or the material may include a derivative of cellulose. The filler component may also be a non-tobacco casting material or a non-tobacco extrusion material.

[0153] In certain embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material such as wood, wood pulp, hemp fiber, cellulose, or a cellulose derivative. Without wishing to be bound by theory, it is believed that the inclusion of a fibrous filler can increase the tensile strength of the material.

[0154] The aerosol-forming material herein may include an aerosol modifier, such as any of the flavorings described herein. In one embodiment, the aerosol-forming material includes menthol. When the aerosol-forming material is incorporated into an article for use in an aerosol delivery system, the article may be referred to as a menthol-containing article.

[0155] In some embodiments, the outer section 27 may comprise an aerosol-forming "amorphous solid," which may alternatively be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may comprise a dry gel. An amorphous solid is a solid material that can retain some amount of fluid, such as a liquid, within it. The amorphous solid may comprise a flavoring. In some embodiments, the amorphous solid further comprises an active agent. The active agent may be a tobacco extract. In some embodiments, the amorphous solid may comprise one or more active agents and / or flavoring agents, one or more aerosol former materials, and optionally one or more other functional materials. The amorphous solid may be provided as multiple elongated strips.

[0156] The aerosol-forming material can include a mixture of an aerosolizable material and an amorphous solid material, as described herein. Such an aerosol-forming material can provide an aerosol having a desirable flavor profile upon use, since additional flavorings can be introduced into the aerosol-forming material by including them in the amorphous solid material component. The flavorings provided in the amorphous solid material can be more stably retained within the amorphous solid material compared to flavorings added directly to the tobacco material, resulting in a more consistent flavor profile between articles produced.

[0157] In this embodiment, core section 26 comprises a hollow tube 31. Hollow tube 31 may be generally cylindrical. Thus, in this embodiment, the cross section of hollow tube 31 is annular in a plane extending perpendicular to the longitudinal axis of core section 26. Hollow tube 31 comprises a first end surface 32 that is coplanar with first end 21 of aerosol-forming material 4 of component 3, and a second end surface 33 that is coplanar with second end 22 of aerosol-forming material 4 of component 3. In this embodiment, both first end surface 32 and second end surface 33 have annular cross sections.

[0158] In this embodiment, the hollow tube 31 includes a peripheral wall 34 surrounding a cavity 35 or hollow portion. In this embodiment, the peripheral wall 34 is annular in cross section. The peripheral wall 34 may have a thickness in the range of about 50 um to about 1 mm. Additionally or alternatively, the peripheral wall 34 may have a hardness or stiffness in the range of about 50% to about 98%. That is, the peripheral wall may be able to withstand a crushing force in the range of about 0.1 N before deformation occurs. The crushing force may be applied in a direction perpendicular to the longitudinal axis X.

[0159] Cavity 35 extends longitudinally along the length of tube 31 from first end surface 32 to second end surface 33. Cavity 35 is configured to receive a heating element during use. Accordingly, cavity 35 may have a diameter in the range of about 1 mm to about 5 mm, and in some embodiments, may have a diameter in the range of about 2 mm to about 4 mm.

[0160] In this embodiment, the first material is paper. Thus, the hollow tube 31 is formed from paper. Thus, the paper tube 31 may be formed from multiple layers of parallel-wound paper with butt seams, or spirally wound paper layers, a cardboard tube, or a tube formed using a papier-mâché type process.

[0161] However, it will be appreciated that in alternative embodiments, the first material may be, for example, but not limited to, one of another paper material, band-cast tobacco, regenerated tobacco, or an amorphous solid.

[0162] The tube 31 is configured to maintain a gap between the outer section 27 of the component 3 and the heating element when the heating element is inserted into the component 3 during use. The tube 31 is configured to prevent contact between the outer section 27 of the component 3 and the heating element. Thus, the core section 26 can prevent residue from forming and / or sticking to the heating element. This improves hygiene and efficiency of the heating element for subsequent use.

[0163] Tube 31 includes an inner surface 37. Inner surface 37 may include at least one embossed portion 38, shown in dotted lines in FIG. 3 . At least one embossed portion 38 is raised from inner surface 37 of tube 31 toward the center of cavity 35. At least one embossed portion 38 is configured to minimize contact between tube 31 and a heating element when the heating element is inserted into cavity 35 of tube 31. Reducing contact between tube 31 and a heating element may reduce the likelihood of damage to tube 31 during heating of component 3.

[0164] Additionally, the at least one embossed portion 38 may be configured to properly align the component 3 with the heating element. That is, the at least one embossed portion 38 may limit how the heating element can be inserted into the cavity 35 of the core section 26 to ensure proper alignment between the article 1 and the heating element of the device.

[0165] 5, another embodiment of component 40 is shown. Component 40 is generally the same as the embodiment of component 3 described above, and therefore will not be described in detail here. Furthermore, features and components of component 40 that are the same as features and components of component 3 retain the same terminology and reference numerals. The primary difference between the second embodiment of component 40 and the previously described component 3 is found in at least core section 26.

[0166] In this embodiment, core section 26 comprises a loosely gathered sheet 41. Loosely gathered sheet 41 is gathered to form a central column 42 of material 30. Central column 42 of material 30 is disposed inside outer section 27. Loosely gathered sheet 41 may be gathered such that the density of column 42 is in the range of about 50 mg / cm to about 800 mg / cm, and in some embodiments, in the range of about 60 mg / cm to about 600 mg / cm. Additionally or alternatively, loosely gathered sheet 41 may be gathered such that the pressure drop across core section 26 is in the range of about 0.01 mm / Wg to about 1 mm / Wg.

[0167] The loosely gathered sheet 41 is formed by a first material 30. The first material 30 may be, for example, but not limited to, at least one of a paper material, band-cast tobacco, recycled paper material, or an amorphous solid material. The loosely gathered sheet 41 may be provided in the form of a plurality of elongated strips 5, as described above.

[0168] In this embodiment, the loosely gathered sheet 41 is formed of a paper material. The paper material may be porous. The porosity of the paper material may be in the range of about 50 Coresta units to about 10,000 Coresta units.

[0169] The loosely gathered sheet 41 is configured to prevent contact between the outer section 27 of the component 3 and the heating element when the heating element is inserted into the core section 26 of the component. Reducing contact between the outer section 27 and the heating element can prevent residue from forming and / or sticking to the heating element, which improves hygiene and efficiency of the heating element for subsequent use.

[0170] In all of the above-described embodiments, the first material 30 can include at least one active substance. Additionally, in all of the above-described embodiments, the first material 30 can include an aerosol-modifying substance. Additionally, in all of the above-described embodiments, the first material 30 can include a fragrance. Thus, when the component 3 is heated by a heating element during use, the first material 30 forming the core section 26 can release at least one active substance and / or aerosol-modifying substance and / or fragrance.

[0171] Additionally, in some embodiments, the first material 30 may include a coating 45. The coating 45 may be configured to provide an aerosol. In some embodiments, the first material 30 may include a barrier coating 46 configured to prevent the first material 30 from burning or otherwise being damaged during heating. As shown in FIG. 3 , the coating 45 or barrier coating 46 may be provided on the inner surface 37 of the first material 30, i.e., closest to the central axis X.

[0172] A method of forming component 3 will now be described with reference to Figure 6. The method of forming a component for non-combustion supply article 1 includes providing an assembly comprising a sheet of aerosol-forming substrate 51 and a first material 30. The sheet of aerosol-forming substrate 51 is formed from an aerosol-forming material 4, as described above. The method further includes arranging the sheet of aerosol-forming substrate 51 and the first material 30 on component 3 such that the sheet of aerosol-forming substrate forms an outer section 27 surrounding a core section 26 formed by the first material 30.

[0173] The method may further comprise forming the first material and the aerosol-generating substrate 51 coaxially. The aerosol-generating substrate 51 and the first material 30 may be transported separately through a manufacturing apparatus 53.

[0174] The method may further include gathering the aerosol-generating substrate 51 around the first material 30 to form a coaxial rod. A stream of the aerosol-generating substrate 51 is fed to the gatherer 54 and gathered around the stream of the first material 30. In some embodiments, multiple streams of the aerosol-generating substrate 51 are fed to the gatherer 54 and gathered around the stream of the first material 30. Multiple streams of the aerosol-generating material may be fed to the gatherer 54 at various positions around the first material 30.

[0175] The method step of preparing the assembly may include providing a preformed tube 31 of the first material 31. The preformed tube 31 may be provided to a gatherer 53. The apparatus 53 may include a tube feeder 55 configured to feed the tube 31 into the center of the gatherer 53. The tube 31 may be a continuous tube 31.

[0176] Alternatively, the method step of preparing the assembly may include providing a sheet of first material 30 and forming a tube 31 from the sheet of first material 30, as shown in Figure 7. To form the tube 31 online, the apparatus 53 may further comprise a tube forming device 56.

[0177] The method step of preparing the assembly may further include providing an adhesive to the sheet of first material 30 and allowing the adhesive to dry before gathering the aerosol-generating substrate 51 around the first material 30. To adhere the first material 30 to form the tube 31, the apparatus 53 may further include a gluing station 57. The gluing station may be located upstream of or integrated into the tube-forming device 56. To dry the adhesive, the apparatus 53 may include a drying device 58 downstream of or integrated into the tube-forming device 56.

[0178] In an alternative method, the method step of preparing the assembly may include providing a sheet of first material 30 and assembling the sheet of first material with a sheet of aerosol-generating material to form a coaxial rod with the loosely assembled sheet in core section 26. Thus, tube-forming device 59 may be omitted.

[0179] The various embodiments described herein are presented solely to aid in the understanding and teaching of the claimed features. These embodiments are provided merely as a representative sample of embodiments and are not intended to be comprehensive and / or exclusive. It should be 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, which is defined by the claims, or limitations on the equivalents of the claims, and that other embodiments may be used and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the present invention may suitably comprise, consist of, or consist essentially of any suitable combination of the disclosed elements, components, features, parts, steps, means, etc., other than those specifically described herein. Furthermore, the present disclosure may include other inventions that are not currently claimed but may exist in the future.

Claims

1. 1. A component for a non-combustion aerosol delivery article for use in a non-combustion aerosol delivery system, comprising: a longitudinally extending core section; a longitudinally extending outer section surrounding the core section and comprising an aerosol-generating substrate configured to generate an aerosol when heated; Equipped with 1. A component wherein the core section is formed from a hollow paper tube, the hollow paper tube having an inner surface defining a cavity configured to receive a heating element, the hollow paper tube configured to maintain a gap from the heating element when the heating element is inserted into the hollow paper tube.

2. The component of claim 1 , wherein the core section and the outer section are coaxially formed.

3. The component of claim 1 , wherein the cavity extends the entire length of the core section.

4. 4. The component of claim 1 or 3, wherein the inner surface of the tube is embossed, the embossed portion configured to minimize contact with the heating element when the heating element is inserted into the tube.

5. The component of claim 1 , wherein the tube has a hardness in the range of about 50% to about 98%.

6. 10. The component of claim 1, wherein the aerosol-generating substrate comprises a plurality of elongated strips extending substantially parallel to one another in a longitudinal direction.

7. 10. The component of claim 1, wherein the aerosol-generating substrate is optionally corrugated to a depth in the range of about 20 um to about 1 mm.

8. 10. The component of claim 1, which is an aerosol-generating component of a non-combustion aerosol delivery system.

9. An article comprising the component of claim 1.

10. A method of forming a component for a non-combustion aerosol delivery article comprises: providing an assembly comprising a sheet of aerosol-generating substrate; providing a sheet of paper; and forming a hollow paper tube from the paper sheet, the hollow paper tube having an inner surface defining a cavity configured to receive a heating element, the hollow paper tube configured to maintain a gap between the article and the heating element when the heating element is inserted into the hollow paper tube; arranging the sheet of aerosol-generating substrate and the hollow paper tube in a component such that the sheet of aerosol-generating substrate forms an outer section surrounding a core section formed by the hollow paper tube; A method comprising:

11. The method of claim 10 , wherein the hollow paper tube and the aerosol-generating substrate are formed coaxially.

12. 12. The method of claim 10 or 11, further comprising the step of gathering the aerosol-generating substrate around the hollow paper tube to form a coaxial rod.

13. The method of claim 12 , wherein the gathering step comprises providing a stream of aerosol-generating substrate to a gatherer and gathering the stream of aerosol-generating substrate around the hollow paper tube.

14. 14. The method of claim 13, wherein the gathering step comprises providing a plurality of streams of aerosol-generating substrate to a gatherer, the plurality of streams of aerosol-generating substrate being disposed at various positions around the hollow paper tube.

15. 12. The method of claim 11 , wherein the step of providing the assembly comprises providing adhesive on the sheet of hollow paper tube and allowing the adhesive to dry before assembling the aerosol-generating substrate around the hollow paper tube.

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