Components for use in non-flammable aerosol delivery systems

Abstract

A component for use in a non-combustion aerosol delivery system. The component comprises at least one spirally wound strip containing an aerosol-generating material. Methods of forming the articles, systems, and components are also described.

Description

[Technical Field]

[0001] The present invention relates to components for use in non-combustion aerosol delivery systems, articles for use in non-combustion aerosol delivery systems, aerosol delivery systems, and methods of forming components for use in non-combustion aerosol delivery systems. [Background technology]

[0002] Certain tobacco industry products generate aerosols during use, which are inhaled by the user. For example, tobacco heating devices heat an aerosol-generating substrate, such as tobacco, to form the aerosol by heating rather than burning the substrate. Such tobacco industry products typically include a mouthpiece through which the aerosol is delivered to the user's mouth. Summary of the Invention

[0003] According to embodiments described herein, in a first aspect, there is provided a component for use in a non-combustible aerosol delivery system, the component comprising at least one spirally wound strip comprising an aerosol-generating material.

[0004] According to embodiments described herein, in a second aspect, there is provided a component for use in a non-combustible aerosol delivery system, the component comprising a plurality of braided strips or spirally wound strips, at least one of the plurality of braided strips and / or spirally wound strips comprising an aerosol-generating material, the component further comprising a cavity extending from a first end of the component.

[0005] According to embodiments described herein, in a third aspect there is provided an article for use in a non-combustible aerosol delivery system, the article comprising a component according to the first or second aspect above.

[0006] According to embodiments described herein, in a fourth aspect there is provided a non-combustible aerosol delivery system comprising an article according to the third aspect and an aerosol delivery device for forming an aerosol from an aerosol-generating material.

[0007] According to embodiments described herein, in a fifth aspect, there is provided a method of forming a component according to the first or second aspect above, comprising the steps of: providing a source of strip material comprising an aerosol-forming material; feeding the strip material toward a mandrel; winding the strip material around a mandrel to form a spirally wound strip containing the aerosol-generating material; A method is provided which includes:

[0008] Embodiments of the present invention will now be described, by way of example only, with reference to the accompanying drawings, in which: [Brief explanation of the drawings]

[0009] [Figure 1a] 1 is a cross-sectional side view of an article for use in a non-combustion aerosol delivery system, the article including a component having at least one spirally wound strip containing an aerosol-generating material. An aerosol delivery device is also shown, the article and device forming a system. [Figure 1b] FIG. 1b is a side view of the components of FIG. 1a. [Figure 2a] 1 is a cross-sectional side view of an article for use in a non-combustion aerosol delivery system, the article comprising a component having a plurality of spirally wound or braided strips. An aerosol delivery device is also shown, the article and device forming a system. [Figure 2b] FIG. 2b is a side view of the component of FIG. 2a. [Figure 3a] FIG. 1c shows a machine for forming the component of FIG. 1b. [Figure 3b] FIG. 2c shows a machine for forming the component of FIG. 2b. [Figure 4] FIG. 1 is a flow diagram illustrating a method of forming a component described herein. DETAILED DESCRIPTION OF THE INVENTION

[0010] [Detailed explanation] As used herein, the term "delivery system" is intended to encompass a system that delivers at least one substance to a user, including: Combustible aerosol delivery systems, such as cigarettes, cigarillos, cigars, and tobacco for pipes or 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 a compound from an aerosol-forming material without burning the aerosol-forming material, such as an electronic cigarette, a tobacco heating product, and a hybrid system for generating an aerosol using a combination of aerosol-forming materials; and aerosol-free delivery systems that deliver 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 or moist snuff.

[0011] According to the present disclosure, a "non-combustible" aerosol delivery system is one in which the aerosol-generating materials (or components thereof) that are components of the aerosol delivery system do not burn or combust to facilitate delivery of at least one substance to a user.

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

[0013] 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 required.

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

[0015] In some embodiments, the non-combustion aerosol delivery system is a hybrid system for generating aerosol using a combination of aerosol-forming materials, one or more of which 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 tobacco or a non-tobacco product.

[0016] Generally, a non-combustible aerosol delivery system can include a non-combustible aerosol delivery device and a consumable item for use with the non-combustible aerosol delivery device.

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

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

[0019] In some embodiments, the non-combustion aerosol delivery system, e.g., the non-combustion aerosol delivery device, can include a power source and a controller. The power source can be, for example, an electrical source or a heat-generating power source. In some embodiments, the heat-generating power source includes a carbon substrate that can be activated to dissipate power in the form of heat to an aerosol-generating material or a heat transfer material in proximity to the heat-generating power source.

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

[0021] In some embodiments, consumables for use with non-combustible aerosol delivery devices can include aerosol-generating materials, aerosol-generating material storage areas, aerosol-generating material transfer components, aerosol generators, aerosol-generating areas, housings, wrappers, filters, mouthpieces, and / or aerosol modifiers.

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

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

[0024] 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, known drugs, and psychoactive substances. The active substance may be naturally derived or synthetically obtained. The active substance may include, for example, nicotine, caffeine, taurine, theine, vitamins such as B6, B12, or C, melatonin, cannabinoids, or components, derivatives, or combinations thereof. The active substance may include one or more components, derivatives, or extracts of tobacco, cannabis, or another botanical substance.

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

[0026] As described herein, the active substance may comprise or be derived from one or more botanical substances, or components, derivatives, or extracts thereof. As used herein, the term "botanical substance" includes any material derived from a plant, including, but not limited to, extracts, leaves, bark, fiber, stems, roots, seeds, flowers, fruits, pollen, husks, shells, etc. Alternatively, the material may comprise active compounds naturally occurring in synthetically obtained botanical substances. The material may be in the form of a liquid, gas, solid, powder, fine powder, ground particles, granules, pellets, fragments, strips, sheets, etc. Examples of botanical substances include tobacco, eucalyptus, star anise, hemp, cocoa, cannabis, fennel, lemongrass, peppermint, spearmint, rooibos, chamomile, flax, ginger, ginkgo biloba, hazel, hibiscus, laurel, licorice, matcha, yerba mate, orange peel, papaya, rose, sage, tea such as green tea or black tea, thyme, cloves, cinnamon, coffee, aniseed, basil, bay leaf, cardamom, coriander, cumin, nutmeg, oregano, paprika, rosemary, saffron, and lavender. , lemon peel, mint, juniper, elderflower, vanilla, wintergreen, shiso, curcuma, turmeric, sandalwood, cilantro, bergamot, orange blossom, myrtle, blackcurrant, valerian, bell pepper, mace, damiana, marjoram, olive, lemon balm, lemon basil, chives, kavi, verbena, tarragon, geranium, mulberry, ginseng, theanine, theacrine, maca, ashwagandha, damiana, guarana, chlorophyll, baobab, or any combination thereof.The mint may be selected from the following mint varieties: common mint (Mentha arvensis), grapefruit mint (Mentha cv), Egyptian mint (Mentha niliaca), peppermint (Mentha piperita), lime mint (Mentha piperita citrata cv), chocolate mint (Mentha piperita cv), curly mint (Mentha spicata crispa), wild mint (Mentha cordifolia), horse mint (Mentha longifolia), pineapple mint (Mentha suaveolens variegata), pennyroyal mint (Mentha pulegium), English spearmint (Mentha spicata cv), and apple mint (Mentha suaveolens).

[0027] 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.

[0028] 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.

[0029] 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.

[0030] In some embodiments, the substance delivered comprises a fragrance.

[0031] As used herein, the terms "flavor" and "flavoring" refer to materials that may be used, where local regulations permit, to create a desired taste, aroma, or other somatosensory sensation in products intended for adult consumers.These ingredients may be naturally derived flavoring materials, botanicals, extracts of botanicals, synthetically derived materials, or combinations thereof (e.g., tobacco, cannabis, licorice, hydrangea, eugenol, magnolia, chamomile, fenugreek, clove, maple, matcha, menthol, Japanese mint, aniseed (aniseed), cinnamon, turmeric, Indian spices, Asian spices, herbs, wintergreen, cherry, berry, red berry, cranberry, peach, apple, orange, mango, clementine, lemon, lime, tropical fruit). , papaya, rhubarb, grapes, durian, dragon fruit, cucumber, blueberry, mulberry, citrus fruits, Drambuie, bourbon, scotch, whiskey, gin, tequila, rum, spearmint, peppermint, lavender, aloe vera, cardamom, celery, cascarilla, nutmeg, sandalwood, bergamot, geranium, khat, naswar, betel quid, shisha, pine, honey essence, rose oil, vanilla, lemon oil, orange oil, orange blossom, cherry blossom, cassia, caraway, cognac, jasmine, ylang ila Sage, fennel, wasabi, bell pepper, ginger, coriander, coffee, hemp, mint oil of any species of Mentha genus, eucalyptus, star anise, cocoa, lemongrass, rooibos, flax, ginkgo biloba, hazel, hibiscus, laurel, yerba mate, orange peel, rose, tea such as green tea or black tea, thyme, juniper, elderflower, basil, bay leaf, cumin, oregano, paprika, rosemary, saffron, lemon peel, mint, shiso, curcuma, cilantro, myrtle, black currant, valerian, bell pepper, mace, damian marjoram, olive, lemon balm, lemon basil, chives, caraway, verbena, tarragon, limonene, thymol, camphene), flavor enhancers, bitter taste receptor site blockers, sensory receptor site activators or stimulants, sugars and / or sugar substitutes (e.g., sucralose, acesulfame potassium, aspartame, saccharin, cyclamate, lactose, sucrose, glucose, fructose, sorbitol, or mannitol), and other additives such as charcoal, chlorophyll, minerals, botanicals, or breath fresheners.The materials may be imitation, synthetic or natural ingredients, or mixtures thereof. The materials may be in any suitable form, for example, a liquid such as an oil, a solid such as a powder, or a gas.

[0032] 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.

[0033] In some embodiments, the flavoring agent may include a sensate intended to achieve a somatosensory sensation typically perceived chemically induced by stimulation of the fifth cranial nerve (trigeminal nerve) in addition to or instead of the scent or taste nerves, and may include agents that provide a heating, cooling, tingling, or anesthetic effect. A suitable heating agent may be, but is not limited to, vanillyl ethyl ether, and a suitable cooling agent may be, but is not limited to, eucalyptol WS-3.

[0034] An aerosol-generating material is a material that can generate an aerosol when activated, for example, by heating, irradiation, or in any other way. The aerosol-generating material may be in solid, liquid, or gel form and may or may not contain active substances and / or flavorings. The aerosol-generating material may also be incorporated into an article for use in an aerosol generating system.

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

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

[0037] A susceptor is a material that can be heated by the penetration of a varying magnetic field, such as an alternating magnetic field. The susceptor may be a conductive material, where the penetration of the varying magnetic field into the conductive material results in induction heating of the heating material. The heating material may be a magnetic material, where the penetration of the varying magnetic field into the magnetic material results in magnetic hysteresis heating of the heating material. The susceptor may be both conductive and magnetic, where the susceptor can be heated by both heating mechanisms. A device configured to generate a varying magnetic field is referred to herein as a magnetic field generator.

[0038] An aerosol modifier is a substance typically located downstream of the aerosol-generation region and configured to modify the generated aerosol, for example, by changing the taste, flavor, acidity, or another characteristic of the aerosol. The aerosol modifier may be provided within an aerosol modifier-releasing component operable to selectively release the aerosol modifier.

[0039] The aerosol modifier may be, for example, an additive or an adsorbent. The aerosol modifier may include, for example, one or more of a flavoring, a colorant, water, and a carbon adsorbent. The aerosol modifier may be, for example, a solid, a liquid, or a gel. The aerosol modifier may be in the form of a powder, a string, or granules. The aerosol modifier may not include a filtration material.

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

[0041] The filament tow materials described herein can include cellulose acetate fiber tow. The filament 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-cotterephthalate) (PBAT), starch-based materials, cotton, aliphatic polyester materials, and polysaccharide polymers, or combinations thereof. The filament tow can be plasticized using an appropriate plasticizer for the tow, such as triacetin, where the material can be cellulose acetate tow or the tow can be unplasticized. The tow can have any suitable specifications, for example, the fibers have other cross sections such as "Y" or "X" shapes, with a single fineness value of 2.5 to 15 denier per filament, for example, 8.0 to 11.0 denier per filament, and a total fineness value of 5,000 to 50,000, for example, 10,000 to 40,000.

[0042] 1a is a cross-sectional side view of an article 1a for use in a non-combustion aerosol delivery system, the article 1a including a component 3 having at least one spirally wound strip 3c containing an aerosol-generating material. FIG. 1a also schematically illustrates an aerosol delivery device 100.

[0043] Article 1a comprises a mouthpiece 2 and a component 3, also referred to as an aerosol-generating portion 3, connected to mouthpiece 2. In this example, aerosol-generating portion 3 includes a recess or cavity 3a extending into component 3. In this example, recess or cavity 3a forms a channel that extends through the entire length of component 3. Article 1a is generally rod-shaped and has a longitudinal axis shown as dotted line X-X'.

[0044] The recess or cavity 3a is formed by a hollow tube 3b. The hollow tube 3b is formed by multiple parallel-wound paper layers abutting at seams. The spirally wound strip 3c is a wrapper around the hollow tube 3b and, in this example, is glued to the tube 3b. Alternatively, the hollow tube can be formed in other ways, such as using spirally or spirally wound paper layers (as described herein), a cardboard tube, a tube formed using a molded pulp or molded fiber-type process, a molded or extruded plastic tube, or the like. The hollow tube 3b is manufactured to be sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacture and use of the article 1. Manufacturing tolerances for the diameter of the cavity may be lower than those typically associated with aerosol-generating materials, for example, less than 0.5 mm, or less than 0.4 mm, or less than 0.3 mm.

[0045] In this example, the aerosol-generating material forming the spirally wound strip 3c is a strip formed from a reconstituted tobacco sheet material. In other examples, the spirally wound strip 3c can be formed from other materials, such as a tobacco-free sheet material, an amorphous solid sheet material, a gelled sheet material, or a paper material onto which the material is deposited. The spirally wound strip 3c can be formed from a sheet material containing an aerosol modifier, such as a flavoring agent, as described herein. The aerosol-generating material can be laminated to a support material, such as a support material formed from a metal foil, such as aluminum foil, paper, a polylactic acid (PLA) material, a starch-based sheet material, or the like.

[0046] The spirally wound strip may have a tensile strength of at least 4N / 15mm, which may ensure that the strip has sufficient tensile strength during the winding process used to wrap the strip 3c around the tube 3b.

[0047] In this example, the recess or cavity 3a extends completely through the component 3. However, in other examples, the recess or cavity 3a may extend only partially through the component 3. The length of the recess or cavity 3a in the direction of the longitudinal axis may be shorter than the length of the component 3 along the longitudinal axis.

[0048] The device 100 comprises a housing 101 and an area 102 for receiving the article 1 a. The area 102 comprises an aerosol-generating element 103, in this case a heatable element, for generating an aerosol from the aerosol-generating material of the article 1 a. The recess or cavity 3 a is arranged to receive at least a portion of the aerosol-generating element 103.

[0049] During use, the article 1a is pressed against the aerosol-generating element 103 of the aerosol-delivery device 100 so that the aerosol-generating element 103 enters the recess or cavity 3a. The article 1a is consumed by inhaling mainstream aerosol through the downstream portion 2 of the article 1a, in this case the mouthpiece 2. Once the smoking session is completed, the aerosol-generating element 103 is removed from the aerosol-generating material 3.

[0050] In this example, component 3 has a circumference of about 22.7 mm. In alternative embodiments, component 3 can have any suitable circumference, for example, a circumference of about 20 mm to about 26 mm.

[0051] The component 3 has a length of, for example, about 5 mm to about 20 mm, or about 8 mm to about 15 mm. The recess or cavity 3a extends through at least 25%, 50%, or 75% of the length of the component 3. For example, for a component 3 having a length of 12 mm, the recess 3a can extend 9 mm or more into the body.

[0052] The maximum diameter of the recess or cavity 3 a may be more than 10%, or more than 15%, or more than 20% of the diameter of the component 3 .

[0053] The maximum diameter of the recess 3a may be less than 60%, or less than 50%, or less than 40% of the diameter of the component 3, for example, 10% to 40% of the diameter of the component 3, or 15% to 30% of the diameter of the component 3.

[0054] The aerosol-forming material of any of the embodiments described herein may include aerosol-forming material in sheet form, extruded form, or molded form. The aerosol-forming material may include, for example, plant-based material that is extruded and / or molded to form strips 3c. Extruded or molded tobacco may be produced by a process such as that described in International Patent Publication No. WO2020148538, which is incorporated herein by reference.

[0055] The recess or cavity 3a of the component 3 may be at least partially filled with a second aerosol-generating material, which may be the same as or different from the aerosol-generating material forming the strip 3c, in this case referred to as the first aerosol-generating material.

[0056] In this example, the spirally wound strip 3c is wound around the hollow tube 3b with a gap 3d between the edges of the strip 3c. This gap 3d creates a path through the component 3, maximizing airflow over the surface of the strip 3c, and therefore air exposure of the aerosol-generating material contained therein, for a given length of the strip. Optionally, the spirally wound strip 3c may be the first of two strips, and a second spirally wound strip (not shown) may be wound around the first spirally wound strip 3c, also with a gap between the edges of the second strip. The second spirally wound strip may at least partially overlap the first spirally wound strip 3c, and may overlap the entire width of the gap. This may allow airflow in the gap formed by the edges of the first strip 3c and the inner surface of the second strip. The size of the gap may be from about 0.5 mm to about 10 mm, or from about 1 mm to about 5 mm, between the edges of the first and / or second strips 3c. In other examples, the spirally wound strip 3c may be tightly wound with no gaps 3d, increasing the amount of strip material provided for a given length of component. Again, the spirally wound strip 3c in this case may be the first of two strips, and a second spirally wound strip (not shown) may be wrapped around the first spirally wound strip 3c, either tightly wound with no gaps or wound with gaps as previously described.

[0057] Component 3 has a longitudinal axis Z-Z', and when viewed from the side relative to the longitudinal axis as shown in Figure lb, the long edge of the spirally wound strip, when projected onto said axis, forms two angles with the longitudinal axis of the component. One of the angles is greater than 90 degrees and the other is less than 90 degrees. In some examples, the angle between the long edge of the spirally wound strip and the longitudinal axis that is less than 90 degrees is less than about 70 degrees, e.g., less than about 60 degrees, or less than about 50 degrees.

[0058] FIG. 3a shows a machine for forming the component 3 of FIG. 1b. A portion of hollow tube 3b is fed / pulled along mandrel 16 in the direction of arrow "X" while rotating. Hollow tube 3b can be formed, for example, from a helically or spirally wound paper forming a core, which can be preformed or formed just prior to wrapping strip material 14 around the core. In this example, a source of first strip material 14 containing an aerosol-generating material is provided. First strip material 14 is wrapped around tube 3b as tube 3b rotates and moves forward. First strip material 14 forms a first spirally wound strip 3 around tube 3b. An optional second strip material 15 is provided, which in this case is used to adhere first strip material 14 to tube 3b. For example, the second strip of material 15 may be a paper material that is dipped into an adhesive reservoir before reaching the hollow tube 3b and then glued to the tube 3b and used to glue the first strip of material 14 to the tube 3b. The second strip of material 15 forms a second spirally wound strip 3c around the tube 3b.

[0059] It is preferred that strip material 14 have a width that is at least twice the diameter of mandrel 16. Correspondingly, it is preferred that the spirally wound strip of component 3 have a width that is at least 1.5 times the diameter of recess or cavity 3a. For example, the width of the spirally wound strip may be 2, 2.5, or 3 times the diameter of the recess.

[0060] A continuous rod is formed using a mechanical device, and a cutting device 17 is provided for cutting the continuously formed rod into individual components 3 or groups of components 3. The cutting device comprises a plurality of blades, such as a rotating circular blade, spaced longitudinally along the travel path of the rod. The cutting device can be arranged to reciprocate along a path parallel to the travel path of the rod and to cut the rod while moving in the same direction as the rod. For example, the cutting device can be arranged to move parallel to the rod at the same speed as the rod and to cut the rod into segments while moving at the same speed as the rod. This can help provide a clean cut through the rod at an angle perpendicular to the travel path of the rod.

[0061] Mouthpiece 2 includes a cooling portion 8, also referred to as a cooling element, located immediately downstream of and adjacent to a source of aerosol-forming material 3. In this example, cooling portion 8 abuts the source of aerosol-forming material. Mouthpiece 2 also includes, in this example, a body of material 6 downstream of cooling portion 8 and a hollow tubular element 4 at the mouth end of article 1 downstream of body of material 6.

[0062] The cooling portion 8 comprises a hollow channel having an inner diameter of about 1 mm to about 4 mm, for example, about 2 mm to about 4 mm. In this example, the hollow channel has an inner diameter of about 3 mm. The hollow channel extends along the entire length of the cooling portion 8. In this example, the cooling portion 8 comprises a single hollow channel. In alternative embodiments, the cooling portion can comprise multiple channels, for example, two, three, or four channels. In this example, the single hollow channel is generally cylindrical, but in alternative embodiments, other channel shapes / cross-sections may be used. The channel may be, for example, a circular cylinder, an elliptical cylinder, a hyperbolic cylinder, or a parabolic cylinder. The hollow channel can provide a space in which aerosol drawn into the cooling portion 8 can expand and cool.

[0063] The cooling portion 8 can have a radial wall thickness, which can be measured, for example, using calipers. The wall thickness of the cooling portion 8 for a given outer diameter of the cooling portion defines the inner diameter of the cavity enclosed by the walls of the cooling portion 8. The cooling portion 8 can have a wall thickness of at least about 1.5 mm and up to about 2 mm. In this example, the cooling portion 8 has a wall thickness of about 2 mm. Providing a cooling portion 8 with a wall thickness within this range improves retention of the supply of aerosol-generating material in the aerosol-generating portion during use by reducing longitudinal displacement of strands and / or strips of aerosol-generating material when the aerosol generator is inserted into an article.

[0064] Cooling portion 8 is formed from filament tow. Other configurations may be used, such as multiple layers of paper wound in parallel and abutting at a seam to form cooling portion 8, or spirally wound paper layers, cardboard tubes, tubes formed using a cohesive paper type process, molded or extruded plastic tubes, etc. Cooling portion 8 is manufactured to be sufficiently rigid to withstand axial compressive forces and bending moments that may occur during manufacturing and use of article 1.

[0065] The wall material of the cooling portion 8 may be relatively non-porous, such that at least 90% of the aerosol generated by the aerosol-generating material 3 passes longitudinally through the one or more hollow channels rather than through the wall material of the cooling portion 8. For example, at least 92% or at least 95% of the aerosol generated by the aerosol-generating material 3 may pass longitudinally through the one or more hollow channels.

[0066] In some examples, the density of the material forming the cooling portion 8 is at least about 0.20 grams per cubic centimeter (g / cc), or at least about 0.25 g / cc. The density of the material forming the cooling portion 8 is less than about 0.80 grams per cubic centimeter (g / cc), more preferably less than 0.6 g / cc. In some embodiments, the density of the material forming the cooling portion 8 is between 0.20 and 0.8 g / cc, more preferably between 0.3 and 0.6 g / cc, or between 0.4 and 0.6 g / cc, or about 0.5 g / cc. These densities have been found to provide a good balance between the increased hardness imparted by higher density materials and minimizing the total weight of the article. For purposes of the present invention, the "density" of the material forming the cooling portion 8 refers to the density of the filament tow forming the element, including any plasticizers incorporated therein. Density can be determined by dividing the total weight of the material forming the cooling portion 8 by the total volume of the material forming the cooling portion 8, which can be calculated using appropriate measurements of the material forming the cooling portion 8, for example, obtained with a caliper. If necessary, the appropriate dimensions can be measured using a microscope.

[0067] Preferably, the length of the cooling portion 8 is less than about 30 mm. More preferably, the length of the cooling portion 8 is less than about 25 mm. Even more preferably, the length of the cooling portion 8 is less than about 20 mm. Additionally or alternatively, the length of the cooling portion 8 is preferably at least about 10 mm. Preferably, the length of the cooling portion 8 is at least about 15 mm. In some preferred embodiments, the length of the cooling portion 8 is between about 15 mm and about 20 mm, more preferably between about 16 mm and about 19 mm. In this example, the length of the cooling portion 8 is 19 mm.

[0068] The cooling portion 8 is disposed around and defines a cavity within the mouthpiece 2 that acts as the cooling portion. The cavity provides a chamber through which heated volatile components generated by the rod of aerosol-generating material 3 flow. The cooling portion 8 is hollow to provide a chamber for aerosol accumulation, yet is rigid enough to withstand axial compressive forces and bending moments that may occur during manufacturing and use of the article 1. The cooling portion 8 provides a physical displacement between the aerosol-generating material 3 and the body of material 6. The physical displacement provided by the cooling portion 8 can provide a temperature gradient across the length of the cooling portion 8.

[0069] Mouthpiece 2 is 110mm 3 Preferably, the mouthpiece 2 has a cavity with an internal volume of at least 120 mm. It has been found that providing a cavity of at least this volume allows for improved aerosol formation. The mouthpiece 2 is formed within the cooling section 8, for example, and has an internal volume of 120 mm. 3 More than 130mm, preferably 3 More preferably, the internal cavity has an internal volume of about 130 mm or more, allowing for further improvement of the aerosol. 3 ~approx. 230mm 3 , for example, about 134 mm 3 or 227 mm 3 It has a volume of

[0070] The cooling section 8 may be configured to provide a temperature difference of at least 40 degrees Celsius between the heated volatile components entering the first upstream end of the cooling section 8 and the heated volatile components exiting the second downstream end of the cooling section 8. Preferably, the cooling section 8 is configured to provide a temperature difference of at least 60 degrees Celsius, preferably at least 80 degrees Celsius, and more preferably at least 100 degrees Celsius between the heated volatile components entering the first upstream end of the cooling section 8 and the heated volatile components exiting the second downstream end of the cooling section 8. This temperature difference across the length of the cooling section 8 protects the temperature-sensitive body 6 from the high temperatures of the aerosol-generating material 3 when heated.

[0071] In use, the aerosol-generating portion may exhibit a pressure drop of about 15 to about 40 mmH 2 O. In some embodiments, the aerosol-generating portion exhibits a pressure drop across the aerosol-generating portion of about 15 to about 30 mmH 2 O.

[0072] The aerosol-forming material has a density of about 400 mg / cm within the aerosol-generating region. 3 ~about 900mg / cm 3 The packing density may be

[0073] In this embodiment, the moisture-impermeable wrapper 10 surrounds the rod of aerosol-forming material and comprises aluminum foil. In another embodiment, the wrapper 10 comprises a paper wrapper, which optionally includes a barrier coating that renders the wrapper material substantially moisture-impermeable. Aluminum foil has been found to be particularly effective in enhancing aerosol formation within the aerosol-forming material 3. In this example, the aluminum foil has a metal layer approximately 6 μm thick. In this example, the aluminum foil has a paper backing. However, in alternative configurations, the aluminum foil may have other thicknesses, for example, a thickness of 4 μm to 16 μm. The aluminum foil need not have a paper backing; for example, it may have a backing formed from another material that helps to provide the foil with adequate tensile strength, or it may have no backing material. Metal layers or foils other than aluminum may also be used. The total thickness of the wrapper is preferably 20 μm to 60 μm, more preferably 30 μm to 50 μm, to provide a wrapper with adequate structural integrity and heat transfer properties.

[0074] In this example, the non-breathable wrapper 10 is also substantially non-breathable. In an alternative embodiment, the wrapper 10 preferably has a breathability of less than 100 Coresta units, more preferably less than 60 Coresta units. It has been found that wrappers with low breathability, for example, having a breathability of less than 100 Coresta units, more preferably less than 60 Coresta units, enhance aerosol formation in the aerosol-forming material 3. The breathability of the wrapper 10 can be measured in accordance with ISO 2965:2009 for measurement of breathability of materials used as cigarette paper, filter plug wrap, and filter bonding paper.

[0075] The body of material 6 and the hollow tubular element 4 each define a generally cylindrical overall outer shape and share a common longitudinal axis. The body of material 6 is wrapped in a first plug wrap 7. The first plug wrap 7 preferably has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 40 gsm. The first plug wrap 7 preferably has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The first plug wrap 7 is preferably a non-porous plug wrap having an air permeability of, for example, less than 100 Coresta units, for example, less than 50 Coresta units. However, in other embodiments, the first plug wrap 7 may be a porous plug wrap having an air permeability of, for example, greater than 200 Coresta units.

[0076] Preferably, the length of the body of material 6 is less than about 15 mm. More preferably, the length of the body of material 6 is less than about 12 mm. Additionally or alternatively, the length of the body of material 6 is at least about 5 mm. Preferably, the length of the body of material 6 is at least about 8 mm. In some preferred embodiments, the length of the body of material 6 is between about 5 mm and about 15 mm, more preferably between about 6 mm and about 12 mm, even more preferably between about 6 mm and about 12 mm, and most preferably about 6 mm, 7 mm, 8 mm, 9 mm, or 10 mm. In this example, the length of the body of material 6 is 10 mm.

[0077] In this example, the body 6 is formed from filament tow. In this example, the tow used in the body 6 has a denier per filament (dpf) of 5 and a total fineness of 25,000. In this example, the tow comprises plasticized cellulose acetate tow. The plasticizer used in the tow comprises approximately 9% by weight of the tow. In this example, the plasticizer is triacetin. In other examples, different materials may be used to form the body 6. For example, the body 6 may be formed from paper rather than tow, similar to the paper filters known for use in cigarettes. For example, the paper or other cellulosic material may be provided as one or more portions of a sheet material, which is folded and / or crimped to form the body 6. The sheet material may have a basis weight of 15 gsm to 60 gsm, for example, 20 to 50 gsm. The sheet material can have a basis weight of, for example, 15 to 25 gsm, 25 to 30 gsm, 30 to 40 gsm, 40 to 45 gsm, or 45 to 50 gsm. Additionally or alternatively, the sheet material can have a width of 50 mm to 200 mm, for example, 60 mm to 150 mm, or 80 mm to 150 mm. For example, the sheet material can have a basis weight of 20 to 50 gsm and a width of 80 mm to 150 mm. This allows, for example, the cellulosic material body to have an appropriate pressure drop for an article having the dimensions described herein.

[0078] Alternatively, the body 6 may be formed from a tow other than cellulose acetate, such as polylactic acid (PLA), other materials described herein for filament tow, or similar materials. Preferably, the tow is formed from cellulose acetate. Whether formed from cellulose acetate or another material, the tow preferably has a denier per filament of at least 5 d.pf. To obtain a sufficiently uniform body 6, the tow preferably has a denier per filament of 12 d.pf or less, preferably 11 d.pf or less, and more preferably 10 d.pf or less.

[0079] The total fineness of the tow forming the body of material 6 is preferably at most 30,000, more preferably at most 28,000, and even more preferably at most 25,000. These total fineness values ​​provide tows that occupy a smaller percentage of the cross-sectional area of ​​the mouthpiece 2, thereby resulting in a lower pressure drop across the mouthpiece 2 than tows having higher total fineness values. For appropriate hardness of the body of material 6, the tows preferably have a total fineness of at least 8,000, more preferably at least 10,000. The denier per filament 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, with the same dpf and total fineness values ​​provided herein.

[0080] Regardless of the material used to form the body of material 6, the pressure drop across the body of material 6 may be, for example, 0.3 to 5 mmWG per mm of length of the body of material 6, such as 0.5 to 2 mmWG per mm of length of the body of material 6. The pressure drop may be, for example, 0.5 to 1 mmWG per mm of length, 1 to 1.5 mmWG per mm of length, or 1.5 to 2 mmWG per mm of length. The total pressure drop across the body of material 6 may be, for example, 3 to 8 mmWG, or 4 to 7 mmWG. The total pressure drop across the body of material 6 may be about 5, 6, or 7 mmWG.

[0081] As shown in FIG. 1a, the mouthpiece 2 of the article 1a has an upstream end 2a adjacent the rod of aerosol-forming material 3 and a downstream end 2b remote from the rod of aerosol-forming material 3. At the downstream end 2b, the mouthpiece 2 has a hollow tubular element 4 formed from filament tow. This has been found to advantageously significantly reduce the temperature of the exterior surface of the mouthpiece 2 at the downstream end 2b of the mouthpiece, which contacts the consumer's mouth during use of the article 1. Additionally, the use of the tubular element 4 has also been found to significantly reduce the temperature of the exterior surface of the mouthpiece 2 upstream of the tubular element 4. Without wishing to be bound by theory, it is hypothesized that this is because the tubular element 4 passes the aerosol near the center of the mouthpiece 2, thereby reducing the transfer of heat from the aerosol to the exterior surface of the mouthpiece 2.

[0082] The "wall thickness" of the hollow tubular element 4 corresponds to the thickness of the wall of the tube 4 in the radial direction. This can be measured, for example, using calipers. Advantageously, the wall thickness is greater than 0.9 mm, more preferably greater than 1.0 mm. Preferably, the wall thickness is substantially constant around the entire wall of the hollow tubular element 4. However, if the wall thickness is not substantially constant, the wall thickness is preferably greater than 0.9 mm, more preferably greater than 1.0 mm, at any point around the hollow tubular element 4. In the present example, the wall thickness of the hollow tubular element 4 is approximately 1.3 mm.

[0083] Preferably, the length of the hollow tubular element 4 is less than about 20 mm. More preferably, the length of the hollow tubular element 4 is less than about 15 mm. Even more preferably, the length of the hollow tubular element 4 is less than about 10 mm. Additionally or alternatively, the length of the hollow tubular element 4 is at least about 5 mm. Preferably, the length of the hollow tubular element 4 is at least about 6 mm. In some preferred embodiments, the length of the hollow tubular element 4 is between about 5 mm and about 20 mm, more preferably between about 6 mm and about 10 mm, even more preferably between about 6 mm and about 8 mm, and most preferably about 6 mm, 7 mm, or about 8 mm. In this example, the length of the hollow tubular element 4 is 7 mm.

[0084] The density of the hollow tubular element 4 is preferably at least about 0.25 grams per cubic centimeter (g / cc), more preferably at least about 0.3 g / cc. The density of the hollow tubular element 4 is preferably less than about 0.75 grams per cubic centimeter (g / cc), more preferably less than 0.6 g / cc. In some embodiments, the density of the hollow tubular element 4 is 0.25-0.75 g / cc, more preferably 0.3-0.6 g / cc, more preferably 0.4 g / cc-0.6 g / cc, or about 0.5 g / cc. These densities have been found to provide a good balance between the high hardness imparted by higher density materials and the lower heat transfer characteristics of lower density materials. For purposes of the present invention, the "density" of the hollow tubular element 4 refers to the density of the filament tow forming the element, including any plasticizers incorporated therein. The density can be determined by dividing the total weight of the hollow tubular element 4 by the total volume of the hollow tubular element 4, which can be calculated using appropriate measurements of the hollow tubular element 4, for example obtained with calipers. If necessary, appropriate dimensions can be measured using a microscope.

[0085] The filament tow forming the hollow tubular element 4 preferably has a total fineness of less than 45,000, more preferably less than 42,000. This total fineness has been found to allow the formation of a tubular element 4 that is not too dense. The total fineness is preferably at least 20,000, more preferably at least 25,000. In a preferred embodiment, the filament tow forming the hollow tubular element 4 has a total fineness of 25,000 to 45,000, more preferably 35,000 to 45,000. The cross-sectional shape of the filaments in the tow is preferably "Y" shaped, although other shapes, such as "X" shaped filaments, may be used in other embodiments.

[0086] The filament tow forming the hollow tubular element 4 preferably has a denier per filament greater than 3. This denier per filament has been found to allow for the formation of a tubular element 4 that is not too dense. The denier per filament is preferably at least 4, more preferably at least 5. In a preferred embodiment, the filament tow forming the hollow tubular element 4 has a denier per filament between 4 and 10, more preferably between 4 and 9. In one example, the filament tow forming the hollow tubular element 4 is formed from cellulose acetate and has a 7.3Y36,000 tow containing 18% plasticizer, such as triacetin.

[0087] Preferably, the hollow tubular element 4 has an inner diameter greater than 3.0 mm. A smaller inner diameter would result in the aerosol passing through the mouthpiece 2 and reaching the consumer's mouth at a higher velocity than desired, causing the aerosol to become too warm, for example reaching temperatures greater than 40°C or 45°C. More preferably, the hollow tubular element 4 has an inner diameter greater than 3.1 mm, and even more preferably greater than 3.5 mm or 3.6 mm. In one embodiment, the hollow tubular element 4 has an inner diameter of about 4.7 mm.

[0088] Preferably, the hollow tubular element 4 comprises 15% to 22% by weight of plasticizer. In the case of cellulose acetate tow, the plasticizer is preferably triacetin, although other plasticizers such as polyethylene glycol (PEG) may also be used. More preferably, the hollow tubular element 4 comprises 16% to 20% by weight of plasticizer, for example, about 17%, about 18%, or about 19%.

[0089] In this example, the first hollow tubular element 4, the body of material 6, and the cooling section 8 are combined using a second plug wrap 9, which is wrapped around all three sections. The second plug wrap 9 preferably has a basis weight of less than 50 gsm, more preferably between about 20 gsm and 45 gsm. The second plug wrap 9 preferably has a thickness of between 30 μm and 60 μm, more preferably between 35 μm and 45 μm. The second plug wrap 9 is preferably a non-porous plug wrap having an air permeability of less than 100 Coresta units, for example, less than 50 Coresta units. However, in alternative embodiments, the second plug wrap 9 may be a porous plug wrap having an air permeability of, for example, greater than 200 Coresta units.

[0090] Tipping paper 5 is wrapped around the entire length of mouthpiece 2, and in this example, the entire length 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 10, which forms a first wrapping material, and tipping paper 5 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 may extend only partially over the rod of aerosol-generating material.

[0091] The tipping paper 5 may extend 5 mm over the rod of aerosol-forming material 3, or alternatively may 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 more than 20 gsm, for example more than 25 gsm, or preferably more than 30 gsm, for example 37 gsm.

[0092] The article has a ventilation level of approximately 10% of the aerosol drawn through the article. In alternative embodiments, the article can have a ventilation level of 1% to 20%, 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 8, which has been found to be particularly advantageous in aiding the aerosol generation process. The ventilation is provided by perforations 12, 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 alternative embodiments, two or more rows of ventilation perforations may be provided. These perforations pass through the tipping paper 5, the second plug wrap 9, and the cooling section 8. In alternative embodiments, the ventilation may be provided elsewhere in the mouthpiece, for example in the body of material 6 or the first tubular element 4. The article is preferably configured so that the perforations are located approximately 28 mm or less from the upstream end of the article 1, preferably 20 mm to 28 mm from the upstream end of the article 1. In this example, the opening is located approximately 25 mm from the upstream end of the article.

[0093] FIG. 2a is a cross-sectional side view of a further article 1b for use in a non-combustion aerosol delivery system, comprising a component 3′ having a plurality of spirally wound or braided strips 3c, 3e. An aerosol delivery device 100 is also shown, with the article and device forming a system. FIG. 2b is a side view of the component 3′ of FIG. 2a. In this example, the component 3′ comprises a plurality of braided or spirally wound strips 3c, 3e, at least one of the plurality of braided and / or spirally wound strips comprising an aerosol-generating material. The component 3′ comprises a cavity that extends from a first end of the component 3′ and, in this example, extends throughout the entire length of the component 3′. In this example, the first braided and / or spirally wound strip 3c comprises a first aerosol-generating material as described herein, and the second braided and / or spirally wound strip 3e comprises a second aerosol-generating material as described herein. The second aerosol-generating material may be different from the first aerosol-generating material. In an alternative embodiment, the second braided and / or spirally wound strip 3e may be a paper strip used to adhere the first braided and / or spirally wound strip 3c to the tube 3b. For example, at least one of the braided and / or spirally wound strips may have an adhesive surface that connects other braided and / or spirally wound strips of the component 3'.

[0094] The braided and / or spirally wound strip 3c containing the first aerosol-generating material is positioned closer to the cavity 3a than the at least one braided and / or spirally wound strip containing the second aerosol-generating material.

[0095] A first gap 3d is provided between the edges of the first braided and / or spirally wound strip 3c, and a second gap 3f is provided between the edges of the second braided and / or spirally wound strip 3e, which first gap 3d and second gap 3f provide a spiral airflow path through component 3'.

[0096] In an alternative embodiment, at least one of the braided and / or spirally wound strips 3c, 3e can include a spacer material, e.g., the spacer material has a ribbed and / or corrugated structure. This spacer material can enable the formation of voids in component 3' and can be provided, for example, as a layer between inner and outer strips each containing an aerosol-generating material.

[0097] As described above with respect to component 3, when viewed from the side relative to the longitudinal axis of component 3′, a long edge of at least one of the braided strips and / or spirally wound strips, when projected onto said axis, forms two angles with the longitudinal axis of the component. One of the angles is greater than 90 degrees and the other is less than 90 degrees. In some examples, the angle between the long edge of at least one of the braided strips and / or spirally wound strips and the longitudinal axis that is less than 90 degrees is less than about 70 degrees, e.g., less than about 60 degrees, or less than about 50 degrees.

[0098] FIG. 3b shows a machine for forming the component 3' of FIG. 2b. A mandrel 16 is provided along which the material forming the component 3' is fed / pulled in the direction of arrow "X." The mandrel 16 may be, for example, stationary. In this example, a source of first strip of material 14 containing the aerosol-generating material is provided. The source of first strip of material 14, e.g., a bobbin of material, is wound around the mandrel 16 as the mandrel moves forward by moving the bobbin around the mandrel 16. The first strip of material 14 forms a first spirally wound strip 3c around the mandrel. A second strip of material 15 is also provided on the bobbin and, in this case, is used to bond to and provide rigidity to the first strip of material 14. For example, the second strip of material 15 may be a paper material. Before reaching the mandrel, the second strip of material 15 is dipped into an adhesive reservoir so that adhesive is present on its outer surface, and then adhered to the first strip of material 14. A bobbin of second strip material 15 is moved around the mandrel such that second strip material 15 forms a second spirally wound strip 3c around tube 3b.

[0099] The bobbins of first and second strips of material 14 and 15 are arranged to rotate in opposite directions around mandrel 16 in this example. As a result, at least one of the braided and / or spirally wound strips is arranged in a left-handed helical pattern, and at least one of the braided strips is arranged in a right-handed helical pattern. This results in a braid-type strip arrangement. A cutting device 17 similar to that described with reference to Figure 3a is provided.

[0100] 4 is a flow diagram of a method for forming components 3, 3′ described herein. In step S201, a source of strip material containing aerosol-generating material is provided. This may be provided, for example, on a bobbin. In step S202, the strip material is advanced toward a mandrel. In step S203, the strip material is wound around the mandrel to form a spirally wound strip containing aerosol-generating material. As previously mentioned, this can be accomplished by rotating the mandrel (with an optional hollow tube) or by moving a bobbin of material around the mandrel.

[0101] The aerosol-generating material 3 according to some of the embodiments described herein can be provided in the form of a sheet or cut sheet having a first side and a second side opposite the first side. The first and second sides have matching dimensions. The first and second sides of the sheet or cut sheet can have any shape. For example, the first and second sides can be square, rectangular, oval, or circular. Irregular shapes are also contemplated.

[0102] The first and / or second sides of the sheet or cut sheet may be relatively uniform (e.g., relatively smooth) or may be uneven or irregular. For example, the first and / or second sides of the sheet may be textured or patterned to define a relatively rough surface. In some embodiments, the first and / or second sides are relatively rough.

[0103] The smoothness of the first and second surfaces can be affected by several factors, such as the surface density of the sheet or cut sheet, the nature of the components that make up the aerosol-generating material, or whether the surface of the material has been treated, e.g., embossed, engraved, or otherwise modified, to impart a pattern or texture.

[0104] The width or cut width of the strands or strips of material 14, 15 may be between 1 mm and 15 mm. For example, the width may be between 5 mm and 12 mm. Preferably, the width of the strands or strips of material 14, 15 is greater than 1.5 times the diameter of cavity 3a. For example, the width of the strands or strips of material 14, 15 may be greater than 2, 2.5, 3, or 4 times the diameter of the cavity. Such a ratio of strip width to cavity diameter results in a more elastic structure of component 3'.

[0105] The strips of material 14, 15 can be formed from a sheet of aerosol-generating material. The sheet of aerosol-generating material has a thickness of at least about 100 μm. The sheet can have a thickness of at least about 120 μm, 140 μm, 160 μm, 180 μm, or 200 μm. In some embodiments, the sheet has a thickness of about 150 μm to about 300 μm, about 151 μm to about 299 μm, about 152 μm to about 298 μm, about 153 μm to about 297 μm, about 154 μm to about 296 μm, about 155 μm to about 295 μm, about 156 μm to about 294 μm, about 157 μm to about 293 μm, about 158 ​​μm to about 292 μm, about 159 μm to about 291 μm, or about 160 μm to about 290 μm. In some embodiments, the sheet has a thickness of about 170 μm to about 280 μm, about 180 to about 270 μm, about 190 to about 260 μm, about 200 μm to about 250 μm, or about 210 μm to about 240 μm.

[0106] The thickness of the sheet can vary between the first and second sides. In some embodiments, the individual strips or sections of aerosol-generating material have a minimum thickness of about 100 μm across their area. In some cases, the individual strips or sections of aerosol-generating material have a minimum thickness of about 0.05 mm or about 0.1 mm across their area. In some cases, the individual strips or sections of aerosol-generating material have a maximum thickness of about 1.0 mm across their area. In some cases, the individual strips or sections of aerosol-generating material have a maximum thickness of about 0.5 mm or about 0.3 mm across their area.

[0107] The thickness of the sheet may be determined using ISO 534:2011 "Paper and paperboard - Measurement of thickness".

[0108] If the sheet of aerosol-generating material is too thick, heating efficiency may decrease. This may adversely affect power consumption during use, for example, the power consumption required to release a fragrance from the aerosol-generating material. Conversely, if the aerosol-generating material is too thin, it may be difficult to manufacture and handle. Very thin materials are more difficult to cast and may be more fragile, which may interfere with aerosol formation during use.

[0109] It is hypothesized that if the sheet of aerosol-generating material is too thin (eg, less than 100 μm), the cut width of the sheet may need to be increased to achieve sufficient tensile strength.

[0110] Approximately 100g / m 2 ~about 250g / m 2 It is hypothesized that a sheet having a thickness of at least about 100 μm with an areal density of at least about 100 μm will be less likely to tear, crack, or otherwise deform during manufacturing. A thickness of at least about 100 μm can have a favorable effect on the overall structural integrity and strength of the sheet or shredded sheet. For example, this thickness can have good tensile strength and therefore be relatively easy to process.

[0111] The thickness of a sheet may also be related to its areal density, i.e., increasing the thickness of the sheet may increase the areal density of the sheet.

[0112] Conversely, reducing the thickness of the sheet may decrease the areal density of the sheet. For the avoidance of doubt, references to areal density herein refer to the average areal density calculated for a given strip, strand, section, or sheet of aerosol-generating material, which is calculated by measuring the surface area and weight of the given strip, strand, section, or sheet of aerosol-generating material.

[0113] The sheet of aerosol-generating material is approximately 100 g / m 2 ~about 250g / m 2 The sheet has an areal density of about 110 g / m 2 ~about 240g / m 2 , about 120g / m 2 ~about 230g / m 2 , about 130g / m 2 ~about 220g / m 2 , or about 140 g / m 2 ~about 210g / m 2 In some embodiments, the sheet may have an areal density of about 130 g / m 2 ~Approx. 190g / m 2 , about 140g / m 2 ~Approx. 180g / m 2 , about 150g / m 2 ~Approx. 170g / m 2 In a preferred embodiment, the sheet has an areal density of about 160 g / m 2 It has an areal density of

[0114] Approximately 100g / m 2 ~about 250g / m 2 The areal density is believed to contribute to the strength and flexibility of the sheet.

[0115] The flexibility of the sheet is believed to depend, at least in part, on the thickness and areal density of the sheet. Thicker sheets may be less flexible than thinner sheets. Also, the greater the areal density of the sheet, the less flexible the sheet. The combination of thickness and areal density of the aerosol-generating materials described herein is believed to provide a relatively flexible sheet. This flexibility can provide various advantages when the aerosol-generating material is incorporated into an article for use in a non-combustion aerosol delivery device. For example, when inserting an aerosol generator into the aerosol-generating material, the strands or strips can easily deform and bend, facilitating insertion of the aerosol generator (e.g., a heater) into the material and improving retention of the aerosol generator by the aerosol-generating material.

[0116] The areal density of the sheet of aerosol-generating material affects the roughness of the first and second sides of the sheet or shredded sheet. By varying the areal density, the roughness of the first and / or second sides can be adjusted.

[0117] The average volume density of a sheet of aerosol-generating material can be calculated from the thickness of the sheet and the areal density of the sheet. The average volume density is about 0.2 g / cm 3 Super, about 0.3g / cm 3 or about 0.4 g / cm 3 In some embodiments, the average bulk density is about 0.2 g / cm 3 ~Approx. 1g / cm 3 , about 0.3g / cm 3 ~Approx. 0.9g / cm 3 , approximately 0.4 g / cm 3 ~Approx. 0.9g / cm 3 , about 0.5g / cm 3 ~Approx. 0.9g / cm 3 , or about 0.6 g / cm 3 ~Approx. 0.9g / cm 3 may be.

[0118] According to an aspect of the present disclosure, there is provided a sheet of aerosol-forming material comprising a tobacco material, an aerosol-forming material, and a binder, wherein the sheet has a density of about 0.4 g / cm3 In some embodiments, the density is greater than about 0.4 g / cm. 3 ~Approx. 2.9g / cm 3 , approximately 0.4 g / cm 3 ~Approx. 1g / cm 3 , about 0.6 cm 3 ~approx. 1.6cm 3 , or about 1.6 cm 3 ~Approx. 2.9cm 3 is.

[0119] The sheet may have a tensile strength of at least 4 N / 15 mm. If the sheet has a tensile strength of less than 4 N / 15 mm, the sheet may be prone to tearing, breaking, or otherwise deforming during manufacture and / or subsequent incorporation into an article for use in a non-combustible aerosol delivery system. Tensile strength may be measured using ISO 1924:2008.

[0120] The aerosol-forming material comprises a tobacco material. The sheet of aerosol-forming material comprises a tobacco material.

[0121] The tobacco material may be a particulate or granular material. In some embodiments, the tobacco material is a powder. Alternatively or additionally, the tobacco material may comprise tobacco flakes, strands, or fibers. For example, the tobacco material may comprise tobacco particles, granules, fibers, flakes, and / or strands. In some embodiments, the tobacco material is comprised of particles or granules of tobacco material.

[0122] The density of the tobacco material affects the rate at which heat is conducted through the material; lower densities, for example densities below 900 mg / cc, allow for a more sustained aerosol release because heat is conducted more slowly through the material.

[0123] The tobacco material can include a reconstituted tobacco material, such as a paper reconstituted tobacco material, having a density of less than about 900 mg / cc. For example, the aerosol-forming material can include a reconstituted tobacco material having a density of less than about 800 mg / cc. Alternatively or additionally, the aerosol-forming material can include a reconstituted tobacco material having a density of at least 350 mg / cc.

[0124] The reconstituted tobacco material may be provided in the form of a shredded sheet. The sheet of reconstituted tobacco material may have any suitable thickness. The reconstituted tobacco material may have a thickness of at least about 0.145 mm, e.g., at least about 0.15 mm or at least about 0.16 mm. The reconstituted tobacco material may have a maximum thickness of about 0.30 mm or 0.25 mm; for example, the reconstituted tobacco material may have a thickness of less than about 0.22 mm or less than about 0.2 mm. In some embodiments, the reconstituted tobacco material may have an average thickness in the range of 0.175 mm to 0.195 mm.

[0125] In some embodiments, the tobacco is a particulate tobacco material. Each particle of the particulate tobacco material can have a maximum dimension. As used herein, the term "maximum dimension" refers to the longest linear distance from any point on the surface or face of a particle of tobacco to any other point on the surface or face of the same particle of tobacco. The maximum dimension of a particle of a particulate tobacco material can be measured using scanning electron microscopy (SEM).

[0126] The maximum dimension of each particle of the tobacco material may be up to about 200 μm. In some embodiments, the maximum dimension of each particle of the tobacco material is up to about 150 μm.

[0127] The population of particles of the tobacco material may have a particle size distribution (D90) of at least about 100 μm. In some embodiments, the population of particles of the tobacco material has a particle size distribution (D90) of about 110 μm, at least about 120 μm, at least about 130 μm, at least about 140 μm, or at least about μm. In embodiments, the population of particles of the tobacco material has a particle size distribution (D90) of about 150 μm. Sieve analysis may be used to determine the particle size distribution of the particles of the tobacco material.

[0128] A particle size distribution (D90) of at least about 100 μm is believed to contribute to the tensile strength of a sheet of aerosol-forming material.

[0129] A particle size distribution (D90) of less than 100 μm can provide a sheet of aerosol-generating material with good tensile strength. However, including such fine tobacco material particles in the sheet can increase the density of the sheet. When the sheet is incorporated into an article for use in a non-combustion aerosol delivery system, this higher density can reduce the fill value of the tobacco material. Advantageously, a particle size distribution (D90) of at least about 100 μm can achieve a balance between sufficient tensile strength and appropriate density (and therefore fill value).

[0130] The particle size of the particulate tobacco material can also affect the roughness of the sheet of aerosol-forming material. It is hypothesized that forming a sheet of aerosol-forming material by incorporating relatively large particles of tobacco material reduces the density of the sheet of aerosol-forming material.

[0131] The tobacco material can include tobacco obtained from any part of the tobacco plant. In some embodiments, the tobacco material includes tobacco leaf. The sheet can include from 5% to about 90% by weight of tobacco leaf.

[0132] The tobacco material can include laminar tobacco and / or tobacco stems, such as midrib stems. The laminar tobacco can be present in an amount of 0% to about 100%, about 20% to about 100%, about 40% to about 100%, about 40% to about 95%, about 45% to about 90%, about 50% to about 85%, or about 55% to about 80% by weight of the sheet and / or tobacco material. In some embodiments, the tobacco material consists of, or consists essentially of, laminar tobacco material.

[0133] The tobacco material may contain tobacco stems in an amount of from 0% to about 100% by weight, from about 0% to about 50% by weight, from about 0 to about 25% by weight, from about 0 to about 20% by weight, or from about 5 to about 1.5% by weight of the sheet or shredded sheet.

[0134] In some embodiments, the tobacco material comprises a combination of lamina and tobacco stems. In some embodiments, the tobacco material may comprise between about 40% and about 95% lamina and between about 5% and about 60% stems, or between about 60% and about 95% lamina and between about 5% and about 40% stems, or between about 80% and about 95% lamina and between about 5% and about 20% stems, by weight of the sheet of aerosol-forming material.

[0135] The incorporation of stems may reduce the stickiness of the aerosol-forming material. The incorporation of tobacco material, including stem tobacco, into the aerosol-forming material may increase its burst strength.

[0136] The sheet or chopped sheet of aerosol-forming material may have a burst strength of at least about 75 g, at least about 100 g, or at least about 200 g.

[0137] If the burst strength is too low, the sheet may be relatively brittle. As a result, the sheet may break during the manufacturing process of the aerosol-generating material. For example, when the sheet is shredded by a cutting process to form a shredded sheet, the sheet may crumble or break into pieces or fragments upon cutting.

[0138] The tobacco material described herein contains nicotine. The nicotine content may be 0.1 to 3% by weight of the tobacco material, for example, 0.5 to 2.5% by weight of the tobacco material. Additionally or alternatively, the tobacco material comprises 10% to 90% by weight of tobacco leaf, with a nicotine content of greater than about 1% or greater than about 1.5% by weight of the tobacco leaf. Tobacco leaf, for example, cut rag tobacco, has a nicotine content of, for example, 1% to 5% by weight of the tobacco leaf.

[0139] The sheet of aerosol-forming material may include nicotine in an amount of from about 0.1% to about 3% by weight of the sheet or shredded sheet.

[0140] Reconstituted tobacco paper may be present in the aerosol-forming materials described herein. Reconstituted tobacco paper refers to tobacco material formed by a process in which tobacco raw material is extracted with a solvent to obtain a residue containing a soluble extract and fibrous material, and then (usually after concentration, and optionally after further processing) the extract is recombined with fibrous material from the residue by depositing the extract on the fibrous material (usually after purification of the fibrous material, and optionally with the addition of a portion of non-tobacco fiber). The recombination process is similar to the papermaking process.

[0141] The reconstituted tobacco may be any type of reconstituted tobacco known in the art. In certain embodiments, the reconstituted tobacco is made from raw materials including one or more of tobacco shreds, tobacco stems, and whole leaf tobacco. In further embodiments, the reconstituted tobacco is made from raw materials consisting of tobacco shreds and / or whole leaf tobacco and tobacco stems. However, in other embodiments, chips, fines, and rice husks may be used instead or in addition to the raw materials.

[0142] Reconstituted tobacco for use in the tobacco materials described herein may be prepared by methods known to those skilled in the art for preparing reconstituted tobacco.

[0143] In embodiments, the reconstituted tobacco is present in an amount of from 5% to 90%, from 10% to 80%, or from 20% to 70% by weight of the aerosol-forming material.

[0144] The aerosol-generating material includes an aerosol-forming material. The aerosol-forming material includes one or more components capable of forming an aerosol. The aerosol-forming material includes one or more of glycerin, glycerol, propylene glycol, diethylene glycol, triethylene glycol, tetraethylene glycol, 1,3-butylene glycol, erythritol, mesoerythritol, ethyl vanillate, ethyl laurate, diethyl suberate, triethyl citrate, triacetin, diacetin mixtures, benzyl benzoate, benzyl phenylacetate, tributyrin, lauryl acetate, lauric acid, myristic acid, and propylene carbonate. Preferably, the aerosol-forming material is glycerol or propylene glycol.

[0145] The sheet of aerosol-forming material includes an aerosol-forming material. The aerosol-forming material is provided in an amount of up to about 50% by weight of the sheet or shredded sheets on a dry weight basis. In some embodiments, the aerosol-forming material is provided in an amount of about 5% to about 40% by weight of the sheet or shredded sheets on a dry weight basis, about 10% to about 30% by weight of the sheet on a dry weight basis, or about 10% to about 20% by weight of the sheet or shredded sheets on a dry weight basis.

[0146] The sheet can also contain water. The sheet of aerosol-forming material can contain water in an amount of less than about 15%, less than about 10%, or less than about 5% by weight of the aerosol-forming material. In some embodiments, the aerosol-forming material contains water in an amount of about 0% to about 15%, or about 5% to about 15% by weight of the aerosol-forming material.

[0147] The sheet of aerosol-forming material may contain water and aerosol-forming material in a total amount of less than about 30% by weight of the sheet of aerosol-forming material, or less than about 25% by weight of the sheet of aerosol-forming material. Incorporating water and aerosol-forming material into the sheet of aerosol-forming material in an amount less than about 30% by weight of the sheet of aerosol-forming material may advantageously reduce the tackiness of the sheet. This may improve the ease with which the aerosol-forming material can be handled during processing. For example, it may be easier to roll a sheet of aerosol-forming material to form a bobbin of material and then unwind the bobbin without the layers of the sheet sticking to each other. Reducing tackiness may also reduce the tendency of strands or pieces of shredded material to clump together or stick to each other, further improving processing efficiency and final product quality.

[0148] The sheet includes a binder. The binder is arranged to bind the components of the aerosol-forming material together to form the sheet or shredded sheet. The binder can at least partially coat the surface of the tobacco material. If the tobacco material is in particulate form, the binder can at least partially coat the surface of the tobacco particles to bind the particles together.

[0149] The binder may be selected from one or more compounds selected from the group consisting of alginate, pectin, starch (and derivatives), cellulose (and derivatives), gums, silica or silicone compounds, clay, polyvinyl alcohol, and combinations thereof. For example, in some embodiments, the binder comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, gum arabic, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some cases, the binder comprises alginate and / or pectin or carrageenan. In a preferred embodiment, the binder comprises guar gum.

[0150] The binder can be present in an amount of about 1 to about 20% by weight of the sheet or shredded sheet, or 1 to about 10% by weight of the sheet of aerosol-forming material. For example, the binder can be present in an amount of about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, or 10% by weight of the sheet of aerosol-forming material.

[0151] The aerosol-forming material can include a filler. In some embodiments, the sheet includes a filler. The filler is typically a non-tobacco component, i.e., a component that does not contain tobacco-derived materials. The filler can 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 can also be a non-tobacco fiber, such as wood fiber or wood pulp or wheat fiber. The filler can also be a material containing cellulose or a material containing a derivative of cellulose. The filler component can also be a non-tobacco cast material or a non-tobacco extruded material.

[0152] 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.

[0153] Fillers can also contribute to the texture of the sheet of aerosol-generating material. For example, a fibrous filler, such as wood or wood pulp, can provide a sheet of aerosol-generating material with a relatively rough first and second surface. Conversely, a non-fibrous particulate filler, such as powdered chalk, can provide a sheet of aerosol-generating material with a relatively smooth first and second surface. In some embodiments, the aerosol-generating material comprises a combination of different filler materials.

[0154] The filler component may be present in an amount of 0 to 20% by weight of the sheet or shredded sheet, or in an amount of 1 to 10% by weight of the sheet or shredded sheet, hi some embodiments, no filler component is present.

[0155] Fillers can help improve the general structural properties of the aerosol-forming material, such as tensile strength and burst strength.

[0156] For the avoidance of doubt, when amounts are expressed in terms of weight percent in the compositions described herein, they refer to a dry weight basis unless otherwise specified. Therefore, any water that may be present in the aerosol-forming material, or any of its components, is completely ignored for purposes of determining weight percent. The water content of the aerosol-forming materials described herein may vary, for example, from 5 to 15 weight percent. The water content of the aerosol-forming materials described herein may vary depending on, for example, the temperature, pressure, and humidity conditions under which the composition is maintained. The water content can be determined by Karl Fischer analysis, as known to those skilled in the art. However, for the avoidance of doubt, even if the aerosol-forming material is a liquid-phase component such as glycerol or propylene glycol, any components other than water are included in the weight of the aerosol-forming material. However, when an aerosol-forming material is provided to the tobacco component of the aerosol-forming material or to a filler component (if present) of the aerosol-forming material instead of or in addition to being added separately to the aerosol-forming material, the aerosol-forming material is not included in the weight of the tobacco component or filler component, but is included in the weight of the "aerosol-forming material" in terms of weight percent as defined herein. Any other materials present in the tobacco component are included in the weight of the tobacco component, even if they are of non-tobacco origin (eg, non-tobacco fiber in the case of reconstituted tobacco).

[0157] The aerosol-forming material herein can include an aerosol modifier, such as any of the flavorings described herein. In one embodiment, the aerosol-forming material includes menthol. When the aerosol-forming material is incorporated into an article for use in an aerosol delivery system, the article can be referred to as a mentholated article. The aerosol-forming material can include 0.5 mg to 20 mg of menthol, 0.7 mg to 20 mg of menthol, 1 mg to 18 mg, or 8 mg to 16 mg of menthol. In this example, the aerosol-forming material includes 16 mg of menthol. The aerosol-forming material can include 1% to 8% by weight of menthol, preferably 3% to 7% by weight of menthol, and more preferably 4% to 5.5% by weight of menthol. In one embodiment, the aerosol-forming material includes 4.7% by weight of menthol. Such high levels of menthol loading can be achieved by using a high percentage of reconstituted tobacco material, for example, greater than 50% by weight of the tobacco material. Alternatively or additionally, for example, using a larger amount of tobacco material can allow for a higher level of menthol loading to be achieved, for example, about 500 mm 3 More than, or preferably about 1000 mm 3 An aerosol-forming material such as tobacco material is used.

[0158] In some embodiments, the composition comprises an aerosol-forming "amorphous solid," which may also be referred to as a "monolithic solid" (i.e., non-fibrous). In some embodiments, the amorphous solid may comprise a dry gel. An amorphous solid is a solid material that can retain some fluid, such as a liquid, within it.

[0159] In some instances, the amorphous solid is 1 to 60 wt % of a gelling agent; 0.1 to 50 wt % of an aerosol-forming material; and 0.1 to 80 wt% of a fragrance, These weights are calculated on a dry weight basis.

[0160] In some further embodiments, the amorphous solid is 1 to 50 wt % of a gelling agent; 0.1 to 50 wt % of an aerosol-forming material; Contains 30 to 60 wt% of fragrance, These weights are calculated on a dry weight basis.

[0161] The amorphous solid material may be provided in the form of a sheet or shredded sheet. The amorphous solid material may take the same form as the sheets of aerosol-forming material, as described above.

[0162] The amorphous solid can suitably comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, or 35 wt% of a gelling agent (all calculated on a dry weight basis). For example, the amorphous solid can comprise 1-50 wt%, 5-45 wt%, 10-40 wt%, or 20-35 wt% of a gelling agent. In some embodiments, the gelling agent comprises a hydrocolloid. In some embodiments, the gelling agent comprises one or more compounds selected from the group including alginates, pectins, starches (and derivatives), celluloses (and derivatives), gums, silica or silicone compounds, clays, polyvinyl alcohols, and combinations thereof. For example, in some embodiments, the gelling agent comprises one or more of alginate, pectin, hydroxyethyl cellulose, hydroxypropyl cellulose, carboxymethyl cellulose, pullulan, xanthan gum, guar gum, carrageenan, agarose, gum arabic, fumed silica, PDMS, sodium silicate, kaolin, and polyvinyl alcohol. In some embodiments, the gelling agent comprises alginate and / or pectin and may be mixed with a hardening agent (such as a calcium source) during formation of the amorphous solid. In some embodiments, the amorphous solid may comprise calcium-crosslinked alginate and / or calcium-crosslinked pectin.

[0163] In some embodiments, the gelling agent comprises alginate, and the alginate is present in the amorphous solid in an amount of 10-30 wt% (calculated on a dry weight basis) of the amorphous solid. In some embodiments, the alginate is the only gelling agent present in the amorphous solid. In other embodiments, the gelling agent comprises alginate and at least one additional gelling agent, such as pectin.

[0164] In some embodiments, the amorphous solid may include a gelling agent including carrageenan.

[0165] Preferably, the amorphous solid can comprise from about 0.1 wt%, 0.5 wt%, 1 wt%, 3 wt%, 5 wt%, 7 wt%, or 10% to about 50 wt%, 45 wt%, 40 wt%, 35 wt%, 30 wt%, or 25 wt% of the aerosol-forming material (all calculated on a dry weight basis). The aerosol-forming material can act as a plasticizer. For example, the amorphous solid can comprise from 0.5 to 40 wt%, from 3 to 35 wt%, or from 10 to 25 wt% of the aerosol-forming material. In some cases, the aerosol-forming material comprises one or more compounds selected from erythritol, propylene glycol, glycerol, triacetin, sorbitol, and xylitol. In some cases, the aerosol-forming material comprises, consists essentially of, or consists of glycerol.

[0166] The amorphous solid comprises a flavoring agent. Suitably, the amorphous solid can comprise up to about 80 wt%, 70 wt%, 60 wt%, 55 wt%, 50 wt%, or 45 wt% flavoring agent.

[0167] In some cases, the amorphous solid can include at least about 0.1 wt%, 1 wt%, 10 wt%, 20 wt%, 30 wt%, 35 wt%, or 40 wt% flavoring (all calculated on a dry weight basis).

[0168] For example, the amorphous solid can include 1-80 wt%, 10-80 wt%, 20-70 wt%, 30-60 wt%, 35-55 wt%, or 30-45 wt% flavoring. In some cases, the flavoring includes, consists essentially of, or consists of menthol.

[0169] In some cases, the amorphous solid may further comprise an emulsifier that emulsifies the molten flavor during manufacture. For example, the amorphous solid may comprise about 5 wt% to about 15 wt%, preferably about 10 wt%, of an emulsifier (calculated on a dry weight basis). The emulsifier may include gum arabic.

[0170] In some embodiments, the amorphous solid is a hydrogel and contains less than about 20 wt% water, calculated on a wet weight basis. In some cases, the hydrogel can contain less than about 15 wt%, 12 wt%, or 10 wt% water, calculated on a wet weight basis. In some cases, the hydrogel can contain at least about 1 wt%, 2 wt%, or at least about 5 wt% water (wet weight basis).

[0171] In some embodiments, the amorphous solid further comprises an active substance. For example, in some cases, the amorphous solid further comprises tobacco material and / or nicotine. In some cases, the amorphous solid can comprise 5 to 60 wt% (calculated on a dry weight basis) of tobacco material and / or nicotine. In some cases, the amorphous solid can comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of the active substance. In some cases, the amorphous solid can comprise from about 1 wt%, 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 70 wt%, 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of tobacco material. For example, the amorphous solid can comprise from 10 to 50 wt%, 15 to 40 wt%, or 20 to 35 wt% of tobacco material. In some cases, the amorphous solid can comprise from about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% of nicotine (calculated on a dry weight basis). For example, the amorphous solid can comprise from 1 to 20 wt%, 2 to 18 wt%, or 3 to 12 wt% of nicotine.

[0172] In some cases, the amorphous solid includes an active substance such as tobacco extract. In some cases, the amorphous solid can include 5-60 wt% (calculated on a dry weight basis) of tobacco extract. In some cases, the amorphous solid can include about 5 wt%, 10 wt%, 15 wt%, 20 wt%, or 25 wt% to about 60 wt%, 50 wt%, 45 wt%, 40 wt%, 35 wt%, or 30 wt% (calculated on a dry weight basis) of tobacco extract. For example, the amorphous solid can include 10-50 wt%, 15-40 wt%, or 20-35 wt% of tobacco extract. The tobacco extract can contain nicotine in a concentration such that the amorphous solid contains from 1 wt%, 1.5 wt%, 2 wt%, or 2.5 wt% to about 6 wt%, 5 wt%, 4.5 wt%, or 4 wt% nicotine (calculated on a dry weight basis).

[0173] In some cases, no nicotine other than that obtained from the tobacco extract may be present in the amorphous solid.

[0174] In some embodiments, the amorphous solid does not contain tobacco material but does contain nicotine. In some such cases, the amorphous solid can contain from about 1 wt%, 2 wt%, 3 wt%, or 4 wt% to about 20 wt%, 18 wt%, 15 wt%, or 12 wt% nicotine (calculated on a dry weight basis). For example, the amorphous solid can contain from 1 to 20 wt%, 2 to 18 wt%, or 3 to 12 wt% nicotine.

[0175] In some cases, the total content of actives and / or fragrances may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of actives and / or fragrances may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0176] In some cases, the total content of tobacco material, nicotine, and flavorings may be at least about 0.1 wt%, 1 wt%, 5 wt%, 10 wt%, 20 wt%, 25 wt%, or 30 wt%. In some cases, the total content of actives and / or flavorings may be less than about 90 wt%, 80 wt%, 70 wt%, 60 wt%, 50 wt%, or 40 wt% (all calculated on a dry weight basis).

[0177] The amorphous solid may be made from a gel, which may further contain a solvent in an amount of 0.1 to 50 wt %. However, the inclusion of a solvent in which the fragrance dissolves may reduce the stability of the gel, and the fragrance may crystallize from the gel. Therefore, in some cases, the gel does not contain a solvent in which the fragrance dissolves.

[0178] In some embodiments, the amorphous solid comprises less than 60 wt% of filler, for example, between 1 wt% and 60 wt%, or between 5 wt% and 50 wt%, or between 5 wt% and 30 wt%, or between 10 wt% and 20 wt%.

[0179] In other embodiments, the amorphous solid contains less than 20 wt%, preferably less than 10 wt%, or less than 5 wt% filler. In some cases, the amorphous solid contains less than 1 wt% filler, and in some cases, no filler.

[0180] When present, the filler may comprise 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 comprise one or more organic filler materials, such as wood pulp, cellulose, and cellulose derivatives. In certain cases, the amorphous solid does not comprise calcium carbonate, such as chalk.

[0181] In certain embodiments that include a filler, the filler is fibrous. For example, the filler may be a fibrous organic filler material, such as wood pulp, hemp fiber, cellulose, or a cellulose derivative. Without wishing to be bound by theory, it is believed that the inclusion of a fibrous filler in an amorphous solid can increase the tensile strength of the material.

[0182] In some embodiments, the amorphous solid does not include tobacco fiber.

[0183] In some cases, the amorphous solid in the form of a sheet can have a tensile strength of about 200 N / m to about 1500 N / m. In some cases, such as when the amorphous solid does not include a filler, the amorphous solid can have a tensile strength of 200 N / m to 400 N / m, or 200 N / m to 300 N / m, or about 250 N / m. Such tensile strengths may be particularly suitable for embodiments in which the amorphous solid material is formed into a sheet and then shredded and incorporated into an aerosol product.

[0184] In some instances, such as when the amorphous solid includes a filler, the amorphous solid may have a tensile strength of 600 N / m to 1500 N / m, or 700 N / m to 900 N / m, or about 800 N / m. Such tensile strengths may be particularly suitable for embodiments in which the amorphous solid material is included in the aerosol product article as a rolled sheet, preferably in the form of a tube.

[0185] In some cases, the amorphous solid may consist essentially of or consist of a gelling agent, water, an aerosol-forming material, a flavoring agent, and optionally an active agent.

[0186] In some cases, the amorphous solid may consist essentially of or consist of a gelling agent, water, an aerosol-forming material, flavorings, and optionally a tobacco material and / or a nicotine source.

[0187] The amorphous solid can include one or more active agents and / or flavorings, one or more aerosol-forming materials, and optionally one or more other functional materials.

[0188] The aerosol-forming material can include reconstituted tobacco paper. The composition can alternatively or additionally include any of the tobacco forms described herein. The aerosol-forming material can comprise a sheet containing tobacco material comprising 10% to 90% by weight of tobacco leaf, the aerosol-forming material being provided in an amount of up to about 20% by weight of the sheet or shredded sheet, and the remainder of the tobacco material comprising reconstituted tobacco paper.

[0189] When the aerosol-forming material comprises an amorphous solid material, the amorphous solid material may be a dry gel comprising menthol. In alternative embodiments, the amorphous solid may have any of the compositions described herein.

[0190] Improved articles can be produced that include an aerosol-generating material that includes a first component that includes a sheet of aerosol-generating material and a second component that includes an amorphous solid, with material properties (e.g., density) and specifications (e.g., thickness, length, and cut width) that fall within the ranges described herein.

[0191] In some cases, the amorphous solid can have a thickness of about 0.015 mm to about 1.0 mm. Suitably, the thickness can range from about 0.05 mm, 0.1 mm, or 0.15 mm to about 0.5 mm or 0.3 mm. Materials having a thickness of about 0.09 mm can be used. The amorphous solid can include two or more layers, and the thicknesses described herein refer to the combined thickness of these layers.

[0192] The thickness of the amorphous solid material can be measured using calipers or a microscope, such as a scanning electron microscope (SEM), as known to those skilled in the art, or any other suitable technique known to those skilled in the art.

[0193] If the amorphous solid is too thick, heating efficiency may decrease. This may adversely affect power consumption during use, for example, the power consumption required to release a fragrance from the amorphous solid. Conversely, if the amorphous solid for aerosol formation is too thin, it may be difficult to manufacture and handle. Very thin materials are more difficult to cast, more fragile, and may interfere with aerosol formation during use. In some cases, the individual strips or slices of the amorphous solid have a minimum thickness of about 0.015 mm across their area. In some cases, the individual strips or slices of the amorphous solid have a minimum thickness of about 0.05 mm or about 0.1 mm across their area. In some cases, the individual strips or slices of the amorphous solid have a maximum thickness of about 1.0 mm across their area. In some cases, the individual strips or slices of the amorphous solid have a maximum thickness of about 0.5 mm or about 0.3 mm across their area.

[0194] In some cases, the thickness of the amorphous solid may vary by no more than 25%, 20%, 15%, 10%, 5%, or 1% over its area.

[0195] By providing a sheet of amorphous solid material and aerosol-generating material with areal density values ​​that differ from each other by less than a certain percentage, the mixture of these materials is less likely to separate. In some examples, the areal density of the amorphous solid material may be 50% to 150% of the areal density of the aerosol-generating material. For example, the areal density of the amorphous solid material may be 60% to 140% of the areal density of the aerosol-generating material, or 70% to 110% of the areal density of the aerosol-generating material, or 80% to 120% of the areal density of the aerosol-generating material.

[0196] In embodiments described herein, the amorphous solid material can be incorporated into the article in the form of a sheet. Suitably, the amorphous solid material in sheet form can be shredded before being incorporated into the article and mixed with an aerosol-forming material, such as a sheet of aerosol-forming material described herein.

[0197] In further embodiments, the sheet of amorphous solid can further be incorporated as a flat sheet, as a collected or bundled sheet, as a pressed sheet, or as a rolled sheet (i.e., in the form of a tube). In some such cases, the amorphous solid of these embodiments can be included in the aerosol product as a sheet, such as a sheet surrounding a rod containing the aerosol-forming material. For example, the sheet of amorphous solid can be formed into a wrapping paper that surrounds an aerosol-forming material, such as tobacco.

[0198] The amorphous solid in the form of a sheet has a density of about 30 g / m 2 ~Approx. 150g / m 2 In some cases, the sheet may have a density of about 55 g / m 2 ~Approx. 135g / m 2 , or about 80 to about 120 g / m 2 , or about 70 to about 110 g / m 2 , or particularly about 90 to about 110 g / m 2 , or preferably about 100 g / m 2These ranges can provide a density similar to that of cut rag tobacco, thereby providing a mixture of these materials that is less likely to separate. Such areal densities can be particularly suitable when the amorphous solid material is included in the aerosol product as a shredded sheet (discussed further below). In some cases, the sheet can have a mass per unit area of ​​about 30-70 g / m. 2 , 40~60g / m 2 , or 25 to 60 g / m 2 and the sheet can be used to encase an aerosol-forming material, such as those described herein.

[0199] The aerosol-forming material can comprise a mixture of the aerosol-forming material described herein and an amorphous solid material. Such aerosol-forming materials can provide a desirable flavor profile for the aerosol during use by incorporating additional flavorings into the aerosol-forming material by including them in the amorphous solid material component. The flavorings provided in the amorphous solid material can be more stably retained within the amorphous solid material compared to flavorings added directly to the tobacco material, resulting in a more consistent flavor profile among articles manufactured according to the present disclosure.

[0200] As previously mentioned, tobacco materials having a density of at least 350 mg / cc to less than about 900 mg / cc, preferably about 600 mg / cc to about 900 mg / cc, have been found to be advantageous in providing a more sustained aerosol release. To provide an aerosol with a consistent flavor profile, the amorphous solid material components of the aerosol-forming material should be uniformly dispersed throughout the rod. This can be achieved by casting the amorphous solid material to provide an amorphous solid material having a thickness as described herein and an areal density similar to that of the tobacco material, and by processing the amorphous solid material as described below to ensure uniform dispersion throughout the aerosol-forming material.

[0201] As previously mentioned, optionally, the aerosol-generating material comprises a plurality of strips of amorphous solid material. When the aerosol-generating portion comprises a plurality of strands and / or strips of a sheet of aerosol-generating material and a plurality of strips of amorphous solid material, the material properties and / or dimensions of these at least two components may be suitably selected to ensure relatively uniform mixing of the components and in other ways to reduce separation or unmixing of the components during or after manufacture of the rod of aerosol-generating material.

[0202] The longitudinal dimension of the plurality of strands or strips may be approximately the same as the length of the aerosol-generating portion. The plurality of strands and / or strips may have a length of at least about 5 mm.

[0203] The various embodiments described herein are presented merely to aid in the understanding and teaching of the claimed features. These embodiments are presented as merely representative examples of embodiments and are not intended to be comprehensive and / or exclusive. The advantages, embodiments, examples, functions, features, structures, and / or other aspects described herein should not be construed as limiting the scope of the invention as defined in the claims or to the equivalents of the claims, and it should be understood that other embodiments may be used and modifications may be made without departing from the scope of the claimed invention. Various embodiments of the 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 explicitly set forth herein. Additionally, the present disclosure may include other inventions not currently claimed but which may be claimed in the future.

Claims

1. 1. A component for use in a non-combustible aerosol delivery system, comprising: a plurality of spirally wound strips containing an aerosol-forming material; A component, wherein the plurality of spirally wound strips include a spacer material layered between inner and outer strips each containing an aerosol-generating material, the spacer material arranged to provide an airflow path through the component.

2. The component of claim 1 , further comprising a cavity extending from the first end of the component.

3. 3. The component of claim 2, wherein the width of at least one of the plurality of spirally wound strips containing the aerosol-generating material is at least 1.5 times the inner diameter of the cavity, or at least 2 times the inner diameter of the cavity, or at least 3 times the inner diameter of the cavity, or at least 4 times the inner diameter of the cavity.

4. 2. The component of claim 1, wherein the component has a longitudinal axis, and a long edge of the spirally wound strip containing the aerosol-generating material projected onto the axis forms an angle with the axis of less than about 70 degrees, e.g., less than about 60 degrees, or less than about 50 degrees.

5. 10. The component of claim 1, wherein the plurality of spirally wound strips containing aerosol-forming material includes a first spirally wound strip containing a first aerosol-forming material and a second spirally wound strip containing a second aerosol-forming material.

6. further comprising a cavity extending from the first end of the component; The component of claim 5 , wherein the first spirally wound strip is positioned closer to the cavity than the second spirally wound strip.

7. 6. The component of claim 5, wherein the first spirally wound strip is arranged in a left-handed spiral pattern and the second spirally wound strip is arranged in a right-handed spiral pattern.

8. further comprising a cavity extending from the first end of the component; The component of claim 1 , wherein the cavity is circumscribed by a hollow tube, and the plurality of spirally wound strips containing aerosol-forming material are disposed around the hollow tube.

9. 10. The component of claim 1, wherein the aerosol-forming material comprises a plant-based material, such as a tobacco material and / or an amorphous solid material.

10. The component of claim 2 , wherein the cavity has a diameter with a manufacturing tolerance of less than 0.5 mm, or less than 0.4 mm, or less than 0.3 mm.

11. The component of claim 1 , wherein the spacer material has a ridged and / or corrugated structure.

12. The component of claim 11 , wherein the spacer material is disposed around at least one of the plurality of spirally wound strips containing aerosol-forming material.

13. The component of claim 1 , wherein at least one of the plurality of spirally wound strips comprises an adhesive surface.

14. 14. The component of claim 13, wherein the adhesive surface connects other spirally wound strips of the component.

15. The component of claim 13 , wherein the adhesive surface comprises an adhesive or bonding agent.

16. 16. The component of claim 15, wherein the adhesive or binder is selected from a starch-based adhesive or binder, a gum-based adhesive or binder, a polysaccharide-based adhesive or binder, or a carboxymethylcellulose-based adhesive or binder.

17. The component of claim 1 , wherein at least one of the plurality of spirally wound strips containing aerosol-forming material has a tensile strength of at least 4 N / 15 mm.

18. A component according to any one of claims 1 to 17; a downstream portion downstream of said component; 1. An article for use in a non-flammable aerosol delivery system, comprising:

19. an article according to claim 18; an aerosol delivery device for forming an aerosol from the aerosol-generating material; A non-flammable aerosol delivery system comprising:

20. 1. A method of forming a component, comprising: providing a source of strip material comprising an aerosol-forming material; feeding the strip material toward a mandrel; winding the strip material around the mandrel to form a spirally wound strip containing aerosol-forming material; providing a source of spacer material; and wrapping the spacer material around the mandrel to provide a layer of spacer material on the component so that the spacer material provides an airflow path through the component, the spacer material being provided as a layer between inner and outer strips each containing an aerosol-generating material.

21. 21. The method of claim 20, wherein the width of the strip material is at least multiple times the diameter of the mandrel, or at least twice the diameter of the mandrel, or at least three times the diameter of the mandrel, or at least four times the diameter of the mandrel.

22. 21. The method of claim 20, further comprising providing a tube on the mandrel, and wherein the wrapping step comprises wrapping the strip material around the tube.

23. 21. The method of claim 20, further comprising the step of laminating the aerosol-forming material to a support material.

24. the strip of material comprising an aerosol-forming material is a first strip of material, and the method comprises: providing a source of second strip material; directing the second strip of material toward a mandrel; winding the second strip of material around the mandrel to form a second spirally wound strip; 21. The method of claim 20, comprising:

25. 25. The method of claim 24, wherein the winding of the first strip of material is performed in a first direction and the winding of the second strip of material is performed in a second direction, the winding forming a spiral pattern of the first strip of material and the second strip of material, the spiral pattern including at least one left-handed spiral and at least one right-handed spiral.

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